Barrier members for containers, related containers, systems, and methods

Abstract

A container for holding at least one article comprises a laminated structure including a body that extends at least partially around the interior of the container, a closing upper engaged with the body, a closing lower engaged with the body, and a barrier member disposed inside the container, the barrier member comprising at least one polymer layer having a continuous lower section.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 468,113, filed May 22, 2023.

[0002] [Incorporation by Reference] The disclosure of U.S. Provisional Patent Application No. 63 / 468,113, filed May 22, 2023, is hereby incorporated by reference in its entirety for all purposes as if fully set forth herein.

[0003] [Background of the Disclosure] The present disclosure generally relates to a container for holding one or more articles. In some embodiments, the present disclosure relates to a container having at least one barrier member.

Summary of the Invention

Means for Solving the Problems

[0004] According to one aspect, the present disclosure generally relates to a container for holding at least one article, the container comprising a body that at least partially extends around the interior of the container, a closure top engaged with the body, a closure bottom engaged with the body, and a barrier member disposed within the interior of the container, the barrier member comprising a laminated structure including at least one polymer layer having a continuous lower portion.

[0005] In another aspect, the disclosure relates generally 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 the body of the container formed from the combination of blanks, a bottom blank for engaging with the body of the container formed from the combination of blanks to form a closed bottom, a lid blank for engaging with the body of the container formed from the combination of blanks to form a closed top, and a barrier blank for forming a barrier member of the container formed from the combination of blanks, the barrier blank comprising a laminated structure including at least one polymer layer having a continuous bottom.

[0006] In another aspect, the disclosure generally relates to a method for forming a container for holding at least one article, the method comprising the steps of: obtaining a body blank; obtaining a bottom blank; obtaining a lid blank; obtaining a barrier blank including a laminated structure having at least one polymer layer having a continuous lower section; positioning the body blank to form a body that extends at least partially around the inside of the container; engaging the bottom blank with the body of the container to form a closed bottom of the container; engaging the barrier blank with the body of the container to form a barrier member inside the container; and engaging the lid blank with the body of the container to form a closed top of the container.

[0007] Those skilled in the art will understand the above-mentioned advantages and other advantages and benefits of various additional embodiments by referring to the drawings listed below and reading the following detailed description of the embodiments.

[0008] By convention, the various features of the drawings described below are not necessarily drawn to a fixed scale. The dimensions of the various features and elements in the drawings may be enlarged or reduced to more clearly illustrate embodiments of this disclosure. [Brief explanation of the drawing]

[0009] [Figure 1]This is a plan view of the outer surface of a body blank used to form the body of a container according to an exemplary embodiment of the present disclosure. [Figure 2] This is a plan view of the outer surface of a lid blank for forming a lid or upper end of a container, according to an exemplary embodiment of the present disclosure. [Figure 3] This is a plan view of the outer surface of a bottom blank for forming the bottom of a container according to an exemplary embodiment of the present disclosure. [Figure 4A] This is a plan view of the outer surface of a barrier blank for forming a barrier member of a container, according to an exemplary embodiment of the present disclosure. [Figure 4B] Figure 4A is a plan view of the internal surface of the barrier blank. [Figure 5A] Figures 4A and 4B show cross-sectional views of exemplary embodiments of laminated structures capable of forming barrier blanks. [Figure 5B] Figures 4A and 4B show cross-sectional views of an alternative exemplary embodiment of a laminated structure capable of forming a barrier blank. [Figure 5C] Figures 4A and 4B show cross-sectional views of another alternative exemplary embodiment of a laminated structure capable of forming the barrier blank. [Figure 5D] Figures 4A and 4B show cross-sectional views of another alternative exemplary embodiment of a laminated structure capable of forming the barrier blank. [Figure 5E] Figures 4A and 4B show cross-sectional views of another alternative exemplary embodiment of a laminated structure capable of forming the barrier blank. [Figure 5F] Figures 4A and 4B show cross-sectional views of another alternative exemplary embodiment of a laminated structure capable of forming the barrier blank. [Figure 6A] This is a first continuous perspective view of the formation of a container from the blank shown in Figures 1 to 4B, according to exemplary embodiments of the present disclosure. [Figure 6B] This is a second continuous perspective view of the formation of a container from the blanks shown in Figures 1 to 4B according to exemplary embodiments of the present disclosure. [Figure 6C]This is a third continuous perspective view of the formation of a container from the blanks shown in Figures 1 to 4B, according to exemplary embodiments of the present disclosure. [Figure 6D] This is a fourth sequential perspective view of the formation of a container from the blanks shown in Figures 1 to 4B, according to exemplary embodiments of the present disclosure.

[0010] Corresponding parts are designated by corresponding reference numbers throughout the drawing. [Modes for carrying out the invention]

[0011] The containers provided in this disclosure can hold a number of articles of different shapes. For illustrative purposes only and not to limit the scope of this disclosure, the following detailed description describes articles such as food. Such food may be provided in individual or granular portions, such as snacks, such as candy, gum, chocolate, granola, cereal, nuts, trail mix, raisins, dried fruit, etc. Without departing from this disclosure, it will be understood that different types of food or articles, such as powdered food or powdered articles, can be held in the containers provided in this disclosure. For example, powdered products / articles may include nutritional supplements such as infant or toddler formula, adult nutritional supplements, and other dry foods that are reconstituted with water or other fluids. It will be further understood that articles other than food can be held in the containers provided in this disclosure.

[0012] In this specification, the terms “bottom,” “bottom,” “top,” and “summit” indicate the orientation determined with respect to a fully assembled container and an upright container. As described herein, a container can be formed from a blank by overlapping multiple panels, parts, and / or end flaps. Such panels, parts, and / or end flaps may be designated herein in continuous or discontinuous reference to one another by terms such as “first,” “second,” “third,” etc., without departing from this disclosure.

