WO2010060613A1

WO2010060613A1 - Container for product portions

Info

Publication number: WO2010060613A1
Application number: PCT/EP2009/008394
Authority: WO
Inventors: Joe Breen
Original assignee: Joe Breen
Priority date: 2008-11-25
Filing date: 2009-11-25
Publication date: 2010-06-03
Also published as: IES20090891A2

Abstract

The present invention is concerned with a container comprising a tray (12) which is displaceable between a storage state and a deployed state and which defines a plurality of discrete receptacles (14) or compartments within which individual doses or measures of a product or substance may be retained, for example consumable products in solid, liquid or gaseous forms.

Description

CONTAINER FOR PRODUCT PORTIONS

Field of the invention

This invention relates to a container, and in particular a container which is displaceable between a storage state and a deployed state and which defines a plurality of discrete receptacles or compartments within which individual doses or measures of a product or substance may be retained, for example consumable products in solid, liquid or gaseous forms, one particular example being ice cubes.

Background of the invention

It is often desirable to store consumable products in discrete doses or portions, allowing the consumer to use a single dose of the product at a time and thus maintaining the integrity and thus freshness/state of the remaining doses or portions for later use. One such example is the use of ice cubes. Ice cubes are generally produced by filling an ice cube tray with water and placing it in a freezer in order to freeze the individual pockets of water into ice cubes, which can then be used in single portions as required while the remaining ice cubes are preserved for later use. Various forms of ice cube tray exist, from conventional plastic or metal trays which produce standard cube shaped ice cubes to novelty ice cube trays which produce ice cubes of various shape and size.

However conventional ice cube trays have fallen out of favour with many people, due to drawbacks associated with same. Many people find filling the trays and locating them in a freezer without spillage a difficult and frustrating task, and often if the freezer is reopened before the water in the tray is frozen, this will result in further spillage. It is also necessary to have a substantially horizontal surface onto which to place the ice cube tray, again in order to avoid spillage, and such a flat surface is often not available in most domestic freezers due to the existing load. As a result many people choose to buy pre-made bags of ice cubes, which are simply placed into the freezer without requiring careful positioning, and can then simply be used as required. However, in order for retailers to stock these bags of ready made ice cubes it is generally necessary to install a dedicated freezer, or to take space in existing freezer compartments. These bags of ice cubes also present problems for the consumer, in that it is necessary to open the entire bag each time a single ice cube is required, and it is often the case that the individual ice cubes begin to stick to one another over time, being in direct contact with one another. Both of these solutions also entail an electrical requirement for the manufacturer, transporter and retailer, which is therefore an additional cost to be met by the retailer.

It is therefore an object of the present invention to overcome these and other problems by providing a container which defines a plurality of discrete compartments within which individual portions or doses of a substance, composition or other consumable product may be stored.

Summary of the invention

According to a first aspect of the present invention there is provided a container comprising a tray defining an array of receptacles; wherein the tray is displaceable between an expanded state and a storage state.

Preferably, when in the expanded state the tray defines a substantially planar array of the receptacles.

Preferably, each receptacle comprises a mouth which is outwardly accessible when the tray is in the storage state.

Preferably, each receptacle is shaped and dimensioned to permit the tray to be displaced into the storage state with substantially no contact between and/or deformation of the receptacles when in the storage state.

Preferably, each receptacle is tapered between the mouth and a base of the receptacle, in order to facilitate displacement into, and retention in, the storage state. Preferably, each receptacle is substantially frusto-conical in cross section.

Preferably, the container comprises a fluid impermeable barrier securable over a mouth of each receptacle to seal the receptacles.

Preferably, the fluid impermeable barrier comprises fluid impermeable material fixed across the mouths of the receptacles.

Preferably, the receptacles are arranged in a substantially rectangular array.

Preferably, the fluid impermeable barrier comprises a plurality of elongate fluid impermeable strips individually removable from the tray.

Preferably, the container comprises securing means for securing the tray in the storage state.

Preferably, the securing means comprises cooperating couplings disposed along at least part of opposed edges of the tray.

