Resealable tray container

A container for food product includes a film affixed to a food tray. The film forms a top of the container and has an access opening. The sealing label, adhesively sealed to the top around the opening, is resealable when a tab of the sealing label is pulled back. The sealing label is resealable against the top layer to seal the opening when the label is moved back against the top. In one form, the sealing label extends along the top of the container and seals along a portion of the film which is affixed to one or more top end surfaces of walls forming the tray.

FIELD OF THE INVENTION

The present invention relates to a resealable tray and in particular to a new and improved resealable tray having a sealing label which can be pulled back and resealed against a top portion of the container.

BACKGROUND OF THE INVENTION

Containers for food products often come packaged in plastic trays. One conventional type includes a thermoformed tray. Several conventional lidding materials are available for covering conventional food trays. Lidding materials may be metal foil, flexible plastic wrap or rigid plastic.

One such package disclosed in U.S. Pat. No. 6,726,054 is designed for containing breath films or other oral care strips in which the package includes a blister pack having a hinged flap which is resealable against the top surface of the blister pack. The package has a top surface which forms a flange around the perimeter opening of the tray compartment. Another package which is disclosed in U.S. Pat. No. 6,691,886 shows a plastic tray with lid film which includes a sealing area around its perimeter which seals to a flange surface of the tray. U.S. Pat. No. 5,647,506 discloses another resealable container comprising a dispenser for moisture-impregnated articles such as moist tissues using a rigid plastic container with an opening formed in its top surface. A resealable label reseals the top opening.

In another prior dispensing package manufactured under the trade name RESEAL-IT, a thermoformed tray includes a lidding film affixed to an upper flange which encircles the opening of the tray. The lidding includes a die cut flap. A label larger than the flap opening is placed over the flap and spans completely across the lidding between but not onto the flange surfaces of the package. Thus, the label abuts the flange but does not extend onto the flange surface.

U.S. Pat. No. 4,156,493 discloses a reclosable dispenser packet. In one form, the packet includes a semi-rigid container which is thermo-formed or injection molded. A thin, flexible material such as vinyl film or aluminum foil is sealed to a flange of the container. An opening is cut into the flexible material. An adhesive flap is placed over the cut opening and seals with the container top so that the cut portion is permanently affixed to the adhesive flap as it is withdrawn from the top to expose the container opening.

There exists a need in the art for improved resealable containers suitable for containing food items.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a new and improved container for food products. The food products may include but are not limited to discrete food items such as cookies, peanuts, cubed or shredded cheese, or other snack items; sliced meats such as cold cuts and bacon, both uncooked and ready-to-eat/ready-to-serve/pre-cooked, and sliced cheese; food spreads such as cream cheese and semi-solid foods such as chocolate dipping sauce and pudding. The container provides protection for the food contents while concurrently facilitating opening of the container and resealing the seal to protect the unused food contents thereof until the contents are fully consumed.

This purpose is achieved by providing a suitable tray for a desired food product in combination with an easily accessible opening seal formed in a top surface, which seal can reseal the container during use. The container can be of any shape including polygonal, such as square or rectangular, cylindrical or in the shape of a tub. The tray portion of the package may have sides which extend upwardly from the bottom of the tray and terminate at their ends or the sides which may include a flanges which extend either inwardly or outwardly relative to the interior of the tray.

In accordance with one embodiment, the present invention comprises a food container comprising a tray having a bottom and sides. The sides have a top end surface opposite the bottom. A film is affixed to the top end surface of the side and the film forms a top over the tray. A sealing layer is provided which has a sealing area adhesively sealing the sealing layer along its perimeter to the film around the opening. The sealing area terminates prior to reaching any side forming the tray. The sealing layer is releasable when the sealing layer is pulled in a direction away from the side to in turn pull and thereby release a portion of the sealing layer to provide access to the top access opening and resealable against the top to seal the opening when the sealing layer is moved back against the top.

In alternative further embodiments, the sealing layer includes a starter portion which can be grasped by a user and the starter portion may comprise a tab which extends from the sealing area of the sealing layer. The film may be composed of different materials which may be flexible, rigid or semi-rigid. In addition, the tray may be composed of either a rigid or semi-rigid material.

