Note: Descriptions are shown in the official language in which they were submitted.
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MULTI-FUNCTION CONDIMENT CONTAINER
BACKGROUND OF THE INVENTION:
[0001] The present invention relates generally to packaging for
condiments. More particularly, the present invention concerns condiment
packaging adapted for opening in at least two different ways.
[0002] Condiment packaging has evolved over the years, starting with
basic glass bottles and jars for display and sale of condiments, including
without limitation ketchup, mustard, mayonnaise, sauces, and the like. That
basic packaging later included larger capacity bottles and jars, and then
containers made from synthetic plastic materials. Eventually, the packaging
concepts turned to providing packaging suitable for individual portions of the
condiments.
[0003] Individual packaging for condiments has, itself, seen changes. At
one time, the packaging was simply an empty cup that could be filled with a
condiment from a large capacity condiment dispenser that may, for example,
have included a pump or other suitable dispensing device. For many years,
condiments have been available in individual portion packets or sachets
which seal the condiment between a pair of generally planar sheets of
material. See, for example, U.S. Patent No. 3,315,801. One or more
weakened zone may be provided to simplify the act of opening the packet to
access the condiment contained therein.
[0004] Condiment packages having a generally rectangular receptacle
portion covered with a substantially planar sheet have been long known
also. See, for example, U.S. Patent 2,705,579. Such condiment packages
were later provided with breakaway corners and exposed corners for the
covering material, thereby providing different access means for the
condiment packaged therein. See, for example, U.S. Patent Application
Publication Nos. 2003/0183637, and 2002/0100760.
[0005] Packages for varied products are also known where the receptacle
portion has a generally frustoconical shape with a spout at one side. See,
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for example, U.S. Patent Nos. 2,898,003, 3,660,960, and 4,863,036.
Typically, receptacles having this configuration have been used for relatively
low viscosity products such as milk and cream.
[0006] Squeezable packages for products are also known where the
package has a spout at one end and the forming materials are weakened in
the vicinity of the spout to permit access to the contents thereof. See for
example, U.S. Patent Nos. 5,529,224, 4,921,137, and WO 2007/126817.
[0007] Containers for liquids have also been proposed which permit dual
access modes. For example, one mode allowing squeezing for product
removal and another mode allowing dipping for product removal. See, for
example, U.S. Patent Application Publication No. 2006/0278562 (commonly
owned, the entire contents of which are incorporated herein by this reference
thereto). It has been proposed to use different opening methods where the
product has different consistencies. See, for example, Fr. Patent No.
2,801,570. Moreover, various designs for containers which permit the varied
kinds of access have also been disclosed. See, for example, U.S. Patent
Application Publication No. 2007/0164045.
[0008] Notwithstanding the development of condiment containers, a
number of difficulties are known to exist with available containers. More
particularly, during use, the containers tend to be messy making them
imperfect for use by children, and for use in vehicles when provided at drive-
thru food sources. In addition, in recognition of environmental concerns,
some retailers impose restrictions on the types of materials that may be used
in products sold or otherwise provided through their retail outlets. When
dealing with individual portion sizes of condiments, shelf-life stability for
the
condiments therein becomes important to maintain wholesomeness of the
condiments. That stability may result from a variety of factors including for
example permeability of container materials to oxygen.
SUMMARY OF SELECTED ASPECTS OF THE INVENTION:
[0009] For purposes of this invention, the word "condiment" should be
interpreted broadly so as to include substances used to enhance larger food
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portions. Thus, as used in this application, "condiment" is intended to cover
traditional condiments such as ketchup, mustard, mayonnaise, tartar sauce,
and the like, as well as to encompass, without limitation, other comestibles
such as sauces, jellies, jams, honey, and the like.
[0010] The improved condiment container according to this invention
includes a cover portion and a container portion. The container portion
preferably includes a receptacle proportioned to receive a predetermined
volume of a condiment. Typically, the predetermined volume corresponds to
the quantity of the condiment that a consumer may personally use during
consumption of a meal.
[0011] Preferably, the receptacle of the container portion includes a
generally planar bottom surface with a nominal length and a nominal width.
The bottom surface provides a stable surface to support the condiment
container during certain aspects of its use by a consumer. The receptacle
also has a nominal depth selected in relation to the nominal width and
nominal length to provide a receptacle that is low, wide, and stable against
lateral tipping when a food item is thrust or poked into the receptacle.
[0012] The container portion preferably includes a flange extending
substantially continuously around the receptacle. Preferably, the flange is
generally planar, is spaced from the generally planar bottom surface, and
parallel thereto. At one side of the receptacle and at the position of the
flange, a spout is provided. The spout has cross-sectional area which is
smaller than the cross-sectional area of the opening at the upper edge of the
receptacle. In this manner, access to the condiment through the spout is
much more restricted that access to the condiment through the upper edge
of the receptacle.
