The invention relates to sealing containers and more particularly, to a multiple compartment sealing container and to closure device and corner tab feature for such containers.
Rigid thermoplastic food containers may be classified into two distinct categories. The first category of containers include containers that the consumer acquires during the purchase of dairy or deli foods at a retail store. This type of container is often referred to as an “inexpensive” container since usually the consumer's intention is to purchase the food in the container irrespective of the type of container. Since the consumer pays the retail price necessary to purchase the food, they often think of the container as an inexpensive item which they may save for re-use at a later date.
With respect to this first type of container, a group includes the inexpensive convenience containers which consumers frequently acquire when purchasing deli foods. Generally, these “deli” containers need only to perform the function of providing a highly visible display and to provide containment of solid foods, such as, bakery items, salads or. fruit at refrigeration temperature to ambient temperature. Often, the material of choice is a high clarity grade of APET (amorphous polyethylene terephthalate) or PS (polystyrene) and the containers are manufactured into many shapes by a thermoforming process so as to provide wall thicknesses of about 10-20 mils. This wall thickness range represents the low end of wall thicknesses generally seen in rigid thermoplastic food containers and as a consequence the containers can be made very inexpensively. Thus, the consumer may deem the container disposable, i.e. discardable without significant monetary loss that can be attributed to the cost of acquiring the container. In addition, the weight to volume ratio (i.e. the weight of the container over the volume of the container) of these containers is approximately 33.8-37.2 grams/liter for the total of the top and bottom of the container.
Since these deli containers have no elevated temperature requirements and thus can be formed from APET or PS, their low heat distortion temperature makes them highly unsuitable for microwave cooking applications. Furthermore, because the containers are not designed to provide a secure seal for liquid foods, the containers may leak if inverted while attempting to contain such foods during re-use by the consumer. Also, because the materials of construction are generally brittle, these containers will generally crack if stressed mechanically and thus are not very durable. Although these “deli” containers are inexpensive, their lack of heat resistance, durability and poor sealing characteristics severally limit their use.
“Dairy” containers also represent another group of thermoplastic containers that can be characterized as “inexpensive.” These containers are designed to hold butters, fresh and processed cheeses, yogurts, and read-serve sauces at retail. Often these containers are filled by a food producer while the food contents are hot enough to flow freely into the container. In these cases, the materials of choice for such containers are generally PP (polypropylene) or HDPE (high density polyethylene) owing to their elevated temperature performance characteristics. The container bottoms are manufactured by an injection molding or thermoforming process. The container bottoms made by injection molding have a wall thickness of about 20-40 mils. The container bottoms made by thermoforming have a wall thickness of about 10-20 mils. Like the “deli” containers, the “dairy” containers can be made very inexpensively and as such the consumer may deem the container disposable after limited re-use. The weight to volume ratio of the injection molded containers is approximately 43.9-57.4 grams/liter for the total of the top and bottom of the container. The weight to volume ratio of the thermoformed containers is approximately 37.2-54.1 grams/liter for the total of the top and bottom of the container.
These dairy containers almost always are formed into a round, somewhat cylindrical shape which is well suited to the requirements of high speed labeling equipment. The cylindrical shape is an inefficient shape compared to other shapes such as a rectangle or square with regard to storage space utilization.
Also the dairy containers should prevent moisture loss, oxygen permeation, and odor absorption which if not prevented would undesirably alter the food contents. The food producer solves these problems by completely enclosing the head space above the food by application of a lidding material, such as, foil or thermoplastic barrier film which is continuously sealed to the upper lip of the container bottom. The container generally will also include a removable rigid thermoplastic lid that is placed over the continuously sealed lidding foil or film so that puncture protection is provided. The lid has a wall thickness of about 10 to 20 mils. The rigid thermoplastic container lid usually engages the container bottom so as to provide a crude fit, but it does not have to provide a secure leakproof seal since the lidding material accomplishes this function. Thus when the consumer goes to re-use the container, they may find that the container's seal is unsuitable for rough transport and handling of liquid foods, since the lidding material has been peeled off during consumption of the original contents and only the crude fitting rigid lid remains.
