Container with barrier member

Abstract

A container for holding at least one article, comprising: a body extending at least partially around an interior of the container; a reclosable cover engaged with the body; a closed bottom engaged with the body; and a barrier member formed of a stacked structure defining an outer surface and an inner surface of the barrier member and positioned inside the container, the barrier member having a central portion at least partially separably connected with the edge portion at a first line of weakness and a second line of weakness, a first line of weakness extends from an outer surface of the barrier member to a first depth, a second line of weakness extends from an inner surface of the barrier member to a second depth, the first depth being different from the second depth, and the edge portion being attached to the body.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 443,100, filed February 3, 2023.

[0003] Incorporated by Reference

[0004] The disclosure of U.S. Provisional Patent Application No. 63 / 443,100 (filed February 3, 2023) is hereby incorporated by reference into this document for all purposes as if fully set forth. Technical Field

[0005] The present invention generally relates to containers for holding one or more items. In some embodiments, the present invention relates to containers having at least one barrier member. Summary of the Invention

[0006] According to one aspect, the present invention generally relates to a container for holding at least one article, the container comprising: a body extending at least partially around an interior of the container; a reclosable lid engaged with the body, the reclosable lid being movable between an open position in which the reclosable lid is moved away from the interior of the container and a closed position in which the reclosable lid at least partially covers the interior of the container; a closed bottom engaged with the body; and a barrier member formed from a laminated structure defining an outer surface and an inner surface of the barrier member and positioned within the interior of the container, the barrier member including a central portion at least partially detachably connected to an edge portion at a first weakening line and a second weakening line, the first weakening line extending from the outer surface of the barrier member to a first depth and the second weakening line extending from the inner surface of the barrier member to a second depth, the first depth being different than the second depth, the edge portion being attached to the body.

[0007] According to another aspect, the present invention generally relates to a combination of blanks for forming a container for holding at least one article, the combination of blanks comprising: a body blank for forming a body that extends at least partially around an interior of a container formed from the combination of blanks; and a lid blank for forming a reclosable lid that engages with the body when the container is formed from the combination of blanks such that the reclosable lid is transitionable between an open position in which the reclosable lid moves away from the interior of the container formed from the combination of blanks and a closed position in which the reclosable lid at least partially covers the interior of the container formed from the combination of blanks. a bottom blank for forming a closed bottom that is engaged with the body of a container formed by the combination of the blanks; and a barrier blank formed from a laminated structure defining an outer surface and an inner surface of the barrier blank and for positioning within the interior of the container formed by the combination of the blanks, the barrier blank comprising a central portion that is at least partially detachably connected to an edge portion at a first weakening line and a second weakening line, the first weakening line extending from the outer surface of the barrier blank to a first depth, the second weakening line extending from the inner surface of the barrier blank to a second depth, the first depth being different from the second depth, the edge portion being for attachment to the body of the container formed by the combination of the blanks.

[0008] According to another aspect, the present invention is generally directed to a method of forming a container for holding at least one article, the method comprising: obtaining a body blank; obtaining a lid blank; obtaining a bottom blank; obtaining a barrier blank formed of a laminated structure defining an outer surface and an inner surface, the barrier blank including a center portion at least partially detachably connected to an edge portion at a first weakening line and a second weakening line, the first weakening line extending from the outer surface of the barrier blank to a first depth, the second weakening line extending from the inner surface of the barrier blank to a second depth, the first depth being different from the second depth; The body blank forms the body of the container so that the body extends at least partially around the interior of the container; the lid blank forms a reclosable lid so that the reclosable lid is engaged with the body, the reclosable lid being movable between an open position in which the reclosable lid moves away from the interior of the container and a closed position in which the reclosable lid at least partially covers the interior of the container; the bottom blank forms the closed bottom so that the closed bottom is engaged with the body of the container; and the barrier blank attaches an edge portion to the body of the container to form a barrier member.

[0009] Those skilled in the art will appreciate the above-mentioned advantages and other advantages and benefits of various additional embodiments by reading the following detailed description of the embodiments with reference to the accompanying drawings listed below. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. The sizes of the various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present invention.

[0011] Figure 1 is a plan view of an exterior surface of a body blank for forming a body of a container according to an example embodiment of the present invention.

[0012] Figure 2 is a plan view of an exterior surface of a lid blank for forming a lid or top end for a container according to an exemplary embodiment of the present invention.

[0013] Figure 3 is a plan view of an outer surface of a bottom blank for forming a container bottom according to an exemplary embodiment of the present invention.

[0014] Figure 4A is a plan view of an outer surface of a barrier blank for forming a barrier member of a container according to an example embodiment of the present invention.

[0015] Figure 4B yes Figure 4A A plan view of the inner surface of the barrier blank.

[0016] Figure 4C yes Figure 4A A cross-sectional view of a barrier blank.

[0017] Figure 5 It means in Figure 4A A cross-sectional view of a barrier blank having a weakening line formed thereon.

[0018] Figures 6A-6C is a perspective view of a sequence for forming a container according to an exemplary embodiment of the present invention.

[0019] Figure 7 This indicates that the method of entering the Figures 1-4C A perspective view of the interior of a container formed from a blank.

