Containers With Removal Tray Inserts

A packaging system is provided wherein a main container is used having an inner ledge section on which one or more insert containers can rest. The ledge is provided below the rim of the main container so that the insert container is supported within the main container, but does not interfere with closing of the main container. The main container and insert containers also preferably include corresponding ridge and recess sections that provide interference fitting of the insert container into the main container. This prevents unwanted movement of the insert container within the main container. The packaging system allows the producer and user to stock, ship and use only the components suited for their particular use, and thus provides flexibility in their particular applications.

FIELD OF THE INVENTION

This invention relates to containers which are primarily used for foodstuffs, but which may also be used for a variety of other products. The claimed containers utilize a container insert system so that the main container components, which includes foodstuffs or the like, can be placed into the main container section, and various other components (e.g. condiments, dressings, utensils, and the like), are added to the main container by use of specifically designed inserts. By use of the system, the other components are kept separate from the main components, but are readily available for use by the consumer, immediately prior to consumption.

BACKGROUND OF THE INVENTION

Clear plastic containers are commonly used for the sale and distribution of a variety of foodstuffs. These include foodstuffs such as lettuce, or other salad greens, strawberries and other berries, prebaked pastries, cookies or cakes, and other foodstuffs which lend themselves to being pre-packaged. Commonly, these types of foodstuffs are intended for use with other components such as condiments, dressings, creams, sauces, and the like, which are to be kept separate from the main components. This keeps the components separated prior to use, allows the consumer to control the amount of other component to be added, and/or aids in delaying or preventing the onset of spoilage in the main component. Currently, this type of separation of components is accomplished by merely inserting a loose, smaller container within the larger main container. This could include a sealed plastic bag of the other component, but might also include one or more small plastic containers which are added to the main container. Typically, these bags or smaller containers are merely inserted into the main container (before or after filling the main container with the main component), and then the main container can be closed or otherwise sealed for delivery to the retailer, or consumer. This allows the bags or smaller containers to move within the larger container which can make them difficult to locate, or leads to an unattractive packaging appearance in which the other component container is merely loose in the main container.

Other approaches include the “Take ‘n’ Go”™ containers, available from Amhil Enterprises, as described in US Patent Publication No. 2013/0068772, in which a small container is affixed to the lid of the larger container prior to closing the larger container, so that the one lid covers both containers. However, it is not always practical or easy to take this approach for a container which includes a hinged lid permanently affixed to the main container body. Moreover, there is no capability of providing multiple smaller containers within the main container body.

In another approach, an inner container is fitted within the body of the main container. Most of these types of containers include a peripheral sealing rim section that extends around the upper section of the main container. The lid includes a corresponding peripheral recess section around its outer edge which is adapted to receive and hold the rim section, and thus, substantially seal the main container. In this prior art approach, the inner container rests on the upper, sealing rim section of the main container body. However, this approach interferes with sealing of the main component lid to the main component body, and as such, leakage can occur. Also, if the other components protrude above the upper level of the other container to any extent, they can interfere with proper closing of the main container.

Also, if the inner container is smaller than the main container, the inner container can move within the main container body as the main container is handled or flexes. As a result, the inner container can become loose within the main container body. This provides a poor appearance to the consumer, and can act to loosen the lid since the inner container no longer rests on the main container rim section.

Moreover, there is no system currently in place wherein a variety of different sized and shaped inner containers can be selected and used for a selected main container, depending on the relevant application.

Accordingly, it would be beneficial to the industry to provide a container having a container insert, which overcame all or at least some of these issues.

SUMMARY OF THE INVENTION

In keeping with the present invention, there is provided a packaging system, comprising a main container having a main container body and an optional lid, wherein, when present, the optional lid and main container body include a closing mechanism so that the lid will substantially close the main container body, andat least one insert container which is smaller than said main container body, and which is capable of being fitted within said main container body,wherein said main container body includes connected side sections and a bottom section, a rim section around the upper surface of the main container body, a inwardly extending ledge, preferably on one or more of the sides of the main container, below the rim section, and one or more ridges or recess sections on one or more side sections, and wherein,said insert container includes connected side sections, a bottom section, and a protruding lip section at or near the top of at least one side of the insert container, wherein, the protruding lip is adapted to be placed onto at least part of the inner ledge of the main container, and wherein one or more side sections of the insert container additionally include a ridge or recess section which corresponds to the ridge or recess section on the main container, and which is adapted to be fitted within the ridge or recess section of the main container when said insert container is placed within said main container.

