Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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TITLE: CONTAINER WITH REMOVABLE PORTION
FIELD
[0001] This specification relates to containers and in particular to a
container, such as a single serve capsule, having a portion that is removable
from the remainder of the container.
BACKGROUND
[0002] The following background discussion is not an admission that
anything discussed below is citable as prior art or common general knowledge.
The documents listed below are incorporated herein in their entirety by this
reference to them.
[0003] Single serve capsules for use in machines for preparing
beverages
or other products are becoming increasingly popular. Such capsules come in a
variety of formats for producing products such as espresso coffee, drip
coffee,
tea or hot chocolate.
[0004] Multi chamber capsules, such as drip coffee capsules, have a
first
chamber defined by a filter (typically a paper filter) that is loosely packed
with
ingredients (such as ground coffee) and a second chamber downstream of the
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first chamber that defines an empty space for receiving a prepared product
that
flows through the filter prior to dispensing into a cup. One example of a
multi
chamber capsule is the Keurig K-Cup TM capsule. This capsule includes a paper
filter having a side wall that is sealed to an inside peripheral edge of the
capsule.
[0005] A problem with conventional multi chamber capsules, such as the
Keurig K-cup TM capsule, is that the capsules are not adapted for recycling.
The
portion containing the precursor ingredients (such as coffee grounds) cannot
be
easily separated from the plastic outer shell. As a result, the used capsules
must
be disposed into garbage destined for landfill.
[0006] One approach to addressing this problem is provided with the
Keurig Vue TM capsule, as described in US patent application 2012/0058226. The
Vue TM capsule includes a filter that is secured to the capsule cover inwardly
from
the sidewall of the outer shell. The capsule cover with attached filter may be
peeled from the outer shell to allow the shell to be disposed into plastics
recycling while the cover and filter (with ingredients) is disposed into
garbage
destined for landfill. As a result, the Vue TM capsule provides a partially
recyclable
solution.
[0007] There are a number of problems with the Keurig VueTM capsule
solution however. The process for filling and sealing the capsule is more
complicated than for conventional capsules and the capsule is more costly to
produce as a result. Also, the used paper filter is weak, in particular when
it is
wet, and prone to tearing and spilling of ingredients when the filter and
cover are
being removed from the capsule following use.
[0008] Other forms of containers having a removable portion are also
well
known. Such containers typically include a component that is adapted to be
manipulated by a user to facilitate removal of the desired portion of the
container.
A problem with such containers is that the component tends to add complexity
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and cost to the manufacturing and packaging of the container. Another problem
with such containers is that they are not adapted to include a filter element
that is
removable.
[0009] There is a need for an improved container having one or more
removable portions that address one or more problems with conventional
containers such as the problems noted above.
SUMMARY
[0010] In one aspect the invention provides a container comprising:
a body defining an interior space having an opening;
a filter disposed in said interior space to define an ingredients chamber,
said filter
being bonded to said body with a first bond, said first bond being a peelable
bond;
ingredients disposed in said ingredients chamber;
a cover disposed over said opening for covering said interior space, said
cover
being bonded to said filter at a periphery to said opening with a second bond;
wherein said cover is adapted to be removed together with said filter upon the
application of sufficient force by hand following use of the container.
[0011] In another aspect the invention provides a container
comprising:
a body defining an interior space having an opening, said body having a flange
surrounding said opening;
a filter disposed in said body to define an ingredients chamber, said filter
being
bonded to a first surface of said flange with a first bond, said first bond
being a
peelable bond;
a separation point defined in said flange, said separation point defining a
tab that
is adapted to be separated from the remainder of said flange upon the
application of sufficient force by hand;
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ingredients disposed in said ingredients chamber;
a cover disposed over said opening for covering said interior space, said
cover
being bonded to said filter with a second bond,
wherein said tab and said cover is adapted to be removed together with said
filter
and said ingredients chamber containing said ingredients following use of the
container by the application of force by hand.
[0012] In another aspect the invention provides a container
comprising:
a body defining an interior space having an opening, said body having a flange
surrounding said opening;
a separation point defined in said flange, said separation point defining a
tab that
is adapted to be separated from the remainder of said flange upon the
application of sufficient force by hand;
ingredients disposed in said ingredients chamber;
a cover disposed over said opening for sealing said interior space, said cover
being bonded to said flange with a peelable bond;
wherein said cover is adapted to be removed by the application of sufficient
force
by hand to separate said tab and peel said cover from the remainder of said
flange.
[0013] In another aspect the invention provides a container
comprising:
a body defining an interior space having an opening, said body having a flange
surrounding said opening;
a separation point defined in said body around its circumference at a desired
location for separating one portion of said body from the remainder of said
body,
ingredients disposed in said ingredients chamber;
a cover disposed over said opening for covering said interior space;
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wherein said separation point is adapted to provide a point of separation
under
the application of sufficient force to separate a portion of said body,
including
said flange with said cover, from the remainder of said body.
[0014]
Other aspects and features of the teachings disclosed herein will
5 become
apparent, to those ordinarily skilled in the art, upon review of the
following description of the specific examples of the specification.
DRAWINGS
[0015]
The drawings included herewith are for illustrating various
examples of articles, methods, and apparatuses of the present specification
and
are not intended to limit the scope of what is taught in any way. For
simplicity
and clarity of illustration, where considered appropriate, reference numerals
may
be repeated among the drawings to indicate corresponding or analogous
elements.
