Pressed paperboard servingware with improved rigidity and rim stiffness

• US 8,584,929 B2
• Filed: 10/13/2004
• Issued: 11/19/2013
• Est. Priority Date: 10/20/2003
• Status: Active Grant

• Current Assignee: GPCP IP Holdings LLC
• Original Assignee: Dixie Consumer Products LLC (KOCH Industries Incorporated)
• Inventors: Littlejohn, Mark B., Van Handel, Gerald J., Zelinksi, Thomas W., Breining, Michael A., Johns, Albert D.
• Primary Examiner(s): Newhouse, Nathan J
• Assistant Examiner(s): DEMEREE, CHRISTOPHER R
• Application Number:
  US10/963,686
• Publication Number:
  US 20060208054A1
• Time in Patent Office: 3,324 Days
• Field of Search: 229/406
• US Class Current: 229/406
• CPC Class Codes: A47G 19/02 Plates, dishes or the like
• CPC Class Codes: A47G 19/03 for using only once, e.g. made of paper
• CPC Class Codes: B65D 1/34 Trays or like shallow containers B65D81/3813 takes precedence
• CPC Class Codes: B65D 2543/00092 circular
• CPC Class Codes: B65D 2543/00296 Plastic
• CPC Class Codes: B65D 2543/00361 placed on a tray like container
• CPC Class Codes: B65D 2543/00527 NO contact
• CPC Class Codes: B65D 2543/00537 on the outside, or a part turned to the outside of the mouth of the container
• CPC Class Codes: B65D 2543/00648 Flange or lip
• CPC Class Codes: B65D 2543/00685 Totality
• CPC Class Codes: B65D 2543/00731 Groove or hollow bead
• CPC Class Codes: B65D 2543/00805 Segments
• CPC Class Codes: B65D 2543/00842 outside of the lid
• CPC Class Codes: B65D 43/0212 only on the outside, or a part turned to the outside, of the mouth B65D43/0206 takes precedence

Abstract

Products and methods of increasing the Rigidity and Rim Stiffness of disposable containers are provided. The containers have an outer flange portion extending outwardly with a brim portion sloping downwardly defining a declivity angle α with respect to a horizontal generally parallel to the bottom portion and generally include an outward turn at the periphery of the container. A preferred method of improving rigidity includes press-forming: (i) a brim transition portion adjoining the downwardly sloping brim portion of the container and (ii) an outwardly extending annular evert portion adjoining the brim transition portion extending outwardly at an eversion angle β of at least about 25 degrees with respect to the downwardly sloping brim portion of the flange.

Claims

1. A disposable servingware container press-formed from a generally planar paperboard blank, the container having a characteristic diameter, D, as well as an overall height and comprising:

a generally planar bottom portion;

a first annular transition portion extending upwardly and outwardly from said generally planar bottom portion;

a sidewall portion extending upwardly and outwardly from said first annular transition portion;

a second annular transition portion extending outwardly from said sidewall portion;

said sidewall portion defining a generally linear, inclined sidewall profile over a length between said first annular transition portion and said second annular transition portion, the profile defining an angle of inclination with respect to the vertical from said generally planar bottom portion;

an arcuate brim portion having a convex upper surface extending outwardly with respect to said second annular transition portion, the radius of curvature of said arcuate brim portion being from about 0.005 to about 0.1 times the characteristic diameter of said disposable servingware container, the arcuate brim portion extending downwardly at its outer part to define at its terminus a declivity angle α

with respect to a horizontal substantially parallel to the bottom portion;

an inner flange portion extending between said second annular transition portion and said arcuate brim portion having a ratio of radial span to the characteristic diameter of from about 0 to about 0.1;

a brim transition portion at the lower edge of the downwardly sloping arcuate brim portion, there being thus defined a brim vertical drop which is the difference between the overall height of the container and a height at which the downwardly sloping brim portion transitions to the brim transition portion, wherein the ratio of the brim vertical drop to the characteristic diameter of the container is greater than about 0.01, the brim transition portion, in turn, transitions to an annular evert portion extending outwardly with respect to the downwardly sloping arcuate brim portion at an eversion angle β

of at least about 25 degrees,

the height of any upward extension of the evert portion above the brim transition portion being no more than about 75% of the brim vertical drop,

and wherein the arcuate brim portion has a plurality of circumferentially spaced pleats.

