US20140161936A1 - Container WIth Removable Portion - Google Patents

Abstract

A container is provided with a body defining an interior space having an opening. A filter is disposed in the body to define an ingredients chamber. Ingredients are disposed in the ingredients chamber and a cover is disposed over the opening to seal the interior space. The container is adapted to allow cover and filter with ingredients contained in ingredients chamber to be separated from the remainder of body.

Description

FIELD
• This specification relates to containers and in particular to a container, such as a single serve capsule, having a portion that is removable from the remainder of the container.
BACKGROUND
• The following background discussion is not an admission that anything discussed below is citable as prior art or common general knowledge. The documents listed below are incorporated herein in their entirety by this reference to them.
• Single serve capsules for use in machines for preparing beverages or other products are becoming increasingly popular. Such capsules come in a variety of formats for producing products such as espresso coffee, drip coffee, tea or hot chocolate.
• Multi chamber capsules, such as drip coffee capsules, have a first chamber defined by a filter (typically a paper filter) that is loosely packed with ingredients (such as ground coffee) and a second chamber downstream of the first chamber that defines an empty space for receiving a prepared product that flows through the filter prior to dispensing into a cup. One example of a multi chamber capsule is the Keurig K-Cup™ capsule. This capsule includes a paper filter having a side wall that is sealed to an inside peripheral edge of the capsule.
• A problem with conventional multi chamber capsules, such as the Keurig K-Cup™ capsule, is that the capsules are not adapted for recycling. The portion containing the precursor ingredients (such as coffee grounds) cannot be easily separated from the plastic outer shell. As a result, the used capsules must be disposed into garbage destined for landfill.
• One approach to addressing this problem is provided with the Keurig Vue™ capsule, as described in US patent application 2012/0058226 the subject matter of which is incorporated in its entirety herein by reference. The Vue™ capsule includes a filter that is secured to the capsule cover inwardly from the sidewall of the outer shell. The capsule cover with attached filter may be peeled from the outer shell to allow the shell to be disposed into plastics recycling while the cover and filter (with ingredients) is disposed into garbage destined for landfill. As a result, the Vue™ capsule provides a partially recyclable solution.
• There are a number of problems with the Keurig Vue™ capsule solution however. The process for filling and sealing the capsule is more complicated than for conventional capsules and the capsule is more costly to produce as a result. Also, the used paper filter is weak, in particular when it is wet, and prone to tearing and spilling of ingredients when the filter and cover are being removed from the capsule following use.
• Other forms of containers having a removable portion are also well known. Such containers typically include a component that is adapted to be manipulated by a user to facilitate removal of the desired portion of the container. A problem with such containers is that the component tends to add complexity and cost to the manufacturing and packaging of the container. Another problem with such containers is that they are not adapted to include a filter element that is removable.
• There is a need for an improved container having one or more removable portions that address one or more problems with conventional containers such as the problems noted above.
SUMMARY
• In one aspect the invention provides a container comprising: a body defining an interior space having an opening;
• a filter disposed in said interior space to define an ingredients chamber, said filter being bonded to said body with a first bond, said first bond being a peelable bond;
  ingredients disposed in said ingredients chamber;
  a cover disposed over said opening for covering said interior space, said cover being bonded to said filter at a periphery to said opening with a second bond;
  wherein said cover is adapted to be removed together with said filter upon the application of sufficient force by hand following use of the container.
• In another aspect the invention provides a container comprising:
• a body defining an interior space having an opening, said body having a flange surrounding said opening;
  a filter disposed in said body to define an ingredients chamber, said filter being bonded to a first surface of said flange with a first bond, said first bond being a peelable bond;
  a separation point defined in said flange, said separation point defining a tab that is adapted to be separated from the remainder of said flange upon the application of sufficient force by hand;
  ingredients disposed in said ingredients chamber;
  a cover disposed over said opening for covering said interior space, said cover being bonded to said filter with a second bond,
  wherein said tab and said cover is adapted to be removed together with said filter and said ingredients chamber containing said ingredients following use of the container by the application of force by hand.
• In another aspect the invention provides a container comprising:
• a body defining an interior space having an opening, said body having a flange surrounding said opening;
  a separation point defined in said flange, said separation point defining a tab that is adapted to be separated from the remainder of said flange upon the application of sufficient force by hand;
  ingredients disposed in said ingredients chamber;
  a cover disposed over said opening for sealing said interior space, said cover being bonded to said flange with a peelable bond;
  wherein said cover is adapted to be removed by the application of sufficient force by hand to separate said tab and peel said cover from the remainder of said flange.
• In another aspect the invention provides a container comprising:
• a body defining an interior space having an opening, said body having a flange surrounding said opening;
  a separation point defined in said body around its circumference at a desired location for separating one portion of said body from the remainder of said body,
  ingredients disposed in said ingredients chamber;
  a cover disposed over said opening for covering said interior space;
  wherein said separation point is adapted to provide a point of separation under the application of sufficient force to separate a portion of said body, including said flange with said cover, from the remainder of said body.
• Other aspects and features of the teachings disclosed herein will become apparent, to those ordinarily skilled in the art, upon review of the following description of the specific examples of the specification.
