Abstract:
The invention encompasses packaging containers and locking features enabling damage resistant closed containers that are suitable for mechanized and automated closing and loading operations.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application No. 61/370,751 filed Aug. 4, 2010 which is incorporated herein by reference for all purposes. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates to an improved method and produce packaging configuration enabling the improved packing, storage, and shipping of produce and other items. More particularly, the present invention has improved resilience to damage during shipping and display. In particular the package has improved resistance to damage induced by consumer mishandling and dropping of the package while full of produce product. 
       BACKGROUND 
       [0003]    When displayed in stores or when moved through distribution channels packages can be mishandled, dropped, or otherwise subject to breakage. In the ordinary course of use, a broken container can spill produce contained within the container throughout the immediate area. This spillage can dirty floors and also pose a slipping and tripping risk to people and machines near the spilled product. This poses particular risks to retailers when such containers are dropped and spill throughout crowded customer environments. This is problematic for a number of reasons, not the least of which is the substantial litigation risks imposed upon a retailer when spilled and frequently slippery produce products spill over consumer areas. Moreover, such risks and problems are compounded when delicate contents such a produce items are mishandled. It would be helpful to have resilient and yet low cost containers to prevent the spillage of produce. 
       SUMMARY OF THE INVENTION 
       [0004]    In accordance with the principles of the present invention, an improved apparatus and method for packaging, transporting, and storing items in a resilient container is disclosed. 
         [0005]    In general, the present invention is directed toward methods and produce packaging configurations that are low cost, easily manufacturable, easy to use, and relatively robust providing increased protection from mishaps caused by mishandling of the containers. increase 
         [0006]    One embodiment of the invention comprises a produce package a packaging container with a lid and a basket, both engageable to form a closed package. Particular utility is achieved using hinged containers but the invention is not limited to such. The lid and basket each include a portion of an engageable locking feature configured to enable secure closure of the container. The locking feature comprises a receiving feature and a complementary engagement member each arranged at the other of the lid or the basket and configured such that when the lid is closed the engagement member engages with the receiving feature reversibly locking the container in a closed configuration. The receiving feature further includes a guide feature and a lock. The complementary lock engagement member includes a protrusion that is configured to mate with the receiving feature and engage with the lock to reversibly lock the container when closed. The operation of the protrusion with the guide feature is particularly helpful in assisting in the closure of the container. In particular, this is useful during a loading operation where items are placed in the container which is then closed. Such a container is of particular utility when used in automated loading processes. 
         [0007]    In another aspect, the invention discloses a method using at least the following operation. A packaging container with a lid attached to a basket with a hinge is provided. This operation can be preceded by a loading step when contents are introduced into the opened container. The container itself is configured to comprise a lid and basket each including a portion of a locking feature configured such that each portion of the locking feature can be engaged together to enable secure closure of the container. The locking feature comprising a receptacle arranged at one of the lid or the basket and a complementary projection arranged at the other of the lid or the basket. The lid is then closed such that the operation of closing the lid comprises guiding the projection into position using a guide feature of the receptacle such that projection engages with the receptacle reversibly locking the container in a closed configuration. 
         [0008]    Other aspects and advantages of the invention will become apparent from the following detailed description and accompanying drawings which illustrate, by way of example, the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The following detailed description will be more readily understood in conjunction with the accompanying drawings, in which: 
           [0010]      FIG. 1  is a simplified perspective view of a robust packaging container in accordance with one embodiment of the present invention. 
           [0011]      FIG. 2  is a simplified close up perspective view of a container showing a locking feature of a packaging container in accordance with one embodiment of the present invention. 
           [0012]      FIG. 3(   a ) is a simplified isolated close up section view of a locking feature of a packaging container in accordance with one embodiment of the present invention. 
           [0013]      FIGS. 3(   b ) and  3 ( c ) are simplified isolated close up section views of a locking feature such as shown in  FIG. 3(   a ) the view depicted is along a section axis that is 90° rotated relative to the view of  FIG. 3(   a ). 