Preferably, the cooperating couplings comprise a tongue and a groove.

Preferably, the tray, when in the storage state, defines a three dimensional shape.

Preferably, the tray, when in the storage state, defines a curvilinear three dimensional shape.

Preferably, the tray, when in the storage state, is substantially cylindrical in form.

Preferably, the container comprises at least one end cap locatable in or about an open end of the storage state cylindrical tray.

Preferably, the container comprises an outer body into which the tray is locatable when in the storage state.

Preferably, the outer body comprises a substantially cylindrical sleeve. Preferably, the tray comprises a frame with which the plurality of receptacles are individually releasably engagable.

Preferably, the frame defines a plurality of sites, the tray and/or receptacles being adapted to releasably retain one of the receptacles at each of the sites.

According to a second aspect of the present invention there if provided a method of manufacturing a product filled container, the method comprising the steps of; providing a tray in a deployed state, the tray defining a plurality of receptacles; filling at least some of the receptacles with the product; sealing each receptacle; and displacing the tray into a storage state.

Preferably, the method comprises displacing the tray into the storage state such that a mouth of each of the receptacles is outwardly accessible when the tray is in the storage state.

Preferably, the method comprises displacing the tray into the storage state with substantially no contact between and/or deformation of the receptacles when in the storage state.

Preferably, the method comprises, in the step of sealing each of the receptacles, securing a fluid impermeable barrier over a mouth of each receptacle.

Preferably, the method comprises manufacturing the tray such that each receptacle is separable from adjacent receptacles.

Preferably, the method comprises manufacturing the tray with lines of weakness separating each receptacle from the adjacent receptacles.

Preferably, the method comprises the step of securing the tray in the storage state. Brief description of the drawings

Figure 1 illustrates a perspective view of a container according to an embodiment of the invention, in a deployed state;

Figure 2 illustrates a plan view of the container of Figure 1 ;

Figure 3 illustrates a sectioned side elevation of the container of Figures 1 and 2;

Figure 4 illustrates perspective view of the container of Figures 1 to 3 when displaced into a storage state;

Figure 5 illustrates a sectioned end elevation of the container of Figure 4;

Figure 6 illustrates an enlarged view of a portion of the container shown in Figure 5;

Figure 7 illustrates the container of Figure 4 with a pair of end caps secured thereto;

Figure 8 illustrates a side view of the container of Figure 7, showing a pair of ice cubes being released therefrom;

Figure 9 illustrates a method of forming, filling and sealing the container of the embodiment illustrated in Figure 1 ;

Figure 10 illustrates a schematic plan view of an alternative embodiment of an ice cube container according to the present invention;

Figure 1 1 illustrates a perspective view of a corner portion of a further alternative embodiment of a container according to the present invention. Detailed description of the drawings

Referring now to Figures 1-9 of the accompanying drawings there is illustrated a container, generally indicated as 10, which for the purposes of the following description will be described when used as an ice cube container. However, it will be appreciated that the container 10 of the invention could be used to store any number of products or substances, in particular consumable products, and for example individual doses of health and beauty products such as shampoo, mouth wash, washing powder/liquid, food stuff or other products such as pharmaceuticals or the like. These products may be in solid, liquid, or gaseous form, and could be powdered, granulated, gel/paste and combinations thereof.

When the container 10 is being used as an ice cube container it is generally intended to be distributed to consumers pre-filled with liquid, preferably water, for subsequent freezing, for example in a domestic freezer or the like, to produce ice cubes. It should be noted that throughout the following description the term "ice cube" is used to denote both frozen portions of water, in addition to other liquids, for example soft drinks, spirits, etc. Thus the use of the term "ice" is intended to refer to a frozen liquid, and preferably frozen water.