DRAWINGS
• The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the present specification and are not intended to limit the scope of what is taught in any way. For simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the drawings to indicate corresponding or analogous elements.
• FIG. 1 is a perspective view of a container in accordance with the present invention;
• FIG. 2 is a perspective view of the container ofFIG. 1 following its use in a machine for preparing products from containers, the cover and filter being partially removed from the body;
• FIG. 3 is a sectional view of the container ofFIG. 1 as viewed along lines3-3, the container being disposed in a chamber for a machine for preparing a product from the container;
• FIG. 4 is an enlarged sectional view of the container shown inFIG. 3 as viewed withincircle4;
• FIG. 5 is an exploded sectional view of a container in accordance with another embodiment of the present invention, the container having a body and cover made from multilayered materials;
• FIGS. 6 (a) to6 (d) are enlarged sectional views of a container in accordance with another embodiment of the present invention showing different examples of a peelable bond between filter and body;
• FIG. 7 is a perspective view of another embodiment of a container in accordance with the present invention, showing the filter being peeled from the body and the cover being peeled from the filter;
• FIG. 8 is a perspective view of another embodiment of a container in accordance with the present invention, showing the filter attached to the sidewall of the body with a tab for peeling filter from body and the cover attached to the flange with a tab for peeling cover from body;
• FIG. 9 is a side view of a container in accordance with another embodiment of the present invention with a portion of the container being separated from the remainder of the container;
• FIG. 10 is a top view of the body for the container ofFIG. 9 showing one variant for the separation point;
• FIG. 11 is a top view of the body for the container ofFIG. 9 showing another variant for the separation point;
• FIG. 12 is a side view of a container in accordance with another embodiment of the present invention showing the tab, cover and filter with ingredients being separated from the remainder of the body;
• FIG. 13 is a bottom view of the container shown inFIG. 12 with the separation point defined in the bottom surface of flange to define tab;
• FIG. 14 is a schematic top view of a mold and material for forming a plurality of bodies with a plurality of tab indicators in accordance with the present invention
• FIG. 15 is a perspective view of another embodiment of a container in accordance with the present invention, showing the cover and filter being peeled from the body;
• FIG. 16 is an enlarged sectional view of the flange for the container ofFIG. 15 as viewed along lines16-16, showing the separation point defining the tab prior to it being separated from the remainder of the flange (the cover is not shown);
• FIG. 17 is a perspective view of another embodiment of a container in accordance with the present invention;
• FIG. 18 is a perspective view of another embodiment of a container in accordance with the present invention;
• FIG. 19 is a perspective view of another embodiment of a container in accordance with the present invention;
• FIG. 20 is a perspective view of another embodiment of a container in accordance with the present invention.
DESCRIPTION OF VARIOUS EMBODIMENTS
• Various apparatuses or methods will be described below to provide examples of the claimed invention. The claimed invention is not limited to apparatuses or methods having all of the features of any one apparatus or method described below or to features common to multiple or all of the apparatuses described below. The claimed invention may reside in a combination or sub-combination of the apparatus elements or method steps described below. It is possible that an apparatus or method described below is not an example of the claimed invention. The applicant(s), inventor(s) and/or owner(s) reserve all rights in any invention disclosed in an apparatus or method described below that is not claimed in this document and do not abandon, disclaim or dedicate to the public any such invention by its disclosure in this document.
• A container in accordance with one embodiment of the present invention is shown generally at10 inFIGS. 1-4.Container10 includes abody12,filter14,ingredients16 andcover18.
• Body12 includes aside wall20 and anend wall22 together defining an enclosedinterior space24. Anopening26 is defined at one end ofbody12.Body12 further includes aflange28 that extends around the perimeter ofopening26. Preferably,side wall20,end wall22 andflange26 are all integrally formed, such as by thermoforming, from one sheet of material.Container10 preferably is symmetrical with anannular flange28 having a uniform width W. Most preferably,container10 has a circular cross section in order that it does not require orientation during manufacture or during use (in cases where container is used in a machine for preparing beverages or other products).
• Cover18 includes at least onetab30 that is adapted to provide a grip forcover18 to be peeled frombody12 following use ofcontainer10 in a machine for preparing products, such as beverages, fromcontainers10.Tab30 may extend fromflange28 and fold over or, more preferably,tab30 is integrally formed withflange28 as shown for example with the embodiment depicted inFIGS. 12 and 13.
• Cover18 is preferably formed of a material that is resistant to tearing upon the application of a peel force. Most preferably, cover18 is formed of a multi-layered material that includes at least one layer that is resistant to tearing upon the application of a peel force.Cover18, or a tear resistant layer ofcover18, preferably has a minimum tensile strength of 3000 psi and a minimum elongation of 50%. Examples of materials that are resistant to tearing include polyethylene (PE), polyethylene terephthalate (PET) and polyamide PA6. A multi-layered material forcover18 may include at least one layer formed of a continuous film of tear resistant material (laminated or extrusion coated) or a non-continuous film such as a non-woven polymer, mesh or perforated film. Examples of a multi-layered material forcover18 include (from outside layer to inside layer): PET/aluminum foil/PE, PET/EVOH/PE, PET/metalized PET/PE or PET/PE.End wall22 includes at least one extraction region32 adapted for being pierced by at least oneextraction needle34 of amachine36 for dispensing product, such as a beverage, from thecontainer10 to a user's cup.
• Filter14 is adapted to be disposed withinbody12 to define at least oneingredients chamber46 in an upper region of theinterior space24 for receiving one ormore ingredients16 and, for filtering applications, at least oneextraction chamber48 exterior to theingredients chamber46 in theinterior space24 for receiving product, such as a beverage, from the at least oneingredients chamber46 prior to extraction using theextraction needle34.
