CONTAINER AND PACKAGING SYSTEM

Abstract

A container is provided and includes a top wall, a bottom wall, and a plurality of sidewalls defining a plurality of side corners. Each of the side corners includes a top corner. At least one of the top corners has a plurality of spherical polygons including at least a first spherical polygon having a first radius of curvature contiguous with a second spherical polygon having a second radius of curvature.

Description

TECHNICAL FIELD

The present disclosure generally relates to a container and package system for food packaging.

BACKGROUND

Food packaging containers can be used with a variety of products. In some cases, such containers are blow molded from suitable plastic resins in a range of shapes and sizes. The empty blow-molded containers can be filled with food, food preparation and/or beverage products at a fill site utilizing automated fill equipment. These food packaging containers, however, can be difficult in handling, for example, to carry and dispense the food, food preparation and/or beverage products.

In some cases, a packaging system includes the food packaging container and an external box, which houses the container and facilitates handling. The box can provide strength and/or protection. The box can also provide packaging for stacking and transport, as well as a surface for advertising and labeling materials relating to the product contained therein. This disclosure describes an improvement over these prior technologies.

SUMMARY

In one embodiment, a container is provided. The container includes a top wall, a bottom wall, and a plurality of sidewalls defining a plurality of side corners. Each of the side corners includes a top corner. At least one of the top corners has a plurality of spherical polygons including at least a first spherical polygon having a first radius of curvature contiguous with a second spherical polygon having a second radius of curvature. In some embodiments, packaging products are also disclosed.

In one embodiment, the container includes a top wall, a bottom wall, and a plurality of sidewalls defining a longitudinal axis and a substantially square cross section. The sidewalls are connected at side corners including a first top corner, a second top corner, a third top corner and a fourth top corner. Each of the top corners including a plurality of spherical polygons including at least a first spherical polygon having a first radius of curvature contiguous with a second spherical polygon having a second radius of curvature.

In one embodiment, a packaging is provided. The packaging includes a container. The container includes a top wall, a bottom wall and a plurality of sidewalls defining a plurality of side corners. Each of the side corners including a top corner. At least one of the top corners includes a plurality of spherical polygons including at least a first spherical polygon having a first radius of curvature contiguous with a second spherical polygon having a second radius of curvature. A box comprises a top cover, a bottom cover and connected sidewalls defining an interior cavity configured for disposal of the container.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more readily apparent from the specific description accompanied by the following drawings, in which:

FIG. 1 is a perspective view of a container, in accordance with the principles of the present disclosure;

FIG. 2 is a top view of the container shown in FIG. 1;

FIG. 3 is a perspective view of the container shown in FIG. 1;

FIG. 4 is an enlarged break away view of the container shown in FIG. 3;

FIG. 5 is a front view of the container shown in FIG. 1;

FIG. 6 is a side view of the container shown in FIG. 1;

FIG. 7 is a rear view of the container shown in FIG. 1;

FIG. 8 is a bottom view of the container shown in FIG. 1; and

FIG. 9 is a perspective view of a container in a box, in accordance with the principles of the present disclosure.

DETAILED DESCRIPTION

The exemplary embodiments of a food packaging system, assembly of its components and related methods of use disclosed are discussed in terms of packaging systems and more particularly, in terms includes a container and a box for food, food preparation and/or beverage products. In some embodiments, the box encases the container. In some embodiments, the box is configured to facilitate stacking and carrying of the container. In some embodiments, the container can be filled with liquids, food, food preparation and/or beverage products. In some embodiments, the container may be made of plastic, for example, polyethylene terephthalate (PET), which can be blow molded into various configurations. In some embodiments, the container can be filled with food, food preparation oils, viscous and/or beverage products. In some embodiments, the container can be employed as a cold fill container. In some embodiments, the container can be employed as a hot fill container. In some embodiments, the container includes a large plastic container for edible oil packaging.