[0016]
Figure 1 is a perspective view of a container in accordance with the
present invention;
[0017]
Figure 2 is a perspective view of the container of Figure 1 following
its use in a machine for preparing products from containers, the cover and
filter
being partially removed from the body;
[0018]
Figure 3 is a sectional view of the container of Figure 1 as viewed
along lines 3-3, the container being disposed in a chamber for a machine for
preparing a product from the container;
[0019]
Figure 4 is an enlarged sectional view of the container shown in
Figure 3 as viewed within circle 4;
[0020]
Figure 5 is an exploded sectional view of a container in accordance
with another embodiment of the present invention, the container having a body
and cover made from multilayered materials;
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[0021]
Figures 6 (a) to 6 (d) are enlarged sectional views of a container in
accordance with another embodiment of the present invention showing different
examples of a peelable bond between filter and body;
[0022]
Figure 7 is a perspective view of another embodiment of a
container in accordance with the present invention, showing the filter being
peeled from the body and the cover being peeled from the filter;
[0023]
Figure 8 is a perspective view of another embodiment of a
container in accordance with the present invention, showing the filter
attached to
the sidewall of the body with a tab for peeling filter from body and the cover
attached to the flange with a tab for peeling cover from body;
[0024]
Figure 9 is a side view of a container in accordance with another
embodiment of the present invention with a portion of the container being
separated from the remainder of the container;
[0025]
Figure 10 is a top view of the body for the container of Figure 9
showing one variant for the separation point;
[0026]
Figure 11 is a top view of the body for the container of Figure 9
showing another variant for the separation point;
[0027]
Figure 12 is a side view of a container in accordance with another
embodiment of the present invention showing the tab, cover and filter with
ingredients being separated from the remainder of the body;
[0028]
Figure 13 is a bottom view of the container shown in Figure 12 with
the separation point defined in the bottom surface of flange to define tab;
[0029]
Figure 14 is a schematic top view of a mold and material for
forming a plurality of bodies with a plurality of tab indicators in accordance
with
the present invention
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[0030]
Figure 15 is a perspective view of another embodiment of a
container in accordance with the present invention, showing the cover and
filter
being peeled from the body;
[0031]
Figure 16 is an enlarged sectional view of the flange for the
container of Figure 15 as viewed along lines 16-16, showing the separation
point
defining the tab prior to it being separated from the remainder of the flange
(the
cover is not shown);
[0032]
Figure 17 is a perspective view of another embodiment of a
container in accordance with the present invention;
[0033] Figure 18 is a perspective view of another embodiment of a
container in accordance with the present invention;
[0034]
Figure 19 is a perspective view of another embodiment of a
container in accordance with the present invention;
[0035]
Figure 20 is a perspective view of another embodiment of a
container in accordance with the present invention.
. DESCRIPTION OF VARIOUS EMBODIMENTS
[0036]
Various apparatuses or methods will be described below to provide
examples of the claimed invention. The claimed invention is not limited to
apparatuses or methods having all of the features of any one apparatus or
method described below or to features common to multiple or all of the
apparatuses described below.
The claimed invention may reside in a
combination or sub-combination of the apparatus elements or method steps
described below. It is possible that an apparatus or method described below is
not an example of the claimed invention. The applicant(s), inventor(s) and/or
owner(s) reserve all rights in any invention disclosed in an apparatus or
method
described below that is not claimed in this document and do not abandon,
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disclaim or dedicate to the public any such invention by its disclosure in
this
document.
[0037] A
container in accordance with one embodiment of the present
invention is shown generally at 10 in Figures 1-4. Container 10 includes a
body
12, filter 14, ingredients 16 and cover 18.
[0038]
Body 12 includes a side wall 20 and an end wall 22 together
defining an enclosed interior space 24. An opening 26 is defined at one end of
body 12. Body 12 further includes a flange 28 that extends around the
perimeter
of opening 26. Preferably, side wall 20, end wall 22 and flange 26 are all
integrally formed, such as by thermoforming, from one sheet of material.
Container 10 preferably is symmetrical with an annular flange 28 having a
uniform width W. Most preferably, container 10 has a circular cross section in
order that it does not require orientation during manufacture or during use
(in
cases where container is used in a machine for preparing beverages or other
products).
[0039]
Cover 18 includes at least one tab 30 that is adapted to provide a
grip for cover 18 to be peeled from body 12 following use of container 10 in a
machine for preparing products, such as beverages, from containers 10. Tab 30
may extend from flange 28 and fold over or, more preferably, tab 30 is
integrally
formed with flange 28 as shown for example with the embodiment depicted in
Figures 12 and 13.
[0040]
Cover 18 is preferably formed of a material that is resistant to
tearing upon the application of a peel force. Most preferably, cover 18 is
formed
of a multi-layered material that includes at least one layer that is resistant
to
tearing upon the application of a peel force. Cover 18, or a tear resistant
layer of
cover 18, preferably has a minimum tensile strength of 3000 psi and a minimum
elongation of 50%. Examples of materials that are resistant to tearing include
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polyethylene (PE), polyethylene terephthalate (PET) and polyamide PA6. A multi-
layered material for cover 18 may include at least one layer formed of a
continuous film of tear resistant material (laminated or extrusion coated) or
a
non-continuous film such as a non-woven polymer, mesh or perforated film.
Examples of a multi-layered material for cover 18 include (from outside layer
to
inside layer): PET/aluminum foil/PE, PET/EVOH/PE, PET/metalized PET/PE or
PET/PE. End wall 22 includes at least one extraction region 32 adapted for
being
pierced by at least one extraction needle 34 of a machine 36 for dispensing
product, such as a beverage, from the container 10 to a user's cup.