[0013] Figures 1 to 4B are plan views of a series of blanks used to form components that are assembled to form a container 105 (Figure 6D) according to an exemplary embodiment of the present disclosure. In this regard, in some embodiments, the container 105 can be regarded as an assembly or system of a plurality of components.

[0014] Referring to Figure 1, a plan view of the outer surface 201 of the body blank 203 for forming the body 205 of the container 105 is shown. As described herein, the body 205 is disposed so as to at least partially extend around the interior 107 of the container 105.

[0015] As shown in the illustration, 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 interchanged. In the illustrated embodiment, the body blank 203 can have a generally rectangular configuration having a pair of opposing lateral 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.

[0016] The body blank 203 can also include a body forming portion 215 defined along a central portion of the body blank 203, a first end or upper end or lid forming portion 217 defined at an upper peripheral portion / upper peripheral edge of the body blank 203, and a second or bottom end forming portion 219 defined at a lower peripheral portion / lower peripheral edge of the body blank 203.

[0017] As shown in the illustration, the lid forming portion 217 of the body blank 203 can be at least partially separably connected to the body forming portion 215 and can be at least partially foldably connected to the body forming portion 215 at a longitudinal weak line 221 that can include at least one tear segment and at least one fold line segment.

[0018] In some embodiments, the bottom end portion forming part 219 of the body blank 203 can be at least partially separably and / or foldably connected to its body forming part 215 at a vertical weak line 224 including one or more of a tear segment and a fold line segment.

[0019] Continuing to refer to FIG. 1, the body blank 203 can include a plurality of lateral weak lines 223 that can facilitate the formation of curved corners when the body 205 is formed from the body blank 203, as further described herein.

[0020] The body blank 203 can also include one or more pluralities of vertical weak lines 225 extending along it. In the illustrated embodiment, the body blank 203 can include a plurality of vertical weak lines 225 extending across the lid forming part 217 and another plurality of vertical weak lines 225 extending along the body forming part 219. As further described herein, the weak lines 225 can facilitate the formation of the body 205 from the body blank.

[0021] In some embodiments, the body blank 203 can be composed of one or more cardboard materials mainly made of cellulose fibers or paper fibers. The material may be provided in the form of a continuous web or as individual sheets of the material. The cardboard material may be a single-layer or multi-layer material, or a laminate including one or more reinforcing moisture-resistant non-cellulose layers of materials such as films and coatings, metal foils, etc. The cardboard material may be coated, printed, embossed, etc., and may include fillers, pigments, binders, and other additives known in the art. In some embodiments, the cardboard material may not include polymer materials and / or metal materials.

[0022] Referring to Figure 2, the outer surface 301 of the lid blank 303 for forming at least partially the lid 109 of the container 105 is shown. As shown, the lid blank 303 may have a longitudinal axis L1 and a transverse axis L2 and may include a central portion 307 and a peripheral portion 309 that extends to the periphery of the lid blank 303.

[0023] In some embodiments, the peripheral portion 309 of the lid blank 303 can be connected to the central portion 307 at least partially foldable by a generally rounded rectangular / elliptical fold line 310. In other embodiments, one or more foldable connections between the peripheral portion 309 and the central portion 307 of the lid blank 303 may be formed when the lid 109 of the container 105 is formed, as further described herein.

[0024] As also illustrated, the lid blank 303 may include a plurality of diagonal and / or curved fragile lines 313 positioned along the corners of the lid blank 303. As further described herein, the fragile lines 313 can facilitate the formation of the lid 109 / container 105.

[0025] It will be understood that the lid blank 303 can be formed from one or more materials, such as cardboard, which are the same or similar materials as those used to form the main body blank 203, as described above.

[0026] Referring to Figure 3, the outer surface 401 of the bottom blank 403 for at least partially forming the closed bottom or closed end 111 of the container 105 is shown.

[0027] As shown in the figure, the bottom blank 403 can have a configuration that is substantially the same as that of the lid blank 303 described above, for example, having a vertical axis L1 and a horizontal axis L2, a central portion 407, and a peripheral portion 409 that extends to the periphery of the bottom blank 403. In the illustrated embodiment, the peripheral portion 409 can be connected to the central portion 407 at least partially foldable by a substantially rounded rectangular / elliptical fold line 410, but the blank 403 may be without the fold line 410 without departing from the present disclosure.

[0028] In some embodiments, the bottom blank 403 may include a number of diagonal and / or curved fragile lines positioned along the corners of the bottom blank 403 to facilitate the formation of the closed bottom 111 / container 105.

[0029] Referring to Figure 4A, the outer surface 501 of the barrier blank 503 for forming the barrier member 505 of the container 105 is shown. Figure 4B is a plan view of the inner surface 502 of the barrier blank 503 and the barrier member 505 formed therefrom.

[0030] The barrier blank 503 may have a vertical axis L1 and a horizontal axis L2 and may include a central portion 507 and a peripheral portion 509 extending to the periphery of the barrier blank 503. In some embodiments, the peripheral portion 509 of the barrier blank 503 may be connected to the central portion 507 at least partially foldable by one or more fragile lines (e.g., fold lines). In other embodiments, one or more foldable connections between the peripheral portion 509 and the central portion 507 of the blank 503 may be formed when the barrier member 505 is formed.

[0031] In some embodiments, the barrier blank 503 and / or the barrier member 505 formed therefrom may have an area of ​​about 143.6 cm².

[0032] As further described herein, the peripheral portion 509 of the blank 503 may be at least partially separable from the central portion 507 of the blank 503 and the barrier member 505 formed therefrom by at least one fragile line.