In some embodiments, the present disclosure includes a container including sidewalls, for example, four sidewalls. In some embodiments, the sidewalls define side corners. In some embodiments, each of the side corners include a top corner. In some embodiments, at least one top corner includes a plurality of spherical polygons. In some embodiments, the plurality of spherical polygons include at least a first spherical polygon having a first radius of curvature contiguous with a second spherical polygon having a second radius of curvature. In some embodiments, the plurality of spherical polygons include six spherical polygons each including a selected radius of curvature. In some embodiments, the radius of curvature is selected in a range of 0.25 through 1.50. In some embodiments, the container is configured for disposal with a box.

In some embodiments, the container includes blow-molded plastic jugs or bottles. In some embodiments, the container includes a 35 pound or a 5 gallon jug. In some embodiments, the container is manufactured via an injection molded preform, which is subjected to a blow mold process. In some embodiments, the container is manufactured and subjected to a trimming process.

In some embodiments, the present disclosure may be useful for manufacturers that run multiple sizes of blow and trim bottles for various end uses. For example, the present disclosure may be useful to produce containers for food items, for example, oils, dressings, sauces and peanuts. In some embodiments, the present disclosure may be useful to produce containers for food items, for example, non-dairy coffee creamers that require color pigment for both fill-line concealment and product protection against UV light penetration. Other containers that can be made from the disclosed process include containers for mayonnaise, salad dressings, peanuts as well as other condiments and/or food products.

In some embodiments, the present container may be formed by manufacturing methods that provide PET enhancements via improved material orientation with selective physical performance features, for example, improved top load performance, improved vacuum resistance performance and/or hoop strength, improved O₂ performance, improved moisture vapor transmission rate (MVTR) performance. In some embodiments, the enhancements include modifications to the manufacturing process or the addition of additives to provide a container made of PET that has a selected crystallinity, as discussed herein.

In some embodiments, the manufacturing methods are configured to produce a container that has a crystallinity of about 10%. In some embodiments, the method is configured to produce a container that has a crystallinity between about 15% and about 20%. In some embodiments, a preform is heated and stretched to produce a container having a crystallinity between about 18% and about 30%. In some embodiments, the preform is heated and stretched to produce a container having a crystallinity between about 20% and about 40%. In some embodiments, the preform includes a molecular weight between about 120,000 g/mol and about 240,000 g/mol. In some embodiments, the preform includes a molecular weight between about 250,000 g/mol and about 450,000 g/mol. In some embodiments, the preform comprises PET and has an axial stretch ratio of about 1.8 to 1 to about 2.4 to 1.

The present disclosure may be understood more readily by reference to the following detailed description of the embodiments taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this application is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting. Also, in some embodiments, as used in the specification and including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It is also understood that all spatial references, such as, for example, horizontal, vertical, top, upper, lower, bottom, left and right, are for illustrative purposes only and can be varied within the scope of the disclosure. For example, the references “upper” and “lower” are relative and used only in the context to the other, and are not necessarily “superior” and “inferior”.

The following discussion includes a description of components of a packaging system. Alternate embodiments are also disclosed. Reference is made in detail to the exemplary embodiments of the present disclosure, which are illustrated in the accompanying figures. Turning to FIGS. 1-9, there are illustrated components of a packaging system 10.

Packaging system 10 includes a container 12, as shown in FIG. 1. Container 12 is configured for use in the storing of food products. In some embodiments, food products include food, food preparation oils, viscous products and/or beverage products. In some embodiments, container 12 may include any size and/or shape and may be filled with any type of food and/or beverage. In some embodiments, container 12 is configured for use in applications that do not include food and/or beverage products.

Container 12 includes a body 13, as shown in FIG. 1. Body 13 includes a top wall 14 and a bottom wall 16. Container 12 and/or body 13 extend along a longitudinal axis AA between wall 14 and wall 16, as shown in FIG. 5. Body 13 includes a substantially rectangular cross section. In some embodiments, body 13 includes a substantially square cross section. In some embodiments, body 13 may have various alternative cross section configurations, for example, circular, oval, oblong, triangular, polygonal, irregular, uniform, non-uniform, variable, tubular and/or tapered.

