Note: Descriptions are shown in the official language in which they were submitted.
-
4869-51U5
- 1 ' 21~8165
. ~
OUTER CONTAINER ~AVING A CONT~INER INSERT
T~EREIN FOR EnT~n~G ~ , N~ VO~:~TTMT'' QF M~T7;!T~r.7~T,
Cross-~ç:ee~qnce ~o Related AT~TJlication
This application is a rnnt;nll~tion-in-part of
co-pending application Serial No. 08/127,399 filed
September 27, 1993, which is a ~-nnt;nl~tion-in-part of
co-pending application Serial No. 07/959,513, filed
October 13, 1992, now U.S. Patent No. 5,315,811, which is a
continuation of application Serial No. 07/756,~09 filed
September 9, 1991, ~ nrlnnPd, which is a divisional of
application 5erial No. 07/707,489 ~iled May 30, 1991, now U.S.
Patent No. 5,197,602.
Field o~ the InveIltion
The present invention relates to packaging a
predetermined volume of material and, more particularly, to a
container insert for holding a predetermined volume of
material within an outer cnnt~; nPr~ :
Back~Tround ~ the Inve~tiQn _ _~
In order to decrease the cost and increase the
efficiency of packaging materials, it would be useful to have
cnnt;~nPr8 of uniform outer dimengions which allow for
packaging of different predetermined volumes of material. For
example, a typical pharmaceutical manufacturer may package
dif~erent quantities of a product for shipment to retail
25 pharmacies in correspondingly sized different cnnt~nPrs. The
manu~acturer may decide to ship a product in two or three
differe~t quantities (e.g., 50 or 200 ta~lets) in two or three
different sized nnt~;nPrS. The tablets or pills to be
shipped may contain dif~erent dosages of medication (e.g., 30
30 mg, 100 mg, etc. ) . The tablets may be sized or shaped
l~iZZ7 . 1
.
-- 2
217gl6~
differently. Each of these factors, and other factors too
numerous to mention, may affect the volume of material to be
packaged in an individual bottle. A manufacturer may,
therefore, need a series of bottles having different interior
volumes to accommodate the disparate volumes of material to be
packaged. Each series of bottles may have different exterior
dimensions and configurations, thereby re~uiring different
equipment lines for packaging and labelling the bottles.
It would be advantageous for a manufacturer to have
available cr)nti~;nors of uniform outer dimension and
configuration in order to standardize systems for filling,
closing, and labelling each bottle and rendering tamper-proof
the bottle closures The size of dispensing and shipping
cartons and the packaging system therefor may also be
standardized.
In addition, it would be advantageous for a
manufacturer to have available a cont~;n~r at least partially
f ormed f rom recycled materials in order to lessen container
cost and to help preserve the environment. E~owever, in areas
- 20 where r~nt~m;ni~tion of the packaged material is of concern, it
is desirable that the recycled portion of the ront~;n,~r not
contact the packaged material . t ont~m; n~tion of the packaged _
material is particularly undesirable in the pharmaceutical
industry, where product integrity is imperative.
Cont~;nPrs suffer from other problems inherent in
their design. For example, containers of certain shapes are = :~
easily tipped over, thereby jostling or spilling the content8.
Tightly closed ront~;n~rs lock in odors given off by the
contents. ~ikewise, odors given off by the conti~;nPr material
may be absorbed by the rnntf~nt~. If odor affecting or odor
controlling substances are placed in the cont~;n.or, the
substances will directly contact the cont~;nf~r rontPnt~ If a
premium item is desired to be delivered with the container,
the item must be placed in the cont~;n~r where it will contact
the ~-~nt~nt~ To prevent light or ultraviolet radiation from
impinging on the r"nt;,;nF-r contents, the ~ ont~;n~r must be
_ 3 _ 2178165
made opar~ue or impervious to ultraviolet radiation. However,
the colors and materials which must be employed to make the
container opaque or impervious to ultraviolet radiation may
clash with marketing considerations for the preferred
5 appearance of the contAinpr. Coloring containers increases
their m-n7lf;7rtl7ring cost because of the co~t of the colorant
and the additional manufacturing steps re-~uired to color the
raw material (typically, plastic).
The present invention fulfills a long-felt need in
the art by overcoming the aforementioned disadvantages of the
prior art rf7ntAinPrs and providing other advantages as set
forth below.
S7~mma-~f of the Invention
The present invention comprises a container for
holding a material. In one embodiment of the invention, the
container comprises an outer container, a container insert and
a mass. The contAinp~ insert is positioned within the outer
rontA;nPr. A wall of the ront_7inP~ in7ert is ~ecured to a
wall of the outer ront 7;nPr. A mas~ posltioned within the
contA;nPr in a space between the insert and the outer ~-
container. The mass stabilizes the ront;7;nPr in an upright
position .
In another embodiment of the invention, the
ront;7inP~ comprises an outer rontA;nPr, a container insert and
an odor affecting substance. The rnnt;7;nPr in7ert is
poiiitioned within the outer cont;7;nP~. A wall of the
container insert i~ secured to a wall of the outer container.
