HERMETICALLY SEALED PACKAGING FOR FRESH FOODSTUFFS

Abstract

An atmosphere controlled foodstuff container includes a base tray and a cover. The cover and base tray are constructed of a substantially gas impermeable material. The cover and base tray are connectable and are hermetically sealed with a sealant or sealing material. The container includes at least one atmosphere control member, such as a membrane or micro-perforations, which controls the flow of gases into and out of the otherwise sealed interior of the container. The base tray may be opaque for use as a serving tray and the cover transparent to permit viewing of the product.

Claims

1. A container for fresh foodstuffs comprising: a cover, said cover having an inner surface, an outer surface and a peripheral edge, said cover defining at least one compartment, said cover comprising a generally rigid, essentially gas impermeable member, said cover further defining a first locking member; a base, said base having an inner surface, an outside surface and a peripheral edge, said inner surface being generally concave and said base comprising a generally rigid, essentially gas impermeable material, said base defining a second locking member, said cover and base connected to one another via engagement of said first and second locking members, said base cooperating with said cover to define an interior area; and said cover and said base directly sealed to one another by a sealant located between said cover and base, and further comprising one or more open perforations formed through said cover and/or base said perforations sized to selectively control the flow of gas there through, whereby an atmosphere controlled interior area is defined between said inner surface of said cover and said inner surface of said base without a removable sealing sheet located between said cover and base.

2. The container in accordance with claim 1 wherein sealant comprises a sealant layer associated with said cover.

3. The container in accordance with claim 1 wherein said sealant is located between said first and second locking members.

4. The container in accordance with claim 1 wherein said at least one compartment is an outwardly extending area of said cover.

5. The container in accordance with claim 1 wherein said base is constructed of an opaque material and said cover is constructed of a transparent material.

6. a container for fresh foodstuffs consisting of: a cover, said cover having an inner surface, an outer surface and a peripheral edge, said cover defining at least one compartment, said cover comprising a generally rigid, essentially gas impermeable member, said cover further defining a first locking member; a base, said base having an inner surface, an outside surface and a peripheral edge, said inner surface being generally concave and said base comprising a generally rigid, essentially gas impermeable material, said base defining a second locking member, said cover and base connected to one another via engagement of said first and second locking members, said base cooperating with said cover to define an interior area; a plurality of open apertures formed through said cover and/or base, said perforations sized to selectively control the flow of gas there through; said cover and said base hermetically sealed to one another via a sealant to define an atmosphere controlled interior area between said inner surface of said cover and said inner surface of said base; and foodstuffs located in said interior area.

7. The container in accordance with claim 6 wherein said apertures are laser-formed.

8. The container in accordance with claim 6 wherein said base is constructed of an opaque material and said cover is constructed of a transparent material.

9. The container in accordance with claim 6 wherein said foodstuffs are selected from the group consisting of fruits and vegetables.

Description

DESCRIPTION OF THE DRAWINGS

[0018] FIG. 1 is a perspective view of a container in accordance with the invention;

[0019] FIG. 2 is an exploded view of the container illustrated in FIG. 1;

[0020] FIG. 3 is an enlarged exploded view of a portion of the container illustrated in FIG. 1;

[0021] FIG. 4 is an enlarged assembled view of the portion of the container illustrated in FIG. 4;

[0022] FIG. 5 is a cross-sectional view of the portion of the container illustrated in FIG. 4 taken along line 5-5 therein; and

[0023] FIG. 6 is a cross-sectional view of a portion of a container in accordance with another embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0024] In the following description, numerous specific details are set forth in order to provide a more thorough description of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without these specific details. In other instances, well-known features have not been described in detail so as not to obscure the invention.

[0025] In general, the invention comprises packaging which is particularly suited for storing and transporting fresh foodstuffs. The packaging has particular applicability to fresh fruits and vegetables. One aspect of the invention is a container which is hermetically sealed. Another aspect of the invention is a container having an atmosphere control member for controlling the atmosphere in the container.