Body 13 includes sidewalls 18, 20, 22, 24, as shown in FIG. 2. Walls 18, 20, 22, 24 each extend from wall 14 to wall 16. Wall 18 opposes wall 22, and wall 20 opposes wall 24. Body 13 is formed such that inner surfaces of walls 14, 16, 18, 20, 22, 24 define a chamber, for example, a cavity 26 configured for disposal of food products, beverage products and/or other products, as described herein. In some embodiments, body 13 is manufactured from a single preform that is blow molded to form container 12 such that walls 14, 16, 18, 20, 22, 24 are monolithically and/or integrally formed. In some embodiments, container 12 is made using an extrusion blow molding process.

Wall 14 and/or wall 16 extend perpendicular to axis AA. In some embodiments, wall 14 and/or wall 16 may be disposed at alternate orientations, relative to axis AA, for example, transverse and/or other angular orientations such as acute or obtuse, co-axial and/or may be offset or staggered. In some embodiments, wall 18, wall 20, wall 22 and/or wall 24 extend parallel to axis AA. In some embodiments, wall 18, wall 20, wall 22 and/or wall 24 may be disposed at alternate orientations, relative to axis AA, for example, transverse, oblique and/or other angular orientations such as acute or obtuse and/or may be offset or staggered.

Sidewalls 18, 20 define a side corner 28. Side corner 28 includes a top corner 30 that defines a plurality of spherical polygons, as shown in FIGS. 2-4. In some embodiments, top corner 30 includes a planar outer surface. In some embodiments, top corner 30 includes a plurality of spherical polygons to reduce the amount of material that is employed during the manufacture of container 12 while also maintaining container 12 strength. In some embodiments, the plurality of spherical polygons include 2 to 20 spherical polygons. In some embodiments, the plurality of spherical polygons include a three sided polygon (triangular), a four sided polygon (quadrilateral), a five sided polygon (pentagonal), a six sided polygon (hexagonal), a seven sided polygon (heptagonal), an eight sided polygon (octagonal), a nine sided polygon (nonagonal) and/or a ten sided polygon (decagonal). In some embodiments, top corner 30 includes alternatively configured geometric configurations including circular, oval, and/or star shaped.

Top corner 30 includes six spherical polygons, as shown for example in FIG. 3. In some embodiments, top corner 30 includes a spherical polyhedron or spherical tiling. In some embodiments, a spherical polyhedron or spherical tiling includes a tiling of the sphere in which the surface is divided or partitioned by arcs into bounded regions called spherical polygons. In some embodiments, top corner 30 is tessellated and includes an arrangement of shapes, for example, polygons, that are closely fit together in a repeated pattern without gaps or overlapping.

Top corner 30 includes spherical polygons 32, 34, 36, 38, 40, 42, as shown in FIGS. 3 and 4. Spherical polygons 32, 34, 36, 38, 40, 42 are contiguous relative to each other. Spherical polygon 32 includes a four sided polygon. Spherical polygon 32 includes a selected radius of curvature R1 relative to longitudinal axis AA. In some embodiments, the selected radius of curvature R1 is in a range of 0.25 through 1.50. In some embodiments, the selected radius of curvature R1 is 0.75. Spherical polygon 34 is adjacent to spherical polygon 32 and includes a four sided polygon. Spherical polygon 34 includes a selected radius of curvature R2 relative to longitudinal axis AA. In some embodiments, the selected radius of curvature R2 is in a range of 0.25 through 1.50. In some embodiments, the selected radius of curvature R2 is 1.10.

Spherical polygon 36 is adjacent to spherical polygon 34 and includes a three sided polygon. Spherical polygon 36 includes a selected radius of curvature R3 relative to longitudinal axis AA. In some embodiments, the selected radius of curvature R3 is in a range of 0.25 through 1.50. In some embodiments, the selected radius of curvature R3 is 1.00. Spherical polygon 38 is adjacent to spherical polygon 36 and includes a four sided polygon. Spherical polygon 38 includes a selected radius of curvature R4 relative to longitudinal axis AA. In some embodiments, the selected radius of curvature R4 is in a range of 0.25 through 1.50. In some embodiments, the selected radius of curvature R4 is 1.0.

