Patent Application
20160031588
1. Technical Field
The present invention relates to a snack container with a three dimensional base and a two dimensional top. Specifically, the invention relates to, in a preferred embodiment, an interior-lined paperboard container filled with a snack food product that is sealed with a flat, two dimensional, seal at the top of the container yet has a square, three dimensional base, such as a square base. Such container is suitable for display on, for example, wire display racks in a convenience store setting. It is also shaped such that it fits into a standard car cup holder and is easy to hold. The container opens by use of a tear strip or tear feature slightly below the top of the container that removes the container top and allows for easy access to the snack food contained therein and a natural reclose functionality due to the container geometry.
2. Description of Related Art
Snack foods (such as potato or tortilla chips or crisps, nuts, popcorn, and other bite-sized savory snacks) are typically packaged in flexible bags called pillow bags. Pillow bags are suitable for display on wire racks, as they can be easily attached to the rack by a clip on the top seal of the pillow bag or by inserting a wire display rod through a hole in the top seal. This attribute can also allow for vending in vending machines that use wire hangers. Because pillow bags are flexible, however, they are not conducive to protecting the product once the bag is opened and the gas pressure inside the pillow bag is released. Pillow bags are also not shaped for use with certain convenience accessories such as a cup holder in an automobile or a cup holder in a seat at an entertainment venue (ballpark, movie theater, etc.). Pillow bags also do not naturally reclose once they are opened. A pillow bag typically requires some type of external clip to close the bag such that the product does not fall out of the bag if the bag falls on its side.
Another container typically used for snacks is a paperboard rectangular container such as traditionally used for Cracker Jack® and other similar products. These rectangular paperboard containers have the benefit of protecting the product even after the container has been opened. The container also allows for package to mouth consumption of the product contained therein. However, such paperboard rectangular containers cannot be displayed in the same manner as a pillow bag, because such containers do not have a flat or two dimensional top seal nor do they typically have a hole through the top through which a display rod can be inserted to hang the package for retail display. The rectangular boxes, depending on the dimensions, are also not typically suitable for use with cup holders. The paperboard rectangular container further typically requires a folding or manipulation of the top to reseal the container.
Another container used in the snack industry is the cylindrical container with a top cap seal, such as is used for the Lay's Stax® chip product. As with the rectangular paperboard container, the cylindrical container, typically made either of a plastic material or paperboard material, readily protects the product even after the cylinder has been opened at the top. The cylindrical container is suitable for use with cup holders and works well with one-hand use. However, the cylindrical container cannot typically be displayed on the wire racks used for pillow bag display, since the cylindrical container has neither a two dimensional top seal nor a hole through which a display rod can be inserted. Also, the cylindrical container requires a manual application of a top cap in order to reseal the container.
A need exists, therefore, for a snack container, for use with savory or sweet food products, that can be displayed on a wire display rack in a retail setting or hung in a vending machine, just like a pillow bag and yet that comprises the rigidity of a paperboard or plastic container for protecting the product. Further, such container should be suitable for use with cup holders and fit ergonomically into the human hand for one-hand use once opened and package to mouth consumption of the product contained therein. Further, the container should be designed to naturally reclose without the need for folding or the application of an external clip or top cap. Such container should be capable of carrying graphics on the exterior and have interior barrier properties sufficient to protect the snack product and promote shelf stability.
In a preferred embodiment, the invention uses a paperboard construction lined on the interior of the container with a barrier material, typically a combination of a low density polyethy base layer with aluminum foil or some other metalized layer, thus promoting shelf stability of the product contained therein. The container comprises a relativity square base that transitions through a geometric design utilizing folds and creases to a flat two dimensional top seal. The term “fold” or “folds” used herein means a bend in the material of greater than 89 degrees. The term “crease” or “creases” used herein means a bend in the material of less than 90 degrees.
This transition from a three dimensional base to a two dimensional top is accomplished by two opposed folds running vertically along opposite edges of the container from opposite corners of the square base to opposite edges of the top seal. Disposed between these two folds are two “V” shaped creases which start at opposite corners of the square base and terminate at a point below the top seal at each of the previously mentioned folds. This gives rise to a container that has side walls shaped of four right triangles divided by two isosceles triangles all below the point where the “V” shaped creases intersect with the folds below the top seal.
Further, in a preferred embodiment, a horizontal tear feature is constructed just below the top seal in order to open the container and remove the top seal. Once this happens, the container can be squeezed from the folds, opening the mouth of the container and allowing for access to the snack product contained therein and direct package to mouth consumption. Because of the geometry of the construction, the container substantially recloses once the pressure on the folds ceases.
