Multi-Compartment To-Go Container

Abstract

Two food elements are supplied in a container assembly which may be placed on a horizontal support surface or supported in an automobile cup holder. A smaller secondary cup is received within a secondary cup cavity cantilevered to one side of a thermoformed thermoplastic primary container which has exterior dimensions suited to a cup holder. The primary container has a main compartment which receives another food element. The base of the primary container is inclined from the rim of the primary container, such that the center of gravity of the primary container with secondary cup and edible material overlies the primary container bottom wall when the bottom wall is supported on a horizontal surface. A column in the primary container side wall extends from a protruding toe portion of the bottom wall to engage and support the secondary cup cavity.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded isometric view of the container assembly of this invention.

PIG. 2 is a front elevational view of the primary container of the assembly of FIG. 1.

FIG. 3 is a top view of the primary container of FIG. 4, taken along line 3-3.

FIG. 4 is a cross-sectional view of the container assembly of FIG. 1, loaded with a dip cup and representative food items.

FIG. 5 is a schematic view illustrating the center of mass of a loaded container of FIG. 1 compared to a container with differently shaped bottom.

FIG. 6 is an exploded cross-sectional view of a loaded container assembly of the invention having a film seal and supported in an automobile cup holder, and with a flat lid.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring more particularly to FIGS. 1-6, wherein like numbers refer to similar parts, a container assembly 20 is shown in FIG. 1. The container assembly 20 is suited to the packaging for sale of two component foods comprised of a first food element 22, for example baked bread sticks, and a second food element 24, for example a liquid condiment or dip, as shown in FIG. 4. The container assembly 20 is comprised of a primary container 26 which receives a smaller secondary cup 28, and may be covered by a lid 30.

Both the primary container 26 and the lid 30 may be formed of plastic in a conventional molding process, for example from sheet material in a conventional thermoforming process, for example, from polypropylene, or alternatively by injection molding. As best shown in FIG. 4, the primary container 26 has a bottom wall 32 with portions extending in a first plane which corresponds to a horizontal supporting surface 34, such as a table or counter. As shown in FIG. 3, the bottom wall 32 is generally circular with a protruding toe 36 which underlies a secondary cup cavity 38. The primary container 26 has a side wall 40 which extends upwardly from the bottom wall 32 and which terminates at a rolled rim 42. The rim 42 extends in a plane which is tilted from the plane of the bottom wall 32, as best shown in FIG. 4. The tilt may be about 8 degrees, but may be as much as 15 degrees, depending upon the particular desired configuration of the primary container.

The bottom wall 32 and the side wall 40 define a main compartment 44, generally frustoconical in shape, which is adapted to contain the first food element 22. The side wall 40 is dimensioned to be received in a conventional automobile cup holder. The side wall 40 extends downwardly from the rim 42 about an axis of revolution which is perpendicular to the plane of the rim 42. In other words, the side wall has a constant draft with respect to the plane of the rim, for example about 5 degrees. As a result, the container assembly 20 may be received within the cup holder so the rim will remain generally parallel to the cup holder. Although cup holders have been designed to hold a variety of sizes of container, they are generally shaped to adequately hold a conventional 12 oz. aluminum beverage can which typically has a diameter of about 2 11/16 inches.

As shown in FIGS. 2 and 3, portions of the primary container side wall 40 protrude outwardly towards the secondary cup cavity 38 to define a column 46 which extends between the bottom wall toe 36 and the lower wall 48 of the secondary cup cavity. The column 46 is defined by two radiused transition walls 50 on either side of a front wall portion 51. The column 46 is inclined with respect to the bottom wall 32 towards the center of the main compartment, or, put another way, the column is inclined away from a plane which is perpendicular to the bottom wall. The primary container side wall 40 defines a substantially frustoconical surface having a center axis. When the bottom wall 32 is supported on a horizontal surface, portions of the bottom wall toe 36 extend away from the center axis to underlie the secondary cup cavity lower wall 48.

The secondary cup cavity 38 is configured to receive the secondary cup 28, which may be a conventionally sized dip or condiment container. Generally the secondary cup 28 will be an axisymmetric generally frustoconical plastic molding with a side wall 52 which extends upwardly from a bottom wall 53 and terminates in an upper rim 54. As shown in FIG. 3, the lower wall 48 of the secondary cup cavity 38 is generally circular, but has a three-sided relief 56 where it joins the column 46. The secondary cup 28 and its contents are supported on the lower wall 48. The lower wall 48 of the secondary cup cavity 38 is preferably formed parallel to the rim 42 of the primary container 26. It will thus be inclined with respect to the bottom wall 32 of the primary container 26.