The odor affecting substance is positioned within the
container in a space between the insert and tae outer
rnntA;nPr The space is in fluid ro-777~n;cation with the
interior of the rontA;nPr insert 70 that when the r- nt;7;nP~ i~
capped, the odor affecting substance alters the odor of the ~ _
material in the interior portion of the insert.
In another embodiment of the invention, the
rontAinPr comprises an outer rr~ntA;nP~ and a cf-nt-7;nPr insert
217816~
-- 4
which is either opaque or clear. The rnnt~1nPr in3ert is
positioned within the outer rnnt~;nPr A wall of the
rnnt~;nPr insert is secured to a wall of the outer container.
In another embodiment of the invention, the
cnnt~;nPr comprises an outer cont~;nPr, a container in~ert and
an object such as a premium item. The container insert is
positioned within the outer rnnt~;nPr A wall of the
rnntil;nPr insert is secured to a wall of the outer cnnt~;npr
The object i3 positioned within the rnnt~;nPr in a space
between the insert and the outer container.
Brie~ DeacriPtion of the Drawinqs
The foregoing summary, as well as the following
~Pti~; 1 Prl description of the preferred embodiments of the
invention, will be better understood when read in conjunction
with the appended drawings. For the purpose of illustrating
the invcntion, there is shown in the drawings Pmhnrl;r^nts
which are presently preferred, it being understood, however,
that the invention is not limited to the specific methods and
instrumentalities disclo3ed. In the drawings:
Fig. 1 is a perspective view of an outer container
having a rnnt~;nPr insert in accordance with a first
embodiment of the present invention therein;
Fig. 2 is an exploded perspective view of the outer
rnntil;nPr and cnnt~;npr insert of Fig. l;
Fig. 3 is a cross-sectional view of the outer
container and cr~nti~;nPr insert of Fig. 1 taken along lines 3-3
of Fig. l;
Fig. 4 is an elevational view, partially in cross
section, of an outer rnnt~;nPr having a rnnt;~;nPr insert in
accordance with a second Pmhorl;mPnt of the invention therein;
Fig. 5 is an elevational view of the rnnt~;nPr
insert of Fig. 4;
Fig. 6 is a perspective view of a second outer -
rnnt;~;nPr having a second rnnt~;nPr insert therein, in
` ~ . 21~816~
-- 5
accordance with the first embodiment of the present invention
therein;
Fig. 7 is an elevational view, partially in cross
section, of an outer rnnt~;n,~r having a container insert in
accordance with a modified version of the second embodiment of
the invention therein, and also including a stabilizing weight
placed between the outer container and container insert;
Fig. 8 is a perspective view of a second outer ~ -
container having a second container insert therein, in
accordance with the f irst embodiment of the present invention
therein, the second outer container being partially broken
away to show a stabilizing weight between the outer rnnt~;nPr
and cnnt~;nPr insert;
Fig. 9 is a perspective view of a second outer
container having a second container insert therein, in
accordance with the f irst embodiment of the present invention
therein, the second outer rnntA;n~r being partially broken
away to show an odor affecting substance between the outer
rnnt~;nPr and container insert;
Fig. 10 is a perspective view of a sec~nd outer - -
cnnti~; nPr having a second container insert therein, in
accordance with the first embodiment o~ the present invention -
therein, and also including an odor affecting substance
located between the outer rnnt~;nPr and rnnt~;n~r insert;
Fig. 11 is a perspective view of a second outer
rnnt~;n~r having a second rnnt:~;nf~r insert therein, in
accordance with the first embodiment of the present invention
therein, the second outer rnnti~;n~or being partially broken
away to show a premium item between the outer container and
cnnt~;nPr insert;
Fig. 12 is a perspective view of an oparlue second
outer container having a clear second rnnt~l;n~r insert
therein, in accordance with the first embodiment of the
present invention therein, the second outer rnnt~;nPr being
partially broken away to show the clear second cnnti~;nPr
insert; and
- 6 - 21 781 65
Fig. 13 18 a perspective view of a clear second
outer rnnti~;nPr having an opaque second rnn~;nPr insert =:
therein, in accordance with the f irst embodiment of the
present invention therein.
Detailed Desqription of Preferred ;r ' ~'~ ts
Referring to the drawings, wherein like numerals
indicate like elements throughout, there is shown in Figs.
through 3 and 6 an outer rnnt~;nPr, generally designated 10,
having a rnnt~;nPr insert 12 therein for holding a
predetPrm; nP-l volume of material (not shown), in accordance
with a first embodiment of the present invention.
The outer cnnt~;npr 10 comprises a container bottom
14 having a periphery 16 and a rnnt~;nPr wall 18 extending
generally upwardly from the periphery 16. It is preferred
that the cnnti~;nPr bottom 14 be generally planar, although the
bottom 14 may be concave ~see Fig. 4). The periphery 16 of
the cn~t~;nPr bottom 14 may be slightly rounded to eliminate
any sharp edges from the container 10. Preferably, the
rnnt~;nPr ~ottom 14 and cnn~;npr wall 18 define an outer
rnnt~;nPr 10 which is generally annular in cross section,
although the outer rrnt~;nPr 10 may be of any shape such as
generally rectangular in cross section, as one of ordinary
skill in the art would understand.