[0020] Corresponding reference characters indicate corresponding parts throughout the several views of the drawings. DETAILED DESCRIPTION

[0021] Container according to the present invention can hold the article of multiple different shapes.For the purpose of illustration rather than for the purpose of limiting the scope of the invention, the following detailed description describes article such as food.These food can be provided with discrete or granular part, for example as snack, for example candy, chewing gum, chocolate, granola, cereal, nuts, assorted dried fruit, raisins, dried fruit etc.Should be understood that dissimilar article (for example dissimilar food or dissimilar article such as powdered food or powdered article) can be retained in container according to the present invention, and do not depart from the present invention.It should also be understood that article except food product can be retained in container according to the present invention.

[0022] Throughout this specification, the terms "lower," "bottom," "upper," and "top" refer to orientations relative to a fully erected and upright container. As described herein, a container can be formed from a blank by overlapping multiple panels, portions, and / or end flaps. These panels, portions, and / or end flaps may be referred to herein by terms relative to one another, such as "first," "second," "third," etc., in sequential or non-sequential reference, without departing from the present invention.

[0023] Figure 1-4C is a plan view of a series of blanks used to form components that assemble to form container 105 ( Figure 6C In this regard, in some embodiments, the container 105 may be considered an assembly or system of components.

[0024] refer to Figure 1 , shows a plan view of an exterior surface 201 of a body blank 203 for forming a body 205 of the container 105. As described herein, the body 205 is arranged to extend at least partially around the interior 107 of the container 105.

[0025] As shown, the body blank 203 can have a longitudinal axis L1 and a transverse axis L2. In some embodiments, the axes L1 and L2 can be reversed. In the illustrated embodiment, the body blank 203 can have a generally rectangular configuration with a pair of opposing transverse free edges 207, 209 and a pair of opposing longitudinal free edges 211, 213 extending from respective endpoints of the free edge 207 to respective endpoints of the free edge 209.

[0026] The body blank 203 may also include: a body forming portion 215 defined along a central portion of the body blank 203; a first or top or cover forming portion 217 defined at an upper peripheral portion / upper edge portion of the body blank 203; and a second or bottom end forming portion 219 defined at a lower peripheral portion / lower edge portion of the body blank 203.

[0027] As shown, the cover forming portion 217 of the body blank 203 can be at least partially detachably connected to the body forming portion 215 and at least partially foldably connected to the body forming portion 215 at a longitudinal weakening line 221, which longitudinal weakening line 221 can include at least one tear segment and at least one folding line segment.

[0028] Continue to refer Figure 1 The body blank 203 may include a plurality of transverse lines of weakness 223 that may facilitate forming curved corners when the body 205 is formed from the body blank 203, as further described herein.

[0029] The body blank 203 may also include one or more longitudinal lines of weakness 225 extending along it. In the illustrated embodiment, the body blank 203 may include a plurality of longitudinal lines of weakness 225 extending across the lid-forming portion 217 and another plurality of longitudinal lines of weakness 225 extending along the body-forming portion 219. As further described herein, the lines of weakness 225 may facilitate forming the body 205 from the body blank 203.

[0030] In some embodiments, the body blank 203 may comprise one or more paperboard materials made primarily of cellulose fibers or paper fibers. The material may be provided in the form of a continuous web or as individual sheets of material. The paperboard material may be a single-layer or multi-layer material and may be a laminate comprising one or more layers of reinforcing, moisture-resistant non-cellulose materials, such as films and coatings, metal foils, and the like. The paperboard material may be coated, printed, embossed, and the like and may include fillers, pigments, adhesives, and other additives known in the art. In some embodiments, the paperboard material may be free of polymers and / or metal materials.

[0031] refer to Figure 2 , shows an outer surface 301 of a lid blank 303 for at least partially forming the lid 109 of the container 105. As shown, the lid blank 303 can have a longitudinal axis L1 and a transverse axis L2, and can include a central portion 307 and an edge portion 309 that extends to a peripheral edge of the lid blank 303.

[0032] In some embodiments, the edge portion 309 of the lid blank 303 can be at least partially foldably connected to the central portion 307 at a generally rounded rectangular / elliptical fold line 310. In other embodiments, as further described herein, one or more foldable connections can be formed between the edge portion 309 of the lid blank 303 and the central portion 307 of the lid blank 303 when forming the lid 109 of the container 105.

[0033] As also shown, the lid blank 303 can include a plurality of angled and / or curved lines of weakness 313 disposed along corner portions of the lid blank 303. The lines of weakness 313 can facilitate forming the lid 109 / container 105, as further described herein.

[0034] It should be understood that the cover blank 303 may be formed from one or more materials that are the same or similar to the materials forming the body blank 203 as described above, such as a paperboard material.

[0035] refer to Figure 3 , shows the outer surface 401 of a bottom blank 403 for at least partially forming the closed bottom or closed end 111 of the container 105.

[0036] As shown, the bottom blank 403 can have a generally similar structure to the lid blank 303 described above, e.g., having a longitudinal axis L1 and a transverse axis L2, a center portion 407, and an edge portion 409 extending to the peripheral edge of the bottom blank 403. In the illustrated embodiment, the edge portion 409 can be at least partially foldably connected to the center portion 407 at a generally rounded rectangular / elliptical fold line 410, but the blank 403 can be devoid of the fold line 410 without departing from this invention.

