Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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NON-ROUND MOISTURE-TIGHT RE-SEALABLE CONTAINERS
WITH ROUND SEALING SURFACES
FIELD OF THE INVENTION
[0001] This invention relates to a non-round moisture-tight re-sealable
container with round
sealing surfaces.
[0002] In another aspect this invention relates to a hinged container.
BACKGROUND
[0003] Background may be found in U.S. Published Application Nos. US 2005 /
0,258,174 Al
and 2004/ 0,173,612 Al.
[0004] The subject of the invention is a container useful, for example, for
the primary bulk
packaging of pharmaceutical and medical device products. These pharmaceutical
and medical
device products degrade in the presence of moisture. Therefore, these products
must be
packaged in a substantially moisture-free environment throughout the product
shelf life.
[0005] Consumers prefer bulk package designs that are flat and incorporate
innovative, user-
friendly shapes (i.e., non-round). These package designs can be conveniently
placed in a pocket
or purse. When a package shape is non-round, the primary sealing surfaces in
the package have
also been non-round.
[0006] Packages that have non-round sealing surfaces typically incorporate a
gasket in the
sealing area. The gasket is a compliant material that when compressed, creates
a moisture-tight
seal in a package sealing region. The gasket, however, is a second material
that increases the
cost of the overall package. Incorporating a gasket requires two-shot
injection molding or a
secondary assembly operation.
SUMMARY
[0007] The inventor has found that if the sealing surface is substantially or
exactly round in
shape, a gasket material is not required to create a moisture-tight seal. In
some embodiments,
this simplifies the mold, the assembly process and the overall cost of the
bulk package. In some
embodiments, the container and seal elements are made of the same material.
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[0008] An aspect of the invention is a hinged container including a base, a
lid, and a hinge
joining the base and lid. The base has an outer perimeter, and so does the
lid. The hinge allows
the lid to pivot open or closed relative to the base.
[0009] The container has an at least substantially circular, outwardly tapered
outer seal member
that defines a center axis and an at least generally frustoconical surface.
The outer seal member
is mounted in fixed relation to one of the base and the lid and is exposed at
least partially within
the corresponding outer perimeter of the base or lid to which it is mounted.
[0010] The container has an at least substantially circular, inwardly tapered
inner seal member
that defines a center axis and an at least generally frustoconical surface.
The inner seal member
is mounted in fixed relation to the other of the base and the lid, relative to
the outer seal member,
and is disposed at least partially within the corresponding outer perimeter of
the part to which it
is mounted.
[0011] The inner and outer seal members are positioned to engage
concentrically to wedge the
inwardly and outwardly tapered surfaces together and form a seal when the base
and the lid are
closed. The inner and outer seal members are positioned to disengage
concentrically to part the
inwardly and outwardly tapered surfaces when the base and the lid are opened.
[0012] Optionally, the inner and outer seal members are configured to provide
a moisture-tight
seal.
[0013] Optionally, the inner and outer seal members are configured to be
resealable.
[0014] Optionally, the base and lid perimeters are substantially congruent.
[0015] Optionally, the base and lid perimeters are substantially registered
when the base and lid
are closed.
[0016] Optionally, the hinged container is generally clam shell shaped.
[0017] Optionally, the hinge is integral with the base and lid.
[0018] Optionally, the base has a non-round outer perimeter.
[0019] Optionally, the lid has a non-round outer perimeter.
[0020] Optionally, the perimeters are registered when the container is closed.
[0021] Optionally, any one or more of the lid, the seal member mounted in the
lid, the base, the
seal member mounted in the base, and the hinge are made of the same material.
[0022] Optionally, any one or more of, or all of, the lid, the seal member
mounted in the lid, the
base, the seal member mounted in the base, and the hinge are made of
polypropylene.
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[0023] Optionally, the hinged container incorporates a child safety feature
that makes the
container more difficult to open by a young child. In one embodiment the child
safety feature
includes at least one push tab that protrudes from a notch in the base when in
its closed or home
position. When the push tab is depressed, it causes a latch mechanism on the
child safety feature
to clear a catch feature on the lid, thereby allowing the lid to be opened. A
spring element
associated with the push tab forces the push tab back to its home position.