[0041] Filter 14 is adapted to be disposed within body 12 to define at
least
one ingredients chamber 46 in an upper region of the interior space 24 for
receiving one or more ingredients 16 and, for filtering applications, at least
one
extraction chamber 48 exterior to the ingredients chamber 46 in the interior
space 24 for receiving product, such as a beverage, from the at least one
ingredients chamber 46 prior to extraction using the extraction needle 34.
[0042]
"Filter" is defined herein to mean any material that is suitable for
defining a chamber for containing ingredients for a desired purpose. Filter
may
perform a filtering or screening function or may simply serve to separate
ingredients from the remainder of container.
[0043] "Ingredients" is defined herein to mean any material that is desired
for use within container for a desired purpose. Ingredients may include food
or
beverage ingredients or other natural or synthetic material (for example
packaging preservatives) desired for use within container.
[0044] In
the case of a container 10 for preparing a beverage as intended
for the present embodiment, ingredients 16 may be coffee grounds, tea leaves,
chocolate powder, milk powder, instant coffee or any other soluble or
insoluble
ingredients or combinations of ingredients that may be used to prepare a
beverage in a beverage preparing machine 36 as described herein.
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[0045] Filter 14 includes a gasket portion 50 that is adapted for
securing
filter 14 to body 12 as described further below. Gasket portion 50 includes a
plurality of pores, openings or channels 62 (collectively referred to as
channels
62 hereafter) suitable for securing filter 14 between cover 18 and flange 28
as
5 described herein. Filter 14 also includes a filter portion 52 that is
disposed within
interior space 24 to define ingredients chamber 46. In a preferred embodiment,
as described further below, filter portion 52 is molded to a desired shape
within
interior space 24 once gasket portion 50 has been secured to body 12 and prior
to filling with ingredients 16.
10 [0046] Filter 14 may be formed of any material suitable for
holding and,
where applicable, filtering the specific ingredients 16 that are intended to
be
disposed within ingredients chamber 46.
[0047] Preferably, for beverage filtering applications, filter 14 is
formed of a
moldable non-woven filtration material that includes a plurality of multi-
component filaments that are bound or interlocked by non-woven manufacturing
techniques (such as spunbond techniques) to form a web having channels 62
extending from one side of filter 14 to the other. The basis weight for filter
14
adapted for filtering ingredients for preparing a single serving of beverage
is in
the range of 8 to 400 grams per square meter (gsm), preferably in the range of
40 to 150 gsm and more preferably in the range of 60 to 120 gsm. More details
of
the preferred moldable nonwoven filtration material for filter 14 are provided
in
co-pending US provisional patent application No. 61/723,644 and regular US
patent application 14/074,024.
[0048] Gasket portion 50 of filter 14 is adapted to be secured by way
of a
first bond 64 to the periphery of opening 16 of body 12 (and most preferably
to
the top surface of flange 28). First bond 64 may be formed by disposing a
separate bonding material between filter 14 and body 12 or it may be
integrally
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formed from the material of one or both of filter 14 and body 12 (as shown for
example in Figure 5).
[0049]
First bond 64 preferably comprises a peelable bond between
second surface 14b of filter 14 and first surface 12a of body 12 (top surface
of
flange 28) in order that filter 14 may be peeled away from body 12.
[0050]
"Peelable bond" is defined herein to mean a bond between two
materials that is sufficiently strong to allow both materials to remain bonded
together during normal conditions for manufacture, shipment and use while
being
sufficiently weak to allow one material to be peeled away from the other
material
by hand following use.
[0051]
First bond 64 is formed from a first bonding material 66 that is
adapted for securing filter 14 to body 12. As noted above, first bonding
material
66 may be a separate material from filter 14 and body 12 or it may be an
integral
part of the material (either a monolayer material or a layer of a multi-
layered
material) for one or both of filter 14 and body 12.
[0052]
One example of a preferred first bonding material 66 is a heat
sealable polymer such as polyethylene (PE) including low density PE, linear
low
density PE and high density PE. This material may be provided as a sealing
layer
for a multi-layered material for body 12 or it may be provided as a separate
first
bonding material 66.
[0053]
Other suitable first bonding materials 66 include other heat sealable
materials such as polypropylene, lacquer, ethylene vinyl acetate (EVA),
ethylene
acrylates, polystyrene or combinations of the above. Adhesive materials
(having
comparable adhesion properties as described above to form a peelable bond)
may be utilized for applications where a heat sealer is not desired or
feasible.
[0054]
Suitable first bonding materials that may be integral with filter 14
include homocomponent materials (such as polyolefin, polyester, and polyamide)
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and multicomponent materials (such as polyester-polyolefin, polyamide-
polyolefin
and polyester-polyamide).
[0055]
Cover 18 is adapted to be secured by way of a second bond 68 to
gasket portion 50 of filter 14. In the embodiments depicted in Figures 1-6,
second
bond 68 preferably is at least as strong and more preferably is stronger than
first
bond 64 in order that filter 14 will remain secured to cover 18 when cover 18
is
peeled from body 12.
[0056]
Second bond 68 is preferably formed from a second bonding
material 70 that is adapted for securing a first surface 18a of cover 18 to
second
surface 14b of filter 14. One example of a preferred second bonding material
is a
heat sealable polymer such as polyolefin. Other suitable second bonding
materials 70 may include other heat sealable materials such as lacquer,
ethylene
vinyl acetate (EVA), and ethylene acrylates or adhesive materials for
applications
where a heat sealer is not desired or feasible.