[0037] refer to Figure 4A , shows an outer surface 501 of a barrier blank 503 for forming a barrier member 505 of the container 105 . Figure 4B is a plan view of the inner surface 502 of the barrier blank 503 and the barrier member 505 formed therefrom. Figure 4C , a schematic cross-sectional view of the barrier blank 503 is shown.

[0038] The barrier blank 503 can have a longitudinal axis L1 and a transverse axis L2, and can include a central portion 507 and an edge portion 509 that extends to a peripheral edge of the barrier blank 503. In some embodiments, the edge portion 509 of the barrier blank 503 can be at least partially foldably connected to the central portion 507 at one or more lines of weakness (e.g., fold lines). In other embodiments, one or more foldable connections can be formed between the edge portion 509 of the blank 503 and the central portion 507 of the blank 503 when the barrier member 505 is formed.

[0039] like Figure 4AAs shown, edge portion 509 of blank 503 can be at least partially separated from center portion 507 of blank 503 and barrier member 505 formed therefrom at an upper, at least partially curved, line of weakness 511a and an upper, angled line of weakness 513a. As shown, line of weakness 511a can include a transverse segment 515a, a curved segment 517a, and a longitudinal segment 519a. In some embodiments, an access feature 521 can be defined in center portion 507 between lines of weakness 511a and 513a to facilitate separation of center portion 507 from edge portion 509.

[0040] The blank 503 and the edge portion 509 of the barrier member 505 formed therefrom can be at least partially defined by a line of weakness 523a (broadly, a "first line of weakness") that includes: a first curved segment 525a that intersects and extends away from an endpoint of the line of weakness 513a; a generally transverse segment 527a that intersects and extends away from segment 525a; a curved segment 529a that intersects and extends away from segment 527a; and a generally transverse segment 531a that intersects and extends away from segment 529a, with segment 531a also intersecting the endpoint of the line of weakness 513a.

[0041] Additional references Figure 4B In the illustrated embodiment, the inner surface 502 of the blank 503 and the barrier member 505 formed therefrom can be provided with a line of weakness that is substantially a mirror image of the line of weakness described above with respect to the outer surface 501 of the blank 503 and the barrier member 505 formed therefrom. Corresponding components are designated by corresponding reference numerals that differ by the suffix "a" or "b," wherein the "a" component corresponds to the outer surface 501 of the blank 503 and the barrier member 505 formed therefrom and the "b" component corresponds to the inner surface 502 of the blank 503 and the barrier member 505 formed therefrom. In one embodiment, the inner surface 502 of the blank 503 and the barrier member 505 formed therefrom can be free of a line of weakness corresponding to the line of weakness 513a of the outer surface 501 of the blank 503 and the barrier member 505 formed therefrom.

[0042] In the illustrated embodiment, additional reference is made to Figure 4C The barrier blank 503 and the barrier member 505 formed therefrom may be formed by a laminated structure 507 forming an outer surface 501 and an inner surface 502 of the blank 503 / barrier member 505 formed therefrom, and the laminated structure 507 comprises a plurality of substantially aligned layers, wherein vertically adjacent layers overlap each other and / or are in at least partial face-to-face contact.

[0043] As shown in the figure, the stacked structure 507 may include: a first polymer layer 533; a second polymer layer 535, which overlaps with the first polymer layer 533 and / or is in at least partial face-to-face contact; a third polymer layer 537, which overlaps with the second polymer layer 535 and / or is in at least partial face-to-face contact; and a composite layer 539, which overlaps with the third polymer layer 537 and / or is in at least partial face-to-face contact.

[0044] In some embodiments, polymer layers 533, 535, 537, 539 comprise polyethylene, but one or more of polymer layers 533, 535, 537, 539 may have a different composition without departing from the invention. In some embodiments, polymer layer 537 may be high-density polyethylene (HDPE), e.g., having a density greater than the density of the material forming polymer layers 533, 535.

[0045] In some embodiments, composite layer 539 may include a paper or paperboard product, such as kraft paper, parchment paper, clay-coated paperboard, solid bleached board (SBB) paperboard, solid bleached sulfate (SBS) paperboard, kraft lined paperboard, cardboard, or other suitable material that may be degradable, compostable, and / or repulpable.

[0046] The layers 533, 535, 537, 539 may be stacked or otherwise combined to form the stacked structure 507, such as by pressing, at least locally heating one or more layers thereof, welding, sealing, and / or bonding with an adhesive such as glue.

[0047] In some embodiments, polymer layer 533 can have a thickness D1 of approximately 0.07 mm, polymer layer 535 can have a thickness D2 of approximately 0.05 mm, polymer layer 537 can have a thickness D3 of approximately 0.03 mm, and composite layer 539 can have a thickness D4 of approximately 0.4 mm, although one or more of layers 533, 535, 537, 539 can have different thicknesses without departing from this invention. In such embodiments, laminated structure 507 can have a total thickness D5 of approximately 0.55 mm.

[0048] Additional references Figure 5, illustrates an example process for forming lines of weakness 511a, 511b, 513a, 523a, 523b (broadly, "second lines of weakness"). In one embodiment, lines of weakness 511a, 513a, 523a, 523b can be at least partially formed by a cutting tool, such as a die cutter or other precision cutting instrument. As shown, a first cutting tool T2 can be provided for cutting into the outer surface 101 of the blank 503 and the barrier member 505 formed therefrom, and a second cutting tool T2 can be provided for cutting into the inner surface 102 of the blank 103 and the barrier member 105 formed therefrom.

