POLYMERIC CEREAL CONTAINER AS WELL AS SYSTEM AND METHOD UTILIZING SAME
A polymeric cereal container includes a first wall, a cereal chamber at least partially formed by the first wall, and a container opening at least partially defined by the first wall. A first quantity of dry cereal can be received within the cereal chamber, and a second quantity of dry cereal can be provided separately. A method can include providing and filling a polymeric cereal container with a quantity of dry cereal. A system can operate to fill a polymeric cereal container with a quantity of dry cereal.
The present novel concept broadly relates to the art of food packaging and, more particularly, to a polymeric container for storing dry cereal and a system and method of packaging dry cereal using the same.
Dry cereal is a popular food item that is often consumed as a part of a meal or as a snack. For example, cereal can be eaten as a breakfast food served in a bowl with milk. Additionally, cereal is commonly eaten as a snack food without milk and is often consumed directly from the package. Dry cereal is sold in great quantities, and much of the dry cereal is packaged and sold to consumers in rectangular cardboard boxes. Typically, the dry cereal is sealed within a plastic bag that is received within the cardboard box. Text and graphics of various sorts are printed on the box to identify the cereal and the manufacturer, as well as to provide nutritional and other information. Furthermore, the boxes are often printed with market-appropriate information, promotional materials and/or other marketing items, such as games and activities for children, for example.
Though such packaging is very common, there are numerous difficulties, inconveniences and/or disadvantages associated with its continued use. One example of such a disadvantage is associated with re-closing the cereal package after the cereal product has been dispensed or consumed therefrom. To fully illustrate the inconvenience to consumers, it will be beneficial to first briefly describe the construction of the cardboard box and plastic bag of usual packaging arrangements.
Typically, the cardboard box is formed from a cardboard blank. Though the blank can be formed in any suitable manner, the same are often cut from a sheet of cardboard material using a die or other suitable device. The rectangular body of the box is constructed by folding the blank in numerous places and adhering together two opposing edges thereof. Flaps located at each of the opposing ends of the box body are then folded over and adhered to one another to form the fully enclosed package.
Due, at least in part, to this method of construction, it is difficult and expensive to manufacture cardboard boxes in anything other than rectilinear shapes, such as squares or rectangles. The sealed plastic bag that contains the cereal can be deposited within the cardboard box at any one of a number of steps or stages of the box assembly process, with the end result being that the plastic bag of cereal is sealed within the box. The plastic bag is used to prevent contamination of the cereal product by the cardboard material and also provides improved sealing of the package. The plastic bag is in direct contact with the cereal products, so a material approved for food contact is normally used. To access the cereal located therein, the consumer permanently opens the box by tearing apart two adhesively secured flaps at one end of the box and then permanently tearing open the polymeric bag to get to the cereal product.
One of the problems associated with opening packaging that has been formed in this manner is that positive re-closure of the package is not assured. First, the plastic bag that contains the cereal is typically not self-sealing. So, the consumer will roll-up or crush-up the open end of the bag in an attempt to close the opening that was previously torn therein. Being formed from a plastic material, however, the bag does not retain this rolled-up shape and normally unrolls a substantial amount.
Additionally, the two flaps that were initially torn apart to access the plastic bag typically include interlocking features, such as a tab on one flap and an opposing slit on another flap, for example, that can be used to attempt to re-close the box. After rolling up the open end of the bag, the consumer will close the two flaps and try to interlock the features to close the box. Unfortunately, flaps secured in this manner, along with the rolled-up bag, do not offer a significant barrier to the ingress of moisture or any significant level of protection against insects, both which are undesirable and can present severe problems in certain geographic areas.
Furthermore, to minimize costs associated with packaging the cereal product, very thin cardboard material is often used for the box. This presents a number of disadvantages and adds to the difficulties associated with re-closing the packaging, as well. For example, the flaps of the box are often inadvertently ripped or otherwise damaged when the box is initially opened, unless substantial care is exercised. This is due, at least in part, to the thinness and/or reduced strength of the cardboard material. This results in the flaps not re-closing securely and, thus, providing access for moisture and/or insects. Because of the increased flexibility of this thin material, the box tends to flex or swell at its midpoint due to the settling of the cereal. This can be particularly problematic for the consumer once the package has been opened, because the flaps of the box are pushed apart or otherwise separated from one another, often to the point that the interlocking features will not properly engage one another. As a result, known cereal boxes are often incapable of being properly and securely closed after being initially opened.
Another disadvantage of the current bag-in-box packaging is that the rolled or crumpled bag and the flaps of the box do not allow for easy or convenient access to the cereal product for the purpose of direct consumption, such as during snacking, for example. Furthermore, the crumpled bag and the box flaps and edges do not provide for easy or convenient pouring of the cereal product, such as into a bowl, for example. This can be particularly problematic for younger children, for whom many types and kinds of cereal are intended. One reason for this is that children tend not to fully unroll or otherwise open the crumpled bag, which can create an opening and/or surface that is not well suited for pouring the cereal. In many cases, the child will then tip the box to a greater degree to cause the cereal to flow from the bag. This, in turn, can lead to a rush of cereal flowing toward the opening, often resulting in spillage or waste of the cereal product.
