Abstract:
A produce packaging container incorporates a basket body with an opening for inserting items inside the container and a pair of lids for covering the opening in the basket body. Each basket also includes latch elements for securing the lids in a closed configuration. A fastener is used as an extra level of security for sealing the container. The fastener can also be employed advantageously as a label. In some implementations the container is vented. Also, containers can include lids having lid-mounted latches to seal the container. Moreover, in some other implementations, the lids are configured in an overlapping manner with top mounted latches employed to engage the lids together in a closed configuration.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS  
       [0001]     This application is a continuation-in-part of co-pending application Ser. No. 11/139,275, filed May 27, 2005 (entitled “Produce Packaging Container With Dual Hinged Resealable Tops”),  
         [0002]     The aforementioned document is a continuation-in-part of co-pending application Ser. No. 10/017,893, filed Dec. 12, 2001 (entitled “Method And Apparatus For Packing And Bi-Directional Cooling Of Produce”) and which in turn is a continuation-in-part of application Ser. No. 09/590,631, filed Jun. 8, 2000, which is a continuation of U.S. Pat. No. 6,074,676, issued on Jun. 13, 2000, which is a continuation of application Ser. No. 08/591,000, filed Jan. 24, 1996 and issued as U.S. Pat. No. 5,738,890 on Apr. 14, 1998, and claims priority from co-pending application Ser. No. 10/017,893, filed Dec. 12, 2001. Additionally, this application is a continuation-in-part of co-pending application Ser. No. 10/302,059, filed Nov. 21, 2002 and entitled “Produce Packaging System Having Produce Containers With Double Arched Bottom Ventilation Channels”. This application claims priority to all of the above-referenced applications and patents and also incorporates the above documents by reference. 
     
    
     TECHNICAL FIELD  
       [0003]     The present invention relates to apparatus and methods for the improved packing, cooling, storage, and shipping of produce. More particularly, the present invention teaches produce containers with dual hinged tops to facilitate the reusability of such containers.  
       BACKGROUND  
       [0004]     Many produce products are harvested and packed in the field into containers, which are ultimately purchased by the end consumer. Examples of such produce items include, but are not limited to, strawberries, raspberries, other berries, tomatoes, grapes, mushrooms, radishes and broccoli florets. Many of these produce can be packaged in the field in large quantities. Such large quantities are well suited to reuse by end users such as restaurateurs or home kitchen users. In order to effectuate efficient usage (and reusage) of the container, effective resealability of the containers is needed.  
       SUMMARY OF THE INVENTION  
       [0005]     In accordance with the principles of the present invention, produce packaging systems are disclosed. Implementations of the present invention include, without limitation, any of the enumerated embodiments below.  
         [0006]     Embodiments of the invention include a resealable produce container having a basket body with an opening for inserting items inside the container and a pair of hinged lids for covering the opening in the basket body. Each basket also includes latch elements for securing the lids in a closed configuration. Additionally, fastener, such as an appliqué label, can be used to further seal the filled container in a closed configuration.  
         [0007]     These and other aspects of the present invention are described in greater detail in the detailed description of the invention set forth herein below.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]     The following detailed description will be more readily understood in conjunction with the accompanying drawings, in which:  
         [0009]      FIG. 1 ( a ) is a schematic perspective view of an opened produce container embodiment according to the principles of the present invention.  
         [0010]      FIG. 1 ( b ) is a schematic cross-section view of a latch embodiment such as can be used on many container embodiments described herein, including the container depicted in  FIG. 1 ( a ).  
         [0011]     FIGS.  2 ( a )- 2 ( c ) are various views of a container embodiment constructed in accordance with the principles of the invention.  
         [0012]      FIG. 2 ( d ) is a schematic cross-section view of an elongate top latch embodiment such as can be employed on many container embodiments described herein, including the container depicted in FIGS.  2 ( a )- 2 ( c ).  
         [0013]     FIGS.  3 ( a ) and  3 ( b ) depict various side latch embodiments that can be used with various container embodiments of the invention.  
         [0014]      FIGS. 4 and 5  depict schematically depict perspective views of various container embodiments constructed in accordance with the principles of the invention.  