[0033] In the illustrated embodiment, the barrier blank 503 and the barrier member 505 formed therefrom can be formed from a laminated structure comprising a plurality of generally aligned layers, wherein vertically adjacent layers overlap and / or are in at least partially face-to-face contact with one another.

[0034] As described herein, the laminated structure may include at least an upper portion and, in some embodiments, a lower portion bonded to the upper portion. In some embodiments, the upper portion may be a laminate of multiple layers forming an upper web, and in some embodiments, the lower portion may include at least one layer forming a base web.

[0035] As shown in Figure 5A, in one exemplary embodiment, a barrier blank 503 and a barrier member 505 formed therefrom may include a laminated structure 507A comprising an upper 521A having a polymer layer 523, an adhesive layer 525 applied to the polymer layer 523 and overlapping and / or in at least partially face-to-face contact, and a composite layer 527 applied to the adhesive layer 525 and overlapping and / or in at least partially face-to-face contact.

[0036] In some embodiments, the polymer layer 523 may include a polymer film, such as an oriented polyethylene terephthalate (OPET) film, or a biaxially oriented polyethylene terephthalate (BOPET) film. The polymer layer 523 may be provided with a thickness of about 12 microns, but the polymer layer 523 may have different configurations and / or arrangements without departing from the disclosure.

[0037] The adhesive layer 525 may include an adhesive, such as a hot melt adhesive, a high-tack adhesive, an epoxy, a polymer cement, or a combination thereof. It will be understood that the adhesive layer 525 may be cured, dried, or otherwise treated to provide desirable properties during the formation of the laminated structure 507A. In some embodiments, the adhesive layer 525 may be supplied at a density of about 3 grams per square meter (gsm), but it will be understood that the adhesive layer 525 may have different configurations or arrangements without departing from the present disclosure.

[0038] In some embodiments, the composite layer 527 may include paper or paperboard products such as kraft paper, parchment, clay-coated cardboard, solid bleached board (SBB) cardboard, solid bleached sulfate (SBS) cardboard, kraft line cardboard, cardboard, or other suitable material that may be biodegradable, compostable, and / or repulpable.

[0039] Optionally, the laminated structure 507A may include a graphic layer 529 applied to, overlapping with, and / or at least partially in face-to-face contact with the composite layer 527. In some embodiments, the graphic layer 529 may include one or more inks, printed materials, etc. In some embodiments, such printed materials may be provided with one or more suitable coatings to facilitate their clear and stable reception on the laminated structure 507A.

[0040] As also illustrated, the laminated structure 507A may include a fragile line 531 formed at least partially through it by a die-cut. The fragile line 531 may be formed at least partially along the blank 503 and a portion of the barrier member 505 formed therefrom, for example, its periphery, to facilitate the relative separation of portions of the barrier member 505 during the process of opening the container 105. The fragile line 531 may be positioned to form one or more selected features, for example, an access tab, a pull tab, etc. Although the fragile line 531 is shown to be generally continuous along each portion of the blank 503 / barrier member 505, it will be understood that the fragile line 531 may include one or more discontinuities without departing from the present disclosure.

[0041] In the illustrated embodiment, the fragile line 531 can be formed by a die-cut that penetrates any graphic layer 529, the top surface of the composite layer 527, the adhesive layer 525, and partially penetrates the polymer layer 523, extending to a distance above the bottom surface of the polymer layer 523. In this regard, the fragile line 531 can be formed by a cutting tool that penetrates the blank 503 / barrier member 505 and is inserted to a desired depth.

[0042] In this regard, the weak line 531 may provide the laminated structure 507A with at least a partially continuous polymer layer 523 along its underside for strength and / or a pre-selected resistance to ease of tearing, for example, to provide desired fluid barrier properties.

[0043] Referring to Figure 5B, an alternative exemplary embodiment of the present disclosure is shown, which includes a laminated structure 507B for forming a blank 503 and a barrier member 505 formed therefrom.

[0044] As shown in the figure, the laminated structure 507B may include an upper 521B having a configuration substantially similar to that of the upper 521A of the laminated structure 507A, for example, including a polymer layer 523, an adhesive layer 525, a composite layer 527, and optionally a graphic layer 529.

[0045] However, as shown in the figure, the laminated structure 507B may include a fragile line 533 formed by one or more die-cuts that at least partially penetrate it. The fragile line 533 may be formed at least partially along the blank 503 and a portion of the barrier member 505 formed therefrom, for example, its periphery, to facilitate the relative separation of portions of the barrier member 505 during the process of opening the container 105. The fragile line 533 may be positioned to form one or more selected features, for example, an access tab, a pull tab, etc.

[0046] In the illustrated embodiment, the fragile line 533 can be formed by at least two separate die-cuts, including an upper part 535 (broadly defined as the "first fragile line") that penetrates any graphic layer 529 and extends at least partially through the upper surface of the composite layer 527, and a lower part 537 (broadly defined as the "second fragile line") that penetrates the polymer layer 523, the adhesive layer 525, and extends upward through partially through the composite layer 527. In this regard, the upper part 535 of the fragile line 533 can be at least partially formed by at least one die-cut passing through the upper surface of the laminated structure 507B, and the lower part 537 can be at least partially formed by at least one die-cut passing through the lower surface of the laminated structure 507B.

[0047] As shown in the figure, the upper part 535 of the weak line 533 can be formed from the outer edge of the laminated structure 507B with a width W1, and the lower part 537 of the weak line 533 can be formed from the outer edge of the laminated structure 507B with a width W2, the width W2 being greater than the width W1 so that the upper part 535 and the lower part 537 of the weak line 533 can be offset from each other.