Still another disadvantage of current bag-in-box packaging arrangements for cereal products is that the packaging is not reusable. That is, current boxes are not sufficiently durable for use as a refillable container for cereal products. Similarly, the typical bag-in-box package is not sufficiently durable or otherwise suitable for usage as a storage container for other products or household items. Furthermore, the secondary uses for such cardboard boxes are generally limited to single-use activities for children, such as puzzles, games or coloring activities, for example. As a result, the entire bag-in-box package is typically disposed of once the cereal product therein has been consumed.
Furthermore, promotional items, such as small books, stickers, activity boards, coupons, toys and compact discs, for example, are often included within known packages of cereal for marketing and promotional purposes. A further disadvantage of typical packaging arrangements is that the promotional item must itself be separately packaged to prevent any inadvertent contamination of the cereal product due to the inclusion of the promotional item within the cereal package. Further still, the item and its separate wrapper are normally designed and arranged such that damage to the cereal product or penetration of the plastic bag and/or cardboard box does not result from the transport and handling of the cereal box prior to purchase and opening by the consumer. This can place constraints on the type, size and/or shape of the items that can be included or used as promotional items, and can increase the costs associated with the inclusion thereof. What's more, since the promotional items can vary greatly in size and shape, circumstances arise in which production equipment is not suited for and/or capable of inserting the promotional item into the packaging in the proper manner. This can lead to off-line processes that can significantly increase the costs associated with including the promotional items.
BRIEF DESCRIPTIONA linerless cereal container is provided in accordance with the present novel concept that includes a first side wall formed from a polymeric material and includes a first opening wall portion. A second side wall is formed from the polymeric material and is spaced from the first side wall and at least partially defines a cereal chamber therebetween. The second side wall includes a second opening wall portion spaced from the first opening wall portion and at least partially defines a container opening therebetween. At least one end wall is formed from the polymeric material. The at least one end wall extends between the first side wall and the second side wall, and includes an end opening wall portion extending between the first and second opening wall portions. A bottom wall is formed from the polymeric material and extends between at least two of the first side wall, the second side wall or the end wall.
A cereal container storing a quantity of dry cereal in accordance with the present novel concept is provided and includes a container body formed from a rigid polymeric material. The container body includes a first side, a cereal chamber at least partially formed by the first side and receiving the quantity of dry cereal, and a container opening at least partially defined by the first side. A container cap is formed from a rigid polymeric material and includes a closed end, an opposing open end and a side wall extending between the open and closed ends. The container cap is received on the container body such that the closed end extends across at least a portion of the container opening. A sealing member either extends across at least a portion of the container opening between the container body and the container cap or extends along the side wall of the container cap.
A method of packaging cereal in accordance with the present novel concept is provided and includes a step of providing a cereal container formed from a polymeric material. The cereal container includes a first wall, a cereal chamber at least partially formed by the first wall and a container opening at least partially defined by the first wall. Another step includes providing a quantity of cereal and dispensing the quantity of cereal into the cereal chamber of the cereal container through the container opening. Further steps include providing a container cap formed from a polymeric material, and securing the container cap on the cereal container across at least a portion of the container opening.
A cereal packaging system in accordance with the present novel concept includes a cereal product source adapted to output a quantity of a cereal product. A polymeric cereal container source is adapted to output a polymeric cereal container that includes a first wall, a cereal chamber at least partially defined by the first wall and a container opening at least partially defined by the first wall. A filling station in communication with the cereal product source and the polymeric cereal container source respectively receives the quantity of cereal product and the polymeric cereal container. The filling station is adapted to dispense the quantity of cereal product into the cereal chamber of the polymeric cereal container through the container opening. A sealing member source is adapted to output a sealing member. A container sealing station is in communication with the filling station and the sealing member source to respectively receive a filled polymeric cereal container and the sealing member. The container sealing station is adapted to apply the sealing member along the filled polymeric cereal container. A container cap source is adapted to output a polymeric container cap, and a capping station is in communication with the container sealing station and the container cap source to respectively receive a sealed polymeric cereal container and the container cap. The capping station is adapted to secure the container cap on the sealed polymeric cereal container.
A cereal container assembly in accordance with the present novel concept is provided and includes a first quantity of dry cereal and a first container body formed from a rigid polymeric material. The first container body includes a first side, a cereal chamber at least partially formed by the first side and receiving the first quantity of dry cereal, and a first container opening at least partially defined by the first side. A container cap is formed from a rigid polymeric material and includes a closed end, an opposing open end and a side wall extending between the open and closed ends. The container cap is received on the container body such that the closed end extends across at least a portion of the first container opening. A sealing member one of extends across at least a portion of the first container opening between the container body and the container cap or extends along the side wall of the container cap. A cereal product refill is secured to the container body and includes a second quantity of dry cereal.