The container 10 comprises a tray 12 which in the embodiment illustrated is substantially rectangular in shape, and contains a plurality of compartments or receptacles 14 for receiving individual portions of a liquid to be frozen into ice cubes. In the embodiment illustrated the receptacles 14 are arranged in a rectangular array of rows and columns, although it will be appreciated from the following description that the receptacles 14 could be arranged in any other suitable form. The tray 12 is adapted to be displaceable between a deployed state as illustrated in Figure 1 and a storage state as illustrated in Figure 4, which in the preferred embodiment illustrated is in the form of a substantially circular cylinder. The tray is preferably made from a polymer but could be formed from any other suitable material, for example aluminium foil, paper or the like.

The ability to be displaced between the deployed and storage states may be facilitated in a number of ways, for example by forming the tray 12 from a flexible material such as a thin walled plastic or rubber, or by providing one or more lines of weakness 15 between adjacent rows of receptacles 14, in order to allow the tray 12 to be folded from the flat deployed state illustrated in Figure 1 into the cylindrical storage state illustrated in figure 4. In addition, and as described in greater detail below, the receptacles 14 are preferably shaped and dimensioned to permit the tray 12 to be displaced into the storage state and to be retained therein, without resulting in deformation of the individual receptacles 14 in order to avoid damaging or distorting the contents of the receptacles 14.

Each receptacle 14 includes a mouth 16 formed in or defined by an upper surface of the tray 12, which provides access to each of the receptacles 14 in order to allow same to be filled with, in the present case, a liquid. The receptacles 14 further comprise a base 18 opposed to the mouth 16, and in the embodiment illustrated tapered sidewalls 20, as illustrated in Figure 3, which provide the receptacles 14 with a truncated conic shape. Referring to Figures 4 and 5, the shape and dimension of each of the receptacles 14 allows the tray 12 to be folded or rolled into the cylindrical storage shape, without adjacent rows of receptacles 14 contacting or deforming one another. If the receptacles 14 did not taper between the mouth 16 and the base 18 it would not be possible to form the substantially cylindrical storage shape illustrated in Figures 4 and 5, or in order to do so it would be necessary to deform the receptacles 14, which is both undesirable and likely to result in difficulty extracting ice cubes from the receptacles 14 once the liquid contained therein is frozen. It will of course be appreciated that there are numerous alternative shapes for the receptacles 14 which will still allow the above-described functionality.

Referring back to Figure 3, in order to retain the unfrozen liquid within each of the receptacles 14, in particular when the tray 12 is in the storage state, sealing means in the form of a liquid impermeable sheet 22 are provided and preferably formed from plastic or the like. In the embodiment illustrated, the sheet 22 extends across the entire upper face of the tray 12, thereby sealing the mouth 16 of each of the receptacles 14. However individual sections (not shown) could be provided over each individual mouth 16.

As mentioned above the embodiment described and shown is primarily intended to be pre-filled^ith^~liquid^~W^~for^~example^~water; and the^~sheet^2 secured in place on the tray 12, for example using an adhesive, RF welding, or any other suitable means. However it is envisaged that the sheet 22 could be replaced by a flexible or otherwise deformable reversibly removable cover (not shown), allowing the tray 12 to be filled or refilled by the end user with a liquid of their choice. However as stated, in the embodiment illustrated the preferred arrangement is for the liquid impermeable sheet 22 to be irreversibly removable form the tray 12, whether in whole or in part. As a further preferred arrangement, the sheet 22 may be divided into an array of strips 24 which are individually removable, in whole or in part, from the respective row/column of receptacles 14 in order to expose either individual receptacles 14 or an entire row or column of receptacles 14, for example as shown in Figure 8. The strips 24 may be, during manufacturing, individually secured to the tray 12, or more preferably are formed by lines of weakness or perforations provided in the sheet 22 between adjacent rows/columns of receptacles 14, as described in greater detail below.

Referring now to Figure 6 the container 10 is preferably provided with securing means in the form of a pair of couplings which in the preferred embodiment illustrated are provided as a tongue 26 and a corresponding groove 28 on opposed longitudinal edges 30, 32 of the tray 12. In this way when the tray 12 is displaced into the storage state illustrated in Figures 4 and 5, the tongue 26 and groove 28 may be engaged with one another in order to retain the container 10 in the storage state. In addition, adhesive or RF welding or the like may be used to supplement the tongue and groove connection of the longitudinal edges 30, 32. In this way the tray 12 may be permanently fixed in the storage state. It will be appreciated that the tongue and groove 26, 28 may be replaced with any other suitable alternative.