2. The disposable servingware container according to claim 1, wherein said inclined sidewall profile has an angle of inclination with respect to the vertical from said generally planar bottom portion of from about 10°

to about 50°

.

3. The disposable servingware container according to claim 1, wherein said inclined sidewall profile has an angle of inclination with respect to the vertical from said generally planar bottom portion of from about 20°

to about 30°

.

4. The disposable servingware container according to claim 1, wherein the ratio of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.013.

5. The disposable servingware container according to claim 1, wherein the ratio of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.015.

6. The disposable servingware container according to claim 1, wherein the ratio of the radius of curvature of said arcuate outer brim portion to the characteristic diameter of said disposable servingware container is from about 0.0175 to about 0.1.

7. The disposable servingware container according to claim 1, wherein the ratio of the radius of curvature of said arcuate outer brim portion to the characteristic diameter of said servingware container is greater than about 0.025.

8. The disposable servingware container according to claim 1, wherein the ratio of the radius of curvature of said arcuate outer brim portion to the characteristic diameter of said disposable servingware container is from about 0.035 to about 0.07.

9. The disposable servingware container according to claim 1, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the disposable servingware container is greater than about 0.025.

10. The disposable servingware container according to claim 1, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the disposable servingware container is greater than about 0.03.

11. The disposable servingware container according to claim 1, wherein said arcuate outer flange portion is characterized by having a single radius of curvature.

12. The disposable servingware container according to claim 1, wherein the ratio of the radius of curvature of said arcuate outer flange portion to the characteristic diameter of said disposable servingware container is from about 0.035 to about 0.06.

13. The disposable servingware container according to claim 1, wherein said convex upper surface of the arcuate outer flange portion is configured so that it defines its radius of curvature over an included angle of from about 30°

to about 80°

.

14. The disposable servingware container according to claim 1, wherein said servingware container is a bowl and wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the bowl is from about 0.1 to about 0.3.

15. The disposable bowl according to claim 1, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the servingware container is from about 0.15 to about 0.25.

16. The disposable servingware container according to claim 1, including an inner flange portion extending between said second annular transition portion and said arcuate outer brim portion over a radial span, wherein the ratio of said radial span to the characteristic diameter of said servingware container is from about 0.01 to about 0.09.

17. A disposable food serving plate press-formed from a paperboard blank, the plate having a substantially planar center section as well as an overall height;

a first rim portion extending outward from and joined to said substantially planar center section, said first rim portion defining an upwardly facing first arc A12, having a radius of curvature of R12;

a second rim portion outward from and joined to said first rim portion, said second rim portion defining a downwardly facing second arc A22, having a radius of curvature of R22;

a third rim portion outward from and joined to said second rim portion, said third rim portion defining a downwardly facing third arc A32, having a radius of curvature of R32, and having a tangent at its outer edge which is substantially parallel to the plane of said substantially planar center section;

a fourth rim portion outward from and joined to said third rim portion, said fourth rim portion defining a downwardly facing fourth arc A42, having a radius of curvature of R42;

wherein the length of the arc S2 of said second rim portion is substantially less than the length of the arc S4 of said fourth rim portion which in turn is less than the length of arc S1 of said first rim portion and wherein the radius of curvature R42 of said fourth rim portion is less than the radius of curvature R32 of said third rim portion which is less than the radius of curvature R22 of said second rim portion; and

wherein the included angle defined by arc A12 exceeds 55 degrees and the included angle defined by arc A32 exceeds 45 degrees, the fourth rim portion also including an outer portion sloping downwardly at its terminus defining a declivity angle α

with respect to a horizontal generally parallel to the center section;

a brim transition portion joined to the fourth rim portion, a brim height being thereby defined as the difference between the overall height of the container and a height at which the downwardly sloping fourth brim portion transitions to the brim transition portion, which brim transition portion transitions to an annular evert portion extending outwardly with respect to the downwardly sloping fourth rim outer portion at an eversion angle i of at least about 25 degrees;

the height of any upward extension of the evert portion above the brim transition portion being no more than about 75% of the brim height,

wherein said container includes a plurality of circumferentially spaced pleats.