[0026] One embodiment of the invention will be described with reference to FIG. 1. FIG. 1 illustrates a foodstuff package or container 20. As best illustrated in FIG. 2, in one embodiment, the container 20 comprise two selectively mateable portions 22,24. As illustrated, a first portion 22 comprises a top, lid or cover of the container 20, while the second portion 24 comprises a bottom, base or tray of the container 20. It will be appreciated that the terms top and bottom are relative, in that the container 20 may be placed in various orientations. These particular terms are utilized with reference to the particular orientation of the container 20 as illustrated.

[0027] In one embodiment, the container 20 is generally rectangular in peripheral shape. The container 20 may have a variety of shapes, however, such as oval, square, round, triangular or even irregular. Generally, the shape of the container 20 is dictated by the shapes of the top and bottom portions 22,24 thereof.

[0028] As indicated, the bottom portion 24 of the container 20 is preferably configured as a tray. The top portion 22 is configured as a cover having one or more compartments. In this configuration, foodstuffs are generally located in the compartments of the top portion 22 and retained or enclosed by the bottom portion 24. In use, the container 20 is generally oriented so that the bottom portion or tray 24 rests upon a support surface, while the top portion or cover 22 is located over and encloses the foodstuffs.

[0029] Referring to FIGS. 2 and 5, the bottom portion or tray 24 has an inside or top surface 26, an outside or bottom surface 28, and a peripheral edge 30. In one embodiment, the bottom portion 24 comprises a base having an outwardly extending (or upwardly extending, when the container is in its normal orientation) wall. As illustrated, the peripheral edge 30 comprises a flange which extends outwardly from the wall generally opposite the base. In this configuration, the bottom portion 24 is generally concave, in that the inside surface 26 has the form of a depression. The depth of the tray may vary depending upon the desired use. In one embodiment, the tray has a relatively shallow depth (for example, having a depth which is less than its peripheral dimension, such as dimension from side to side or end to end).

[0030] The top portion 22 may have a variety of configurations. Generally, the top portion 22 is configured as a container for containing foodstuffs. The top portion 22 has a periphery or outer edge 32, an outside or top surface 34, and an inside or bottom surface 36. In one embodiment, the top portion 22 has a top with an outwardly extending (or downwardly extending, when the container is in its normal orientation) wall. As illustrated, the peripheral edge 32 extends outwardly beyond a U shaped trough 42. This trough 42 is configured to tightly engage upstanding wall of the bottom portion 24, thereby permitting the top and bottom portions 22,24 to engage one another in a press-fit locking arrangement, as described in more detail below.

[0031] Still referring to FIGS. 2 and 5, in this configuration, the top portion or cover 22 is generally convex, such that one or more portions of the outside surface 34 are raised or extend away from the edge 32. In a preferred embodiment, the top portion 22 defines a plurality of compartments 38. These compartments 38 are at least partially divided or separated from one another. As illustrated, certain portions of the top are raised or extend outwardly farther than others relative to the peripheral edge or flange 32. The portions which extend outwardly define the compartments 38, while the portions there between generally serve as dividers between the compartments. It will be appreciated that the number of compartments and their shapes and sizes may vary. As illustrated, there are three central compartments with two side compartments on either side thereof. There may be as few as one compartment (where the entire top of the top portion raised), but there are preferably at least two compartments and there may be, as illustrated, numerous compartments.

[0032] In a preferred embodiment, the top and bottom portions 22,24 are preferably constructed of a generally gas or air-impermeable material. Preferably, by air-impermeable it is meant that atmospheric gas at normal room pressures does not readily pass through the top and bottom portions 22,24. For example, the top and bottom portions 22,24 may be vacuum formed from a plastic material. So that the food stuffs may be viewed by a consumer, the top portion 22 may be constructed of a generally clear or transparent material. In a preferred embodiment, the bottom portion 24 is constructed of a generally opaque material, such as a black plastic. In this manner, the bottom portion 24 may be used as a serving tray. The top and bottom portions 22,24 are also preferably formed to be semi-rigid or generally rigid, whereby they maintain their shape, including so that the container 20 does not substantially deform in normal use. This protects the foodstuffs therein, such as during shipping.

[0033] Means are provided for selectively connecting the top and bottom portions 22,24 to form a closed container. More preferably, the means allow the top and bottom portions 22,24 to be connected in a manner which causes the container 20 to define a generally sealed interior space (i.e. generally atmospherically sealed or controlled). Most preferably, the means for connecting allows the top and bottom portions 22,24 to be selectively connected and disconnected, meaning that the container 20 can be opened and closed, as desired.

