FOOD PACKAGE WITH WINDOW

Abstract

Various embodiments of packages are disclosed. In some embodiments, the package is made of PS foam and includes an aperture covered with a transparent window panel. The package can provide excellent thermal benefits, while also enabling a user to view the contents of the package without needing to open the package.

Description

CROSS REFERENCE

This application claims the priority benefit under at least 35 U.S.C. §119 of U.S. Patent Application No. 62/364,686, filed Jul. 20, 2016, entirety of which is hereby incorporated by reference herein.

BACKGROUND

Field

The present disclosure relates to packages, such as packages for holding food items.

Description of Certain Related Art

A package is an object that can be used to hold or transport an item. Commonly, food items are held in packages to facilitate storage, protection, and/or transport of the food item.

SUMMARY

Various types of packages are commonly used for holding products, such as food items for human consumption. Some packaging is paper-based, such as being made of paper, paperboard, paper laminates, or fibers. These materials are typically sheet materials that are manufactured in a flat configuration, and then assembled (e.g., folded) into the final package shape. The sheet of material can be laminated, coated, or otherwise treated during production. For example, wax or resins can be added to the paper material to prepare it for use in the packaging. Some paper packages can include a section of transparent material (e.g., clear plastic), otherwise referred to as a window, which can allow a user to view the contents of the package.

A problem with paper packages is that they are generally ineffective thermal insulators. For example, for holding hot or cold food, a paper package usually does not provide sufficient insulating properties to maintain the temperature and freshness of the food. Moreover, paper packages typically have a high tendency to leak from the sides, the top, the bottom, and/or the closure area. Furthermore, paper packages that use a non-paper material for the transparent window are made from multiple materials, which can make them difficult and/or costly to recycle. Additionally, it is typically more difficult and/or expensive to manufacture rounded (e.g., circular or oval) packages with paper materials.

Some packages are made from plastic materials. For example, the package can be made out of polyethylene (PE), polyethylene terephthalate (PET), high density polyethylene (HDPE), low density polyethylene (LDPE), or polypropylene (PP). Some plastic packages are colored and/or opaque, such as the entire package being black. In certain packages, the color is not exclusively black. Some embodiments are made from white foam. Some embodiments are made from black foam. Some embodiments are other colors, such as gray, brown, blue, green, purple, yellow, orange, red, or otherwise. Some packages are uncolored and/or clear. Some packages are a combination, such as having an opaque (e.g., black) lower portion and a clear upper portion, which can allow a user to view the contents. While this can allow an individual to view the contents within, to maintain the transparency of the package, the material's thickness is typically required to be too thin to provide adequate thermal insulation. Thus, the package may be unable to maintain the temperature and freshness of the food inside. Additionally, certain plastic packages that are a combination of clear and opaque portions are generally more expensive to manufacture than packages that are a single color.

Certain packages are made of a type of plastic called polystyrene (PS) foam, such as extruded polystyrene (XPS) or expanded polystyrene (EPS). Certain packages are made of Styrofoam®, which is a particular brand of PS foam. PS foam can be made into many different shapes and has good thermal properties. Packages made from PS foam are typically manufactured in a non-flat configuration using manufacturing techniques such as vacuum forming. Some PS foam containers are difficult to recycle and are banned in certain communities.

PS foam packages are excellent at keeping hot food hot and cold food cold. However, because PS foam packages are opaque, a user may need to open a given package to discern the contents. For example, a restaurant operator may open the package to verify that the proper food item is being provided to a customer. In addition, cafeterias and buffets may open the package at the cash register so that a cashier can identify the contents in order to charge the appropriate amount. Opening and re-closing the package to determine its contents and/or adding a label to the package to state the contents is an additional step that takes time, requires a certain amount of dexterity, and increases workload. Moreover, opening the package allows heat inside the package (in the case of hot food) to escape from the package, or heat in the ambient environment (in the case of cold food) to enter the package. This greatly reduces the ability to maintain the food at the proper temperature and/or reduces freshness. For example, the hot food becomes cooler or the cold food becomes warmer. Further, opening the package increases the risk of contamination of the food, such as if a nearby person were to sneeze during the time that the package was open. Additionally, opening the package may allow dirt, dust, pathogens, or other unwanted materials to contaminate the food.