• “Filter” is defined herein to mean any material that is suitable for defining a chamber for containing ingredients for a desired purpose. Filter may perform a filtering or screening function or may simply serve to separate ingredients from the remainder of container.
• “Ingredients” is defined herein to mean any material that is desired for use within container for a desired purpose. Ingredients may include food or beverage ingredients or other natural or synthetic material (for example packaging preservatives) desired for use within container.
• In the case of acontainer10 for preparing a beverage as intended for the present embodiment,ingredients16 may be coffee grounds, tea leaves, chocolate powder, milk powder, instant coffee or any other soluble or insoluble ingredients or combinations of ingredients that may be used to prepare a beverage in abeverage preparing machine36 as described herein.
• Filter14 includes agasket portion50 that is adapted for securingfilter14 tobody12 as described further below.Gasket portion50 includes a plurality of pores, openings or channels62 (collectively referred to aschannels62 hereafter) suitable for securingfilter14 betweencover18 andflange28 as described herein.Filter14 also includes afilter portion52 that is disposed withininterior space24 to defineingredients chamber46. In a preferred embodiment, as described further below,filter portion52 is molded to a desired shape withininterior space24 oncegasket portion50 has been secured tobody12 and prior to filling withingredients16.
• Filter14 may be formed of any material suitable for holding and, where applicable, filtering thespecific ingredients16 that are intended to be disposed withiningredients chamber46.
• Preferably, for beverage filtering applications,filter14 is formed of a moldable non-woven filtration material that includes a plurality of multi-component filaments that are bound or interlocked by non-woven manufacturing techniques (such as spunbond techniques) to form aweb having channels62 extending from one side offilter14 to the other. The basis weight forfilter14 adapted for filtering ingredients for preparing a single serving of beverage is in the range of 8 to 400 grams per square meter (gsm), preferably in the range of 40 to 150 gsm and more preferably in the range of 60 to 120 gsm. More details of the preferred moldable nonwoven filtration material forfilter14 are provided in co-pending U.S. provisional patent application No. 61/723,644 and regular U.S. patent application Ser. No. 14/074,024 which are incorporated in their entirety herein by reference.
• Gasket portion50 offilter14 is adapted to be secured by way of afirst bond64 to the periphery of opening16 of body12 (and most preferably to the top surface of flange28).First bond64 may be formed by disposing a separate bonding material betweenfilter14 andbody12 or it may be integrally formed from the material of one or both offilter14 and body12 (as shown for example inFIG. 5).
• First bond64 preferably comprises a peelable bond betweensecond surface14boffilter14 andfirst surface12aof body12 (top surface of flange28) in order that filter14 may be peeled away frombody12.
• “Peelable bond” is defined herein to mean a bond between two materials that is sufficiently strong to allow both materials to remain bonded together during normal conditions for manufacture, shipment and use while being sufficiently weak to allow one material to be peeled away from the other material by hand following use.
• First bond64 is formed from afirst bonding material66 that is adapted for securingfilter14 tobody12. As noted above,first bonding material66 may be a separate material fromfilter14 andbody12 or it may be an integral part of the material (either a monolayer material or a layer of a multi-layered material) for one or both offilter14 andbody12.
• One example of a preferredfirst bonding material66 is a heat sealable polymer such as polyethylene (PE) including low density PE, linear low density PE and high density PE. This material may be provided as a sealing layer for a multi-layered material forbody12 or it may be provided as a separatefirst bonding material66.
• Other suitablefirst bonding materials66 include other heat sealable materials such as polypropylene, lacquer, ethylene vinyl acetate (EVA), ethylene acrylates, polystyrene or combinations of the above. Adhesive materials (having comparable adhesion properties as described above to form a peelable bond) may be utilized for applications where a heat sealer is not desired or feasible.
• Suitable first bonding materials that may be integral withfilter14 include homocomponent materials (such as polyolefin, polyester, and polyamide) and multicomponent materials (such as polyester-polyolefin, polyamide-polyolefin and polyester-polyamide).
• Cover18 is adapted to be secured by way of asecond bond68 togasket portion50 offilter14. In the embodiments depicted inFIGS. 1-6,second bond68 preferably is at least as strong and more preferably is stronger thanfirst bond64 in order that filter14 will remain secured to cover18 whencover18 is peeled frombody12.
• Second bond68 is preferably formed from asecond bonding material70 that is adapted for securing afirst surface18aofcover18 tosecond surface14boffilter14. One example of a preferred second bonding material is a heat sealable polymer such as polyolefin. Other suitablesecond bonding materials70 may include other heat sealable materials such as lacquer, ethylene vinyl acetate (EVA), and ethylene acrylates or adhesive materials for applications where a heat sealer is not desired or feasible.
• The selection of thefirst bonding material66 andsecond bonding material70 are interdependent and also depend on the selection of other components withincontainer10 includingfilter14. The strength or weakness of the bonds is related to the compatibility of the respective materials being bonded together. Less compatible bonds are adapted to separate prior to more compatible bonds. More details concerning the preferred choice of bonding materials are provided below with reference toFIGS. 6(a)-(d).
• For the embodiments depicted inFIGS. 1-6, the bond strength ofsecond bond68 is preferably at least as strong as thefirst bond64 and more preferably 50% higher than that offirst bond64 and even more preferably 100% higher or more. For example, using the ASTM F88 protocol, the bond strength offirst bond64 is preferably no more than 20 N/15 mm and more preferably no more than 10 N/15 mm. The bond strength ofsecond bond68 is preferably no less than 15 N/15 mm and more preferably no less than 25 N/15 mm.