           [0014]      FIG. 3(   d ) is a simplified perspective view a portion of a container showing an extension and associated engagement groove in accordance with one embodiment of the present invention. 
           [0015]      FIG. 4  is a section view of another embodiment of a locking feature of the present invention. 
           [0016]      FIG. 5  provides a number of views of an example package in accordance with an embodiment of the invention. 
           [0017]      FIG. 6  is a flow diagram illustrating a method of the present invention. 
       
    
    
       [0018]    It is to be understood that in the drawings like reference numerals designate like structural elements. Also, it is understood that the depictions in the Figures are not necessarily to scale. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0019]    The present invention has been particularly shown and described with respect to certain embodiments and specific features thereof. The embodiments set forth hereinbelow are to be taken as illustrative rather than limiting. It should be readily apparent to those of ordinary skill in the art that various changes and modifications in form and detail may be made without departing from the spirit and scope of the invention. 
         [0020]    Generally, the principles of the invention encompass robust packaging devices and containers as well as an associated mode of packing such containers. 
         [0021]    One approach to the problem of relatively delicate containers is problem is to provide an improved container. In particular the container is enhanced by the use of improved locking features that are also suited to automated loading and closure. 
         [0022]    To that end, an improved packaging container for the packaging of produce and other items is disclosed. 
         [0023]    Having reference to  FIG. 1 , a first preferred embodiment of the produce basket  100  of the present invention is shown. Produce basket  100  is a one-piece structure incorporating both basket body  102  and lid  101 . That portion of produce basket  100  joining basket body  102  and lid  101  is formed as a hinge,  103 . While a first preferred embodiment is a vacuum formed plastic structure, the principles of the present invention are equally applicable to alternative materials and manufacturing technologies. In a first preferred embodiment of the present invention, the basket is formed of Kodapak® PET Copolyester  9921 , available from Eastman Kodak. Alternative materials include, but are not limited to various polymeric and monomeric plastics including but not limited to styrenes, polyethylenes including HDPE and LPDE, polyesters and polyurethanes; metals and foils thereof; paper products including chipboard, pressboard, and flakeboard; wood and combinations of the foregoing. Alternative manufacturing technologies include, but are again not limited to thermocasting; casting, including die-casting; thermosetting; extrusion; sintering; lamination; the use of built-up structures and other processes well known to those of ordinary skill in the art. 
         [0024]    The container  100  embodiment of  FIG. 1  has a lid  101  and a body  102  arranged in a closable package. As shown here, the lid  101  includes raised circumferential ridge  104  that is mated to engage a raised circumferential ridge  105  of the body  102 . The locking of the two ridges  104 ,  105  can be enhanced with the sidewall locking bumps  106  shown here on the lid ridge  104 . It is pointed out that while disclosed here as a contiguous raised ridge, the ridges can include a recessed feature as well. Additionally, not all embodiments require that a ridge be contiguous. Other embodiments can used a plurality of shorter ridges arranged around the outer circumference if the lid and basket. In particular embodiments, such ridges can be those located at the corners. The bumps  106  of one ridge (i.e., the lid ridge  104 ) can be sized and arranged to press fit against the other ridge (i.e., basket ridge  105 ). In one case, where a first ridge circumscribes a greater “diameter” than the inner ridge, bumps arranged on an outer surface of inner ridge can be press fit against an inner surface of the inner ridge. Also, the position of the bumps can be placed on an outer surface of the inner ridge or a combination of inner and outer surface to enable the press fit. 
         [0025]    Importantly, one or more locking features  200  are arranged in the sidewall portions of the lid  101  and body  102 . Each locking feature  200  includes a locking member  201  for engagement with a locking receptacle  202 . In this embodiment the locking member  201  is part of the lid  101  and the locking receptacle  202  is formed in the body  102 . When engaged they lock the lid and body tightly together. It should be pointed out that the position of the locking member and the locking receptacle can be reverse (i.e., member  201  on the basket  102 ). 