A low-cost, linerless cereal container assembly in accordance with the present novel concept for storing an associated quantity of dry cereal is provided and includes a container including a container wall formed from a first thin-walled polymeric material. The container wall at least partially defines a cereal chamber for receiving the associated quantity of dry cereal. The container wall includes an opening wall portion that at least partially defines a container opening that provides access to the cereal chamber. A container cap includes a cap wall formed from a second thin-walled polymeric material. The container cap is received on the container such that the cap wall extends across at least a portion of the container opening. A sealing member is formed from a third thin-walled polymeric material. The sealing member is one of disposed across at least a portion of the container opening or extended along the cap wall of the container cap.
The term “cereal,” as used herein is to be broadly interpreted to mean any ready-to-eat foodstuff in dry form that uses a grain from a cereal grass, such as wheat, oats, corn, barley or rice, for example, alone or in combination and in whole or refined form as its base product. This can include any known or future commercial cereal product in any natural or man-made shape or configuration. Examples of such ready-to-eat foodstuffs include, without limitation: whole grains; flakes of corn, wheat or oat; puffed corn or rice; and toasted or baked rice; coated or uncoated; and with or without other ingredients.
The term “rigid” as used herein is to be broadly interpreted to mean firm rather than pliant in composition or structure, and can include any construction, configuration and/or material. “Rigid” is intended to be a relative term contrasted with “flexible” or other similar terms. Thus, a “rigid” wall can be formed from a different material or combination of materials than a corresponding “flexible” wall. Alternately, a “rigid” wall could be formed from the same material as a corresponding “flexible” wall, but include a shape or one or more geometric features to increase the rigidity of the wall, such as an increased wall thickness or one or more stiffening ribs or other features, for example. Examples of “flexible” walls include common plastic bags, such as trash bags and freezer bags, for example, and plastic sheeting, such as may be used to cover an area or object, for example.
Turning now to the drawings, wherein the showings are for the purposes of illustrating exemplary embodiments of the present novel concept only, and not for limiting the same,
As can be better seen in
Returning again to
As shown in
Bottom 114 of cereal container 100 includes a bottom wall 154 that extend between the sides and ends of the container. Bottom wall 154 can be of any suitable shape or configuration, and is shown in the present exemplary embodiment as being substantially planar and having rounded corners 156 transitioning to the side and end walls. Additionally, a grip or handle feature can optionally be included along container 100 and can take any suitable size, shape and/or configuration. In the exemplary embodiment, recesses 158 and 160 are formed along end 108 and include recess walls 162 and 164 that extend into sides 104 and 106, respectively, and together function as a grip or handle feature. Though, it will be appreciated that any other suitable arrangement could alternately be used.
Container cap 102 is supported along top 112 of the cereal container and includes a first or closed end 166 and an opposing second or open end 168. The container cap includes an end wall 170 and a side wall 172 that extends peripherally along the end wall to respectively form the closed and open ends. An interlocking feature, such as a groove 174 or a projection (not shown), for example, is formed along side wall 172 and, in one exemplary embodiment, is adapted to engage the corresponding interlocking feature, such as projection 152, for example, on the opening wall portions of the cereal container. Thus, the container cap can be secured and retained on the container to repeatedly re-close the container and cereal chamber therein, and thereby prevent or minimize the ingress of moisture and substantially eliminate the entry of insects.
To prevent or minimize any inadvertent spillage of cereal product from the cereal container and to maintain freshness, a sealing member of any suitable type, kind or construction can be used to seal the cereal container. In the exemplary embodiment shown in
As discussed above, container cap 102 includes a closed end 166 and an open end 168. Thus, the container cap and walls thereof define a cap cavity 180 (
Cereal container 100 and container cap 102 can be marketed and sold together with one or more cereal product refills RFL in low-cost, bulk packaging. In the exemplary embodiment shown in
First side 204 of cereal container 200 includes a first side wall 218 that has a first or outer wall portion 220 and an optional second or inner wall portion 222. One or more contoured surfaces can be formed along one or more of wall portions 220 and/or 222. In the present exemplary embodiment, second or inner wall portion 222 includes a first contoured portion 224 that projects outwardly from cereal chamber 216 and a second contoured portion 226 that projects inwardly toward cereal chamber 216 from along first contoured portion 224. Additionally, a third contoured portion 228 is formed adjacent the first and second contoured portions. It will be appreciated that the inner and outer wall portions as well as any contoured portions thereof can take any suitable shape, form or configuration. For example, outer wall portion 220 is shown as being substantially planar and second contoured portion 226 is shown as being bowl shaped and forming a cavity 230 extending inwardly toward cereal chamber 216. Furthermore, third contoured portion 228 is shown as being shaped as a spoon. As can be seen in
Second side 206 includes a second side wall 232 that has a first or outer wall portion 234 and an optional second or inner wall portion 236. As with first side 204, second side 206 can include one or more contoured portions along either or both of wall portions 234 and/or 236. In the present exemplary embodiment, inner wall portion 236 includes two separate contoured portions 238 and 240, which can take any suitable shape, form or configuration. As shown in
Side walls 218 and 232 respectively include opening wall portions 242 and 244 that at least partially define a container opening 246 in communication with cereal chamber 216. Additionally, ends 208 and 210 include end walls (not numbered) that have end opening wall portions (not numbered) extending between opening wall portions 242 and 244 and forming a periphery about container opening 246. The opening wall portions include a top wall 248 and an interlocking feature, such as a groove (not shown) or a projection 250, for example.