         [0015]      FIG. 6 ( a ) is a perspective view of a simplified container embodiment constructed in accordance with the principles of the invention.  
         [0016]      FIG. 6 ( b ) depicts a label used in accordance with the principles of the invention.  
         [0017]      FIG. 7  schematically depicts a methodology and system for loading and sealing containers constructed in accordance with the principles of the 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 figurative representations of selected embodiments of the inventions that facilitate understanding of the invention. Such figures are explanatory in nature and not intended to limit the scope of the invention. Moreover, the figures provided are illustrative and not necessarily drawn 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 herein below 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]     Embodiments of the invention include dual lid produce containers. Particular embodiments include containers constructed with latches at the sides of the dual lids. Also, the lids can be constructed in an overlapping fashion. Additionally, the lids can have a top latching mechanism. In one example, the top latch element can comprise an elongate plug and socket mechanism that engage to secure the dual lids in place. Many other additional and alternate example embodiments are described herein.  
         [0021]     Having reference to  FIG. 1 ( a ), a first embodiment of a produce container  1  of the present invention is shown. Produce basket  1  is a one-piece structure incorporating both basket body  10  and a dual hinged lid  11   a,    11   b.  That portion of produce basket  1  joining basket body  10  and lid  11  is formed as a hinge. The basket body  10  further can include one or more concavities formed in the bottom portion of the basket body  10 . These concavities can define ventilation channels under the container. The cooling induced by air flow under the container can be enhance by openings at the bottom of the container in the concavities.  
         [0022]     In the depicted embodiment, the dual hinged lids  11   a,    11   b  are arranged to be held in a closed configuration by latches  12  on either side of the lid. The depicted button latch configuration can, in other alternative embodiments, be comprised of any one of a number of latching devices known to those having ordinary skill in the art. Therefore, although the previously discussed latch configuration has been shown to be particularly effective, the principles of the present invention specifically contemplate alternative latching methodologies. These include, but are specifically not limited to, edge catches, snaps, hook-and-loop closures, and other closure methodologies well-known to those having ordinary skill in the art. Moreover, the term “latch” as used herein may further comprise alternative lid closure methodologies known to those having ordinary skill in the art including the use of elastic bands or adhesive tapes to perform this reusable latching function.  
         [0023]     Reference to  FIG. 1 ( b ) depicts a close up cross-section view of a latch  12  (shown here in the dashed line circle) such as that shown in  FIG. 1 ( a ). In the depicted latch  12 , a plug and socket type latch are shown. In the depicted example, the body  10  is shown with a socket A for receiving a lid (e.g.,  11   a ) mounted plug B. The lid is secured by engaging the plug B with the socket A to secure the lid. Of course, the plug B and socket A portions can be readily interchanged between the basket body and lid portions without departing from the scope of the invention.  
         [0024]     While depicted embodiment is shown as a vacuum formed plastic structure, the principles of the present invention are equally applicable to alternative materials and manufacturing technologies. In the depicted embodiment, the basket can be formed of a PET material such as 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 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.  
         [0025]     FIGS.  2 ( a )- 2 ( e ) depict another embodiment.  FIG. 1 ( a ) depicts a side view of a container embodiment having a pair of hinged lids where one lid overlaps the other. In the depicted embodiment, a produce container  20  is constructed as a one-piece structure incorporating both basket body  22  and a dual hinged lid  21   a,    21   b.  Again, the lids  21   a,    21   b  are joined to the basket body  22  using a hinge  23 .  FIG. 2 ( a ) shows a top lid  21   a  that overlaps a lower lid  21   b  to close the container  20 . The dotted line depicts the portion of the lower lid  21   b  overlapped by the upper lid  21   a ). The upper lid  21   a  can have a latch  24  at one or both side edges of the lid. The latch  24  can for example interlock with a mated latching portion of the side of the lower lid  21   a.  Additionally, the lower lid can have a latching portion that interlocks with a mated portion of the basket body  22 . Although not limited exclusively to such, certain preferred embodiments of the container include hinges  23  located at outer edges of the container (e.g., as depicted in  FIG. 2 ( a ) and others). As described above, many different implementations of such latches are known to those having ordinary skill in the art and can readily be used. A few helpful examples will be discussed later in this patent.  
