Cylindrical container and serving bowl

A cylindrical container having a plastic overcap and flexible panels that can be assembled into a serving bowl are provided. The cylindrical container may hold snack foods or other items. The flexible bowl panels lock together and may mate with the overcap to form the serving bowl. The flexible bowl panels may be packaged outside one or more cylindrical containers or may fit inside a container.

BACKGROUND OF THE INVENTION

Field of the Invention

This disclosure relates to a container for holding snack foods and other items. More particularly, this disclosure relates to a cylindrical container for holding snack foods and other items that can be transformed into a bowl-like serving container, or a container system comprising a cylindrical container and flexible interlocking panels that can be stored either inside or outside the cylindrical container and assembled into a serving bowl.

Description of the Related Art

Composite containers are commonly used to hold snack foods, drink mixes and other consumable foods. A typical composite container has a cylindrical body or sidewall, a plastic or metal bottom and a plastic overcap. The container body may be comprised of a polyfoil inner liner, a paperboard structural layer and a paper outer label. The polyfoil inner layer has a moisture-proof thermoplastic layer that may contact the container contents, a metallic foil layer adjacent the thermoplastic layer, and an outer paper layer. A membrane seal may be positioned under the plastic overcap and sealed to the top edge of the container to help maintain the freshness of the contents and extend its shelf life. To access the contents the user lifts off the overcap and peals away the membrane seal.

When used for snack foods, such containers do not readily lend themselves to sharing the contents of the container unless the container is passed around. The present disclosure is designed to address this problem by providing a container that can be transformed into a serving container for easy sharing or a container system comprising a cylindrical container and flexible interlocking panels that can be stored either inside or outside the cylindrical container and assembled into a serving bowl.

BRIEF SUMMARY OF THE INVENTION

The present disclosure relates to a container for holding a product such as snack food.

In a first embodiment a segmented container is transformable into a serving bowl.

In a second embodiment a container system is provided comprising a cylindrical container and flexible panels that can be locked together to form a bowl using an overcap as base.

In a third embodiment a container system is provided comprising a cylindrical container and flexible panels that can be locked together to form a bowl with integral bottom tabs as a base.

In a fourth embodiment a container system is provided comprising a cylindrical container and flexible panels that can be removed from the container and locked together to form a bowl using an overcap as base.

In a fifth embodiment a container system is provided comprising a cylindrical container and flexible panels that can be removed from the container and locked together to form a bowl with integral bottom tabs as a base.

In a sixth embodiment a pleated container is transformable into a serving bowl.

DETAILED DESCRIPTION OF THE INVENTION

While the invention described herein may be embodied in many forms, there is shown in the drawings and will herein be described in detail one or more embodiments with the understanding that this disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the disclosure to the illustrated embodiments.

First Embodiment—Container Transforms into a Bowl

Turning to the drawings, there is shown inFIG. 1-5one embodiment of the disclosure, a container10for holding a product48such as snack food or other items, the container10being transformable into a serving bowl.

FIG. 1is a perspective view of the container10. The container10comprises a sidewall12, an overcap14, a bottom or end cap16, an inner sleeve18and an optional seal membrane20. The plastic overcap14is removably secured to the top rim22. The plastic overcap14may have a covering portion44and a sidewall46extending orthogonally from the periphery of the covering portion44and may form a snap fit with the beaded top rim22. The end cap16may be permanently secured to the bottom rim24. The end cap16may be made from plastic, metal or any other suitable material and may be glued or otherwise affixed to the bottom rim24.

FIG. 2is perspective view of the container10with the wrapped product11removed and the container10partially transformed into a bowl.FIG. 3is perspective view of the container10shown transformed into a bowl and holding the product48. The product48may be snack food or any suitable product.

FIG. 4is an exploded view of the container10ofFIG. 1shown without the inner sleeve18or wrapped product11. The sidewall12, overcap14and end cap16define an interior30for holding the product48. The seal membrane20may be adhered to the top rim22by glue or by any suitable means. The sidewall12is cylindrical and has a top rim22and a bottom rim24and defines a longitudinal central axis (A). Preferably the top rim22is beaded and the bottom rim24is straight (not beaded).

The sidewall12comprises a plurality of longitudinally extending sidewall panels26. Eight sidewall panels26are shown in the figures, although the sidewall12may be divided into any suitable number of panels26. In the unopened container10each sidewall panel26is connected to adjacent sidewall panels26by frangible (breakable) lines28. The frangible lines28may be perforated lines, scored lines, slits or any other suitable frangible lines that allow the sidewall panels26to be broken apart by a consumer. Each sidewall panel26has an inner facing surface32and extends from the top rim22down to a circumferential hinge line34or to the bottom rim24. The hinge line34may be scored and may be located about ¼ inch above the bottom rim24. The frangible lines28may extend from the top rim22down to the circular hinge line34or to the bottom rim24.