As best shown in Figs . 2 and 3, the cnnt~; nPr bottom
14 and the cnnti~;npr wall 18 define an interior rnnt~;nPr
portion, generally indicated at 2 0, having a predetermined
volume. The intPr;rr rnnt~;nPr portion 20 is sized to
accommodate the rnnti~;nrr insert 12, as described in more
detail hereinafter. The container wall 18 comprises a neck
portion 22 defining an opening, indicated generally at 24, for
receiving the rrnt~1nPr insert 12 therein. Preferably, the
opening 24 in the neck portion 22 is generally circular in
cross section and has a diameter which is smaller than the
inner ~ nPtPr of the cnnt~inPr wall 18. The neck portion 22
includes a transition surface or shoulder 25 between the neck
2~7816~
-- 7 --
-. portion 22 and cnnt~inpr wall 18. The shoulder 25 is
preferably curved to eliminate sharp edges and increase
structural integrity. The neck portion 22 has an interior
surface 26 complementarily sized to accommodate an exterior
surface 28 of the ~nnt~;nPr insert 12 for securely fixing the
container insert 12 within the interior container portion 20,
as described in more detail hereinafter. The interior surface
26 is preferably generally textured to reduce the surface area ~-
of the interior surface 26 and friction between the interior
surface 26 and the exterior surface 28 when the cnnt~;nPr ==~-=
insert 12 is positioned within the outer container 10, as is
also described in more detail hereinafter.
As best shown in Fig. 3, it is preferred that the
interior surface 26 of the neck portion 22 include a lip 54
P7~tPn(l; ng radially inwardly along the upper end thereof for
preventing the insert 12 from being removed from the interior
container portion 20. That is, the insert 12 is ;n;t;;~lly
positioned within the outer container 10 with a snap fit. The
lip 54 prevents the insert 12 ~rom moving upwardly out of the
outer container 10. The neck portion 22 has an exterior
surface 30 which preferably includes threads 32 for receiving
a cap tnot shown). One skilled in the art would understand
that other means besides threads 32 may be used to accommodate
the cap, such as a friction fit or a child-proof fastener (not
shown). In addition, any gap between the cap and the opening
24 of the neck portion 22 may be sealed by a sheet of
material, such as plastic, in order to inhibit tampering, as
is well known by those of ordinary skill in the art.
As best shown in Figs. 2 and 3, the present
invention further comprises a .nnt~;nPr insert 12 positioned
within the interior ,nnt~;nPr portion 20 of the outer
rnnt 2;nPr 10. The rnnt;~;nPr insert 12 comprises a bottom 34
having a periphery 36 and a wall 38 extending generally
upwardly from the periphery 36. Presently, it is preferred
that the bottom 34 and wall 38 of the cont~;npr insert 12
define a cnn~;npr in3ert 12 which is generally annular in
21 7~
-- 8
cross section, although one skilled in the art would
understand that the shape of the cnnt~;n~r insert 12 may be
generally rectangular in cross section, or any other
compl PmF~nt~ry shape which may be accommodated within the
interior rm~nt~inrr portion 20 and neck portion 22 of the outer
cr~nti~inrr 10, in keeping with the spirit and scope of the
present invention.
The bottom 34 and the wall 38 of the r~ntA1nPr
insert 12 def ine an interior portion, generally indicated at
40, of predetermined volume for holding the predetermined
volume of material. The predetermined volume of the interior
portion 40 of the insert 12 shown in Fig. 1 is less than the
predetermined volume of the interior rt~nti~inf~r portion 20 of
the outer cf~nt~in~'r 10 In Fig. 6 there is shown a second
outer container 10, which is generally identical to the outer
cnnt~inPr 10 shown in Fig. 1, having a second container insert
12 therein. The predetermined volume of the interior portion
40 of the second insert 12 shown in Fig. 6 is less than the :
predetermined volume of the interior rr~nt:: ;n~r portion 20 of
the outer ~rnti~;nf~r 10 as well as the predetermined volume of
the interior portion 40 of the insert 12 shown in Fig. 1.
As best shown in Fig. 2, the wall 38 comprises an
upper portion 42 spaced apart from the bottom 34. The upper
portion 42 defines an opening, indicated generally at 43, for
receiving the material to be packaged. A8 shown in Fig. 3, ~~
the upper portion 42 has an exterior surface 44 in facing
engagement with the interior surface 26 of the neck portion
22. Preferably the exterior surface 44 and interior surface
26 are securely engaged together by a friction fit, although
one skilled in the art would understand that other means, such
as adhesive or fasteners, may be used to m~;nt~;n the surfaces
44, 26 in engagement. The surfaces 44, 26 are aligned such
that the top edge of the exterior surface 44 is in ~ eLlt
with the lip 54, as best shown in Fig. 3. The upper portion
42 has a height which corresponds to the height of the neck
portion 22 of the outer rmnt::l;nF~r 10.