[0049] The cutting tools T1, T2 can be formed with a generally tapered structure that converges at a cutting point or cutting tip. In this respect, the cutting tools T1, T2 can at least partially comprise a hardened material suitable for cutting, such as a metal and / or composite material. In certain embodiments, the cutting tools T1, T2 can be defined by cutting edges that are arranged at approximately 42 ° of angles, but it should be understood that one or both of the cutting tools T1, T2 can have different sizes and / or arrangements without departing from the present invention.

[0050] In the illustrated embodiment, each cutting tool T1, T2 can be movably supported at a distance from the respective surfaces 501, 502 of the blank 503 and the barrier member 505 formed thereby, and can be moved toward or away from the blank 503 / barrier member 505, for example, by an actuator coupled thereto, and can be moved upon receipt of one or more electrical signals from a controller C. Such a controller C may include a processor configured to execute one or more instructions stored on a non-transitory storage medium, and may be configured for operator input and / or manual control. In this regard, the controller C may be or may form part of a software program running on a computer, a programmable logic controller (PLC), another processor-implemented controller, or other control feature. In the illustrated embodiment, each tool T1, T2 is electrically connected to a respective controller C, but it should be understood that a single controller or a network of controllers may be electrically connected to both tools T1, T2.

[0051] It should be understood that the weakened lines as described herein can be achieved by the relative movement of the blank 503 and the cutting tools T1, T2. Thus, in some embodiments, the blank 503 can move relative to the cutting tools T1, T2. For example, in other embodiments, the cutting tools T1, T2 can be the edges of cutting blades supported in a frame and protruding from the frame in a die-cutting assembly. In some embodiments, the cutting tools T1, T2 can be the edges of cutting blades supported in different frames and protruding from different frames. In these embodiments, for example under the control of the controller C, the die-cutting tool can be driven to push the blank 503 into contact with the cutting tools T1, T2 to effect at least partial cutting thereof. In other embodiments, cutting can be achieved using tools known to employ knives or cutting edges, such that the cutting tools T1, T2 can be an electromagnetic beam such as a laser. Thus, the cutting operations as described herein are schematically represented.

[0052] As shown, the cutting tool T1 can be driven and moved towards the outer surface 501 of the blank 503 / barrier member 505 and vice versa, so as to pierce and extend through the composite layer 539, the third polymer layer 537, and partially through the second polymer layer 535 to a depth D6 (broadly, "the first depth") (this depth D6 is measured from the outer surface 501) so as to form weakened lines 511a, 513a, 523a. As shown, the cutting tool T2 can be driven and moved towards the inner surface 502 of the blank 503 / barrier member 505 and vice versa, so as to pierce and extend through the first polymer layer 533, and partially through the second polymer layer to a depth D7 (broadly, "the second depth") (this depth D7 is measured from the inner surface 502) so as to form weakened lines 511b, 523b.

[0053] In this regard, the depth D6 can be such that D3 + D4 < D6 < D2 + D3 + D4, and the depth D7 can be such that D1 < D7 < D1 + D2. In some embodiments, D6 can be approximately 0.46 mm and D7 can be approximately 0.1 mm, but one or both of D6 and D7 can be different without departing from the present invention.

[0054] Thus, the cutting tool T1 can be inserted from the outer surface 501 of the blank 503 / barrier member 505 to the depth D6 and vice versa, so as to partially pierce but not completely extend through the second polymer layer 535, and the cutting tool T2 can be inserted from the inner surface 502 of the blank 503 / barrier member 505 to the depth D7 and vice versa, so as to partially pierce but not completely extend through the second polymer layer 535.

[0055] Therefore, the weakening lines 511a, 513a, 523a can be formed by the cutting tool Tl, and the weakening lines 511b, 523b can be formed by the cutting tool T2, and the weakening lines 511a, 513a, 523a are separated from the weakening lines 511b, 523b by the thickness D8 of a portion of the second polymer layer 535, where D8 = D5-(D6+D7).

[0056] The arrangement of the above-described lines of weakness allows a portion of the blank 503 / barrier member 505 to remain intact, for example, such that none of the lines of weakness 511a, 511b, 513a, 523a, 523b extend therethrough. In the illustrated embodiment, such a portion of the blank 503 / barrier member 505 may be part of the second polymer layer 535, which may advantageously maintain the barrier properties of the blank 503 / barrier member 505 near the lines of weakness 511a, 511b, 513a, 523a, 523b.

[0057] One or more blanks 203, 303, 403, 503 and one or more of their associated features may be arranged and / or configured differently without departing from the present invention. For example, as further described herein, the body blank 203 may form the body 205 of the container 105, having a generally rounded rectangular or oval vertical cross-section, wherein each blank 303, 403, 503 has a corresponding cross-section so as to be at least partially received within the interior 107 of the container 105 / body 205. In some embodiments, the body 205 may be formed with different vertical cross-sectional configurations, and the blanks 303, 403, 503 may have different configurations corresponding to such vertical cross-sectional configurations.