[0048] Referring to Figure 5C, a laminated structure 507C for forming a blank 503 and a barrier member 505 formed therefrom is shown according to another alternative exemplary embodiment of the present disclosure.

[0049] As shown, the laminated structure 507C may include an upper 521C having a configuration substantially similar to that of the upper 521A of the laminated structure 507A, for example, including a polymer layer 523, an adhesive layer 525, a composite layer 527, and optionally a graphic layer 529. However, the upper 521C may further include a second polymer layer 539 that is applied to, overlaps with, and / or at least partially faces the polymer layer 523 (broadly speaking, the "first polymer layer").

[0050] In some embodiments, the polymer layer 539 comprises polyethylene, but the polymer layer 539 can have different compositions without departing from the present disclosure. In some embodiments, the polymer layer 539 may consist of polyethylene that can be activated, for example, by the application of high-frequency energy to excite one or more of its molecules and thereby facilitate sealing to the body blank 203 / body 205 formed therefrom.

[0051] Such application of RF energy may include the application of electromagnetic waves in the range of about 10 GHz to about 300 GHz. In some embodiments, the barrier blank 503 / barrier member 505 may be exposed to electromagnetic waves in the range of about 10 MHz to about 50 MHz. In some embodiments, electromagnetic waves in the range of about 20 MHz to about 30 MHz can be applied to the barrier blank 503 / barrier member 505.

[0052] Such application of RF energy to the barrier blank 503 / barrier member 505 can facilitate the realignment of dipoles within the polymer layer 539 in the presence of an alternating electric field, inducing molecular rotation and subsequent intermolecular friction to generate heat within the first polymer layer 523, thereby facilitating the sealing of the barrier blank 503 / barrier member 505 with the body blank 203 / body 205 and / or other parts of the barrier blank 503 / barrier member 505 formed therefrom.

[0053] In this regard, RF energy can be applied to the laminated structure 507C to heat, soften, melt, etc., the polymer layer 539, so that it has adhesive properties for joining the layers of the laminated structure 507C. In some embodiments, such heating of the polymer layer 539 promotes bonding between the polymer layer 539 and the rest of the laminated structure 507C, so as to form a sealing film or barrier on it.

[0054] In some embodiments, such RF energy can be supplied by a tool or system such as that described in U.S. Patent Application No. 18 / 386,287, filed November 2, 2023, entitled “Laminate Construct, Blanks And Containers Formed Therefrom, Sealing Apparatus Therefor, And Associated Methods,” the entirety of which is incorporated herein by reference as if it were described in whole.

[0055] In some embodiments, the polymer layer 539 may be provided with a density of about 15 gsm, but it will be understood that the polymer layer 539 may have different configurations and / or arrangements without departing from the present disclosure.

[0056] The laminated structure 507C may further include a lower section 522C comprising a third polymer layer 541 having desirable barrier properties, such as suitable resistance to tearing and / or migration of fluid particles across it. In some embodiments, the polymer layer 541 may include an ethylene-vinyl alcohol copolymer (EVOH) having a thickness of about 40 microns, but it will be understood that the polymer layer 541 may have different configurations and / or arrangements without departing from the present disclosure.

[0057] In the illustrated embodiment, the polymer layer 541 may have a width W3 that is generally smaller than the width W4 of the upper part 521C of the laminated structure 507C. In some embodiments, the difference between widths W3 and W4 may correspond to the periphery of the upper part 521C, which may be, for example, upward or downward, for attachment to the blank 203 / body 205 during the process of forming the barrier member 505 from the blank 503. Thus, the polymer layer 541 may be sized and configured to avoid operations according to attachment to the rest of the container 105, for example, to avoid fragility and / or interruption of its profile.

[0058] As shown in the figure, the weak line 531 is provided such that at least a portion of it does not extend into the polymer layer 539, for example, to provide the lower / lower surface of the polymer layer 541 of the laminated structure 507C having a continuous barrier structure that provides excellent barrier properties for a barrier structure containing such a weak line.

[0059] Referring to Figure 5D, a laminated structure 507D for forming a blank 503 and a barrier member 505 formed therefrom is shown according to another exemplary embodiment of the present disclosure.

[0060] As shown, the laminated structure 507D may include an upper 521D having a configuration substantially similar to that of the upper 521A of the laminated structure 507A, for example, including a polymer layer 523, an adhesive layer 525, a composite layer 527, and optionally a graphic layer 529. However, the upper 521D may further include a polymer layer 540 (broadly defined as a "second polymer layer") applied to, overlapping with, and / or at least partially in face-to-face contact with the polymer layer 523.

[0061] In some embodiments, the polymer layer 540 comprises polyethylene, but the polymer layer 540 may have a different composition without departing from the disclosure. In some embodiments, the polymer layer 540 may be provided at a density of about 15 gsm, but it will be understood that the polymer layer 540 may have a different configuration and / or arrangement without departing from the disclosure.

[0062] The laminated structure 507D may further include a lower section 522D comprising a third polymer layer 542 having desirable barrier properties, such as suitable resistance to tearing and / or migration of fluid particles across it. In some embodiments, the polymer layer 542 may include an ethylene-vinyl alcohol copolymer (EVOH) having a thickness of about 40 microns, but it will be understood that the polymer layer 542 may have different configurations and / or arrangements without departing from the present disclosure.

[0063] The polymer layer 542 can be configured to be activated / sealed by applying RF energy to the polymer layer 539 in the manner described above.

[0064] In the illustrated embodiment, the polymer layer 542 can have approximately the same width as the upper part 521D of the laminated structure 507D.