` ~ 217816~
The cont~;npr insert 12 preferably includes vent
means in the exterior surface oi the wall 38 for allowing
fluid, such as air, to pass from the interior cont~inpr -= -
portion 20 to the atmosphere when the cont~;npr insert 12 is
5positioned within the outer ront~;nf~r 10.
In the first embodiment, the vent means preferably
includes four grooves 46 in the exterior sur~ace of the wall
38 of the insert 12, each groove 46 having a first end 48 and
a second end 50. Because of the arcuate periphery of the lip
1054, the first end 48 of the grooves 46 is in fluid
communication with the atmosphere surrounding the outer
container 10 and the insert 12. The second end 50 of the
grooves 46 is in fluid ~:~ ; ration with the interior
ront~;nPr portion 20 of the outer ronti:l;nPr 10 for allowing
15fluid, such as air, to pass through the grooves g6 from the
interior ront~;nPr portion 20 to the atmosphere when the
cont~;nPr insert 12 is positioned within the outer ront~inPr
10 .
Preferably, the second end 50 of the grooves 46
20extends to the periphery 36 of the bottom 34, such that the
grOQVeS 46 extend the length of the insert 12. Therefore, as
the insert 12 is positioned within the interior container =
portion 2 0, the interior container portion 2 0 is in continuing
~luid r~lmTm~n; r~tion with the ~,u--~ullding atmosphere to allow
25air within the interior ront~;nf~r portion 20 which is
displaced by insertion of the insert 12 to pass to the
atmosphere .
A skilled artisan understands that the grooves 46
may be of any length sufficient to span the exterior surface
3044 of the upper portion 42 of the ~ont;l;nf~r insert 12. The
width of the grooves 46 may be any width sufficient to allow
the air within the interior container portion 20 to escape to
the atmol phere without impeding insertion of the insert 12 .
However, a sufficient portion of the exterior surface 44 must
35remain to ensure sufficient contact between the exterior
surface 44 of the upper portion 42 and interior surface 26 of
lO - 21 781 S~
the neck portion 22 to maintain the desired friction fit. One
skilled in the art would understand that any number of grooves
g6 may be provided in the wall 38 of the container insert 12
including one, two or six. Presently, it is preferred that
the four grooves 46 be formed equidistantly around the
exterior surface 44, although they may be randomly placed
thereabout .
It is understood by those skilled in the art that
other vent means may be provided in the rnnt~;nPr insert 12 or
outer container 10 for allowing air to pass from the interior
rnnti~;nPr portion 20 to the surrounding atmosphere. For
instance, an opening (not shown) can extend through the wall
3 8 of the insert 12 or the wall 18 of the outer container 10
for allowing fluid to pass therethrough between the interior -
cnnt~inPr portion 20 and the atmosphere without departing from
the spirit and scope of the invention.
Preferably, at least one of the insert 12 and the
outer rnnt~;nPr 10 is constructed of a thermoplastic, such as
a high density polyethylene or polypropylene. For
pharmarP-ltir~l applications, it is preferred that the insert
12 and outer rnnt~inPr 10 be formed from virgin material to
inhibit rnnt~m;n~t;nn of the material to be packaged therein.
However, one skilled in the art would understand that the
insert 12 and outer rnnt~inPr 10 may be formed from any
suitable material, such as glass. It is preferred that the
outer container 10 be formed from an injection-blow moldable
material which contracts upon cooling to ambient temperature
in order to maintain the friction fit between the exterior : -
surface 44 o~ the insert 12 and the interior surface 26 of the
outer cnnt~;npr 10, as described in more detail hereinafter.
Referring now to Figs. 4 and 5, there is shown a
second embodiment of an outer rnnt~;nPr 10 and rnnt~;nPr
insert 12. The outer rnnt~inPr 10 is generally identical to .
the outer ,-nnt~inPr described above in connection with the
f irst embodiment shown in Figs l through 3 . Similarly, the
rnnt~inPr insert 12 is generally identical to the cnnti~inPr
217~16~
-- 11 --
insert 12 described above in connection with the f irst
embodiment, except that the upper portion includes a flange 60
PYtPn~l;ng generally radially outwardly a distance sufficient
to substi~nt; ~l l y overlap an upper edge 56 of the neck portion
5 22.
As best shown in Fig. 5, the exterior surface of the
rnnti~;nPr insert 12 include~ a complementary groove 58 just
below the flange 60 for receiving the lip 54 of the neck
portion 22 to assist in securely locking the rnnt~; nPr insert
10 12 within the outer container 10. In order to allow the air
within the interior container portion 20 to escape to the
atmosphere, the grooves 46 extend to the periphery of the
f lange 6 0 .
