CONTAINER HAVING UPPER RIM WITH IMPROVED SEAL

Abstract

A paperboard container is provided for receiving a sealed lid. The container includes a bottom panel, a sidewall, and an upper rim. The sidewall extends upward from the bottom panel to define an interior of the container. The upper rim extends outward from the sidewall. The upper rim includes an overlapping seam having a first overlapping portion and a second overlapping portion. The first overlapping portion of the upper rim wraps around the second overlapping portion. The first overlapping portion includes a bonding tape positioned on an inner surface and an outer surface thereof. The first overlapping portion includes a corner cut defining at least a portion of an outer edge of the first overlapping portion.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application Ser. No. 63/584,121, filed on Sep. 20, 2023, to Michael Helberg et al., entitled “Container Having Upper Rim with Improved Seal,” currently pending, the entire disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

Solid, semi-solid and flowable food items as well as liquids and other products are often provided in containers having a sealed flexible membrane lid or cover for protecting the contents within the container. The lid for such containers is typically heat sealed onto the upper rim of the container to fully secure the membrane lid to the container. Such containers are often constructed from injection molded plastic or polymer-based material where a uniformly flat rim can be easily formed in the upper end of the container for providing a complete seal of the lid or cover member. However, it is now preferable to make such containers from paper or paperboard materials for sustainability and other purposes.

One problem with paperboard containers is that the overlapped side seam created when forming the container obstructs the uniformity of the upper rim, which can result in an incomplete or ineffective seal due to pinhole openings at the overlapped seam portion. In particular, the overlapped seam of the container has a double layer of paperboard material thickness, which extends into the upper rim of the container. As a result, the upper rim includes a step of elevation change when the rim transitions from the overlapped side seam area to the sidewall area. This transition region impacts the ability to completely seal a lid or cover onto the upper rim.

Accordingly, a need exists for an improved container constructure that can provide a more uniform rim and enable an improved seal between the container rim and membrane lid or cover member.

SUMMARY

The present invention is directed generally to a container having a sidewall construct that wraps around a bottom to form an overlapping side seam and define an interior of the container that is open at its upper end as defined by an upper rim. The upper rim may be configured to receive a cover or lid that encloses the open upper end of the container. The upper rim may be especially configured to maximize sealing between the cover or lid and the upper rim and to minimize leaks even at the seam.

The sidewall construct of the container may be formed by wrapping a blank in a furstoconical or cylindrical configuration such that first and second ends of the blank overlap to form a seam. The first and second ends may be at least partially fixed together by bonding tape. The bonding tape may be applied to one of the first or second ends and may extend all or a portion of the height of the sidewall construct. The blank may include a corner cut at one or more of the upper ends of the blank such that a corner or diagonal cut may be located at the upper rim where the seam is formed. The bonding tape may extend at least partially into this upper rim region, and the bonding tape, which may be attached after the corner cut in the blank is made, may at least partially extend into and fill the void space left by the corner cut at the upper rim to form a triangle tape portion. The corner cut and triangle tape portion can provide an improved sealing surface for a lid or cover, particularly a foil-type or membrane sealing cover, to fully seal to and engage the upper rim at the seam transition.

The additional thickness and smoothed transition provided by triangle tape portion extending beyond corner cut can provide a reduced and gradual transition between the increased thickness of seam and the thickness of the upper rim. This results in a smoother sealing surface for a cover or lid to seal to upper rim at and adjacent to the seam. In addition to providing a smoother and more gradual surface transition, the triangle tape portion may provide a tackier surface for the lid or seal member to seal to at the transition, which further enhances the seal integrity.

According to one embodiment, a paperboard for receiving a sealed lid includes a sidewall construct, an upper rim, and bonding tape. The sidewall construct includes a perimeter sidewall and an overlapping seam extending the height of the sidewall construct. The overlapping seam includes a first overlapping portion and a second overlapping portion. The upper rim is formed into an upper end of the sidewall construct and extends outwardly from the perimeter sidewall. The upper rim includes at least a portion of the overlapping seam. The bonding tape is located on the first overlapping portion of the overlapping seam. An upper end of the first overlapping portion includes a corner cut. The bonding tape extends into a cutout region defined by the corner cut.

According to another embodiment, a blank for forming a paperboard container having an upper rim is provided. The blank includes a sidewall surface having a first end, a second end, an upper end, and a lower end. The upper end includes an upper end rim margin. A diagonal corner cut defines an outer edge of the first end and extends to the upper end within the upper end rim margin. A bonding tape is provided on at least a portion of the first end. The bonding tape extends above the diagonal corner cut and fills at least a portion of a void space in the blank created by the corner cut.

Further advantages, features and details of the invention are elucidated on the basis of preferred embodiments thereof, wherein reference is made to the accompanying drawings.

DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

In the accompanying drawings, which form a part of the specification and are to be read in conjunction therewith in which like reference numerals are used to indicate like or similar parts in the various views:

FIG. 1 is a top perspective view of a container with an upper rim in accordance with an embodiment of the present invention;

FIG. 2 is a plan view of a unitary blank for forming a sidewall construct of the container of FIG. 1;

FIG. 3 is an enlarged partial view of a first side portion of the unitary blank of FIG. 2;

FIG. 3A is an enlarged partial view of the first side portion of FIG. 3;

FIG. 4 is a top plan view of the container of FIG. 1;

FIG. 5 is a partial sectional elevation view of the sidewall construct seam of the container of FIG. 4 taken at section line 5-5;

FIG. 6 is a partial sectional elevation view of the sidewall construct of the container of FIG. 4 taken at section line 6-6;

FIG. 7 is a schematic top view of the seam portion of the container of FIG. 1;

FIG. 8 is a schematic partial sectional view of the upper rim of the container of FIG. 1, illustrating the seam of the sidewall construct at the upper rim;

FIG. 9 is a top plan view of a container with an upper rim in accordance with another embodiment of the present invention;

FIG. 10 is a sectional elevation view of the container of FIG. 9 taken at section line 10-10; and

FIG. 11 is an enlarged partial sectional elevation view of the sidewall construct seam of the container of FIG. 9; and

FIG. 12 is a schematic partial sectional view of the upper rim of the container of FIG. 9, illustrating the seam of the sidewall construct at the upper rim.

DETAILED DESCRIPTION OF THE INVENTION

The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not necessarily been maintained in the drawing figures. It will be appreciated that any dimensions included in the drawing figures are simply provided as examples and dimensions other than those provided therein are also within the scope of the invention.

The following detailed description of the invention references specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The present invention is defined by the appended claims and the description is, therefore, not to be taken in a limiting sense and shall not limit the scope of equivalents to which such claims are entitled.

The present invention is directed generally to a container 10 having a sidewall construct 20, an upper rim 30 formed at the upper end of sidewall construct 20, and a bottom 70 as illustrated in the various figures. As best shown in FIG. 1, sidewall construct 20 wraps around bottom 70 to form an overlapping side seam 40 and define an interior of container 10 that is open at its upper end as defined by upper rim 30. Upper rim 30 may be configured to receive a cover or lid (not shown) that encloses the open upper end of the container 10. According to one embodiment, upper rim 30 may be configured for use with a flexible, foil or membrane-type lid that can be sealed onto upper rim 30. Upper rim 30 may also be configured for use with alternative types of lids, including without limitation, snap on lids, overcap lids or any other lid-type. Container 10 may be configured for receiving and storing various food or beverage items, including without limitation, flowable food items such as yogurt, where it is preferable to have a flexible membrane lid fully sealed onto upper rim 30. It is also recognized that container 10 can be suitably used and configured for other items, including non-food or non-beverage items.

Container 10 may be constructed of paperboard or a similar material, such as but not limited to a coated or laminated paperboard material in order to resist migration of liquids or semi-liquid items contained within the interior volume of container 10 defined by sidewall construct 20. One non-limited example of the paperboard material includes a multi-layer construction where the material includes an inner paperboard layer with outer LDPE coating layers on each side of the paperboard layer. However, it will also be appreciated that container 10 may be constructed from any other suitable material, including without limitation, a polymer or thermoplastic material, or combination of materials.

As described in greater detail below, sidewall construct 20 and upper rim 30 of container 10 may be formed from a unitary blank 50 constructed from a paperboard or other material, where unitary blank 50 is wrapped around a bottom panel 70 and an overlapped seam 40 is formed by overlapping the ends of the unitary blank 50 to form sidewall construct 20 of container 10. Upper rim 30 may be formed at the upper end of sidewall construct 20 after sidewall construct 20 is formed from unitary blank 50. As illustrated in the several figures, seam 40 may extend the entire height of sidewall construct 20, including upper rim 30. According to one embodiment as best shown in FIG. 1, seam 40 may include a sidewall seam portion and an upper rim seam portion. Seam 40 may also include a lower end seam portion that extends below bottom panel 70 and into the lower end construction of sidewall construct 20 and container 10.

In traditional containers constructed from a sidewall paperboard blank, the sidewall is wrapped to form an overlapping sidewall seam arrangement that extends the entire height of the sidewall. After the sidewall is formed, the upper end of the sidewall is bent, folded, rolled, or otherwise shaped to form an upper rim portion of the container that includes the overlapped seam. In these types of containers, the seam at the upper rim creates a height increase due to the overlapping material at the seam, which can cause “pin hole” leaks when the membrane lid member is sealed to the container by heat sealing or other methods. These pin hole leaks can allow water or air to pass from the exterior to the interior of the container or allow the contents within the container to leak outside the container. As described in greater detail below, container 10 of the present invention may be configured to reduce or eliminate formation of any pin hole leaks and to create a better seal at seam 40.