• First andsecond bonding materials66,70 are preferably adapted to become at least partially embedded withinchannels62 ofgasket portion50 offilter14. Heat sealable polymers for example will flow intochannels62 when melted during a heat sealing process and then form a bond withinchannels62 upon cooling. In the case offilter14 being formed of filtration material having multi-component fibers, one or more portions of the multi-component fibers may melt during the heat sealing process and combine with the first or second bonding materials while other portions of the multi-component fibers remain intact (do not melt) during the heat sealing process to maintain aweb defining channels62. Preferably,second bonding material70 is chemically compatible in order that it may be sealed to all the components offilter material14 to give a sufficiently strong seal strength. More details offilter14 and the manner for securingfilter14 and cover18 to flange28 ofbody12 are provided in co-pending patent application Ser. No. 13/600,582 which is incorporated in its entirety herein by reference.
• Referring toFIG. 5, an exploded sectional view of acontainer10 in accordance with another embodiment of the present invention is shown. The same reference numerals are provided for elements that are similar to the elements described above.
• Container10 includesbody12,filter14,ingredients16 andcover18. While thebody12 and cover18 ofcontainer10 shown inFIGS. 1-4 could be formed of a monolayered material,body12 and cover18 for the embodiment shown inFIG. 5 are each formed of multilayered materials that include one or more barrier layers providing barriers against one or more environmental factors such as light, oxygen, and moisture as described further below.
• Body12 is formed of a conventional multilayered material MM1 that includes a barrier layer B1 preferably formed of ethylene vinyl alcohol (EVOH) and a sealing layer S1 preferably formed of polyethylene (PE). As well,body12 may include outer base layer O1 preferably formed of polyolefin or polystyrene or other materials adapted to cover and protect barrier layer B1.
• Cover18 is formed of a conventional multilayered material MM2 that includes a barrier layer B2 preferably formed of aluminum foil or metalized polyester or Ethylene Vinyl Alcohol (EVOH) and a sealing layer S2 preferably formed of polyethylene or modified polyethylene or polyethylene copolymer. Sealing layer S2 may be formed from a lamination process, extrusion coating or lacquer coating process. As well, cover18 may include an outer base layer O2 preferably formed of polyester and a graphics layer G2 preferably formed of ink. Depending upon the type of packing machinery, cover18 could be provided as roll stock or in die-cut format.
• It is preferred that cover18 is formed of multilayered material MM2 (such as described above) that is resistant to tearing as described above and that shrinks when exposed to heat. This allows cover to be peeled away frombody12 and also reduces the likelihood ofcover18 being torn during the process of puncturing with injection nozzle and injecting fluid intoingredients chamber46. Multilayered material MM2 ofcover18 will also preferably shrink around the opening formed by injection nozzle when exposed to injection of hot fluid to reduce the size of opening. These characteristics can be achieved by choosing a proper outer base layer O2 such as polyester for providing rigidity to thecover18.
• Filter14 is formed by disposing filtration material overopening26 ofbody12.Gasket portion50 offilter14 engages sealing layer S1 disposed on the top surface offlange28 andfilter portion52 extends acrossopening26.Gasket portion50 is then sealed with a heat sealer to sealing layer S1 disposed on the top surface offlange28. A portion of sealing layer S1 on top surface of flange28 (also referred to herein as first bonding material66) is melted by heat sealer and flows intochannels62 withingasket portion50. Thegasket portion50 offilter14 may be partially melted during this process if it contains multiple component fibres while other portions of the multi-component fibers remain intact (do not melt) during the heat sealing process to maintain aweb defining channels62.
• In addition to choosing desired first andsecond bonding materials66,70, the temperature, pressure and time parameters for the heat sealing process are optimized to ensure the desired bonding strength is achieved for bothfirst bond64 andsecond bond68. For example, with respect to bothfirst bond64 andsecond bond68, the sealing temperature is preferably in the range of 100-250 C and more preferably in the range of 160-220 C. The sealing pressure is preferably in the range of 0.5-4 bar and more preferably in the range of 1-3 bar. The sealing time is preferably in the range of 50-5000 milliseconds and more preferably in the range of 500-3000 milliseconds.
• Once the meltedfirst bonding material66 sufficiently cools to formfirst bond64 to securegasket portion50 toflange28, then filter14 may be molded for instance by engagingfilter portion52 using a heated mandrel tomold filter portion52 to a desired shape within interior space ofbody12 to form theingredients chamber46. Theningredients16 are disposed withiningredients chamber46 offilter14 and cover18 is positioned overgasket portion50 to coveropening26.
• Cover18 may then be partially sealed togasket portion50 using a heat sealer. A portion of the sealing layer S2 (also referred to herein as second bonding material70) on bottom surface ofcover18 is melted by a heat sealer and flows intochannels62 ofgasket portion50. The air withininterior space16 ofcontainer10 may then be evacuated and replaced with an inert gas such as nitrogen in accordance with a modified atmosphere packaging process. The remainder ofcover18 may then be fully sealed tobody12 overgasket portion50 as described above to formsecond bond68 and sealinterior space16 ofcontainer10.
• Body12 preferably includes anotch72 cut into at least sealing layer S1 (first bonding layer66) below the periphery ofopening16.Notch72 may, in certain applications where barrier properties are not excessively compromised, also extend into barrier layer B1 if necessary to provide a sufficient area weakness as discussed below.Notch72 provides an area of weakness for ingredients chamber and first bonding material66 (in this instance sealing layer S1 at gasket50) to be separated frombody12 whentab30 is pulled to peelcover18 frombody12 following use ofcontainer10.
• Adhesion or tie layers T may be disposed in known manner between the respective layers B1, S1, O1 and G1 as described above to adhere or tie the respective layers together. Adhesion or tie layers T inbody12 may provide a relatively weak connection between adjoining surfaces to allow for separating layers when peelingcover18 andingredients chamber46 frombody12.
• Referring toFIGS. 6 (a)-(d), a number of examples of a peelable bond betweenfilter14 andbody12 are shown.
• FIGS. 6(a) and6(b) showfirst bond64 being formed using a separate material (first bonding material66) disposed betweenfirst surface14aoffilter14 andfirst surface12aofbody12.