The secondary cup cavity 38 has a side wall 58 which extends from the primary container side wall 40 and which extends upwardly from the secondary cup cavity lower wall 48. The secondary cup cavity side wall 58 is generally frustoconical and of a similar diameter to the side wall 52 of the secondary cup 28, such that the secondary cup is received securely within the secondary cup cavity. To prevent the escape of the secondary cup 28 from the secondary cup cavity into the adjoining main compartment 44 with which it communicates, the secondary cup cavity side wall 58 wraps more than 180 degrees around the secondary cup, preferably at least 210 degrees, and in the illustrated example, about 240 degrees. The secondary cup 28 is thus restricted from entering the main compartment 44 by two projecting corners 60 where the primary container 26 side wall 40 adjoins the secondary cup cavity 38 side wall 52 above the secondary cup cavity lower wall 48.

As the secondary cup cavity 38 is cantilevered off to one side of the primary container 26, the main compartment 44 is unobstructed, and offers ample capacity for receiving the first food element 22. Moreover, because the secondary cup cavity 38 only extends sidewardly from the primary container 26 at an upper region of the container, adjacent the rim 42, it does not unduly extend the effective diameter of that portion of the container (that is the lower portion), which is received within the cup holder. For example, about the lower two inches of the primary container may be received within the cup holder. However, it will be readily observed that this unsymmetric cantilevered secondary cup cavity, when loaded with the secondary cup and its contents, will tend to cause the center of gravity of the entire assembly to move away from the vertical axis of the primary container.

As shown in FIG. 5, in broken line outline 62, if the bottom wall of the primary container were formed in a plane which was parallel to the rim, so that the axis of the primary container extended simply vertically, the center of gravity 64 of the primary container and the loaded secondary cup would be outside the bottom wall of the primary container. The weight of the first food element loaded in the primary container main compartment may be adequate to counterbalance the off-center secondary cup, but when some or all of the first food clement is removed, the primary container and secondary cup may no longer be supported on the bottom wall, and the cup would tip over. However, because the bottom wall of the primary container is tilted with respect to the axis of the primary container, the toe of the bottom wall extends beneath the center of gravity of the loaded secondary cup and the primary container, giving the entire assembly 20 a desirable stability when supported on a horizontal support surface.

The lid 30 has two levels to accommodate tall product within the main compartment, while restricting the vertical escape of the secondary cup from the secondary cup cavity. The lid 30 has a dome 66 with a top wall, and a downwardly extending side wall 67. A lower level wall 68 extends outwardly from the lid dome side wall 67 to encircle the dome as a narrow flange and to overlie the secondary cup cavity. A skirt 70 extends downwardly from the lower level wall 68, and a lower flange 72 extends outwardly from the skirt 70. A plurality of detents 74, shown in FIG. 1, extend inwardly from the lid skirt 70, and engage beneath the primary container rim 42 to removably secure the lid to the primary container.

To aid in ejecting the primary container from its thermoforming mold, the primary container 26 is preferably formed with an ejection platform 76 which is parallel to the plane of the primary container nm.

As shown in FIG. 6, the primary container 26 may be film sealed for preserving the freshness of the contents, for providing tamper evidence, or for use without a lid. The film seal 78 is applied in a conventional fashion to a flat region 80 which extends in a plane at the top of the primary container. The secondary cup 28 with its contents 24 may also be sealed with a film 92. The primary container 26 is shown supported in an automobile cup holder 86 in FIG. 6. Although the domed lid shown in FIG. 4 allows the primary container to hold a food element which is taller than the side wall, when used with food elements 122 which do not protrude above the level of the rim, a simple flat lid 84 may be employed.

For most food elements 22, 24, it is desirable to allow the potential customer to see within the container assembly 20 before purchase. Therefore the primary container and lid are preferably formed from transparent plastic. However, when a warm moist food element, such as a warmed bakery product is placed within the container, there is a possibility for vapor condensation on the primary container or lid. This fogging can obstruct the potential customer's view of the container assembly's contents. One way to avoid fogging is to enclose the food element in a cellophane bag which retains any vapor. Another approach is to form a rib along the lid which allows a free exchange of the container's interior air with the outside environment. Such a rib may be formed, for example, in the lower level wall 68 of the lid, the rib extending from the skirt 70 across the lower level wall 68. Alternatively, the lid 30 may be formed so as not to form a tight seal with the primary container 26, such as by making the perimeters of the primary container rim 42 and the lid skirt 70 different, thereby allowing ventilation of the main compartment 44 between the lid and the primary container. In another alternative approach, conventional antifog additives or coatings may be used with the lid and primary container.