In a preferred embodiment the container is of such dimensions that it easily fits in a cup holder and ergonomically fits well within the human hand for one hand use. The use of an end seal at the top allows for the retail display of the container in a similar fashion to that used for pillow bags in both retail settings and vending machines. Specifically, in one embodiment a hole or opening is fashioned in the center of the top seal such that the container can be hung off a rod on a wire display by pushing the rod through the hole. The flat end seal also allows the container to be hung on displays using clips.
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:
Also shown in
In one embodiment of the invention a barrier layer, such as a film consisting of MG bleached kraft, low density polyethylene, aluminum foil, and Surlyn 1652 sealant, is attached to the paperboard blank 102 on the back side of the blank 102 such that when the side flap 104 is sealed to the left side 106, the partially constructed container then has a barrier layer on the interior of the partially constructed container. The paperboard is, in a preferred embodiment, .014, .015, .016, .018, or .020 caliper paperboard and is SBS, SUS, CCNB, or some combination thereof. The front of the paperboard includes a graphical treatment that includes, but is not limited to: UV (high gloss) coating, matte coating, registered matte or gloss coating, embossing, and/or debossing. Additionally, specialty inks can be used such as thermochromic and/or phosphorescent inks.
A partially constructed container, as described above, is loaded with a product through the base of the partially constructed container. Such product includes, but is not limited to, bite size savory or sweet snack foods, such as: chips or crisps, nuts, popcorn, hard candy, extruded snacks, puff snacks, fried snacks, baked snacks, fruit pieces, soft candy pieces, chocolate, pretzels, cereals, and mixtures thereof. Once loaded, the construction is completed by fashioning a relatively square base using four bottom or base flaps 116, 118, 120, 122.
Returning to a description of the blank 102, in a preferred embodiment, the distance 124 from the top of the blank 102 to the bottom of the bottom flaps 116, 118, 120, 122 is about 10 inches. The distance 126 from the top of the blank 102 to the top of the bottom flaps 116, 118, 120, 122 is about 8 inches. The distance 128 from the top of the top sections 108, 110 to the bottom of the top sections 108, 110 is about .5 inches. The length 130 and width 132 of the side flap 104 is approximately 7.134 inches and .5 inches, respectively. The width 134 of the blank 102 less the side flap 104 is approximately 8 inches. The maximum width 136 of the slightly tapered bottom or base flaps 116, 118, 120, 122 is approximately 2 inches, thereby resulting in a square base upon final construction of the container of about 2 inches by 2 inches. The distance 138 from the top of the blank 102 to the top of the “V” shaped creases 166 is between 1 inch and 1.75 inches, and in a preferred embodiment is about 1.5 inches.
Referring now to
When fully constructed the container, in a preferred embodiment consists of a square base 250 and a two-dimensional flat top seal 252. The left side of the container is defined by a left fold 256. The right side of the container is defined by a right fold 254. Thus, the right fold 254 starts at the right corner 258 of the square base 250 and runs to the top right point 260 of the end seal 252. Likewise, the left fold 256 starts at the left corner 262 of the base and runs upward to the top left edge 264 of the top seal 252.
The container thus has two side walls which are in planar contact with each other above the horizontal crease 272 that defines the bottom of the end seal 252. Also depicted in the end seal 252 is a hole or opening 274. The geometry of the two folds 254, 256 and the two “V” shaped creases 266 provides a container (below the termination points 270 of the top of the “V” shaped creases 266) defined by four right triangle shaped side walls 276 and two isosceles triangle shaped side walls 278.
The embodiment of the container depicted in
The exact dimensions of the formed container can vary from embodiment to embodiment. For example, in a preferred embodiment the dimension of the square base 250 is less than 3 inches by 3 inches. In a more preferred embodiment the dimensions of the square base 250 is about 2 inches by 2 inches. In a preferred embodiment the length of the two folds 254, 256 is less than 10 inches long each and greater than 6 inches long each. In a more preferred embodiment the length of the two folds, 254, 256 is less than 9 inches long each and greater than 7 inches long each. In a preferred embodiment the vertical distance from the top corners 260, 264 of the top seal 252 to the top 270 of the “V” shaped crease 266 is between 1 inch and 2 inches.
Returning to
Once the container is partially constructed it is then filled through the opening in the base with a snack product. Finally, a square base is formed using the four base flaps 116, 118, 120, 122.
The method can include the step of scoring a tear feature 180 near the top of the blank 102. Further, openings can be cut in two locations 112, 114 near the top of the blank 102 such that the openings 112, 114 align upon formation of the end seal, thus forming a single opening through the end seal through which a rod can be inserted for displaying the container in a hanging configuration.
The foregoing is merely illustrative of the principles of this invention, and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention. It should be understood, for example, that the materials used in construction, the methods used to construct the container, and the products that fill the container may vary and are not limited by the specific disclosure stated herein.