Container cap 202 includes a first or closed end 252 and a second or open end 254. The container cap also includes an end wall 256 and a side wall 258 disposed along end wall 256 and extending therefrom to form a cap cavity 260 accessible from open end 254. A suitable interlocking feature, such as a groove 262 or a projection (not shown), for example, is disposed along side wall 258 for engaging a corresponding interlocking feature, such as projection 250, for example. It will be appreciated, however, that any other suitable feature or combination of features can alternately be used, and that the interlocking features shown and described are merely exemplary.
One or more sealing members can be used to secure a cereal product CER in the cereal compartment of container 200, as discussed above with regard to cereal container 100, prior to installation of container cap 202. For example, a sealing member 264 can be secured along top wall 248 to seal the cereal product within the cereal chamber. Additionally, or in the alternative, an exterior sealing member (not shown) can be used. Once container cap 202 is installed on the container, cap cavity 260 can be used as a storage compartment (not numbered) in conjunction with a suitable wall, such as sealing member 264, for example. The storage compartment can receive and store any suitable size or type of promotional item or items, including food or non-food items, and is indicated generally by rectangular box ITM. Additionally, or in the alternative, cavity 230 can be used to store one or more items ITM, and a label or other suitable cover CVR can be used to secure these items in the cavity and/or hide from view the contents thereof.
First side 304 includes a first side wall 314 having a first opening wall portion 316, and second side 306 includes a second side wall 318 having a second opening wall portion 320. Similarly, ends 310 and 312, if provided, include end walls 322 and 324 respectively having opening wall portions 326 and 328. Opening wall portions 316, 320, 326 and 328 extend peripherally around a container opening 330 formed in the container and generally define the same.
As can be better seen in
Polymeric container cap 302 is adapted to be received on polymeric cereal container 300 along the opening wall portions forming container opening 330. Container cap 302 includes a first or closed end 338 and an opposing second or open end 340. Closed end 338 includes a cap end wall 342. A cap side wall 344 extends from the cap end wall and peripherally along the same to form open end 340 and at least partially define a cap recess 346.
As discussed above, it is desirable for the polymeric cereal container and polymeric container cap to include complimentary interlocking features suitable for securing the container cap on the cereal container. In the present exemplary embodiment, opening wall portions 316, 320, 326 and 328 are collectively operative as a first interlocking feature. A complimentary second interlocking feature is formed on container cap 302 and in the present exemplary embodiment includes a groove or channel 348 adapted to receive the opening wall portions and form an interlocking fit or seal with the same. Channel 348 is formed between an inner channel wall 350 and an outer channel wall 352 that are joined at a closed end of the channel by a channel end wall 354. It will be appreciated that channel 348 and walls 350, 352 and 354 can take any suitable form, shape and/or configuration. In the exemplary embodiment shown in
Polymeric cereal container 300′ and polymeric container cap 302′ differ from the container and cap described above with regard to
In the exemplary embodiment shown, polymeric cereal container 300′ includes first and second sides 304 and 306, which include container side walls 314 and 318, respectively, as described above. Additionally, ends 310 and 312 include end walls 322 and 324, respectively, as described above. Side wall 314 and end walls 322 and 324 respectively include opening wall portions 316, 326 and 328, as discussed above. Side wall 318, however, includes an opening wall portion 320′ that differs slightly from opening wall portion 320 described above. Optional projection or ridge 336 extends along opening wall portions 316, 326 and 328 of cereal container 300′. However, ridge 336′ is shown extending along opening wall portion 320′ of the cereal container. Similarly, optional lip 356 extends along the portions of cap 302′ corresponding to opening wall portions 316, 326 and 328 of container 300′. However, optional lip 356′ is shown extending along the portions of cap 302′ corresponding to opening wall portion 320′. In the exemplary embodiment shown, hinge wall 360′ extends between ridge 336′ and lip 356′ and forms a living hinge securing polymeric container cap 302′ to polymeric cereal container 300′.
Additionally, polymeric container cap 302′ differs from cap 302 in
First side 404 includes a first side wall 414 having a first opening wall portion 416, and second side 406 includes a second side wall 418 having a second opening wall portion 420. Similarly, ends 410 and 412, if provided, include end walls 422 and 424 respectively having opening wall portions 426 and 428. Opening wall portions 416, 420, 426 and 428 extend peripherally around a container opening 430 formed in the container and generally define the same. Though it will be appreciated that the opening wall portions can take any suitable form, shape and/or configuration, in the exemplary embodiment shown in
Polymeric container cap 402 includes a first or closed end 438 and a second or open end 440. Closed end 438 includes an cap end wall 442. A cap side wall 444 extends from cap end wall 442 toward open end 440 and at least partially defines a cap recess 446 within cap 402. An outer interengaging wall 448 extends from cap side wall 444 and is suitable for being received within container opening 430 along opening wall portions 416, 420, 426 and 428. Outer interengaging wall 448 can optionally include one or more interlocking features, such as a rib 450 extending along the interengaging wall, for example. If included, any interlocking features can engage opening wall portions 416, 420, 426 and 428 to secure or assist in securing cap 402 on container 400. In the exemplary embodiment shown, rib 450 extends along at least a portion of interengaging wall 448 and is in abutting engagement with inner opening surface 432 to form an interference fit with the opening wall portions.