In accordance with another aspect of the present invention, a food container comprises a tray having a bottom and sides. The sides have a top end surface opposite the bottom. A food product is disposed in the tray. A film is affixed to the top end surface of the sides of the tray which forms a top over the tray. A sealing layer includes a sealing area adhesively sealing the sealing layer along its perimeter to the top around the opening and terminating prior to reaching any side forming the tray. The sealing layer is releasable when the sealing layer is pulled in a direction away from the side to in turn pull and thereby release at least a portion of the sealing layer to provide access to the top opening and resealable against the top to seal the opening when the sealing layer is moved back against the top.

In accordance with another aspect of the present invention, a food container comprises a tray having a bottom and sides. The sides have a top end surface opposite the bottom. A film is affixed to the sides, thereby forming a top over the tray. The top has an access opening to allow access to the contents inside the container. A sealing layer, having a sealing area, adhesively seals the sealing layer along its entire perimeter to the film around the access opening and extends along the film to overlap at least a portion of the film which is affixed to the top end surface of the side. The sealing layer is releasable when the sealing layer is pulled in a direction away from the side to, in turn pull, and thereby release a portion of the sealing layer to provide access to the access opening and is resealable against the top to seal the opening when the sealing layer is moved back against the top.

In alternative further embodiments, the sealing layer overlaps the film along at least a portion of the film at each side to which the film is affixed, and a starter portion comprises a tab extending from a corner of the sealing layer.

Thus, it is an object of the present invention to provide a new and improved resealable container comprising a tray with a film top.

These and other objects of the present invention will become apparent from the detailed description which follows.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings, like elements are represented by like numbers throughout the several views.

Referring toFIGS. 1-3, resealable container10includes tray11which forms bottom13and opposing sides14aand14band opposing ends15aand15b. A flange16extends outwardly from the exterior surface of the opposing sides14a,14band15a,15b. Tray11is preferably manufactured as a thermoformed tray. Alternatively, any other appropriate manufacturing process and materials can be used to form a tray which is suitable for use in accordance with the present invention.

Film17is affixed to flange16. Film17may be composed of a flexible material, semi-rigid material or a rigid material. A broken line21indicates the exterior surface of the respective sides14a,14,b,15a,15bfrom which the flange16extends which is covered by film17.

Alternatively, tray11may not include flange16, in which case, film17is affixed to the end surface of sides14a,14b,15a,15b, opposite bottom13where the sides14,15are sufficiently thick to allow the film17to be affixed to end surfaces thereof. In another alternative embodiment, the flange may extend inwardly toward the center of the container rather than outwardly as depicted in container10.

A flap18is cut in the film17as indicated by broken line23. As depicted inFIGS. 1 and 2, flap18is cut completely around its perimeter on all sides. Alternatively, the flap may only be cut on part of its perimeter, such as three sides, leaving the fourth side attached to the film17. When flap18is pulled back from the container10, it forms opening19.

A sealing layer in the form of a sealing label20is affixed to the flap18. Advantageously, the sealing label20is permanently affixed to the flap18using an appropriate, first adhesive. The sealing label20covers a substantial portion of the top formed by film17, extending from the proximity of end15ato the proximity of end15band from the proximity of side14ato the proximity of side14b. The sealing area of label20, i.e., the portion of sealing label20which is resealably affixed to top12, terminates prior to any side14a,14b,15a,15bof container10. Thus, the sealing area does not abut or extend completely to any end surface or flange of any side of container10.

The size of the opening19and hence the size of flap18is at least around 30% of the surface area of film17and advantageously at least 50% the surface area of film17so as to more easily gain access to the food contents contained within container10.

The surface area of sealing label20is advantageously proportional to the size of opening19. Advantageously, the surface area of the sealing label should be approximately 1.3 to 2 times and more preferably around 1.8 times the size of opening19. Further, it is advantageous to have the size of opening19be proportional to the size of container10and food products.

Graphics may be formed on the sealing label20which align with corresponding graphics on top12when the sealing label20is sealed or otherwise in a flap position on top12. Alternatively, sealing label20may be transparent, allowing the graphics of top12to be visible through the sealing label20.

A starter portion, for example a tab22, extends from sealing label end24. As a result, tab22can be grasped by one's fingers and thumb such that the tab22is easily accessible for one to pull. Further, the tab22facilitates closing of the container. The side of tab22and its shape are optimized for functionality. Advantageously, the tab22has a surface area of 1% to 6% that of the total surface area of sealing label20.