Turning to the figures, FIG. 1 illustrates container 10 in accordance with one embodiment. As shown in FIG. 1, container 10 may include bottom panel 70 provided at the lower end of container 10 and sidewall construct 20 extending upwardly therefrom. Sidewall construct 20 may include a perimeter sidewall 22 and upper rim 30 that defines the upper end of container 10. As shown in FIG. 1, perimeter sidewall 22 may extend upwardly to upper rim 30, which may be folded outwardly to form the upper end portion of sidewall construct 20. As further shown in FIG. 1, seam 40 of sidewall construct 20 may extend the entire height of sidewall 22 and into upper rim 30 at the upper end of sidewall construct 20 and into the lower end construction of container 10 below bottom panel 70.

As further shown in FIG. 1, perimeter sidewall 22 may wrap around bottom panel 70 and extend upwardly from bottom panel 70 such that bottom panel 70 is positioned at the lower end of container 10. According to one embodiment, bottom panel 70 may have a generally circular shape with a downwardly extending annular wall or leg (see FIG. 10) secured to perimeter sidewall 22 to enclose the lower end of container 10. Any suitable lower end container construction may be used to secure sidewall 22 and bottom panel 70 together. Nonlimiting examples include securing the annular leg of bottom panel 70 to the inner surface of sidewall 22 and/or wrapping the lower end of sidewall 22 around the annular leg of bottom panel 70 to form an overlapped hem secured on both sides of the annular leg. It is also recognized that alternative configurations may be used for bottom panel 70 and the lower end construction of container 10.

As further shown in FIG. 1, perimeter sidewall 22 and sidewall construct 20 may be configured with a generally frustoconical shape where the diameter at upper rim 30 is greater than the diameter at bottom panel 70 and perimeter sidewall 22 has a tapered construction. However, it is recognized that container 10 and perimeter sidewall 22 may have any suitable shape, including without limitation, a cylindrical shape or an elliptic cylinder shape. Container 10 may alternatively have any other desired geometric configuration, including without limitation, configurations with a substantially rectangular or orthogonal cross-sectional shape.

As shown in FIGS. 2 and 3, sidewall construct 20 may be formed from a unitary sidewall blank 50. Unitary blank 50 may include a first end or overlapped seam portion 52 and a second end or overlapped seam portion 54 on each side of unitary blank 50. Unitary blank 50 may further include a lower end 56 and an upper end 58 extending between the first and second ends 52 and 54 at the respective upper and lower portions of unitary blank 50. As described herein, when container 10 is formed with seam 40, first and second ends 52 and 54 may be arranged in an overlapped arrangement to provide a first overlapped portion 52 and a second overlapped portion 54.

Unitary blank 50 may be wrapped and shaped such that first end 52 and second end 54 overlap and unitary blank 50 forms a generally circumferential shape (or other desired shape depending on the preferred configuration of container 10). As best shown in FIG. 2, according to one embodiment, unitary blank 50 may have a generally arcuate shape such that lower end 56 is shorter than upper end 58. Thus, when unitary blank 50 is wrapped and formed into sidewall construct 20 where first and second ends 52 and 54 overlap, the shape formed is generally frustoconical with lower end 56 having a smaller diameter than upper end 58. In other embodiments, a rectangular blank could be used such that the wrapped blank forms a generally cylindrical shape, and it is recognized that unitary blank 50 may have any suitable shape for forming a sidewall.

As best shown in FIGS. 4-6, once unitary blank 50 is shaped into sidewall construct 20 with perimeter sidewall 22 and overlapped first and second ends 52 and 54 forming seam 40, the upper end 58 of unitary blank 50 may be folded or shaped to form upper rim 30 of sidewall construct 20. As shown in FIGS. 2 and 3, unitary blank 50 may include an upper rim transition line 42 that may define an upper end rim margin located along upper end 58 of blank 50. Sidewall construct 20 may be folded along the upper rim transition line 42 in order to form upper rim 30 from upper end 58.

As shown in FIG. 6, according to one embodiment, upper end 58 may include a rim top layer 32 and a rim bottom layer 34. Upper end 58 may first be folded outwardly to provide rim top layer 32 and then be folded again approximately 180 degrees in a reverse bend configuration to form rim bottom layer 34. Rim top layer 32 may extend outward from sidewall 22 in a generally horizontal arrangement so that rim top layer 32 is positioned at an angle slightly greater than 90 degrees relative to sidewall 22 in a configuration where sidewall construct 20 has a frustoconical shape (or at an angle approximately 90 degrees for a configuration where sidewall construct 20 has a cylindrical shape). Rim top layer 32 may alternatively extend with an upward angle or downward angle relative to sidewall 22 in various alternative embodiments. Rim bottom layer 34 is formed from the terminal portion of upper end 58 and may extend inward below rim top layer 32. As shown, according to one embodiment, rim bottom layer 34 may be folded into overlapping contact with rim upper portion to provide upper rim 30 with two adjacent layers. The double fold arrangement may operate to provide additional strength for upper rim 30 and provide an increased flange surface along rim top layer 32 to facilitate sealing a lid or cover (not shown) to upper rim 30.