• InFIG. 6(a) the peel strength of thefirst bond64 betweenfirst surface14aoffilter14 andfirst bonding material66 is greater than the peel strength of thefirst bond64 betweenfirst bonding material66 andfirst surface12aofbody12. As a result,filter14 andfirst bonding material66 are peeled away fromfirst surface12aofbody12 upon the application of a sufficient peeling force to filter14.
• The choice of materials for the example shown inFIG. 6(a) include the following.Filter14 may be formed of ≧20% LDPE or LLDPE and cover18 may be formed of PE, EVA, EAA or a combination of two or more of these materials. In this case,first bonding material66 andsecond bonding material70 may be formed from LDPE, EVA (Dupont Bynel™) or modified PE (Dow Sealution™). It will be understood that other choices of materials may selected as well.
• InFIG. 6(b) the peel strength of thefirst bond64 betweenfirst surface14aoffilter14 andfirst bonding material66 is less than the peel strength of thefirst bond64 betweenfirst bonding material66 andfirst surface12aofbody12. As a result,filter14 is peeled away fromfirst bonding material66 upon the application of a sufficient peeling force to filter14.
• The choice of materials for the example shown inFIG. 6(b) include the following.Filter14 may be formed of ≦20% LDPE or LLDPE, PP, PA or Polyester and cover18 may be formed of a PE, EVA, EAA or a combination of two or more of these materials. In this case,first bonding material66 may be formed from LDPE, EVA (Dupont Bynel™) or modified PE (Dow Sealution™).Second bonding material70 may be formed from polyester or other suitable materials provided that thesecond bond68 is stronger thanfirst bond64. It will be understood that other choices of materials may selected as well.
• FIGS. 6(c) and6(d) showfirst bond64 being integrally formed from a layer of a multilayered materialMM1 forming body12.
• InFIG. 6(c) the peel strength of thefirst bond64 betweenfirst surface14aoffilter14 and first bonding material66 (which is the sealing layer S1 of the multilayered material MM1 forming body12) is greater than the peel strength of thefirst bond64 betweenfirst bonding material66 and the adjacent layer of the multilayered material MM1. The adjacent layer may be a tie layer formed of a low compatibility material such as Surlyn™ or Bynel™ or adjacent layer may be barrier layer B1. As a result,filter14 and first bonding material66 (ie a portion of the sealing layer S1 of multilayered material MM1) are peeled away upon the application of a sufficient peeling force to filter14. This example is described in more detail above with reference toFIG. 5.Notch72 defines a break point to allow a portion of sealing layer S1 to be removed withfilter14 while the remainder of sealing layer S1 stays withinbody12.
• The choice of materials for the example shown inFIG. 6(c) include the following.Filter14 may be formed of ≧20% LDPE or LLDPE, PP, PA or Polyester and cover18 may be formed from PE, EVA, EAA or a combination of two or more of these materials. In this case,first bonding material66 may be formed from LDPE, LLDPE, HDPE, EVA or a combination of two or more of these materials.Second bonding material70 may be formed from PE, EVA, EAA or a combination of two or more of these materials. It will be understood that other choices of materials may selected as well.
• InFIG. 6(d) the peel strength of thefirst bond64 betweenfirst surface14aoffilter14 andfirst bonding material66 is less than the peel strength of thefirst bond64 betweenfirst bonding material66 and the adjacent layer of the multilayered material MM1. As a result,filter14 is peeled away from first bonding material66 (ie away fromfirst surface12aofbody12 or, in other words, away from sealing layer S1 of multilayered material MM1 that forms body12) upon the application of a sufficient peeling force to filter14.
• The choice of materials for the example shown inFIG. 6(d) include the following.Filter14 may be formed of ≧20% LDPE or LLDPE and cover18 may be formed of PE, EVA, EAA or a combination of two or more of these materials. In this case, first bonding material66 (sealing layer S1) may be formed from HDPE, PP or PS.Second bonding material70 may be formed from PE, EVA, EAA or a combination of two or more of these materials. It will be understood that other choices of materials may selected as well.
• Referring toFIG. 7, acontainer10 in accordance with another embodiment of the present invention is shown. The same reference numerals are provided for elements that are similar to the elements described above.
• Container10 includesbody12,filter14,ingredients16 andcover18. If desired,body12 and cover18 may each be formed of multilayered materials that include one or more barrier layers providing barriers against one or more environmental factors such as light, oxygen, and moisture as described further below.
• In this embodiment,second bond68 betweenfilter14 and cover18 comprises a peelable bond similar tofirst bond64 as described for the embodiments above. For example, the peel strength of thesecond bond68 betweensecond surface14boffilter14 andsecond bonding material70 may be less than the peel strength of thesecond bond68 betweensecond bonding material70 and thefirst surface18aofcover18. As a result, filter14 may be peeled away from second bonding material70 (ie away fromfirst surface18aof body12) upon the application of a sufficient peeling force to filter14.
• Filter14 and cover18 also preferably each includetabs30aand30bthat are preferably aligned to provide a common grip for peelingfilter14,ingredients16 and cover18 frombody12.Tabs30aand30bmay then be separately gripped to peelcover18 away fromfilter14 andingredients16. This allows the user to dispose ofbody12,filter14,ingredients16 and cover18 in one of multiple desired locations.
• The choice of materials for the example shown inFIG. 7 include the following.Filter14 may be formed of ≧20% LDPE or LLDPE and cover18 may be formed of HDPE, PP or PS. In this case, first bonding material66 (sealing layer S1) and second bonding material70 (sealing layer S2) may be formed from HDPE, PP or PS. Alternatively, filter14 may be formed of ≦20% LDPE or LLDPE, PP, PA or Polyester and cover18 may be formed from LDPE, LLDPE, HDPE, EVA or a combination of these materials. In this case, first bonding material66 (sealing layer S1) and second bonding material70 (sealing layer S2) may be formed from LDPE, LLDPE, HDPE, EVA or a combination of these materials. It will be understood that other choices of materials may selected as well.
• Referring toFIG. 8, acontainer10 in accordance with another embodiment of the present invention is shown. The same reference numerals are provided for elements that are similar to the elements described above.
• Container10 includesbody12,filter14,ingredients16 andcover18. If desired,body12 and cover18 may each be formed of multilayered materials that include one or more barrier layers providing barriers against one or more environmental factors such as light, oxygen, and moisture as described further below.