The lid is usually made from a softer polyethylene material which often does not have the same heat resistance of the container bottom. Thus, when the consumer goes to re-use the container, they may find that the lid is easily distorted during microwave heating.
Finally, the dairy container materials are usually highly pigmented to provide opacity in order to prevent light-induced oxidation of fat-containing dairy products so as to extend store shelf-life. The consumer may prefer a see-through container which allows easy recognition of food contents during re-use of the container. Thus, dairy containers would be unsuitable in this regard. Although these dairy containers are inexpensive, their round shape, lack of a heat resistant lid, poor sealing characteristics, and opacity severely limit their re-use after the original food contents have been consumed.
For example, many consumers choose to take their lunch to work. While in transit, containers are frequently resting on uneven surfaces or being jostled from ordinary movements, and as a result, the contents of an inexpensive container may leak onto clothing, upholstery, and/or other food. In addition, the inexpensive containers may not be suitable for microwave use, and the food must be removed from the container and placed on dishware suitable for microwave cooking before being heated.
The second category of food containers consists of expensive durable containers which may utilize more expensive plastic materials and thick container walls. These containers address the shortcomings of the inexpensive containers in that they may be suitable for microwave, dishwasher, and freezer use and provide a secure seal which will not leak. However, these containers may employ costly materials. In addition, due to their sophisticated design elements, these containers generally require heavier construction to enable manufacture within the limitations associated with the injection molding process from which these containers are made. These containers have wall thicknesses of about 20 to 80 mils. Thus, this second category of containers become too expensive for disposable use. As a result, a consumer taking his or her lunch to work in an expensive durable container must be burdened with also transporting the container from work to home. The weight to volume ratio of these containers is approximately 67.6-219.6 grams/liter for the total of the top and bottom of the container.
Thus, it would be advantageous if a container were available that possessed the durability, sealing characteristics and features (i.e. microwaveable, freezable, and dishwasher safe) of the expensive containers at a cost which affords the user the option to dispose of it either after very limited use or after extended use.
It is a general object of the present invention to provide a multi-compartment food container having a tight leak proof seal around each compartment of the container that is inexpensive for disposable use. Another object of the present invention is to provide a semi-transparent container to ensure satisfactory visibility of the container contents. Another object of the present invention is to provide a container that is suited for microwave use. A further object of the invention is to create a container that is top-shelf dishwasher safe. Another object of the present invention is to provide a container that maintains its sealing characteristics while in freezer type temperatures.
A further object of the present invention is to provide a corner tab feature that will facilitate removing the container top from the container bottom. Another object of the invention is to provide a container top which may be positioned in a manner to permit container venting.
Another object of the present invention is to provide a container top which will receive a container bottom during container stacking. Another object of the invention is to provide a container bottom which is nestable with other container bottoms. A further object of the present invention is to provide a container top which is nestable with other container tops.
Another object of the present invention is to provide a sealable container which reduces manufacturing costs, while enabling diverse shapes other than round, such as, rectangle or square.
The present invention consists of an inexpensive tight sealing plastic container suited for microwave cooking, top-shelf dishwashing and freezer use. In accordance with a preferred embodiment, the container is provided with two compartments, one large and one small. The container utilizes a dual cut-back closure device of which the retaining bead of the container bottom maintains the container top in a secure position. The inside dimensions of the container top are slightly larger than the container bottom in both compartments. The difference in sizes provides an interference fit and forms a substantially leak proof seal along the inside perimeter of both compartments of the container. The container top provides at least one gripping tab, which facilitates the separation of the container top from the container bottom and permit container venting. In accordance with one embodiment of the invention, the container top is provided with two gripping tabs with one gripping tab allocated to each of the two compartments. In accordance with another embodiment, the closure devices on the container top and bottom are widened at the corner regions. Each of the four corners of the container top is provided with surface texturing in the form of upraised ribs to improve handling by a user.
Methods and apparatus which incorporate the features described above and which are effective to function as described above constitute further specific objects of the invention. Other objects and advantages of the invention will become apparent upon reading the following description and upon reference to the drawings.