In the alternative, the present invention also provides a packaging system consisting of a main container, and at least one insert container, of the type described hereinabove.

Preferably, there is a flexible hinge between the lid and main container body so that the lid and main container body can be at least temporarily affixed, one to the other, by use of the hinge.

The inwardly extending ledge is generally a substantially flat section, of typically less than 2 cm, more preferably less than 1 cm in width, still more preferably less than 0.5 cm, and most preferably, in the range of between 1 and 5 mm. The ledge is preferably placed immediately below the rim section so as to typically be less than 3 cm, more preferably less than 2 cm from the rim section. Still more preferably the ledge is less than 1.5 cm, most preferably, is between 0.2 to 12 mm from the rim section. As such, the ledge is typically located in the upper part, and preferably at least in the upper half, of the main container body sides. In a preferred embodiment, the ledge is preferably provided at the normal “fill line” of the main container, wherein the fill line is the normal filling point for the rated size of the selected container. As such, the ledge provides an indication of the normal filling line for the container. The ledge is a sufficient distance from the rim section so that the ledge does not interfere with normal closing of the main container body by its corresponding or attached lid. At a minimum, the ledge should be below the rim by a distance equal to the thickness of the material used to form the lid.

More preferably, however, the ledge and/or the insert container are positioned away from the lid, and thus, the lid will typically have little or no contact with the insert container.

Preferably, the inwardly extending ledge is continuous and extends completely around the inside of the main container body. For example, for a rounded main container, the ledge preferably extends around the entire main container. For a four sided container, the ledge preferably is placed on all four sides, and also preferably extends around the entire main container.

The insert container is smaller than the main container so that it will fit inside the main container, and the protruding lip section will rest on the main container ledge. In one embodiment, the insert container is sized and shaped so that its lip section rests on the ledge section completely around the main container. Using this approach, the insert container covers the entire opening of the main container, and can be lifted out of the main container prior to use. In this embodiment, the insert container preferably has a shorter depth than the main container so that it is held off of the bottom of the main container. However, having the insert container rest on the bottom of the main container is not excluded.

In another embodiment, the insert container is sized and shaped so as to be smaller than the opening in the main container body. As a result, the protruding lip section will only rest on part of the ledge section. Typically, this smaller insert container will only cover a portion of the opening of the main container body. Typically, this would be approximately 50% of the main container body opening, but the insert container can be used to cover any desired main container body opening desired by the user.

Preferably, in this approach, for a four sided main container, the insert container is also sized so as to preferably rest completely across the ledge at only one end of the main container, but also extend at least part way along the ledge section on the two connected side sections for that end. As a result, only a portion of the opening of the main container is covered.

Again, in this approach, the insert container can rest on the bottom of the main container, but more typically, the insert container is shorter in depth than the main container, so that the insert container is held off of the main container bottom.

Also, in this approach, the insert container might only include a lip section on three sides, and the lip-free side will face into the main container.

More than one insert container can be fitted into the main container, and thus, the present invention also provides a packaging system having a main container and two or more insert containers fitted within the main container. The insert containers used can have the same size and shape as each other, but they can also have different sizes and shapes. In this fashion, different sized insert containers can be provided that will fit within a selected main container. In this fashion, the user can select the desired shape and size of the insert container, or containers, to be used for a selected main container size. This packaging system thereby allows the user to select a main container, and one or more insert containers, that meet the requirements of the user.

For example, for a four sided main container, two insert containers might be used, wherein both insert containers are fitted to the opposite ends, and extend along the two connecting sides. The insert containers can be sized so that they contact each other, or they can be sized so as to be held apart from one another.