         [0026]     Reference to  FIG. 2 ( b ) shows another aspect of an embodiment of the invention.  FIG. 2 ( b ) is a top down view of an embodiment as shown in  FIG. 2 ( a ). The overlapping top lid  21   a  is shown closed over lower lid  21   b.  Also shown are the overlapped portion of the lower lid  21   b  (as depicted here with dotted lines). The inventors point out that the top portions of the lids ( 21   a,    21   b ) include a long top latch  25  (encircled by dashed line). Such top latches can be of many different types as discussed before. In the depicted embodiment, the latch  25  comprises an upper elongate latch portion  25   a  that runs substantially parallel to the hinges  23  at the distal edge (far from the lid hinge) of the top lid  21   a.  The portion  25   a  interlocks with a mated latch portion  25   b  (as depicted with dotted line) on the lower lid  21   b  to form a stable latch that can be readily opened or closed as needed.  
         [0027]     It is to be pointed out that the side latches  24  can be incorporated with the top latches  25 . Alternative embodiments can employ the side latches  24  only or can employ the top latches  25  only. The inventors point out that although the top latch  25  is depicted here as a single elongate latching structure, it is contemplated that many latching features can be employed. For example, more than one set of elongate latches or many smaller latches (e.g., button latches) can be employed. The applicants prefer the elongate latches because it is believed that they provide a surprising degree of stability to the container when latched using such a latch. The depicted elongate latch configuration can, in other alternative embodiments, be comprised of any one of a number of latching devices known to those having ordinary skill in the art. Therefore, although the previously discussed latch configuration has been shown to be particularly effective, the principles of the present invention specifically contemplate alternative latching methodologies including, but not limited to those discussed above.  
         [0028]      FIG. 2 ( c ) further describes and shows an elongated top latch embodiment constructed in accordance with the principles of the invention.  FIG. 2 ( c ) depicts a container embodiment (such as shown in  FIG. 2 ( b )) having the top open showing the elongate latching portions. In the depicted embodiment lower lid  21   b  is closed first. The lower lid  21   b  has a socket portion  25   b  arranged so that when the lid is closed an open portion of the socket  25   b  is facing upward. In such an arrangement, when the upper lid  21   a  is closed the plug portion  25   a  of the latch engages with the socket  25   b  to form a closed latch when the lids are closed. It is noted that in this depicted embodiment the latch  25  has a major axis (parallel to the long direction of the latch) and a minor axis (parallel to the thin direction of the latch). In this view the hinge axis can also be seen. For clarity the hinge axis  26  is depicted by arrows and is defined is the axis about which the hinge turns. Accordingly, the elongate late is configures so that the major axis of the elongate latch extends in a direction substantially parallel to a hinge axis  26 .  
         [0029]     Reference to  FIG. 2 ( d ) shows a cross-section view of  FIG. 2 ( b ) illustrating the engagement of the elongate latch  25 . Lower lid  21   b  is closed with the open portion of the socket  25   b  facing upward. Closing the upper lid  21   a  engages the plug portion  25   a  of the latch with the socket  25   b  to close the latch. As explained above, the socket and plug can be readily interchanged between top lid and bottom lid without departing from the scope of the invention.  
         [0030]     FIGS.  3 ( a ) and  3 ( b ) depicted a pairs of possible embodiments employed as side latches. FIGS.  3 ( a ) and  3 ( b ) are both cross section views of a top down view of one side of a container showing the basket body, upper lid, lower lid, and various latching features. Referring now to  FIG. 3 ( a ), a basket body with a latching feature  31  (here a detent or socket) is engaged with a first mated latching feature  32  of the lower lid  33  when closed. Also, a second latching feature  34  of the lower lid  33  is engaged with a mated latching feature  35  of the upper lid  36  to secure the lids in place when the container is closed. In this embodiment, the first mated latching feature  32  of the lower lid  33  and the second latching feature  34  of the lower lid  33  are in substantially the same portion of the lower lid  33 .  