[0024] The present invention enables non-round package shapes by maintaining a
round, re-
sealable surface between the base and top package components. In some
embodiments, a
separate gasket material is not required to obtain a moisture-tight seal. In
some embodiments,
the advantages of a round sealing surface can be provided in a non-round
package shape.
BRIEF DESCRIPTION OF DRAWING FIGURES
[0025] Figure 1 is a side elevation of a container according to the present
invention, with the
container base and lid shown in section to illustrate the elements of the seal
within the container.
[0026] Figure 2 is a plan view of the base of the container of Figure 1, with
the lid removed.
[0027] Figure 3 is a detail view of the seal elements of the container of
Figures 1 and 2.
[0028] Figure 4 is an exploded sectional view of the components of the
container of Figures 1-3.
[0029] Figure 5 is an exploded view of the components of an alternative
embodiment of the
container.
[0030] Figure 6 is a top plan view of the child safety component of the
alternative embodiment
of Figure 5.
[0031] Figure 7 is a front view of the alternative embodiment of the container
as assembled, and
cut away to show the latching mechanism of the child safety component.
[0032] Figure 8 is a top plan view of the assembled container of Figure 5
shown with the side
tabs of the child safety feature in their depressed position.
[0033] Figure 9 is a cross sectional view taken along line 9-9 in Figure 8.
DETAILED DESCRIPTION
[0034] A typical bulk package of the present invention includes at least two
components: (1) a
base or first component and a (2) lid or second component. In an embodiment,
the base can
function as a lid or vice versa. A flip-top hinge may join the two components,
forming what is
sometimes referred to as a clamshell package or a hinged container assembly.
The bulk package
is manufactured using an injection molding process. In one embodiment, the lid
and base
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components are composed of polypropylene (PP) or polyethylene (PE). PP and PE
are
commodity plastic resins that have good moisture barrier properties. Other
suitable materials
may include, but are not limited to: polyethylene (PE - high density, low
density, LLD, VLLD),
polypropylene (PP), polyvinyl chloride (PVC), high impact polystyrene (HIPS),
cyclic olefin co-
polymer (CoC) polyethylene vinyl acetate (EVA), polystyrene (PS),
polycarbonate (PC),
polyester terephthalate (PET), polyamide (nylon), acetal copolymer or
homopolymer resin, and
liquid crystal polymer. In another embodiment, the base component may
incorporate a desiccant
plastic material and be composed of a PP or PE exterior surface and a
desiccant plastic interior
surface.
[0035] The product is typically bulk filled into the base component. In one
embodiment, a
product guide component is assembled on to the filled base component. After
product filling, the
lid component is closed onto the base component. In one embodiment, the lid
component is
closed onto the product guide component that is assembled into the base
component. During the
closing process (i.e., snapping the components together), a moisture-tight
seal is created between
the lid and base components. In one embodiment, during the closing process, a
moisture-tight
seal is created between the lid and the product guide component that is
assembled into the base
component.
[0036] The present invention relates to a resealable container, more
particularly, an edible film
package assembly having an internal sealing mechanism for storing and
packaging moisture-
sensitive items.
[0037] The assembly comprises an upper and lower component that may be
attached by a hinge.
The upper component has a circular inner skirt or seal partially or completely
spaced inward
from the outer perimeter. The lower component has a skirt or seal surface
partially or completely
spaced inward from the outer perimeter. In various embodiments the outer
perimeters can be
round or non-round, and can optionally be substantially congruent and
registered.
[0038] In an embodiment, within the lower component is a rectangular feature,
referred to as the
product tray. The product tray is formed on three sides by vertical walls or
stops and on the
fourth side by a sloped wall, referred to as the ramp. The compartment created
by these walls
may be used to hold a stack of edible films.
[0039] The circular sealing surface of the lower component includes a wall
that engages with the
upper lid, providing a tight interference fit between the upper and lower
components. In an
embodiment, when the package is in the closed position, a moisture-tight seal
is created.
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[0040] In one embodiment, the container may be molded in accordance with the
mold(s) similar
to that disclosed in U.S. Patent Nos. 4,783,056 and 4,812,116 respectively. In
a further
embodiment, with such a process and mold, the assembly, including the cap,
container, spring,
and hinge may be produced in accordance with the operation disclosed in U.S.