[0013] Preferably, the container portion is fashioned from a material having
a first bending stiffness sufficient that the receptacle retains its shape,
even
in the absence of the cover portion. Moreover, that first bending stiffness is
also sufficient to ensure that the flange will retain its shape and
orientation
relative to the receptacle, even in the absence of the cover portion. To this
end, container portion may be fabricated from a material selected from the
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group consisting of polyethylene terephthalate (PET), amorphous
polyethylene terephthalate (APET), oriented polyethylene terephthalate
(OPET), metalized polyethylene terephthalate (MET-PET), polyethylene
(PE), low density polyethylene (LDPE), linear low density polyethylene
(LLDPE), metalocene linear low density polyethylene (mLLDPE), high,
density polyethylene (HDPE), metalocene polyethylene (mPE), ethylene
vinyl acetate (EVA), polypropylene (PP), metalized oriented polypropylene
(mOPP), polystyrene (PS), high impact polystyrene (HIPS), foil, ethylene
vinyl alcohol (EVOH), polyamide, Nylon, polyvinyl chloride (PVC), biaxially
oriented materials, materials complying with 21 C.F.R. Part 177, and
combinations thereof. While the container portion may comprise a single
layer of material, the container portion may also be fabricated of multiple
layers bonded, coextruded or otherwise formed together into a cohesive
structure, where one or more of the layers is selected from the group of
materials set forth above. Regardless of the particular composition used for
the lid portion, all surfaces of the lid portion which face the receptacle are
required to be food-safe.
[0014] The thickness of the container portion may preferably lie in the
range of about 3 mils to about 20 mils - a mil being 0.001 inches.
Depending upon the particular material and the thickness selected, it may
also be desirable to further stiffen the bottom surface of the receptacle.
Such stiffening may be accomplished by embossing a three-dimensional
pattern into the bottom surface, thereby increasing its bending stiffness. A
logo may be used to provide that three-dimensional pattern, if desired.
[0015] The cover portion is substantially planar and preferably is
configured to have a perimeter substantially the same as the perimeter of the
container portion. Moreover, the cover portion substantially covers the
flange of the container portion. The cover portion, however, is preferably
fabricated from a material having a second bending stiffness, where the
bending stiffness of the cover portion is lower than the bending stiffness of
the container portion. This difference in stiffness causes the cover portion
to
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be more flexible and more readily separable from the container portion along
the flange.
[0016] The material from which the cover portion is fabricated may be the
same as, or different from, the material used for the container portion.
Accordingly, the material of the cover portion may be selected from the
group. consisting of PET, APET, OPET, MET-PET, PE, LDPE, LLDPE,
mLLDPE, HDPE, mPE, EVA, PP, mOPP, PS, HIPS, foil, EVOH, polyamide,
Nylon, PVC, biaxially oriented materials, materials complying with 21 C.F.R.
Part 177, and combinations thereof. Typically, the thickness of the cover
portion will lie in the range of about 1 mil to about 5 mils. While the cover
portion may comprise a single layer of material, the cover portion may also
be fabricated of multiple layers bonded, co-extruded or otherwise formed
together into a cohesive structure, where one or more of the layers is
selected from the group of materials set forth above. Regardless of the
particular composition used for the lid portion, all surfaces of the lid
portion
which fact the receptacle are required to be food-safe.
[0017] To hold the cover portion and the container portion together in a
condiment package, an adhesive is preferably positioned between the cover
portion and the container portion, in the flange area, and surrounding the top
edge of the receptacle. The adhesive preferably is a food-grade adhesive
and may be conventionally cured, for example, thermally,
electromagnetically, or time cured. Preferably, the adhesive is integral with
the cover portion and/or the container portion. Application of heat and
pressure can be used to cause the adhesive to bond the cover portion
and/or the container portion. Alternatively, adhesive may be applied around
the receptacle of the container portion in a separate step. Preferably the
adhesive is applied such that the adhesive defines a non-bonded region in
alignment with the spout, although the adhesive otherwise surrounds the
spout. If desired, pressure may be applied to assure that the adhesive
bonds the cover portion and the container portion so as to define a sealed
compartment defined by the receptacle and the cover portion. Moreover, the
adhesive is applied such that an non-bonded region exists between the lid
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portion and the flange of the container portion in general alignment with the
spout.
[0018] Preferably, the non-bonded region is located opposite the spout
and at the periphery of the container assembly. The non-bonded region is
operable to define a lift tab at an edge of the lid portion. The lift tab is
graspable so that it can be pulled away from the flange of the container
portion so as to expose the receptacle and the contents thereof. Moreover,
the adhesive is applied such that a peel-initiating region, such as a
substantially angular region, partially defines an edge of the non-bonded
region. The peel-initiating region is engaged as the lid portion is pulled by
the tab from the container portion before the lid portion engages the full
linear extent of the adhesive extending from side to side of the receptacle,
and offers reduced resistance to separation between the lid portion and the
container portion of the assembled package. For example, the required
opening force may lie in the range of 1 to 5 lbs. Depending upon the
opening scheme desired, the non-bonded region and the peel-initiator may
be positioned in alignment with the spout or on the opposite side of the
receptacle. Regardless of the position, when the lid portion is peeled back
away from the container portion, the receptacle is exposed so as to be
available for dipping a food item in the condiment.