[0058] As described herein, the blanks 203, 303, 403, 503 can also be formed to provide components that assemble to form the container 105. In this regard, the blanks 203, 303, 403, 503 can be provided in combination to form a system in the form of the container 105.

[0059] refer to Figures 6A-6C , the formation of a container 105 from a blank 203, 303, 403, 503 will be described according to an exemplary embodiment of the present invention.

[0060] The body blank 203 can be positioned to extend at least partially around the interior 107 of the container 105. In one embodiment, the body blank 203 can be at least partially bent, curved, folded, etc., e.g., at a fold line 223, into a generally oval or rounded rectangular cross-section, wherein portions of the body blank 203 proximate the free edges 207, 209 at least partially overlap to form a seam arrangement that can be maintained with a tape strip. In some embodiments, the free edges 207, 209 of the blank 203 can be in generally edge-to-edge contact.

[0061] The overlapping / joining portions of the body blank 203 may be joined, for example, with an adhesive (eg, glue), with an adhesive-coated tape or substrate, and / or by another joining method (eg, welding, an interference lock arrangement, etc.).

[0062] As shown, the body 205 of the container 105 can thus be formed, wherein respective portions of the body-forming portion 215 of the blank 203 form a front wall or panel 223, a first side wall or panel 225, a second side wall or panel 227, and a rear wall or panel 229. Respective curved corners 231, 233, 235, 237 can be formed between respective panels 223, 225, respective panels 223, 227, respective panels 225, 229, and respective panels 227, 229.

[0063] As described above, in some embodiments, the body 205 of the container 105 can be formed into different cross-sectional configurations, such as circular, oval, triangular, rectangular, square, pentagonal, hexagonal, heptagonal, octagonal, etc., including variations thereof with rounded or curved corners.

[0064] Continue to refer Figures 6A-6C According to the illustrated embodiment, the closed bottom 111 of the container 105 can be formed by positioning the bottom blank 403 within the interior 107 of the container 105, wherein the central portion 407 of the bottom blank 403 is positioned in a generally perpendicular relationship with the panels 223, 225, 227, 229 to form the bottom panel 411 of the container 105. As shown, the bottom blank 403 can be positioned a vertical distance above the longitudinal free edge 213 of the blank 203.

[0065] The edge portion 409 of the bottom blank 403 can be bent or folded downward relative to the center portion 407 of the blank 403 / bottom panel 411, for example at the fold line 410, and attached (for example, bonded, welded or otherwise attached using an adhesive such as glue) to the inner surface of one or more panels 223, 225, 227, 229 and corners 231, 233, 235, 237 of the body 205 of the container 105, thereby joining the closed bottom 111 to the body 205 of the container 105.

[0066] At the same time or thereafter, the bottom-forming portion 219 of the blank 203 can be bent / curled or folded over the edge portion 409 of the bottom blank 403, for example, at the fold line 225, to form the bottom flange 113 of the container 105, which extends downwardly from the bottom panel 411. In some embodiments, the bottom-forming portion 219 of the blank 203 can be hemmed in this arrangement. The bottom flange 113 can define the bottom edge 115 of the container 105.

[0067] Continue to refer Figures 6A-6C , a container 105 having a closed bottom 111 can be positioned, for example, with the bottom flange 113 extending downwardly, supported on a surface (e.g., a conveyor) so as to be positioned below a filling station, into which one or more articles A can be placed and retained within the interior 107 of the container 105. In some embodiments, the container 105 can be supported in a generally stationary position, and one or more filling devices can be brought into proximity with the container 105 to place articles within the interior 107 of the container 105.

[0068] After the interior 107 of the container 105 is filled with the product, the barrier blank 503 can be positioned in the interior 107 of the container 105 over the product with the central portion 507 of the barrier blank 503 positioned in a generally perpendicular relationship to the panels 223, 225, 227, 229. As shown, the barrier blank 503 can be positioned a vertical distance below the longitudinal free edge 211 of the blank 203 / body 205.

[0069] In some embodiments, the barrier blank 503 can be inserted into the interior 107 of the container 105, formed into the barrier member 505, and / or attached to the body 205 of the container 105 by contact with a plunger or other movable tool to position the blank 503 / member 505.

[0070] In this regard, at least a portion of the edge portion 509 of the blank 503 / barrier member 505 can be bent or folded downward relative to the center portion 507 of the barrier blank 503 and attached (e.g., bonded with an adhesive such as glue, welded, or otherwise attached) to the inner surface of one or more panels 223, 225, 227, 229 and corners 231, 233, 235, 237 of the body 205 of the container 105 to form the barrier member 505.

[0071] After forming and positioning the barrier member 505, the lid blank 303 can be positioned in the interior 107 of the container 105 over the barrier member 505. As shown, the lid blank 303 can be positioned a vertical distance below the longitudinal free edge 211.

[0072] The central portion 307 of the lid blank 303 may be positioned in a generally perpendicular relationship to the panels 223 , 225 , 227 , 229 to form a lid panel 311 for the container 105 .

[0073] The edge portion 309 of the lid blank 303 can be bent or folded downward relative to the center portion 307 of the blank 303 / lid panel 311, for example, at a fold line 310 and attached (e.g., bonded with an adhesive such as glue, welded, or otherwise attached) to the inner surface of one or more panels 223, 225, 227, 229 and corners 231, 233, 235, 237 of the body 205 of the container 105. It will be appreciated that the line of weakness 313 can facilitate positioning of the edge portion 309 relative to the corners 231, 233, 235, 237.

