Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
WO 2017/096410 PCT/US2017/015814
TITLE OF THE DISCLOSURE
[0001] Container Having a Retained, Externally Displaceable Drain Insert
BACKGROUND OF THE DISCLOSURE
[0002] The invention relates generally to the field of shaped
containers, especially those
intended to segregate liquid and solid contents.
[0003] Shaped thermoplastic containers such as trays, bowls, and boxes
are widely used to
contain materials for shipping, display, and sale, such as for single-serving
containers including
meat containers and cups containing enough tea or coffee to make a single
serving of a
beverage. When wet items are to be contained, containers that are relatively
impervious to
liquid are employed, together with a lid, cover, or enveloping wrap to retain
liquid within the
container. For example, wrapped trays, cover-sealed boxes, and other
containers are commonly
used to contain and display food items at the point of sale. By way of
example, cuts of meat
and poultry are commonly sold at retail outlets (e.g., in supermarkets or at
butcher shops) in
packaging containers in which the cut is supported by a plastic or foam tray
and wrapped with a
polymeric sheet, at least a portion of which includes a clear window through
which the cut may
be viewed by potential purchasers. By way of further example, prepared solid
or semi-solid
foods arc sometimes packaged in containers having a clear film or cover
through which the
food can be viewed.
[0004] In such containers, liquid that runs off from or is exuded from
items on the container
can form a pool or puddle within the container, and it can be undesirable for
such a pool or
puddle to be visible to one handling the container (e.g., a customer
considering whether to
purchase the container and its contents). Liquid in a food container can also
harbor
microorganisms, support their growth, and facilitate their transfer among
items within the
container, leading to spoilage of food items, appearance of spoilage, or both.
Furthermore,
transfer of free liquid from one component of a packaged food item to another
(e.g., liquid
exuded from a cooked meat item and absorbed by a pasta component packaged in
the same
container) can degrade the desirability or other properties of the food
components. In each of
these situations, it is desirable that liquid within the container be
sequestered. Contact between
solid and liquid components can also contribute to degradation of one or the
other. For
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example, a cut of meat can spoil or develop an undesirable appearance more
quickly when left
in contact with exudate from the meat.
[0005] Sequestration of undesirable liquids within containers has been
effected by others by
configuring containers such that they include a portion into which liquid may
drain under the
influence of gravity. An example of such a container is a meat tray having a
roughly planar
region for supporting a cut of meat and a trough surrounding the planar region
into which meat
exudate (often termed "purge" by workers in this field) or other fluids can
flow under the
influence of gravity. A drawback of such containers is that when a potential
purchaser handles
the container, liquid within the trough can flow under gravity to other
portions of the container,
potentially spilling or becoming visible in a clear portion of a flexible
polymeric wrapper that
encompasses the container. Gravity-dependent packaging can also be of little
assistance for
separating liquids from items capable of absorbing it.
100061 Liquid sequestration within containers has also been effected by
others by including
within a container a material (e.g., silica gel, porous paper, and liquid-
absorbing fibrous or
amorphous polymer materials) that absorbs intra-container liquid. Such
absorbent materials
can reduce spilling and intra-container flow of purge and other liquids.
However, whether
imbued with liquid or not, absorbent materials can adversely affect disposal
of the packaging
once it is no longer needed. By way of example, absorbent materials
(especially those having
fluid retained therein) can adversely affect the recyclability of the
packaging or the willingness
of a refuse source to accept the used packaging. In the context of food
packaging, the absorbent
materials can also be unsightly upon unpackaging and can harbor pathogens or
organisms
which cause or promote spoilage when maintained in close contact with food
items. The
absorbent material can segregate these fluids and organisms from stored
articles (e.g., a cut of
meat physically segregated from the absorbent material).
100071 Use of drain trays within containers which include compartments
(e.g., channels or
voids) therein for sequestering undesirable fluid is also known. Drain trays
are substantially
planar sheets of (usually) plastic having one or more perforations extending
therethrough and
typically having 'feet' or 'legs' extending perpendicular to the tray, which
serve to maintain an
upper portion of the drain tray above the container surface upon which the
drain tray rests,
thereby maintaining a space into which can flow liquid which passes from the
upper portion of
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the drain tray through a perforation. The feet or legs typically also serve to
support the weight
of items placed atop the drain tray without breaking or buckling the drain
tray. An example of
such a drain tray is the Cambro model 9OPPD 1/9 Size translucent polypropylene
drain tray
product (top and oblique underside views shown in Figs. 11A and 11B,
respectively),
manufactured by Cambro USA (Huntingdon Beach, CA). The complicated shape of
such drain
trays contributes to their expense and the difficulty of manufacturing them
and containers that
include them. For example, drain trays are less or ineffective if inserted in
an inverted position
(i.e., with the upper tray surface resting on the container surface on which
the feet or legs are
intended to rest). The complex shape of such drain trays also complicates
packaging and
shipment of the drain trays to an assembler.
[0008] A shortcoming of existing drain trays is that they typically
simply rest within a
container (i.e., are contained within the interior of the container and remain
there owing to the
influence of gravity). Another shortcoming is that it can be difficult or
cumbersome to
sandwich other components (e.g., an absorbent pad) between the drain tray and
the bottom of
the container within which it rests, and compression of an absorbent pad can
reduce its
absorbent capacity. Still another shortcoming is that containers which include
a drain tray must
typically be assembled at the site of use, including insertion of an absorbent
material between
the drain tray and the container, and such assemblies can be easily disturbed
between the time
of their assembly and when they are actually used.
[0009] Disposal of used containers accounts for a tremendous amount of
solid waste and
burned rubbish. In recent decades, significant effort has been expended to
reduce the quantity
of such waste and to increase the amounts of such waste that are usable and
used in recycled
products. Food containers in particular have proven to be recalcitrant to
waste-reduction
efforts, especially those which include absorbent materials to absorb
exudates. Although many
containers can be disassembled by an end user to remove non-recyclable
materials (e.g., soiled
absorbent materials), the undesirable appearance, odor, or texture or the
amount of effort
required to effect such removal dissuades some end users from disassembling
used containers
and separating their recyclable and non-recyclable components. Reluctance by
end users to
disassemble such containers can be caused by the need for such users to touch
the soiled
interior of the container and its remaining contents after the product has
been removed.
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100101 Food trays and other food packages need to have sufficient size,
bulk, and rigidity to
contain and support food products throughout the handling involved in food
harvesting,
preparation, shipping, and selling processes. Such containers need also comply
with sanitary
and regulatory needs to prevent food contamination and spoilage. They also
need to contain
and display contained foodstuffs in a manner consistent with ordinary retail
marketing.
Furthermore, in order to avoid being considered non-recyclable refuse by end
users and
recyclers, such containers need also be readily separable from visible and
perceived
contamination by food residue.
[0011] A need exists for containers which are capable of containing
segregating solids and
liquids contained therein in a safe, practical, and marketable condition and
which are
nonetheless substantially recyclable. Such containers are disclosed herein, as
are methods of
making and using them.
[0012] A need also exists for containers which have the capacity to
sequester fluid present
within the container and which have favorable disposability characteristics
even upon
sequestration of fluid. Such containers are disclosed herein, as are methods
of making and
using them.
BRIEF SUMMARY OF THE DISCLOSURE
[0013] The disclosure relates to a container for containing articles,
and preferably for
segregating those articles from liquids or small particles that may be or be
generated within the
storage compartment of the container. The container includes a shaped (e.g.,
thermoplastic)
body and an insert. The body has a shape that includes an exterior surface, a
peripheral rim,
and an interior surface within the rim. The interior surface defines a storage
space, a reservoir
recessed away from the storage space at an opening between the storage space
and the
reservoir, a shelf portion within the reservoir, and an overhang extending
into the storage space.
The overhang is distally spaced from the shelf, relative to the reservoir. The
insert is interposed
between the shelf portion and the overhang at a position at which the shape
and conformation
of the insert arc sufficient to segregate the interior of the reservoir from
the storage space, other
than at one or more channels having dimensions sufficient to occlude articles
from passing
from the storage space into the reservoir, while permitting passage of liquid
or small particles
through the channel(s). At least a portion of the body is sufficiently
flexible that the insert can
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be displaced from the body by manually applying pressure to the exterior of
the body by a
person of ordinary strength who is holding the container at one or both of its
rim and its exterior
face. By way of example, the body can be made sufficiently flexible at the
reservoir that the
insert can be displaced from the body by pressure manually applied to the
exterior face of the
body at the reservoir. Alternatively, the body can be made sufficiently
flexible at its rim that
the insert can be displaced from the body by flexing the rim sufficiently to
deflect one or more
shelf portions or overhangs to a position at which the insert is no longer
interposed between at
least one shelf portion-overhang pair. As yet another example, the insert can
be made
sufficiently flexible that it can be substantially bent when pressure is
applied to the insert by
impingement thereon of a portion of the body that is deflected by pressure
manually applied to
the exterior of the body by a person of ordinary strength.