[0019] For access to the spout, a weakened area is preferably positioned
so as to be transverse to the spout. The weakened area may be provided by
mechanically cutting or fracturing the package materials in the vicinity of
the
spout. The weakened area may be fashioned by cutting the lid portion and
the container portion so that a pair of aligned slits straddle the spout.
Alternatively, the weakened area may be provided by laser scoring either the
lid portion or the container portion or both. The end of the assembled
container may then be broken away along the weakened area to expose the
spout. By then squeezing the assembled container, the condiment will be
released through the spout in a controlled manner.
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[0020] In the assembled package, the adhesive preferably has sufficient
strength that the container will resist bursting when subjected to a force of
50
lbs. or greater, and preferably when subject to a force of 70 lbs. or greater.
[0021] If desired, the container assembly may be adapted for attachment
to the sidewall of a paperboard container. To this end, a pair of slits may be
provided in the container and extending through both the lid portion and the
container portion, where the slits are, symmetrically disposed and cooperate
to define a pair of ears. The ears can be bent out of the plane of the flange
to define an angular (when viewed from the side) hook. Resilience of the
materials used to fabricate the lid portion and the container portion
cooperates to pinch an edge of the paperboard container. To further
enhance the grip between the ears and an associated paperboard container,
the surface of each ear may be suitable treated. For example, a tacky
coating, or a roughened surface may be provided for such a purpose.
[0022] If desired, either or both of the lid portion and the container portion
may include an oxygen control barrier or an oxygen scavenger layer. Such a
barrier layer can be helpful to reduce or eliminate degradation of the
condiment packaged in the container assembly. If desired, either or both of
the lid portion and the container portion may be opaque. Opaqueness may
enhance the packaged product where exposure to light degrades the
product over time.
[0023] When the condiment packaged in the container is ketchup, the
materials for the lid portion and the container portion are preferably
selected
such that the packaged condiment will have a shelf-life of at least about six
months. One technique for evaluating shelf-life involves use of a colorimeter
operating in the L*a*b* color space. Shelf-life may be evaluated by
monitoring degradation of the color components of the packaged product
according to measurements in that color space. For example, shelf-life may
be determined by requiring that the L* and/or the ratio of a*/b* does not
degrade more than a specified amount during the specified period, e.g., by
less than 10% over a six-month period.
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BRIEF DESCRIPTION OF THE DRAWINGS:
[0024] Many objects and advantages of the present invention will be
apparent to those skilled in the art when this written specification is read
in
conjunction with the appended drawings wherein like reference numerals are
applied to like elements and wherein:
FIG. 1 is a perspective view of the condiment container;
FIG. 2 is an inverted perspective view of a condiment container with
the bottom surface positioned on top;
FIG. 3 is a bottom plan view of the condiment container;
FIG. 4 is a side elevational view of the condiment container;
FIG. 5 is a top plan view of the condiment container;
FIG. 6 is an end elevational view of the condiment container;
FIG. 7 is a top plan view of a second embodiment of the condiment
container;
FIG. 8 is a top plan view of a third embodiment of the condiment
container;
FIG. 9 is an enlarged cross-sectional view taken along the line 9-9 of
FIG. 5;
FIG. 10 is an enlarged detail view of spout end encircled FIG. 9;
FIG. 11 depicts the condiment container opened for squeeze
application;
FIG. 12 is a cross-sectional view of the condiment container of FIG. 1
showing access for dipping;
FIG. 13 is a perspective view of a fourth embodiment of the
condiment container viewed from the top;
FIG. 14 is a cross-sectional view of the fourth embodiment of the
condiment container taken along the line 14-14 of FIG. 13;
FIG. 15 is a perspective view of the fourth embodiment of the
condiment container;
FIG. 16 is a top plan view of a fifth embodiment of the condiment
container;
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FIG. 17 is a side elevational view of the fifth embodiment of the
condiment container;
FIG. 18 depicts use of the fifth embodiment in conjunction with a food
container;
FIG. 19 is a side elevational view of FIG. 18.
FIG. 20 is a perspective view of the sixth embodiment of the
condiment container;
FIG. 21 is an inverted perspective view of a sixth embodiment of the
condiment container;
FIG. 22 is a top plan view of the sixth embodiment;
FIG. 23 is a bottom plan view of the sixth embodiment;
FIG. 24 is a side elevational view of the sixth embodiment;
FIG. 25 is an end elevational view of the sixth embodiment;
FIG. 26 is a cross-sectional view of the sixth embodiment showing
opening and access to the spout for squeezing; and
FIG. 27 is a cross-sectional view of the sixth embodiment showing
opening and access for dipping.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS:
[0025] Turning now to FIG. 1 a first embodiment of the condiment
container 20 according to this invention is adapted for marketing, and
delivery to a consumer as an individual portion of a condiment. The
condiment container 20 is formed by a container or cup portion 22 (see FIG.
2) and a lid or cover portion 24 (see FIG. 1) which are sealed together by an
adhesive along a flange 26.
