Abstract:
There is disclosed a container for receiving and sealing material in an internal cavity. The container is configured to be shiftable about an intermediate hinge portion and provides a dispensation port defined by a frangible connected panel of the container. The panel can be reclosed after initial severing of the frangible connection upon initial opening.

Description:
FIELD 
     The invention relates to a container and, more particularly, to a reclosable container formed from a single component or multiple components and a method of making the same. 
     BACKGROUND 
     Containers of various sizes and shapes have long been used for packaging material. Generally, the style and configuration of packaging is selected based on packaging cost and the characteristics of material to be packaged. 
     Alternatively, when the material to be packaged is a liquid, has a granular consistency or includes a plurality of pieces, it may be preferable to have a sealed container which provides an internal cavity for the material to be stored and access to the cavity upon opening or rupturing the container. Further, with many materials, it may be desirable to provide a tamper evident feature to indicate whether or not the container has been previously opened. 
     A variety of tamper evident features have been employed in packaging. Exemplary tamper evident features include plastic wrapped about the container, a foil or paper seal secured to and extending across a container opening, and a removable cap having a break-off portion which cannot be reconnected to the removable cap after having been broken upon initial opening of the container. 
     As a result, the practice of packaging material within a sealed container and having a tamper evident feature requires multiple components which must be optimized and coordinated for the particular material to be packaged and potential environment of use. Further, a processor who packages various materials may be required to stock different containers and tamper evident features for each different material to be packaged. 
     In addition, given the variety of tamper evident features used in packaging today, a consumer may have difficulty ascertaining whether a product has been opened for the first time. For example, as noted above, some tamper evident features include only a thin plastic wrap around a portion of the container, while some may use a seal under a removable cap, and some may use both. As a result, it can be difficult for consumers to ascertain by a quick visual examination whether a container has been opened for a first time. Another consideration in the ease of being able to open the container, particularly upon initial opening which requires overcoming the tamper evident feature as well. For example, shrink wrap and seal types of tamper evident features can be extremely difficult to remove particularly to those with limited dexterity. 
     It also is important to extend consideration to being able to recycle discarded containers. Recycling is made more difficult by containers made of multiple components because the different components are made from different materials. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a container with a base and lid in an open configuration; 
         FIG. 2  is a side elevational view of the container of  FIG. 1 ; 
         FIG. 3  is a top plan view of the container of  FIG. 1 ; 
         FIG. 4  is a bottom plan view of the container of  FIG. 1 ; 
         FIG. 5  is a perspective view of the container of  FIG. 1  with the base and lid of the container in an intermediate configuration; 
         FIG. 6  is a perspective view of the container of  FIG. 1  with the base and lid of the container in a closed configuration; 
         FIG. 7  is a side elevational of the container of  FIG. 1  with the container in the closed configuration; 
         FIG. 8  is a top plan view of the container of  FIG. 1  with the container in the closed configuration; 
         FIG. 9  is a side elevational view of the container of  FIG. 1  with the container in the closed configuration and an opening panel in a partially open orientation; 
         FIG. 10  is a side elevational view of the container of  FIG. 1  with the container in the closed configuration and the opening panel in a fully open dispensing configuration; 
         FIG. 11  is a detail view of the container of  FIG. 1  with the container in the closed configuration showing the interaction between the base and the lid; 
         FIG. 12  is a detail view of the container of  FIG. 1  with the container in the closed configuration showing a mechanical interengagement seal between the base and the lid; 
         FIG. 13  is a detailed view of the container of  FIG. 1  with the container in the closed configuration showing an alternative mechanical interengagement seat between the base and lid; 