         [0026]    It is specifically pointed out that although disclosed as a pair of mated ridge elements  104 ,  105 , the packaging container need not have ridges and the described features can be formed in the associated lid and basket of the container. 
         [0027]      FIG. 2  provides a closer view of the locking feature  200 . Here, the locking member  201  comprises a protrusion that is configured to engage the receptacle  202  by insertion of the member  201  into the locking receptacle  202 . 
         [0028]    Importantly, in many embodiments, the tip  201   t  of the member is intended to have a narrower dimension than the base (not shown in this view) of the member. This generates a member that becomes narrower (in at least one dimension) as it extends toward the tip  201   t . Additionally, the opening  202   o  of the receptacle  202  wider than the tip  201   t  of the member. And also wider than the bottom  202   b  of the receptacle  202 . This is helpful in that the small tip  201   t  can easily fit into the much larger opening  202   o  enabling a machine to easily fit the two components together during a mechanized closing operation. Smooth sidewalls of the member  201  and receptacle  202  will enable an easier engagement of the member  201  with receptacle  202  during automated processing. Thus, the receptacle uses the tapered smooth walls as a guide feature that easier closure of the container during processing and closing. 
         [0029]    As an added securement feature the member  201  has an engagement tab (not shown in the view) that is sized to engage with a mated lock catch, depicted here as recess feature  202   r  located inside the receptacle  202 . Upon closing, the catch and tab engage to further lock the locking feature  201 / 202  together. 
         [0030]    It is also to be pointed out that further locking aspects can be included. For example, here another protuberance  211   p  can be arranged on the one or another of the ridges (here, ridge  104 ) such that when closed the protuberance engages with a complementary recess  211   r  on the other ridge (here, ridge  105 ). 
         [0031]    Importantly, in one embodiment of the invention, the inside walls of the receptacle  202  are sized such that when the member  201  is inserted into the receptacle  202 , the walls of the receptacle  202  engage outer walls of the member  201  to establish a first lock a the receptacle walls are press fitted against the outer walls of the member. In particular, the tip region  201   t  of the member is sized such that it engages in a press fit with a bottom portion  202   b  of the receptacle  202  to form the first lock. This first lock can be replaced by a bulbous locking feature such as discussed with respect to  FIG. 4 . Alternatively, both the press fit and the feature of  FIG. 4  can be used together to enhance the locking of the container. To establish an even more robust lock the receptacle  202  and member  201  include an engagement bump  201   e  configured to engage a recess feature  202   r  in the receptacle  202  forming a second lock. It should be pointed out that one particularly useful implementation uses the press fit first lock together with the second lock of  201   e / 202   r  to establish an embodiment using two locks. This two lock (or more) implementation is more robust that containers currently in the market. 
         [0032]    Further reference is made to  FIG. 3(   a ) which is a different view of the locking feature  200  and also  FIG. 3(   b ) which is a simplified diagrammatic side section view of embodiments of the locking feature  200 . 
         [0033]      FIG. 3(   a ) shows the narrower dimensions of the tip  201   t  of the locking feature member  201  relative to the wider base portion  201   b . Also, shown is the wider dimension  212  of the receptacle opening  202   o . The dimension  212  is wider in at least one dimension as compared with both the receptacle “bottom”  202   b  and the member tip  201   t  (e.g., dimension  211 )). Also, shown are some added securement feature components. For example, one embodiment of tab  201   e  of the member  201  sized to engage the mated recess feature  202   r  of the receptacle  202 . Also shown are the smooth sidewalls S of the member  201  and receptacle  202 . As is shown by arrow  203 , the member  201  is pushed into the receptacle  202  to engage and lock the feature  200  together. The wider upper opening  202   o  and smooth sidewalls S ease the insertion of member  301  into the receptacle  201 . The wider opening  202   o  can account for misalignments and other difficulties in automated closing processes. The smaller dimension  211  of the member tip  201   t  enable easy engagement of the narrower member tip  201   t  with the wider  212  opening  202   o  of the receptacle  202 . Thus, the tapered aspect of the engagement feature  200  enables easy engagement of the member  201  with the mated receptacle  202 . The smooth sidewalls S can enable easier seating of the member  201  into the receptacle  202  during closure as well. 