Patent Nos.
4,783,056 and 4,812,116 or, in another embodiment, may be produced in
accordance with U.S.
Patent No. 5,723,085 or 6,303,064.
In these references, the container is closed immediately after molding to
create
a moisture-tight seal.
[0041] In yet another embodiment, a moisture-tight seal may be achieved in the
container using
a flexible lip feature. The flexible lip seal is disclosed in publication W/O
2005/074571 A3.
[0042] In an embodiment a film guide is assembled onto the lower component.
The film guide
is assembled after product filling. The film guide snaps onto the lower
component forming a
permanent sealed or unsealed connection with the lower component. The film
guide has a
circular feature along the top surface which forms a resealable moisture-tight
seal with the
sealing surface of the upper component.
[0043] The overall shape of the bulk package of the present invention is very
flexible. The
shape may be symmetrical or asymmetrical in nature. Suitable shapes include a
square,
optionally with rounded corners, a triangle, optionally with rounded corners,
an ellipse, a
rectangle, optionally with rounded corners, a trapezoid, optionally with
rounded corners, and
numerous others.
[0044] In another embodiment, the present invention relates to a moisture-
tight and resealable
container and lid assembly. The term "resealable" means that the lid of the
container can be
opened or reopened and closed or reclosed many times (e.g. more than 10 times)
and still retain
its moisture-tight properties. As used herein, the terms "moisture-tight" and
"moisture-
sensitive" mean the moisture ingress of the container (after 1 day) is less
than about 1500
micrograms of water, in another embodiment, about 500 micrograms of water, in
a further
embodiment, about 300 micrograms of water, determined by the following test
method: (a) place
one gram plus or minus 0.25 grams of molecular sieve in the container and
record the weight;
(b) assemble the container; (c) place the closed container in an environmental
chamber at
conditions of 80% relative humidity and 22.2 C; (d) after one day, weigh the
container
containing the molecular sieve; (e) after 14 days, weigh the container
containing the molecular
sieve; and (f) subtract the 14-day sample weight from the initial weight and
divide by the
number of days (14) to calculate the moisture ingress of the container in
units of micrograms of
water per day.
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[0045] In a further embodiment, the container is resealable after repeated lid
openings and
closings. For example, the seal maintains a low ingression rate after repeated
lid
openings/closings. In one specific example, the seal maintains its low
moisture ingress
performance after 50 cycles of lid openings and closings. U.S. Patent Nos.
4,812,116,
4,807,425, 5,723,085, and 6,769,558 describe examples of embodiments of the
sealing
arrangement. In another specific
example, a resealable container can be achieved by incorporating a flexible
lip seal geometry.
The flexible lip seal is disclosed in publication W/O 2005/074571 A3.
[0046] In another embodiment a desiccant may be incorporated into the package
by making one
or more of the package components using a desiccant plastic. In one embodiment
the base
component of the hinged container has a desiccant plastic interior surface and
a PP or PE
exterior surface. The base component may be made using a 2-shot injection
molding process.
In yet another embodiment, the film guide may be made of desiccant plastic.
[0047] When the container is repeatedly opened and closed, the desiccant-
entrained plastic re-
establishes the low relative humidity environment inside the container
assembly in a short period
of time (e.g. in as low as less than about 10-minutes).
[0048] The desiccant-entrained plastic may contain a desiccant such as silica
gel or molecular
sieve as the desiccant. Depending on the application, such as the application
intended by the
end user, molecular sieve or silica gel desiccant can be provided in the
sleeve. For example,
molecular sieve can be used for applications that require a low relative
humidity (RH) (e.g. less
than <10% RH) maintained over the shelf life. In another example, silica gel
can maintain a RH
of 10-30% over the product shelf life.
[0049] Suitable desiccant entrained plastics include, but are not limited to,
the desiccant plastics
disclosed in U.S. Patent Nos. 5,911,937, 6,214,255, 6,130,263, 6,080,350,
6,174,952, 6,124,006,
and 6,221,446. By varying the desiccant
loading and polymer types in the formulation, the overall moisture capacity
and uptake rate of
the desiccant entrained plastic can be controlled.