Since the cnnt~;~Pr insert 12 includes a flange 60,
15 the material to be packaged does not contact the outer
container 10 during packaging and dispensing. Therefore, in
the second embodiment, it is preferred that the outer
container 10 be formed fro;n a recyclable material, such as
plastic. In the pharmaceutical industry, where maintaining
20 product purity is imperative, it is particularly desirable
that the recycled portion of the cnnt~;npr not contact the
packaged material.
In the present invention, the portion of the
container insert 12 which receives the material to be packaged
25 is insulated from the outer rnnt~;nPr 10 by the wall 38 of the
cnnt~;nPr insert 12 and an air barrier or space 61 between the
cnnti~inPr ingert 12 and the outer container 10 which prevents
rnntAni n~tion of the park~rP~ material as a result of contact
with the recycled outer rnnt:~inPr 10. Thus, the second
3 0 embodiment is advantageous because recycled plastic is
generally less costly than virgin plastic and is beneficial to
the environment.
The method according to the present invention f or
assembling the outer rnnt~inPr 10 having a container insert 12
35 therein will now be described generally. The following
description of the method of assembly, while directed to the
- 12 - 21 781 6~
. first embodiment, is er~ually applicable to the second
embodiment .
With reference to Fig. 2, the method comprises the
initial steps of forming the outer rr>ntA~nPr 10 and rnntA;nPr
insert 12. The rnn~A;nPr 10 and insert 12 are preferably
formed by injection-blow molding, although other molding
processes, such as extrusion blow molding or injection
molding, may be used. It i8 preferred that the portion of the
mold (not shown) which forms the interior surface 26 of the
neck portion 22 be sandblasted with 30 grit ~ m; nllm oxide at
a pressure of 3 0 psi . and then be chrome plated. Thi~ results
in the interior surface 26 being generally textured such that
it has a plurality of minute pits and projections 26a. While
it is preferred that 30 grit Alllm;nllm oxide at a pressure of
30 psi. be used, it is under~tood by those skilled in the art
that other grit sizes, materials and/or pressures could be
used to achieve the generally textured surface without
departing from the spirit and scope of the invention.
It was found that if the interior surface 26 of the
neck portion 22 and the exterior surface 44 of the upper
portion 44 were formed to be generally smooth, during the
process of inserting the container insert 12 into the outer
container 10 from ten to eleven percent of the assembled
product would be unusable. More particularly, even with the
venting, the relatively high degree of friction between the
interior and exterior surfaces 26, 44 during insertion of the
rnntAinrr insert 12 often resulted in the interior and
exterior surfaces 26, 44 her- ;nrJ bound together before the
rnntA;nr-r insert 12 is entirely positioned within the outer
rnntA;nPr 10 causing the shoulder 25 to collapse due to the
force o~ the assembling device ~not shown) .
~3y molding the interior surface 26 to be generally
rough, the surface area of the interior surface 26 which
engages the exterior surface 44 is reduced resulting in less
~riction between the interior and exterior surfaces 26, 44
during insertion of the cont~;nr-r insert 12 into the outer
2I 7~I 6~
-- 13
container 10. With less friction between the interior and
exterior surfaces 26, 44 the problem of collapsin~ the
shoulder 25 during assembly is obviated.
While it is preferred that the interior surface 26
be generally rough to reduce friction during assembly, it is
understood by those skilled in the art that only the exterior
surface 44 could be generally rough or both the interior and
exterior surfaces 26, 44 could be generally rough, without
departing from the spirit and scop~ of the invention.
To aid in the removal of the cn~t~;npr insert 12
during the molding process, the exterior surface 44 of the
container insert 12 includes a second groove 52 to provide a
gripping surface. In addition, the lip 54 of the outer =_
container 10 also provides a gripping surface to facilitate
removal of the heated outer ~nnt;3;n~r 10 from the injection
molding apparatus. Xowever, it is understood by those skilled
in the art that the present invention is not limited to any
particular method of removing the container insert 12 or=
~nnt;l;nPr 10 from the injection blow molding apparatus and
that other methods could be used without departing from the
spirit and scope of the i~vention.
Next, the temperature of the ,-nnt~inPr insert 12 is
controlled such that the container insert 12 is at a f irst
predet.orrn;nPr~ temperature. Preferably, the step of
controlling the temperature of the ~nnt~;nPr insert 12
comprises cooling the ~rnnt~n~r insert 12 to the first
predetermined temperature after it has been formed. This
cooling may be affected by exposing the container insert 12 to
air at ambient conditions or by refrigeration. It is
preferred that the first predetermined temperature be ambient
temperature, generally between 50F to 80F, although one
skilled in the art would understand that the first
predetermined temperature may be any temperature which is less
than the temperature of the cnnt~;nPr 12, as discussed below.
The temperature of the outer r nnt~;nPr 10 is
controlled such that the outer ~nnt~;nPr 10 iS at a secorLd
~ 21781~5
- 14 -
predetermined temperature greater than the f irst predetermined
temperature of the rnntA;nPr insert 12. The elevated second
temperature is achieved when the outer rnnti~;nPr 10 is removed
from the injection molding apparatus, prior to significant
cooling. Preferably, the second predetPrm;np~i temperature is
between 100F and 150F. Xowever, it is understood by those
skilled in the art that the second predetPrrn; nPd temperature
of the outer rnntA;n~r 10 can be achieved by reheating the
outer container 10 by other means, such as an oven (not
shown), if the outer container 10 has cooled to a temperature
below 100F.