[0034] In one embodiment, the top and bottom portions 22,24 are connectable by mating first and second locking or connecting members. As described above and illustrated in FIGS. 2 and 5, the bottom portion 24 includes an upwardly extending wall 40. The wall 40 may have various shapes and sizes. In one embodiment, the wall 40 is located adjacent to the periphery 30 and slopes upwardly and outwardly to work with the trough 42 of the top portion 22 in a wedging arrangement to lock the top and bottom portions 22,24.

[0035] As indicated above, the top portion 22 includes a mating trough or tongue 42. The trough or tongue 42 is preferably defined at the bottom of the top portion 22, near the periphery 32 thereof. The trough 42 and wall 40 are configured to mate, and as such, the trough 42 is located in a position on the top portion 22 which corresponds to the location of the wall 40 of the bottom portion 24.

[0036] In a preferred embodiment, the trough 42 is sized and shaped to fit tightly against the wall 40. When the wall 40 is continuous, the trough 42 is preferably continuous. As illustrated, an outside surface of the trough 42 is configured as a wall portion with the same slope and shape as the wall 40. Preferably, that portion of the trough 42 is movable relative to the remaining portion of the top portion 22 (will flex inwardly towards the portion of the top separated therefrom by the trough), so that the wall portion will spring fit or compress into engagement with the wall 40. In this manner, the top portion 22 may be press-fitted tightly into engagement with the bottom portion 24.

[0037] In a preferred embodiment, the container 20 also includes means for controlling the atmosphere therein. When the top and bottom portions 22,24 are connected, they define a generally closed, sealed interior space. In other words, the atmosphere within the container 20 does not interact with the atmosphere outside of the container, owing to the generally atmosphere impermeable nature of the top and bottom portions 22,24 and their sealing connection. Preferably, however, the container 20 includes a means for controlling exchange of gases between the interior and exterior of the container 20.

[0038] As illustrated in FIGS. 2-5, in one embodiment, the container 20 includes an atmosphere control member 44. In one embodiment, the member 44 comprises a membrane which selectively allows gas to flow therethrough.

[0039] Referring to FIGS. 2, 3 and 5, the container 20 defines an opening 46. In one embodiment, the opening 46 is located in the top portion 22. The atmosphere control member 44 is associated with the opening 46, preferably by being located over the opening, to selectively control the passage of gases through the opening 46.

[0040] In one embodiment, the atmosphere control member 44 is a microporous film made from polyolefin polymers such as polypropylene or polyethylene. The member 44 is generally planar and is dimensionally larger than the opening 46, whereby at least a portion of the member 44 extends beyond the opening around the periphery thereof. The member 44 may be sealed to the top portion 22, such as with a pressure sensitive adhesive that is applied to the periphery of the atmosphere control member 44.

[0041] The size and shape of the member 44 (and thus associated opening 46) may vary. The size of the member 44 and associated opening 46 may vary, at least in part, by the size of the container 20 (or the interior space), the types of foodstuffs to be stored, or other factors. The number of members 44 may also, or instead, be varied depending upon such factors.

[0042] For convenience, the member 44 may be located at the outside or top 34 of the top portion 22. Preferably, the member 44 is inset from the very top of the top portion 22, whereby if the containers 20 are stacked or if other items are placed on the container 20, the member 44 is not blocked. In one embodiment, as illustrated, the member 44 is located at an inset portion 48 of the top of the top portion 22. The inset portion 48 may comprise a slightly recessed area of one of the compartments 38. One or more raised areas 50 at least partially surround the inset portion 48.

[0043] The depth of the inset portion 48 relative to the raised areas 50 may vary. The depth need not be particularly great, but only sufficient to prevent a container or other object from resting directly on the member 44 and preventing or obstructing the flow of gases therethrough. Preferably, the inset portion 48 is relatively small, so that the raised areas 50 will support a portion of another container 50 or other object without that portion or object fitting within the inset portion 48 (i.e. the raised areas 50 generally prevent a portion of a container or other object from resting upon the member 44).