The sidewall panels26may be somewhat rigid as is characteristic of containers of this kind. The sidewall panels26are rotatable about the hinge line34between a first position (shown inFIGS. 1 and 4) in which the sidewall panels26are vertically upright to form the cylindrical sidewall12, and a second position (shown inFIG. 3) in which the sidewall panels26are splayed outwardly, away from the central axis (A), so that the inner sleeve18forms a bowl-like truncated cone shaped structure large enough to hold the product48of one or more containers10.

The sidewall12may be any suitable construction. For example, the sidewall12may comprise a polyfoil inner liner, a paperboard structural layer and a printed-paper label wrapped around the paperboard structural layer and adhered thereto. The polyfoil inner liner may comprise, from the inside out, a thermoplastic layer (typically polyethylene or polypropylene), a metal foil layer, a second thermoplastic layer and a paper layer, the paper layer adjoining and bonded to the paperboard structural layer of the sidewall12.

The inner sleeve18is disposed in the interior30between the product48and the sidewall12. Preferably the inner sleeve18is flexible and is adhered to the inner facing surface32of each sidewall panel26. The inner sleeve18may be folded over upon itself to form a substantially cylindrical structure in the closed container10. When the container10is transformed into a serving bowl the inner sleeve18unfolds to assume a bowl shape.

The inner sleeve18may comprise, from the inside out, a thermoplastic layer (typically polyethylene or polypropylene), a metal foil layer, a second thermoplastic layer and a paper layer, the paper layer adjoining and bonded to the sidewall panels26.

FIG. 5is a planar view of a sheet19of material that may be used to make the inner sleeve18. The sheet19has a curved top edge37and a curved bottom edge39and comprises a plurality of substantially rectangular inner sleeve panels36. The inner sleeve panels36are connected along vertical inner sleeve fold lines38on either side to first and second triangular gusset panels40,42. The first gusset panels40may extend from a point along the sheet bottom edge39to the sheet top edge37. The second gusset panels42may extend from the same point along the sheet bottom edge39to the sheet top edge37and are foldably attached to the first gusset panels40along a gusset fold line41. The sheet19may be folded along the fold lines38and along the gusset fold lines41to form the inner sleeve18shown in the figures. The inner sleeve panels36may be of similar dimensions to the sidewall panels26and are affixed to the inner facing surfaces32of the sidewall panels26so that the vertical fold lines38in the inner sleeve18substantially coincide with the frangible lines28in the sidewall12. The gusset panels40,42extend in accordion fashion between the sidewall panels26.

Method of Manufacture

The container10may be made as follows:1. Wind a web of material into a cylindrical tube.2. Cut the tube into can bodies.3. Convey the can bodies to rotary perforation unit.a. Load the can bodies onto a mandrel.b. Perforate or otherwise weaken the can bodies along a plurality of longitudinally oriented lines to form a sidewall12having frangible lines28.4. Bead the sidewall top rim22. Apply an end cap16.5. Convey the sidewall12to an inner sleeve insertion station.6. At the inner sleeve insertion station:a. Apply hot melt adhesive (web design) in two adhesive locations on each sidewall panel26(middle and top).b. Insert a pre-folded/pleated inner sleeve18and apply pressure from inside the inner sleeve18to the adhesive locations.c. Discharge the sidewall12to a product filling station.7. Fill with product48.8. Apply a seal membrane20and an overcap14.

Second Embodiment—Separate can and Bowl; Overcap Used as Bowl Base

FIG. 6is a planar view of a retail package55according to a second embodiment. The retail package55includes three containers50and two bowl panels56. The containers50are positioned in a tray51and the bowl panels56are wedged between the containers50and the tray51on either side of the containers50. (One bowl panel56inFIG. 6is obscured by the containers50.) Transparent flexible wrap53may be used to secure and protect the retail package55. As explained in more detail below, the flexible bowl panels56fit together to form a bowl shaped serving container57. The flexible bowl panels56may be packaged with one or more of the containers50and may be configured to fit closely with the outside contours of one or more containers50.

FIG. 7is an exploded view of one of the containers50ofFIG. 6. The container50may be conventional in design and may have a cylindrical sidewall54, an overcap14, a seal membrane20and a bottom or end cap16. The sidewall54, overcap14and end cap16define an interior30for holding the product (not shown). The cylindrical sidewall54has a beaded top rim58and a bottom rim60. The overcap14is removably secured to the top rim58. The end cap16is secured to the bottom rim60.