Additionally, an outwardly extending peripheral flange or lip 452 extends around cap 402 along wall 448. Lip 452 provides a positive stop for cap 402 to be received within container opening 430. Furthermore, lip 452 can be heat staked, welded, thermoformed or otherwise secured to wall portion end 436 to secure the cap on the container. A tear-groove 454 or other suitable feature can be provided or formed along lip 452. The tear-groove is preferably operable to unseal and detach the cap and the container. However, it will be appreciated that sealing members, such as sealing members 176, 178 and/or 264 shown and described hereinbefore, for example, can alternately or additionally be used.
Container cap 502, however, differs from earlier described caps, such as polymeric container caps 102, 202, 302 and 402, for example, in that container cap 502 includes cap sections 504 and 506 that are, in one preferred embodiment, independently securable on container 500. A hinge 508 is formed between the two cap sections, and can take any suitable shape, form or configuration. In the exemplary embodiment shown, hinge 508 is integrally formed between sections 504 and 506 as a living hinge. Preferably, hinge 508 will permit one of the cap sections, such as cap section 504, for example, to be dislodged or otherwise separated from on or along container 500, as indicated by cap section 504′ shown in dashed lines and arrow AR1, for example, to provide access to the cereal chamber (not shown) of the polymeric cereal container.
Container cap 502 can be secured on cereal container 500 in any suitable manner. For example, one or more sealing members, such as sealing members 176, 178 and/or 264, for example, can be used to initially secure the cap on the container. Thereafter one or more of the interlocking features or other suitable arrangements can be used to maintain the closure of the cap. As another example, a tear seal, such as that shown in and described with regard to
Container cap 602, however, differs from earlier described caps, such as polymeric container caps 102, 202, 302, 402 and 502, for example, in that container cap 602 includes cap body 604 that includes an end wall 606 and a projection or boss 608 extending from end wall 606. Boss 608 includes one or more interlocking or interengaging features, such as threads 610, for example, formed along an outside wall (not numbered) thereof. Boss 608 also includes an inside wall 612 extending through end wall 606 and forming a passage 614 providing access to the cereal chamber (not shown) within the polymeric cereal container. Boss 608 and passage 614 are suitable for operation as a pouring spout to pour cereal product out of the cereal container. A passage cap 616 includes one or more complimentary interlocking or interengaging features, such as complimentary threads (not shown), for example, and is suitable for threadably engaging boss 608 to close passage 614.
For manufacturing, filling and/or other reasons, container cap 602 is preferably removable from cereal container 600 in a conventional manner, such as has been described herein with regard to earlier embodiments, for example. As such, a suitable sealing member, such as sealing member 176, 178 and/or 264, for example, can be used to secure the container cap on the container. Alternately, or additionally, a tear seal or other suitable arrangement could be used on the container cap and/or the passage cap.
Container 700 and cap 702 differ from other embodiments, such as container 600 and cap 602 in
Container 700 also differs from other embodiments illustrated and/or described herein in that the container is shown as being formed from an at least partially transparent or translucent polymeric material, such that a feature or characteristic (e.g., color, shape, size, composition, container fill level) of any cereal product stored within the container chamber (not shown) thereof can be at least partially observed, determined or otherwise distinguished through the container sides, ends or other portions. Additionally, it will be appreciated that any of the other polymeric cereal container embodiments disclosed herein could optionally include one or more parts, areas, walls and/or other portions formed from such an at least partially transparent and/or translucent material.
In one embodiment, an opaque wall portion 726 is provided along the polymeric cereal container, and is suitable for including text and graphics of various sorts, such as to identify the cereal and the manufacturer, to provide nutritional and other information, to provide market-appropriate information, promotional materials and/or other marketing items, such as games and activities for children, for example. Opaque wall portion 726 can be formed on or along the sides, ends and/or walls of the polymeric cereal container in any suitable manner. For example, opaque wall portion 726 could be formed from colored polymeric material formed into the sides, ends, and/or walls. As another example, opaque wall portion 726 could be formed from a colored polymeric material disposed on or along the sides, ends and/or walls, such as a polymeric label or over-molded layer, for example. As still another example, opaque wall portion 726 could be formed from an ink or other colorant applied on or along the sides, ends and/or walls. Additionally, opaque wall portion 726 can be of any suitable size, shape, configuration and/or arrangement, and can include text, markings and/or indicia of any type or kind and in any suitable configuration. For example, in the exemplary embodiment shown in
Outer container portion 802 can be of any suitable size, shape and/or configuration, and can include any suitable geometric features, other characteristics or any combination thereof. In the exemplary embodiment shown in
As can be better seen in
Furthermore, sections 802A and 802B of the outer container portion can be secured together in any suitable manner. For example, a securement member, such as a securement clip 842, for example, can be flexed or pivoted along a suitable feature or component, such as an integrally formed hinge 844, for example, to selectively engage a corresponding feature or component (not shown) on the opposing section of the outer container portion, such as section 802B, for example.