         FIG. 14  is a perspective view of the container of  FIG. 1  showing nine empty nested containers; 
         FIG. 15  is a perspective view of a second container embodiment with a base and a lid in a closed configuration; 
         FIG. 16  is a side elevational view of the container of  FIG. 15  with the base and the lid in the closed configuration; 
         FIG. 17  is a perspective view of the container of  FIG. 15  with the base and the lid in the open configuration and a distal end of a panel secured to the upper surface of the lid; 
         FIG. 18  is a perspective view of the container of  FIG. 15  with the base and the lid in the closed configuration and the distal end of the panel secured to the lid; 
         FIG. 19  is a side elevational view of the container of  FIG. 15  with the base and the lid in the closed configuration and the distal end of the panel secured to the lid; 
         FIG. 20  is a perspective view of the container of  FIG. 15  showing 9 nested containers and one unnested container and the distal end of the panel secured to the lid; 
         FIG. 21  is a perspective view of a third container embodiment with a base and a lid in an open configuration; 
         FIG. 22  is an exploded perspective view of the container of  FIG. 21  in the closed configuration; 
         FIG. 23  is a perspective of the container of  FIG. 21  showing eight nested lids and eight nested bases; 
         FIG. 24  is a detail view of the lid showing an intact frangible portion; 
         FIG. 25  is a detail view of the lid of  FIG. 24  showing a tab defined by the fractured frangible portion; 
         FIG. 26  is a detail view of the lid of  FIG. 24  showing a lip of the tab positioned within a cavity of the container; 
         FIG. 27  is a detail view of the lid showing an intact alternative frangible portion; 
         FIG. 28  is a detail view of the lid of  FIG. 27  showing a tab defined by the fractured frangible portion; 
         FIG. 29  is detail view of the lid of  FIG. 27  showing a lip of the tab positioned within a cavity of the container; and 
         FIG. 30  is a side elevational view comparing the space requirements of the sealed containers and unsealed nested containers. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As shown in  FIGS. 1-10 , a container  2  for storing material, such as liquids or solid pieces, is disclosed. The container  2  includes a lid portion  4 , a base portion  6  and a hinge portion  8  therebetween. The container  2  is formed as a unitary or single component  10 . The lid  4  and base  6  can be shifted about the hinge portion  8  between an open configuration  12 , as shown in  FIGS. 1-4 , and a closed configuration  14 , as shown in  FIGS. 6-10 . The container  2  can be sealed in the closed configuration  14  such that, if the container  2  is shifted back toward the open configuration  12  so as to disrupt the seal, the container  2  cannot be readily sealed back in the closed configuration  14 . More particularly, the container  2  is not intended to be opened by separating the lid  4  and base  6  after the lid  4  and base  6  have been sealed together. To access the material stored within the container  2 , the container  2  includes an opening panel  16  that covers a dispensing port for expelling the contents from the container  2 . 
     As shown in  FIGS. 1-10 , both the lid portion  4  and the base portion  6  have a concave configuration  18  and  20 , which face one another in the closed configuration  14 , creating an internal sealed cavity  15  therebetween. However, it is noted that either of the lid and base portions  4  and  6  can have a flat configuration or a convex configuration such that, in the closed configuration  14 , the convex shaped portion would extend into the concave shaped portion of the other half. In any configuration, a cavity  15  is to be formed between the lid and base portions  4  and  6 . 
     Both the size and the configuration of the lid and base portions  4  and  6  can be optimized depending on the material to be stored or for aesthetic purposes. For example, the lid and base portions  4  and  6  can be configured to provide 200 cubic centimeters or 400 cubic centimeters of space and have various geometrical configurations. 
     As shown in  FIG. 1 , the lid portion  4  includes a curved wall portion  24  defining an opening  22  and the curvature of the lid portion  4 . As shown in  FIG. 2 , the curved wall  24  tapers along the lid portion  4  towards the hinge portion  8 . Opposite the tapered end  26  of the lid portion  4  is the opening panel  16 . It, however, is contemplated that the opening panel  16  may be located at alternative locations on the lid portion  4  of the container  2  or even on the base portion  6  of the container  2 . 