[0014] The container body can include a sufficient number of paired
shelf portions and
overhangs about the opening of the reservoir that the insert is not displaced
from the body when
the container is gently tumbled in space. The shelves can, for example, extend
from the interior
surface of the container body into the reservoir and can abut the reservoir. A
single shelf
portion can, for example, abut the reservoir and extend along a substantial
portion (e.g., at least
about one quarter, one half, or even the entirety) of the periphery of the
reservoir. The shelf
portion(s) are preferably integral parts of the body, but they need not be.
[0015] Within the container at least one overhang preferably overlaps
at least one shelf
portion. The body can include multiple overhangs and the insert can be
interposed between the
multiple overhangs and one or more shelf portions at at least two positions
about the periphery
of the reservoir, such as positions on opposite sides of the reservoir or at
four positions about
the periphery of the reservoir. Like the shelf portion, the overhang can, for
example, extend
along a substantial portion (e.g., at least about one quarter, one half, or
even the entirety) of the
periphery of the reservoir. Also like the shelf portion, the overhang(s) are
preferably integral
parts of the body, but they need not be. In some embodiments, the spacing
between the shelf
portion and the overhang is preferably not more than ten times (or, more
preferably, about
twice) the thickness of the portion of the insert that is interposed between
the shelf portion and
the overhang.
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100161 The container body can include a support bearing the shelf
portion that extends
inwardly from the interior of the reservoir toward the insert. Such a support
can be integral
with the body and extends approximately to the insert. The body can include
two or more
supports, each supports positioned sufficiently close to the rim that an adult
human having
hands of ordinary size can insert the thumb of each hand into one of the
supports while gripping
the rim with the at least one other finger of each hand. The body can include
multiple supports
spaced at varying distances from the rim, to accommodate human hands of
various ordinary
sizes.
100171 In one embodiment the insert is a substantially flat plate
having a shape that
substantially covers the periphery of the reservoir, other than at an
indentation at the peripheral
edge of the insert. The insert can includes multiple peripheral indentation.
In another
embodiment, the insert is a substantially flat plate having a shape that
substantially covers the
periphery of the reservoir, the insert having at least one perforation
extending therethrough.
100181 The container body can be made from a variety of materials, such
as a sheet of a
thermoformable plastic (i.e., thermoformed into the shape of the body) or a
paper pulp material.
Examples of such materials include polyesters, polypropylenes, polyvinyl
chlorides,
polyethylene terephthalates, polystyrenes, and combinations of these. The body
can have a
peelable liner adhered to it and interposed between the body and the insert.
The insert can be
made of the same material as the body, if desired.
100191 An absorbent material positioned can be positioned within the
reservoir of the
container. Such a material may, for example, be a woven material. The
absorbent material can
be in the form of an integral piece that is not fixedly attached to either of
the body and the
insert, so as to facilitate its removal from the container. Alternatively, the
absorbent material is
attached to the insert, or to the body.
BRIEF SUMMARY OF THE SEVERAL VIEWS OF THE DRAWINGS
100201 Figure 1 includes Figures IA, 1B, IC, and ID and illustrates an
embodiment of a
tray-shaped container described herein. Figure IA is an overhead view of the
shaped article 10
(which here has the form of a tray), looking into the concave interior of the
tray. Visible in this
view are the rim 12 of the tray 10, a downwardly-sloping inner wall 14 from
which multiple
overhangs 15 extend above a shelf 16 formed in the tray 10, and the bottom 18
of the tray 10.
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The tray-shaped container is shown disassembled, with the drain insert 20
illustrated in Figure
1B. In this embodiment, the drain insert 20 is sized and shaped to sit upon
the shelf 16 of the
tray 10 (for example, the width w of the drain insert 20 is not greater the
outer width w' and not
less than the inner width w" of the shelf 16 of the tray 10). The drain insert
20 includes
multiple perforations 21, at least one of which is spaced sufficiently from
the periphery 23 of
the drain insert 20 that it is not occluded when the drain insert 20 rests
upon the shelf 16.
Figure IC is a cross-section of the tray-shaped container taken along line 1C-
1C in Figure 1A.
In this view, the underside 5 of overhang 15 can be seen. Also seen is how the
underside 5 of
the overhang 15, the shelf 16, and the portion of the tray 10 that extends
between them forms an
outward bulge 2 in the wall of the tray 10. The edge 11 of the tray 10 and its
position away
from the rim 12 in this embodiment is also visible. Figure 1D is a cross-
section of the tray-
shaped container taken along line ID-1D in Figure 1A. In this view, the
reservoir wall 17
portion of the tray 10 is visible below (relative to the bottom 18 of the tray
10) the shelf 16.
[0021] Figure 2 includes Figures 2A, 2B, and 2C and illustrates the
same tray-shaped
container illustrated in Figure 1, but in an assembled state. In Figure 2A, it
can be seen that
drain insert 20 rests between shelf 16 (which is obscured in Figure 2A) and
overhangs 15.
Figure 2B is a cross-section of the tray-shaped container taken along line 2B-
2B in Figure 2A.
In this view, the position of the drain insert 20 between shelf 16 and
overhang 15 is visible.
Figure 2C is a cross-section of the tray-shaped container taken along line 2C-
2C in Figure 2A at
a position at which the drain insert 20 rests upon the shelf 16 but is not
positioned beneath an
overhang 15. Figures 2B and 2C illustrate that the drain insert 20 rests above
the reservoir 30
in the tray, the drain insert 20 having a width w that is greater than both
the width w" of the
reservoir 30 and the width w" of the opening between opposed overhangs 15, but
less than the
outer width w' of the shelf 16.
[0022] Figure 3 includes Figures 3A, 3B-1, 3B-2, and 3B-3, and illustrates
a tray-shaped
container like the one illustrated in Figure 1A, with the following
difference. Instead of having
four overhangs 15 arranged around the periphery of the shelf 16 as in the tray
illustrated in
Figure 1A, the tray illustrated in Figure 3A has a single overhang 15 that
extends about the
entire periphery of the shelf 16. Each of Figures 3B-1, 3B-2, and 3B-3 is a
cross-section of the
tray-shaped container taken along line 3B-3B in Figure 3A and shows an
alternative
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conformation of the outwardly-projecting bulge 2 formed by the underside 5 of
the overhang
15, the shelf 16, and the portion of the tray 10 that extends between them. In
the trays
illustrated in each of Figures 3B-1 and 3B-2, the surface of the shelf 16 is
substantially parallel
to the bottom 18 of the tray, while in the tray illustrated in Figure 3B-3,
the surface of the shelf
16 is slanted upwardly relative to the bottom 18 of the tray. Similarly, in
the tray illustrated in
Figure 3B-1, the underside 5 of the overhang 15 is nearly parallel to the
bottom 18 of the tray,
while in the trays illustrated in each of Figures 3B-2 and 3B-3, the the
underside 5 of the
overhang 15 is slanted downwardly relative to the bottom 18 of the tray.
100231 Figure 4 includes Figure 4A, 4B-1, and 4B-2. Figure 4A
illustrates the same tray-
shaped container illustrated in Figure 3A, but having the drain insert 20
inserted beneath the
overhang 15 that is formed into inner wall 14. Each of Figures 4B-1 and 4B-2
is a cross-
section of the tray-shaped container taken along line 4B-4B in Figure 4A and
shows an
alternative embodiment. In the embodiment illustrated in Figure 4B-1, the
reservoir 30 is left
empty beneath the drain insert 20. In the embodiment illustrated in Figure 4B-
2, an absorbent
material 40 occupies a portion of the reservoir 30 beneath the drain insert
20,
100241 Figure 5 includes Figure 5A, 5B, and 5C. Figure 5A illustrates a
tray-shaped
container like the one illustrated in Figure 3A, with the following
difference. Two supports 25
arise from the bottom 18 of the tray 10, within the reservoir 30. Figure 5B is
a cross-section of
the tray-shaped container taken along line 5B-5B in Figure 5A, and Figure 5C
is a cross-section
of the tray-shaped container taken along line 5C-5C in Figure 5A. Figure 5C
illustrates that
support 25 is molded into the tray 10, extending upwardly from the bottom 18
thereof
sufficiently that the upper surface 26 of the support 25 is approximately even
with the shelf 16
in this embodiment.