For a more complete understanding of this invention reference should now be had to the embodiments illustrated in greater detail in the accompanying drawings and described below by ways of examples of the invention. In the drawings:
Referring to
As illustrated in
The sidewalls 122, 124, 126, 128 extend upwardly and slightly outwardly from the periphery of the bottom surface 120. At the termination of the sidewalls, an outwardly and substantially horizontally extending denesting shoulder 134 is provided which merges into the base of the closure device 136. The bottom surface 120 provides a stacking recess 130 extending upwardly to an upper substantially horizontal surface 132.
Referring to
The vertical sealing wall 150 extends from the denesting shoulder 134 and merges into the retention bead 140. The retention bead 140 may include an upwardly and outwardly extending cut-back portion 152, an inner vertical portion 153, an upwardly and inwardly extending lead-in portion 154, a horizontal rim surface 156, a downwardly and outwardly extending lead-in portion 158, an outer vertical portion 159, and a downwardly and inwardly extending cut-back portion 160.
The outer vertical wall 162 joins the retention bead 140 and the skirt 142. The skirt 142 may include a first downwardly and outwardly extending portion 164, a second downwardly and outwardly extending portion 166 of a more vertical position than the first portion 164, and a substantially horizontal lip 168.
As shown in
The container top 104 as illustrated in
Referring to
As depicted in
The gripping tabs 306 are formed adjacent to the corners of the container top, outside the perimeter of the closure device 308. As viewed in
Referring to
The gripping tab may also include cross-ribs to improve the grip on the tab. The cross-ribs may be perpendicular to the other ribs or the tab may only include the cross-ribs. Referring to
Furthermore, the tab 306B may include an indented portion on the tab or on the ribs to improve the grip on the tab. Referring to
In another embodiment, the indented portion(s) could be located on the upper rib(s) 316B. In a further embodiment, the upper and lower ribs 316B, 318B are eliminated from the tab and instead the tab includes indented portion(s).
Referring to
By utilizing the tab 306 and the recess 320, less force is required to remove the container top 104 from the container bottom 102. For example, the force required to close the container top 104 onto the container bottom 102 is approximately 27 pounds. However, the force required to open the container top 104 from the container bottom 102 using the tab 306 is approximately 1.8 pounds. Similarly, the force required to close the container top 604 onto the container bottom 602 in
In addition, the lower opening force may be beneficial when the container is used in a freezer. Some materials which may be used to make the container may become brittle at or near freezer temperatures. Consequently, if the container is removed from the freezer and immediately opened, the material for the container (and thus the container) are subject to the failure if the opening force is too high. Therefore, the lower opening force reduces the possibility of failure when the container is removed from the freezer and immediately opened.
The tab recess 320 also permits container venting by allowing the corner of the container top 104 to be removed from the container bottom 102 while still maintaining a seal around the remaining perimeter of the container. This feature is useful in microwave cooking where the container top 104 prevents food from splattering onto the inside surface of the microwave while still allowing the container to vent.
In one embodiment depicted by
As shown in
As shown in
The container top 104 is also designed slightly larger than the container bottom 102. This difference in size forms an interference fit between the cut-back portion 364 of the container top 104 and the inner sealing wall 150 of the container bottom 102. In one embodiment, the range of interference fit is 5 to 80 mils. As a result, when the two pieces are engaged, a strong inside seal 402 is formed around the inside perimeter of the container. Due to variations resulting from the thermoforming process and the polypropylene material, it is beneficial to have additional sealing points. Thus, the closure devices may have several other sealing areas when the container top engages the container bottom. Referring to
Both the container bottom 102 and the container top 104 may be made of a plastic material. More particularly, the top and bottom may be fabricated by thermoforming a clarified polypropylene homopolymer material. In one embodiment, the container is made from clarified polyprohomo with the trade name 3289M and sold by Fina Oil and Chemical Co. which has the following properties:
In another embodiment, the container may be fabricated by thermoforming a clarified random copolyer polypropylene material, such as Pro-fax SR-256M from Montell North America Inc., Wilmington, Del., which has the following properties:
Furthermore, if the material is transparent or semi-transparent, it permits satisfactory visibility of the container contents.