     The base portion  6 , as shown in  FIGS. 1-10 , includes a curved wall portion  30  defining an opening  28  and the curvature of the base portion  6 . As shown in  FIG. 2 , the curved wall  30  can be tapered along the length of the base portion  6 . As shown in  FIG. 2 , the curved wall  30  is tapered from a smaller end  32  toward a larger end  34  adjacent the hinge portion  8 . As such, the tapered configuration can be used to accommodate a larger end portion  34 . As shown in  FIGS. 9 and 10 , the larger end  34  includes a surface  36  configured to allow the container  2  to stand on the surface  36  in an upright orientation for being displayed or stored. The base surface  36  has a flat configuration  38 ; however, other configurations which permit the container  2  to balance thereon are contemplated. 
     The container  2  is produced as an open single component piece that can be stacked in a nested configuration for transport from manufacturing to a filling operation. More specifically, as shown in  FIG. 14 , the lid and base portions  4  and  6  of the container  2  can be configured to nest in an identical container  2  or allow an identical container  2  to be nested therein. In particular, outer surfaces  40  and  42  of the lid and base portions  4  and  6 , respectively, can be configured to be received in the openings  22  and  28  of the lid and base portions  4  and  6 , respectively, allowing the containers  2  to be stacked in the open configuration  12 . As a result, the containers  2  can be densely packed and stored prior to filling. Further, the configurations of the outer surfaces  40  and  42  and the openings  22  and  28  are sized relatively to one another such that the containers  2  can be easily removed when nested with other like containers  2 . This nesting of the containers for transport can decrease transport volume required by 60-90% over typical jars and lids. As shown in  FIG. 30 , for example, fifty nested containers  2  can be stored in the space which would be occupied by eighteen identical containers  2  in the closed configuration  14 . 
     About the perimeter of the opening  28  of the base portion  6  is a lower flange  44 . As shown in  FIGS. 1 ,  2 ,  5 ,  6 ,  11  and  12 , the lower flange  44  includes a rim portion  46  and a skirt portion  48 . The rim  46  extends generally orthogonal to the curved wall  30  of the base portion  6 . The skirt  48  extends generally orthogonal to the rim  46  along the curved sidewall  30  of the base portion  6 , except along the hinge  8  and the opening panel  16 . 
     The lid portion  4  includes an upper flange portion  50  extending about the perimeter of the opening  22  and corresponding to the lower flange  44 . A rim portion  52  of the upper flange  50  has a width which generally corresponds to the width of the rim  46 . An upper skirt portion  54  extends along an outer edge  56  of the rim  52  and corresponds to the skirt  48  of the lower portion  6 . Guide posts  58  extend from an inner surface  60  of the lid portion  4 . The guide posts  58  are configured to guide the flange  44  of the base portion  6  so that the lower rim  46  engages the upper rim  52  and the lower skirt portion  48  engages the upper skirt portion  54 . As shown in  FIGS. 1 and 5 , the guide posts  58  can include a curved or tapered terminal edge  62  upon which the lower flange can slide to further ease the lower flange  44  into engagement with the upper flange  50 . 
     To provide a tamper evident feature the flanges  44  and  50  are sealed together to form a seal  64 . Once the seal  64  is formed between the flanges  44  and  50  with the lid and base portions  4  and  6  in the closed configuration  14 , separating the upper and lower flanges  44  and  50  breaks the seal  64 . As previously discussed, the seal  64  is not intended to be resealable. 
     In one embodiment, as shown in  FIG. 11 , the flanges  44  and  50  are slip fit with one another such that prior to applying the seal  64  the flanges  44  and  50  can be engaged and disengaged without structural failure. In lieu of a mechanical locking engagement, the flanges  44  and  50  of the upper and lower portions  4  and  6  can be secured in place by other methods. In particular, an adhesive  51  can be used to from the seal  64  to lock the flanges  44  and  50  of the lid and base portions  4  and  6  together. Other methods of sealing the flanges  44  and  50  of the lid and base portions  4  and  6  include the use of heat, ultrasonic welding, or any other known method or process of sealing members or portions to one another. 