When the outer container 10 is at the second
predetermined temperature and the insert is at the first
predetermined temperature, the container insert 12 is
positioned through the opening 24 in the neck portion 22 into
the interior container portion 20 of the outer rrntA;nF.r 10
such that the exterior surEace 44 o~ the upper portion 42 is
initially in facing sliding engagement with the interior
surface 26 of the neck portion 22. The first end 48 of the
grooves 46 is in fluid communication with the atmos~here
surrounding the outer cnnt~;npr 10 and the second end 50 of
the grooYes 46 is in fluid communication with the interior
container portion 20 for allowing fluid, such as air, to pass
through the grooves 46 from the interior rrntA;nPr portion 20
to the atmosphere, as best shown in Fig. 3.
The outer rnntA;nPr 10 is cooled to a third
predetermined temperature less than the second predetermined
temperature such that the interior surf ace 2 6 of the neck
portion 22 contracts into tight engagement with the exterior
surface 44 of the upper portion 42 of the container insert 12,
whereby the rnnt~;n~r insert 12 is frictionally secured to the
neck portion 22. A8 the outer rnntAin~r 10 contracts, the
volume of the interior rnntA;n~r portion 20 decreases causing
air to pass through the grooves 46 to the surrounding
atmosphere.
21 78~ 65
-- 15 --
The method of packaging a predetermined volume of
material, such as pills, liriuids, or powders, by use of an
outer container 10 having a rrnt~;nPr insert 12 therein will
now be described generally.
The method generally comprises the initial step of
determining a volume of material to be packaged. This
determination need not involve the counting of individual
portions of material, such as tablets. However,
pharmaceutical products are preferably packaged by count. A
number of closely packed individual portions of material, such
as tablets, generally occupy a known volume even though there
may be small gaps between the tablets. This known volume
corresponds to the volume of material to be packaged. Where
the material to be packaged is f luid, such as a liquid or
powder, the volume of the material to be packaged is directly
ascertainable .
Next, the person who is packing the material selects
an outer rr~nti~;n~r 10 having a volume greater than the
detPrm;nP-l volume of material to be packaged and a r~nt~;nPr ~ -
insert 12 therein having an interior portion 40 of a
predetermined volume ~rom a group of outer c~)ntA;n.ors 10 with
r~nt~;nPr inserts 12 having predetermined volumes different
than the volume oi material to be packaged. Preferably, the
step of selecting an outer rrnt~;nPr 10 comprises selecting an
outer container 10 with a rnnti:l;nrr insert 12 therein having
an interior portion 40 of a predetermined volume which
corresponds to the volume of material to be packaged. By
choosing an appropriately sized container insert, the need for
cushioning material, such as cotton, to fill the unoccupied
3 o volume of the container may be reduced or altogether
eliminated without having different sized outer rr~nt~;nPrs
The material to be packaged is then inserted into
the interior portion 40 of the rrnt~;nPr insert 12.
Preferably, the step o~ inserting the material into the
interior portion 40 comprises inserting a number of individual
portions of material, such as tablets. However, a skilled
21~816~
- 16 -
artisan understands that a liquid or powdered material may be
similarly packaged. After the material to be packaged is
deposited into the container insert 12 the outer cnnt~l;nPr is
then sealed with a cap or the like. If the rnnti~;nPr insert
5 is 12 is employed for delivering a liquid material such as
nail polish, the cap (not shown) may include a brush for :
applying the material.
Using the oregoing method allows the manufacturer
to have a æmall number of differently sized rnnti:l;nPrS,
10 wherein the outer containers have differently sized rr,nt~;n.or
inserts therein. By reducing the number o different outer
rrnti~;nPrS, automatic packaging processes are simple and
ef f icient because the conveying system of the packaging
equipment does not have to be reset each time a change in
15 volume occurs. Moreover, the number of diferent shipping
cartons and labels is significantly reduced.
It is understood by those skilled in the art that
all of the aforementioned steps may be carried out by an
individual person or automatically, as by a robotic assembly
line.
The combination of an outer container 10 having a
r~nt~;nPr insert 12, the combination being referred to
hereafter as cnnt~;nPr 62, provides an ideal packaging medium
for solving many problems inherent in containers as described
above in the Background of the Invention. Figs. 7 and 8 show
how the c~nt~;nPr 62 may be stabilized in an upright position,
thereby reducing its tendency to tip over. Figs. 9 and 10
show how the ~nntA;nPr 62 may be employed to affect or control
odors within the container insert 12, without allowing the
odor affecting or controlling substance to contact the
contents of the rrnt~;nPr insert 12. Fig. 11 shows how the
container 62 may be employed to deliver a premium item without
allowing the premium item to contact the contents of the
crnti~;n~r insert 12. Figs. 12 and 13 show how the rrnt~;nPr
may be made opaque, clear or impervious to ultraviolet
2~ 7~1 6~
-- 17 --
radiation ln a manner which minimizes manufacturing costs and
steps .