Alternative plastic materials which would be suitable for fabricating the container by thermoforming include PS (polystyrene), CPET (crystalline polethylene terephthalate), APET (amorphous polethylene terephthalate), HDPE (high density polyethylene), PVC polyvinyl chloride), and PC (polycarbonate). A disadvantage of PS and APET is that their limited heat resistance makes these materials unsuitable for microwave cooking. A disadvantage of HDPE is lack of see-through clarity though this material is readily recyclable by current waste handling practices. A disadvantage of CPET is that it lacks see-through clarity though its heat resistance is suitable for convection oven use. Fabrication using PC will yield a container with enhanced functional performance over PP (polypropylene) except that its cost may be prohibitive for a limited, re-use disposable product.
The container bottom 102 is formed from a starting sheet thickness in the range of 15 to 120 mils and preferably 25-40 mils. In one embodiment, the container bottom 102 is formed from a starting sheet thickness of approximately 40 mils. Referring to
The container bottom 102 has a sufficient thickness to withstand the heat of microwave cooking and remain sturdy during lifting while laden with hot food and also withstand the heat of top-shelf dishwashing without deforming.
The container top 104 is formed from a starting sheet thickness in the range of 7 and 60 mils and preferably 12-18 mils. In one embodiment, the container top is formed from a starting sheet thickness of approximately 15 mils. Referring to
The thinner container top reduces material costs and increases flexibility to more easily accommodate its removal from and engagement onto the container bottom. The container top 104 will maintain adequate flexibility for proper sealing even during typical freezer temperatures. Furthermore, the lack of surface detail in the container material provides for easy washing. The size of the container 100 as depicted in
The closure device 136B shares many of the same features as the closure devices 136 and 136A shown in
The vertical sealing wall 150 extends from a denesting shoulder (not shown) and merges into the retention bead 140A. The retention bead 140A includes an inner cutback portion of generally S shape configuration defined by a pair of arc segments 152A and 152B, an inner vertical portion 153A, an upwardly and inwardly extending lead-in portion 154, a horizontal rim surface 156, a downwardly and outwardly extending lead-in portion 158, an outer vertical portion 159, and an outer cut-back portion of generally S shaped configuration defined by arc segments 160A and 160B.
The outer vertical wall 162 joins the retention bead 140 and the skirt 142. The skirt 142 may include a first downwardly and outwardly extending portion 164, a second downwardly and outwardly extending portion 166 of a more vertical position than the first portion 164, and a substantially horizontal lip 168.
The container top closure device 308A include an upwardly and inwardly extending lead-in portion 360, an inner cut-back portion of generally S shaped configuration defined by arc segments 364A and 364B, an upwardly and inwardly extending portion 366, a horizontal surface 368, a downwardly and outwardly extending portion 370, an outer cut-back portion of generally S shaped configuration defined by arc segments 372A and 372B, a downwardly and outwardly extending lead-in portion 376 and a substantially horizontal lip 378. The terms “inner” and “outer” are used with respect to the reference line 137A shown in
As shown in
As described above, the closure devices may also have several other sealing areas when the container top engages the container bottom. For example, a second seal 404A may occur where the inwardly extending portion 366 engages the lead-in portion 154, a third seal 406A may occur where the horizontal surface 368 engages the horizontal rim surface 156, a fourth seal 408A may occur where the outwardly extending portion 370 engages the lead-in portion 158 and a fifth seal 410A may occur where the arc segment pair 372A, 372B defining the container top outer cut-back portion engages the arc segment pair 160A, 160B defining the container bottom outer cut back portion.
The contact points which generate the desired continuous inside and outside seals (i.e., first seal 402A and fifth seal 410A) may be comprised of (1) matching arc segments on the container top and bottom that align concentrically or (2) adjacent arc segments on the container top and bottom that may not align concentrically due to non-ideal alignment but nonetheless contact each other tangentially owing to design interference and the resiliency of material selected.
Under certain conditions, the arc segments of the
Additional embodiments for the configuration of the inner and outer cut-back portions may include, but are not limited to, a combination of linear and arc segments, a plurality of arc segments, and use of single arc segments.