18. The disposable food serving plate according to claim 17, wherein the angle of arc A42 is less than about 75 degrees.

19. The disposable food serving plate according to claim 17, wherein the length of said first arc is substantially equivalent to the length of said third arc and said first radius of curvature of said first arc is substantially equivalent to said third radius of curvature of said third arc.

20. The disposable food serving plate according to claim 17, wherein the height of the center of curvature of said first rim portion above the plane of said center section is substantially less than the distance by which the center of curvature of said second rim portion is below the plane of said center section.

21. The disposable food serving plate according to claim 17, wherein the horizontal displacement of the center of curvature of said second rim portion from the center of curvature of said first rim portion is at least about twice said first radius of curvature of said first rim portion.

22. The disposable food serving plate according to claim 17, wherein said height of the center of curvature of said third rim portion above the plane of said center section is less than the height of the center of curvature of said fourth rim portion above the plane of said center section.

23. The disposable food serving plate according to claim 17, wherein the center of curvature of said second rim portion is located outwardly from the center of curvature of both said third and fourth rim portions.

24. The disposable food serving plate according to claim 17, wherein the height of the center of curvature of said third rim portion above the plane of said center section is less than about 0.3 times the radius of curvature of said fourth rim portion and the height of the center of curvature of said fourth rim portion above the plane of said center section is at least about 0.4 times said first radius of curvature of said first rim portion.

25. The disposable food serving plate according to claim 17, wherein the ratio of the length of said fourth radius of curvature to the diameter of said plate is at least about 0.03.

26. The disposable food serving plate according to claim 17, wherein the ratio of the length of said third radius of curvature to the diameter of said plate is at least about 0.050.

27. The disposable food serving plate according to claim 17, wherein the ratio of the length of said second radius of curvature to the diameter of said plate is at least about 0.2.

28. The disposable food serving plate according to claim 17, wherein the ratio of the length of said first radius of curvature to the diameter of said plate is at least about 0.045.

29. The disposable food serving plate according to claim 17, wherein the length of said first arc is substantially equivalent to the length of said third arc.

30. A disposable servingware container press-formed from a generally planar paperboard blank, the container having a characteristic diameter, D, as well as an overall height and comprising:

a generally planar bottom portion;

a first annular transition portion extending upwardly and outwardly from the generally planar bottom portion;

an optional sidewall portion extending upwardly and outwardly from the first annular transition portion;

a second annular transition portion flaring outwardly with respect to the first annular transition portion;

an outer flange portion extending outwardly with respect to the second annular transition portion, the outer flange portion having;

(i) a downwardly sloping brim portion defining a declivity angle, a, at its terminus with respect to a horizontal substantially parallel to the bottom portion and wherein the downwardly sloping brim portion transitions to

(ii) a brim transition portion, a brim height being thereby defined as the difference between the overall height of the container and a height at which the downwardly sloping brim portion transitions to the brim transition portion, which, in turn, transitions to

(iii) an annular evert portion extending outwardly with respect to the downwardly sloping brim portion at an eversion angle β

of at least about 25 degrees;

(iv) the height of any upward extension of the evert portion above the brim transition portion being no more than about 75% of the brim height,

(v) provided further that the evert portion, the brim transition portion and at least a part of the downwardly sloping brim portion is provided with shading operative to cloak the geometry of the brim transition portion and the outwardly extending annular evert such that these features visually blend with the downwardly sloping brim portion of the container, and

wherein the outer flange portion has a plurality of circumferentially spaced pleats.