Adhesive26is applied to sealing area27which is in contact with top12along a perimeter of flap18. Advantageously, the second adhesive26provides a removable seal between the sealing label20and the top12. As the first adhesive permanently affixes the sealing label20to the flap18and the second adhesive26provides a removable seal, the strength of the first adhesive is greater or stronger than the second adhesive. Adhesive26is not applied to tab portion22. Alternatively, if adhesive is applied to the back surface of tab portion22, i.e., the surface adjacent the sealing area27, a deadening agent, either chemical or a layer is applied thereto, to prevent the tab portion22from adhering to the top12.

The absence of an adhesive on tab22or the application of a deadening agent to the back surface of tab22allows a consumer to more easily grasp the starter portion in order to open the container10since tab22will not be adhered to the top12. In addition, by giving a consumer a specific portion of the sealing cover to pull, the consumer is not drawn to touching the adhesive portion of the sealing label20. Such touching could cause the sealing layer to lose its adhesiveness and thus not provide a proper reseal against the top12of the container10. This could, in turn, allow air to gain access to the interior of the container10and the food product contained therein.

Container10is transformed from a closed condition shown inFIG. 1to a partially opened condition depicted inFIG. 2by grasping the tab22between one's finger and thumb and pulling back on the sealing layer20to gain access to opening19. Once container10is opened, one can remove food product28such as cookies inside the food container through opening19. Although the food product28is depicted as cookies, the food product28can be virtually any food item which includes but is not limited to discrete food items such as cookies, peanuts, cubed or shredded cheese, or other snack items; sliced food items such as sliced deli meats or sliced cheese; solid food items such as a brick of cheese and semi-solid food items such as food spreads, cream cheese, chocolate dipping sauce and pudding.

In an alternative form of the present invention, container40has a hexagonal shape formed by tray41depicted inFIG. 4. Aspects of the functionality of the opening of container40are identical to those of container10except for those distinctions described herein. Film47is affixed to the top ends of sides45which unlike container10does not include an extending flange. The sides45are sufficiently thick to allow the film47to be affixed to end surfaces thereof. Flap48is die cut into film47on five sides leaving a sixth side45buncut as indicated by broken line49, thereby permanently attaching flap46to film47on that sixth side45b. Tab42extends from side45awhich advantageously allows one to easily grasp the tab44. Like tab22, there is no adhesive on the bottom surface of tab44so that tab44is not sealed to film47. Further, although tab42extends past side45a, the sealing area of sealing label46does not extend all the way to sides45. Pulling back on tab42allows one to remove sealing layer46affixed to flap48to gain access to the contents of container40.

In an alternative embodiment,FIG. 5depicts a generally cylindrical container50with circular sealing label56with tab52sealed to film57. The access opening and flap are shown by broken line59.FIG. 6depicts yet another shaped container60having a contoured half peanut-shaped form for holding food product68such as peanuts. In the embodiments ofFIGS. 5 and 6, as in the embodiments ofFIGS. 1-4, one gains access to the contents of containers50,60by pulling back on tabs52,62of sealing labels56,66, respectively, and reseals container50by returning sealing label56,66to its original position over the film57,67. If necessary, one can apply pressure to sealing label56,66, when relocated over film57,67to ensure a sufficient seal is achieved therebetween.

In an additional alternative embodiment,FIGS. 7 and 8depict container70which is similar to container10, where like elements have reference numbers increased by60, but differs from container10in that sealing label80extends along film77to overlap a portion of film77affixed to flange76, along the entire perimeter of top72. Broken line81is used inFIGS. 7 and 8to delineate the sides74,75covered by both film77and sealing label80. Broken line83is used inFIG. 7to depict the die cut forming flap78. A tab82extends from a corner of the sealing area of sealing label80. One gains access into the container70by pulling back on tab82of the sealing label80, thereby exposing opening79.

One advantage of having the sealing label80overlapping the film77along a portion of the film77which is affixed to the flange76is that this configuration allows one to reseal the container70by pressing the flexible sealing label80along a more rigid flange material of the tray rather than an unsupported portion of the film.

The present invention offers numerous features and advantages over previous food containers. For example, in one form, the present invention includes a tab element which extends beyond a corner or edge of a top or side of the container which makes the tab easily accessible for being grasped and for withdrawing the sealing label from the container.

Another feature of the present invention is provided by a resealable sealing label which can be pulled back and resealed against a top portion of a flexible or rigid container.

Yet another feature of the present invention is provided by a sealing layer which extends over an opening in a container, but terminates prior to reaching any side of the container.

Although the invention has been described above in relation to preferred embodiments thereof, it will be understood by those skilled in the art that variations and modifications can be effected in these preferred embodiments without departing from the scope and spirit of the invention.