Referring now to Figure 7, the container 10 may comprise one or two end caps 34 which are locatable about either free end of the container 10 when in the storage state illustrated. The end caps 34 serve both to provide stability to the container 10 in order to allow it to be stood in an upright position as illustrated, in addition to improving the aesthetic appeal of the container 10. The end caps 34 may be secured by any suitable means, for example using a press fit, adhesive, RF welding, or any other suitable means. In a particularly preferred arrangement, the tray 12 is dimensioned such that when in the storage state illustrated in Figures 7 and 8, the container 10 is equivalent in size to a conventional 1.5 litre or 2 litre bottle, for example as used for mineral water, soft drinks or the like. In this way, existing infrastructure such as crates, transport means, and shelving for example in retail outlets or the like can be used for the transport and storage/display of multiple units of the container 10. This is particularly advantageous for storage and display of the container 10 at retail outlets, where it can be positioned alongside bottled mineral water and soft drinks, thus improving the likely sales of the product. In addition, the fact that the water W or other liquid is sealed into each of the receptacles 14 allows the ice cube container 10 to be stored on conventional shelving as it does not require a freezer compartment, the consumer being responsible for freezing the contents of the container 10. It will of course be appreciated that the container 10 could be of any other size, for example corresponding in size to a 0.25 litre or 0.5 litre bottle, or any other desired size. This is particularly relevant when the container 10 is being used to store other products, for example pharmaceuticals or the like. In such a situation it is envisaged that each receptacle could be filled with a single tablet (not shown) or individual dose of a pharmaceutical, and the receptacles 14 and therefore overall container 10 could be relative small in size. It is also envisaged that for such applications, the receptacles 14 and/or sheet 22 could be provided with markings such as calendar markings indicating for example days of the week and/or "morning", "afternoon", "evening". The sheet 22 could also be in the form of a foil covering allowing the contents of the individual receptacles 14 to be pressed out in convention blister pack style.

Referring now to figure 9, there is illustrated one preferred method of manufacturing the ice cube container 10 according to the preferred embodiment illustrated in Figures 1-8. Figure 9a shows the tray 12 being moulded from a flat sheet of material, whereby a mould M is pressed into the sheet of material to form the tray 12 in conventional fashion. The mould M may be heated, or the sheet forming the tray 12 may be heated in order to allow the receptacles 14 to be formed therein. Figure 9b shows the moulded tray 12. Figure 9c shows a number of nozzles N filling each of the receptacles 14 with the liquid W, for example water. It should be noted that if the tray 12 is arranged to be displaced into, for example, a cone or bullet shape or the like, that the receptacles 14 at different positions on the tray 12 will be of different dimensions and therefore have different liquid capacities. It may then be necessary to modify the filling process from the nozzles N, in order to ensure that each receptacle receives the correct amount of liquid W to achieve the correct fill.

Figure 9d shows the sheet 22 being located onto the tray 12 in order to seal each of the receptacles 14, in order to prevent leakage of the liquid W contained therein. Figure 9e shows an array of knives K, the tip of each of which may or may not be heated or serrated, piercing the sheet 22 between each row of receptacles 14 in order to form the individual strips 24. At this point the formed, filled and sealed container 10 is ready for shipping to retail outlets or the like. The container 10 may be shipped in the flat deployed state illustrated in Figure 9e, or may prior to shipping be displaced into the storage state, for example as illustrated in Figure 7, and the pair of end caps 34 may be fitted thereto.