100251 Figure 6 includes Figure 6A, 6B, and 6C. Figure 6A illustrates
the same tray-
shaped container illustrated in Figure 5A, but having the drain insert 20
inserted beneath the
overhang 15 that is formed into inner wall 14. Figure 6B is a cross-section of
the tray-shaped
container taken along line 6B-6B in Figure 6A, and Figure 6C is a cross-
section of the tray-
shaped container taken along line 6C-6C in Figure 6A. Figure 6C illustrates
that the drain
insert 20 can rest upon both the shelf 16 and the upper surface 26 of the
supports 25.
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[0026] Figure 7 includes Figure 7A, 7B, and 7C. Figure 7A illustrates
the same tray-
shaped container illustrated in Figure 5A, but having a bolt of absorbent
material 40 inserted
within the reservoir 30 formed in the tray 10. Figure 7B is a cross-section of
the tray-shaped
container taken along line 7B-73 in Figure 7A, and Figure 7C is a cross-
section of the tray-
shaped container taken along line 7C-7C in Figure 7A. Figures 7B and 7C
illustrates that the
bolt of absorbent material can be more tightly packed into sections of the
reservoir 30 adjacent
the lateral walls 24 of a support 25 than it is in sections of the reservoir
30 where no support
occurs. Not pictured here is the drain insert 20, but it can be inserted as
shown in Figure 6,
effectively enclosing the absorbent material 40 within the reservoir 30
between the drain insert
20 and the tray 10.
100271 Figure 8 includes Figures 8A and 8B and illustrates a cutaway
portion of a larger
shaped article 10. Figure 8A is a top view, and Figure 8B is a side view of
the same portion.
These figures illustrate that, extending from the shaped article are four
overhangs 15 that secure
the drain insert 20 against a shelf 16 that is formed in the shaped article 10
about the periphery
of a reservoir 30. As shown in Figure 8B, the shelf 16 can be spaced away from
the surface of
the article 10 a sufficient distance ("d" in the figure) that the entire
thickness of the drain insert
can be accommodated below the surface of the article 10 beneath the overhangs
15.
[0028] Figure 9 includes Figures 9A, 9B-1, 9B-2, 9C, 9D-1, and 9D-2 and
illustrates parts
ca the
on rdn er assembly o tstb e t roafyaltor abyepg describedto touched
e b herein.ed wwith
a p rFigureprobe
e 9P, A and
dan F iimageof
9B -2thies componentsaststill
lelos er ovfi oneew o
20 embodiment of a tray described herein, including a shaped tray 10, a
drain insert 20, and an
absorbent material 40 that fits within the reservoir 30 portion of the tray 10
and includes two
holes sized and positioned to fit around the supports 25 in the tray 10 when
the absorbent
material 40 is disposed against the bottom 18 of the tray 10. The tray 10 has
a planar rim 12 for
securing a cover or film (neither shown) thereto if desired. Figure 9B-1 is a
closer view of a
portion of the tray 10 being touched with the probe P. In Figure 9B-2,
interposition of the
probe P in the space between the overhang 15 and the shelf 16 can be seen,
illustrating the
manner in which the drain insert 20 can fit within this space. Figure 9C is an
image of a tray 10
having an absorbent pad 40 inserted within it. The pad 40 has two holes
extending through it,
the holes being sized and positioned to accommodate two supports 25 that
extend upwardly
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from the bottom 18 of the tray 10, the supports 25 extending through the pad
40. Figure 9D-1
is an image of the tray shown in Figure 9C, having the drain insert 20
inserted into the tray 10
within the space shown in Figure 9B-2. A probe P is shown also inserted into
the same space.
Figure 9D-2 is a closer view of the portion of the tray shown in Figure 9D-1
at which the probe
P is inserted into the space between the overhang 15 of the tray 10 and the
upper surface of the
drain insert 20. Although not visible in this image, the drain insert 20 rests
upon the shelf 16
that is visible in Figure 9B-2.
100291 Figure 10 includes Figures 10A, 10B, 10C, 10D, and 10E and
illustrates ejection of
the drain insert 20 and absorbent material 40 from an assembled container 1.
Figure 10A is an
image of the assembled container 1, which includes a moistened absorbent
material 40
sandwiched between a clear tray 10 and a clear, perforated drain insert 20.
Visible through the
drain insert 20 are two supports 25 that extend through the absorbent material
40. Figure 10B
is an image of the inverted assembled container 1, lying rim-side down on a
surface; visible
about the outer periphery of the assembled container 1 is the edge 11 of the
shaped tray 10 and
the outwardly-projecting bulge 2 corresponding to the space between the
overhang 15 and the
shelf 16 visible in Figure 9B-2. The absorbent material 40 can be seen through
the bottom 18
of the clear tray 10. Also visible are the lateral walls 24 of the two
supports 25 that are visible
in Figure 10A. Figure 10C is an image of an individual gripping the assembled
tray 1 in
preparation for ejecting the drain insert 20 and absorbent material 40
therefrom. The individual
has gripped the rim 12 of the assembled tray 1 with fingertips and has
inserted a thumb into the
underside of each of the two supports 25. Figure 10D is an image of the result
of the individual
pressing on the supports 25 in the direction of the rim 12, thereby flexing
the bottom 18 of the
assembled tray 10; the drain insert 20 has been ejected from the space
corresponding to the
outwardly-projecting bulge 2 and has fallen onto the surface beneath the tray
10. Because it
was no longer retained within the tray 10 after the drain insert 20 had been
ejected, the
absorbent material 40 has also fallen from the tray 10 onto the surface
beneath it. In Figure
10E, the tray 10 from which the drain insert 20 and the absorbent material 40
have been ejected
has been set on the surface beside them. Ejection of the drain insert 20 and
the absorbent
material 40 were accomplished without the individual touching either of them
or any other
portion of the interior of the tray 10.
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[0030] Figure 11 includes Figures 11A and 11B, which are a top-view
image (11A) and an
oblique underside view (11B) of a drain tray described by others for use in
food containers.
DETAILED thermoplastic
containers
[0031] The disclosure relates DtoEsThapId h
that include a drain insert
which can segregate solid and liquid contents of the container, which is
retained within the
container even when it is inverted or tumbled, and which can be displaced from
the container
by a user without the user having to touch the interior of the container. Such
containers can be
to contain materials such as foods and foodstuffs for shipping, display, and
sale.
[0032] The container includes a shaped thermoplastic body, at least
some of which is
flexible, and the drain insert. The container has an interior portion that
includes a concave
reservoir portion. The drain insert divides the interior portion of the
container into the reservoir
portion and a storage space within which articles (e.g., cuts of meat,
vegetables, or frozen
liquid-containing items) can be stored. Liquids or small particles in the
storage space can pass
through (e.g., through a perforation or pore in) the drain insert or around it
to reach the
reservoir, for example under the influence of gravity. By way of example, the
container can
have the appearance of a common grocery meat tray, with the concave storage
section of the
tray segregated from a recessed reservoir at the (gravitational) bottom of the
storage section by
a perforated plastic plate (i.e., the drain insert). Rather than including
perforations, the drain
insert can have a shape (e.g., scalloped or indented edges) which permits
fluid or small particles
to pass between the reservoir and the remainder of the interior of the
container (i.e., through
and/or around one or more edges of the drain insert). The reservoir can
contain an absorbent
material, so that liquid exuded by a cut of meat in the storage section of the
tray passes through
perforations in the plastic plate to the reservoir and is there absorbed into
the absorbent
material. The container can be wrapped or sealed (e.g., with a thin plastic
film, as with
conventional grocery containers) at a rim that defines the interior portion,
so that any liquid that
exists or is generated in the interior portion of the container remains in
that interior portion.
[0033] A significant aspect of the container is that the drain insert
is interposed between
Iwo elements of the container's body ¨ a shelf and an overhang ¨ to limit or
prevent its
displacement within or from the container, except when such displacement is
desired by a user
of the container. Preferably, the number, placement, and/or circumferential
coverage (i.e.,
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about the circumference of the drain insert) of the shelf(ves) and overhang(s)
are sufficient to
prevent the drain insert from displacing substantially within or from the
container, even when
the container is tumbled in space or subjected to normal container-handling
conditions. That is,
the drain insert can be caused to remain in place until and unless the user
decides to remove it
from the body of the container.