     In an alternative embodiment, as shown in  FIG. 12 , the seal  64  can be a mechanical seal  66  between the upper and lower flanges  44  and  50 . The mechanical seal  66  includes an inner extension  68  of the rim  46  of the lower flange  44 . The guide posts  58  of the upper portion  6  include a cut-out  70  extending from below the rim  52  of the upper flange  50  and corresponding to the inner extension  68  of the lower flange  44 . As a result, engaging the lower flange  44  with the upper flange  50  to create the mechanical seal  66  requires an application of force sufficient to urge at least one of the guide posts  58  and the upper skirt  54  away from the lower flange  44  to permit the inner extension  68  to shift along the guide post  58  and be snapped into the guide post cut-out  70 , thereby mechanically locking the upper and lower flanges  44  and  50 . Subsequent separation of the upper and lower flanges  44  and  50  results in guide post  58  or upper skirt  54  failure, which would further not allow for a future mechanical seal  66  between the upper and lower portions  4  and  6 . The mechanical seal  66  can be formed by a number of the guide posts  58  each having a cut out  70  to receive the inner extension  68 . 
     In another alternative embodiment, as shown in  FIG. 13 , the seal  64  can be a mechanical seal  66  between the upper and lower flanges  44  and  50 . The mechanical seal  66  includes an enlarged distal head portion  128  of the lower skirt  54 . As shown in  FIG. 13 , the lower skirt  54  extends downward from the flange rim  52  at a distance  138  inward from the flange rim distal edge  56 . The enlarged head portion  128  is configured to be secured between spaced portions  130  and  132  of the lower skirt  48 . The spaced portions  130  and  132  are spaced from each other a distance less than the size of the enlarged head portion  128  and include an enlarged cavity  134  at the bottom of the lower skirt  48 . The enlarged cavity  134  is sized to securely receive the enlarged head portion  128  of the upper skirt  54  therein. To insert the enlarged head portion  128  into the cavity, the enlarged head portion  128  includes a tapered leading edge  136  to urge the spaced skirt portions  130  and  132  away from one another an amount sufficient to permit the enlarged head portion  128  to be received in the enlarged cavity  134 , thereby mechanically locking the upper and lower flanges  44  and  50 . Subsequent separation of the upper and lower flanges  44  and  50  results in failure of the spaced skirt portions  130  and  132  and/or enlarged head portion  128 , which would not allow for a future mechanical seal  66  between the lid and base portions  4  and  6 . While not shown, guide posts of the lid  4  can be used to align the mating of the lid and base portions  4  and  6 , as described above. 
     The contents being stored inside the container  2  depends on the size of the container  2  and the opening panel  16  and the compatibility of the materials of the container with the contents to be stored. As indicated above, liquids and solids can be stored in the container. The size of the opening panel  16  can be optimized depending on the viscosity of the fluid, the size of the particles, or the desired flow rate through the dispensing port formed by opening the opening panel  16 . 
     As shown in  FIGS. 1-10 , the opening panel  16  includes a weakened, frangible portion  72  of the lid  4  of the container  2 . Exemplary dispensing ports are disclosed in D560,442 to Teys et al., D560,443 to Teys et al., D570,164 to Teys et al., D572,089 to Teys et al., and U.S. patent application Ser. No. 11/771,372 to Teys et al., which issued as U.S. Pat. No. 8,091,242 on Jan. 10, 2012, which are hereby incorporated by reference as if included in their entirety herein. 
     The frangible portion  72  extends from the upper flange  50 , toward the curved wall portion  24 , and back to the upper flange  50 . As shown in  FIG. 1  the frangible portion has a wide base  74  adjacent the upper flange  50  and tapers to a pointed distal end  76  away from the upper flange  50 . As shown in FIGS.  2  and  4 - 8 , a force application member  78 , such as a ring-shaped handle  80 , extends from the pointed distal end  76  and provides a user a graspable handle to pull to exert a concentrated force upon the frangible portion  72 . The pulling acts as a lever to easily maximize and concentrate the opening force. As the force applied overcomes the strength of the frangible portion  72 , the frangible portion  72  breaks or fractures therealong, creating an opening  82  into the sealed cavity  15 . 