Turning now to FIGS. 2-3A and 5, the configuration and construction of seam 40 of sidewall construct 20 will be described in greater detail. When forming sidewall construct 20, unitary blank 50 may be wrapped into a frustoconical shape (or cylindrical depending on the desired shape of container 10) and first and second ends 52 and 54 are placed in an overlapping arrangement. As best shown in FIGS. 2 and 3, a bonding tape 80 may be provided on first end 52. As described in greater detail below, bonding tape 80 may function to strengthen first end 52 within the overlapping arrangement forming seam 40 and may assist in securing first and second ends 52 and 54 together in the overlapping arrangement forming seam 40. In alternative embodiments, bonding tape 80 may be applied to second end 54, or both first and second ends 52 and 54.

Bonding tape 80 may be a pre-formed strip of material that is applied to first end 52 (or second end 54 or both ends 52 and 54). Bonding tape 80 may be constructed from any suitable materials and may include one or more layers of material. According to one embodiment, bonding tape 80 includes a sealing layer, a lamination layer, a rigidity layer, a second lamination layer, and a second sealing layer. In such a configuration, the rigidity layer may be the inner layer of material with laminating layers on each side of the rigidity layer and subsequent sealing layers on each side of the laminating layers. According to one embodiment, bonding tape 80 may be made of multiple layers of material including a LDPE layer (sealing layer) and a primer layer (laminating layer) located on each side of a PET layer (rigidity layer); however, it is recognized that other arrangements may be suitably used. According to one embodiment, heat can be applied to bonding tape 80 to partially melt one or more layers of bonding tape 80 and create and assist in bonding first and second ends 52 and 54 together to form seam 40. In the example identified above, upon the application of heat at seam 40 when forming container 10, the PET layer of bonding tape 80 may maintain its shape and structure while the LDPE and primer layers may melt to secure first and second ends 52 and 54 together and also fill the spaces and gaps within upper rim 30 as described in greater detail below. In certain embodiments, bonding tape 80 may be made of food-grade or food-safe materials; however, it is recognized that any tape or bonding material suitable for bonding or holding surfaces together may be used.

As shown, bonding tape 80 may be positioned onto both sides or surfaces of first end 52 (i.e., the inner and outer surfaces). Bonding tape 80 may include a first tape strip portion 82 located on the first (inner) surface of unitary blank 50 at first end 52 and a second tape strip portion 84 located on the second (outer) surface of unitary blank 50 at first end 52. When unitary blank 50 is shaped into sidewall construct 20 for container 10, the first (inner) surface of unitary blank 50 (with first end 52 and first tape strip portion 82 located thereon) forms an interior perimeter sidewall 24. Second tape strip portion 84 may be located on the outer surface of unitary blank 50 at first end 52 (opposite first tape strip portion 82) that forms an exterior perimeter sidewall 26 of container 10. Second tape strip portion 84 may also be positioned between first end 52 and second end 54 at seam 40 when sidewall construct 20 is formed. Bonding tape 80 may be constructed of a single, unitary component where first and second tape strip portions 82, 84 form two sides or portions of the unitary bonding tape 80. In this configuration, bonding tape 80 wraps around the terminal edge of first end 52. During manufacturing, blank 50 may be cut from a larger sheet of paperboard material (that may have a coating applied thereto), which results in first and second ends 52 and 54 having a raw terminal edge that is susceptible to degrading in the presence of moisture due to wicking. The raw terminal edge of first and second end 52 and 54 may also lack the coating applied to the paperboard sheet used to construct blank 50. Because first end 52 is positioned on the interior of sidewall 22 and container 10, it may be exposed to the interior contents of container 10 when in use, and therefore exposed to moisture. Bonding tape 80 may be provided around the raw edge of first end 52 and protect first end 52 from moisture wicking and degradation. The wrapped bonding tape 80 can provide a sealant or a barrier to moisture, liquids and the like for an uncoated raw edge at the first end 52, which could otherwise be exposed to the contents of the container 10 once formed.

As described above, bonding tape 80 may be configured as a single integral structure that is folded to form first tape strip 82 and second tape strip 84. In such a configuration, first tape strip portion 82 of bonding tape 80 may be positioned on the inner surface of first end 52 and then bonding tape 80 may be folded over at the outer edge of first end 52 and the remaining second tape strip portion 84 may be positioned on the outer surface of first end 52. In an alternative embodiment, first tape strip 82 and second tape strip 84 may be separable components that are individually applied to the respective inner and outer surfaces of first end 52. Each of first tape strip portion 82 and second tape strip portion 84 may have a width approximately equal to or less than the width of first end 52. According to one embodiment as best illustrated in FIGS. 2-3A, bonding tape 80 may be folded and secured onto first end 52 so that each portion 82 and 84 have a width equal to approximately one-half of the width of first end 52; however, in alternative embodiments, bonding tape 80 may have any suitable length relative to first end 52.