10034] Another significant aspect of the container is that the drain
insert can be maintained
at a distance from the surface(s) that define the reservoir, so as to maintain
a space within the
interior of the reservoir where liquid (and/or an absorbent material to absorb
liquid) can be
stored. Such spacing of the drain insert away from a surface defining the
reservoir can be
maintained in a variety of ways, and those ways can be combined. For example,
one or more
shelves can be positioned within, adjacent to, or simply near the opening of
the reservoir and
paired with one or more corresponding overhangs extending from the interior of
the container
body, so that when the drain insert is interposed between the shelves and
overhangs, it is
maintained at a distance from a surface of the reservoir. The drain insert can
also be spaced
apart from a surface of the reservoir by positioning a support between that
surface and the drain
insert. The support can be attached to (or integral with) one of the reservoir
surface and the
drain insert, or it can be attached to neither. Alternatively, some supports
can be attached to (or
integral with) the reservoir surface and other supports can be attached to (or
integral with) the
drain insert. Combinations of supports and shelf-overhang pairs can be
employed. Indeed, if a
support is sufficiently close to the opening of the reservoir, it may be
indistinguishable from a
shelf¨ the "top surfaces" (i.e., the portion that faces or is opposed against
the drain insert) of
both shelves and supports that extend from the container body have the same
function ¨ to
prevent the drain insert from being urged flush against the interior container
surface that defines
the reservoir.
[0035] Yet another significant aspect of the container is that the drain
insert can be removed
from the container body by a user, preferably without the user having to touch
any interior
portion of the container body (i.e., without having to touch the inside of the
storage space, the
inside of the reservoir, or the drain insert). The drain insert can be
displaced from the container
body by flexing one or more flexible parts of the body. In an important
embodiment, the drain
insert is held in place between several pairs of shelves and overhangs (or
between a shelf-
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overhang pair that extends completely, or almost completely, about the opening
of the
reservoir), and the drain insert is displaced by gripping the container body
by its exterior,
including the rim that surrounds the storage space and i) manually depressing
a portion of the
reservoir toward the drain insert to apply pressure to the reservoir-face of
the insert, thereby
urging it to 'pop out' from between the shelf-overhang pairs, ii) manually
flexing the gripped
ends of the container body outwardly to disengage the drain insert from one or
more shelf-
overhang pairs positioned on those ends, or iii) both i and ii. In one
embodiment, the container
body has a reservoir from the bottom of which one or more supports extend
across the reservoir
space and toward (or against) the reservoir-face of the drain insert. Owing to
the close position
of the insert-face of the support to the reservoir-face of the drain insert,
less manual pressure
may need to be applied to the exterior of the container body at positions
corresponding to the
locations of these supports in order to displace the insert from the body than
would be
necessary if the manual pressure were applied against portions of container
body located farther
from the drain insert; less flexibility of the container body is necessary for
the same reason.
[0036] In another embodiment, the drain insert is fixed (removably or not)
to the interior of
the container body, such as to one or more shelves or supports which it
contacts. Such fixation
can be achieved in any conventional way, such as through use of adhesives,
heat fusion, sonic
welding. In this embodiment, the reservoir of the container can include an
absorbent material
(e.g., a fibrous pad) that is inserted between the drain insert and the
container body before the
drain insert is fixed to the container body. Alternatively, the reservoir can
be left empty, so that
liquid or small particles can pass into the reservoir during use of the
container, the container can
be inverted or shaken to remove materials from the reservoir after use, and
the assembled
container (i.e., having the drain insert still fixed to the container body)
can be recycled as a unit.
One embodiment of such a container resembles the container illustrated in
Figures 5 and 6,
except that the upper surface 26 of the supports 25 are nearer the floor 18 of
the container body
than are the perimeter shelves 16. If a flat drain insert 20 is pressed into
the perimeter groove
corresponding to perimeter shelves 16, the drain insert 20 will be spaced
above (i.e., not
touching) the upper surface 26 of the supports 25. If the central portion of
the drain insert 20 is
depressed against the upper surface 26 of the supports 25 (i.e., flexing the
drain insert 20) and
the portion of the drain insert 20 that contacts the upper surface 26 of the
supports 25 is fixed to
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that surface, then the drain insert 20 will retain a bowl-shaped (i.e.,
concave, relative to the
storage compartment) conformation. Such a conformation would tend to cause
fluid exuded
from art article stored above the drain insert to flow through or past the
drain insert and into the
reservoir when the container is placed on its bottom, as illustrated in Fig.
6B, for example.
Similarly, if such a container were inverted, any fluid present in the
reservoir would contact the
underside of the drain insert; that underside will be dome-shaped (i.e.,
convex, relative to the
reservoir, when the container is in this inverted position), so fluid in the
reservoir will tend to
flow toward the periphery of the container, away from perforations extending
through the
insert, and away from articles stored in the storage compartment (i.e.,
generally away from the
central portion of the drain insert) when the container is inverted;
furthermore, if the drain
insert is sealed about the edge or rim of the container body, fluid will be
retained between the
container body and the drain insert when the container is inverted. Such a
container can cause
liquid to be drawn away from a stored article when the container is upright,
and can cause
liquid to be directed away from the stored article when the container is
handled or inverted.
[0037] Various aspects and parts of the containers described herein are now
separately
described in discrete sections.
[0038] The Container Body
[0039] The container described herein includes a container body that
has an interior portion
that includes the storage space described herein. The storage space is
circumscribed by a rim
and has within it the concave reservoir, the reservoir communicating with the
storage space by
way of an opening between the two. Each of the storage space and the reservoir
are defined by
the interior surface of the container body. Preferably (at least for ease of
manufacture), the
reservoir is simply portion of the storage space that is recessed away from
the remainder of the
storage space. The container body can be conveniently made from a single piece
of material,
such as by thermoforming an initially flat thermoplastic sheet to confer the
desired shape to it
(and cutting any excess sheet material from the body) or by molding a
thermoplastic material
into a desired shape.
[0040] The container body includes at least one overhang which serves
to mechanically
inhibit movement of the drain insert from within the interior of the container
body toward or
through the rim of the container body. The container body also includes at
least one shelf or
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support which serves to mechanically inhibit movement of the drain insert from
a first position
in which the insert is spaced apart from a surface of the reservoir portion to
a second position in
which the insert is flush against that surface. That is, the drain insert is
interposed between at
least one overhang and at least one shelf or support of the container body.
Preferably, the size,
number, and/or placement of the overhangs, shelves, and supports of the
container body arc
selected sufficient to maintain the drain insert at a relatively fixed
position between the storage
space and the reservoir.
[0041] By way of example, if the reservoir is a disk-shaped recess from
the storage space, a
shelf situated circumferentially about the opening of the reservoir can
prevent movement of a
drain insert that rests upon the shelf into the reservoir, and three overhangs
which extend over
the shelf from the interior of the container body at positions 120 degrees
offset from one
another (relative to the center of the disk-shaped recess) can be used to
prevent movement away
from the opening of the drain insert that rests upon the shelf, so long as the
spacing between the
shelf and each of the overhangs is sufficiently large to accommodate the
thickness of the drain
insert, but not so large as to permit the drain insert to fall out from
between the shelf and
overhangs when the container is tumbled in space.
[0042] Another example of the interactions between overhangs, shelves,
and a drain insert
is illustrated in Figure. Figure 2C is a cross-sectional view of a container
body having a drain
insert within its interior, resting on a pair of shelves formed on either side
of a central reservoir.
As can be seen from the figure, the width of the insert (w) is greater than
the width of the
reservoir (w"), but smaller than the width of the furthest extents of the
paired shelves (w'). As
a result, the insert can lay flat upon the paired shelves, and can be shifted
slightly from side to
side (see spaces between the right and left ends of the insert and the sloped
portions of the
container's inner wall adjacent the paired shelves). Figure 2B illustrates the
same container
body and insert, but is a cross-section taken at a portion of the container at
which a pair of
overhangs extend from the container body over the paired shelves. The width of
the insert (w)
is greater than the distance (w") between the innermost edges of the
overhangs, meaning that
the overhangs will inhibit upward movement of the insert when it contacts the
undersides of the
overhangs. Figure 2B also illustrates that the spacing between the shelves and
the overhangs is
less than twice the thickness of the insert interposed between them. Thus,
displacement of the
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insert from the container body will not occur, even if the container is placed
on its side (i.e., so
that a first end of the insert can drop into the slot defined by the portion
of the body including a
paired overhang-and-shelf and the body surface between them) and the opposite
end of the
insert is pivoted about the first end. Figure 2A is a top view of the
container corresponding to
Figures 2B and 2C, and illustrates that the container body includes four
overhangs which
extend over a single shelf that extends circumferentially about the reservoir.