[0026] The lid portion 24 is preferably fabricated from a material selected
from the group consisting of polyethylene terephthalate (PET), amorphous
polyethylene terephthalate (APET), oriented polyethylene terephthalate
(OPET), polyester (PE), low density polyester (LDPE), linear low density
polyester (LLDPE), metalocene linear low density polyester (mLLDPE), high
density polyester (HDPE), metalocene polyester (mPE), ethylene vinyl
acetate (EVA), polypropylene (PP), high impact polystyrene (HIPS), foil,
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ethylene vinyl alcohol (EVOH), polyamide, Nylon, polyvinyl chloride (PVC),
and combinations thereof. Where foil is used, that foil may be an aluminum
foil, or other metal foil. Typically, the thickness of the lid portion 24 will
lie in
the range of about 1 mil to about 5 mils. More preferably, the lid portion 24
may have a thickness in the range of about 1 mil to about 3 mils. The
thickness of the lid portion 24 is selected to be more flexible than the cup
portion, to have sufficient tensile integrity that the lid portion 24 can be
pulled
away from the cup portion overcoming the tackiness of the adhesive, and to
have a surface texture that is graspable but not too slippery. The lid portion
24 preferably has a peripheral contour that substantially corresponds to the
perimeter of the flange 26.
[0027] While the lid portion 24 may comprise a single layer of the selected
material, the lid portion 24 may also be fabricated of multiple layers bonded,
co-extruded or otherwise formed together into a cohesive structure, where
one or more of the layers is selected from the group of materials set forth
above. Regardless of the particular composition used for the lid portion 24,
all surfaces of the lid portion 24 which face the packaged condiment are
required to be food-safe. If the condiment to be packaged experiences
oxygen degradation over time, the lid portion 24 may include an oxygen
control layer or an oxygen scavenger layer in its structure. One suitable
material for an oxygen control layer is EVOH which can function not only as
an oxygen barrier but.may also function as a moisture barrier. Depending on
the condiment, the material from which the lid portion 24 is fabricated may
be transparent, translucent, or opaque. Moreover the material may be
colored, if desired.
[0028] While the combinations of acceptable material combinations for the
lid portion 24 is large, the following table identifies some combinations
known to be useful for the lid stock.
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TABLE 1 - Lid Stock Structures
PET / foil / LDPE-based sealant
PET / foil / EVA-based sealant
PET / LDPE-based sealant
OPET / PE / foil / LDPE / mLLDPE
OPET / PE / foil / PE / mLLDPE
Metalocene PE
EVA
PET / MET-PET / EVA-based sealant
[0029] The cup portion 22 (see FIG. 2) includes a receptacle 30 which
extends away from the flange 26 and includes a generally planar bottom
surface 32 which may be generally rectangular. In addition, the receptacle
30 includes a sidewall 36 extending between the bottom surface 32 and the
flange 26. The flange 26 extends generally radially from the edge 40 (see
FIG. 2) and defines a substantial area which is exposed until the lid portion
24 is applied. In addition, one side of the receptacle may include a generally
triangular or generally trapezoidal surface 34 which is inclined relative to
the
generally planar flange 26 and the bottom surface 32. At one side of the
receptacle 30 a spout 38 is provided. Preferably, the cup portion 22 is
designed so as to be symmetrical about a longitudinal plane extending
perpendicularly to the plane of FIG. 5 and generally coincident with the line
9-9.
[0030] When the lid portion 24 is in place, that symmetry of the cup portion
22 coupled with the inclined surface 34 and the lid portion 24 creates a
funnel or converging cross-sectional area at the side of the receptacle so
that the funnel communicates with the spout 38. Thus, the spout 38 exhibits
a cross-sectional area that is much smaller than the area exposed at the top
edge of the receptacle 34 (see FIG. 4).
[0031] The cup portion 22 (see FIG. 3) is preferably fabricated from a
material that is more rigid than the stock from which the lid portion is made.
Thus, the bending stiffness of the cup portion 22 exceeds the bending
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stiffness of the lid portion 24. That difference in stiffness makes the lid
portion more readily deform for removal and opening of the assembled
container. Although the cup portion 22 is stiffer than the lid portion 24, the
cup portion 22 preferably is sufficiently pliable that it can be deflected by
squeezing with hand pressure - i.e., pressure applied by fingers of an
unaided human hand. Nevertheless, the cup portion 22 is sufficiently stiff
that it does not deform or deflect in the absence of force. With those
constraints and in the absence of the lid portion 24, the cup portion 22 can
be supported by the bottom surface to provide a sufficiently rigid container
to
hold a condiment without spilling. In this connection, the generally planar
flange 26 extending outwardly from the perimeter 40 of the receptacle also
functions to stiffen the receptacle region of the cup portion 22.
[0032] In some applications, it may be desirable to have a bottom surface
32 (see FIG. 4) having increased stiffness. Such an increased stiffness may
be accomplished by providing an embossed feature 44 in the bottom surface
32. Such an embossed feature 44 may also extend onto the inclined surface
34, if desired. In some applications, that embossed feature 44 may
comprise a logo of the manufacturer. The enhanced stiffness results from
the depth of the embossed feature 44 relative to the plane of the bottom
surface 32.