Additionally, it should be noted that more than two insert containers might be used. For example, for a three insert container packaging system, two insert containers can rest on the ledge at the two ends of the main container, and part way along the ledge on the sides of the main container. A gap could be provided between the two insert container, and a third insert container could be added having a lip that rests on the ledge on the two sides of the main container.

In embodiments where two or more insert containers are used, preferably each, or all of the insert containers include a protruding lip section that extends completely around the insert container. This can permit the adjoining lip sections of the insert containers to overlap. The lip sections can however, as be placed so as to be separated from each other—preferably by a gap of less than 1 cm,—or the lip sections can be placed so as to abut one another. When overlapping, the adjoining protruding lip sections can also include a mating section that allows the two lip sections to interlock. This might be provided by a post-and-hole arrangement, but more preferably, is provided by including an interlocking ridge on the lip section in the overlap area. This interlocking of the lip sections can assist in providing additional structural integrity to the packaging system of the present invention.

Typically, the lip section on the insert containers is generally a substantially flat section, which is preferably slightly smaller than the ledge width. As such, the protruding lip section typically preferably has a width of less than 2 cm, more preferably, less than 1 cm, and still more preferably, less than 5 mm. A preferred lip section therefore preferably has a width of between 1 mm and 5 mm. As a result, the lip section is sized so as to rest on the main container ledge section.

Where appropriate, the lip sections of the insert containers can also overlap or mate with the lip section of an adjoining insert container, as previously described.

Numerous options exist for selection of different sized and shape inserts for a selected main container. As such, a container supplier can provide a limited number of main containers, and the user can select a suitable main container and one or more inserts that fit within that main container that meets their requirements. In a preferred approach, main containers can be provided having the same width and length, so that the same insert containers might be used, for all main containers. However, the main container depth can vary to provide different main container volumes. The supplier thus can provide a series of insert containers that can be mixed or matched for use within a selected main container.

The insert containers can also vary in size, shape or design. For example, the insert container compartment might be continuous, or might include openings such as slots or holes, to connect with the main container. For non-liquid materials in the insert container, this would lower the amount of plastic used.

It can also be noted that, commonly, the insert container includes only a single compartment. This compartment can be open at its top, or it can be sealed using, for example, a foil seal that extends across the top of the insert container. The compartment might also be made resealable by, for example, use of a film having a resealable glue, or by providing a compartment with a zipper storage lock, or the like. The insert container can also include two, three or even more compartments, each of which might also be continuous compartments (e.g. no side or bottom openings), or include side or bottom openings. Any or all of the compartments might also be open at their tops, or each of the compartments might be sealed. The insert container(s) can thereby be customized for different applications and uses.

The insert container can also include tabs, ridges, pinch points, or finger openings, to facilitate insertion or removal of the insert container from the main container.

The main container, and the insert container also include corresponding ridges and recesses on their side sections, and these ridges and recesses on the main container and the insert container are placed so that they fit, one into the other, when the insert container is positioned in the main container. In one approach, the side sections of the main container include one or more preferably vertical ridges that protrude inwardly into the main container. The side section of the insert container includes at least one preferably vertical recess that protrudes into the insert container, and which is positioned so as to mate with the main container side wall ridges when the insert container is placed into the main container. The positioning and number of ridges and recesses on the main container, and/or the insert container side walls can vary depending on the size and shape of the main container and the insert container. Preferably, at least one, and more preferably, at least two ridge and recess sections are mated for each insert container, when inserted into the main container.

The vertical ridges and recesses can be positioned in a symmetrical arrangement on the side wall sections, or on the front and back of the main container. However, asymmetrical designs can also be used. For example, the front wall section might include fewer vertical ridges or recesses in order to permit a better view of the main container contents. Structural ridges or recesses might also be provided on the insert container even on sides which are not intended to be in contact with the main container, in order to provide structural rigidity and strength in the insert container.

Preferably, the ridges and recesses allow for the insert container to have anywhere from a slight clearance fit to a slight interference, fit within the main container. As such, the insert container can be easily inserted into the main container body without any significant deformation of the main container body, or insert container. The positioning of the ridges and recesses can be varied, so that either the main container or the insert container can include either the ridges or recesses. For example, if the main container includes ridges or recesses, the corresponding insert container will include recesses or ridges, respectively, in order to fit in place in the main container.