[0044] To allow gases to flow to and from the inset area 48, one or more slots 52 or other passageways may be defined through or between the raised areas 50. In this manner, if a container 20 or other object is resting upon the raised areas 50, that container or object not only does not contact the member 44, but does not occlude the inset area 48 from the atmosphere around the container 20.

[0045] In a preferred embodiment, a packaging label 54, such as containing consumer information, is located over the inset area 48, and thus the member 44, thus obscuring the member 44 from view, but not preventing its operation. In the embodiment illustrated in FIG. 5, the label 54 may be sized so that it is associated with the raised areas 50, but covers or extends over the inset area 48. In this manner, the member 44 is hidden from view, but gases are allowed to flow to and from the member 44 via the passageways 52.

[0046] It will be appreciated that the container 20 may have a variety of other configurations which provide for one or more atmosphere control members 44, but which ensure the proper operation thereof.

[0047] Use of the container 20 will now be described. As indicated, in a preferred embodiment, the top portion 22 defines one or more compartments 38. As such, the top portion 22 is inverted (so that the inside surface 36 is facing upwardly) and loaded with foodstuffs. Different foodstuffs may be loaded into the various compartments, as desired.

[0048] Once filled, the bottom portion 24 is inverted and placed over the top portion 22 and the foodstuffs (i.e. the bottom portion 24 is oriented so that its inside surface 26 faces the top portion 22 and the foodstuffs). The top and bottom portions 22,24 are preferably connected to one another. In one embodiment, this comprises engaging the connecting or sealing means, such as by pressing the trough 42 of the top portion 22 into engagement with the wall 40 of the base portion 24.

[0049] The container 20 may then be inverted so that it rests upon the bottom portion 24 and so that the foodstuffs are viewable through the top portion 22. If not already applied, a packaging label 54 may be affixed to the container 20 over the atmosphere control member(s) 44.

[0050] Once the top and bottom portions 22,24 are connected, the interior of the container is generally sealed. However, the atmosphere control member 44 selectively allows gas to exchange between the interior and exterior of the container 20. In this manner, the atmosphere inside the container 20 is controlled. This ensures that the foodstuffs remain fresh.

[0051] Upon purchase by a consumer, the consumer may open the container 20. The consumer may utilize the bottom portion 24 as a serving tray or simply remove the contents from the container.

[0052] Advantageously, a consumer may reseal the container 20. In particular, the consumer may seal the top and bottom portions 22,24 back together, thus again sealing the interior space of the container and the foodstuffs therein. At that time, the atmosphere control member 44 again regulates the flow of gases between the exterior and interior of the container 20 to prolong the freshness of the foodstuffs during subsequent storage.

[0053] The container of the invention may have a variety of other configurations. In one embodiment, the bottom portion of the container may be relatively deep and the top may be shallow, so that the foodstuffs are filled into the bottom portion. In this configuration, the lid could be generally flat (except for preferably including an inset area or areas for the atmosphere control member(s)).

[0054] The top and bottom portions may connect one another in other fashions. For example, the top and bottom portions might engage one another in a tongue and groove configuration.

[0055] It is possible for the container to include more than one atmosphere control member and those members may be located on the cover or elsewhere (such as on the tray). In one embodiment, the atmosphere control or breathable member might comprise one or more perforations. Preferably, such perforations are sized to selectively permit the flow of gas therethrough, but not permit the free flow of atmosphere or other material, such as water or the like, there through. The perforations might be provided in various locations of the tray, including the top or cover, and their number and size may vary depending upon the rate of gas exchange which is desired. In this configuration, the atmosphere control member is thus not a separate element from the top, but is part of the top. In one embodiment, one or more of the perforations may be located in a recessed area and/or under a covering label as detailed above in order to prevent them from being occluded.

[0056] If desired, a seal may be associated with the container 20 to provide an indication to the consumer that the container 20 has not been opened prior to purchase. For example, a sealing member, such as a shrink or stretch band, may be located around the edge of the container 20 where the peripheral portions 30,32 of the top and bottom portions 22,24 are located adjacent one another (see FIG. 5).