When the insert is
interposed between the overhangs and the shelf, the insert will not be
displaced from the
container body, even if the assembled container is rotated in space or even
gently shaken.
[0043] The relative sizes and shapes of the storage space and the
reservoir are not critical.
Generally, the size and shape of the storage space should be selected to
accommodate articles
that are anticipated to be stored therein. By way of example, it is well known
that grocery
containers arc manufactured in a variety of sizes and shapes intended to
accommodate common
grocery items, such as individual pieces or plants (e.g., cherries,
strawberries, or salad greens)
or animals (e.g., beef steaks, chicken wings, legs, and gizzards or hamburger
patties), and
similar shapes and sizes can be selected for the storage space of the
containers described herein.
The size of the reservoir is preferably selected to be sufficiently large to
accommodate the
amount of liquid expected to occur in the storage space (e.g., the quantity of
liquid expected to
be exuded by a cut of meat upon storage or the quantity of liquid expected to
be retained by
salad greens upon washing incident to packaging). The shape of the reservoir
is ordinarily
unimportant, and can be selected to correspond to expected locations of
liquid, to provide a
suitable base upon which the container can rest, to accommodate a desired
amount of absorbent
material, or using other considerations.
100441 An important characteristic of the container body is that at
least a portion of the
body is sufficiently flexible to facilitate displacement of the drain insert
from the body by a user
without the user having to touch the interior of the body. The body must be
sufficiently rigid
that it can perform its storage function. As is well known in the plastic
container arts, the
composition, thickness, and geometry (e.g., overall shape, inclusion of ribs)
of a shaped plastic
body can strongly influence the flexibility and rigidity of various portions
of a that body. A
skilled artisan in this field understands a variety of ways in which
combinations of these factors
can be employed to make containers having the functionality described herein.
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[0045] By way of example, the insert in the container illustrated in
Figure 2 can be
displaced from the container body holding the rim 12 thereof with the fingers
of both hands and
pressing the thumbs (and/or, optionally, the bases of the palms) against the
undersides of
opposite ends of the reservoir 30 in the direction of the rim. Provided that
the thickness,
material, and construction of the body 10 are selected appropriately, this
action can induce
sufficient flexion in the sides of the container (i.e., in one or more of side
walls 14, overhangs
15, bulge region 2, shelf 16, and reservoir walls 17) that the upward force on
the insert 20 will
cause the insert 20 to 'pop' or 'burst' past the overhangs 15, resulting in
displacement of the
insert 20 from the container body 10, even if the insert 20 is completely
rigid. If the insert 20
exhibits flexibility as well, these actions can also cause the insert 20 to
flex, effectively
reducing the linear distance (w) between its two ends, which will reduce the
amount of force
required to cause the insert 20 to 'pop' or 'burst' past the overhangs 15.
[0046] Further by way of example, the insert 20 in the container
illustrated in Figure 6 can
be displaced from the container body 10 in a similar manner. In this
container, a single
overhang 15 extends peripherally around and above a single shelf 16 that
extends peripherally
around the reservoir 30. A pair of supports 25 within the reservoir 30 extend
from the bottom
18 of the container body 10 up to and against the insert 20. When this
container is gripped in
the manner described in the preceding paragraph and manual pressure is applied
to the supports
at the exterior of the container body 10 (e.g., by inserting the thumbs within
the supports 25
20 and applying pressure to the upper surface 26 thereof, or by applying
pressure at points at
which the supports 25 intersect the bottom 18), pressure is applied to the
central portion of the
insert 20, which will tend to increase flexion of the insert 20 (at least
relative to the situation
described in the preceding paragraph, where upward force is applied
substantially only near the
periphery of the insert 20), thereby easing its displacement from the
container body 10. Figure
25 10 illustrates this method of displacing the drain insert 20 from the
container body 10.
[0047] Torsional pressure applied to the container body 10 can also
induce flexing of the
container body 10 and/or insert 20 that is sufficient to result in
displacement of the insert 20
from the body 10. By way of example, the short ends of the containers
illustrated in Figures 2
and 6 can be grasped with one hand each and twisted in opposite directions.
Sufficient twisting
of the opposite ends will cause the insert 20 to be displaced from beneath the
overhang(s) 15,
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the degree of necessary twisting being dependent on the extent to which the
overhang(s) 15
overlap the insert 20.
[0048] Combinations of the methods (i.e., torsional twisting,
application of pressure at the
from the bottom side of the container, and application of pressure at
supports) can be used to
effect displacement of the insert from the body. Likewise, stretching and/or
folding of the body
can be used to effect sufficient flexion of the body and/or insert to effect
displacement of the
two. These operations are well understood. What is important is not so much
the precise
manipulations necessary to displace the support from the body, but rather that
manual forces
applied to the exterior of the container by a person of ordinary strength are
sufficient to effect
such displacement, preferably as easily as possible when desired by that
person, consistent with
the insert remaining engaged with the body prior to such intentional
application of displacing
forces. That is, the container should remain assembled during use for storage,
but should be
easily disassemblable when a user desires to disengage the drain insert from
the body.
100491 In the figures included with this disclosure, the container
body is illustrated having
the shape of a rounded rectangular tray in which the reservoir has the shape
of a rounded
rectangular cavity with a shelf extending completely around the opening of the
reservoir, the
shelf being substantially parallel to the rim of the container, and the insert
being a rounded
rectangular plate having a plurality of perforations extending therethrough.
However, these
shapes and conformations are illustrations only. The container body 10 can be
round, square,
or irregularly shaped, or it can have a shape selected to conform to the shape
of an article
expected to be stored therein (e.g., a violin case or an egg carton).
100501 The container can be constructed so that the reservoir 30 has a
substantially flat
bottom 18 that is substantially parallel to the rim of the container and
generally rests at the
gravitational bottom of the container during its intended use. However, this
conformation and
arrangement are not necessary. As illustrated in Figure 8, for example, the
shape of the
container away from the portion of its interior near the reservoir 30 is
substantially immaterial.
Figure 8 illustrates a body 10 of undefined shape in which a reservoir 30
extends away from the
interior of the body 10. The insert 20 is interposed between the reservoir 30
and the interior of
the body A shelf 16 is approximately parallel to and displaced a distance old
away from the
interior surface of the body to, so that when the insert 20 is interposed
between the shelf and a
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plurality of overhangs 15 that extend away from the wall of the body 10, the
surface of the
insert 20 is approximately flush with the surface of the body 10. These
elements can be
situated in the gravitational bottom, a gravitational side, or even the
gravitational roof of the
body 10, and permit passage of liquids, gases, and small solids between the
reservoir 30 and the
interior of the body 10.
100511 The containers described herein are useful for containing
foodstuffs, but have a
variety of other uses. They are useful in any situation in which it is
desirable to segregate
articles or substances incapable of passing through the channels between the
storage space and
the reservoir, those channels having dimensions defined, at least in part, by
the insert.
100521 The containers can also be useful for processing foodstuffs or
otherwise contacting
solids with either liquids or small particles. In such an embodiment, a
foodstuff is contained
within the storage compartment of the container (i.e., on the rim-face of the
drain insert), and a
liquid or a plurality of small particles is directed toward the foodstuff from
the direction of the
rim. The liquid (e.g., hot water) can contact the foodstuff (e.g., ground
coffee) and thereafter
pass into the reservoir (e.g., as brewed coffee). If desired, the liquid or
small particles can be
collected from the reservoir.
[0053] In a particular embodiment, coffee grounds are contained within
the storage
compartment, the opening of the concavity being sealed with a foil or film to
retain them
therein and the drain insert having perforations and/or a peripheral shape
sufficient to retain the
coffee grounds within the storage compartment. In this embodiment, the foil or
film can be
pierced by a nozzle that delivers hot water into the storage compartment, and
the bottom of the
container can be pierced by a fluid conduit (e.g., a hollow needle-shaped
conduit) to drain fluid
from the reservoir. Hot water can be injected by the nozzle into the storage
compartment,
wherein it mixes with the coffee grounds, becoming liquid coffee. The liquid
coffee is able to
pass through and/or around the drain insert into the reservoir, whence it can
flow through the
fluid conduit to a desired location (e.g., to a cup held opposite the other
end of the fluid
conduit). The coffee grounds, however, are too large to pass through the
perforations, gaps, or
pores in and around the drain insert, so they are retained within the storage
compartment. After
passage of liquid is complete, the still-assembled container can be discarded
as waste.