In use, the two opposing sections are opened, such as in the manner shown in
Outer container portion 902 can be of any suitable size, shape and/or configuration, and can include any suitable geometric features, other characteristics or any combination thereof. In the exemplary embodiment shown in
Outer container portion 902 differs from outer container portion 802 shown in and discussed with regard to
In use, bottom portion 932 is separated or otherwise disassociated with the remainder of outer container portion 902, such as is shown in
One exemplary embodiment of a polymeric cereal container 1000 that is suitable for use as an inner container portion, such as inner container portion 804 or 904, for example, is shown in
Polymeric cereal container 1000 includes a first side 1004, an optional second side (not shown), and optional first and second ends 1006 and 1008. In the embodiment shown, the first side is approximately planar and includes a first side wall 1010. The second side, if provided, can be of a similar configuration or can alternately include additional features. The first side, optional second side, and optional first and second ends extend between a top 1012 and a bottom 1014 of container 1000. Container 1000 includes a top wall 1016 disposed along top 1012 and a bottom wall 1018 disposed along bottom 1014.
Polymeric cereal container 1000 includes a cereal cavity (not shown) formed by first side 1004 as well as by any optional sides and/or ends, such as the second side (not shown) and first and second ends 1006 and 1008, for example. A passage wall 1020 extends from top wall 1016 and at least partially defines a passage (not shown) in communication with the cereal cavity. The passage provides access to the cereal chamber and is preferably dimensioned or otherwise provided for dispensing a cereal product stored within the cereal cavity. Optionally, the passage can also be suitable for refilling the cereal cavity from another bulk package.
In another arrangement, however, polymeric cereal container 1000 is itself suitable for use as a refill container. That is, in one exemplary application an outer container portion, such as outer container portion 802 and/or 902, for example, can be provided. The outer container portion acts as a high visibility (e.g., highly decorated, highly marked) outer shell within which an inner container portion, such as polymeric cereal container 1000, for example, is received. Due to the additional decorative detail (not shown) on the outer container portion, the same may have an increased cost associated therewith. In such an arrangement, it is then desirable to provide a lower cost refill container that can be received within the outer container portions, such as is shown, for example, in
In use as a bulk refill container, a polymeric cereal container, such as polymeric cereal container 1000, for example, can optionally include an external support feature for supporting the polymeric cereal container, such as on a hook or hanger (not shown) in a retail store, for example. One example of a suitable external support feature is shown in
If used as a bulk refill container, polymeric cereal container 1000 can be provided as a single refill container, as shown in
It is generally well recognized that food packaging applications demand the use of a packaging material that will provide a wide variety of properties and characteristics, such as approval for food contact, suitable gas and moisture barrier properties, low cost, recycleability, suitable clarity, suitable gloss/finish, desirable shrinkage/molding characteristics, printability and receptiveness to adhesive labels, for example. It is also well recognized that no single ideal material is normally available that can provide any normally desired combination of these properties and characteristics. Thus, it will be appreciated that the selection of a suitable material or combination of materials for a given packaging application will include balancing numerous desired performance properties with cost, manufacturing and other issues.
To provide a suitable packaging material for food packaging applications, it is common for suitable materials in sheet or film form to be manufactured from two or more different materials that together provide all of the desired properties and characteristics associated with the particular packaging application. Typically, multi-material sheets or films are formed by co-extrusion or other suitable processes and, thus, the various materials normally take the form of discrete layers of material of the sheet or film. For this reason, it will be recognized that manufacturing processes such as injection molding are often less well suited for producing food packaging that will utilize these multi-material sheets or films. Rather, processes such as vacuum forming and blow molding are more desirable. Utilization of one of the latter processes, in conjunction with the multi-material sheet or film, can result in a container in which each layer of material is formed continuously around and/or along approximately all of the walls of the container. It will be appreciated, however, while one or more methods of manufacture may be preferred, any suitable method or process of manufacturing can be used.
In one exemplary embodiment, first material 1102 forms the inside surface of the container and is in direct contact with the cereal product that is to be stored within cereal chamber CCH. As such, first material 1102 is preferably a grade of polymeric material that is approved for food contact. Additionally, it is desirable for at least one of the two or more materials to provide a suitable gas (e.g., oxygen and carbon dioxide) barrier to provide sufficient shelf life for the cereal product to be stored therein. Furthermore, it is desirable for at least one of the two or more materials to provide a suitable external cosmetic appearance, such as a high gloss finish, for example, and provide sufficient durability to maintain the finish for the life of the container, which may include usage as a refill container or a general storage container. Further still, it is desirable for at least one of the two or more materials, and preferably the outermost material or materials, to provide a surface receptive to printing or adhesive labels. Exemplary materials for one or more of materials 1102, 1104, 1106, 1108 and/or 1110 can include, without limitation, low density polyethylene, high density polyethylene, polypropylene, glycol-modified polyethylene terephthalate (PETG) and ethylene vinyl alcohol (EVOH), alone or in combination with one another. It is to be distinctly understood, however, that any other suitable material or materials, alone or in combination, can additionally or alternately be used.