As further illustrated in FIGS. 2-3A, bonding tape 80 may extend along a substantial portion of the height of first end 52 between lower end 56 and upper end 58 of unitary blank 50. As shown, the lower end 56 includes a lower diagonal or corner cutout portion located at first end 52 and the lower edge of bonding tape 80 may be positioned at or just above the outermost terminal edge of the lower cutout portion. As also shown in FIGS. 2-3A, the upper portion 58 of first end 52 (and second end 54) may include an upper diagonal cutout portion or corner cut 44. As best shown in FIG. 3, corner cut 44 may extend diagonally inward and upward within the upper end rim margin from upper rim transition line 42 to the upper terminal edge of upper end 58. As shown, corner cut 44 defines an angled terminal edge portion of first end 52 adjacent upper end 58 in order to define a triangular-shaped voided region or cutout region where the material of blank 50 is absent relative to the remainder of blank 50 at first end 52.

According to one embodiment, corner cut 44 may have an angle of 29 degrees relative to upper rim transition line 42 (or 151 degrees relative to the outer longitudinal edge of first end 52); however, it is recognized that corner cut 44 may be formed at a greater or lesser angle than described above or any other suitable angle. Corner cut 44 may operate to partially reduce the thickness of upper rim 30 along seam 40 when container 10 is formed from unitary blank 50 as best illustrated in FIGS. 4 and 7. Because seam 40 includes overlapped portions of first end 52 and second end 54, the removed corner cuts 44 on each of first and second ends 52 and 54 reduce the total area of overlapped material at seam 40 and facilitate a gradual thickness change between sidewall construct 20 and seam 40.

As also shown in FIGS. 2-3A and as described above, bonding tape 80 may extend along the longitudinal edge of first end 52. Bonding tape 80 may extend longitudinally upward from its lower end (adjacent lower end 56 of unitary blank 50) toward upper end 58 and may extend beyond upper rim transition line 42 so that at least a portion of bonding tape 80 is positioned above upper rim transition line 42 (which defines the lower boundary of upper end rim margin) and into the removed or voided portion formed by corner cut 44. As shown in FIGS. 3 and 3A, bonding tape 80 includes a lower tape portion coextensive with the inner and outer surfaces of first end 52 and an upper triangular tape portion 90 that extends into the cutout region formed by diagonal corner cut 44. Upper triangular tape portion 90 extends a least partially into and at least partially fills the voided portion formed by corner cut 44. This triangular tape portion 90 does not overlie either surface 24/26 of blank 50 at first end 52 and instead first tape strip portion 82 overlies second tape strip portion 84. As shown, upper triangular tape portion 90 may be defined by an outer longitudinal edge 96 extending upward from upper rim transition line 42 and outer lateral edge 98 extending from the diagonal edge of corner cut 44 and converging to longitudinal edge 96.

When unitary blank 50 is formed into sidewall construct 20, the first end 52 and second end 54 are overlapped to form the seam 40 with perimeter sidewall 22 extending therefrom. As best shown in FIG. 5, interior perimeter sidewall 24 at second end 54 attaches to and adheres to the second tape strip portion 84 (of bonding tape 80) that is attached to exterior perimeter sidewall 26 at first end 52. As further shown in FIG. 5, according to one embodiment, the upper rim 30 at second end 54 includes rim top layer 32 and rim bottom layer 34 similar to as shown in FIG. 6. First end 52 wraps around second end 54 at upper rim 30 to provide an outer portion of rim 30 at seam 40. As shown in FIG. 5, first end 52 includes a rim seam top layer 36 attached to and overlying the top side of rim top layer 32 of second end 54, and also wraps around second end 54 to form a rim seam bottom layer 38 that abuts the bottom side of rim bottom layer 34 of second end 54. As further shown in FIG. 5, first tape strip portion 82 located on the interior surface of rim seam top layer 36 of first end 52 and second tape strip portion 84 is located on the bottom surface of rim seam top layer 36 and above top rim layer 32 of second end 54. As also shown in FIG. 7, triangular tape portion 90 extends into the voided area of rim seam top layer 36 defined by corner cut 44. Second tape strip portion 84 (of bonding tape 80) may also operate to at least partially attach and adhere rim seam top layer 36 to the rim top layer 32 as further shown in FIG. 5.

At the edge of seam 40 where first end 52 terminates, upper rim 30 transitions from having the rim seam top layer 36 as its uppermost layer, to having the rim top layer 32 of the second end 54 as its uppermost top layer. As described above, in conventional paper container designs, the double layer of material at the overlapped seam creates a sharp transition to the adjacent sidewall portion, which has only a single layer of material (i.e., the seam portion as two times the thickness of the sidewall). This creates a sharp transition in thickness and therefore an immediate change in height or elevation at the uppermost surface of the upper rim, which tends to cause pin hole leaks at the transition area due to a lid or seal not being able to fully seal to the upper rim at this transition point. The configuration of seam 40 in container 10 addresses this deficiency through the construction of first and second ends 52 and 54 and bonding tape 80 at the transition region between the seam 40 and adjacent sidewall construct 20. In particular, triangular tape portion 90 extends within this transition region defined by corner cut 44, which can provide an improved sealing surface for a lid or cover, particularly a foil-type or membrane-type sealing cover to fully seal to and engage the upper rim 30.