Spherical polygon 40 is adjacent to spherical polygon 38 and includes a four sided polygon. Spherical polygon 40 includes a first portion 44 having a radius of curvature R5 relative to longitudinal axis AA in a range of 0.25 through 1.50, and a second portion 46 having a radius of curvature R6 relative to longitudinal axis AA in a range of 0.25 through 1.50. In some embodiments, radius of curvature R5 is 0.60 and radius of curvature R6 is 0.9. Spherical polygon 42 is adjacent to spherical polygon 32 and includes a four sided polygon. Spherical polygon 42 includes a first portion 48 having a radius of curvature R7 relative to longitudinal axis AA in a range of 0.25 through 1.50, and a second portion 50 having a radius of curvature R8 relative to longitudinal axis AA in a range of 0.25 through 1.50. In some embodiments, radius of curvature R7 is 0.60 and radius of curvature R8 is 0.75.

Sidewalls 20, 22 define a side corner 52, similar to side corner 28, as shown in FIG. 2. Side corner 52 includes a top corner 54, similar to top corner 30. Top corner 54 includes spherical polygons 32A, 34A, 36A, 38A, 40A, 42A, as shown in FIG. 6, similar to spherical polygons 32, 34, 36, 38, 40, 42, described above.

Sidewalls 22, 24 define a side corner 56, similar to side corner 28. Side corner 56 includes a top corner 58, similar to top corner 30. Top corner 58 includes spherical polygons 32B, 34B, 36B, 38B, 40B, 42B, as shown in FIG. 7, similar to spherical polygons 32, 34, 36, 38, 40, 42, as described above.

Sidewalls 18, 24, define a side corner 60, similar to side corner 28. Side corner 60 includes a top corner 62, similar to top corner 30. Top corner 62 includes spherical polygons 32C, 34C, 36C, 38C, 40C, 42C, as shown in FIG. 5, similar to spherical polygons 32, 34, 36, 38, 40, 42, as described above.

Sidewall 18 includes two longitudinal ribs 64, 66, as shown in FIG. 1. Sidewall 20 includes two longitudinal ribs 68, 70. Sidewall 22 includes two longitudinal ribs 72, 74, as shown in FIG. 7. Sidewall 24 includes two longitudinal ribs 76, 78, as show in FIG. 1. Longitudinal ribs 64, 66, 68, 70, 72, 74, 76, 78 are disposed adjacent corresponding side corners 28, 52, 56, 60 and are disposed adjacent wall 16. In some embodiments, longitudinal ribs 64, 66, 68, 70, 72, 74, 76, 78 are strengthening features of container 12. In some embodiments, longitudinal ribs 64, 66, 68, 70, 72, 74, 76, 78 are grooves that each extend into an outer surface of at least one of walls 18, 20, 22, 24. In some embodiments, longitudinal ribs 64, 66, 68, 70, 72, 74, 76, 78 are aligned with one another along longitudinal axis AA such that each of longitudinal ribs 64, 66, 68, 70, 72, 74, 76, 78 begin at the same point along longitudinal axis AA and terminate along the same point along longitudinal axis AA. In some embodiments, longitudinal ribs 64, 66, 68, 70, 72, 74, 76, 78 may be disposed at alternate orientations, relative to longitudinal axis AA, for example, transverse, oblique and/or other angular orientations such as acute or obtuse, co-axial and/or may be offset or staggered. In some embodiments, longitudinal ribs 64, 66, 68, 70, 72, 74, 76, 78 each include a linear portion oriented between opposing rounded ends to provide longitudinal ribs 64, 66, 68, 70, 72, 74, 76, 78 with an oblong shape.