Various packages are disclosed herein that remedy one or more of the above-identified concerns, or other concerns. In that regard, some embodiments of a package can comprise PS foam and a window. The package can provide excellent thermal benefits, while also enabling a user to view the contents of the package without needing to open the package. In some embodiments, the package is black in color. For example, the package can have a body that is black. The window can be transparent and/or a different color than the body of the package. The package can be predominantly a single material, such as a body (e.g., including upper and lower portions) that is a single material, such as PE. This can reduce manufacturing costs. Some embodiments have a film over the window. The film can be a different material than the body and/or can comprise a small portion of the mass of the container, such as less than about: 5%, 3%, or 1% by mass.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments are depicted in the accompanying drawings for illustrative purposes, and should in no way be interpreted as limiting the scope of the embodiments. Various features of different disclosed embodiments can be combined to form additional embodiments, which are part of this disclosure.

FIG. 1 illustrates a perspective view of an embodiment of a package with a window on a top surface.

FIG. 2 illustrates a perspective view of another embodiment of a package with a window on a top surface.

FIG. 3 illustrates a perspective view of another embodiment of a package with a window spanning a corner, such as a corner between top and front surfaces.

FIG. 4 illustrates a perspective view of another embodiment of a package with a window on a front surface.

FIG. 5 illustrates a perspective view of another embodiment of a package with a window on a side surface.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

Various food packages are described below to illustrate various examples that may achieve one or more desired improvements. These examples are only illustrative and not intended to restrict the general disclosure presented and the various aspects and features of this disclosure. The general principles described herein may be applied to embodiments and applications other than those discussed herein without departing from the spirit and scope of the disclosure. Indeed, this disclosure is not limited to the particular embodiments shown, but is instead to be accorded the widest scope consistent with the principles and features that are disclosed or suggested herein.

FIGS. 1-5 illustrate various embodiments of a package 10 (also called a container). The package 10 can have an inner space for receiving an item, such as a food item. The package 10 shown may be for holding a sandwich or other food item. For example, the package 10 may be a “clamshell” container. A clamshell container is a one-piece container with two portions that are joined by a hinge that allows the portions to come together to enclose the food item. In some embodiments, the package 10 comprises a cup or bowl, such as for holding a soup, beverage, or other item. In some embodiments, the package 10 has a generally rectangular (e.g., square) shape when viewed from above. See, for example, the embodiment shown in FIG. 1. In some variants, the package 10 has a shape that, when viewed from above, is generally: triangular, circular, oval, diamond, star-shaped, octagonal, hexagonal, or other shapes.

As shown, the package 10 can comprise a body with a hinged configuration, such as with a first portion 12 and a second portion 14 that are connected by a hinge and configured to engage together. Some embodiments have discrete portions that can separate from each other to open the package 10 and that can engage together to close the package 10. The illustrated embodiment includes a closure tab 16. Certain embodiments of the package 10 can include multiple closure tabs. Other embodiments can include any other type of suitable closure mechanism.

The package 10 can be made from any polymer material safe for use in a food application. In several embodiments, the body of the package 10 is made of PS, such as PS foam. In certain variants, the body is made of PE, PET, HDPE, LDPE, PP, and/or another plastic material. The body can comprise combinations of material. The body can comprise one or multiple layers of material, such as a layer of PE and a layer of PET. In certain implementations, the body is formed from a sheet of material. The body can be opaque or semi-opaque. For example, the body can be made of black PS foam, white PS foam, or another color of PS foam. In certain embodiments, the body of the package is opaque and/or dark in color, such as being black. The body can have a thickness of less than or equal to about: 0.010 inch, 0.020 inch, 0.035 inch, 0.050 inch, 0.075 inch, 0.10 inch, or other thicknesses. In some embodiments, the body has a thickness of about 0.018 inch.

The package 10 can include a window 18. The shape of the window 18 can be rectangular (e.g., FIG. 1), round (e.g., FIG. 2), triangular, or any other shape suitable for viewing the contents of the package 10. Various locations of the window are contemplated, such as on the top (e.g., FIGS. 1 and 2), spanning a corner or edge (e.g., FIG. 3), on a front side (e.g., FIG. 4), or on a lateral side (e.g., FIG. 5). In some embodiments, the window 18 is long and narrow. For example, the window 18 can be vertically oriented so as to aid in identifying a volume and/or amount of material (e.g., soup, rice, etc.) in the package 10. The package 10 can include indicia (e.g., lines) to indicate characteristics, such as size (e.g., small, medium, or large), volume, etc.

In some embodiments, the window 18 comprises an aperture that is shielded with and/or covered by a window panel, which can be transparent. This can permit visual access of the contents of the package 10 without the need to open the package 10. In some implementations, the window panel is a separate component (e.g., not integral with) the body of the package. For example, the window panel can comprise a thin film that is different from the body of the package. The window panel can be attached to an area near the aperture. For example, the window panel can be attached to the area bounding the aperture. The window panel can be connected with glue, heat sealing, ultrasonic welding, or other connection techniques. In some embodiments, the window panel is connected with an outside surface of the body of the package. In certain variants, the window panel is connected with an inside surface of the body of the package. The window panel can be the same or a different color than the body of the package.