[0065] As also shown in the figure, the weak line 531 is provided such that none of its portions extends into at least the polymer layer 542, for example, providing a lower part of the laminated structure 507D / polymer layer 539 having a continuous barrier structure that provides excellent barrier properties for a barrier structure including such a weak line.

[0066] Referring to Figure 5E, a laminated structure 507E for forming a blank 503 and a barrier member 505 formed therefrom is shown according to another exemplary embodiment of the present disclosure.

[0067] As shown in the figure, the laminated structure 507E may include an upper 521E having a configuration substantially similar to that of the upper 521C of the laminated structure 507C, for example, including polymer layers 523, 539, an adhesive layer 525, a composite layer 527, and optionally a graphic layer 529.

[0068] The laminated structure 507E may also include a lower section 522E having a polymer layer 541.

[0069] However, as shown in the figure, the upper part 521E of the laminated structure 507E may include a weak line 533.

[0070] Referring to Figure 5F, a laminated structure 507F for forming a blank 503 and a barrier member 505 formed therefrom is shown according to another exemplary embodiment of the present disclosure.

[0071] As shown in the figure, the laminated structure 507F may include an upper 521F having a configuration generally similar to that of the upper 521D of the laminated structure 507D, for example, including polymer layers 523, 540, an adhesive layer 525, a composite layer 527, and optionally a graphic layer 529.

[0072] The laminated structure 507F may also include a lower section 522F having a polymer layer 542.

[0073] However, as shown in the figure, the upper part 521F of the laminated structure 507F may include a weak line 533.

[0074] As described herein, the continuous lower portion of the laminated structure can substantially lack fragile lines so as to have a generally continuous polymer portion that can minimize, suppress, avoid, and / or prevent the passage of fluid therethrough, and can be configured to maintain such a configuration during operations associated with placement in and / or attachment to the container 105. Such a configuration can facilitate the maintenance of a sealed state of a portion of the interior 107 of the container 105.

[0075] One or more of the blanks 203, 303, 403, and 503, and one or more of their associated features, may have different arrangements and / or configurations without departing from the present disclosure. For example, as further described herein, body blank 203 may be formed on the body 205 of a container 105 having a substantially rounded rectangular or elliptical vertical cross-section, and each of the blanks 303, 403, and 503 may have a corresponding cross-section for at least partially being received inside 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, and 503 may have different configurations corresponding to such vertical cross-sectional configurations.

[0076] As described herein, blanks 203, 303, 403, and 503 can be further formed to provide components that are assembled to form a container 105. In this regard, blanks 203, 303, 403, and 503 may be provided in combination to form a system in the form of a container 105.

[0077] Referring to Figures 6A to 6D, the formation of container 105 from blanks 203, 303, 403, and 503 will be described according to exemplary embodiments of this disclosure.

[0078] The main body blank 203 can be positioned to extend at least partially around the interior 107 of the container 105. In one embodiment, the main body blank 203 can be bent, curved, folded, etc., at least partially at a fold line 223, to form a substantially elliptical or rounded rectangular cross-section, and the portion of the main body blank 203 adjacent to the free edges 207, 209 can at least partially overlap and form a seam arrangement that can be maintained using strips of adhesive tape T. In some embodiments, the free edges 207, 209 of the blank 203 can be brought into substantially edge-to-edge contact.

[0079] The overlapping / intersecting portions of the main body blank 203 can be joined by, for example, an adhesive such as glue, an adhesive-coated tape or substrate, and / or another joining method such as welding or an interference lock configuration.

[0080] As shown in the figure, the body 205 of the container 105 can be formed in this manner, with each portion of the body forming portion 215 of the blank 203 forming the front wall or front panel 223, the first side wall or first side panel 225, the second side wall or second side panel 227, and the rear wall or rear panel 229. The curved corners 231, 233, 235, and 237 can be formed between the respective panels 223, 225, the respective panels 223, 227, the respective panels 225, 229, and the respective panels 227, 229. In some embodiments, the blank 203 may have one or more weak lines to facilitate the formation of such rounded or curved corners of the body 205.

[0081] As described above, in some embodiments, the body 205 of the container 105 can be formed in different cross-sectional configurations, such as circular, elliptical, triangular, rectangular, square, pentagonal, hexagonal, heptagonal, octagonal, etc., including variations in their rounded or curved corners.

[0082] Continuing to refer to Figures 6A to 6D, the closed bottom 111 of the container 105 can be formed by placing a bottom blank 403 inside 107 of the container 105, and the central portion 407 of the bottom blank 403 is positioned in a substantially perpendicular relationship with panels 223, 225, 227, and 229 so as to form the bottom panel 411 of the container 105. As shown in the figures, the bottom blank 403 can be positioned at a vertical distance above the vertical free edge 213 of the blank 203.

[0083] The peripheral portion 409 of the bottom blank 403 is bent or folded downward relative to the central portion 407 of the blank 403 / bottom panel 411, for example along a fold line 410, and attached to the inner surface of one or more of the panels 223, 225, 227, 229 and corners 231, 233, 235, 237 of the body 205 of the container 105, and may be attached by bonding with an adhesive such as glue, welding, or by other means.

[0084] Simultaneously or thereafter, the bottom forming portion 219 of the blank 203 may be bent / curled or folded, for example, along the fold line 225, onto the periphery 409 of the bottom blank 403 to form the bottom flange 113 of the container 105 extending downward from the bottom panel 411. In some embodiments, the bottom forming portion 219 of the blank 203 may be crimped in such configuration. The bottom flange 113 can define the bottom edge of the container 105.

[0085] Continuing to refer to Figures 6A to 6D, the container 105 having a closed bottom 111 may be positioned with a bottom flange 113 that extends downward and is supported on a surface such as a conveyor for placement below a filling station where one or more articles can be placed and held inside 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 positioned close to the container 105 to place articles inside 107 of the container 105.