[0057] The selection of the first bonding material 66 and second bonding
material 70 are interdependent and also depend on the selection of other
components within container 10 including filter 14. The strength or weakness
of
the bonds is related to the compatibility of the respective materials being
bonded
together. Less compatible bonds are adapted to separate prior to more
compatible bonds. More details concerning the preferred choice of bonding
materials are provided below with reference to Figures 6(a)-(d).
[0058]
For the embodiments depicted in Figures 1-6, the bond strength of
second bond 68 is preferably at least as strong as the first bond 64 and more
preferably 50% higher than that of first bond 64 and even more preferably 100%
higher or more. For example, using the ASTM F88 protocol, the bond strength of
first bond 64 is preferably no more than 20 N/15 mm and more preferably no
more than 10 N/15 mm. The bond strength of second bond 68 is preferably no
less than 15 N/15 mm and more preferably no less than 25 N/15 mm.
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[0059] First and second bonding materials 66, 70 are preferably
adapted
to become at least partially embedded within channels 62 of gasket portion 50
of
filter 14. Heat sealable polymers for example will flow into channels 62 when
melted during a heat sealing process and then form a bond within channels 62
upon cooling. In the case of filter 14 being formed of filtration material
having
multi-component fibers, one or more portions of the multi-component fibers may
melt during the heat sealing process and combine with the first or second
bonding materials while other portions of the multi-component fibers remain
intact (do not melt) during the heat sealing process to maintain a web
defining
channels 62. Preferably, second bonding material 70 is chemically compatible
in
order that it may be sealed to all the components of filter material 14 to
give a
sufficiently strong seal strength. More details of filter 14 and the manner
for
securing filter 14 and cover 18 to flange 28 of body 12 are provided in co-
pending
patent application No 13/600,582.
[0060] Referring to Figure 5, an exploded sectional view of a container 10
in accordance with another embodiment of the present invention is shown. The
same reference numerals are provided for elements that are similar to the
elements described above.
[0061] Container 10 includes body 12, filter 14, ingredients 16 and
cover
18. While the body 12 and cover 18 of container 10 shown in Figures 1-4 could
be formed of a monolayered material, body 12 and cover 18 for the embodiment
shown in Figure 5 are each formed of multilayered materials that include one
or
more barrier layers providing barriers against one or more environmental
factors
such as light, oxygen, and moisture as described further below.
[0062] Body 12 is formed of a conventional multilayered material MM1 that
includes a barrier layer B1 preferably formed of ethylene vinyl alcohol (EVOH)
and a sealing layer Si preferably formed of polyethylene (PE). As well, body
12
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may include outer base layer 01 preferably formed of polyolefin or polystyrene
or
other materials adapted to cover and protect barrier layer B1.
[0063]
Cover 18 is formed of a conventional multilayered material MM2
that includes a barrier layer B2 preferably formed of aluminum foil or
metalized
polyester or Ethylene Vinyl Alcohol (EVOH) and a sealing layer S2 preferably
formed of polyethylene or modified polyethylene or polyethylene copolymer.
Sealing layer S2 may be formed from a lamination process, extrusion coating or
lacquer coating process. As well, cover 18 may include an outer base layer 02
preferably formed of polyester and a graphics layer G2 preferably formed of
ink.
Depending upon the the type of packing machinery, cover 18 could be provided
as roll stock or in die-cut format.
[0064] It
is preferred that cover 18 is formed of multilayered material MM2
(such as described above) that is resistant to tearing as described above and
that shrinks when exposed to heat. This allows cover to be peeled away from
body 12 and also reduces the likelihood of cover 18 being torn during the
process of puncturing with injection nozzle and injecting fluid into
ingredients
chamber 46. Multilayered material MM2 of cover 18 will also preferably shrink
around the opening formed by injection nozzle when exposed to injection of hot
fluid to reduce the size of opening. These characteristics can be achieved by
choosing a proper outer base layer 02 such as polyester for providing rigidity
to
the cover 18.
[0065]
Filter 14 is formed by disposing filtration material over opening 26
of body 12. Gasket portion 50 of filter 14 engages sealing layer 51 disposed
on
the top surface of flange 28 and filter portion 52 extends across opening 26.
Gasket portion 50 is then sealed with a heat sealer to sealing layer 51
disposed
on the top surface of flange 28. A portion of sealing layer 51 on top surface
of
flange 28 (also referred to herein as first bonding material 66) is melted by
heat
sealer and flows into channels 62 within gasket portion 50. The gasket portion
50
of filter 14 may be partially melted during this process if it contains
multiple
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component fibres while other portions of the multi-component fibers remain
intact
(do not melt) during the heat sealing process to maintain a web defining
channels
62.
[0066] In
addition to choosing desired first and second bonding materials
5 66,
70, the temperature, pressure and time parameters for the heat sealing
process are optimized to ensure the desired bonding strength is achieved for
both first bond 64 and second bond 68. For example, with respect to both first
bond 64 and second bond 68, the sealing temperature is preferably in the range
of 100-250 C and more preferably in the range of 160-220 C. The sealing
10
pressure is preferably in the range of 0.5-4 bar and more preferably in the
range
of 1-3 bar. The sealing time is preferably in the range of 50-5000
milliseconds
and more preferably in the range of 500-3000 milliseconds.