As illustrated in FIGS. 7 and 8, after container 10 is formed with sidewall construct 20 and upper rim 30, the triangle tape portion 90 of bonding tape 80 that extends above upper rim transition line 42 (i.e., the upper inner edge of upper rim 30) at first end 52 overlies the second end 54. More specifically, as illustrated in FIG. 8, triangular tape portion 90 includes a first triangular tape portion 92 corresponding to the first tape strip portion 82 and a second triangular tape portion 94 corresponding to second tape strip portion 84. As further shown in FIG. 8, the first triangle tape portion 92 of first tape strip 82 overhangs the rim seam top layer 36 and transitions via a bend or a wrap in the bonding tape 80 to the second triangle tape portion 94 of the second tape strip 84 that is exposed and overlying the rim top layer 32 of the second end 54.

As shown in phantom/dashed lines in FIG. 8, due to the stiffness of the bonding tape 80, the first triangle tape portion 92 can overhang a portion of the rim top layer 32 rather than immediately “fall” down to rest on the rim top layer 32. The overhanging first triangle tape portion 92 can provide an attachment surface for a lid or sealing member to attach to at the seam 40. Specifically, a portion of the lid or sealing member near the portion that attaches to the rim seam top layer 36 can attach to the overhanging first triangle tape portion 92 without abruptly having to fold or bend to attach to the rim top layer 32 at a different height. As the lid or sealing member is attached to the rest of the rim top layer 32 beyond the first triangle tape portion 92, a force used to apply the lid or sealing member can cause the first triangle tape portion 92 to taper down and create a smooth transition from the rim seam top layer 36 to the rim top layer 32 as shown in FIG. 8. The stiffness of the bonding tape 80 can give the bonding tape 80 a spring-like characteristic, and the first triangle tape portion 92 may have a spring-like upwards force that pushes back against the application force of the lid or seal member to create a better bond between the two. The additional thickness and smoothed transition provided by triangle tape portion 90 extending beyond corner cut 44 provide a reduced and gradual transition between the increased thickness of seam 40 and the thickness of upper rim 30. This results in a smoother sealing surface for a lid or a sealing member to seal to upper rim 30 at and adjacent to seam 40. In addition to providing a smoother and more gradual surface transition, triangle tape portion 90 may provide a tackier surface for the lid or seal member to seal to at the transition, which further enhances the seal integrity.

During the formation of container 10, heat may be applied to the area around seam 40 when first end 52 and second end 54 are secured together and when the lid or sealing member is attached to the upper rim 30. Applying heat to partially melt bonding tape 80 can further enhance the smoothness of the transition from the top of rim seam top layer 36 to the top of the rim top layer 32. As described above, one or more layers of bonding tape 80 may melt during the heating process to secure seam 40 while other layers of bonding tape 80 may remain un-melted. Collectively, the remaining un-melted layer and the melted layers can fill in the transition region between upper rim layers at seam 40.

As further shown in FIGS. 1, 4, and 7, the angled edge configuration of corner cut 44 provides an angled height change along the edge of seam 40 as opposed to a height change that is entirely transverse to the circumference of upper rim 30. The angled corner cut 44 creates a longer transition than if the transition were orthogonal to the circumference of the upper rim 30. This provides a larger surface for a lid or sealing member to attach to at the transition from seam 40 to sidewall construct 20, which further reduces the likelihood that a continuous pin hole leak can develop that connects the interior to the exterior of container 10.

According to one embodiment, the ratio of the thickness of bonding tape 80 to the thickness of the unitary blank 50, which forms the layers of upper rim 30, is approximately 1:5. For example, bonding tape 80 may have a thickness of approximately 0.003 inches and unitary blank 50 may have a thickness of approximately 0.015 inches. However, it is recognized that the ratios and thicknesses of bonding tape 80 and of unitary blank 50 may vary and remain within the scope of the present invention.

FIGS. 1-8 illustrate an embodiment of container 10 where bonding tape 80 is positioned onto first end 52 that forms the rim seam top and bottom layers 36, 38, which wrap around the rim top and bottom layers 32, 34. However, according to an alternative embodiment (not shown) bonding tape 80 may be attached to second end 54 of unitary blank 50. In such an embodiment, second end 54 may include a corner cut 44 as shown in FIG. 2 and a corresponding triangle tape portion 90 extending above upper rim transition line 42 adjacent corner cut 44.