It is also desirable for a polymeric cereal container and/or polymeric container cap in accordance with the present novel concept to have a “thin” wall structure. That is, it is desired to use a wall structure that is as thin as possible, yet thick enough to form a sturdy container that is capable of at least limited reuse. The use of thin-walled containers is desirable for a variety of reasons, including minimizing manufacturing material costs and reducing the amount of material discarded or recycled by consumers. The term thin-walled can be contrasted with known polymeric containers designed and marketed as reusable storage containers (e.g., TUPPERWARE® brand containers). Such containers are of a far more robust construction and can be considered and referred to as thick-walled containers.
Other polymeric containers are also know that are usually associated with the purchase of particular food items (e.g., COOL WHIP® brand topping containers). Once the food item has been consumed, these containers are often cleaned and kept by the consumer for storage or other uses. One reason that these containers are kept by the consumer is that the containers are capable of withstanding repeated reuse as storage containers. Such foodstuff containers are formed from material having less thickness than those designed to be reusable storage containers. However, such foodstuff containers typically have a wall thickness substantially greater than that of the containers and/or caps of the present novel concept, and can be considered and referred to as medium-walled containers.
Additionally, polymeric cereal containers and polymeric container caps are preferably formed as substantially rigid containers, as defined herein, rather than being flexible. It will be appreciated, however, that the degree to which a particular container will flex will be a combination of the structural design of the container wall or walls and of the mechanical properties of the polymeric material selected. Thus, the rigid container could be formed from a more pliant or flexible material or grade of material where substantial stiffness is provided by the geometry and/or geometric features of the wall or walls of the container, such as in container 200, for example. Whereas, a somewhat rigid material or combination of materials might be selected where a lesser degree of stiffness will be provided by the features of the wall or walls of the container, such as in container 100, for example.
In light of the foregoing, it will be appreciated that a wide variety of combinations of polymeric materials and/or grades thereof could be used to form a cereal container and/or a container cap in accordance with the present novel concept. In selecting suitable materials and/or material and design combinations, it will be desirable for the resulting container and cap to withstand repeated openings and closings without significant degradation or performance loss of the interlocking features. It will also be desirable for the resulting container to resist significant deformation or swelling, particularly along its middle, when refilled with cereal products or other suitable household items that may be stored therein, such as small toys, for example.
A sealing member source 1208 is adapted to output or otherwise supply sealing members, such as sealing members 176 or 264, for example, suitable for forming a seal along or across the container opening of the filled polymeric cereal container. A sealing station 1210 is in communication with filling station 1206 and receives the filled polymeric cereal containers therefrom. The sealing station is also in communication with sealing member source 1208 and receives sealing members therefrom. Sealing station 1210 is adapted to position the sealing member along or across the container opening of the filled container and secure the same thereon in a suitable manner.
A container cap source 1212 is adapted to output or otherwise provide polymeric container caps, such as container cap 102, 202, 302, 402, 502, 602, 702, 808, 908 or 1002 for example, suitable for being secured along or across the container opening of a sealed polymeric cereal container. One example of a suitable polymeric container cap source 1212 is a storage area housing a quantity of pre-manufactured polymeric container caps. Another example of a suitable polymeric container cap source is an in-house or in-line molding machine, such as a blow molding machine or an injection molding machine, for example, adapted to produce polymeric container caps. A capping station 1214 is in communication with sealing station 1210 and receives sealed polymeric cereal containers therefrom. The capping station is also in communication with container cap source 1212 and receives container caps therefrom. Capping station 1214 is adapted to position the polymeric container cap on the sealed polymeric cereal container and secure the polymeric container cap across the container opening, such as by snap fitting interlocking features together or threadably engaging complimentary threads, for example.
Optionally, system 1200 can include a promotional item source 1216 adapted to output or supply promotional items for inclusion on or with the packaged cereal product. If a promotional item source is included, an optional item insertion station 1218 can also be included that is in communication with the promotional item source and receives promotional items therefrom. Optional item insertion station 1218 is also shown as being in communication between sealing station 1210 and capping station 1214 and, as such, can receive sealed polymeric cereal containers before the same are capped at capping station 1214. However, it is to be distinctly understood that the item insertion station could alternately be positioned in any other suitable place in the system. Item insertion station 1218, if provided, is adapted to position the promotional item or items to be included with the packaged cereal product in abutting engagement with the sealed polymeric cereal container, such as along the sealing member, for example. The capping or other operation can then secure the promotional item in place, such as by forming a storage compartment 182, for example.
System 1200 can also optionally include a second sealing member source 1220 adapted to output sealing members, such as sealing member 178, for example, suitable for securing the polymeric container cap on the sealed polymeric cereal container. It will be appreciated that either or both of the foregoing sealing members of can also include tamper evident materials. A second sealing station 1222 is in communication with second sealing member source 1220 for receiving the sealing members therefrom. The second sealing station is also in communication with capping station 1214 and receives capped polymeric cereal containers therefrom. Second sealing station 1222 is adapted to secure the second sealing member along at least a portion of the polymeric container cap or the polymeric cereal container, and preferably a portion of both.
