Abstract:
A thermoformed dispensing container comprises a plastic tray with a dispensing cavity having side walls that include a circular radial side wall portion with a gap, and a disc-shaped thermoformed plastic lid positioned for rotation within the circular radial side wall portion of the tray, the lid having side walls that include a door. The dispensing container can be placed in an open condition by rotating the lid to align the door of the lid with the gap of the tray, or in a closed position by moving the door of the lid away from the gap of the tray.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to design patent application No. 29/277,799, filed Mar. 9, 2007, the disclosure of which is incorporated by reference. This application claims priority to design patent application No. 29/277,872, filed Mar. 12, 2007, the disclosure of which is incorporated by reference. 
     FIELD OF THE INVENTION 
     This invention relates generally to the field of containers. More particularly, the present invention relates to thermoformed containers having features to allow controlled dispensing of materials, such as foods, contained within the containers. 
     BACKGROUND OF THE INVENTION 
     The consumer products industry is constantly adapting containers for consumable products, such as ready-to-eat food items, in response to the increasingly sophisticated demands of consumers. For example, consumers increasingly desire food products that can be consumed at a time and location of the consumer&#39;s choosing. In a variety of industries, including but not limited to the food service industry, innovative packaging features can increase consumer demand and help differentiate product offerings in a competitive marketplace. 
     Thermoformed plastic containers are well known as containers for the sale of products, including but not limited to ready-to-eat foods. In the thermoforming or vacuum forming process for producing plastic articles, a section of a sheet or web of thermoplastic is heated to soften it, then the sheet is drawn into a mold by a vacuum, to assume the form of the mold before the sheet cools and hardens. Multiple individual plastic parts can be formed in this manner, such as the common “clamshell” plastic containers. The plastic containers can be sized and shaped to hold a wide variety of products. Additionally, the containers can be decoratively embossed. 
     Many thermoformed plastic containers, such as the common “clamshell” containers, include a base and a cover that together form a chamber. A consumable product, such as a ready-to-eat food, can be placed within the chamber formed by the base and cover. The cover may be attached to the base by a hinge and the cover may be fit to the base using an interference fit to hold the cover onto the base or to hold a hinged cover closed. Tabs and slots can also be used to hold the cover on the base, or to hold a hinged cover closed. However, thermoformed plastic containers are often pliable and the interference fit or tab connection can fail during storage or transportation of the container. Failure of the interference fit or tab and slot connection can cause the container to open, thereby spilling the contents of the container. 
     Other thermoformed plastic or foam containers, such as a disposable coffee cup and lid, also include a base and a cover that together form a chamber, with the cover fit to the base using an interference fit to hold the cover onto the base. The cover will often have an opening that allows some degree of controlled dispensing, for example using a cutout area that flexes to provide an opening for liquid. Other disposable coffee cup designs use a flap to cover an opening in the cover, with the flap held on the opening by an interference fit when the cup is in a closed position. Failure of the flexed cutout area or failure of the interference fit between the flap and the opening can cause the container to open, thereby spilling the contents of the container. 
     What is needed is a thermoformed dispensing container that allows controlled dispensing of materials or liquids while reducing the risk of spills during consumption, storage, and transport. What is further needed is such a container adapted for preparing and/or dispensing a combination of at least one liquid or semi-liquid material with one or more additional materials, while reducing the risk of spills during consumption, storage, and transport. 
     SUMMARY OF THE INVENTION 
     A first embodiment of the invention is a dispensing container comprising a thermoformed plastic tray that includes a dispensing cavity with side walls having a circular radial side wall portion with a gap; and a disc-shaped thermoformed plastic lid positioned for rotation within the circular radial side wall portion of the tray, the lid having side walls that include a door. The dispensing container can be placed in an open condition by rotating the lid to align the door of the lid with the gap of the tray, or in a closed position by moving the door of the lid away from the gap of the tray. 
     A second embodiment of the invention is a dispensing container kit comprising a thermoformed plastic tray that includes a dispensing cavity with side walls that include a circular radial side wall portion with a gap; and a disc-shaped thermoformed plastic lid dimensioned and configured to fit for rotation within the circular radial side wall portion of the tray, the lid having side walls that include a door. 