31. A disposable servingware container press-formed from a generally planar paperboard blank, the container having a characteristic diameter, D, as well as an overall height and comprising:

a generally planar bottom portion;

a first annular transition portion extending upwardly and outwardly from the generally planar bottom portion;

an optional sidewall portion extending upwardly and outwardly from the first annular transition portion;

a second annular transition portion flaring outwardly with respect to the first annular transition portion;

an outer flange portion extending outwardly with respect to the second annular transition portion, the outer flange portion having;

(i) a downwardly sloping brim portion defining a declivity angle α

at its terminus with respect to a horizontal substantially parallel to the bottom portion and wherein the downwardly sloping brim portion transitions to

(ii) a brim transition portion, a brim height being thereby defined as the difference between the overall height of the container and a height at which the downwardly sloping brim portion transitions to the brim transition portion, which, in turn, transitions to

(iii) an annular evert portion extending outwardly with respect to the downwardly sloping brim portion at an eversion angle β

of at least about 25 degrees;

(iv) a flange stabilizing projection disposed on the downwardly sloping brim portion sized to engage an adjacent container in a stack of like containers to promote stack stability;

(v) the height of any upward extension of the evert portion above the brim transition portion being no more than about 75% of the brim height, and

wherein the outer flange portion has a plurality of circumferentially spaced pleats.

32. The container according to claim 31, wherein the stabilizing projection includes a plurality of stabilizing nodules formed by way of a forming contour provided with an annular groove.

33. The container according to claim 32, wherein the groove has a depth of from about 3 to about 10 mils.

34. The container according to claim 32, wherein the plurality of stabilizing nodules are formed on pleats of the container.

35. The container according to claim 32, having from about 25 to about 80 circumferentially spaced stabilizing nodules.

36. The container according to claim 32, having from about 30 to about 60 circumferentially spaced stabilizing nodules.

37. The container according to claim 32, having from about 35 to about 50 circumferentially spaced stabilizing nodules.

38. The container according to claim 32, wherein the groove is in a die forming contour and has an inner wall which is substantially vertical or slopes outwardly.

39. The container according to claim 31, wherein the stabilizing projection is formed on the underside of the container.

40. The container according to claim 31, wherein there is provided a spacer projection between the first and second annular transition portions sized to engage an adjacent like container in a stack so as to abate taper lock.

41. A disposable servingware container press-formed from a generally planar paperboard blank, the container having a characteristic diameter, D, as well as an overall height and comprising:

a generally planar bottom portion;

a first annular transition portion extending upwardly and outwardly from said generally planar bottom portion;

a sidewall portion extending upwardly and outwardly from said first annular transition portion;

a second annular transition portion extending outwardly from said sidewall portion;

an arcuate brim portion having a convex upper surface extending outwardly with respect to said second annular transition portion, the radius of curvature of said arcuate brim portion being from about 0.005 to about 0.1 times the characteristic diameter of said disposable servingware container, the arcuate brim portion extending downwardly at its outer part to define at its terminus a declivity angle α

with respect to a horizontal substantially parallel to the bottom portion;

an inner flange portion extending between said second annular transition portion and said arcuate brim portion having a ratio of radial span to the characteristic diameter of from about 0 to about 0.1;

a brim transition portion at the lower edge of the downwardly sloping arcuate brim portion, there being thus defined a brim vertical drop which is the difference between the overall height of the container and a height at which the downwardly sloping brim portion transitions to the brim transition portion, wherein the ratio of the brim vertical drop to the characteristic diameter of the container is greater than about 0.01, the brim transition portion, in turn, transitions to an annular evert portion extending outwardly with respect to the downwardly sloping arcuate brim portion at an eversion angle β

of at least about 25 degrees,

the height of any upward extension of the evert portion above the brim transition portion being no more than about 75% of the brim vertical drop,

and wherein the arcuate brim portion has a plurality of circumferentially spaced pleats.