         [0034]      FIG. 3(   b ) is a side section view of a locking feature embodiment  200 . The view can be taken, for example, along the section  209  of  FIG. 3(   a ). This view shows another optional aspect with a taper in a second axis as shown. Thus, if  FIG. 3(   a ) shows a side-to-side arrangement of a feature  200 , then  FIG. 3(   b ) shows a “front-to-back” arrangement of a similar feature. In this view, similar tapering dimensions can be included in some embodiments. For example, the wider base  201   b  can also taper into the narrower dimensions of the tip  201   t  in this axis. Also, the dimension  222  of the receptacle opening  202   o  is generally wider than that of the bottom  202   b . Also shown is the added securement feature components including the engagement bump (e.g., tab  201   e ) of the member  201  sized to engage the mated recess feature (e.g., catch  202   r ) of the receptacle  202 . Also shown are further smooth sidewalls S of the member  201  and receptacle  202 . As is shown by arrow  213 , the member  201  is pushed into the receptacle  202  to engage and lock the feature  200  together as shown in the embodiment of  FIG. 3(   c ) which is a closed feature. As shown, the member  201  is seated and locked in position inside the receptacle  202 . The engagement bump  201   e  of the member  201  is shown engaged with the mated recess feature  202   r  of the receptacle  202 . 
         [0035]    With reference to circle  301  of the closed feature  200  shown in  FIG. 3(   c ), a bottom portion of one possible embodiment of a locking feature  200  is shown. 
         [0036]    In one embodiment, the packaging container can comprise a ridge, but also a mated groove sized to receive the ridge. One simplified example of such an embodiment is shown and described with respect to  FIG. 3(   d ). For example, a corner portion of one embodiment is depicted. The basket  352  and lid  351  are arranged to be closed. Here, the basket  352  can include a ridge feature  353  having a groove  354  formed therein. It is the pointed out that the ridge is not required. Instead the groove  354  can be formed in an upper portion of the basket without a deliberately formed ridge. In any case, the groove is adapted to receive an extension  355  sized to engage the groove  354 . 
         [0037]    To continue with the discussion of  FIG. 3(   d ), in this embodiment, a package  350  having a lid  351  and a basket  352  can be used to secure the container in a closed configuration. The basket  352  and lid  351  are arranged to be closed. Although disclosed here as having a groove  354  formed in a ridge feature  353  it is the pointed out that the ridge  353  is not required to practice the invention. Instead the groove  354  can be formed in an upper portion of the basket  352  without a deliberately formed ridge. 
         [0038]    In any case, the groove  354  can operate as an engagement feature suitable for engaging a complementary extension  355  in one of the lid or basket. The extension being in one of the lid or basket and the groove being in the other (here, in the lid  351 ). The groove  354  is sized to engage the sized to engage the extension  355 . As with the ridges previously described, the groove can extend around the full circumference of the container or only a portion of as desired by the designer. The groove  354  and extension  355  can both comprise tapered sidewalls configured to improve engagement and machine operation and can also include locking features as with the previous embodiments. For example, the extension  355  can have a cross section similar to that of  201  as shown in  FIGS. 3(   a ),  3 ( b ) and  4  thereby optionally including locking features ( 201   e ,  202   r ,  201   t ,  202   b , etc.) designed to assist in securing the container in a closed configuration. Additionally, the separate locking features shown in  FIG. 2  can be used in addition to those of the groove an extension of  FIG. 3(   d ). 