[0067]
Once the melted first bonding material 66 sufficiently cools to form
first bond 64 to secure gasket portion 50 to flange 28, then filter 14 may be
15 molded
for instance by engaging filter portion 52 using a heated mandrel to mold
filter portion 52 to a desired shape within interior space of body 12 to form
the
ingredients chamber 46. Then ingredients 16 are disposed within ingredients
chamber 46 of filter 14 and cover 18 is positioned over gasket portion 50 to
cover
opening 26.
[0068] Cover 18 may then be partially sealed to gasket portion 50 using a
heat sealer. A portion of the sealing layer S2 (also referred to herein as
second
bonding material 70) on bottom surface of cover 18 is melted by a heat sealer
and flows into channels 62 of gasket portion 50. The air within interior space
16
of container 10 may then be evacuated and replaced with an inert gas such as
nitrogen in accordance with a modified atmosphere packaging process. The
remainder of cover 18 may then be fully sealed to body 12 over gasket portion
50
as described above to form second bond 68 and seal interior space 16 of
container 10.
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[0069]
Body 12 preferably includes a notch 72 cut into at least sealing
layer Si (first bonding layer 66) below the periphery of opening 16. Notch 72
may, in certain applications where barrier properties are not excessively
compromised, also extend into barrier layer B1 if necessary to provide a
sufficient area weakness as discussed below. Notch 72 provides an area of
weakness for ingredients chamber and first bonding material 66 (in this
instance
sealing layer Si at gasket 50) to be separated from body 12 when tab 30 is
pulled to peel cover 18 from body 12 following use of container 10.
[0070]
Adhesion or tie layers T may be disposed in known manner
between the respective layers B1, 51, 01 and G1 as described above to adhere
or tie the respective layers together. Adhesion or tie layers T in body 12 may
provide a relatively weak connection between adjoining surfaces to allow for
separating layers when peeling cover 18 and ingredients chamber 46 from body
12.
[0071] Referring to Figures 6 (a)-(d), a number of examples of a peelable
bond between filter 14 and body 12 are shown.
[0072]
Figures 6(a) and 6(b) show first bond 64 being formed using a
separate material (first bonding material 66) disposed between first surface
14a
of filter 14 and first surface 12a of body 12.
[0073] In Figure 6(a) the peel strength of the first bond 64 between first
surface 14a of filter 14 and first bonding material 66 is greater than the
peel
strength of the first bond 64 between first bonding material 66 and first
surface
12a of body 12. As a result, filter 14 and first bonding material 66 are
peeled
away from first surface 12a of body 12 upon the application of a sufficient
peeling
force to filter 14.
[0074]
The choice of materials for the example shown in Figure 6(a)
include the following. Filter 14 may be formed of 20% LDPE or LLDPE and
cover 18 may be formed of PE, EVA, EAA or a combination of two or more of
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these materials. In this case, first bonding material 66 and second bonding
material 70 may be formed from LDPE, EVA (Dupont Bynel TM) or modified PE
(Dow Sealution ).
It will be understood that other choices of materials may
selected as well.
[0075] In Figure 6(b) the peel strength of the first bond 64 between first
surface 14a of filter 14 and first bonding material 66 is less than the peel
strength
of the first bond 64 between first bonding material 66 and first surface 12a
of
body 12. As a result, filter 14 is peeled away from first bonding material 66
upon
the application of a sufficient peeling force to filter 14.
[0076] The choice of materials for the example shown in Figure 6(b)
include the following. Filter 14 may be formed of 20% LDPE or LLDPE, PP, PA
or Polyester and cover 18 may be formed of a PE, EVA, EAA or a combination of
two or more of these materials. In this case, first bonding material 66 may be
formed from LDPE, EVA (Dupont BynelTM) or modified PE (Dow SealutionTm).
Second bonding material 70 may be formed from polyester or other suitable
materials provided that the second bond 68 is stronger than first bond 64. It
will
be understood that other choices of materials may selected as well.
[0077]
Figures 6(c) and 6(d) show first bond 64 being integrally formed
from a layer of a multilayered material MM1 forming body 12.
[0078] In Figure 6(c) the peel strength of the first bond 64 between first
surface 14a of filter 14 and first bonding material 66 (which is the sealing
layer
51 of the multilayered material MM1 forming body 12) is greater than the peel
strength of the first bond 64 between first bonding material 66 and the
adjacent
layer of the multilayered material MM1. The adjacent layer may be a tie layer
formed of a low compatibility material such as Surlyn TM or Bynel TM or
adjacent
layer may be barrier layer B1. As a result, filter 14 and first bonding
material 66
(ie a portion of the sealing layer 51 of multilayered material MM1) are peeled
away upon the application of a sufficient peeling force to filter 14. This
example is
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18
described in more detail above with reference to Figure 5. Notch 72 defines a
break point to allow a portion of sealing layer Si to be removed with filter
14
while the remainder of sealing layer Si stays within body 12.
[0079]
The choice of materials for the example shown in Figure 6(c)
include the following. Filter 14 may be formed of 20% LDPE or LLDPE, PP, PA
or Polyester and cover 18 may be formed from PE, EVA, EAA or a combination
of two or more of these materials . In this case, first bonding material 66
may be
formed from LDPE, LLDPE, HDPE, EVA or a combination of two or more of
these materials. Second bonding material 70 may be formed from PE, EVA, EAA
or a combination of two or more of these materials. It will be understood that
other choices of materials may selected as well.