In addition to being used with bread sticks and dip, as illustrated, the container assembly may be used with a wide variety of food elements, for example with vegetables or fruit and a dip; ice cream and a topping; etc. Thus it will be seen that the products to be contained are varied, and, based on product need, the material from which the primary container is formed could be adjusted to be suitable for temperatures ranging from freezer applications to oven temperatures, from direct fill to retail display with a limited shelf life. Besides polypropylene, then, the primary container and lid may be formed of polyethylene terephthalate (PET); high-heat styrenic copolymers such as Nova Chemicals DYLARK® resins; Styrene Maleic Anhydride (SMA) resin, or other appropriate moldable plastic materials.

It is understood that the invention is not limited to the particular construction and arrangement of parts herein illustrated and described, but embraces all such modified forms thereof as come within the scope of the following claims.

Claims

1. A container assembly comprising: a secondary cup having an edible material therein;a primary container having a bottom wall with an upwardly extending side wall, the bottom wall and the side wall defining a main compartment, the side wall extending upwardly from the bottom wall to terminate at an upper rim which extends in a first plane; anda secondary cup cavity which projects outwardly from the primary container 10 main compartment and which communicates with the main compartment, the secondary cup cavity having a lower wall which extends outwardly from the primary container side wall, and a secondary cup cavity side wall which extends upwardly from the secondary cup cavity lower wall, and which adjoins the primary container side wall, the secondary cup being positioned within the secondary cup cavity and supported on the secondary cup cavity lower wall within the secondary cup cavity side wall.

2. The assembly of claim 1 further comprising: portions of the bottom wall which define a protruding toe; andportions of the primary container side wall which define a column which extends upwardly from the bottom wall toe to the secondary cup cavity lower wall.

3. The assembly of claim 1 wherein the primary container is thermoformed of thermoplastic material.

4. A primary container for receipt therein of a first food element and a secondary cup containing a second food element, the primary container comprising: a bottom wall;a main compartment side wall which extends upwardly from the bottom wall and terminates at an upper rim which extends in a first plane, the bottom wall and the side wall defining a main compartment for receipt of the first food element; andportions of the side wall which define a secondary cup cavity which projects outwardly from the main compartment and which communicates with the main compartment, the secondary cup cavity having a lower wall which extends outwardly from the side wall, and a secondary cup cavity side wall which extends upwardly from the secondary cup cavity lower wall, and which adjoins the main compartment side wall, the secondary cup cavity being configured to receive the secondary cup and second food element therein and to support the secondary cup on the secondary cup cavity lower wall within the secondary cup cavity side wall.

5. The primary container of claim 4 further comprising: portions of the bottom wall which define a protruding toe; andportions of the primary container side wall which define a column which extends upwardly from the bottom wall toe to the secondary cup cavity lower wall.

6. The assembly of claim 1 wherein the primary container is thermoformed of thermoplastic material.

7. A container assembly comprising: a secondary cup having an edible material therein;a primary container having a bottom wall with an upwardly extending side wall, the bottom wall and the side wall defining a main compartment, the side wall extending upwardly from the bottom wall to terminate at an upper rim which extends in a first plane; andportions of the primary container side wall which define a secondary cup cavity which projects outwardly from the primary container main compartment and which communicates with the main compartment, the secondary cup cavity having a lower wall which extends outwardly from the primary container side wall, and a secondary cup cavity side wall which extends upwardly from the secondary cup cavity lower wall, and which adjoins the primary container side wall, the secondary cup being positioned within the secondary cup cavity and supported on the secondary cup cavity lower wall within the secondary cup cavity side wall, wherein the primary container bottom wall has portions which extend in a second plane which is below the first plane, wherein the center of gravity of the primary container with secondary cup and edible material overlies the primary container bottom wall when the bottom wall is supported on a horizontal surface.

8. The assembly of claim 7 wherein the secondary cup cavity side wall wraps around more than 180 degrees of the secondary cup to restrict the displacement of the secondary cup from the secondary cup cavity to the main compartment.

9. The assembly of claim 7 wherein the bottom wall has portions which extend in a second plane which is not parallel to the first plane defined by the upper rim, such that when the bottom wall portions in the second plane are supported on a horizontal surface, the secondary cup cavity is tipped toward a center of the primary container.

10. The assembly of claim 7 further comprising: portions of the bottom wall which define a protruding toe; andportions of the primary container side wall which define a column which extends upwardly from the bottom wall toe to the secondary cup cavity lower wall, the column being inclined with respect to the bottom wall away from a plane which is perpendicular to the bottom wall.