[0033] In general, the material from which the cup portion 22 is fabricated
may be selected from the same group of materials available for the lid
portion 24, namely the group consisting of PET, APET, OPET, MET-PET,
PE, LDPE, LLDPE, mLLDPE, HDPE, mPE, EVA, PP, mOPP, PS, HIPS, foil,
EVOH, polyamide, Nylon, PVC, biaxially oriented materials, materials
complying with 21 C.F.R. Part 177, and combinations thereof. Where foil is
used, that foil may be an aluminum foil, or other metal foil. Typically, the
thickness of the cup portion 22 will lie in the range of about 3 mils to about
20 mils. More preferably, the cup portion 22 may have a thickness in the
range of about 8 mils to about 12 mils. The thickness of the cup portion 22
is selected to be less flexible than the lid portion 24 so that the lid
portion 24
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can be pulled away from the cup portion 22 overcoming the tackiness of the
adhesive.
[0034] As with the lid portion 24, certain combinations of the materials for
the cup portion 22 have been found to be particularly suitable, as set forth
in
the table below.
Table 2 - Suitable Cup Portion Material Combinations
PVC / adhesive layer / sealant film
APET / adhesive layer / sealant film
APET / sealant film
PP / adhesive layer / sealant film
HIPS
APET / EVOH
APET / PE / EVOH / PE
APET / HDPE / EVOH/ LDPE
APET / Nylon / APET
APET / Nylon / EVOH
PS / EVA / EVOH / EVA / sealant
[0035] The receptacle of the condiment container 20 is preferably sized to
contain a suitable individual serving of the condiment, for example, a
nominal volume of about one ounce. While larger and smaller nominal
volumes are within the scope of this invention, the nominal volume will
generally correspond to the quantity of the particular condiment desired by a
typical individual. As seen in FIG. 3, the receptacle portion of the package
has a nominal width corresponding to the maximum distance between the
opposed sidewalls at the location of the edge 40 and extending transverse to
the plane of symmetry between opposed sidewalls, a nominal length being
the maximum length between sidewalls of the receptacle at the location of
the edge 40 and measured along the plane of symmetry, and a nominal
depth (see FIG. 4) also measured in the plane of symmetry but extending
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from the bottom surface 32 to the flange 26. These nominal dimensions
define the nominal volumetric capacity for the receptacle portion.
[0036] Another important feature of the cup portion 22 is lateral stability
against tipping. Furthermore these nominal dimensions can be used to
establish guidelines that provide adequate tipping stability. More
specifically,
the ratio of the nominal height to the nominal width is preferably less that
about 0.5, and more preferably less than about 0.45. In addition, the ratio of
the nominal height to the nominal length is preferably less that about 0.3,
and more preferably less than about 0.26. When the receptacle of the cup
portion 22 has nominal dimensions within these ranges, the receptacle is
sufficiently stable that it does not tip when a food item is dipped in the
condiment contained therein.
[0037] The lid portion 24 and the cup portion 22 are sealed together using
a food-grade adhesive so as to define an encapsulated volume isolated from
the environment. One technique for accomplishing the seal is to include a
heat-sealable layer on the inside of the lid portion 24 and on the inside of
the
cup portion 22. Upon application of heat and pressure applied to the flange
26, the adjacent surfaces bond together forming the appropriate seal
surrounding the periphery of the edge 40 of the receptacle. Alternatively, a
suitable food-grade adhesive compatible with the materials of the container
may be used. The adhesive is preferably applied so as to surround the edge
40 of the receptacle (see FIG. 3), but not so at to be contiguous therewith -
i.e., some space exists between the adhesive and the edge 40. Moreover,
the adhesive is applied so that it does not cover the spout 38. Preferably,
the condiment container is capable of withstanding an applied force of at
least about 50 lbs without bursting or breaking through the seal. More
preferably, an applied force of about 70 lbs. will not burst the seal.
[0038] The adhesive preferably extends to the peripheral edge 50 of the
flange 26, but provides an non-bonded region 52 at one side of the
receptacle. That non-bonded region 52 extends inwardly along the flange
26 from the peripheral edge 50 of the flange by a distance sufficient that a
pull-tab portion 54 (see FIG. 5) of the lid portion 24 not adhesively
connected
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to the flange 26 is sufficiently large to be graspable between fingers. A
distance of about 0.5 inches or more is graspable for the pull-tab 54. It will
be apparent to those skilled in the art that attempting to peel a lid portion
away from the flange 26 (see FIG. 3) is difficult due to the width of the
seal.
It has been found, however, that inclusion of a generally angular feature 56
aligned with the plane of symmetry and defining part of one edge of the non-
bonded region 52 provides a peel-initiator that reduces the necessary force
to peel the lid portion away from the flange 26. Inclusion of a peel-initiator
at
the edge of the non-bonded region materially enhances the ease with which
the lid portion can be removed from the container.
[0039] From the foregoing discussion, it will be apparent to those skilled in
the art that the tab 54 can be grasped to pull the lid portion 24 away from
the
flange 26 of the cup portion 22 to expose the receptacle and its contents.