[0086] The article can be inserted into the interior 107 of the container 105 when its bottom 111 is formed, or the bottom 111 can be formed after the article is placed in the interior 107 of the container 105 in an inverted orientation, as will be further described below. In this regard, one or more tops of the container 105 may be closed before the closed bottom 111 of the container 105 is formed, and as a result, the interior 107 of the container 105 may be filled into the container 105 in an inverted orientation, for example, before the closed bottom 111 is formed. As described herein, the article may be a fluid product or material, such as a granular material / material with a relatively small particle size, such as a liquid food, but the article may be other products without departing from the present disclosure.

[0087] After the interior 107 of the container 105 is filled with articles, the barrier blank 503 may be placed on top of the articles inside the container 105, with the central portion 507 of the barrier blank 503 positioned substantially perpendicular to the panels 223, 225, 227, and 229. As shown, the barrier blank 503 may be placed at a vertical distance below the longitudinal free edge 211 of the blank 203 / body 205.

[0088] 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 via contact with a plunger or other movable tool for positioning the blank 503 / member 505.

[0089] In this regard, at least a portion of the peripheral edge 509 of the blank 503 / barrier member 505 is bent or folded upward relative to the central portion 507 of the barrier blank 503 and attached to one or more of the inner surfaces of the 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, which may be attached, for example, by bonding with an adhesive such as glue, welding, or by other means.

[0090] Following the formation and positioning of the barrier member 505, the lid blank 303 can be positioned on the barrier member 505 inside the container 105 107. As shown in the figure, the lid blank 303 can be positioned at a vertical distance below the longitudinal free edge 211.

[0091] The central portion 307 of the lid blank 303 can be positioned in a generally perpendicular relationship with panels 223, 225, 227, and 229 so as to form the lid panel 311 of the container 105.

[0092] The periphery 309 of the lid blank 303 is bent or folded downward relative to the central portion 307 of the blank 303 / lid panel 311, for example, along a fold line 310, and attached to the inner surface of one or more of the panels 223, 225, 227, 229 and corners 231, 233, 235, 237 of the body 205 of the container 105, and may be attached by bonding with an adhesive such as glue, welding, or by other means. It will be understood that the weak line 313 can facilitate the positioning of the periphery 309 relative to the corners 231, 233, 235, 237.

[0093] Simultaneously or thereafter, the lid-forming portion 217 of the blank 303 may be bent / curled or folded, for example along a fold line 225, on the peripheral portion 309 of the blank 203 to form the lid collar or lid flange 119 of the lid 109 of the container 105. In some embodiments, the lid-forming portion 217 of the blank 203 may be crimped in such configuration. The lid flange 119 may define the upper edge of the lid 109 / container 105.

[0094] It will be understood that the container 105 may be formed in different ways without departing from the present disclosure. For example, in an embodiment in which articles are loaded into the interior 107 of the container 105 in an inverted state, the body 205 of the container 105 may be formed, and one or more of the barrier member 505 and the lid panel 311 / lid 109 may be formed and attached to the body 205, after which the container 105 is inverted and articles are loaded, for example, at a loading or filling station. Next, the bottom panel 411 may be formed and attached to the body 205 of the container 105 as described above.

[0095] 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 fragile line 221, and move the lid 109 hingely / foldably around the fold line segment of the fragile line 221 to position the lid 109 in an open position where it moves away from the interior 107 of the container 105, and in a closed position where the lid 109 at least partially overlaps and / or is at least partially accepted into the interior 107 of the container 105. In this regard, the lid panel 311 / lid 109 may provide a selectively closed and / or re-closeable top of the container 105.

[0096] When the lid 109 is in the open position, the user can remove the barrier member 505 and access the article held beneath it. In one embodiment, the user can press the barrier member 505 in an access feature area or another selected area to at least partially separate the central portion 507 of the barrier member 505 from the peripheral portion 509 of each fragile line.

[0097] Once the central portion 507 of the barrier member 505 described above is separated at least partially, the user can insert one or more fingers into the interior 107 of the container 105 below the barrier member 505 and engage with the inner surface 502 of the barrier member 505, and pull the central portion 507 upward to separate it from the rest of the peripheral portion 509 along each fragile line.

[0098] In this regard, when the user pushes or pulls the barrier member 505, one or more weak lines propagate further along it, facilitating the separation of the central portion 507 from the peripheral portion 509 of the barrier member 505.

[0099] The configuration of the barrier member 505 and the laminated structure forming the blank 503 / barrier member 505, for example, the continuous lower part of the laminated structure forming the blank 503 / barrier member 505, may provide superior barrier properties to maintain one or more states of articles inside the container 105 107, for example, to maintain freshness, to maintain its sealed state, to maintain a moisture barrier, to avoid contact with debris from the environment, to prevent access by pests, for example, compared to a barrier member in which the fragile wire completely penetrates such a structure. Furthermore, this arrangement of the fragile wire in the blank 503 / barrier member 505 may provide superior tear resistance to accidental forces, for example, forces not intentionally applied by the user, such as during opening, for example, during installation of the blank 503 / barrier member 505 inside the container 105 107, during storage and / or transport, during pressure changes, etc.

[0100] Furthermore, the arrangement of weak lines extending at least partially through the blank 503 / barrier member 505 allows the integrity of the laminated structure, such as its sealing ability, to be maintained when attached to the body 205 of the container 105, in conjunction with the operation of plunger tools, sealing tools, or other mechanical components for positioning and / or attaching the blank 503 / barrier member 505 relative to the rest of the container 105.