[0050] In a further embodiment the container is provided with a child safety
feature that allows
the container to be opened relatively easily by an adult, but makes opening
the container more
difficult for a child. In a preferred aspect of this embodiment, the child
safety feature can meet
the standards for a Child Resistant Closure (CRC). The U.S. government has
established a CR
protocol to evaluate the effectiveness of closures. Child Resistant Protocol
testing is defined
under CFR Title 16, Part 1700 by the Food and Drug Administration. In general,
a child
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resistant closure must be effective with children under 5 years old and be
generally user friendly
for users over 50 years old, particularly with users over 60 years old.
[0051] Referring to Figures 1-4, an embodiment of a hinged container 10 is
shown including a
base 12, a lid 14, and a hinge 16 joining the base and lid. In the illustrated
embodiment, the
hinged container 10 is generally clam shell shaped, although this is not
essential. For example,
the hinge 16 could be omitted, or the base 12 and lid 14 could be differently
configured.
Optionally, the base 12, the lid 14, or both can have a non-round outer
perimeter, as shown in
the Figures, although the perimeter could instead be round.
[0052] The base 12 has an outer perimeter 18, and the lid 14 has an outer
perimeter 20.
Optionally, the base and lid perimeters 18 and 20 are substantially congruent
(have substantially
the same shape), and are substantially registered (i.e. the perimeters are
substantially aligned
with each other all the way around) when the base and lid are closed.
Congruence and
registration are not, however, required because it is not essential that the
base and lid perimeters
18 and 20 meet to form a seal, in the illustrated embodiment. Further, the
perimeters 18 and 20
could be congruent but not registered. For example, they could be offset.
[0053] The hinge 16 allows the lid 14 to pivot open or closed relative to the
base 12.
Optionally, the hinge is integral with the base 12 and the lid 14, although it
does not need to be
integral with the base 12, the lid 14, or either of them. Optionally, a pin
hinge or other type of
hinge can be used.
[0054] A film guide 22 is provided as well to dispense a stack of product
sheets 24. The
construction, features, and attachment of the film guide are described in more
detail later.
[0055] The container 10, and in this embodiment the lid 14, has a circular,
outwardly tapered
outer seal member 26 that defines a center axis 28. The taper is outward,
proceeding vertically
down (as shown in Figures 3 and 4) to the distal end of the flange forming the
outer seal member
26. In other words, the distal end has a larger diameter than a point spaced
above the distal end
of the flange forming the outer seal member 26.
[0056] The outer seal member 26 is mounted in fixed relation to one of the
base and the lid (as
illustrated, the lid), and is disposed at least partially within the
corresponding outer perimeter of
the base or lid to which it is mounted. In this embodiment, the outer seal
member 26 and the lid
14 are integral, and as illustrated are parts of a single piece of material.
Alternatively, they could
be separate parts, or could instead be made in a single injection mold with
one shot of material.
[0057] The container 10, and in this embodiment the base 12, has a circular,
inwardly tapered
inner seal member 30 that defines a center axis (also 28, as the two axes are
collinear in this
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embodiment when the container is closed). The taper is inward, proceeding
vertically up the
side wall 32 of the film guide 22 as shown in Figures 3 and 4). In other
words, the side wall 32
has a smaller diameter at the top corner as shown in Figures 1, 3, and 4 than
in the seal area
beneath the top corner.
[0058] The degrees of taper illustrated in the Figures are just examples, and
may vary if the
materials used are harder, softer, or more or less resilient than
polypropylene, or if the
dimensions of the seal members are set to make them more or less flexible, or
depending on the
coefficient of friction between the seal members 26 and 30, among other
factors.
[0059] The side wall 32 does not need to be tapered from bottom to top, nor
does the flange
defining the outer seal member 26 need to be tapered from bottom to top. It
will suffice if the
portions of the inner seal member 30 and the outer seal member 26 that engage
each other are
tapered, which facilitates wedging them together to form a seal.
[0060] The inner seal member 30 is mounted in fixed relation to the other of
the base and the lid
(here, the base), relative to the outer seal member 26, and is disposed at
least partially within the
corresponding outer perimeter 18 of the part to which it is mounted. In the
illustrated
embodiment, the inner seal member 30 is an upper and outer part of the film
guide 22, which is a
separate part from the base 12. In alternative embodiments, the inner seal
member 30 and the
base 12 can be integral or made in a single injection mold with one shot of
material.