As mentioned above, the window panel can comprise a thin film of material. For example, the window panel can have a thickness of less than or equal to about: 0.001 inch, 0.002 inch, 0.005 inch, 0.010 inch, 0.025 inch, 0.050. 0.075 inch, 0.10 inch, or other thicknesses. In some embodiments, the window panel material comprises polyester, PP, crystalized PET, or other clear or generally clear materials. In certain implementations, the window panel is made of the same material as the remainder of the package 10, such as both being made of PS foam. In some variants, the window panel is made of a different material from the remainder of the package 10, such as the window panel comprising PP and the remainder of the package comprising PS foam. In some implementations, by mass, at least about 90% of the package comprises PS foam and less than or equal to about 10% comprises the window panel material. For example, the package 10 can comprise about 30 g of PS foam and about 2 g of the window panel material. Some implementations include multiple apertures and/or window panels, such as on opposite sides of the package (e.g., front and back, left and right sides, top and bottom, etc.).

Certain variants have multiple window panels. For example, as shown by the dashed lines in FIG. 3, the window panel can include first, second, and third panels 18a, 18b, 18c. As shown, in some embodiments, one or more of the window panels can span the distance between faces of the body, such as cutting the corner between the faces. The one or more window panels can be non-parallel with the aperture. In some variants, the body comprises radially inwardly extending fins. For example, the panels 18b, 18c can be part of the body (e.g., made of polymer).

The window panel and/or the body can be constructed of one or multiple materials and/or layers. For example, the body may comprise a layer of PET and a layer or PE, and/or the window panel may comprise multiple layers or laminated structures. In some embodiments, the package 10 (e.g., the body) comprises a mono-layer of material, such as being constructed of a single layer of material. In certain variants, the package 10 (e.g., the body) comprises a multi-layer construction, such as being made of multiple layers of material. In certain embodiments, the window panel and the body are formed of the same material and/or are in the same layer of material. In some variants, the window panel has at least one layer that is a different material than the body. In some embodiments, the window panel is applied to (e.g., connected with) the inside or the outside of the body, such as by using adhesive or direct heat seal.

In some embodiments, a method of manufacturing the package comprises forming an upper portion and a lower portion. In some implementations, the method includes forming a first connection mechanism that connects the upper portion and the lower portion. For example, the method can include forming a hinge between the upper portion of the package and the lower portion of the package. In some variants, the method includes forming a second connection mechanism that connects the upper portion and the lower portion. For example, the method can include forming a locking mechanism, such as a tab and slot, detent, interference fit, latch, button, or other locking mechanism. The method can include thermoforming, vacuum forming, or continuously extruding PS material into PS foam in the shape of the package in a configuration. For example, a clamshell package can be formed in a configuration in which the first and second portions are separated and/or not engaged. In some embodiments, the method includes forming (e.g., cutting) the aperture in the first and/or second portion. The method can include obtaining (e.g., die cutting) the window panel. The method can include attaching the window panel to the area near and/or bounding the aperture. For example, the window panel can be connected in such a way as to inhibit or prevent air from passing through the aperture. For example, in some embodiments, the window panel is attached to the body by welding, adhesive, mechanical fasteners, or otherwise. In certain embodiments, the window panel (e.g., film) is configured to allow for venting, such as of air. For example, the film may include micro-perforations (e.g., perforations with a diameter of less than about: 0.003 inch, 0.001 inch, 0.0005 inch, or other diameters). In some embodiments, the film can include an indicia. For example, the film can be printed with a retailer's logo.

The package 10 is advantageous for several reasons. The window 18 allows easy visual identification of the contents of the package 10 without needing to open the package 10. This can reduce unwanted heat transfer to or from the contents and/or the chance of contamination of the contents. For example, by avoiding the need to open the container, the freshness of food in the container (e.g., cold food, such as cold salad) can be maintained and/or the ambient environment (such as dust or air) can be inhibited or prevented from contaminating the food. Also, the window 18 can increase efficiency by eliminating the need to label the package 10 or go through the extra step of opening and then closing the package 10. Thus, the package 10 can benefit both the business operator and the consumer by saving the business time, streamlining the consumer experience, and enhancing temperature management.

Moreover, package 10 and/or PS foam can be made in many shapes (e.g., round, oval, etc.) that are difficult, expensive, or otherwise not practical with some other types of packages (e.g., paper-based packages). The package 10 can effectively store food at an appropriate temperature during transport and inhibit or prevent leaks. Further, the package 10 is relatively easy to recycle because the materials used in certain embodiments are all plastic-based, including the window panel material.