Such a step would prepare the container for dipping a food item into the
condiment. However, a different opening scheme is also available with the
container of this invention. More particularly, the container may be provided
with a weakened region in the vicinity of the spout 38 for the purpose of
opening the spout 38 as an alternative to removal of the lid portion 24. The
weakened region may, for example, comprise a pair of aligned slits 60, 62 in
the vicinity of the spout 38. The slits 60, 62 are aligned with one another
and straddle the spout 38. The slits 60, 62 may extend through the
thickness of both the lid portion 24 and the cup portion 22. With this
arrangement, the distal end of the container 20 can be bent to fracture the
material of the container and expose a channel through the spout 38 into the
receptacle. At that point application of pressure to the receptacle will cause
the condiment to be expelled through the spout 38 in directionally controlled
and defined way.
[0040] The aligned slits 60, 62 can be applied to the container before,
during, or after assembly of the condiment container 20. However, an
efficient mechanical way of creating the aligned slits 60, 62 is to form them
at
the same time that the lid portion 24 is applied to the cup portion 22 and
adhesively connected thereto. Alternatively, a laser scoring process may be
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employed to weaken the container around the spout 38 so that an end of the
container can be snapped or twisted off to expose the end of the spout
passage.
[0041] The materials selected for the lid portion 24, the cup portion 22, and
the adhesive are preferably chosen so that the condiment has a desired
shelf life. In the case of a condiment such as ketchup, a shelf-life of at
least
six months is desirable. With condiments like ketchup, shelf-life can be
evaluated by changes in the color characteristics of the condiment. Testing
for shelf-life can, therefore, be conducted using colorimetric analyses. The
Hunter Lab color space and the L*a*b* color space use three coordinates to
define any particular color. For example, in the L*a*b* color space, the
coordinates L*, a*, and b* define the three-dimensional color space. The L*
component measures lightness and correlates particularly well with human
eye perceptions. The L* value ranges between 0 corresponding to pure
black and 100 corresponding to pure white. The a* coordinate measures the
color position between red/magenta and green, with negative values
indicating green and positive values indicating magenta. The b* component
measures the color position between yellow and blue, with negative values
indicating blue, while positive values indicate yellow. Accordingly, changes
in ketchup color over time can be evaluated by the value of and changes in
the value of the L*, a*, and b*, or L, a, b components. For purposes of shelf-
life analysis, it has been found that the lightness component, L* or L,
provides a reliable parameter to correlate with shelf-life. More particularly,
as long as the L* component value remains within about 10% of its initial
value, during the shelf-life, the shelf-life requirement is satisfied. In
addition,
the ratio of a*/b* or alb is also indicative of product degradation. Thus, in
some instances, satisfactory shelf-life may be determined when the L* (or L)
component and the a*/b* (or a/b) ratio remain within about 10% of their
initial
values, respectively. Other condiments for which color changes over time
can also be colorimetrically evaluated for shelf-life using one or more of the
L*a*b* color space components.
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[0042] An alternative embodiment of the invention is shown in FIG. 7. In
this arrangement, the peel initiator 56' and the adjacent seal portion are
constructed such that the peel-initiator blends to a seal presenting a
gradually increasing resistance, as opposed to the step-wise increasing
resistance of the first embodiment. This arrangement is characterized by the
angularly converging portions of the seal that terminates with the peel-
initiator 56'.
[0043] Yet another embodiment of the invention includes a pair of peel-
initiator structures in the adhesive bonding between the lid portion 24 and
the cup portion (see FIG. 8). In this arrangement, a peel initiator 64, 66 is
provided at corresponding corners of the adhesive seal. With this
arrangement, the lid portion 24 may be peeled away from either corner with
a corresponding reduction in the force needed to initiate the peel-away.
[0044] To assemble the condiment container 20, the cup portion 22 may
be exposed to a dispensing mechanism that deposits a metered volume of
condiment 70 (see FIG. 9) in the receptacle. The metered volume supplied
is less than the actual volume of the receptacle so that some head space
exists above the condiment. After the adhesive is applied to the flange 26,
the lid portion 24 is positioned in overlying relationship to the cup portion
22
and sealed thereto. The resulting structure includes an adhesive 72 bonding
the lid portion 24 and the cup portion 22 (see FIG. 10).
[0045] In another embodiment of the condiment container 20 (see FIG. 7),
the non-bonded region 54 may be enlarged insofar as its width in the
direction of the plane of symmetry is concerned. Other than the peel-initiator
56' and associated structure, the condiment container 20 of this embodiment
has the same features and characteristics as the embodiment described
above in connection with FIGs. 1-6. Accordingly, those common features
will not be repeated here. The peel-initiator 56' of this second embodiment
extends farther into the region 54 than in the first embodiment while the
adhesive seal 70 has a substantially uniform width around the edge of the
receptacle. Here, the peel-initiator 56' is shaped substantially as a chevron,
caret, or curly bracket. Moreover, the peel-initiator 56' is positioned in
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general longitudinal alignment with the spout 38 but is located on the
opposite side of the receptacle from the spout 38. With such an
arrangement, the alternative structures for opening the package are
separated from one another so that the user or consumer makes a
conscious decision as to whether to open the condiment container by
breaking or tearing open the spout 38 for a squeeze application, or to peel
back the lid portion 24 so that the container 20 can be used for a dipping
application.