The ridges and recesses are preferably 0.5 to 5 cm in depth, and more preferably, between 1 and 3 cm, for a typical container. However, smaller depth ridges and recesses might also be used, and in particular, smaller depth ridges and recesses having a wider base area might also be used. These types of ridges and recesses might be referred to as “waves”, and each of the main container and insert containers being used will preferably have a corresponding wave pattern.

By use of the ridges and recesses on the side walls of the main container and insert container, and by use of the lip section resting on the ledge section, the insert container is essentially prevented from movement within the main container. This provides a better appearance for the packaging system of the present invention. Depending on the nature of the insert container, the insert container can also provide additional strength and rigidity to the packaging system

For most purposes, the material of the main container and the insert container is preferably transparent. However, it will be understood that in some instances it may be convenient or advisable for the material of the main container and/or the insert container to be translucent, or even opaque. The materials of the main container or the insert container can also be coloured, or non-coloured. Printing can also be provided on either or both of the main container, or the insert container.

The material of the main container and the insert container can be separately chosen from any suitable materials, but most preferably, both the main container and the insert containers are made of plastic. The main container and the insert container can be made of different materials, but preferably, both made of the same material. Preferably, the main container and the insert container are made from polyethylene, polypropylene, polystyrene, polycarbonates, polyethylene terephthalate (PET), or vinyl, or mixtures thereof and therebetween. Section of the construction material can be influenced by the nature of the material to be stored in the main container and/or the insert container. For example, hot or cold materials might require different construction materials.

While a variety of production techniques can be employed, in general, the main container and the insert container of the packaging system, are preferably formed by thermoforming, and usually by being pressure formed from sheet material, followed by stamping operations to separate each formed container from the sheet material. Other production processes however, can include injection moulding of the main container and/or the insert container, and the like.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The novel features which are believed to be characteristic of the present invention, as to its structure, organization, use and method of operation, together with further objectives and advantages thereof, will be better understood from the following discussion. In the drawings, unless otherwise noted, the packaging system is shown comprising a opaque main containers, and opaque insert containers, in order for the drawings to be more easily understood. However, it will be understood that the packaging system can comprise opaque, translucent, transparent, or clear main and insert containers.

Turning first toFIG. 1A, there is shown a packaging system10consisting of a main container12, having a main container body14and a lid16. Main container body14and lid16are attached together by hinge18. Main container12can be used as is, on its own, but in keeping with the present invention, main container12is intended to receive insert container20which is adapted to be fitted within main container12in the manner described in the present invention. As such, the assembled packaging system10is shown inFIG. 1Bwherein insert container20has been inserted into the body14of main container12.

Main container12and insert container20are pressure formed from PET, in a manner known to those skilled in the art.

Details of the construction of main container12are shown inFIG. 2. In this figure, the four side walls of main container12are shown and these include two end walls22, front wall24and back wall26. Each of end walls22have four vertical ridges28which protrude into main container body14. Front wall24has two vertical ridges30, and back wall26has a total of four vertical ridges32, in two sets of two vertical ridges, which also protrude into main container body14.

Around the top peripheral edge of main container body14is a rim section34. A corresponding recess section36is provided around the peripheral edge of lid16. In a manner known to those skilled in the art, lid16can be used to cover and essentially seal main container body14, by inserting rim section34into recess section36.

A peripheral ledge38is provided around the top of the main container body14, immediately below the rim section34.

Details of the construction of insert container20are shown inFIGS. 3A and 3B. In these figures, insert container20includes only a single compartment40which substantially fills insert container20. It will be noted that insert container20, in this embodiment, is intended to essentially cover the entire top section of main container body14.

The end walls42of insert container20each include vertical recesses44. Front and back walls46also include vertical recesses48. When placed into main container body14, vertical ridges28on end walls22will be positioned into vertical recesses44, or vertical ridges28will extend into a gap located under pinch section50. Pinch sections50can be used to insert or remove insert container20into main container12.