Optionally, any one or more of the lid, the seal member mounted in the lid,
the base, the seal
member mounted in the base, and the hinge are made of the same material.
Optionally, they can
all be made of the same material, which does not need to be soft enough to
form a conventional
gasket. Thus, the material can be substantially rigid, not noticeably flexing
while the container
is normally used. Optionally, any one or more of, or all of, the lid, the seal
member mounted
in the lid, the base, the seal member mounted in the base, and the hinge can
be made of
polypropylene.
[0061] The inner and outer seal members are positioned to engage
concentrically to wedge the
inwardly and outwardly tapered surfaces together and form a seal when the base
and the lid are
closed. The inner and outer seal members 30 and 26 are positioned to disengage
concentrically
(i.e. with both axes substantially coinciding, as shown in the Figures) to
part the inwardly and
outwardly tapered surfaces when the base and the lid are opened. The seal or
contact length of
the inner and outer seal members 30 and 26 from top to bottom is relatively
short, so the
deviation from concentricity as the lid 14 is pivoted relative to the base 12
is slight. Another
expedient is to allow some lateral "play" in the hinge 16 in a direction
perpendicular to the axis
28 as the lid 14 is pivoted open, so the lid 14 and base 12 can be kept more
nearly concentric
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while the seal members 26 and 30 are parting. This can be provided in an
integral hinge by
elongating the narrow cross-section at the fold of the hinge, making the fold
of the hinge thinner
or weaker, providing a longer, more strap-like integral hinge, or in other
ways known in the art.
[0062] Optionally, the inner and outer seal members 30 and 26 are configured
to provide a
moisture-tight seal, as defined in this specification. Optionally, the inner
and outer seal
members 30 and 26 are configured to be resealable, as defined in this
specification.
[0063] Return now to the film guide 22. The film guide 22 has a side wall or
outer flange 32
and an inner flange 34 (shown in Figure 4), which in this embodiment is
concentric with the
outer flange 32, although it does not need to be concentric. The flanges are
joined by a circular
web 36. The web 36 has a dispensing opening 38 and a depending lip 40.
[0064] The base 12 has certain features that cooperate with the film guide 22
to define a
dispenser for the stack of sheets 24 within the container 10. The base 12 has
a circular flange
42, a re-entrant portion 44 defining a ramp that rises from left to right as
shown in Figure 4, and
a stop 46 to confine the product stack 24 to a well-defined location on the
ramp. Additional
stops (not shown) can be placed on the sides of the stack to further define
its location.
[0065] Figure 4 is an exploded view of the container 10, and in particular the
film guide 22 is a
separate piece, shown raised above its assembled position. When the film guide
22 is lowered
into assembled position, its inner and outer flanges 32 and 34 receive the
flange 42 of the base
12, and either or both of the flanges 32 and 34 engage the flange 42 to fasten
the film guide 22
in position relative to the base 12. It is useful to precisely locate the film
guide 22 in a fixed
position relative to the base 12, so the inner and outer seal members 30 and
26 will mate
properly. The flanges 32, 34, and 42 need to be complementary, but do not need
to be round,
although they can be round and, if desired, they can define inner and outer
sealing members
analogous to the inner and outer seal members 30 and 26. This might be useful
if an inner
sealed container within the outer sealed container is desired, or if the film
guide 22 functions as
the lid of the container.
[0066] Additionally, when the film guide 22 is lowered into assembled
position, the angled lip
40 can abut the ramp defined by the re-entrant portion 44, and the stops such
as 46 can abut the
web 36. This may be useful to prevent sheets from the stack 24 from sliding
laterally out of
position. In the assembled container, with the lid 14 open, a user can insert
a finger through the
dispensing opening 38, adhere the top sheet of the stack 24 to the finger, and
slide the top sheet
up the inclined top surface of the depending lip 40 to dispense the top sheet
of the stack. This
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motion can be repeated to dispense additional sheets. The sheets can be
edible, for example,
dissolving sheets of a breath freshening compound.