[0057] As indicated, it is desired that the container 20 define a closed interior space which is atmosphere controlled. Before the present invention, semi-rigid or rigid containers having connectable lids and bases would leak, preventing the atmosphere in the container from being completely controlled. Thus, in one embodiment, a heat-sealable lidding film may be applied over the flange of the container 20. For example, referring to FIGS. 2 and 5, in one embodiment, a film or sealing sheet 56 may be applied to the edge 32 of the top or cover portion 22 of the container 20 at the inside or bottom 36 thereof. The film or sealing sheet 56 may be of a variety of types, including polymer types such as heat-seal coated polyester and polylactic acid and heat-sealable laminates of polyester and polyolefins. It is preferred that the sealing sheet 56 be essentially gas impermeable, so that when sealed to the top or cover portion 22 of the container 20, the sealing sheet 56 cooperates therewith to define a generally enclosed space. In a preferred embodiment, this film or sealing sheet 56 is applied after the top of the container 22 is loaded with foodstuffs, and before the bottom portion 24 is applied. In this manner, the foodstuffs are completely sealed when initially packaged and shipped to the consumer. The consumer can verify that the container 20 has not been opened by checking the integrity of the film or sealing sheet 56 and, if acceptable, peel back and/or remove the sealing sheet 56.

[0058] In a preferred embodiment, the container 20 including a sealing sheet 56 includes at least one atmosphere control member. Preferably, the atmosphere control member is associated with the portion of the container 20 which is sealed, such as the top 22 as illustrated in FIG. 1. In this manner, the atmosphere is controlled in the portion of the container 20 housing the foodstuffs.

[0059] FIG. 6 illustrates a preferred embodiment of the invention. In the description and illustration of this embodiment, like reference numbers have been used for like elements to those of the embodiments described above, except that a 100 series designation has been utilized. In this embodiment, the top and bottom portions 122,124 of the container 120 are preferably connected to one another to define a generally closed or sealed interior space without the need for a separate sealing sheet. Preferably, unlike containers of the prior art wherein a lid may merely connect or attached to the base but does not effectively seal the container (from the perspective of gas flow), the top and bottom portions 122,24 of the container 120 of the invention are, for the first time, connected in a manner which provides a hermetic seal.

[0060] In this preferred embodiment, a sealing material or sealant 160 is located between the top and bottom portions 122,124 in order to create a hermetic seal. The sealing or sealant material 160 may vary.

[0061] In one embodiment, the sealant 160 is located between a sealing edge or other sealing or connecting surface of the top and bottom portions 122,124. For example, relative to the embodiment illustrated in FIG. 6, sealant 160 may be located between the edges/flanges 130,132 of the top and bottom portions 122,124, or between the wall 140 and trough 142 thereof.

[0062] Preferably, the top and bottom portions 122,124 are sealed along or around a closed periphery or path. This may comprise a path around an entire interior space or one or more interior compartments or spaces. In this manner, the entire interior area of the container 120 or at least one or more compartments or areas within the container are sealed.

[0063] In a preferred embodiment, the top or bottom portion 122,124 of the container 120 is thermo-formed from a generally planar sheet of polyethylene terephthalate (PET). The sealant 160 comprises a layer of sealing material which is located onto the PET sheet. This multi-layer sheet is then be thermo-formed into the top or bottom portion 122,124 of the container 120.

[0064] Once the container 120 is loaded, such as by placing foodstuffs therein, the seal or sealant may be activated to seal the container 120. In one embodiment, heat and pressure are applied to the top and bottom portions 122,124, at least in the area where it is desired to seal them, in order to activate the sealant 160 to hermitically seal the container 120. The amount of heat and or the time of application (dwell) may vary, such as depending on the size of the container and the type of sealant, to ensure that the sealant 160 effectively seals the top and bottom portions 122,124 together. For example, heat and pressure may be applied in the location of the edges/flanges 130,132 to activate a sealant layer which is associated with the lid/top 122 in order to seal the top and bottom portions 122,124 of the container 120.

[0065] Once the top and bottom portions 122,124 are sealed, they define a closed and sealed interior space (or one or more compartments or areas). The seal is hermetic, meaning that air is not permitted to pass into or out of the container 120 at the intersection/connection of the top and bottom portions 122,124. (or through the top and bottom portions of the container 20, owing to the gas-impermeability of those portions, unless such portions are provided with an atmosphere control member as detailed herein). This sealed interior space for foodstuffs is also created without the need for a sealing sheet, greatly simplifying the configuration of the container 120 and the manufacture thereof.