         [0031]     Referring now to  FIG. 3 ( b ), a basket body with a latching feature  31 ′ (here a detent or socket) is engaged with a first mated latching feature  32 ′ of the lower lid  33 ′ when closed. Also, a second latching feature  34 ′ of the lower lid  33 ′ is engaged with a mated latching feature  35 ′ of the upper lid  36 ′ to secure the lids in place when the container is closed. In this embodiment, the first mated latching feature  32 ′ of the lower lid  33 ′ and the second latching feature  34 ′ of the lower lid  33 ′ are offset relative to each other.  
         [0032]      FIGS. 4 &amp; 5  depict some other embodiments of dual lidded hinged produce containers in accordance with the principles of the invention. In  FIG. 4  the container  40  includes a basket body  41  having a double axis arched bottom. A first arch orientation  42  enabling cooling airflow to pass under the container along one axis  43  and a second arch orientation  44  enabling cooling airflow to pass under the container along another axis  45 . Such a configuration enables cooling airflow to pass under the container in at least two different directions (commonly transversely oriented directions). Additionally, the hinges  46  connecting the lids  47  with the basket body  10  each can include ventilation apertures  48  than enable a cooling flow to pass through the container  40 . The inventors point out that in some embodiments it will be advantageous to have no ventilation apertures to enhance freshness of certain agricultural products. However, in some embodiments ample ventilation will be desired. As depicted here further ventilation can be supplied by adding side vents  49  which lie at the upper portion of the container. Such vents  49  can be in the lids  47  or at an upper portion of the basket body  41 . Alternatively, as depicted in  FIG. 4 , the vents  49  can be formed at the interface between the lid and body of the container. The inventors point out that  FIG. 4  depicts a “smooth walled” container which is substantially free of ribbing. Such containers can be valuable in holding and storing delicate fruits or vegetables that can be damaged by the presence of structural ribbing and the like.  
         [0033]      FIG. 5  depicts another container  50  embodiment having a first arch orientation  52  in the basket body  51  enabling cooling airflow to pass under the container along one axis  53 . Also, the walls parallel to the axis  53  can be flat bottomed  54 . However, the bottom can include feet or other support structures  55  enabling cooling airflow to pass under the container along another axis  56 . Such a configuration enables cooling airflow to pass under the container in at least two different directions. Additionally, the inventors point out that  FIG. 5  depicts the presence of ribbing  57  that represents, generally, depressions or raised features in the container wall. Such ribbing can substantially improve the strength of containers and can provide a substantial advantage during shipping. The inventors contemplate that all embodiments can be constructed using either ribbed containers or smooth walled containers.  
         [0034]     FIGS.  6 ( a ) and  6 ( b ) depict additional aspects of the invention.  FIG. 6 ( a ) depicts a perspective view of a closed container  60  constructed in accordance with the principles of the invention. The depicted container  60  is similar to the embodiment depicted, for example, in  FIG. 2 ( c ). In other word, the container has a pair of hinged lids configured so that one lid overlaps the other. In the depicted embodiment, a produce container  60  is constructed as a one-piece structure incorporating both basket body  22  and a dual hinged lid  21   a,    21   b.  Again, the lids  21   a,    21   b  are joined to the basket body  22  using a hinge  23 . In the depicted embodiment, a vent  64  is included in the hinge  63 . This vent  64  is of course optional. The top lid  21   a  is depicted overlapping the lower lid  21   b  thereby closing the container  60 . The underlying lower lid  21   b  is depicted in part by the dotted line to illustrate where it is covered by the top lid  21   a.  Additionally, the top portions of the lids ( 21   a,    21   b ) include a pair of long top latches  61  that extend along the long axis of the container  60 . As previously discussed, the top latches  61  can be of many different types and configurations. In the depicted embodiment, the latch  61  runs substantially parallel to the hinges  23  in the overlapping region of the two lids. As shown previously in FIGS.  2 ( a )- 2 ( d ), the latch  61  interlocks the upper lid  21   a  with the lower lid  21   b  to form a stable latch that can be readily opened or closed as needed. Although depicted with two latches  61 , the invention is not limited to such. As already described, single latch implementations can be used as well as embodiments having many latches. It is noted that in this particular implementation, the latch elements  61  are arranged with their elongate axes extending in a direction parallel to the hinge  23  axis. This not a required configuration, but is merely one possible implementation. Additionally, the inventors contemplate that any shape, orientation, or general configuration can be used for the latches.  