Additionally, when insert container20is placed into main container12, vertical ridges30and32on front wall24and back wall26, will be positioned into vertical recesses48. In this embodiment, insert container20is reversible so that the front and back walls can be reversed.

An essentially flat protruding lip52is provided around the peripheral edge of insert container20, and this lip52is intended to rest on ledge38of main container body14. Details of ledge38and lip52, in the assembled packaging system10, are shown inFIG. 4, and inFIG. 4, it can clearly be seen that protruding lip52rests on ledge38, and not on rim section34, since ledge38is positioned in the main container body14, at a point below rim section34. As such, insert container20can be inserted into main container body14in a manner where it does not interfere with rim section34or recess section36. As a result, insertion of insert container20into main container12, does not interfere with the normal closing and sealing of main container12by lid16. Moreover, whether or not insert container20has been inserted into main container12, it is clear that main container12can be closed with lid16, in a regular manner without having the insert container affect the rim and recess closing mechanism.

InFIGS. 5A and 5B, a top view and a perspective view, respectively, of an alternative embodiment of an insert container60are provided wherein the insert container only partial covers the opening in the main compartment. In this embodiment, insert container60is sized so as to cover approximately 50% of the opening of the main container. Insert container60has only a single compartment62, and includes a protruding peripheral lip64, and a protruding central lip section64A, that extends around insert container60. Lip64is provided so that it will rest on the ledge38at one end wall22of main container12, and will rest on part of ledge38extending along the front and back walls (24,26), of main container12.

A structural rib65is preferably provided on the insert container60, in the area under the central lip section64A. This provides additional rigidity to the insert compartment60.

Vertical recesses66are provided on one end of insert container60, and vertical recesses68are also provided on the sides of insert container60. These vertical recesses (66,68) are positioned so that they provide a slight clearance fit with the vertical ridges (28,30and32) at the sides and end of one end of main container12.

InFIG. 6, a completed packaging system70according to the present invention is shown, which includes a main container12, and insert container60. Details of the insert container60resting on ledge38of main container12, can be seen in the enlarged view provided inFIG. 7, which more clearly shows protruding lip section64and ledge38. It can also be seen that ledge38is well below rim section34.

InFIGS. 8A and 8B, a top view and a perspective view, respectively, of a further alternative embodiment of an insert container80are provided wherein the insert container again only partial covers the opening in the main compartment. In this embodiment, insert container80is again sized so as to cover approximately 50% of the opening of the main container. However, insert container80has two compartments82and83, and includes a protruding peripheral lip84, and a protruding central lip section84A, that extends around insert container80. Lip84is provided so that it will rest on the ledge38at one end wall22of main container12, and will also rest on part of ledge38extending along the front and back walls (24,26), of main container12.

Again, a structural rib85is preferably provided on the insert container80, in the area under the central lip section84A. This provides additional rigidity to the insert compartment80.

Vertical recesses86are provided on one end of insert container80, and vertical recesses88are also provided on the sides of insert container80. These vertical recesses (86,88) are positioned so that they provide a slight clearance fit with the vertical ridges (28,30and32) at one end of main container12.

InFIG. 9, a completed packaging system90according to the present invention is shown, which includes a main container12, and insert container80, wherein insert container80has been inserted into main container12in a manner consistent with that described in respect ofFIG. 6.

InFIG. 10A, the various components of a version of a completed packaging system100, according to the present invention, are shown separately. This includes main container12, insert container60and insert container80. InFIG. 10B, insert containers60and80are shown after both have been inserted into main container12. Lips64and84rest on ledge38where they contact main container12. In the centre of main container12, central lip sections64A and84A are positioned so as to provide a slight gap87between central lip sections64A and84A. Gap87is typically approximately less than 1 cm, more preferably between 1 to 5 mm, and most preferably, about 3 mm. However, the width of gap87can be any suitable value.