     As shown in  FIGS. 7 ,  9  and  10 , tab portion  84  of the opening panel  16 , defined by the fractured frangible portion  72 , extends along the lid portion  4  toward the upper flange  50 . Preferably, the upper flange  50  remains intact and acts as a hinge while the tab portion  84  is shifted outwardly  86  to provide the opening  82  into the cavity  15 . More specifically, as the tab portion  84  is shifted outwardly  86 , a portion of the flange  50  which intersects with the fractured frangible portion  72  bends or deforms with the movement of the tab portion  84 . Further, as the tab portion  84  is shifted inwardly  88 , the outer edge  90  of the tab portion  84  can interact with the remainder of the frangible portion  72  about the opening  82  to close the opening  82  so that the remaining contents are closed in the cavity  15 . As a result, the tab portion  84  can be used to manipulate the opening panel  16  to open and close the opening  82  throughout the useful life of the container  2 . This allows a user to dispense a specific amount of the contents within the cavity  15 , with the rest being safely stored within the container cavity  15 . 
     In a second embodiment, as shown in  FIGS. 15-20 , opening panel  16  includes a flap portion  98  affixed to the tab  84  that can lock to the top of the lid, as described below. In all other material respects, this container is the same as that described above. As shown in  FIGS. 15 and 16 , the flap portion  98  is connected at one end  100  to the upper flange  50  and includes a graspable distal end  102  having an opening  104  therethrough. Preferably, the flap portion  98  is formed as a single piece with the lid  4  and the base  6 . An inner surface  106  of the flap  98  is secured to the tab portion  84 , such as by an adhesive, heat adhesion, or ultrasonic welding. As a result, as the distal end  102  of the flap portion  98  is pulled to pivot outwardly  86  to cause the frangible portion  72  of the lid  4  to fracture or break as discussed above. 
     As shown in  FIGS. 18 and 19 , the flap portion  98  can be shifted toward the tab  84  by pulling the distal end  102  of the flap portion  98  to pivot inwardly  88  toward the lid  4 . The lid  4  includes a hitch portion  108  formed and extending from the surface  24  of the lid  4  and provides a securing location for distal end  102  of the flap  98 . As shown in  FIGS. 18 and 19 , an inner portion  110  of the opening  104  of the flap  98  can be positioned around a portion of the hitch  108 , thereby securing the flap  98  in place. As a result, the tab  84  and the flap  98  close the opening  82  of the lid  4 . If desired, a force can be applied against a central portion  112  of the flap  98  to ensure that tab  84  has closed the opening  82 . 
     As shown in  FIGS. 15-19 , adjacent the hitch  108  of the lid  4  is a recessed portion  114 . The recessed portion  114  provides a user with a gap between the curved surface  24  of the lid  4  and the distal end  102  of the flap  98 , thereby allowing a user to grasp the flap  98  and shift the flap  98  toward an open configuration. 
     As shown in  FIG. 20 , the container  2  of  FIGS. 15-19  can be nested, such as shown in  FIG. 14 . Preferably, the flap portion  98 , hitch  108  and recess  114  are configured to minimize the space occupied while like containers are nested. 
     A third exemplary embodiment of the container  2  is shown in  FIGS. 21-23 . This embodiment is a two-piece version of container  2 . The only difference is that the container  2  does not include the hinge portion  8 ; otherwise, the container is the same, including the attachment structure between the lid and base and the open and reclose structure for the opening panel. It is contemplated that the container  2  shown in  FIGS. 15-20  also can be a two-piece container. 
     The frangible portion  72  of the container  2  acts as a tamper evident feature because a fractured or broken frangible portion  72  is easily recognizable by a user. If fractured, the container  2  has been opened for a first time. 