FIG. 8is a front planar view of the two bowl panels56ofFIG. 6. Each flexible bowl panel56may be formed from a flat blank and have a top edge65, a bottom edge66and side edges67,68extending between the top edge65and the bottom edge66. Locking tabs62extend outwardly from one side edge67. Slots64located near the other side edge68are configured to receive the locking tabs62. To construct a two piece “bowl” shaped serving container57, each bowl panel56may be bent so that the top edge65and the bottom edge66both describe a 180 degree arc.

FIG. 9is a side perspective view of an assembled bowl or serving container57according to the second embodiment. The flexible bowl panels56are configured to lock together to form a truncated cone, the truncated cone having a circular bottom rim60configured to mate with the overcap14to form a bowl shaped serving container57large enough to hold the product48(not shown) of one or more containers50. The bowl panels56may lock together in tab62in slot64fashion. The outer surface59of each bowl panel56may carry graphics while the inner surface61may be treated to make it suitable for contacting food.

In another aspect, the bowl panels56may be folded up and placed inside the container50.FIG. 10is an exploded view of a container assembly70comprising a container50, a seal membrane20, an overcap14and two bowl panels56. The container50may comprise a sidewall54and an end cap16. Instead of being packaged outside the containers50like inFIG. 6, the bowl panels56are rolled up and placed inside the container50. The product48is contained in a flexible wrapper11and placed inside the container50within the space defined by the rolled up bowl panels56.

The bowl panels56may be the same as or similar to those depicted inFIG. 8, and may be formed from a blank comprising locking tabs62and slots64. The bowl panels56lock together to form a truncated cone shape having a circular bottom rim60configured to mate with the overcap14to form a bowl shaped serving container57.

Second Embodiment—Separate can and Bowl; Tabs Form the Bowl Base

Alternatively, the container assembly70may comprise two flexible bowl panels72having bottom tabs78that form the bowl base.

FIG. 11is a front planar view of such a bowl panel72. The bowl panel72is formed from a flat blank comprising a main panel74having a top edge75, a bottom edge76and side edges77,79extending from the top edge75and converging toward each other until they terminate at the bottom edge76. A plurality of locking tabs73extend laterally outwardly from one side edge77. Slots81located near the other side edge79are configured to receive the locking tabs73of a second bowl panel72. Unlike the bowl panels56inFIGS. 8 and 9, the bowl panels72further comprise a plurality of bottom tabs78rotatably connected to the bottom edge76. The tabs78are configured to interlock to form the bottom82of the bowl80.

FIG. 12is a top view an assembled serving bowl80made from two bowl panels72like the one shown inFIG. 11. The two bowl panels72lock together to form a truncated cone shaped serving bowl80large enough to hold the product48of one or more containers50. For a two piece “bowl”, each panel72may be bent as shown inFIG. 12so that the top edges75and the bottom rims76both describe a 180 degree arc.

The bowl panels72may be packaged with one or more the containers50and may be folded, bent or otherwise configured to fit closely with the outside contours of one or more container50. Alternatively, the bowl panels72may be rolled up and placed inside the container50. The product may be contained in a flexible wrapper11and may be located inside the rolled up bowl panels72.

Third Embodiment—Pleated Container

In a third embodiment shown inFIG. 12a container100is provided comprising a pleated container body102, an overcap104and a label106.

The pleated container body102is substantially cylindrical and has a bottom wall110and a sidewall112that defines a longitudinal central axis (A). The sidewall112may have a beaded or unbeaded top rim108.

The plastic overcap104may be removably secured to the top rim108. The pleated container body102and overcap104define an interior130for holding the product (not shown).

The label106encircles the sidewall112and keeps the pleated container body102from opening up.

The pleated container body102is configured to splay outwardly after the label106has been removed, away from the central axis A, to form a frustoconical shaped structure—similar to the bowl-like structure116shown inFIG. 12, large enough to hold the product of one or more containers100.

Method of Manufacture

The container100may be made as follows:

Step 1: Provide a round flat body blank114. The body blank114may be pre-folded

Step 2: Form the flat body blank114around a cylindrical mandrel to create a cylindrical or container shaped pleated container body102having a bottom wall110and a sidewall112.

Optionally, form a bead on the top rim of the sidewall112using a forming machine. This step is not shown inFIG. 12.

Step 3. Apply the overcap104onto the top rim108of the pleated container body102.

Step 4. Convey the pleated container body102to a labelling unit and apply a label106to the pleated container body102using a convolute winding machine to create the finished container100.

It is understood that the embodiments of the invention described above are only particular examples which serve to illustrate the principles of the invention. Modifications and alternative embodiments of the invention are contemplated which do not depart from the scope of the invention as defined by the foregoing teachings and appended claims. It is intended that the claims cover all such modifications and alternative embodiments that fall within their scope.