• In this embodiment,filter14 is secured to sidewall20 ofbody12 by way offirst bond64 usingfirst bonding material66.First bond64 is a peelable bond as described above.Filter14 includestab30athat provides a grip for peelingfilter14 frombody12.Tab30ais preferably folded away fromflange28.
• Cover18 is secured to flange28 ofbody12 by way ofsecond bond68 usingsecond bonding material70.Second bond68 is also a peelable bond as described above.Cover18 includestab30bthat provides a grip for peelingcover18 frombody12.
• As a result, oncecontainer10 has been used for its intended purpose, a user will griptab30bto peel cover away frombody12. The user will then griptab30ato peelfilter14 together withingredients16 away frombody12. This allows the user to dispose ofbody12,filter14,ingredients16 and cover18 in one of multiple desired locations.
• The choice of materials for the example shown inFIG. 8 include the following.Filter14 may be formed of ≧20% LDPE or LLDPE and cover18 may be formed of LDPE, LLDPE, HDPE, EVA, modified PE or a combination of these materials. In this case, first bonding material66 (sealing layer S1) and second bonding material70 (sealing layer S2) may be formed from HDPE, PP or PS. Alternatively, filter14 may be formed of ≦20% LDPE or LLDPE, PP, PA or Polyester and cover18 may be formed from LDPE, LLDPE, HDPE, EVA or a combination of these materials. In this case, first bonding material66 (sealing layer S1) and second bonding material70 (sealing layer S2) may be formed from LDPE, LLDPE, HDPE, EVA or a combination of these materials. It will be understood that other choices of materials may selected as well.
• Referring toFIGS. 9-11, acontainer10 in accordance with another embodiment of the present invention is shown. The same reference numerals are provided for elements that are similar to the elements described above.
• Container10 includesbody12,filter14,ingredients16 andcover18. If desired,body12 and cover18 may each be formed of multilayered materials that include one or more barrier layers providing barriers against one or more environmental factors such as light, oxygen, and moisture as described further below.
• Instead of having a separation ofcover18 andingredients chamber46 frombody12, this embodiment provides a separation of one portion ofbody12, such asflange28, from the rest ofbody12.Cover18 withfilter14 definingingredients chamber46 containingingredients16 remains connected to the removed portion ofbody12, such asflange28, following such separation.
• Continuing with the example whereflange28 is being removed from the remainder ofbody12, aseparation point80 is defined inbody12 preferably proximate to the interface betweenflange28 andside wall20.Separation point80 may be a score line (a continuous indentation) or perforation line (a line of discrete indentations) that is adapted to break or separate upon the application of force.Separation point80 may be defined inbody12 either during or following the process for formingbody12 for instance by thermoforming. Theseparation point80 may be defined only in the outer surface (second surface12b) ofbody12 or it may be defined in both the outer surface and inner surfaces (second surface12bandfirst surface12a) ofbody12. Preferably,separation point80 is formed through an in-mold cutting process during thermoforming ofbody12 or at a separate station following formation ofbody12.
• In one variant as shown inFIG. 10,separation point80 may extend about circumference ofbody12 and be adapted to separate upon application of opposing twisting forces to flange28 and side wall20 (as shown inFIG. 6) similar to twisting a cap from a bottle.Separation point80 is shown defined inflange28 adjacent to the interface withside wall20. It will be understood thatseparation point80 could alternatively be defined inside wall20 proximate to interface withflange28.Filter14 may be bonded toside wall20 betweenseparation point22 andflange28.Filter14 is preferably formed of a non-woven material as described above but may alternatively be formed from a conventional paper filter material if desired since it is not subjected to significant tear forces.
• In another variant as shown inFIG. 11,separation point80 may be defined inflange28 about circumference ofbody12 and include a portion extending to peripheral wall offlange28 to definetab30 for peelingflange28 withcover18 and filter14 withingredients chamber46 from the remainder ofbody12.
• Referring toFIGS. 12-13, acontainer10 in accordance with another embodiment of the present invention is shown. The same reference numerals are provided for elements that are similar to the elements described above.
• Container10 includesbody12,filter14,ingredients16 andcover18. If desired,body12 and cover18 may each be formed of multilayered materials that include one or more barrier layers providing barriers against one or more environmental factors such as light, oxygen, and moisture as described further below.
• In this embodiment, cover18 is bonded withsecond bonding material68 to thefirst surface12aof body12 (top surface of flange28) in the same manner as described for the embodiments shown inFIGS. 1-6.
• Aseparation point80 is defined along at least one portion ofbody12, such asflange28, to form at least one tab30 (and preferably twotabs30 as shown).Separation point80 may be formed for example by a score line or perforation line that is adapted to break or separate fromflange28 upon the application of sufficient force. The force for instance may be applied by upward pressure, for instance by a person's thumb, along the bottom side oftab30 untiltab30 snaps and separates fromflange28.
• Separation point80 is preferably made through scoring or perforating during the same operation that is utilized forthermoforming body12 or at a subsequent station.Separation point80 may be defined along thesecond surface12bof body12 (bottom surface of flange28) without significantly disrupting or negatively impacting the ability ofcover18 to be peelably sealed to the top surface offlange28 such as described for the embodiments shown inFIGS. 1-6.Separation point80 may for instance extend a desired distance into the bottom surface offlange28 without breaking the top surface. Preferably,separation point80 is defined in both the outer surface and inner surfaces (second surface12bandfirst surface12a) ofbody12. Preferably, forcontainers10 formed of multilayered materials MM,separation point80 does not break or significantly disrupt the barrier layer B.
• Preferably, atab indicator82 is disposed onbody12 to indicate the location oftab30. Tab indicator may be embossed onto the outer surface ofsidewall20 ofbody12 in the same operation utilized forthermoforming body12.Tab indicator82 may alternatively be printed or adhered onto the material for formingbody12 at locations that align with themolds84 that are adapted for formation ofbody12 andseparation point80 as shown inFIG. 14.