Fig. 7 i8 an elevational view, partially in cross
section, of an alternative version of the second embodiment of
the invention. The rnnt~;nPr 62 in Fig. 7 is identical to the
container in Fig. 4, except that the cnnt~;npr insert 12 in
Fig. 7 is shorter in length than the rnntA;nPr insert 12 in
Fig. ~. The shorter length increases the volume of space 61
between the rnnt~; nPr insert 12 and the outer container 10,
particularly between the bottom 34 of the insert 12 and the
bottom 14 of the outer rnnti~;nPr 10. To inhibit the rnnt~3;nPr
62 from easily moving from an upright position, one or more
stabilizing masses or weights 66 are placed in the space 61.
Preferably, the weight 66 is attached to either the inner =:
surface of the outer rnnti~lnPr~s wall 18 or bottom 14, or the
outer surface of the container insert~ 8 wall 38 or bottom 34 .
To aderiuately stabilize the rnnt~; nPr 62, the weight 66 should
be placed in the space 61 80 that the center of gravity of the
cr,nti~;nPr 62 is closer to the bottom 14 of the outer container
10 than to the opening 24. Fig. 7 shows one weight 66
attached to the inner surface of the outer rnnt~;npr~s bottom
14 and another weight attached to the outer surface of the
container insert' 8 bottom 34 . The weights 66 in Fig. 7 are
constructed of packed sand. However, the weights may be
constructed o any relatively dense and inexpensive material
such a8 metal, glass or the like.
Fig. 8 shows a perspective view of a rnnti~;npr 62
which is identical to the container in Fig. 6, but which
includes a weight 66 attached to the inner surface of the
outer rrnt~;nPr~s bottom 14. A portion of the outer container
10 is broken away to show the space 61.
Figs. 9 and 10 show how the space 61 may be employed
to provide the cr,nt~;nPr 62 with an odor affecting substance,
generally designated as 68. Referring to the first embodiment
of the invention in Fig. 9, the odor affecting substance 68 is
preferably located anywhere in the space 61 80 long as the
217816~
-- 18 --
substance 68 is in fluid communication with the vent means or
grooves 46. The odor affecting substance 68 interacts with
the f luid in the space 61 and the interior portion 40 of the
insert 12 to impart odor to the material within the interior
portion 40 of the insert 12, or to ma3k or absorb an odor
associated with the material within the interior portion 40 of
the insert 12. As shown in Fig. 9, the odor affecting
substance 68 and the material within the interior portion 40
of the insert 12 are separated by the wall 3 8 of the insert
12. When the cap (not shown) is positioned over the opening
24 of the mouth of the outer rnntA;n~r 10, odors flow between
the odor affecting substance 68 and the interior portion 40 of
the insert 12. By separating the odor affecting substance 68
and the material within the interior portion 40 of the insert
12 such that the substance 68 is n~t accessible from outside
of the outer container 10, the risk that an individual who is
to ingest the material will confuse the odor affecting
substance 68 with the material is minimized. Further, special
packaging labeling and hAn-ll ;n~ of the odor affecting
substance 68 can be avoided. Hence, the present invention
physically isolates the odor affecting substance 68 and the
material within the insert 12, while allowing the substance 68
to interact with the interior portion 40 of the insert 12.
It is understood by those of ordinary skill in the
art that the present invention i8 not limited to the use of
any particular odor affecting substance 68, since the
particular type and amount of 3ubstance 68 used will depend on
the type and amount of material packaged within the interior
portion 40 of the insert 12, the amount of odor control which
is desired, as well as the size of the outer cnntA;n~r 10,
insert 12 and vent means. However, to prevent the odor
affecting substance 68 from -nntAf-t;ng the material within the
interior portion 40 of the insert 12, it is preferred that the
physical carrier for the substance 68 (if one is employed) be
sized so that it is greater than the dimensions of the vent
means or grooves 46.
21781~
-- 19 -
The second embodiment of the invention may also
include an odor affecting substance 68 in the space 61 as
described above in connection with the first embodiment. Fig.
10 shows an alternatiYe version of the second embodiment of
the invention. The container 62 in Fig. 10 is identical to
the r~r~nti~ln.~r in Fig. 7, except that weight 66 is replaced
with an odor affecting substance 68. When the cap (not shown)
is placed over the neck 22 of the outer container 10 in the
second ~Inhnrl;l -nt of the invention, the space 61 may not be in
fluid communication with the interior portion 40 of the insert
12 because the second end 48 of the grooves 46 faces
outwardly. Accordingly, to permit the odor affecting
substance 68 to be in fluid communication with the interior
portion 40 of the insert 12, one or more openings 70 are
provided in the wall 38 and/or bottom 34 of the insert 12
The openings are preferably sized to prevent the material in
the interior portion 40 of the insert 12 from passi}~g into the
space 61 and to prevent the physical carrier of the odor
affecting substance 68 (if one is employed) from passing into
the interior portion 40 of the insert 12.