     A third embodiment of the invention is a method of using a dispensing container, comprising (a) providing a thermoformed plastic tray that includes a dispensing cavity with side walls that include a circular radial side wall portion with a gap; (b) providing a disc-shaped thermoformed plastic lid positioned for rotation within the circular radial side wall portion of the tray, the lid having side walls that include a door; and (c) rotating the lid to align the door of the lid with the gap of the tray to place the dispensing container in an open condition. 
     Further objects, features, and advantages of the invention will be apparent from the following detailed description when taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG. 1  is an exploded perspective view of a first embodiment of a dispensing container according to the invention; 
         FIG. 2  is a perspective view of the assembled dispensing container of  FIG. 1  in a closed state; 
         FIG. 3  is a perspective view of the assembled dispensing container of  FIG. 1  in an open state; 
         FIG. 4  is a perspective view of the lid of  FIG. 1 ; 
         FIG. 5  is a top view of the lid of  FIG. 1 ; 
         FIG. 6  is a bottom view of the lid of  FIG. 1 ; 
         FIG. 7  is a side view of the lid of  FIG. 1 , looking at the open side; 
         FIG. 8  is a side view of the lid of  FIG. 1 , looking at a closed side orthogonal to the open side of the lid; 
         FIG. 9  is a perspective view of the tray of  FIG. 1 ; 
         FIG. 10  is a top view of the tray of  FIG. 1 ; 
         FIG. 11  is a bottom view of the tray of  FIG. 1 ; 
         FIG. 12  is a side view of the tray of  FIG. 1 , looking at the short side adjacent to the receiving cavity; 
         FIG. 13  is a side view of the tray of  FIG. 1 , looking at the long side adjacent to the receiving cavity and the secondary cavity; 
         FIG. 14  is a perspective view of a second embodiment of a lid for use in a dispensing container according to the invention; 
         FIG. 15  is a top view of the lid of  FIG. 14 ; 
         FIG. 16  is a bottom view of the lid of  FIG. 14 ; 
         FIG. 17  is a side view of the lid of  FIG. 14 , looking at an open side; 
         FIG. 18  is a side view of the lid of  FIG. 14 , looking at a closed side orthogonal to the open sides of the lid; 
         FIG. 19  is a perspective view of an embodiment of a cup for use in a dispensing container according to the invention; 
         FIG. 20  is a top view of the cup of  FIG. 19 ; 
         FIG. 21  is a bottom view of the cup of  FIG. 19 ; 
         FIG. 22  is a side view of the cup of  FIG. 19 , looking at the side that includes the rim opening and receiving cavity; and 
         FIG. 23  is a side view of the cup of  FIG. 19 , looking at a side orthogonal to the side that includes the rim opening and receiving cavity. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIGS. 1-13  provide various views of a first embodiment of a dispensing container according to the invention, indicated generally at  10 . The dispensing container  10  includes a tray  12  and a lid  14 . The exemplary tray  12  includes a dispensing cavity  20 , a receiving cavity  30 , and a third cavity  40 , but this particular structure is not required. For example, a different number of cavities could be provided for particular applications, and the tray itself or the individual cavities could be different sizes and/or shapes. 
       FIGS. 2-3  illustrate the basic operation of the dispensing container  10 , with the lid  14  engaged with the dispensing cavity  20  of the tray  12 .  FIG. 2  shows the dispensing container  10  with the lid  14  rotated to a closed position, where liquid or other material, such as ready-to-eat food, is retained within the dispensing cavity  20 .  FIG. 3  shows the dispensing container  10  with the lid  14  rotated to an open position, where liquid or other material, such as ready-to-eat food, can flow from the dispensing cavity  20  to the receiving cavity  30 . 