The container bottom 602 is formed from a starting sheet thickness in the range of 18 to 140 mils and preferably 22-35 mils. In one embodiment, the container bottom 602 is formed from a starting sheet thickness of approximately 35 mils. Referring to
The container top 604 is similar to the container top 104 except the overall size corresponds to container bottom 602. Specifically, the dimensional parameters including the starting sheet thicknesses and the finished wall thicknesses are the same as for the container top 104 noted above.
The weight to volume ratio (i.e., the weight of the container over the volume of the container) for the container 100 shown in
The container may include additional features. For example, the container top and/or the container bottom may have an area which allows the user to write information, such as, the date. The write-on area could be an opaque color, such as, an opaque white, which would receive a contrasting color from a writing instrument, such as, a marker with black ink. The write-on area could be incorporated into the material for the container or could be applied to the material, such as, by printing.
Another feature which can be included on the container are volume marks. The container bottom can have marks on the side of the container indicating a specific volume, such as, ounces, pints, cups, or milliliters. For example, the marks may indicate one ounce, two ounces, etc. and include the appropriate text. The marks may be formed into the material or the marks may be applied to the material, such as, by printing.
The container may also include a visual indication of closure between the container top and the container bottom. The visual indication may be a color change in the area where the container top engages the container bottom. In one embodiment, the closure device on the container top may be a first color, such as, a translucent blue and the closure device on the container bottom may be a second color, such as, an opaque yellow. When the closure devices are occluded, the first and second colors produce a third color, such as, a green which is visible to the user to indicate that the container is sealed. Alternatively, the color change can result from the appearance or loss of a color as a result of hindrance by the closure portions. Examples of color change closures and techniques for forming a color change seal are shown in U.S. Pat. Nos. 4,186,786, 4,285,105, 4,829,641, 4,907,321, 5,248,201, 5,356,222, 5,252,281 and 5,427,266 which are incorporated herein by reference.
The colors may be incorporated into the material for the container or a portion of the container, such as in the closure area, or the colors may be applied to the material, such as, by printing. The actual inclusion of a color change closure or visual indication closure can be effected by use of established commercially available techniques. For example, if the lid and tub are to have a different color at the interface where the lid attaches to the tub the two respective surfaces can be fashioned with a color or design by use of screen printing (also known as silk-screen printing), pad printing (also known as transfer pad printing)or ink jet printing. The printing may be performed on the unformed material or the printing may be performed on the formed container. In addition, other approaches for forming a color or pattern on the lid and tub surfaces where such mate includes the use of coextruded sheet material which is then thermoformed. The aforementioned techniques are well known for use in providing decorative surfaces to plastic surfaces.
Furthermore, the colors may be incorporated into the material by using in-mold labeling during the thermoforming process. The process for in-mold labeling for thermoforming involves the following steps. The label, such as an opaque yellow label, is positioned in a predetermined location on the thermoforming cavity for the part. The plastic is then positioned over the label and over the thermoforming cavity. The part is then formed and the label is embedded into the part. As an example, the closure device on the container top may include a translucent blue in-mold label and the closure device on the container bottom may be an opaque yellow in-mold label. When the closure devices are occluded, the in-mold labels produce green which is visible to the user to indicate that the container is sealed.
The container may also include an audible indication of closure or a tactile indication of closure. In one embodiment, the closure device on the container top includes interior protrusions which engage exterior detents on the closure device on the container bottom. When the closure devices are engaging, the closure devices will make a clicking sound and cause a vibration in the container which is perceptible to the user to indicate that the container is sealed. Examples of audible closures and/or tactile closures disclosing techniques to provide this functionality are shown in U.S. Pat. Nos. 4,944,072, 5,070,584, 5,138,750, 5,140,727, 5,154,086, 5,363,540, 5,403,094 and published European applications EP A 90314084.5 and EP A 92301996.2 which are incorporated herein by reference.
The container bottom may also include vertical ribs on the sidewalls. The vertical ribs would increase the strength of the sidewalls and allow the sidewalls to be thinner.
The container top may also include a shape to hold an aluminum can, water bottle or second container in either a horizontal or vertical position. For example, the container top may include a two upwardly extending arms or a cradle surface which would hold the second container in a horizontal position. As another example, the container top may include a circular recess which would hold the second container in a vertical position.