Container 12 includes a spout 80 extending from wall 14 and an extension, for example, a flange 82, as shown in FIGS. 1 and 6. Flange 82 includes an end 84 that engages wall 14 and an opposite end 86. In some embodiments, flange 82 is tapered from end 84 to end 86. Container 12 includes a handle 88 having an end 90 that engages spout 80, and an opposite end 92 that engages end 86 of flange 82. Handle 88 includes a transverse grip portion 93. Spout 80 defines an opening 94 that is in communication with cavity 26 to allow contents that are stored within cavity 26 to exit container 12 through opening 94. In some embodiments, opening 94 may have various cross section configurations, for example, circular, oval, oblong, triangular, rectangular, square, polygonal, irregular, uniform, non-uniform, variable, tubular and/or tapered. In some embodiments, opening 94 may be disposed at alternate orientations, relative to longitudinal axis AA, for example, transverse, parallel and/or other angular orientations such as, oblique, acute or obtuse, co-axial and/or may be offset or staggered. In some embodiments, handle 88 is spaced apart from wall 14. In some embodiments, container 12 includes a strut 96 that engages wall 14 and handle 88 to provide strength to handle 88 to prevent movement of handle 88 relative to body 13.

In some embodiments, at least a portion of flange 82 and a portion of handle 88 are hollow and define a passageway 98 that is in communication with cavity 26 and opening 94 such that liquid contents in cavity 26 can travel through passageway 98 and into opening 94 as such liquid contents are being expelled from container 12 through opening 94, as discussed herein. In some embodiments wherein container 12 includes passageway 98, container 12 may include an aperture 100 disposed between spout 80 and handle 88, as shown in FIG. 6. Aperture 100 is in communication with opening 94 and passageway 98 to facilitate liquid contents in cavity 26 to travel through passageway 98 and into opening 94 through aperture 100. In some embodiments, flange 82 and handle 88 are solid such that liquid contents in cavity 26 is prevented from moving through flange 82 and/or handle 88 as such liquid contents are being expelled from container 12 through opening 94, as discussed herein.

In some embodiments, body 13 includes an indent 102 extending into an outer surface of wall 14, as shown in FIG. 2. Indent 102 is configured for disposal of a hand of a user when the user grasps handle 88 by hand. For example, indent 102 is configured for disposal of the user's fingers when the user's palm engages a surface of handle 88. In some embodiments, indent 102 is variously shaped, for example, oval, oblong, triangular, square, rectangular, polygonal, irregular, uniform, non-uniform, offset, staggered, undulating, arcuate, variable and/or tapered.

Packaging system 10 includes a box 200, as shown in FIG. 9. See, for example, the packaging systems and method disclosed in U.S. Pat. No. 7,726,503, the entire contents of the reference being incorporated by reference herein.

Box 200 is configured to facilitate carrying of container 12. Box 200 is configured to facilitate stacking of one or more containers 12 for transport and/or display. Box 200 includes a top cover 202. Top cover 202 defines an opening 204 configured to provide access to spout 80 of container 12 such that spout 80 is exposed to facilitate dispensing of material within container 12. Box 200 includes a bottom cover 206. Top cover 202 and bottom cover 206 are connected to sidewalls 208, 210, 212, 214. Sidewalls 208, 210, 212, 214 define an interior cavity 216 configured for disposal of container 12.

In assembly and use, a sheet (not shown) is cut by a die-cutter into a selected configuration of box 200. In some embodiments, a trimmer cuts a design of box 200. In some embodiments, the trimmer includes sharp and rubber blades to allow for forming lines that are scored not cut. A bending machine folds the sheet along scored lines and glue or stitches is applied to form assembled box 200.

In some embodiments, container 12 is formed by blow-molding. In some embodiments, container 12 is pre-filled via an automated fill machine. Container 12 is disposed within cavity 216 of box 200. Box 200 is configured to facilitate gripping of container 12 for carrying and/or a selected pouring material.

In some embodiments, container 12 may be fabricated from plastic and formed using injection and compression molding processes. In some embodiments, container 12 may be fabricated from polyester (PES), polyethylene (PE), high-density polyethylene (HDPE), polyvinyl chloride (PVC), polyvinylidene chloride (PVDC) (Saran), low-density polyethylene (LDPE), polypropylene (PP), polystyrene (PS), high impact polystyrene (HIPS), polyamides (PA) (Nylons), acrylonitrile butadiene styrene (ABS), polyethylene/acrylonitrile butadiene styrene (PE/ABS), polycarbonate (PC), polycarbonate/acrylonitrile butadiene styrene (PC/ABS), and/or polyurethanes (PU).