[0080] In
Figure 6(d) the peel strength of the first bond 64 between first
surface 14a of filter 14 and first bonding material 66 is less than the peel
strength
of the first bond 64 between first bonding material 66 and the adjacent layer
of
the multilayered material MM1. As a result, filter 14 is peeled away from
first
bonding material 66 (ie away from first surface 12a of body 12 or, in other
words,
away from sealing layer Si of multilayered material MM1 that forms body 12)
upon the application of a sufficient peeling force to filter 14.
[0081] The choice of materials for the example shown in Figure 6(d)
include the following. Filter 14 may be formed of 20% LDPE or LLDPE and
cover 18 may be formed of PE, EVA, EAA or a combination of two or more of
these materials. In this case, first bonding material 66 (sealing layer Si)
may be
formed from HDPE, PP or PS. Second bonding material 70 may be formed from
PE, EVA, EAA or a combination of two or more of these materials. It will be
understood that other choices of materials may selected as well.
[0082]
Referring to Figure 7, a container 10 in accordance with another
embodiment of the present invention is shown. The same reference numerals are
provided for elements that are similar to the elements described above.
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[0083]
Container 10 includes body 12, filter 14, ingredients 16 and cover
18. If desired, body 12 and cover 18 may each be formed of multilayered
materials that include one or more barrier layers providing barriers against
one or
more environmental factors such as light, oxygen, and moisture as described
further below.
[0084] In
this embodiment, second bond 68 between filter 14 and cover 18
comprises a peelable bond similar to first bond 64 as described for the
embodiments above. For example, the peel strength of the second bond 68
between second surface 14b of filter 14 and second bonding material 70 may be
less than the peel strength of the second bond 68 between second bonding
material 70 and the first surface 18a of cover 18. As a result, filter 14 may
be
peeled away from second bonding material 70 (ie away from first surface 18a of
body 12) upon the application of a sufficient peeling force to filter 14.
[0085]
Filter 14 and cover 18 also preferably each include tabs 30a and
30b that are preferably aligned to provide a common grip for peeling filter
14,
ingredients 16 and cover 18 from body 12. Tabs 30a and 30b may then be
separately gripped to peel cover 18 away from filter 14 and ingredients 16.
This
allows the user to dispose of body 12, filter 14, ingredients 16 and cover 18
in
one of multiple desired locations.
[0086] The choice of materials for the example shown in Figure 7 include
the following. Filter 14 may be formed of 20% LDPE or LLDPE and cover 18
may be formed of HDPE, PP or PS. In this case, first bonding material 66
(sealing layer Si) and second bonding material 70 (sealing layer S2) may be
formed from HDPE, PP or PS.. Alternatively, filter 14 may be formed of 20%
LDPE or LLDPE, PP, PA or Polyester and cover 18 may be formed from LDPE,
LLDPE, HDPE, EVA or a combination of these materials. In this case, first
bonding material 66 (sealing layer Si) and second bonding material 70 (sealing
layer S2) may be formed from LDPE, LLDPE, HDPE, EVA or a combination of
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these materials.. It will be understood that other choices of materials may
selected as well.
[0087]
Referring to Figure 8, a container 10 in accordance with another
embodiment of the present invention is shown. The same reference numerals are
5 provided for elements that are similar to the elements described above.
[0088]
Container 10 includes body 12, filter 14, ingredients 16 and cover
18. If desired, body 12 and cover 18 may each be formed of multilayered
materials that include one or more barrier layers providing barriers against
one or
more environmental factors such as light, oxygen, and moisture as described
10 further below.
[0089] In
this embodiment, filter 14 is secured to sidewall 20 of body 12 by
way of first bond 64 using first bonding material 66. First bond 64 is a
peelable
bond as described above. Filter 14 includes tab 30a that provides a grip for
peeling filter 14 from body 12. Tab 30a is preferably folded away from flange
28.
15 [0090]
Cover 18 is secured to flange 28 of body 12 by way of second bond
68 using second bonding material 70. Second bond 68 is also a peelable bond
as described above. Cover 18 includes tab 30b that provides a grip for peeling
cover 18 from body 12.
[0091] As
a result, once container 10 has been used for its intended
20
purpose, a user will grip tab 30b to peel cover away from body 12. The user
will
then grip tab 30a to peel filter 14 together with ingredients 16 away from
body 12.
This allows the user to dispose of body 12, filter 14, ingredients 16 and
cover 18
in one of multiple desired locations.
[0092]
The choice of materials for the example shown in Figure 8 include
the following. Filter 14 may be formed of 20% LDPE or LLDPE and cover 18
may be formed of LDPE, LLDPE, HDPE, EVA, modified PE or a combination of
these materials. In this case, first bonding material 66 (sealing layer 51)
and
second bonding material 70 (sealing layer S2) may be formed from HDPE, PP or
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21
PS.. Alternatively, filter 14 may be formed of 20% LDPE or LLDPE, PP, PA or
Polyester and cover 18 may be formed from LDPE, LLDPE, HDPE, EVA or a
combination of these materials. In this case, first bonding material 66
(sealing
layer Si) and second bonding material 70 (sealing layer S2) may be formed from
LDPE, LLDPE, HDPE, EVA or a combination of these materials. It will be
understood that other choices of materials may selected as well.
[0093]
Referring to Figures 9-11, a container 10 in accordance with
another embodiment of the present invention is shown. The same reference
numerals are provided for elements that are similar to the elements described
above.