     This structure allows the dispensing container  10  to provide reclosable and controlled dispensing of liquids or semi-liquid materials (such as ready-to-eat foods including microwaveable sauces, nacho cheese, hot fudge, etc.) from the dispensing cavity  20  to the receiving cavity  30 . The receiving cavity may hold complementary materials (for example, foods such as ribs, tortilla chips, or ice cream). The dispensing container  10  can also help to maintain temperature of materials in the dispensing cavity  20 , for example after they have been heated in a microwave. The dispensing container  10  can also provide reclosable storage during use or transport. 
     The tray  12  and lid  14  of the dispensing container  10  are preferably made using thermoforming methods, from a suitable thermoformable material. For example, a dispensing container  10  for ready-to-eat foods might be formed of a thermoformable plastic such as oriented polystyrene (OPS), talc-filled polypropylene (TFPP), polypropylene (PP), high impact polystyrene (HIPS), polyethylene terepthalate (PET), amorphous PET (APET), crystalline polyethylene (CPET) polystyrene copolymer blends, styrene block copolymer blends, and the like. The materials forming the tray  12  and lid  14  may be different, and those materials are not necessarily homogeneous, but may be, for example, a laminate, co-extruded material, or multilayer material. 
       FIGS. 5-8  illustrate the lid  14  of the dispensing container  10 . The lid  14  is generally shaped as a circular disc, with a floor  51  and side walls  52  integrally formed with and extending upward from the floor  51 . The side walls  52  may terminate in a flange or lip  53 . The floor  51  includes a lower portion  55  and a raised portion  57  that terminates in a side wall  52 . The raised portion  57  forms a door  60  in the side wall  52  with an upper door edge  63  and lateral door edges  64 , although the door  60  is not necessarily rectangular. The raised portion  57  includes lateral walls  65  integrally formed with and extending from the lower portion  55  to a ceiling  66 . The side walls  52  include a protrusion  68 . 
       FIGS. 9-13  illustrate the tray  12  of the container  10 . The dispensing cavity  20  includes a floor  21 , and side walls  22  integrally formed with and extending upward from the floor  21  through a circular radial side wall portion  23  that includes a groove  24 . The side walls  22  terminate in a dispensing cavity rim  25  that includes a dispensing cavity rim top surface  26 . The receiving cavity  30  includes a floor  31 , and side walls  32  integrally formed with and extending upward from the floor  31 . The side walls  32  terminate in a receiving cavity rim  33  that includes a receiving cavity rim top surface  34 . The third cavity  40  includes a floor  41 , and side walls  42  integrally formed with and extending upward from the floor  41 . The side walls  42  terminate in a third cavity rim  43  that includes a third cavity rim top surface  44 . 
     The tray  12  includes a substantially planar top surface  45  that includes the dispensing cavity rim top surface  26 , the receiving cavity rim top surface  34 , and the third cavity rim top surface  44 . In a particular application, a sheet material (not shown) could be affixed to the top surface  45  of the tray  12 , for example by thermal bonding or by glue, to seal materials such as ready-to-eat foods into the separate cavities. 
     The receiving cavity  30  is adjacent to the dispensing cavity  20 , and separated by a partition  35  formed by the receiving cavity side walls  32 , rim  33 , and rim top surface  34 , and the dispensing cavity side walls  22 , radial side wall portion  23 , cavity rim  25 , and rim top surface  26 . The partition  35  includes a gap  36  that includes a gap floor  37  and lateral walls  38 . The gap floor  37  can be sloped from the dispensing cavity  20  to the receiving cavity  30  to facilitate the gravity flow of material from the dispensing cavity  20  to the receiving cavity  30 . 
     As best shown in  FIGS. 2-3 , the dispensing container  10  is assembled by engaging the lid  14  with the dispensing cavity  20  of the tray  12 . The lid  14  is configured to fit the circular radial side wall portion  23  of the dispensing cavity  20 , and the protrusion  68  of the side walls  52  of the lid  14  is configured to nest into the groove  24  of the circular side wall portion  23 . In this way, the lid  14  can be “snapped” into the circular radial side wall portion  23  so that the protrusion  68  and groove  24  provide an interference fit to retain the lid  14  on the dispensing cavity  20  while leaving the lid  14  free to rotate within the circular radial side wall portion  23 . The protrusion  68  and groove  24  can also provide a seal to retain the contents of the dispensing cavity  20 , for example during storage or transport. 