[0101] It will be understood that container 105 and / or one or more of its components may have different configurations without departing from the present disclosure. For example, it will be understood that one or more of the blanks and components described herein may be molded, sized, or otherwise configured to engage with such container structures. Such container structures may include, to name a few, Boardio®, available from Graphic Packaging International, LLC, Atlanta, Georgia; Sealio®, available from Graphic Packaging International, LLC, Atlanta, Georgia; and Cekacan®, available from Graphic Packaging International, LLC, Atlanta, Georgia.

[0102] The blanks according to this disclosure can be formed from, for example, coated cardboard and similar materials. For example, the inside and / or outside of the blank can be covered with a clay coating. Then, products, advertisements, price codes, and other information or images can be printed on the clay coating. Next, the blank can be coated with varnish to protect any information printed on the blank. According to the embodiments described above, the blank may be made of cardboard of a thickness such that it is heavier and more rigid than ordinary paper. The blank can also be constructed from other materials such as cardboard, rigid paper, or any other material having properties suitable for enabling the container to function at least more generally as described above. The blank can also be laminated with one or more sheet materials in a selected panel or panel section, or coated with one or more sheet materials.

[0103] According to the embodiments described above of the present disclosure, the fold line can be any substantially linear weakening form that facilitates bending along it, although it is not necessarily a straight line. More specifically, without the intent to limit the scope of the present disclosure, the fold line includes notches, such as lines formed with a blunt cutting knife, which create a portion of the material that is crushed along a desired weakening line; cuts that partially extend into the material along a desired weakening line; and / or a series of cuts that partially and / or completely penetrate the material along a desired weakening line; and various combinations of these features.

[0104] As an example, a tear line can include slits that partially extend into the material along a desired weak line, and / or a series of spaced slits that partially and / or completely penetrate the material along a desired weak line, or various combinations of these features. In a more specific example, one type of tear line is in the form of a series of spaced slits that completely penetrate the material, and adjacent slits are slightly spaced so that a nick (e.g., a small, somewhat bridging piece of material) is defined between adjacent slits to typically temporarily connect the material across the tear line. The notches are broken while tearing along the tear line. The notches are typically a relatively small proportion of the tear line, and alternatively, the notches can be omitted from the tear line or torn along the tear line so that the tear line is a continuous break. That is, each of the spaced slits can be replaced by a continuous slit, a continuous score, etc., which is within the scope of this disclosure. For example, the cut may be a continuous slit, or it may be wider than a slit, without departing from this disclosure. The tear line may also be a series of cut scores that pass through the material completely or partially, separated by the cut.

[0105] The term "adhesive" is intended to encompass all types of adhesives commonly used to secure container panels or container components in place.

[0106] The foregoing description of this disclosure illustrates and describes various exemplary embodiments. Various additions, modifications, changes, etc., can be made to the exemplary embodiments without departing from the spirit and scope of this disclosure. All matters included in the foregoing description or shown in the accompanying drawings are intended to be conspicuous and not to be construed restrictively. In addition, although this disclosure shows and describes only selected embodiments of this disclosure, this disclosure can be used in various other combinations, modifications, and environments, and can be modified or altered within the scope of the concept of the invention as expressed herein, corresponding to the teachings above, and / or within the art or knowledge of the relevant art. Furthermore, some features and characteristics of each embodiment can be selectively interchanged and applied to other illustrated and unillustrated embodiments of this disclosure.

Claims

1. A container for holding at least one article, A main body that extends at least partially around the inside of the container, The closing upper part engaged with the main body, The closed bottom portion engaged with the main body, A container comprising a barrier member disposed inside the container, the barrier member comprising a laminated structure including at least one polymer layer having a continuous lower section.

2. The container according to claim 1, wherein the continuous lower portion lacks one or more fragile lines so as to be a substantially continuous portion of the at least one polymer layer configured to avoid the passage of fluid.

3. The container according to claim 2, wherein the laminated structure further comprises a composite layer on top of the at least one polymer layer.

4. The container according to claim 3, wherein the laminated structure comprises at least one fragile line that partially penetrates the laminated structure and extends so as to terminate above the lower surface of the at least one polymer layer and form the continuous lower part of the at least one polymer layer.

5. The aforementioned at least one polymer layer is a second polymer layer, The laminated structure includes a first polymer layer between the first polymer layer and the composite layer, The container according to claim 4, wherein the at least one weak line extends at least partially through the first polymer layer.

6. The at least one weak line is a second weak line that extends at least partially through the composite layer and the first polymer layer. The laminated structure includes a first fragile line extending at least partially through the composite layer, The container according to claim 4, wherein the first weak line is spaced apart from the second weak line.

7. The container according to claim 5, wherein the second polymer layer comprises polyethylene.

8. The container according to claim 7, wherein the second polymer layer is configured to be activated upon exposure to high-frequency energy in order to facilitate the sealing of the barrier member to the body of the container.

9. The container according to claim 7, wherein the second polymer layer has a density of about 15 gsm.

10. The container according to claim 7, wherein the first polymer layer comprises an oriented polyethylene terephthalate (OPET) film.

11. The container according to claim 10, wherein the OPET film is a biaxially oriented polyethylene terephthalate (BOPET) film.

12. The container according to claim 11, wherein the first polymer layer has a thickness of about 12 microns.

13. The composite layer, the first polymer layer, and the second polymer layer form at least partially the upper part of the laminated structure. The laminated structure further includes a lower part that contacts the upper part, The container according to claim 12, wherein the lower part of the laminated structure includes a third polymer layer in contact with the second polymer layer.

14. The container according to claim 13, wherein the third polymer layer comprises an ethylene-vinyl alcohol (EVOH) copolymer.

15. The container according to claim 14, wherein the third polymer layer has a thickness of about 40 microns.

16. The container according to claim 14, wherein the third polymer layer has a width smaller than the width of the upper part of the laminated structure.