         [0035]     The container  60 , once latched can be further sealed using a supplemental fastener  63 . The fastener  63  is commonly embodied by an appliqué having an adhesive on one surface. After the container  60  is closed and latched the fastener  63  can be applied as a secondary sealing mechanism to more securely close and secure the container  60  in the closed configuration. Typically, the fastener  63  is affixed to the closed lids  21   a,    21   b  after the latch  61  is closed. In the embodiment depicted in  FIG. 6 ( a ) the fastener  63  covers the upper lid  21   a  and extends onto the exposed portion of the lower lid  21   b.  Typically, the adhesive of the fastener  63  adheres to both lids. The fastener  63  covers portions of both the upper lid  21   a  (depicted in part by the dashed line to illustrate where it is covered by the fastener  63 ) and the lower lid  21   b.  Also, the fastener  63  can cover the latches  61  (also, depicted here by dashed lines) for a more effective seal. It should be noted that the fastener can be affixed to the container  60  using methods other than adhesive. Heat sealing, photostatic attraction, and other methods of affixing known to those having ordinary skill in the art can be employed. A wide range of materials can also be employed. In certain implementations, a substantially transparent fastener  63  can be employed. Such a fastener is useful in agricultural implementations where it is helpful to be able to inspect produce sealed in a transparent container  60 . Additionally, paper or other opaque materials can be used to form the fastener  63 .  
         [0036]     In a particularly advantageous implementation, the fastener  63  comprises a label. The label can take any form, but is typically used as an appliqué with an adhesive surface for affixing to a container.  FIG. 6 ( b ) depicts one such appliqué fastener  63 . The fastener  63  can include a logo and/or other labeling information of an infinite variety.  
         [0037]     The inventors point out that such fasteners can substantially increase food safety by providing a verifiable seal on each package. The fasteners  63  seal each package and provide a tamper proof seal that maintains the packages in a closed configuration and allows the end user to verify that the package has not been opened along the entire distribution chain. Additionally, the seal provides a customer with safety confidence when buying sealed containers. Additionally, the sealed containers prevent individuals from stealing portions of the contents. Thus, the seals provide a theft deterrent and device for monitoring theft from the containers.  
         [0038]     The containers of this patent can be easily sealed using a variety of different techniques.  FIG. 7  schematically depicts a simplified packing system  700  that can be employed to load and seal the containers of this patent. At a loading station  701  open containers  63  are loaded with a selected material. Typically, this will be an agricultural produce product such as strawberries, grapes, cherries, or other such product. A conveyor system or other such motive system moves the filled container  63  to closing stations  703   a  and  703   b.  Station  703   a  closes the lower lid  21   b  first and then Station  703   b  closes the upper lid  21   a.  Station  705  then engages the latch to secure the lid. Typically, this can be accomplished by applying a roller mechanism that rolls over the container to snap the latch components together. Then, the label is applied at Station  707 . Lastly, the completed containers are packaged for shipping. Typically, loaded into shipping boxes. In some embodiments, many of these steps can be combined at a single station. For example, the components could be easily latched and the label applied at the same station. In another example, the upper and lower lids can be closed at the same station or in the same process. All of the foregoing operations can be accomplished manually or using machinery constructed to facilitate the above-referenced operations. Such machinery is capable of being constructed by those of ordinary skill in the art.  
         [0039]     The applicants point out that embodiments having varying numbers and sizes of vents and latches are intended to fall within the scope of the present invention. Moreover, although present invention has been particularly shown and described with respect to certain preferred embodiments and features thereof, 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 inventions as set forth in the appended claims. In particular, the many described features set forth here can be freely interchanged among container styles and implementations. Also, the use of alternative container forming technologies, container materials and specifications, container shapes and sizes to conform to differing produce requirements, and vent configurations are all contemplated by the principles of the present invention