[0074] At the same time or thereafter, the lid-forming portion 217 of the blank 203 can be bent / curled or folded over the edge portion 309 of the lid blank 303, for example, at a fold line 225, to form a lid ring or lid flange 119 of the lid 109 of the container 105. In some embodiments, the lid-forming portion 217 of the blank 203 can be hemmed in such an arrangement. The lid flange 119 can define a top edge 121 of the lid 109 / container 105.

[0075] In some embodiments, the above-described assembly of the components of the container 105 can be performed in a different order. For example, in some embodiments, the lid 109 of the container 105 can be assembled before forming the closed bottom 111 of the container 105, and the barrier member 505 can be formed and positioned within the interior 107 of the container 105 and attached to the body 205 of the container 105. In such embodiments, the container 105 with the formed lid 109 and barrier member 505 can be positioned in an inverted orientation below the filling station, so that an article A can be placed in the interior 107 of the container 105 on top of the barrier member 505. The closed bottom 111 of the container 105 can then be formed in the manner described above to provide the filled container 105 in an inverted orientation, which can be reoriented as needed.

[0076] Additional references Figure 7 To access the interior 107 of the container 105, the user can separate the lid 109 from the body 205 of the container 105 along the tear line segment of the weakened line 221 and can hingedly / foldably move the lid 109 about the fold line segment of the weakened line 221 to allow the lid 109 to be arranged in an open position and a closed position, in which the lid 109 is moved away from the interior 107 of the container 105 and in which the lid 109 at least partially covers the interior 107 of the container 105 and / or is at least partially received in the interior 107 of the container 105. It should be understood that the lid 109 can be positioned in the closed position again by reversing the aforementioned steps, thereby giving the lid 109 a reclosable configuration.

[0077] When the lid 109 is in the open position, the user can remove the barrier member 505 to access the item A held thereunder. In one embodiment, the user can press downward on the access feature 515 to cause the central portion 507 to at least partially separate from the edge portion 509 of the barrier member 505 at the weakening lines 511a, 511b, 513a, 523a, 523b. The movement of the access feature 521, which is foldably connected to a portion of the central portion 507 of the barrier blank 503 / barrier member 505 at the weakening line 513a, can be at least partially facilitated by the weakening line 513a.

[0078] When the central portion 507 of the barrier member 505 is at least partially separated, the user can insert one or more of his or her fingers into the interior 107 of the container 105 below the barrier member 505 to engage the inner surface 502 of the barrier member 505 and pull the central portion 507 thereof upward, thereby separating the central portion 507 from the rest of the edge portion 509 along the corresponding sections of the weakening lines 523a, 523b.

[0079] In this regard, when a user pushes and / or pulls on the barrier member 505, one or both of the lines of weakness 523a, 523b can be caused to extend further along the second polymer layer 535 to allow the central portion 507 of the barrier member 505 to separate from the edge portion 509, thereby exposing the barrier opening in the interior 107 of the container 105 for access to one or more items A in the interior 107 of the container 105.

[0080] Due to the construction of the barrier member 505 and the weakened lines formed along it (which are formed by separately cutting along opposing surfaces of the blank 503 / barrier member 505 with tools T1, T2), a portion of the blank 503 / barrier member 505 (e.g., a portion of the second polymer layer 535) is retained until manually broken by a user. In this regard, the blank 503 / barrier member 505 can provide superior barrier properties to maintain one or more conditions of the item A in the interior 107 of the container 105, such as maintaining freshness, maintaining its sealed state, maintaining a moisture barrier, protecting from environmental debris, preventing pests from entering, etc., compared to barrier members in which the weakened lines completely penetrate these structures. Furthermore, this arrangement of the weakened lines in the blank 503 / barrier member 505 can provide superior tear resistance against accidental forces (e.g., those accidentally applied by a user during the opening process), such as during installation of the blank 503 / barrier member 505 into the interior 107 of the container 105, during storage and / or transportation, during pressure changes, etc.

[0081] It should be understood that the container 105 and / or one or more of its components may have different configurations without departing from the present invention. For example, it should be understood that one or more of the blanks and components described herein may be shaped, sized, or otherwise configured to engage with these container structures. These container structures may include those available from Graphic Packaging International, LLC of Atlanta, Georgia. Available from Graphic Packaging International, LLC, Atlanta, Georgia and available from Graphic Packaging International, LLC, Atlanta, Georgia etc.

[0082] The blank according to the present invention can be formed, for example, from coated paperboard and similar materials. For example, the inside and / or outside of the blank can be coated with a clay coating. Products, advertisements, price codes, and other information or images can then be printed on the clay coating. The blank can then be coated with a varnish to protect any information printed on the blank. For example, a moisture barrier can also be applied to either or both sides of the blank. According to the above embodiment, the blank can be made of paperboard of a certain thickness, making it heavier and more rigid than ordinary paper. The blank can also be made of other materials, such as cardboard, hard paper, or any other material having a property suitable for enabling the container to function at least roughly as described above. The blank can also be laminated or coated with one or more sheet materials at a selected plate or plate portion.