     More specifically,  FIG. 24  shows in greater detail one embodiment of a frangible portion  72  that has not been previously fractured or broken. Close inspection reveals that the frangible portion  72  includes the tab outer edge  90 , a lid latch  92 , and a connecting failure portion  94 . The outer edge  90  extends above the lower surface  96  of the lid latch  92 , while the failure portion  94  forms a “Z” like configuration with the outer edge  90  and the latch  92 . 
     As shown in  FIG. 25 , after the failure portion  94  of the frangible portion  72  has been fractured, the outer edge  90  and latch  92  are spaced from one another because the failure portion  94  is no longer present. In some circumstances, remnants of the failure portion  94  may be attached to either the outer edge  90  or the latch  92  after the opening panel  16  has been opened, but for all practical purposes, it is no longer present. The tab  84  can then be hinged back so that the contents of the container  2  can be dispensed. 
     As described above, the outer edge  90  extends above the lower surface  96  of the latch  92 . Accordingly, as shown in  FIG. 26 , rotating the tab  84  back towards and into engagement with the latch  92  deforms either or both of the tab  84  and the latch  92  until the outer edge  90  has extended beyond the latch  92 . In this manner, the tab  84  is reclosed and locked. 
     Another embodiment of the frangible portion  72  is shown in  FIGS. 27-29 . The frangible portion  72  includes a recessed outer tab portion  116  having a tab ridge  118  along the edge  120  of the tab  84 , a lid latch portion  122 , and a connecting failure portion  124 . The tab ridge  118  extends above the lower surface  126  of the lid latch  122 , while the failure portion  124  connects the tab edge  120  and the latch  122 . 
     As shown in  FIG. 28 , after the connecting failure portion  124  of the frangible portion  72  has been fractured, the tab edge  120  and latch  122  are spaced from one another because the failure portion  124  is no longer present. In some circumstances, remnants of the failure portion  124  may be partly attached to either the outer tab edge  120  or the latch  122  after the opening panel  16  has been opened, but for all practical purposes, it is no longer present. The tab  84  can then be hinged back so that the contents of the container  2  can be dispensed. 
     As described above, the outer tab edge  120  extends above the lower surface  126  of the latch  122 . Accordingly, as shown in  FIG. 29 , rotating the tab  84  back towards and into engagement with the latch  122  deforms either or both of the tab  84  and the latch  122  until the outer tab edge  120  has extended beyond the latch  122 . In this manner, the tab  84  is reclosed and locked. 
     The container can be suitable for a wide range of products, such as dry powder/granular through liquid. The enclosed volume would typically be in the range of 50 cubic centimeters to 200 cubic centimeters but could be smaller or larger depending on the volumetric needs. The container may be rigid or semi rigid. The container  2  can be produced from any suitable material, preferably an environmentally friendly moldable plastic. Further, the container  2  can be produced by any known method, including injection molding and thermoforming. 
     Further, with the one-piece versions of the container  2 , the container can be easily used to package goods. In particular, after a container  2  has been provided and inspected to ensure that the flanges are engageable and the frangible line  72  has not been fractured. Upon a successful inspection, at least one of the lid and base portions  4  and  6  are filled with material. It is preferred that the base portion  6  is filled in that it is typically the larger of the two portions. The unfilled portion of the lid and base portions is shifted about the hinge portion  8  such that the flanges  44  and  50  engage one another. A non-resealable tamper indicating seal  64  is then produced between the upper and lower flanges  44  and  50 . 
     The same applies for the two-piece versions with the exception that the lid is not hinged into engagement with the base. Preferably, the lid is aligned to overlap the base and is placed directly onto the base with one of the above desirable features locking them together. 
     The use of in-mold labeling to the final package can be utilized in the container forming process. This involves placing a printed polymer label into the injection mold. During injection of the polymer material, the label becomes integral with the molded container. This allows for the container to be labeled while manufacturing of the container and for labeling to be completed on all faces of the package. 
     While the invention has been particularly described with specific reference to particular methods and product embodiments, it will be appreciated that various alterations, modifications, and adaptations may be based on the present disclosure, and are intended to be within the scope of the invention as defined by the following claims.