[0046] In a further embodiment (see FIG. 8), the condiment container 20
has a different position and arrangement for the peel-initiator but is
otherwise
fully described by the discussion above in connection with FIGs. 1-6, which
discussion will not be repeated here. In this further embodiment, a pair of
peel-initiators 64, 66 are provided, and each peel-initiator 64, 66 is
positioned at a corresponding corner of adhesive seal 70 generally aligned
with a corner of the receptacle. Recognizing that some consumers may find
it easier, or more intuitive to start peeling back the lid portion 24 from a
corner, the corner location of the peel initiators 64, 66 facilitates the peel
opening. As shown, the peel-initiators 64, 66 are symmetric with respect to
the plane of symmetry for the condiment container so that either corner may
be randomly chosen by the consumer or user to start the peel opening
process.
[0047] It is also within the purview of this disclosure that only one peel-
initiator be used and that that peel-initiator be located at a corner of the
condiment container offset from the plane of symmetry. Such a container
may look like the embodiment of FIG. 8 but with only one of the peel-
initiators 64, 66 being present. It is likely that with such an embodiment
directions might be provided on the outside surface of the lid portion 24
focusing consumer attention on the appropriate corner for peel initiation.
Alternatively, the cup portion 22 and the lid portion 24 could be trimmed
more closely to the adhesive line at one corner, leaving a tab projecting from
the other corner and the peel-initiator so that peel-type opening would
necessarily occur at the peel-initiator, whether it is centrally positioned or
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arranged at that other corner of the container. Here again, the features of
such a condiment container are adequately described above in connection
with FIGs. 1-6 and will not be repeated here.
[0048] To use the condiment container 20, (see FIG. 11), the consumer
initially decides whether to have controlled dispensing of the condiment or to
have full access to the receptacle. Where controlled dispensing is desired,
the end of the container is broken off or twisted off at the location of the
weakened area to expose the end of the spout 38. By applying finger
pressure to the receptacle area, condiment is squeezed out of the spout so
that it can be applied selectively, directionally, and in a controlled manner
to
a food item. Where fuller access to the condiment is desired (see FIG. 12),
the tab 54 may be pulled away from the flange, past the peel-initiator, and
away from the upper edge of the receptacle to expose as much (or all) of the
receptacle as may be desired.
[0049] Yet another embodiment of the condiment container 20 (see FIG.
13) has a different position for the peel-initiator 84. The features of this
condiment container not specifically described are adequately described in
connection with FIGs. 1-6 and will not be repeated here. In this
arrangement, the peel initiator 84 is aligned with the spout 38 and positioned
so that the spout 38 is between the peel initiator 84 and the receptacle of
the
cup portion 22 (see FIG. 14). Here, the flange 26 of the cup portion 22
includes a tongue 80, which may be generally rectangular, symmetrically
disposed with respect to the spout 38 and extending beyond the spout. The
peel-initiator 84 may have a generally angular or generally pointed feature
oriented outwardly away from the spout 38 and the receptacle, but in general
alignment therewith. Preferably, the tongue 80 extends beyond the peel-
initiator 84 by a distance of 0.5 inches or more. The lid portion 24 (see FIG.
13) also includes a tongue 82 adapted, sized, and arranged to overlie and
conform to the tongue 80 of the cup portion.
[0050] To open the condiment container 20, the tongue 86 of the lid
portion 22 (see FIG. 14) is grasped and peeled away from the tongue 80 of
the cup portion 22, for example in the direction of arrow 86. After the
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separation begins at the peel-initiator 84, the tongue 82 of the lid portion
22
exposes the end of the spout 38. At this point, the condiment container 20
may be squeezed by the user so that condiment is expressed through spout
38 in a controlled and readily directed manner. Rather than stopping when
the spout is exposed, the lid portion 24 may be peeled farther away from the
tongue 80 of the cup portion 22 to expose a portion or all of the receptacle
and the condiment 70 therein. Thus, the container 20 can provide a dipping
container for a food item. It will be apparent to those skilled in the art
that it
is not required that the lid portion either open the spout or open the
receptacle. If desired, the consumer may first open the spout and dispense
some of the condiment therethrough, and later open the lid portion to expose
the receptacle to use some of the condiment by dipping. Moreover, if
desired, the lid portion may be partially opened or completely removed.
[0051] Another embodiment of the condiment container 20 (see FIG. 16)
may have the spout 38 located at one end with the graspable tongue
extending in a generally triangular configuration beyond the spout 38. The
features of this condiment container not specifically described are
adequately described in connection with FIGs. 1-6 and will not be repeated
here. This embodiment also includes a generally pentagonal receptacle 90,
but with sides meeting at obtuse angles. One end of the container has a
generally straight edge 91 extending generally perpendicularly to the plane
of symmetry for the container 20, and having a length corresponding to the
maximum width of the container 20. The container also includes side edges
93, 95 extending from corresponding ends of the straight edge 91 to
corresponding corners of the container. A pair of symmetrically disposed
slits 92, 94 extend from the corresponding side edge 93, 95 toward the
straight edge 91, but do not intersect that straight edge 91. The slits 92, 94
may be straight or arcuate, as desired, but the blind end of each slit 92, 94
is
spaced from the straight edge 91 as well as from both side edges 93, 95.