System 1200 can further include an optional label source 1224 adapted to output or supply labels, such as cover CVR, for example, for securement along at least one of the polymeric container cap or the polymeric cereal container. If the optional label source is provided, a labeling station 1226 can also optionally be provided and is in communication with label source 1224 for receiving labels therefrom. The optional labeling station is also in communication with capping station 1214 or optionally with second sealing station 1222, if provided, for receiving capped and/or sealed polymeric cereal containers therefrom. Labeling station 1226 is adapted to apply one or more labels to and/or along at least one of the polymeric container cap and/or the polymeric container. After exiting capping station 1214 and optionally one of stations 1222 and/or 1226, the polymeric cereal container can be conveyed to a further downstream packaging or shipping station 1228.
The various components of system 1200 can be in communication with one another in any suitable manner or combination of manners, indicated generally as conveying devices CVD in
Another step 1304 includes providing a polymeric cereal container, such as cereal container 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000, for example, that is to be filled with at least a portion of the quantity of cereal product provided in step 1302. In one exemplary embodiment, step 1304 optionally includes a step 1306 of forming a polymeric cereal container and a step 1308 of transporting the container to a cereal dispensing or filling station. In one exemplary method, step 1306 of forming the polymeric cereal container is performed by molding, such as blow molding or injection molding, for example, the polymeric cereal container. This can be performed in-house or in-line with a cereal production or filling line so that the container is molded just prior to being filled by with a quantity of a cereal product. In such an exemplary method, step 1308 could include transporting the polymeric cereal container along a conveyor to a filling station, such as filling station 1206 in
Another step 1310 includes filling or otherwise dispensing the quantity of cereal product provided in step 1302 into the cereal chamber of the polymeric cereal container provided in step 1304 through the container opening therein. In one exemplary embodiment, this step can be performed by filling station 1206. A further step 1312 includes sealing the container opening using a suitable sealing member. In one exemplary embodiment, this step can be performed by sealing station 1210.
Still a further step 1314 includes providing a polymeric container cap for securement on the polymeric cereal container across the sealed container opening thereof. Step 1314 can optionally include steps 1316 of forming a polymeric container cap and step 1318 of transporting the polymeric container cap. In one exemplary method, step 1316 of forming the polymeric container cap is performed by molding, such as blow molding or injection molding, for example, the polymeric container cap. This can be performed in-house or in-line with a cereal production or filling line so that the container cap is molded just prior to being secured on the polymeric cereal container. In such an exemplary method, step 1318 could include transporting the polymeric container cap along a conveyor to a capping station, such as capping station 1214 in
Another step 1320 includes securing the polymeric container cap on the sealed polymeric cereal container. In one exemplary embodiment, step 1320 could be performed by capping station 1214. An optional step 1322 includes inserting a promotional item in, on or along the polymeric cereal container. In one exemplary embodiment, this optional step could be performed by a combination of promotional item source 1216 and item insertion station 1218. A further optional step 1324 includes sealing the polymeric cereal container and polymeric container cap together using a second sealing member. In one exemplary embodiment, step 1324, if performed, could be performed by second sealing member source 1220 and second sealing station 1222. Still a further step 1326 includes applying one or more labels on or along the polymeric cereal container and/or polymeric container cap. In one exemplary embodiment, optional step 1326, if performed, could be performed by label source 1224 and/or labeling station 1226.
While the subject novel concept has been described with reference to the foregoing embodiments and considerable emphasis has been placed herein on the structures and structural interrelationships between the component parts of the embodiments disclosed, it will be appreciated that other embodiments can be made and that many changes can be made in the embodiments illustrated and described without departing from the principles of the subject novel concept. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. Accordingly, it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the present novel concept and not as a limitation. As such, it is intended that the subject novel concept be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims and any equivalents thereof.
Claims
1. A linerless cereal container comprising:
- a first side wall formed from a polymeric material and including a first opening wall portion;
- a second side wall formed from said polymeric material, said second side wall spaced from said first side wall and at least partially defining a cereal chamber therebetween, said second side wall including a second opening wall portion spaced from said first opening wall portion and at least partially defining a container opening therebetween;
- at least one end wall formed from said polymeric material, said at least one end wall extending between said first side wall and said second side wall and including an end opening wall portion extending between said first and second opening wall portions; and,
- a bottom wall formed from said polymeric material and extending between at least two of said first side wall, said second side wall or said end wall.
2.-64. (canceled)
Type: Application
Filed: Jan 6, 2011
Publication Date: May 5, 2011
Inventors: J. Evan Spirk (Gates Mills, OH), Craig M. Saunders (Rocky River, OH), Patrick Brown (Mantua, OH), John Spirk (Gates Mills, OH), John R. Nottingham (Bratenahl, OH), Wilson Pan (Cleveland, OH)
Application Number: 12/986,010
International Classification: B65D 8/04 (20060101);