Fig. 9 shows an odor affecting substance 68 in the
form of a solid block of material, whereas Fig. 10 shows the
substance 68 as being a sponge-like material. However, the ~:
substance 68 may be any gas, liquid or solid, or carrier
holding a gas, liquid or solid which is capable of imparting
odors to another material, masking odors associated with
another material, or absorbing odors emanating from a
material. Accordingly, the odor affecting substance 68 may be ..
odiferous, such as a fragrance, or it may be a malodor
3 0 counteractant, such as an odor absorber or an odor masker . A
malodor is any odor that one does not want to be present,
including a bad odor. Some types of malodor counteractants
include zeolites, activated charcoal and baking soda. The
brain registers an odor only when specific nose receptor sites
35 are filled with odor molecules (so-called 'llock and key"
mechanism). An odor masking substance produces an odor which
21 781 65
-- 20 --
interferes with one or more of the nose receptor sites
associated with the undesired odor. Thus, even though the
undesired odDr is still present, the odor masking substance
blocks the brain from experiencing the undesired odor.
Fig. 11 shows how the space 61 may be employed in
the f irst embodiment of the invention to deliver a premium
item 72, such as a prize toy, with the container 62. The item
72 is preferably placed in the bottom of the outer crntir;nr~r
10 before the insert 12 is set into place. The item 72 may be
placed loosely in the space 61 80 that it moves around when
the rr,nti:liner 62 is picked up, thereby rr~rn;nrl;n-q the person
using the rnntA;nr~r that the item 72 is inside. Score lines,
cut lines or guide lines (not shown) may be placed on the
outer 6urface of the outer container:10 to assist a user in
gaining access to the item 72. The second embodiment of the
invention is equally suitable for delivering a premium item
72 .
Fig. 12 shows a container 62 ' according to the first
embodiment of the invention, as depicted in Fig. 6, wherein
the outer rr~nti3;nr~r 10~ is opaque (i.e., impervious to rays of
light) and the container insert 12 ' is clear or colorless
(i.e., transparent to light). Oftentimes, a container must be
made opaque because light may alter the properties of the
crnt~ntq. ~he outer container 10 ~ may be made opaque by
employing either light reflecting (e.g., a light reflective
film or coating) or light absorbing material (e.g., black
coloring). When employing the crnt~in~Dr 62' of the invention,
it is not necessary to color the insert 12 ' if the outer
crnt~;n-~r 10' i8 sufficiently opaque to block the rays of
light. Accordingly, the inserts 12 ' can be made cheaper by
being used clear. As noted above, coloring container~
increases their manufacturing cost because of the cost of the :
colorant and the additional manufacturing step~ required to
color the raw material (typically, plastic).
Fig. 13 shows a rr~nti~;nr~r 62n according to the first
embodiment of the invention, as depicted in Fig. 6, wherein
2~ 78165
-- 21 --
. the outer rnn~;nPr 10" i8 colorless and the cnntainer insert
12" i~ opariue. Such a container provides the same advantages
as the container in Fig. 12, as well as providing the illusion
of the insert suspended from, and floating in the outer
container 10". A rnnti3;nPr label 74 may be placed on the
cnntA;n~r insert 12", thereby avoiding the necessity to
separately label the outer container- 10 " . By placing the
label within the outer container 10 ", it makes it more
difficult to tamper with the label 74 or remove it from the
0 rnnt:~ i nPr 62 " .
In addition to being either clear or opariue, the
outer rnnt~inPr 10 and container insert 12 may include a
coating or be made from a material which i8 impervious to
ultraviolet radiation. Again, the coating or material may
either reflect or absorb the ultraviolet radiation.
The outer container 10 and rnnt~inPr insert 12 may
also be made from different colored materials. For example,
the outer container 10 may be white and the container insert
12 may be black. A black insert 12 provides maximum light
blockage while still allowing the rnnt;~in~r 62 to have a light
appearance ~rom a perspective view.
From the foregoing description of the pre~erred
Pmhn~; nt, it can be seen that the present invention
comprises a container having an outer cnntA;nf~r and a
container insert therein, a method for assembling the
cnnti~;nPr insert within the outer rnnti~;nPr, a method of
packaging a predetermined volume of material using the
aforementioned combination, and methods of taking advantage of ~=
the space between the outer container and the rnnt~;nPr insert
to stabilize the container, to control odors and to deliver
items. It will be appreciated by those skilled in the art
that changes could be made to the embodiment described above
without departing from the broad inventive concept thereo~.
For instance, the present invention is not limited to the
pharmaceutical industry and is useful in other industries
which package different volumes of material, including
21 781 SS
- 22 -
confectionery and personal care products. It i3 under~tood,
therefore, that this invention is not limited to the
particular embodiment disclo~ed, but is intended to cover all
modifications which are within the ~3pirit and scope of the
invention a~ de~ined by the appended claim~.