The container may include a clip-on drink container. For example, the container bottom may have two outwardly extending arms and a bottom platform which would hold a drink container.
The container top may include a dome surface to increase the volume of the container and/or to allow the user to create a vacuum in the container upon sealing. For example, in order to create a vacuum, the user may depress the dome surface during the closing of the container. The dome surface will attempt to return to its relaxed position and create a vacuum.
In addition, the container may include a self-venting feature. The pressure in the sealed container may increase when the sealed container and contents are heated in a microwave oven. Thus the container top may include a self-venting mechanism which opens when the pressure in the container exceeds a predetermined value.
The container bottom may include a peelable lid with a super seal. Specifically, in a commercial use, the container bottom may include an interior peelable lid which is glued to the closure device.
In another embodiment, the peelable lid would release or vent when the sealed container and contents are heated in a microwave oven. Specifically, the heat would weaken the glue and allow the pressure to escape and /or the glue would be the weakest point of the container and allow the pressure to escape.
The container may be divided to separate various foods in the container. The divider would permit the user to store one food in one compartment and another food in another compartment. The divider may be integral with the container or a separate component. In addition, only the container bottom may include a divider or both the container bottom and the container top may each include a divider.
The dual compartment container 700 consists of a flexible plastic container bottom 702 and a flexible plastic container top 704.
Referring to
The first closure portion or closure device 708 preferably uses the same dual cut-back configuration as previously described in connection with the single compartment container embodiments. On the other hand, the second closure portion or closure device 716 is a little different and has a closure width that varies in correspondence to the divider width, which is designed to flare at the junction points with the first closure portion 708.
As is best seen in
Referring to
As is best seen in
With reference now to
As seen in
Preferably, the container bottom partition 710 is curved to provide increased rigidity along a length-wise direction of the container bottom 702 (the container top partition 730 is conformingly curved to match the contour of the curved container bottom partition 710). As best seen in
The dual compartment container 700 may also be provided with centering means for assisting in centered engagement between the dual compartment top 704 and the dual compartment bottom 702. In a preferred embodiment, the centering means include depressions 790 formed in the horizontal rim surface 756 adjacent the opposed flared ends of the container bottom partition 710. The depressions 790 are sized to receivingly engage, with an interference fit, conformingly shaped protrusions 792 formed in the horizontal rim surface 778 of the container top partition 730. In a preferred embodiment, the depressions 790 and protrusions 792 are substantially isosceles trapezoidal in configuration with a long dimension in the lengthwise orientation of the dual compartment bottom 702.
The container may also include a rough exterior surface to reduce slipping and improve grasping by the user. For example, the exterior of the container bottom may have a textured surface, as opposed to a smooth surface, to improve handling by the user, especially if the user's hands are wet or greasy.
The container may also include a temperature-indicating strip which would indicate the temperature of the container and contents. In one embodiment, the temperature strip could indicate the approximate temperature of the container and contents. In another embodiment, the temperature strip could indicate whether the container and content are within one of several temperature ranges. In a third embodiment, the temperature strip could indicate whether the container and contents are either hot or cold.
While the invention is described in connection with these embodiments, it will be understood that it is not intended to limit the invention to these embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
This application is a continuation of U.S. application Ser. No. 10/272,080, filed Oct. 16, 2002 now U.S. Pat. No. 6,910,599; which is a continuation of U.S. application Ser. No. 09/698,776, filed Oct. 27, 2000, now U.S. Patent No. 6,467,647, which is a continuation-in-part of U.S. application Ser. No. 08/819,826, filed Mar. 18, 1997, now U.S. Pat. No. 6,170,696.
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Number | Date | Country | |
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20050199639 A1 | Sep 2005 | US |
Number | Date | Country | |
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Parent | 10272080 | Oct 2002 | US |
Child | 11118204 | US | |
Parent | 09698776 | Oct 2000 | US |
Child | 10272080 | US |
Number | Date | Country | |
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Parent | 08819826 | Mar 1997 | US |
Child | 09698776 | US |