FIGS. 9-12 illustrate a second embodiment for a container 110 with bonding tape 180 to secure a seam 140 of the sidewall construct 120 together. While container 110 includes several components and features of container 10 described above, the upper rim 130 of container 110 includes a rim intermediate layer 135 in addition to a rim top layer 132 and rim bottom layer 134 (i.e., the upper rim 130 has a three-layer, double-fold construction compared to the two-layer, single-fold construction of the upper rim 30). Features that are similar to the container 10 shown in FIGS. 1-8 are identified with similar reference numbers, plus 100 (e.g., corner cut 144 and corner cut 44). Similar to container 10, container 110 may include a bottom panel 170 secured to the sidewall construct 120, which may be formed from a unitary blank (not shown) wrapped to form a frustoconical or cylindrical shape. The unitary blank for container 110 and sidewall construct 120 may be configured in an identical manner to unitary blank 50 of FIGS. 2-3A. Container 110 may include a corner cut 144 at the seam 140 of the upper rim 130 such that a triangle tape portion 190 extends beyond the corner cut 144 at the upper rim 130. Corner cut 144 may be configured in the same manner as corner cut 44 of sidewall construct 20 where bonding tape 180 extends along first end 152 of the unitary blank and triangular tape portion 190 into a voided region left by corner cut 144.

As shown in FIGS. 10-12, upper rim 130 of container 110 may include a rim top layer 132, a rim bottom layer 134, and a rim intermediate layer 135 sandwiched between the rim top and rim bottom layers 132, 134. To form the upper rim 130, an upper end of the blank may be folded approximately 180 degrees in a reverse bend configuration to form the rim intermediate layer 135 that can abut the rim bottom layer 134. The upper end of the blank (i.e., the rim intermediate layer 135 and rim bottom layer 134) may be folded in a second reverse bend configuration such that the rim intermediate layer 135 also abuts the rim top layer 132 on an opposite surface from the surface that abuts the rim bottom layer 134. The upper end of the blank (i.e., the rim top, bottom, and intermediate layers 132, 134, 135) may be folded outwardly such that rim top layer 132 is in a generally horizontally arrangement positioned at an angle slightly greater than 90 degrees relative to the substantially vertical perimeter sidewall 122 in a configuration where sidewall construct 120 has a frustoconical shape, as illustrated. Rim top layer 132 may alternatively extend at an upward or downward angle in alternative embodiments. The order of making the various folds to form the three-layer upper rim 130 as described above may be modified.

The three-layer upper rim 130 can provide a more rigid upper rim 130. The three-layer upper rim 130 can provide more resistance and deflect less when a lid or cover (not shown) is pressed or forced against upper rim 130 to seal and engage the lid or cover to upper rim 130. This can prevent deformation of upper rim 130 during the lid application and can promote a stronger adhesion or bond as a greater proportion of the application force contributes to pressing the lid or cover to rim top layer 132 rather than deflecting upper rim 130.

As shown in FIGS. 11 and 12, the three-layer upper rim 130 may have six layers at seam 140 where first end 152 and second end 154 of the blank overlap. First end 152 may include a rim seam top layer 136 attached to and overlying the top side of rim top layer 132 of second end 154, and also wraps around second end 154 to form a rim seam bottom layer 138 that abuts the bottom side of rim bottom layer 134 of second end 154, and further wraps around the second end 154 to form a rim seam intermediate layer 139 that abuts the top side of rim intermediate layer 135 and the bottom side of rim top layer 132. In other embodiments, the layers of second end 154 may remain together (i.e., rim intermediate layer 135 sandwiched directly between and abutting rim top and bottom layers 132, 134). In such embodiments, first end 152 may be wrapped around second end 154 such that rim seam intermediate layer 139 abuts a bottom side of rim bottom layer 134 (i.e., rim seam intermediate layer 139 is sandwiched between rim bottom layer 134 and rim seam bottom layer 138). In either embodiment, first tape strip 182 and second tape strip 184 may only be separated by a thickness of rim seam top layer 136, and corner cut 144, first triangle tape portion 192, and second triangle tape portion 194 can provide a smoother transition and better attachment for a lid or cover at the seam 140 similar to as described relative to FIGS. 1-8 above.

Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the invention. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations, locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the invention.

Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any of the individual embodiments described above. The embodiments described herein are not meant to be an exhaustive presentation of how the various features of the subject matter herein may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.

The numerical ranges in this disclosure are approximate, and thus may include values outside of the range unless otherwise indicated. Numerical ranges include all values from and including the lower and the upper values, in increments of one unit, provided that there is a separation of at least two units between any lower value and any higher value. These are only examples of what is specifically intended, and all possible combinations of numerical values between the lowest value and the highest value enumerated, are to be considered to be expressly stated in this disclosure.

As used herein, “a,” “an,” or “the” can mean one or more than one. For example, “an” image can mean a single image or a plurality of images.