17. A combination of blanks for forming a container for holding at least one article, A body blank for forming the body of the container formed from the combination of the aforementioned blanks, A bottom blank for engaging with the main body of the container formed from the combination of the blanks to form a closed bottom, A lid blank for engaging with the main body of the container formed from the combination of the blanks to form a closed upper part, A combination of blanks comprising: a barrier blank for forming a barrier member of the container formed from the combination of the blanks, the barrier blank comprising a laminated structure including at least one polymer layer having a continuous lower part; and a combination of blanks.

18. The blank combination according to claim 17, wherein the continuous lower portion lacks one or more fragile lines so as to be a substantially continuous portion of the at least one polymer layer configured to avoid the passage of fluid.

19. The blank combination according to claim 18, wherein the laminated structure further comprises a composite layer on top of the at least one polymer layer.

20. The blank combination according to claim 19, wherein the laminated structure comprises at least one fragile line extending partially through the laminated structure so as to terminate above the lower surface of the at least one polymer layer and form the continuous lower part of the at least one polymer layer.

21. The aforementioned at least one polymer layer is a second polymer layer, The laminated structure includes a first polymer layer between the first polymer layer and the composite layer, The blank combination according to claim 20, wherein the at least one weak line extends at least partially through the first polymer layer.

22. The at least one weak line is a second weak line that extends at least partially through the composite layer and the first polymer layer. The laminated structure includes a first fragile line extending at least partially through the composite layer, The blank combination according to claim 20, wherein the first weak line is spaced apart from the second weak line.

23. The blank combination according to claim 21, wherein the second polymer layer comprises polyethylene.

24. The blank combination according to claim 23, wherein the second polymer layer is configured to be activated upon exposure to high-frequency energy in order to facilitate the sealing of the barrier member to the body of the container.

25. The blank combination according to claim 23, wherein the second polymer layer has a density of about 15 gsm.

26. The blank combination according to claim 23, wherein the first polymer layer comprises an oriented polyethylene terephthalate (OPET) film.

27. The blank combination according to claim 26, wherein the OPET film is a biaxially oriented polyethylene terephthalate (BOPET) film.

28. The blank combination according to claim 27, wherein the first polymer layer has a thickness of about 12 microns.

29. The composite layer, the first polymer layer, and the second polymer layer form at least partially the upper part of the laminated structure. The laminated structure further includes a lower part that contacts the upper part, The blank combination according to claim 28, wherein the lower part of the laminated structure includes a third polymer layer in contact with the second polymer layer.

30. The blank combination according to claim 29, wherein the third polymer layer comprises an ethylene-vinyl alcohol (EVOH) copolymer.

31. The blank combination according to claim 30, wherein the third polymer layer has a thickness of about 40 microns.

32. The blank combination according to claim 30, wherein the third polymer layer has a width smaller than the width of the upper part of the laminated structure.

33. A method for forming a container for holding at least one article, Steps to obtain the main body blank, Steps to obtain the bottom blank, Steps to obtain a lid blank, A step of obtaining a barrier blank including a laminated structure having at least one polymer layer having a continuous lower section, The steps include positioning the body blank to form a body that extends at least partially around the inside of the container, The steps include engaging the bottom blank with the main body of the container to form the closed bottom of the container, The steps include: engaging the barrier blank with the main body of the container to form a barrier member inside the container; A method comprising the step of engaging the lid blank with the body of the container to form the closed upper part of the container.

34. The method according to claim 33, wherein the continuous lower portion lacks one or more fragile lines so as to be a substantially continuous portion of the at least one polymer layer configured to avoid the passage of fluid.

35. The method according to claim 34, wherein the laminated structure further comprises a composite layer on top of the at least one polymer layer.

36. A method according to claim 35, wherein the laminated structure comprises at least one fragile line extending partially through the laminated structure so as to terminate above the lower surface of the at least one polymer layer and form the continuous lower part of the at least one polymer layer.

37. The aforementioned at least one polymer layer is a second polymer layer, The laminated structure includes a first polymer layer between the first polymer layer and the composite layer, The method according to claim 36, wherein the at least one fragile line extends at least partially through the first polymer layer.

38. The at least one weak line is a second weak line that extends at least partially through the composite layer and the first polymer layer. The laminated structure includes a first fragile line extending at least partially through the composite layer, The method according to claim 36, wherein the first vulnerable line is spaced apart from the second vulnerable line.

39. The method according to claim 37, wherein the second polymer layer comprises polyethylene.

40. The method according to claim 39, wherein the second polymer layer is configured to be activated upon exposure to high-frequency energy in order to facilitate the sealing of the barrier member to the body of the container.

41. The method according to claim 39, wherein the second polymer layer has a density of about 15 gsm.

42. The method according to claim 39, wherein the first polymer layer comprises an oriented polyethylene terephthalate (OPET) film.

43. The method according to claim 42, wherein the OPET film is a biaxially oriented polyethylene terephthalate (BOPET) film.

44. The method according to claim 43, wherein the first polymer layer has a thickness of about 12 microns.

45. The composite layer, the first polymer layer, and the second polymer layer form at least partially the upper part of the laminated structure. The laminated structure further includes a lower part that contacts the upper part, The method according to claim 44, wherein the lower part of the laminated structure includes a third polymer layer in contact with the second polymer layer.

46. The method according to claim 45, wherein the third polymer layer comprises an ethylene-vinyl alcohol (EVOH) copolymer.

47. The method according to claim 46, wherein the third polymer layer has a thickness of about 40 microns.

48. The method according to claim 46, wherein the third polymer layer has a width smaller than the width of the upper part of the laminated structure.

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