• Following use ofcontainer10, allowing sufficient time for thecontainer10 to cool if necessary, a user will apply force totab30 along the bottom portion oftab30 until thetab30 snaps free from the remainder offlange28 alongseparation point80. The user may hear a snap sound to indicate thattab30 has separated fromflange28. The user then applies a peeling force totab30 in order to peelcover18 and filter14 with ingredientschamber containing ingredients16 frombody12.Body12 may be disposed into plastics recycling and cover18 and filter14 with ingredients chamber andingredients16 may be disposed into garbage destined for landfill or further processed or separated for disposal or recycling purposes.
• As noted earlier,container10 preferably is symmetrical with anannular flange28 having a uniform width W withseparation point80 definingtab30 within the uniform width W offlange28. This is preferable to having a portion offlange28 withtab30 extend beyond the uniform width W of the remainder offlange28 which could complicate the manufacture and packaging ofcontainer10 and which may prevent conta8iner from being utilized in amachine36.
• Referring toFIGS. 15 and 16, acontainer10 in accordance with another embodiment of the present invention is shown. The same reference numerals are provided for elements that are similar to the elements described above.
• Container10 includesbody12,ingredients16 andcover18. If desired,body12 and cover18 may each be formed of multilayered materials that include one or more barrier layers providing barriers against one or more environmental factors such as light, oxygen, and moisture as described further below.
• This embodiment ofcontainer10 is similar to the embodiment shown inFIGS. 12 and 13 but does not includefilter14. Atab30 is defined in body12 (preferably in flange28) byseparation point80.Cover18 is bonded bysecond bond68 to the portion of body12 (preferably to flange28) that includestab30 defined byseparation point80.Second bond68 is a peelable bond as described above to allowcover18 to be peeled away withtab30 from the remainder ofbody12.Tab indicator82 is provided, as described above, to assist the user in locatingtab30.
• This embodiment may be applied to a wide variety ofcontainers10. Theseparation point80 definingtab30 may be integrally formed within thebody12 ofcontainer10 without adding significant costs or adding significant complexity to the overall structure of the container.
• Referring toFIG. 17, acontainer10 in accordance with another embodiment of the present invention is shown. The same reference numerals are provided for elements that are similar to the elements described above.
• Container10 includesbody12,filter14,ingredients16 andcover18. In this embodiment,body12 comprisesflange28 and apartial side wall20 adapted to supportfilter14.Body12 does not include afull side wall20 andend wall22 for defining a fully enclosed interior space.
• In all other respects,container10 is similar to the embodiments described above with a portion ofcontainer10 being removable from the remainder ofcontainer10. For example, filter14 may be bonded to body12 (either to flange28 or side wall20) with afirst bond64 that is a peelable bond.Cover18 may be bonded to filter14 or to body12 (such as to flange28) with a second bond that may also be a peelable bond if desired.
• Referring toFIG. 18, acontainer10 in accordance with another embodiment of the present invention is shown. The same reference numerals are provided for elements that are similar to the elements described above.
• Container10 includesbody12,filter14,ingredients16 andcover18. If desired,body12 and cover18 may each be formed of multilayered materials that include one or more barrier layers providing barriers against one or more environmental factors such as light, oxygen, and moisture as described further below.
• In this embodiment,body12 further comprises ashoulder90 disposed inwardly fromflange28 to supportfilter14.Filter14 may be bonded to asupport ring92 that is adapted to either rest loosely uponshoulder90 as shown or be bonded to shoulder with afirst bond64 that is preferably a peelable bond (not shown).Cover18 is bonded to flange28 withsecond bond68 that is a peelable bond as described for the embodiments above.
• This embodiment of container allowsfilter14 to be disposed withincontainer10 without bonding to the same flange surface ascover18. Upon peeling awaycover18 following the use ofcontainer10,filter14 andingredients16 may be removed from container either by tipping container upside down (if ring rests loosely upon shoulder90) or by peeling away ring and filter14 preferably with the aid of a tab (not shown).
• Referring toFIG. 19, acontainer10 in accordance with another embodiment of the present invention is shown. The same reference numerals are provided for elements that are similar to the elements described above.
• Container10 includesbody12,filter14,ingredients16 andcover18. If desired,body12 and cover18 may each be formed of multilayered materials that include one or more barrier layers providing barriers against one or more environmental factors such as light, oxygen, and moisture as described further below.
• In this embodiment,container10 is similar to the container shown inFIG. 18.Shoulder90 includes aslot94 that is adapted to receive a portion offilter14 andsupport ring92.Support ring92 is preferably configured to supportfilter14 withinslot94 by way of a friction fit.
• This embodiment of container also allowsfilter14 to be disposed withincontainer10 without bonding to the same flange surface ascover18. Upon peeling awaycover18 following the use ofcontainer10,filter14 andingredients16 may be removed from container by peeling away ring and filter14 preferably with the aid of atab30.
• Referring toFIG. 20, acontainer10 in accordance with another embodiment of the present invention is shown. The same reference numerals are provided for elements that are similar to the elements described above.
• Container10 includesbody12,filter14,ingredients16 andcover18. If desired,body12 and cover18 may each be formed of multilayered materials that include one or more barrier layers providing barriers against one or more environmental factors such as light, oxygen, and moisture as described further below.
• In this embodiment,container10 is similar to the container shown inFIG. 19 however noshoulder90 is provided. Instead, slot94 is defined inflange28.Slot94 is adapted to receive a portion offilter14 andsupport ring92.
• Cover18 is bonded to supportring92 as well as to flange28 by a peelable bond. Upon peeling awaycover18 following the use ofcontainer10,filter14 andingredients16 may be removed from container.
• While the above description provides examples of one or more processes or apparatuses, it will be appreciated that other processes or apparatuses may be within the scope of the accompanying claims.