The term “and/or” as used in a phrase such as “A and/or B” herein can include both A and B; A or B; A (alone); and B (alone). Likewise, the term “and/or” as used in a phrase such as “A, B, and/or C” can include at least the following embodiments: A, B, and C; A, B, or C; A or C; A or B; B or C; A and C; A and B; B and C; A (alone); B (alone); and C (alone).

As used herein, the term “about” when referring to a measurable value such as an amount, a temporal duration, and the like, can include variations of +/−20%, more preferably +/−10%, even more preferably +/−5% from the specified value, as such variations are appropriate to reproduce the disclosed methods and systems.

From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are inherent to the structure and method. It will be understood that certain features and sub combinations are of utility and may be employed without reference to other features and sub combinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments of the invention may be made without departing from the scope thereof, it is also to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative and not limiting.

The constructions described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present invention. Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required”. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.

Claims

1. A paperboard container for receiving a sealed lid, the paperboard container comprising:

a sidewall construct comprising a perimeter sidewall and an overlapping seam extending the height of the sidewall construct, wherein the overlapping seam comprises a first overlapping portion and a second overlapping portion;

an upper rim formed into an upper end of the sidewall construct and extending outwardly from the perimeter sidewall, the upper rim including at least a portion of the overlapping seam; and

a bonding tape located on the first overlapping portion;

wherein an upper end of the first overlapping portion includes a corner cut; and

wherein the bonding tape extends into a cutout region defined by the corner cut.

2. The paperboard container of claim 1, wherein the bonding tape comprises a first tape portion located on an inner surface of the first overlapping portion and a second tape portion located on an exterior surface of the first overlapping portion.

3. The paperboard container of claim 1, wherein the upper rim extends away from the perimeter sidewall generally horizontally.

4. The paperboard container of claim 1, wherein the upper rim includes a top rim portion extending from the perimeter sidewall and a lower rim portion positioned directly below the top rim portion.

5. The paperboard container of claim 1, wherein the upper rim includes a top rim portion extending from the perimeter sidewall, a lower rim portion positioned below the top rim portion, and an intermediate rim portion positioned between the top rim portion and the lower rim portion.

6. The paperboard container of claim 5, wherein the top rim portion is connected to the lower rim portion by a first reverse bend fold and the intermediate rim portion is connected to the lower rim portion by a second reverse bend fold.

7. The paperboard container of claim 1, wherein the first overlapping portion includes a first surface and a second surface opposite the first surface, and wherein the bonding tape is located on both the first surface and the second surface.

8. The paperboard container of claim 1, wherein the upper rim at the overlapping seam comprises a first rim portion and a second rim portion, wherein the first rim portion at least partially overlaps the second rim portion, and wherein the corner cut of the first overlapping portion is located on the first rim portion.

9. The paperboard container of claim 8, wherein the bonding tape includes a triangular tape portion located in the cutout region defined by the corner cut, and wherein the cutout region is located directly above at least a portion of the second rim portion.

10. A blank for a paperboard container having an upper rim, the blank comprising:

a sidewall surface comprising a first end, a second end, an upper end, and a lower end, wherein the upper end includes an upper end rim margin;

a diagonal corner cut defining an outer edge of the first end and extending to the upper end within the upper end rim margin; and

a bonding tape provided on at least a portion of the first end, wherein the bonding tape extends above the diagonal corner cut.

11. The blank of claim 10, wherein the bonding tape includes a first tape portion secured to an inner surface of the first end and a second tape portion secured to an outer surface of the first end.

12. The blank of claim 11, wherein the bonding tape comprises a unitary strip of material.

13. A paperboard container comprising:

a bottom panel;

a sidewall extending upward from the bottom panel and defining an interior of the container; and

an upper rim extending outward from the sidewall, the upper rim including an overlapping seam having a first overlapping portion and a second overlapping portion;

wherein the first overlapping portion of the upper rim wraps around and overlaps the second overlapping portion; and

wherein the first overlapping portion includes a bonding tape positioned on an inner surface and an outer surface thereof.

14. The paperboard container of claim 13, wherein the first overlapping portion includes a corner cut defining at least a portion of an outer edge of the first overlapping portion.

15. The paperboard container of claim 14, wherein the bonding tape includes a triangular tape portion extending away from the corner cut.

16. The paperboard container of claim 15, wherein the triangular tape portion includes a first layer of bonding tape and a second layer of bonding tape overlapping the first layer.

17. The paperboard container of claim 13, wherein the upper rim includes a top rim portion and a lower rim portion positioned directly below the top rim portion.

18. The paperboard container of claim 17, wherein the top rim portion is connected to the lower rim portion by a reverse bend fold.

19. The paperboard container of claim 13, wherein the upper rim includes a top rim portion, a lower rim portion positioned below the top rim portion, and an intermediate rim portion positioned between the top rim portion and the lower rim portion.

20. The paperboard container of claim 19, wherein the top rim portion is connected to the lower rim portion by a first reverse bend fold and the intermediate rim portion is connected to the lower rim portion by a second reverse bend fold.