Alternatively, the foil or film can be removed from the container rim, the
coffee grounds
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removed from the storage compartment, and the drain insert can be ejected from
the container
as described herein, the drain insert and/or the container body being
recycled. As still another
alternative, if the interior of the container body has a thin peelable liner
attached to it, ejection
of the drain insert as described herein (e.g., effected by holding the rim of
the container and
pressing inwardly on the bottom of the container in the direction of the rim)
can both displace
the drain insert from the container and displace the peelable liner from the
interior of the
container. So long as the foil/film remains mostly sealed across the orifice
of the container rim,
it is possible to separate from the container body a unit that includes the
liner, the drain insert,
the foilifilm, and the contents of the storage compartment. That unit can be
discarded and the
container body (which can include the bulk of recyclable material) can be
recylced.
100541 Shelves and Supports
100551 The containers described herein include at least one shelf that
occludes movement of
the insert toward at least one surface that defines the reservoir. The purpose
of this shelf is to
maintain an open (or, optionally, partially or completely filled with an
absorbent material)
reservoir into which materials can move from the storage space of the
container (at least, if
those materials are able to pass through a channel that extends through or
around the edge of
the insert). The shelf confers positional stability to the insert when
materials within the storage
space exert force upon the insert in the direction of the reservoir surface. A
shelf can be an
extension of the inner wall 17 of a container body 10, that extends inwardly
from the periphery
into the interior of a reservoir 30 and accommodates the insert 20, such as
the shelf 16
illustrated in Figures 1-6 and 8. Alternatively, or in addition, a container
can includes shelf
portions that are formed by the upper surface 26 (i.e., the surface nearest
the insert 20) of one or
more supports 25 that are not extensions of the periphery of a reservoir 30,
but rather extend
from the bottom 18 of the container into the reservoir 30. Figure 5
illustrates such a container,
the container including two cylindrical, post-shaped supports 25 which extend
upwardly from
the bottom 18 of the container body 10 into the reservoir 30 thereof, the
upper surfaces 26 of
the supports 25 being spaced equally far from the bottom 18 as the shelf 16
that extends
peripherally about the reservoir 30. As shown in Figure 6, the container
illustrated in Figure 5
can support a drain insert 20 on the shelf surfaces defined by both the
shelf16 and the upper
surfaces 26 of the supports 25.
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[0056] The shelves and supports are preferably unitary with the
container body, but need
not be. They can be attached to (e.g., fused with or attached by adhesive) to
the container body,
or they can be simply placed within the interior of the container body to
separate the insert from
a surface of the reservoir against which the insert would fall if the shelf or
support were not
present. However, both for case of manufacture and to facilitate recycling of
used containers,
the container body preferably includes one or more shelves and/or supports as
integral parts
thereof. By way of example, a container body including shaped portions
(shelves and/or
supports) suitable for use as shelf portions can be made by thermoforming a
flat thermoplastic
sheet against a mold that confers such shaped portions (as well as the other
features of the
container body) to the flat sheet during a conventional thermoforming process.
Suitable
thermoforming processes are well known and described elsewhere.
[0057] The container body can include a single shelf (e.g., as
illustrated in Figures 1-6 and
8) or multiple shelves (e.g., only portions of the single, pen-reservoir shelf
illustrated in Figures
1-6 and 8, the portions forming non-continuous shelf portions, such as shelves
only at the
curved comer portions of the shelf illustrated in Figure 1). Likewise, the
container body can
include a single support or multiple supports within the reservoir. The
container body can
include both shelves and supports. The precise number, size, shape, and
arrangement of
shelves and supports is not critical, so long as, together, the shelves and
support of a container
body prevent the insert from lying flat against a surface of the container
body that would
otherwise (i.e., if there were space between the surface and the insert)
define a reservoir. These
factors should take into account flexation that may occur in the container
body and/or the insert
when articles are stored within the storage space of the container (e.g.,
resting upon the insert
supported by the shelf portions of shelves and supports).
[0058] The drain insert and its interactions with sides of the
container body and/or with
shelves and supports formed in the container body can contribute to the
structural
characteristics of the container. By way of example, if the sides of the
container body 10
illustrated in Figure 1 are thin and relatively easily deflected inwardly
toward the interior of the
container, such inward deflection can be limited or inhibited when the drain
insert 20 is
assembled within the container body 10, as illustrated in Figure 2. The drain
insert can also
serve a physical barrier function, physically segregating material (e.g.,
liquid or an absorbent
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material) that is contained within the reservoir 30 from stored articles that
are stored within the
container on the face of the drain insert opposite the reservoir. The color,
opacity, surface
printing, or other optical characteristics of the drain insert can also
contribute to the overall
appearance of the container, for example by obscuring a consumer's view of an
absorbent pad
retained within the reservoir portion of the container. Similarly, optical
properties of the
container body and any lidding or overwrap used to cover or seal the opening
of the concavity
in the container body can contribute to the overall visual appearance of the
assembled
container.
100591 Another important consideration when selecting the number, size,
shape, and
arrangement of shelves and supports is the role that these structures serve in
facilitating and
inhibiting displacement of the insert from the container body when a user
wishes to accomplish
such displacement. The insert is held within the container body by the
combined motion-
limiting capacities of overhangs (inhibiting movement of the insert toward the
rim of the
container) and of shelves/supports (inhibiting movement of the insert toward
the face of a
reservoir). Force manually applied by a user to the exterior of the container
at the location of a
shelf or support can be transmitted to the insert when the shelf or support
contacts the insert.
For this reason, it can be advantageous to position shelves and supports at
locations at which
externally-applied pressure can be transmitted to the insert to overcome the
outward-
movement-inhibiting influence of overhangs. Positioning of shelves and
supports can also
reduce or prevent compression of an absorbent material positioned in the
reservoir space; that
is, if the weight of an article that rests upon the drain insert described
herein is carried by one or
more shelves or supports, rather than by the absorbent material, then the
absorbent material can
be left free to absorb as much liquid as possible, rather than having its
absorbent capacity
limited by compression transmitted by the weight of the article on the drain
insert and thence
upon the absorbent material. That is, non-compression of absorbent material
and non-blockage
of its surface by a stored article (e.g., when the stored article is
segregated from the surface of
the absorbent material by the drain insert) can each improve the ability of
the absorbent
material to absorb liquid and 'wick' it away from the stored article.
100601 By way of example, the container 1 illustrated in Figure 10
includes two supports 25
formed within in the container body 10. The supports 25 extend upwardly from
the bottom 18
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of the container to or near the reservoir-side face of the insert 20. When a
user grips the
container body 10 by its rim 12 with the user's thumbs inserted within the
peripheral faces 24
of the supports 25 and presses upwardly (as illustrated most clearly in Figure
10D), against the
insert 20, the flexible lower surface of the container body 10 is displaced
toward the insert 20,
and force applied to the insert 20 facilitates its displacement from the
peripheral bulge 2 in
which the insert 20 is positioned. When this action is performed with the rim
of the container
pointing gravitationally downward, as shown in Figure 10D, the insert 10 is
displace from and
falls out of the container body 10, together with any materials that were
interposed between the
insert 20 and the container body 10, such as the absorbent material 40 visible
in Figure 10D. 22.
The container of claim 21, wherein the body includes at least two supports,
each of the two
supports positioned sufficiently close to the rim that an adult human having
hands of ordinary
size can insert the thumb of each hand into one of the supports while gripping
the rim with the
at least one other finger of each hand.
[0061] For ease of assembly, simplicity of design, and stability of the
resulting container
(even when articles are loaded into its storage space), it can be advantageous
if the container
body includes one or more shelves which abut the reservoir. Figures 1-6 and 8
illustrate such
an embodiment, in which a single shelf 16 completely encircles the reservoir
30. The container
can, for example, includes multiple shelves that abut the reservoir at at
least two positions about
the periphery of a reservoir (e.g., on opposite sides or at the four corners
of a rectangular
reservoir). Such shelves, extending from a peripheral wall of the container,
are not necessary,
however. The upper surface 26 of supports can serve substantially the same
purpose as shelves,
that is, spacing the drain insert away from the bottom of the container, so as
to permit presence
and/or passage of fluid or small particles between the two. Overhangs,
likewise, need not
extend inwardly from the peripheral sides of the container, but can instead
extend from other
portions of the container. For example, three supports that are spaced away
from a peripheral
edge of the container could space the drain insert away from the bottom of the
container (i.e.,
on the upper surfaces of the supports), while extensions of one or more the
supports (or another
element that includes the overhand but does not act as a support) can include
an overhang that
tends to hold the drain insert against the upper surfaces of the supports.