Terms of orientation used herein, such as “top,” “bottom,” “horizontal,” “vertical,” “longitudinal,” “lateral,” and “end” are used in the context of the illustrated embodiment. However, the present disclosure should not be limited to the illustrated orientation. Indeed, other orientations are possible and are within the scope of this disclosure. Terms relating to circular shapes as used herein, such as diameter or radius, should be understood not to require perfect circular structures, but rather should be applied to any suitable structure with a cross-sectional region that can be measured from side-to-side. Terms relating to shapes generally, such as “circular” or “cylindrical” or “semi-circular” or “semi-cylindrical” or any related or similar terms, are not required to conform strictly to the mathematical definitions of circles or cylinders or other structures, but can encompass structures that are reasonably close approximations.

Some embodiments have been described in connection with the accompanying drawings. Some of the figures are drawn to scale, but such scale should not be limiting, since dimensions and proportions other than what are shown are contemplated and are within the scope of the disclosed invention. Distances, angles, etc. are merely illustrative and do not necessarily bear an exact relationship to actual dimensions and layout of the devices illustrated. Components can be added, removed, and/or rearranged. Further, the disclosure herein of any particular feature, aspect, method, property, characteristic, quality, attribute, element, or the like in connection with various embodiments can be used in all other embodiments set forth herein. Additionally, any methods described herein may be practiced using any device suitable for performing the recited steps.

The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, in some embodiments, as the context may permit, the terms “approximately”, “about”, and “substantially” may refer to an amount that is within less than or equal to 10% of the stated amount. The term “generally” as used herein represents a value, amount, or characteristic that predominantly includes or tends toward a particular value, amount, or characteristic. As an example, in certain embodiments, as the context may permit, the term “generally parallel” can refer to something that departs from exactly parallel by less than or equal to 20 degrees.

Although this invention has been disclosed in the context of certain embodiments and examples, the scope of this disclosure extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. Any system, method, and device described in this application can include any combination of the preceding features described in this and other paragraphs, among other features and combinations described herein, including features and combinations described in subsequent paragraphs. While several variations of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the invention. Various features and aspects of the disclosed embodiments can be combined with, or substituted for, one another in order to form varying modes of the disclosed invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.

Claims

1. A package for holding a food item, the package comprising:

a body made of a polymer, the body comprising: an upper portion; a lower portion; an aperture; and a hinge connecting the upper portion and the lower portion;

a transparent window panel covering the aperture, the window panel being a separate component from the body, the window panel being attached to an area of the upper portion that bounds the aperture.

2. The package of claim 1, wherein the window panel comprises polypropylene.

3. The package of claim 1, wherein the package comprises a clamshell package.

4. The package of claim 1, wherein the aperture is on a top surface of the upper portion.

5. The package of claim 1, wherein the aperture comprises a generally rectangular shape.

6. The package of claim 1, wherein the aperture is positioned on the upper portion.

7. The package of claim 1, wherein the aperture is positioned on the lower portion.

8. The package of claim 1, further comprising a second aperture, wherein the aperture is positioned on the upper portion and the second aperture is positioned on the lower portion.

9. The package of claim 1, wherein the body comprises polystyrene foam.

10. The package of claim 1, wherein the body is black in color.

11. A method of manufacturing a container that enables a person to view the contents of the container without needing to open the container, the method comprising:

forming an upper portion of the container and a lower portion of the container;

forming a first connection mechanism that connects the upper portion and the lower portion;

forming a second connection mechanism that connects the upper portion and the lower portion;

forming an aperture in the first portion of the container;

obtaining a window panel; and

attaching the window panel to an area bounding the aperture in the first portion of the container.

12. The method of claim 11, wherein forming the first connection mechanism comprises forming a hinge between the upper portion of the container and the lower portion of the container.

13. The method of claim 11, wherein forming the second connection mechanism that connects the upper portion and the lower portion comprises forming a tab and slot.

14. The method of claim 11, wherein forming the upper portion of the container and the lower portion of the container comprises thermoforming, vacuum forming, or continuously extruding polystyrene material into polystyrene foam.

15. The method of claim 11, wherein forming the upper portion of the container and the lower portion of the container comprises forming the first and second portions together.

16. The method of claim 11, wherein attaching the window panel to the area bounding the aperture comprises attaching the window panel in such that substantially no air can pass through the aperture.

17. The method of claim 11, wherein attaching the window panel to the area bounding the aperture comprises providing venting between the inside and outside of the container.

18. The method of claim 17, wherein providing venting comprises providing micro-perforations in the window panel.