Referring now to Figure 10 there is illustrated an alternative embodiment of a container according to the invention, generally indicated as 1 10. In this alternative embodiment like components have been accorded like reference numerals, and unless otherwise stated perform a like function. The container 1 10 is illustrated in schematic form, and in the deployed state, with a tray 1 12 of substantially rectangular shape. While forming part of this embodiment, receptacles (not shown) are not illustrated in the schematic representation, simply for clarity. However what is shown is that one or more portions P of the tray 12 may either be removed or omitted from the tray 1 12, or a concertina/collapsible/compressible type section substituted therefore. The configuration shown in Figure 10, having four portions P of the tray 112 either omitted or collapsible, allows the tray 112 to be displaced from the deployed state illustrated to a storage state in which the tray 1 12 will take on a substantially prolate spheroid shape, similar to a rugby ball. Similar modifications could be made to the tray 1 12, again either by omitting portions thereof or redesigning the overall shape of the tray 1 12, in order to achieve other desired three dimensional, in particular three dimensional curvilinear, shapes when displaced into the storage state, for example spherical, conic, cuboidal, bullet shaped or the like.

In general, the process for displacing the tray 12; 112 from the deployed to the collapsed or storage state involves rolling up the tray 12; 1 12 such that opposed free edges touch or are in close proximity, essentially forming a tube or cylinder with the tray 12; 1 12. It will however be appreciated that other processes of displacing between the deployed and collapsed states may be employed, such as folding one or more sections of the tray 12; 112. It can also be seen that when the container 10; 110 is in the storage state that the mouth 16 of each of the receptacles 14 is outwardly accessible by the consumer when the container 10; 110 is in the storage state. Thus there is no requirement to displace the container 10; 1 10 back into the expanded state in order to access and remove an ice cube or other dose/unit from the respective receptacle 14, as every receptacle 14 is accessible when the container 10; 1 10 is in the storage state. The container 10; 1 10 may also comprise an outer sleeve (not shown) into which the tray 12; 1 12 is located when in the storage state, and which may be used to retain the tray 12; 1 12 in addition to provide a surface on which to print branding or other advertising information. The sleeve (not shown) is preferably shrunk wrapped around the tray 12; 1 12 as part of the manufacturing process.

Referring now to figure 1 1 there is illustrated a further alternative embodiment of a container according to the invention, generally indicated as 210. In this further alternative embodiment like components have been accorded like reference numerals and unless otherwise stated perform a like function. Figure 11 shows only a corner portion of the container 210, which again comprises a tray 212 defining a plurality of receptacles 214 in which consumable products or the like may be stored. Unlike in the previous embodiments the receptacles 214 are not formed integrally with the tray 212 and are removable, preferably reversibly removably, from the tray 212 in order to allow the consumer to take away individual receptacles containing a single dose of the product/substance therein, as will be described in detail hereinafter.

The tray 212 therefore comprises a frame 213 defining a plurality of sites in the form of apertures 215 within each of which one of the receptacles 214 may be cradled and retained. In figure 11 the receptacle 214 is shown partially separated from the tray 212, as would be the case when that receptacle 214 is being separated and removed from the tray 212. An empty aperture 215 is also illustrated, from which a receptacle (not shown) has been previously removed. In the embodiment illustrated each receptacle 214 comprises an open mouth 216 around which is defined a lip 217 which is dimensioned to be seated against the rim of the aperture 215, in order to prevent the receptacle 214 from passing completely through the frame 213. Securing means (not shown) may be provided for securing each receptacle 214 to the tray 212 once fully seated within the respective aperture 215. For example, one or more frangible elements (not shown) could be provided between the frame 213 and the receptacle 214, which could then be easily broken by the consumer in order to allow the receptacle 214 to be removed from the frame 213. Similarly an adhesive or the like could be used to secure each of the receptacles 214 in position on the frame 213. Each receptacle 214 is therefore preferably provided with a discreet cover or seal (not shown) provided across the mouth 216, in order to seal the interior of the receptacle 214, such as to retain the contents therein. A user can therefore simply remove one or more of the receptacles 214 from the container 210, each of which will then contain a unit dose of for example, shampoo, mouthwash or the like. This allows a user to bring individual doses of the product, without having to bring the entire container 210. This will allow the consumer to travel on flights, to the gym, or simply have one or more of the receptacles 214 in a hand bag or the like instead of carrying bulky bottles or other packaging. Once all of the receptacles 214 have been removed from the container 210 the user is simply left with the empty frame 213.