100621 Overhangs
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[0063] The containers described herein include at least one, and
preferably two or more,
overhangs which extend inwardly from one or more sidewalls of the container to
inhibit
movement of the insert outwardly from the interior of the container, such as
when the container
is tumbled in space or gently shaken. Together with the shelves and/or
supports described
herein, the overhangs serve to restrain the drain insert within the container
during its use for
storage, but to permit its intentional displacement from the container body
when the user
desires to do so.
[0064] Whereas the purposes of the shelves and supports are both to
secure the drain insert
in place and to maintain the patency of the reservoir between the container
body and the insert,
the primary purpose of the overhangs is to secure the drain insert in place.
It is primarily the
resistance to movement of the insert that is effected by the overhangs that
must be overcome in
order to achieve displacement of the insert from the body. That resistance can
be overcome
because one or both of the body and the insert are flexible.
[0065] Flexibility of the container body can permit stretching or
outward displacement of
the portions of the body that bear the overhangs such that the overhangs no
longer overlap one
or more shelves or supports. Flexibility of the container body can also permit
compression or
outward displacement (i.e., away from the interior) of the overlaps
themselves, permitting the
insert to move past the overhangs when force is applied to the insert in the
direction of such
movement. Flexibility of the insert can permit it to bend or deflect, such
that the bent or
deflected insert "fits" through the space adjacent the overlaps (e.g., through
the space denoted
w' in Figure 2B).
100661 Overhangs of the container body can be aligned with shelves
and/or supports of the
body, so that portions of the insert overlap an overlap on one face and
overlap a shelf or support
on at the same position on the opposite face of the insert. That is, the
overhangs can overlap
one or more shelves or supports. Alternatively, the overhangs can be
positioned such that they
do not overlap shelves or supports. A container body can have multiple non-
continuous
overhangs (e.g., the four overhangs 15 of the container body illustrated in
Figure IA) or a
single continuous overhang (e.g., the single overhang that is both continuous
and completely
surrounds a reservoir, such as in the containers illustrated in Figures 3-7).
The number, size,
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shape, and arrangement of overhangs is not critical, so long as the overhangs
perform the
functions set forth above.
[0067] Overhangs can be paired with shelves or supports such that when
the insert is
interposed between a paired overhang/shelf or a paired overhang/support, the
ability of the
insert to move from that position to the exterior of the container is
obstructed by the presence of
the overhang and the ability of the insert to move from that position against
the face of an
adjacent reservoir is obstructed by the presence of the shelf or support.
Paired overhangs and
shelves/supports can be spaced closely enough to one another that the insert
is substantially
immobilized between them (e.g., if the spacing is not significantly greater
than the thickness of
the insert or if flexation induced in the insert when interposed causes the
insert to abut both of
the pair simultaneously).
[0068] In one embodiment (illustrated in Figures 2-7 and picture in
Figures 9 and 10), a
single overhang extends inwardly from the inner wall of the container body
about the entire
periphery of a reservoir. In this embodiment, the overhang overlaps a single
shel f that also
extends inwardly from the inner wall of the container body about the entire
periphery of the
reservoir. In this container, the container body has a bulge 2 that extends
outwardly from the
body about the entire reservoir, as can be seen most clearly in Figure 10D,
the outermost
portion of the bulge being the portion of the container body joining the shelf
and the overhang.
[0069] Displacement of the insert from the container body can involve
moving one or both
of the insert and an overhang-shelf/-support pair from a position in which the
insert is
interposed between the pair to a position in which the insert is no longer
interposed between the
pair (and is therefore no longer constrained from moving past the overhang and
out of the
container body interior). Such movement can be induced by flexation of the
container body,
the insert, or both, as described herein. Movement of the insert within the
space between paired
overhangs and shelves/supports is tolerable, so long as such movement will not
permit the
insert to be displaced from the container body under ordinary storage
conditions (e.g., when the
container is tumbled in space or shaken gently). Such displacement can
generally be limited by
decreasing the spacing between the pairs, by increasing the degree of overlap
between each half
of the pair and the insert, or both. By way of example, if the distance
between paired overhangs
and shelves/supports is less than about twice the thickness of the insert,
significantly less
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movementadhesive) to the container andccoonnsequeenr
btlyodsymtaollperrelvikeenit thihoeodinosferdtifsrpolm reacemaednitty
mcanobveineg from thexpeoctedtteio
hainnifrthr of
distance between the paired elements is ten or twenty times the thickness of
the insert.
[0070] As with shelves and supports, the overhangs are preferably
unitary with the
container body, but need not be. They can be attached to (e.g., fused with or
attached by
h
the container body to its exterior, as it could if the overhangs were not
present. In another
alternative, the overhangs can be a portion of the container body wall that
has been partially cut
therefrom (e.g., a 'U-shaped cut that produces a finger-shaped displaceable
portion of the wall)
and displaced so that it extends into the interior of the container body and
overhangs the insert,
thereby obstructing its egress from the interior of the container body.
However, both for ease
of manufacture and to facilitate recycling of used containers, the container
body preferably
includes one or more overhangs as integral parts thereof. By way of example, a
container body
including shaped portions (e.g., multiple lobes as shown in Figure 1 or a
single pen-reservoir
bulge as shown in Figures 2-7) suitable for use as overhangs can be made by
thermoforming a
flat thermoplastic sheet against a mold that confers such shaped portions (as
well as the other
features of the container body) to the flat sheet during a conventional
thermoforming process.
Suitable thermoforming processes are well known and described elsewhere.
[0071] The Drain Insert
[0072] The containers described herein include a drain insert that is
interposed between one
or more overhangs and one or more shelf portions (e.g., shelves or supports)
and which divides
the interior of the container body into a storage portion and one or more
reservoirs. Then thus
assembled, the container has one or more channels that extend between the
storage portion and
at least one of the reservoirs, at least one of the channels being defined at
least in part by the
insert. Although the channels permit passage therethrough of liquids and
gasses, the channels
have dimensions that are sufficient small to occlude stored articles from
passing from the
storage space into the reservoir. By way of example, the insert can be a flat
plate having a
plurality of perforations extending therethrough from the storage space on one
face to a
reservoir on the opposite face.
100731 An important characteristic of the containers described herein
is that the drain insert
is manually displaceable from the interior of the container by a user who
desires to achieve
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such displacement. Preferably, the insert can be displaced by the user without
touching any
surface on the interior of the container (i.e., which surfaces may be
undesirable to touch, for
example, on account of unsanitary conditions or substances present on the
interior). Thus, the
containers have the characteristic that a user can grasp the container by its
exterior (including
the rim of the container) and displace the insert from the container by
applying manual force
sufficient to flex at least a portion of the container body sufficiently to
displace the insert.
Flexibility of the insert can facilitate its displacement from the container
body, since forces that
are manually exerted on the exterior of the container body can be transmitted
through the
container body to the insert by flexing portions of the body.
[0074] By way of example, Figure 10 illustrates displacement of a flexible
drain insert 20
from a container body 10. Manual application of force by a user against two
supports 25 in the
container body 10 exerts force against the underside of the insert 20, causing
it to flex and to be
displaced from a peripheral bulge 2 that extends about the container body 10
between a paired
peripheral overhang and peripheral shelf.
[0075] The insert should cover the opening between the storage space and
the reservoir
sufficiently that articles to be stored in the container cannot move between
the two spaces
around the periphery of the insert. The insert need not be flat, but can
instead be curved or
shaped to match the conformation of this opening. Channels between the storage
space and the
reservoir can be provided by way of pores, tortured passageways, or
perforations extending
through the insert, by way of one or more gaps or indentations at the insert
periphery that leave
uncovered at least a portion of the opening between the two spaces, or a
combination or these.
By way of example, a non-perforated drain insert can have a toothed or zig-zag
shaped
periphery such that it retains articles to be stored in the storage
compartment, but permits
passage of fluid or small particles between the storage compartment and the
reservoir.