It will be understood that various modifications may be made to the embodiments disclosed herein. Therefore, the above description should not be construed as limiting, but merely as exemplification of the various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.

Claims

1. A container comprising: a top wall;a bottom wall; anda plurality of sidewalls defining a plurality of side corners, each of the side corners including a top corner,wherein at least one of the top corners has a plurality of spherical polygons including at least a first spherical polygon having a first radius of curvature contiguous with a second spherical polygon having a second radius of curvature.

2. A container as recited in claim 1, wherein the plurality of spherical polygons includes at least one four sided polygon.

3. The container as recited in claim 1, wherein the plurality of spherical polygons includes at least one three sided polygon.

4. The container as recited in claim 1, wherein the first spherical polygon comprises a four sided polygon and the second spherical polygon comprises a three sided polygon.

5. The container as recited in claim 1, wherein a first top corner includes a first spherical polygon having four sides and a radius of curvature of 0.75, a second spherical polygon having four sides and a radius of curvature of 1.10, and a third spherical polygon having three sides and a radius of curvature of 1.00.

6. A container as recited in claim 1, wherein a first top corner includes a four sided polygon defining a planar outer surface.

7. A container as recited in claim 1, wherein the first spherical polygon includes a first portion having a radius of curvature of 0.60 and a second portion having a radius of curvature of 0.75.

8. A container as recited in claim 1, further defining a longitudinal axis, the first spherical polygon having a first radius of curvature relative to the longitudinal axis and the second spherical polygon having a second radius of curvature relative to the longitudinal axis.

9. A container as recited in claim 1, further defining a substantially rectangular cross section and including a first top corner, a second top corner, a third top corner and a fourth top corner.

10. A container as recited in claim 1, wherein at least one of the sidewalls includes at least two longitudinal ribs.

11. A container as recited in claim 1, wherein at least one of the sidewalls includes longitudinal ribs disposed adjacent the side corners and longitudinal ribs disposed adjacent the bottom wall.

12. A container as recited in claim 1, wherein at least one of the radius of curvature is a radius of curvature selected in a range of 0.25 through 1.50.

13. A container as recited in claim 1, further comprising a spout extending from the top wall and a handle extending from the spout, the handle being in fluid communication with the spout and including a transverse grip portion.

14. A container comprising: a top wall; a bottom wall; and a plurality of sidewalls defining a longitudinal axis and a substantially square cross section,the sidewalls being connected at side corners including a first top corner, a second top corner, a third top corner and a fourth top corner,each of the top corners including a plurality of spherical polygons including at least a first spherical polygon having a first radius of curvature contiguous with a second spherical polygon having a second radius of curvature.

15. A container as recited in claim 14, wherein each of the sidewalls includes at least two longitudinal ribs.

16. A container as recited in claim 14, wherein each of the sidewalls includes longitudinal ribs disposed adjacent the side corners and longitudinal ribs disposed adjacent the bottom wall.

17. A container as recited in claim 14, wherein at least one of the radius of curvature is a radius of curvature selected in a range of 0.25 through 1.50.

18. A packaging comprising: a container comprising a top wall, a bottom wall and a plurality of sidewalls defining a plurality of side corners, each of the side corners including a top corner, wherein at least one of the top corners has a plurality of spherical polygons including at least a first spherical polygon having a first radius of curvature contiguous with a second spherical polygon having a second radius of curvature; anda box comprising a top cover, a bottom cover and connected sidewalls defining an interior cavity configured for disposal of the container.

19. A packaging as recited in claim 18, wherein a first top corner includes a first spherical polygon having four sides and a radius of curvature of 0.75, a second spherical polygon having four sides and a radius of curvature of 1.10, and a third spherical polygon having three sides and a radius of curvature of 1.00.

20. A packaging as recited in claim 18, wherein the top cover defines an opening configured to provide access to a spout of the container.