[0083] According to the above-described embodiments of the present invention, a fold line can be any substantially linear weakening pattern that facilitates folding along it, but is not necessarily straight. More specifically, but not for the purpose of narrowing the scope of the present invention, fold lines include: score lines, such as lines formed with a blunt scoring knife, which create a crushed portion in the material along the desired weakening line; cuts that extend partially into the material along the desired weakening line; and / or a series of cuts that extend partially into the material along the desired weakening line and / or extend completely through the material; and various combinations of these features.

[0084] As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness; and / or a series of spaced slits that extend partially into the material along the desired line of weakness and / or extend completely through the material; or various combinations of these features. As a more specific example, one type of tear line takes the form of a series of spaced slits that extend completely through the material, wherein adjacent slits are slightly spaced apart, thereby defining a notch (e.g., a small, slightly bridging sheet of material) between adjacent slits, typically used to temporarily connect the materials across the tear line. Upon tearing along the tear line, the notch is destroyed. The notch is typically a relatively small percentage of the tear line; alternatively, the notch can be omitted from the tear line or torn within the tear line, such that the tear line is a continuous cut line. That is, it is within the scope of the present invention to replace the spaced slits with a continuous slit, a continuous score, etc. For example, the cut line can be a continuous slit or can be wider than a slit without departing from the present invention. Also, the tear line may be a series of cut scores that pass completely or partially through the material, separated by notches.

[0085] The term "glue" is intended to include all adhesives commonly used to secure container panels or parts in place.

[0086] The foregoing description of the present invention represents and describes various example embodiments. Various additions, modifications, changes, etc. may be made to the example embodiments without departing from the spirit and scope of the present invention. All content contained in the foregoing description or shown in the accompanying drawings should be interpreted as illustrative, not restrictive. In addition, this disclosure only represents and describes selected embodiments of the present invention, but the present invention can be used in various other combinations, variations and environments, and can be changed or varied within the scope of the inventive concept commensurate with the above teachings as expressed herein and / or within the skill or knowledge of the relevant field. Moreover, the specific features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and unillustrated embodiments of the present invention.

Claims

1. A container for holding at least one article, the container comprising: a body extending at least partially around an interior of the container; a reclosable lid engaged with the body, the reclosable lid being indexable between an open position in which the reclosable lid is moved away from an interior of the container and a closed position in which the reclosable lid at least partially covers the interior of the container; a closed bottom engaged with the body; as well as A barrier member formed of a laminated structure defining an outer surface and an inner surface of the barrier member and positioned in the interior of the container, the barrier member including a central portion at least partially detachably connected to an edge portion at a first weakening line and a second weakening line, the first weakening line extending from the outer surface of the barrier member to a first depth, the second weakening line extending from the inner surface of the barrier member to a second depth, the first depth being different from the second depth, the edge portion being attached to the body.

2. The container of claim 1 , wherein the central portion of the barrier member is at least partially separable from the edge portion of the barrier member to expose the barrier opening for accessing at least one item in the interior of the container.

3. The container according to claim 2, wherein: The laminate structure includes a composite layer and at least one polymer layer.

4. The container according to claim 3, wherein: The at least one polymer layer is one polymer layer among a plurality of polymer layers.

5. The container according to claim 4, wherein: The polymer layer includes high density polyethylene (HDPE).

6. The container according to claim 5, wherein: The polymer layer is a third polymer layer in at least partial face-to-face contact with the composite layer, and the laminate structure includes a second polymer layer in at least partial face-to-face contact with the third polymer layer and a first polymer layer in at least partial face-to-face contact with the second polymer layer.

7. The container according to claim 6, wherein: The first polymer layer and the second polymer layer each include polyethylene, and each of the first polymer layer and the second polymer layer has a density lower than a density of the third polymer layer.

8. The container according to claim 6, wherein: The first depth of the first line of weakness extends through the composite layer and partially through the third polymer layer.

9. The container according to claim 8, wherein: The second depth of the second line of weakness extends through the first and second polymer layers and partially through the third polymer layer.

10. The container according to claim 9, wherein: The third polymer layer is free of a line of weakness at a depth greater than a first depth from the outer surface of the barrier member and at a depth greater than a second depth from the inner surface of the barrier member.

11. The container according to claim 10, wherein: The first depth is approximately 0.46 mm.

12. The container according to claim 11, wherein: The second depth is approximately 0.1 mm.

13. The container according to claim 12, wherein: The central portion of the barrier member has a thickness of approximately 0.55 mm.

14. The container of claim 10, wherein: The barrier member includes an entry feature to facilitate at least partial separation of a central portion from an edge portion of the barrier member.

15. The container of claim 14, wherein: The access feature is foldably connected to a portion of the central portion of the barrier member.

16. A combination of blanks for forming a container for holding at least one article, the combination of blanks comprising: a body blank for forming a body extending at least partially around an interior of a container formed from the combination of the blanks; a lid blank for forming a reclosable lid that engages with the body when a container is formed from the combination of the blanks, such that the reclosable lid is indexable between an open position in which the reclosable lid is moved away from an interior of the container formed from the combination of the blanks, and a closed position in which the reclosable lid at least partially covers the interior of the container formed from the combination of the blanks; a bottom blank for forming a closed bottom that engages with the body of a container formed from the combination of the blanks; as well as A barrier blank formed from a laminated structure defining an outer surface and an inner surface of the barrier blank and adapted to be positioned within a container formed from the combination of the blanks, the barrier blank comprising a central portion at least partially detachably connected to the edge portion at a first weakening line and a second weakening line, the first weakening line extending from the outer surface of the barrier blank to a first depth, the second weakening line extending from the inner surface of the barrier blank to a second depth, the first depth being different from the second depth, the edge portion adapted to be attached to the body of the container formed from the combination of the blanks.