[0067] Other dispensing expedients can also be provided. For example, the film
guide 22 can be
omitted, the flange 42 can extend further to abut the lid 14 when the
container 10 is closed, and
the flanges 26 and 42 can interact as the inner and outer sealing members, or
vice versa. Then a
supply of tablets, capsules, a cake of cosmetic powder, cream, or gel, or
other items or materials
to be dispensed can be contained within the flange 42 and bounded by the webs
of the base 12
and lid 14.
[0068] Referring to Figures 5-9, an alternative embodiment of the container
employing a child
safety feature is illustrated. In this embodiment, the inner seal member 130
and the outer seal
member (not shown) are similar in shape, and function in a similar manner as
the inner seal
member 30 and the outer seal member 26 illustrated in Figures 1-4, to form a
seal when the base
112 and the lid 114 are closed. The base 112, however, has alternative
features that cooperate
with the film guide 122 to fasten the film guide 122 in its fixed position
relative to the base 112.
These alternative features include a plurality of locating pins 150, for
example, four locating
pins 150, mounted on the base 112, which fit within corresponding recesses on
the lower surface
of the film guide when the film guide 122 is lowered into its assembled
position on the base 112.
The locating pins keep the film guide 122 in a fixed position relative to the
base 112.
[0069] The child safety feature 152 employed in this embodiment is formed from
a flexible
plastic material and includes a latch mechanism, shown generally at 154, and
at least one push
tab, here shown as two push tabs 156, one on each side of the child safety
feature. The latch
mechanism engages a catch feature 170 on the lid 114 to lock the lid to the
base 112 when the
lid is closed. When the push tabs are depressed, as shown in Figures 8 and 9,
the latch
mechanism is released from the catch to thereby allow the lid to be opened, as
will be explained
in detail below. Associated with each push tab 156 is a spring 158 which is
deflected by the
push tab 156 when the push tab is depressed. This action creates a bias in the
spring which
causes the push tab 156 to return back to its home position when pressure on
the push tab is
released.
[0070] As illustrated in Figure 6, the child safety feature 152 can be mounted
on a bottom plate
160, which can then be joined to the base 112. Alternatively, the child safety
feature could be
incorporated into the base 112. The base 112 is provided with a notch 162 on
each side of the
base to receive each push tab 156 when the child safety feature 152 and bottom
plate 160 are
assembled to the base 112. When assembled, the push tabs 156 project outwardly
from the
sidewalls of the base 112 through the notches 162.
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[0071] The latch mechanism 154 projects through an opening 155 in the base 112
and includes
at least one latch portion 164 (here shown as two latch portions 164) having a
downward facing
abutment 166. In this instance, "downward" means facing away from the
direction in which the
lid 114 opens, and not necessarily referring to the orientation of the
container relative to its
surroundings. Each latch portion 164 engages a catch 170 (here shown as two
catches 170) that
extends downwardly from the lid 114. Each catch has an upward facing abutment
172 that
receives the downward facing abutment 166 of the latch portion 164 when the
lid 114 is in its
closed position on the base 112 to lock the lid 114 onto the base 112. In this
instance "upward"
means facing in the direction in which the lid 114 opens, and not necessarily
referring to the
orientation of the container relative to its surroundings.
[0072] To unlock the lid 114 and open the container, a user depresses the push
tabs 156 inward
toward the container. This action causes each downward facing abutment 166 on
each latch
portion 164 to move away from the upward facing abutment 172 on each catch 170
so that the
latch portion 164 clears the catch 170. Once the latch portion clears the
catch, the lid 114 can be
opened. Releasing pressure on the push tabs 156 enables each spring 158 to
force each push tab
back to its outwardly projecting home position.
[0073] Although the child safety feature is illustrated as being joined to the
base, it is
contemplated that the child safety feature could be incorporated into the lid.
In such an
embodiment, the latch mechanism could be located on the lid while the catch
feature could be
located on the base. Further, although the child safety feature is shown
incorporated into a
container that is relatively flat, it is contemplated that the child safety
feature could be
incorporated into a container of virtually any shape, as long as the container
employed a base, a
lid, and a hinge joining the lid to the base.
[0074] The foregoing description is illustrative of many contemplated
embodiments of the
invention, and does not limit the scope of the invention as defined by the
claims.
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