[0094]
Container 10 includes body 12, filter 14, ingredients 16 and cover
18. If desired, body 12 and cover 18 may each be formed of multilayered
materials that include one or more barrier layers providing barriers against
one or
more environmental factors such as light, oxygen, and moisture as described
further below.
[0095]
Instead of having a separation of cover 18 and ingredients chamber
46 from body 12, this embodiment provides a separation of one portion of body
12, such as flange 28, from the rest of body 12. Cover 18 with filter 14
defining
ingredients chamber 46 containing ingredients 16 remains connected to the
removed portion of body 12, such as flange 28, following such separation.
[0096]
Continuing with the example where flange 28 is being removed
from the remainder of body 12, a separation point 80 is defined in body 12
preferably proximate to the interface between flange 28 and side wall 20.
Separation point 80 may be a score line (a continuous indentation) or
perforation
line (a line of discrete indentations) that is adapted to break or separate
upon the
application of force. Separation point 80 may be defined in body 12 either
during
or following the process for forming body 12 for instance by thermoforming.
The
separation point 80 may be defined only in the outer surface (second surface
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22
12b) of body 12 or it may be defined in both the outer surface and inner
surfaces
(second surface 12b and first surface 12a) of body 12. Preferably, separation
point 80 is formed through an in-mold cutting process during thermoforming of
body 12 or at a separate station following formation of body 12.
[0097] In one variant as shown in Figure 10, separation point 80 may
extend about circumference of body 12 and be adapted to separate upon
application of opposing twisting forces to flange 28 and side wall 20 (as
shown in
figure 6) similar to twisting a cap from a bottle. Separation point 80 is
shown
defined in flange 28 adjacent to the interface with side wall 20. It will be
understood that separation point 80 could alternatively be defined in side
wall 20
proximate to interface with flange 28. Filter 14 may be bonded to side wall 20
between separation point 22 and flange 28. Filter 14 is preferably formed of a
non-woven material as described above but may alternatively be formed from a
conventional paper filter material if desired since it is not subjected to
significant
tear forces.
[0098] In
another variant as shown in Figure 11, separation point 80 may
be defined in flange 28 about circumference of body 12 and include a portion
extending to peripheral wall of flange 28 to define tab 30 for peeling flange
28
with cover 18 and filter 14 with ingredients chamber 46 from the remainder of
body 12.
[0099]
Referring to Figures 12-13, a container 10 in accordance with
another embodiment of the present invention is shown. The same reference
numerals are provided for elements that are similar to the elements described
above.
[00100] Container 10 includes body 12, filter 14, ingredients 16 and cover
18. If desired, body 12 and cover 18 may each be formed of multilayered
materials that include one or more barrier layers providing barriers against
one or
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23
more environmental factors such as light, oxygen, and moisture as described
further below.
[00101] In
this embodiment, cover 18 is bonded with second bonding
material 68 to the first surface 12a of body 12 (top surface of flange 28) in
the
same manner as described for the embodiments shown in Figures 1-6.
[00102] A
separation point 80 is defined along at least one portion of body
12, such as flange 28, to form at least one tab 30 (and preferably two tabs 30
as
shown). Separation point 80 may be formed for example by a score line or
perforation line that is adapted to break or separate from flange 28 upon the
application of sufficient force. The force for instance may be applied by
upward
pressure, for instance by a person's thumb, along the bottom side of tab 30
until
tab 30 snaps and separates from flange 28.
[00103]
Separation point 80 is preferably made through scoring or
perforating during the same operation that is utilized for thermoforming body
12
or at a subsequent station. Separation point 80 may be defined along the
second
surface 12b of body 12 (bottom surface of flange 28) without significantly
disrupting or negatively impacting the ability of cover 18 to be peelably
sealed to
the top surface of flange 28 such as described for the embodiments shown in
Figures 1-6. Separation point 80 may for instance extend a desired distance
into
the bottom surface of flange 28 without breaking the top surface. Preferably,
separation point 80 is defined in both the outer surface and inner surfaces
(second surface 12b and first surface 12a) of body 12. Preferably, for
containers
10 formed of multilayered materials MM, separation point 80 does not break or
significantly disrupt the barrier layer B.
[00104] Preferably, a tab indicator 82 is disposed on body 12 to indicate
the
location of tab 30. Tab indicator may be embossed onto the outer surface of
sidewall 20 of body 12 in the same operation utilized for thermoforming body
12.
Tab indicator 82 may alternatively be printed or adhered onto the material for
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24
forming body 12 at locations that align with the molds 84 that are adapted for
formation of body 12 and separation point 80 as shown in Figure 14.
[00105]
Following use of container 10, allowing sufficient time for the
container 10 to cool if necessary, a user will apply force to tab 30 along the
bottom portion of tab 30 until the tab 30 snaps free from the remainder of
flange
28 along separation point 80. The user may hear a snap sound to indicate that
tab 30 has separated from flange 28. The user then applies a peeling force to
tab
30 in order to peel cover 18 and filter 14 with ingredients chamber containing
ingredients 16 from body 12. Body 12 may be disposed into plastics recycling
and cover 18 and filter 14 with ingredients chamber and ingredients 16 may be
disposed into garbage destined for landfill or further processed or separated
for
disposal or recycling purposes.
[00106] As
noted earlier, container 10 preferably is symmetrical with an
annular flange 28 having a uniform width W with separation point 80 defining
tab
30 within the uniform width W of flange 28. This is preferable to having a
portion
of flange 28 with tab 30 extend beyond the uniform width W of the remainder of
flange 28 which could complicate the manufacture and packaging of container 10
and which may prevent conta8iner from being utilized in a machine 36.