It should be noted that in an alternative design, central lip sections64A and84A can abut one another, or overlap with one another. When they overlap, preferably, the combined thickness of the two overlapping central lip sections is small enough that the overlap does not cause any interference with the closing of lid16. Still further, the central lip sections can include an interlocking feature, which aids in providing structural support for the packaging system. These possible arrangements are shown inFIGS. 11A, 11B, 11C and 11D, which respectively show enlarged views of the relative positions of central lip sections64A and84A. InFIG. 11A, central lip sections64A and84A have a gap87between them. InFIG. 11B, central lip sections64A and84A abut one another. InFIG. 11C, central lip sections64A and84A overlap with each other. InFIG. 11D, central lip sections64A and84A each include a ridge89that allows central lip sections64A and84A to be connected to each other.

It can be noted though that central lip sections64A and/or84A are not necessary. As such, in a further option, as shown inFIG. 11Ecentral lip sections64A and84A have been omitted from insert containers60and80.

In general, it will therefore be seen, that the size and shape of the various components of the present invention, allows for mixing and matching of the main containers and insert containers to provide a customized package for each user. As such, the packaging system of the present invention allows for flexibility in stocking, storing and shipping of only those components required by a particular customer.

As such, inFIG. 12, an alternative main container110is shown which is essentially identical to main container10, with the exception that main container110has a reduced depth, and that lid112is separated from main container body114. However, as will be clearly understood by the skilled artisan, lid112can still be easily used to close main container body114.

As shown inFIG. 13, a packaging system116is provided wherein main container body114is used to receive the same insert containers60and80that have been previously described. In this embodiment, the user can use main container body114on its own (with or without lid112), or with insert container60and/or insert container80. InFIG. 13, both insert containers60and80are shown, but either could be omitted depending on the user's specific application.

Other design options are possible. For example, inFIGS. 14A and 14B, a further insert container120is shown having two compartments122and124. Compartment122is the same as compartment82inFIG. 8B, but compartment124is a circular compartment. Compartment124can be open, or can be sealed by, for example, a foil seal (not shown). It will be clear though, that numerous options exist for the size, shape and design of both the insert container, and the main container, and that the user is freely able to mix and match the insert containers and the main containers to prepare a customized packaging system suited for their particular application.

Other container body shapes are possible, as is seen inFIGS. 15A and 15B. InFIG. 15A, a circular shaped main container130, having a main container body132connected to lid134by a hinge133. Main container body132is shown adjacent to semi-circular insert container136. Insert container136is sized and shaped so as to be capable of being inserted into main container body132, in a manner similar to that previously described wherein ridges in the main container body are adapted to fit into recesses in the insert container. The resultant assembled packaging system140, is shown inFIG. 15B.

Clearly many other shapes and sizes are possible.

Also, it should be noted that while the primary application for this invention is for providing foodstuffs, other suitable applications are known or possible. As such, the packaging system of the present invention might also be used for the sale or dispensing of manufactured materials, such as nuts, bolts, screws, or the like, or electrical components, such as resistors, capacitors, batteries, or the like. A wide variety of other uses can be envisioned. It will therefore by clear to the skilled artisan that various other modifications and alterations may be used in the design and setup of the present invention, without departing from the spirit and scope of the accompanying claims.

Accordingly, it is apparent that there has been provided, in accordance with the present invention, a packaging system which fully satisfies the goals, objects, and advantages set forth hereinbefore, or inherent thereto. Therefore, having described specific embodiments of the present invention, it will be understood that alternatives, modifications and variations thereof may be suggested to those skilled in the art, and that it is intended that the present specification embrace all such alternatives, modifications and variations as fall within the scope of the appended claims.

Moreover, words such as “substantially” or “essentially”, when used with an adjective or adverb is intended to enhance the scope of the particular characteristic; e.g., substantially or essentially planar is intended to mean planar, nearly planar and/or exhibiting characteristics associated with a planar element.

Further, use of the terms “he”, “him”, or “his”, is not intended to be specifically directed to persons of the masculine gender, and could easily be read as “she”, “her”, or “hers”, respectively. Also, relative terms such as “inwardly” or “outwardly” are to be interpreted in their normal manner when the device of the present invention is used in its intended manner.

Also, while this discussion has addressed prior art known to the inventor, it is not an admission that all art discussed is citable against the present application.