       FIG. 2  shows the dispensing container  10  with the lid  14  rotated to a closed position, wherein the door  60  of the lid  14  is not aligned with the gap  36  in the partition  35  between the dispensing cavity  20  and the receiving cavity  30 . In  FIG. 2 , the door  60  is rotated diametrically opposite the gap  36 , although this is not the only closed position since any rotation that does not align any portion of the door  60  with any portion of the gap  36  is a closed position. 
       FIG. 3  shows the dispensing container  10  with the lid  14  rotated to an open position, wherein the door  60  of the lid  14  is fully aligned with the gap  36  in the partition  35  between the dispensing cavity  20  and the receiving cavity  30 . In  FIG. 2 , the door  60  is rotated to be fully aligned with the gap  36 , although this is not the only open position since any rotation that aligns a portion of the door  60  with a portion of the gap  36  is a partially or completely open position. 
       FIGS. 14-18  illustrate an alternative lid  70  for use in a dispensing container. Like the lid  14 , the lid  70  is generally shaped as a circular disc, with a floor  71  and side walls  72  integrally formed with and extending upward from the floor  71 . The side walls  72  may terminate in a flange or lip  73 . The floor  71  includes a lower portion  75 , a central raised grip portion  76 , and two convex lateral raised portions  77  each terminating in a side wall  72 . Each of the lateral raised portions  77  forms a door  80  in the side wall  72  with a roughly semi-circular door edge  83 , although the door  80  is not necessarily that shape. The central raised portion  76  is preferably shaped to provide an easy-to-grip knob for easier rotation of the lid  70 . The side walls  72  include a groove  78 . 
       FIGS. 19-23  illustrate a tray  84  for use in a dispensing container, for example in combination with the alternative lid  70 . The tray  84  includes a catcher  85  and a dispensing cavity  90  that may be generally cup-shaped, although this is not required. The dispensing cavity  90  includes a floor  91 , and side walls  92  integrally formed with and extending upward from the floor  91  through a circular radial side wall portion  93  that includes a protrusion  94 . The side walls  92  terminate in a dispensing cavity rim  95  that includes a dispensing cavity rim top surface  96 . 
     The circular radial side wall portion  93  includes a gap  97  between the dispensing cavity  90  and the catcher  85 . The catcher  85  includes integrally formed floor  86  and side walls  87  extending from the circular radial side wall portion  93 . The side walls  87  terminate in a catcher rim  88  that includes a catcher rim top surface  89 . 
     The alternative tray  84  includes a substantially planar top surface  98  that includes the dispensing cavity rim top surface  96  and the catcher rim top surface  89 . In a particular application, a sheet material (not shown) could be affixed to the top surface  98  of the tray  84 , for example by thermal bonding or by glue, to seal materials such as ready-to-eat foods into the separate cavities. 
     As with the dispensing container  10  of  FIGS. 2-3 , an alternative dispensing container can be assembled by engaging the lid  70  with the tray  84 . This alternative dispensing container can be used, for example, with ready-to-eat foods such as cereal, candies, nuts, raisins, or granola. The lid  70  is configured to fit the circular radial side wall portion  93 , with the protrusion  94  of the tray configured to nest into the groove  78  of the lid  70 . In this way, the lid  70  can be “snapped” into the circular radial side wall portion  93  so that the protrusion  94  and groove  78  provide an interference fit to retain the lid  70  on the dispensing cavity  90  while leaving the lid  70  free to rotate, and to provide a seal. 
     The alternative dispensing container operates like the dispensing container  10 . The alternative dispensing container has an open position with the lid  70  rotated to align a door  80  with the gap  97 , and a closed position with the lid  70  rotated so that no part of a door  80  is aligned with the gap  97 . During use, the alternative dispensing container can be placed in an open position, then shaken to dispense a limited portion from the dispensing cavity  90  into the catcher for consumption. 
     It is understood that the invention is not confined to the embodiments set forth herein as illustrative, but embraces all such forms thereof that come within the scope of the following claims.