It will be appreciated that the container 10; 110 of the previous embodiments could be adapted to provide similar functionality, by forming the tray 12; 112 such that each receptacle 14 can be individually removed therefrom. This could be achieved in a number of ways, for example by separating each receptacle 14 from adjacent receptacles 14 by perforated lines of weakness, allowing a receptacle to be separated from the tray 12; 112. When such as arrangement is employed it is preferred that each receptacle 14 is provided with a individual cover or seal across the mouth 16 thereof.

Claims

1. A container comprising a tray defining an array of receptacles; wherein the tray is displaceable between an expanded state and a storage state.

2. A container according to claim 1 which, when in the expanded state the tray defines a substantially planar array of the receptacles.

3. A container according to claim 1 or 2 in which each receptacle comprises a mouth which is outwardly accessible when the tray is in the storage state.

4. A container according to any preceding claim in which each receptacle is shaped and dimensioned to permit the tray to be displaced into the storage state with substantially no contact between and/or deformation of the receptacles when in the storage state.

5. A container according to any preceding claim in which each receptacle is tapered between the mouth and a base of the receptacle, in order to facilitate displacement into, and retention in, the storage state.

6. A container according to any preceding claim in which each receptacle is substantially frusto-conical in cross section.

7. A container according to any preceding claim comprising a fluid impermeable barrier securable over a mouth of each receptacle to seal the receptacles.

8. A container according to claim 7 in which the fluid impermeable barrier comprises fluid impermeable material fixed across the mouths of the receptacles.

9. A container according to any preceding claim in which the receptacles are arranged in a substantially rectangular array.

10. A container according to any of claims 7 to 9 in which the fluid impermeable barrier comprises a plurality of elongate fluid impermeable strips individually removable from the tray.

11. A container according to any preceding claim comprising securing means for securing the tray in the storage state.

12. A container according to claim 12 in which the securing means comprises cooperating couplings disposed along at least part of opposed edges of the tray.

13. A container according to claim 12 in which the cooperating couplings comprise a tongue and a groove.

14. A container according to any preceding claim in which the tray, when in the storage state, defines a three dimensional shape.

15. A container according to any preceding claim in which the tray, when in the storage state, defines a curvilinear three dimensional shape.

16. A container according to any preceding claim in which the tray, when in the storage state, is substantially cylindrical in form.

17. A container according to any preceding claim comprising at least one end cap locatable in or about an open end of the storage state cylindrical tray.

18. A container according to any preceding claim comprising an outer body into which the tray is locatable when in the storage state.

19. A container according to claim 18 in which the outer body comprises a substantially cylindrical sleeve.

20. A container according to any preceding claim in which the tray comprises a frame with which the plurality of receptacles are individually releasably engagable.

21. A container according to claim 20 in which the frame defines a plurality of sites, the tray and/or receptacles being adapted to releasably retain one of the receptacles at each of the sites.

5

22. A method of manufacturing a product filled container, the method comprising the steps of; providing a tray in a deployed state, the tray defining a plurality of receptacles; filling at least some of the receptacles with the product; 10 sealing each receptacle; and displacing the tray into a storage state.

23. A method according to claim 22 comprising displacing the tray into the storage state such that a mouth of each of the receptacles is outwardly accessible when the tray is in the

15 storage state.

24. A method according to claim 22 or 23 comprising displacing the tray into the storage state with substantially no contact between and/or deformation of the receptacles when in the storage state.

20

25. A method according to any of claims 22 to 24 comprising, in the step of sealing each of the receptacles, securing a fluid impermeable barrier over a mouth of each receptacle.

26. A method according to any of claims 22 to 25 comprising manufacturing the tray 25 such that each receptacle is separable from adjacent receptacles.

27. A method according to claim 26 comprising manufacturing the tray with lines of weakness separating each receptacle from the adjacent receptacles.

30 28. A method according to any of claims 22 to 27 comprising the step of securing the tray in the storage state.