[0076] At least one of the insert and the container body should be
sufficiently flexible that
it can be substantially bent, stretched, or displace by pressure sufficient to
cause the insert to
become interposed between the overhangs and shelves or supports of the
container body. Such
flexibility also facilitates displacement of the insert from the container
body when desired by a
user.
100771 The Absorbent Material
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[0078] At least in some embodiments, the purpose of the reservoir of
the container
described herein is to provide a space into which can flow fluids which occur
or are generated
in the storage space. By way of example, plant or animal parts (e.g., cuts of
meat or sliced
vegetables) can exude liquid that can be visually undesirable or induce
spoilage.
[0079] Although it can be desirable simply to facilitate movement of liquid
from the
storage space to the reservoir, it can sometimes be even more desirable to
sequester liquid
within the reservoir, so as to prevent it from moving back to the storage
space. Such
sequestration can be achieved by including an absorbent material in the
reservoir.
[0080] Numerous absorbent materials are known (e.g., cotton fibers,
absorbent papers, and
woven and non-woven fabrics), and substantially any of these materials can be
used. Naturally,
any absorbent material should be selected to be consistent with the intended
use of the
container. For example, if the container is intended to be used to store food
items, absorbent
materials suitable for use with consumable food items should be employed.
[0081] The absorbent material may be present as a single, unitary
absorbent body (e.g., the
non-woven mat shown in Figure 9A), in multiple discrete pieces, or as a
multiplicity of pieces.
For containers in which migration of the absorbent material from the reservoir
to the storage
space is undesirable, pieces of absorbent material should be sufficiently
large that the cannot
pass through the channels defined by the insert and/or the container body,
retained by a screen
or sieve that prevents the pieces from reaching those channels, or attached to
the container body
or the insert, for example.
[0082] It can be desirable that the absorbent material can be displaced
From the container
body when the drain insert is displaced therefrom, either simultaneously or
sequentially. In one
embodiment, the absorbent material is attached to the drain insert (e.g., by
adhering or fusing
the two), so that it is displaced from the container body together with the
insert. Alternatively,
the absorbent material can be separate from both the insert and the container
body, so that it can
be removed separately. If desired, the absorbent material can be attached to
the container body,
so that it will not be displaced therefrom when the insert is displaced from
the container body.
[0083] Liddings and Wraps
[0084] In an important embodiment, the container is sealed at the open
end outs interior to
prevent transit of liquid between the exterior of the container and the
storage space of the
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container body. By way of example, the container can be sealed by a plastic
film that is
adhered or fused to the rim of the container about the entire perimeter of
that rim, creating a
fluid-resistant barrier. Alternatively, the entire container can be wrapped in
a sheet of a fluid-
resistant film (e.g., the sorts of films used to wrap conventional grocery
packages of meats and
plants), and overlapping portions of the film can be sealed to prevent transit
of liquid between
the interior of the film-wrapped bundle (i.e., where the container is located)
and the exterior of
the film-wrapped bundle (i.e., the portion handled by users prior to opening
the bundle).
[0085] Materials and Construction
[0086] The identities of the materials used to make the container body,
the drain insert, and
(if present) the absorbent material are not critical. Many materials (e.g.,
plastics, foamed or
expanded plastics, paperboards, metal foils, and absorbent materials) used to
make
conventional containers can be used to make the containers described herein.
100871 The materials and dimensions used for the body and the insert
should be selected so
that the resulting container exhibits the flexibility properties described
herein. That is, at least
certain portions described herein of the container body should be sufficiently
flexible that a
person of ordinary strength can manually apply force to the exterior of the
container that will
deform the container sufficiently to facilitate displacement of the insert
from the container
body. Flexibility exhibited by the insert can affect the required flexibility
of the container
body. The materials used should also be sufficiently resilient to withstand
the expected stresses
and strains incident to manufacture, use for storage, and displacement of the
insert from the
container body as described herein (i.e., the materials will preferably not
break or tear under
such conditions).
100881 The container body described herein can advantageously be made
from a single
sheet of a thermoformable plastic using conventional thermoforming processes.
Briefly
summarized, the sheet is heated within a thermoforming apparatus to a
temperature at which the
plastic softens sufficiently that it attains the shape of one or more molds
(e.g., female or male
molds, optionally assisted by application of positive or negative air pressure
to portions of the
sheet) into which the softened sheet is inserted. Upon cooling the sheet
retains the molded
shape and the shaped article (e.g., the container body) can be cut from a
larger sheet or the
plastic. If desired, the cut-out article can be further processed, for example
to turn the sharp
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edge of the cut sheet to a position at which it will not impinge upon a
plastic film used to seal
an adjacent portion of the article (e.g., to form the turned-under edge 11 of
the rim 12 shown in
Figure 1C).
[0089] A wide variety of thermoformable plastics can be used to make
the container body,
such as one selected from the group consisting of polyesters, polypropylenes,
polyvinyl
chlorides, polyethylene terephthalates, polystyrenes, and combinations of
these. Recyclable
materials are preferred, so that the container body can be recycled after
removing the stored
articles therefrom and displacing the drain insert and any absorbent
material(s) from the
container body.
[0090] The identity of the material(s) from which the drain insert are made
are likewise not
critical, nor is the manner by which the insert is made critical.
Substantially any material
capable of maintaining segregation between the storage space and the reservoir
of the container
body in the presence of stored articles and under the ordinary conditions of
filling, storage,
shipping, and handling can be used. The drain insert can, for example, be a
molded,
thermoformed, or cast plastic materials. Preferably, the insert is made from a
recyclable plastic,
so as to encourage recycling of the materials. Alternatively, the drain insert
can be made from a
paper slurry product, such as filter paper type material, a perforated
cardboard or paperboard.
The drain insert can also be made from a woven or non-woven fibrous material,
so long as it
retains the physical properties (e.g., rigidity) required in the drain insert
of a particular
embodiment,
100911 If the drain insert is stiffer than the container body, then
this stiffness can facilitate
stretching or displacement of flexible portions of the container body when
force is applied by a
user to the insert (by pressing another portion of the container body against
the insert), thereby
facilitating displacement of the insert from the body. If the drain insert is
more flexible than the
container body, then this flexibility can facilitate bending or folding of the
insert when force is
applied by a user to the insert (by pressing another portion of the container
body against the
insert), thereby facilitating displacement of the insert from the body.
[0092] The container described herein is made by forming the container
body and the insert
and then assembling the container. The insert is interposed between one or
more overhangs and
one or more shelf portions (carried by either a shelf or a support) of the
container body.
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Generally, the insert is placed within the interior of the container adjacent
the position at which
it will be interposed between the overhangs and shelves/supports, and then one
or both of the
container body and the insert are stretched, bent, folded, or deflected
sufficiently to effect such
interposition. Next, forces that were applied to achieve such stretching,
bending, folding, or
deflection are released so as to at least partially reverse those effects,
effectively 'locking' the
insert in the interposed position. Now, if the assembled container is tumbled
in space or gently
shaken, the insert will remain in the interposed position and will not be
displaced from the
container body until a user applies manual pressure to its exterior as
described herein.
[0093] If desired, an absorbent material can be inserted within a
reservoir prior to
assembling the container body and the insert. Following assembly, articles can
be placed
within the storage space of the container, and the container can be sealed
with a lidding or by
wrapping it, if desired.
[0094] Intentionally deleted.
[0095] While this subject matter has been disclosed with reference to
specific
embodiments, it is apparent that other embodiments and variations can be
devised by others
skilled in the art without departing from the true spirit and scope of the
subject matter described
herein. The appended claims include all such embodiments and equivalent
variations.
[0096] Parts list
[0097] 1 Assembled Container
[0098] 2 Outwardly-Projecting Bulge
[0099] 5 Underside of Overhang 15
[00100] 10 Container Body (e.g., a tray)
[0101] 11 Edge of shaped article
[0102] 12 Rim
[0103] 13 Slot
[0104] 14 Inner Wall
[0105] 15 Overhang
[0106] 16 Shelf
[0107] 17 Reservoir Wall
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[0108] 8 Bottom
101091 20 Drain Insert
[0110] 21 Perforation
[0111] 23 Periphery
[0112] 24 Lateral Wall of Support 25
[0113] 25 Support
[0114] 26 Upper Surface of Support 25
101151 30 Reservoir
[0116] 40 Absorbent Material (e.g. an absorbent pad)
[0117] 50 Concave Interior Portion of Shaped Article 10
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