11. The assembly of claim 10 wherein the column is defined by two radiused transition walls extending on either side of a central column wall, and wherein the lower wall of the secondary cup cavity is generally circular, and has a three-sided relief where it joins the column.

12. The assembly of claim 7 further comprising a flat lid which overlies the primary container rim.

13. The assembly of claim 7 wherein the primary container rim has a flat region which extends in a plane, and further comprising a film seal which overlies said flat region.

14. A primary container for receipt therein of a first food element and a secondary cup containing a second food element, the primary container comprising: a bottom wall;a main compartment side wall which extends upwardly from the bottom wall and terminates at an upper rim which extends in a first plane, the bottom wall and the side wall defining a main compartment for receipt of the first food element; andportions of the side wall which define a secondary cup cavity which projects outwardly from the main compartment and which communicates with the main compartment, the secondary cup cavity having a lower wall which extends outwardly from the side wall, and a secondary cup cavity side wall which extends upwardly from the secondary cup cavity lower wall, and which adjoins the main compartment side wall, the secondary cup cavity being configured to receive the secondary cup and second food element therein and to support the secondary cup on the secondary cup cavity lower wall within the secondary cup cavity side wall, wherein the bottom wall has portions which extend in a second plane which is not parallel to the first plane defined by the upper rim, such that when the bottom wall portions in the second plane are supported on a horizontal surface, the secondary cup cavity is tipped toward the center of the primary container.

15. The primary container of claim 14 wherein the secondary cup cavity side wall defines more than 180 degrees of a frustoconical surface to wrap around a secondary cup when positioned within the secondary cup cavity, and to restrict the displacement of said secondary cup from the secondary cup cavity to the main compartment.

16. The primary container of claim 14 fierier comprising: portions of the bottom wall which define a protruding toe; andportions of the main compartment side wall which define a column which extends upwardly from the bottom wall toe to the secondary cup cavity lower wall, the column being inclined with respect to the bottom wall away from a plane which is perpendicular to the bottom wall.

17. The primary container of claim 16 wherein the column is defined by two radiused transition walls extending on either side of a central column wall, and wherein the lower wall of the secondary cup cavity is generally circular, and has a three-sided relief where it joins the column.

18. The primary container of claim 14 wherein the main compartment side wall extends downwardly from the upper rim at a first draft angle, the draft angle being substantially constant all around the upper rim.

19. The primary container of claim 14 further comprising a flat lid which overlies the primary container rim.

20. The assembly of claim 14 wherein the primary container rim has a flat region which extends in a plane, and further comprising a film seal which overlies said flat region.

21. A primary container for receipt therein of a first food element and a secondary cup containing a second food element, the primary container comprising: a bottom wall having a main region and a toe which projects in a first direction from the main region;a main compartment side wall which extends upwardly from the bottom wall and terminates at an upper rim, the bottom wall and the side wall defining a main compartment for receipt of the first food element;portions of the side wall which define a secondary cup cavity which projects outwardly in the first direction from the main compartment and which communicates with the main compartment, the secondary cup cavity having a lower wall which extends outwardly from the side wall, and a secondary cup cavity side wall which extends upwardly from the secondary cup cavity lower wall, and which adjoins the main compartment side wall, the secondary cup cavity being configured to receive the secondary cup and second food element therein and to support the secondary cup on the secondary cup cavity lower wall within the secondary cup cavity side wall; andportions of the main compartment side wall which define a column which extends upwardly from the bottom wall toe to the secondary cup cavity lower wall, the column being inclined with respect to the bottom wall in the first direction, the column being inclined away from a plane which is perpendicular to the bottom wall.

22. The primary container of claim 21 wherein the main compartment side wall defines a substantially frustoconical surface having a center axis, and wherein, when the bottom wall is supported on a horizontal surface, portions of the bottom wall foot extend in the first direction away from the center axis to underlie the secondary compartment lower wall.

23. The primary container of claim 21 wherein the secondary cup cavity side wall defines more than 180 degrees of a frustoconical surface to wrap around a secondary cup when positioned within the secondary cup cavity, and to restrict the displacement of said secondary cup from the secondary cup cavity to the main compartment.

24. The primary container of claim 21 wherein the column is defined by two radiused transition walls extending on either side of a central column wall, and wherein the lower wall of the secondary cup cavity is generally circular, and has a three-sided relief where it joins the column.

25. The primary container of claim 21 wherein the main compartment side wall extends downwardly from the upper rim at a first draft angle, the draft angle being substantially constant all around the upper rim.

26. The assembly of claim 21 fisher comprising a flat lid which overlies the primary container rim.

27. The assembly of claim 21 wherein the primary container rim has a flat region which extends in a plane, and further comprising a film seal which overlies said flat region.