17. The combination of claim 16, wherein: The central portion of the barrier blank is at least partially separable from the edge portion of the barrier member for exposing a barrier opening for accessing at least one item within the interior of a container formed by the combination of the blanks.

18. The combination of claim 17, wherein: The laminate structure includes a composite layer and at least one polymer layer.

19. The combination of claim 18, wherein: The at least one polymer layer is one polymer layer among a plurality of polymer layers.

20. The combination of claim 19, wherein: The polymer layer includes high density polyethylene (HDPE).

21. The combination of claim 20, wherein: The polymer layer is a third polymer layer in at least partial face-to-face contact with the composite layer, and the laminate structure includes a second polymer layer in at least partial face-to-face contact with the third polymer layer and a first polymer layer in at least partial face-to-face contact with the second polymer layer.

22. The combination of claim 21, wherein: The first polymer layer and the second polymer layer each include polyethylene, and each of the first polymer layer and the second polymer layer has a density lower than a density of the third polymer layer.

23. The combination of claim 21, wherein: The first depth of the first line of weakness extends through the composite layer and partially through the third polymer layer.

24. The combination of claim 23, wherein: The second depth of the second line of weakness extends through the first and second polymer layers and partially through the third polymer layer.

25. The combination of claim 24, wherein: The third polymer layer is free of a line of weakness at a depth greater than a first depth from the outer surface of the barrier member and at a depth greater than the second depth from the inner surface of the barrier member.

26. The combination of claim 25, wherein: The first depth is approximately 0.46 mm.

27. The combination of claim 26, wherein: The second depth is approximately 0.1 mm.

28. The combination of claim 27, wherein: The central portion of the barrier member has a thickness of approximately 0.55 mm.

29. The combination of claim 28, wherein: The barrier member includes an entry feature to facilitate at least partial separation of the central portion of the barrier member from the edge portion.

30. The combination of claim 29, wherein: The access feature is foldably connected to a portion of the central portion of the barrier member.

31. A method of forming a container for holding at least one article, the method comprising: obtaining a body blank; obtaining a cover blank; obtaining a bottom blank; obtaining a barrier blank formed from a laminated structure defining an outer surface and an inner surface, the barrier blank including a central portion at least partially detachably connected to an edge portion at a first line of weakness and a second line of weakness, the first line of weakness extending from the outer surface of the barrier blank to a first depth, the second line of weakness extending from the inner surface of the barrier blank to a second depth, the first depth being different from the second depth; forming a body of the container from the body blank such that the body extends at least partially around an interior of the container; forming a reclosable lid from the lid blank such that the reclosable lid engages the body, the reclosable lid being indexable between an open position in which the reclosable lid is moved away from an interior of the container and a closed position in which the reclosable lid at least partially covers the interior of the container; forming a closed bottom from the bottom blank such that the closed bottom engages the body of the container; as well as The edge portion of the barrier blank is attached to the body of the container to form a barrier member.

32. The method of claim 31 , wherein: The central portion of the barrier blank is at least partially separable from the edge portion of the barrier blank for exposing the barrier opening for accessing the at least one item within the interior of the container.

33. The method of claim 32, wherein: The laminate structure includes a composite layer and at least one polymer layer.

34. The method of claim 33, wherein: The at least one polymer layer is one polymer layer among a plurality of polymer layers.

35. The method of claim 34, wherein: The polymer layer includes high density polyethylene (HDPE).

36. The method of claim 35, wherein: The polymer layer is a third polymer layer in at least partial face-to-face contact with the composite layer, and the laminate structure includes a second polymer layer in at least partial face-to-face contact with the third polymer layer and a first polymer layer in at least partial face-to-face contact with the second polymer layer.

37. The method of claim 36, wherein: The first polymer layer and the second polymer layer both include polyethylene, and each of the first polymer layer and the second polymer layer has a density lower than a density of the third polymer layer.

38. The method of claim 36, wherein: The first depth of the first line of weakness extends through the composite layer and partially through the third polymer layer.

39. The method of claim 38, wherein: The second depth of the second line of weakness extends through the first and second polymer layers and partially through the third polymer layer.

40. The method of claim 39, wherein: The third polymer layer is free of a line of weakness at a depth greater than a first depth from the outer surface of the barrier member and at a depth greater than a second depth from the inner surface of the barrier member.

41. The method of claim 40, wherein: The first depth is approximately 0.46 mm.

42. The method of claim 41 , wherein: The second depth is approximately 0.1 mm.

43. The method of claim 42, wherein: The central portion of the barrier member has a thickness of approximately 0.55 mm.

44. The method of claim 40, wherein: The barrier member includes an entry feature to facilitate at least partial separation of a central portion from an edge portion of the barrier member.

45. The method of claim 44, wherein: The access feature is foldably connected to a portion of the central portion of the barrier member.

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