With that arrangement, the slits 92, 94, and the side edges 93, 95 cooperate
to define a pair of symmetrically disposed ears 96, 98. At the time of
manufacture, the ears 96, 98 lie in the plane of the flange 26 (see FIG. 17).
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[0052] In use, the condiment container 20 of this embodiment provides an
additional convenience feature (see FIG. 18). The ears 96, 98 may be
pushed out of the plane of the flange 26 so that an upper edge of a package
100 can be received between the ears 96, 98 and the flange 26. In this
fashion, the condiment package 20 can be dispensed with the package 100
where appropriate. The condiment container 20 can be configured for
opening a described above in any of the other embodiments. Moreover,
when opened for dipping use (see FIG. 19), the cooperation between the
ears 96, 98 and the side of the package 100 will support the condiment
container 20 in cantilevered position so that the condiment is readily
accessible.
[0053] If desired, the surface of each ear 96, 98 may be treated to
enhance frictional engagement with a package 100. For example, the
surface of the ears 96, 98 could be roughened relative to other surfaces of
the container 20, or may have a low tack adhesive applied to at least a
portion thereof.
[0054] The shape of the receptacle in the cup portion may be generally
generally pentagonal as depicted in the embodiments described above, but
may also have other desired shapes. For example, generally rectangular,
generally square, generally triangular, generally polygonal, oblong, generally
elliptical, and other shapes for the receptacle are all within the scope of
this
disclosure. For example, another embodiment of the condiment container
20 may include a generally cylindrical receptacle 110 (see Fig. 4A). The
features of this condiment container not specifically described are
adequately described in connection with FIGs. 1-6 and will not be repeated
here. As seen from the various embodiments shown and described in this
disclosure, the flange 26 surrounding the receptacle may follow the shape of
the upper edge of the receptacle, or may have a larger area. In FIG. 21, for
example, the flange 26 is generally rectangular thereby providing multiple
locations from which the lid portion can be peeled back, some of which
access the spout and some of which access the receptacle.
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[0055] To make a container in accordance with this disclosure, the
material for the cup portion is typically provided in a roll. That roll of
material
is unwound into a forming device as a substantially continuous sheet where
a plurality of receptacles are formed. Typically, the receptacles may be
formed in a row having two to about twelve or more receptacles therein,
thereby forming a sheet with receptacles in straight transverse rows and
straight longitudinally extending rows running in the direction of the length
of
the sheet unwound from the roll.
[0056] The sheet with formed receptacles then advances to filling
apparatus. In that filling apparatus, the desired condiment is deposited in
the receptacles through a conventional metering device to control the
quantity and volume of condiment for each receptacle. Ordinarily, there is a
filling head for each longitudinal row of receptacles in the sheet. Moreover,
these filling heads may supply the same condiment in each of the
longitudinal rows. However, if desired, it is within the scope of this
disclosure that adjacent fill heads may deliver different condiments so that
different condiments are filled in the receptacles of adjacent longitudinal
rows of the sheet.
[0057] Next, the sheet with filled receptacles is flushed with gas
compatible with the product and helpful in retarding product degradation. At
this point a second sheet of material for the lid portion is unrolled and
advanced into overlying relationship with the receptacle sheet where it is
sealed into position with respect to each of the receptacles.
[0058] The filled, covered, receptacles in the substantially continuous
sheet then advance to a die cutting machine where individual containers are
cut from the continuous sheet. Conventional accumulation, packaging,
palletizing, storing, and shipping of the individual containers then occurs.
[0059] The word "about" is used in connection with numerical values at
various locations throughout this specification with the intent of avoiding
mathematical precision for those numerical values. Accordingly, when the
word "about" is used in connection with a numerical value or range of values,
it is intended that the word "about" should be interpreted as including a
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tolerance of 10% around the stated numerical value. To similar effect, the
words "generally" and "substantially" are used throughout this specification
in
connection with various geometric words, terms, and/or phrases. The intent
of the words "generally" and "substantially" in such a context is to avoid
strict
geometrical definitions, to encompass structures which approximate the
geometrical definitions, and to include features that are not precisely met by
the related terms and/or phrases.
[0060] Moreover, it is expressly intended that this invention be interpreted
so as to be consistent with all parts of this specification. Thus, the
summary,
abstract, drawing description, and the like are not intended to be limiting
but
are intended to summarize some, but not all, features, or to provide an
overview of the entire specification, or of a particular drawing.
[0061] It will now be apparent to those skilled in the art that this
specification describes a new, useful, and nonobvious condiment container.
Moreover, it will be apparent to those skilled in the art that numerous
modifications, variations, substitutions, and equivalents exist for the
various
features of the invention described in the appended claims. Accordingly, it is
expressly intended that all such modifications, variations, substitutions, and
equivalents which fall within the spirit and scope of the invention, as
defined
in the appended claims, be embraced thereby.
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