[00107]
Referring to Figures 15 and 16, a container 10 in accordance with
another embodiment of the present invention is shown. The same reference
numerals are provided for elements that are similar to the elements described
above.
[00108]
Container 10 includes body 12, ingredients 16 and cover 18. If
desired, body 12 and cover 18 may each be formed of multilayered materials
that
include one or more barrier layers providing barriers against one or more
environmental factors such as light, oxygen, and moisture as described further
below.
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[00109]
This embodiment of container 10 is similar to the embodiment
shown in Figure 12 and 13 but does not include filter 14. A tab 30 is defined
in
body 12 (preferably in flange 28) by separation point 80. Cover 18 is bonded
by
second bond 68 to the portion of body 12 (preferably to flange 28) that
includes
5 tab 30
defined by separation point 80. Second bond 68 is a peelable bond as
described above to allow cover 18 to be peeled away with tab 30 from the
remainder of body 12. Tab indicator 82 is provided, as described above, to
assist
the user in locating tab 30.
[00110]
This embodiment may be applied to a wide variety of containers 10.
10 The
separation point 80 defining tab 30 may be integrally formed within the body
12 of container 10 without adding significant costs or adding significant
complexity to the overall structure of the container.
[00111]
Referring to Figure 17, a container 10 in accordance with another
embodiment of the present invention is shown. The same reference numerals are
15 provided for elements that are similar to the elements described above.
[00112]
Container 10 includes body 12, filter 14, ingredients 16 and cover
18. In this embodiment, body 12 comprises flange 28 and a partial side wall 20
adapted to support filter 14. Body 12 does not include a full side wall 20 and
end
wall 22 for defining a fully enclosed interior space.
20
[00113] In all other respects, container 10 is similar to the embodiments
described above with a portion of container 10 being removable from the
remainder of container 10. For example, filter 14 may be bonded to body 12
(either to flange 28 or side wall 20) with a first bond 64 that is a peelable
bond.
Cover 18 may be bonded to filter 14 or to body 12 (such as to flange 28) with
a
25 second bond that may also be a peelable bond if desired.
[00114]
Referring to Figure 18, a container 10 in accordance with another
embodiment of the present invention is shown. The same reference numerals are
provided for elements that are similar to the elements described above.
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26
[00115]
Container 10 includes body 12, filter 14, ingredients 16 and cover
18. If desired, body 12 and cover 18 may each be formed of multilayered
materials that include one or more barrier layers providing barriers against
one or
more environmental factors such as light, oxygen, and moisture as described
further below.
[00116] In
this embodiment, body 12 further comprises a shoulder 90
disposed inwardly from flange 28 to support filter 14. Filter 14 may be bonded
to
a support ring 92 that is adapted to either rest loosely upon shoulder 90 as
shown or be bonded to shoulder with a first bond 64 that is preferably a
peelable
bond (not shown). Cover 18 is bonded to flange 28 with second bond 68 that is
a
peelable bond as described for the embodiments above.
[00117]
This embodiment of container allows filter 14 to be disposed within
container 10 without bonding to the same flange surface as cover 18. Upon
peeling away cover 18 following the use of container 10, filter 14 and
ingredients
16 may be removed from container either by tipping container upside down (if
ring rests loosely upon shoulder 90) or by peeling away ring and filter 14
preferably with the aid of a tab (not shown).
[00118]
Referring to Figure 19, a container 10 in accordance with another
embodiment of the present invention is shown. The same reference numerals are
provided for elements that are similar to the elements described above.
[00119]
Container 10 includes body 12, filter 14, ingredients 16 and cover
18. If desired, body 12 and cover 18 may each be formed of multilayered
materials that include one or more barrier layers providing barriers against
one or
more environmental factors such as light, oxygen, and moisture as described
further below.
[00120] In
this embodiment, container 10 is similar to the container shown
in Figure 18. Shoulder 90 includes a slot 94 that is adapted to receive a
portion of
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27
filter 14 and support ring 92. Support ring 92 is preferably configured to
support
filter 14 within slot 94 by way of a friction fit.
[00121] This embodiment of container also allows filter 14 to be
disposed
within container 10 without bonding to the same flange surface as cover 18.
Upon peeling away cover 18 following the use of container 10, filter 14 and
ingredients 16 may be removed from container by peeling away ring and filter
14
preferably with the aid of a tab 30.
[00122] Referring to Figure 20, a container 10 in accordance with
another
embodiment of the present invention is shown. The same reference numerals are
provided for elements that are similar to the elements described above.
[00123] Container 10 includes body 12, filter 14, ingredients 16 and
cover
18. If desired, body 12 and cover 18 may each be formed of multilayered
materials that include one or more barrier layers providing barriers against
one or
more environmental factors such as light, oxygen, and moisture as described
further below.
[00124] In this embodiment, container 10 is similar to the container
shown
in Figure 19 however no shoulder 90 is provided. Instead, slot 94 is defined
in
flange 28. Slot 94 is adapted to receive a portion of filter 14 and support
ring 92.
[00125] Cover 18 is bonded to support ring 92 as well as to flange 28
by a
peelable bond. Upon peeling away cover 18 following the use of container 10,
filter 14 and ingredients 16 may be removed from container.
[00126] The scope of the claims should not be limited by the
embodiments
set forth in the examples, but should be given the broadest interpretation
consistent with the description as a whole.