         [0039]      FIG. 4  can be used to illustrate another optional aspect of a locking mechanism as illustrated expanded view  301 . The receptacle  202  is again shown with a receptacle bottom  202   b  and the member  201  with a tip  201   t . Here the receptacle  202  has an inner sidewall having a neck  231  that is sized to be narrower in at least one dimension than a bulge portion of the bottom  202  which opened up to an expanded size. Additionally, the member includes a sidewall  232  that tapers as it extends toward a flared distal to tip  201   t . It is pointed out that the flared tip  201   t  is slightly wider than the neck  231  of the receptacle  202 . Additionally, the tip flare  201   t  of the member  201  has a size and dimension that is generally closer to that of the bulge  202   b  than it is to that of the neck  232 . The idea being that the neck  231  is narrower than the flared tip  201   t  thus, when closed, the tip  201   t  is pressed through the tight neck  231  until it is seated in the expanded region on the other side of the neck (here depicted as the bulge portion  202   b  arranged at a bottom portion of the receptacle  202 ). 
         [0040]    Also, in another embodiment a portion of the member  201  has a somewhat larger dimension than a complementary portion of the receptacle  202 . The difference in sizes enables a reversible lock of the lid to the basket. In such a case, the member  201  is simply larger in one or more of the dimensions than the similar dimension of a mated portion of the receptacle. By press fitting the two elements together a tight fit at the bottommost portion of the receptacle can assist in forming a resiliently closed locking feature. 
         [0041]    In one application, the container can include a number of these features suitable for locking a container together in a durable closure. In one approach, the container can be filled with one or two pound of product (e.g., strawberries) and rugged enough to be dropped from 4 feet to a floor without the lid opening. This will enable the contents to not scatter and create a hazard in the immediately surrounding area. This design enables a rugged container while still providing an automation friendly container suitable for machine closing processes. 
         [0042]      FIG. 5  is a generalized example of one possible embodiment of a container  500  in many views. In this embodiment, the container  500  can have two locking features  200  along one of the sidewalls. Even this level of locking features achieves excellent results. Here, an example feature  200  can be 1-1.5 inches long; 0.5-1.5 inches deep, and 0.4-1.0 inches deep to achieve excellent results. However, it is pointed out that there can be as few as one locking feature per container and can also be many such features. The features can be present on 1, 2, 3, or all side walls depending on container shape and the needs of the user/manufacturer. 
         [0043]      FIG. 6  is a generalized flow diagram illustrating aspects of a method aspect of the invention. To begin, a container of the type described herein is provided (Step  601 ). The desired articles are inserted into the basket of the open container (Step  603 ). This can be done in an automated matter or by hand depending on the need of the user. Once, filled the containers are then closed, typically using an automated manufacturing machine. The guide features of the container guide the engagement members into the receiving members enabling a reversible lock to be established. 
         [0044]    Aspects of this invention have been particularly shown and described with respect to certain selected embodiments and specific features thereof. However, it should be noted that the above-described embodiments are intended to describe the principles of the invention, not limit its scope. Therefore, as is readily apparent to those of ordinary skill in the art, various changes and modifications in form and detail may be made without departing from the spirit and scope of the invention as set forth in the appended claims. In particular, specific dimensions are subject to a wide range of flexibility in accordance with the principles of the present invention. Moreover, the number and shape of the locking feature are also subject to a great degree of flexibility in accordance with the principles of the present invention. Other embodiments and variations to the depicted embodiments will be apparent to those skilled in the art and may be made without departing from the spirit and scope of the invention as defined in the following claims. Although only a few specific configurations are expressly disclosed herein, it should be appreciated by anyone having ordinary skill in the art that, using the teachings disclosed herein, many different packaging configurations can be implemented and still fall within the scope of the claims. Further, reference in the claims to an element in the singular is not intended to mean “one and only one” unless explicitly stated, but rather, “one or more”. Furthermore, the embodiments illustratively disclosed herein can be practiced without any element which is not specifically disclosed herein.