Claims (27)

I/We claim:

1. A container comprising:

a body defining an interior space having an opening;

a filter disposed in said interior space to define an ingredients chamber, said filter being bonded to said body with a first bond, said first bond being a peelable bond;

ingredients disposed in said ingredients chamber;

a cover disposed over said opening for covering said interior space, said cover being bonded to said filter at a periphery to said opening with a second bond;

wherein said cover is adapted to be removed together with said filter upon the application of sufficient force by hand following use of the container.

2. A container as claimed inclaim 1, further including a tab adapted for providing a grip to remove said cover with said filter and said ingredients chamber from said body.

3. A container as claimed inclaim 1, wherein a notch is defined in the interior surface of said body, said notch providing a predicted point of weakness in said body.

4. A container as claimed inclaim 3 wherein said notch extends substantially about the periphery of said opening.

5. A container as claimed inclaim 3 wherein said body is formed of a multilayered material that includes a barrier layer disposed between a sealing layer and an outer layer, and wherein said notch is defined in said sealing layer.

6. A container as claimed inclaim 1, wherein said filter has a basis weight in the range of 8 to 400 gsm.

7. A container as claimed inclaim 2, wherein said tab is formed from said cover.

8. A container as claimed inclaim 2, wherein said tab is formed from a portion of said body defined by a separation point at a location where said filter is bonded to said body.

9. A container as claimed inclaim 8, wherein said separation point is defined in said flange of said body to define said tab.

10. A container as claimed inclaim 1 wherein said first bond is formed with a first bonding material disposed between a first surface of said filter and a first surface of said body.

11. A container as claimed inclaim 1, wherein said body is formed of a multilayered material that includes a barrier layer disposed between a sealing layer and an outer layer, and wherein said first bond between said filter and said body is formed with said sealing layer.

12. A container comprising:

a body defining an interior space having an opening, said body having a flange surrounding said opening;

a filter disposed in said body to define an ingredients chamber, said filter being bonded to a first surface of said flange with a first bond, said first bond being a peelable bond;

a separation point defined in said flange, said separation point defining a tab that is adapted to be separated from the remainder of said flange upon the application of sufficient force by hand;

ingredients disposed in said ingredients chamber;

a cover disposed over said opening for covering said interior space, said cover being bonded to said filter with a second bond,

wherein said tab and said cover is adapted to be removed together with said filter and said ingredients chamber containing said ingredients following use of the container by the application of force by hand.

13. A container as claimed inclaim 12, wherein said flange has a uniform width.

14. A container as claimed inclaim 12, further comprising a tab indicator disposed on the exterior of said body to indicate the location of said tab.

15. A container as claimed inclaim 12, wherein a notch is defined in the interior surface of said body, said notch providing a predicted point of weakness in said body.

16. A container as claimed inclaim 15 wherein said notch extends substantially about the periphery of said opening.

17. A container as claimed inclaim 15 wherein said body is formed of a multilayered material that includes a barrier layer disposed between a sealing layer and an outer layer, and wherein said notch is defined in said sealing layer.

18. A container as claimed inclaim 12, wherein said body is formed of a multilayered material that includes a barrier layer disposed between a sealing layer and an outer layer, and wherein said first bond between said filter and said body is formed with said sealing layer.

19. A container comprising:

a body defining an interior space having an opening, said body having a flange surrounding said opening;

a separation point defined in said flange, said separation point defining a tab that is adapted to be separated from the remainder of said flange upon the application of sufficient force by hand;

ingredients disposed in said ingredients chamber;

a cover disposed over said opening for sealing said interior space, said cover being bonded to said flange with a peelable bond;

wherein said cover is adapted to be removed by the application of sufficient force by hand to separate said tab and peel said cover from the remainder of said flange.

20. A container as claimed inclaim 19, wherein said flange has a uniform width.

21. A container as claimed inclaim 19, further comprising a tab indicator disposed on the exterior of said body to indicate the location of said tab.

22. A container as claimed inclaim 19, wherein a notch is defined in the interior surface of said body, said notch providing a predicted point of weakness in said body.

23. A container as claimed inclaim 22 wherein said notch extends substantially about the periphery of said opening.

24. A container as claimed inclaim 22 wherein said body is formed of a multilayered material that includes a barrier layer disposed between a sealing layer and an outer layer, and wherein said notch is defined in said sealing layer.

25. A container as claimed inclaim 19, wherein said body is formed of a multilayered material that includes a barrier layer disposed between a sealing layer and an outer layer, and wherein said first bond between said filter and said body is formed with said sealing layer.

26. A container comprising:

a body defining an interior space having an opening, said body having a flange surrounding said opening;

a separation point defined in said body around its circumference at a desired location for separating one portion of said body from the remainder of said body,

ingredients disposed in said ingredients chamber;

a cover disposed over said opening for covering said interior space;

wherein said separation point is adapted to provide a point of separation under the application of sufficient force to separate a portion of said body, including said flange with said cover, from the remainder of said body.

27. A container as claimed inclaim 6, wherein said force is an opposing twisting force applied to said flange and the remainder of said body.

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