[0066] In addition, the container 120 may be opened to access the foodstuffs therein. In a preferred embodiment, the sealant 160 hermetically seals the top and bottom portions 122,124, but also permits a user to separate the top and bottom portions 122,124 using a reasonable amount of force, to open the container 120. In one embodiment, the top portion 122 may be peeled or separated from the bottom portion 124 by applying a removal force to the top portion 122 while maintaining the bottom portion 124 in a fixed position. In order to aid a user in applying such a force to the top portion 122, the top portion 122 may be configured to include an outwardly extending tab that the user may grasp. In this regard, the sealant preferably seals the top and bottom portions 122,124 but does not weld them together.

[0067] In a preferred embodiment, the container 120 still includes at least one atmosphere control member. As indicated above, the atmosphere control member may comprise a membrane 144 which is located over an opening 146 in the bottom portion 124. Such a membrane 144 may be again located in a recessed area 148 and under a covering label 154.

[0068] Advantageously, however, because the top and bottom portions 122,124 are sealed without any sealing sheet, the atmosphere control member may be associated with the top portion and/or the bottom portion 122,124. In one embodiment, as indicated above, the atmosphere control member may comprise one or more perforations 145 located in the top and/or bottom member. The perforation might be formed, for example, with a laser.

[0069] In one embodiment, the top or bottom portion of the container might be configured as an atmosphere control member, such as by having a unique polymer composition which permits, in a controlled fashion, the flow of gas therethrough.

[0070] In one or more embodiment of the invention, the individual compartments of the container 20 may be independently sealed and atmosphere controlled. For example, the base may be configured to seal the compartments of the container 20. Laser perforations may be utilized to control the atmosphere in each compartment. The number and/or size of the perforation associated with each compartment might vary, such as depending on the foodstuffs which are to be located in each compartment and the desired atmosphere for those foodstuffs.

[0071] It will be appreciated that while the container is particularly suited for use in storing and transporting foodstuffs such as fresh fruits and vegetables, it could be used to store other foodstuffs or other materials. Also, while the container has been described as having a tray and lid, the container may be configured with a base and lid (i.e. the container need not have particular use as a serving tray and need not have specific loading configurations). In this regard, the container may have various configurations depending upon the desired use. For example, if the container is used to store and transport a single foodstuff, the container might define a single compartment or interior area, rather than multiple compartments. Also, in such configurations the container might have other shapes (the container might, for example, have a depth which is great in relation to the width/length rather than being shallow as illustrated in the figures herein).

[0072] The container of the invention has numerous advantages. First, the container is simple in construction. In the preferred embodiment, the container can be sealed merely by connecting the top and bottom portions without the application of a sealing sheet.

[0073] The interior of the container is atmosphere controlled. Once closed, the interior is isolated from the exterior and gasses or fluids are not allowed to freely flow into or out of the interior foodstuff space. Instead, the flow of gasses and fluids is strictly controlled via the one or more atmosphere control member(s). This promotes foodstuff freshness.

[0074] In one embodiment, once opened, the container can again be closed and sealed (the consumer may peel the top portion away from the bottom portion to open the container and then press the top portion back into engagement with the bottom portion to substantially re-seal the package). In this manner, the consumer can access the foodstuffs, store unused foodstuffs in the same container, and re-access the unused foodstuffs in the future. When the foodstuffs are re-stored, their freshness is extended because the foodstuffs are again located in an atmosphere controlled interior space.

[0075] In embodiment, location of the one or more atmosphere control members in an inset area permits the containers to be stacked upon one another or permits other items may be placed on the container without interfering with the operation of the atmosphere control member.

[0076] The atmosphere control member is preferably associated with the container itself, so that it is positioned between the interior and exterior and is thus the sole control there between. This ensures that the flow of gases is not prohibited.

[0077] A packaging label may be located over the atmosphere control member(s) so that they are not visible, without interfering with their operation.

[0078] It will be understood that the above described arrangements of apparatus and the method there from are merely illustrative of applications of the principles of this invention and many other embodiments and modifications may be made without departing from the spirit and scope of the invention as defined in the claims.