Clamshell Packaging Container

This patent application is a continuation of and claims the benefit of priority to U.S. application Ser. No. 18/258,935, filed on Jun. 22, 2023, which is a U.S. national phase entry under 35 U.S.C. § 371 of International Application No. PCT/US2021/064676, filed on Dec. 21, 2021, which claims the benefit of priority to U.S. Provisional Application No. 63/132,111, filed on Dec. 30, 2020, the entireties of which are incorporated herein by reference.

The present disclosure relates to packaging and methods of packaging consumer goods such as comestibles.

Consumer goods are often disposed in any of a variety of package types to organize, display, and protect products. Rigid packaging provides several advantages over other forms of packages such as increased protection of product housed within, improved reusability and durability, and strong potential for attractive branding and designs.

A common form of rigid packaging is a clamshell container, where two complementary container portions are coupled together at a hinge. As such, the container can be opened and closed to access and secure contents housed within. Sturdy construction and reliable opening and closing movements are desirable characteristics for clamshell containers.

Clamshell containers can be manufactured through various molding and casting processes, for example injection molding. However, a challenge that can occur when using molds to create clamshell containers is known in the packaging arts as a “thin steel condition,” where the thinness of one or more portions of a given mold gives rise to several manufacturing issues with respect to warping, temperature management, maintenance difficulties, and poor lifespan of the mold. This is a particularly prominent issue with respect to molding hinge or coupling portions between container portions.

In addition, rigid clamshell containers are often bulky with relatively narrow branding surfaces that only provide limited visibility when presented among competing products on shelf and can be inconvenient for consumers to carry. As such, there is also a need for rigid containers with a stronger presence on shelf with broader branding space while being shaped for convenient transport by consumers.

One embodiment relates to a container. The container includes a first shell portion and a second shell portion sized and shaped to complement the first shell portion to define a product cavity. The container further includes a bridging portion coupled to the first shell portion at a first hinge and the second shell portion at a second hinge, wherein the bridging portion is pivotable relative to each of the first shell portion at the first hinge and the second shell portion at the second hinge in a disassembled configuration and the bridging portion is pivotable relative to one of the first shell portion at the first hinge and the second shell portion at the second hinge in an assembled configuration.

Another embodiment relates to a method of manufacturing a container. The method includes providing a mold shaped to define a first shell portion, a second shell portion sized and shaped to complement the first shell portion to define a product cavity, and a bridging portion coupled to the first shell portion at a first hinge and the second shell portion at a second hinge, wherein the bridging portion is pivotable relative to each of the first shell portion at the first hinge and the second shell portion at the second hinge in a disassembled configuration and the bridging portion is pivotable relative to one of the first shell portion at the first hinge and the second shell portion at the second hinge in an assembled configuration. The method further includes forming the container using the mold. The method also includes coupling permanently the bridging portion to one of the first shell portion and the second shell portion.

It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. All combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein.

The features and advantages of the inventive concepts disclosed herein will become more apparent from the detailed description set forth below when taken in conjunction with the drawings.

Following below are more detailed descriptions of various concepts related to, and embodiments of, inventive rigid clamshell containers and methods of making such containers. It should be appreciated that various concepts introduced above and discussed in greater detail below may be implemented in any of numerous ways, as the disclosed concepts are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.

Referring to, a containeris shown in an open, unassembled configuration in accordance with example embodiments. In the arrangement shown, the containeris overall rectangularly shaped with rounded corners in a closed configuration, and openable to complementary halves in an open configuration. Other sizes and shapes of the containerare contemplated by and usable for the concepts provided in this disclosure, such as round shapes, oval shapes, square shapes, irregular, symmetrical, or asymmetrical shapes, and so on. In addition, as discussed below, the containermay or may not be disposed in equal sized halves in the open configuration. The containermay be used to house and protect consumer packaged goods such as food items, including but not limited to chewing gum. The containermay be made from any of a variety of materials used in the packaging arts, and in particular may be made of materials used in molding or casting processes that ultimately give rise to rigid packages, such as plastics, metals, or alloys or a combination thereof. In some arrangements, the containeris formed from materials derived from natural sources or may be made from biodegradable, compostable, recyclable, or otherwise sustainable materials.

The containeris configured as a clamshell and includes a first shell portionconfigured to complementarily and releasably engage a second shell portion. Either or both of the first shell portionand the second shell portionmay be formed such that the containerdefines a product cavity that is sized and configured to fit a productwithin the containerwhile in the closed configuration. In some arrangements, one shell portion may be formed as a lid while productis primarily housed in the other shell portion. In other arrangements, each shell portion may be formed to house product, even when the containeris in the open configuration.

The productmay be any of a variety of items sold as consumer-packaged goods, as described above. In the arrangement shown, the productis embodied as a plurality of chewing gum sticks in a side-by-side arrangement of gum stacks. In various arrangements, each stack of gum may be secured together by an article organizing membersuch as a belly band, and in turn the stacks of gum may be further secured in the side-by-side arrangement by an article stack organizing membersuch as a sheath, a larger belly band, and so on to attractively maintain the organization of gum sticks as individual gum sticks are removed. In some such arrangements, a given article organizing memberor the article stack organizing membermay be secured to the first shell portionor the second shell portion, for example with adhesive, clips, tabs, and so on. This side-by-side arrangement of the productprovides the benefit of large surfaces for branding, designs, text, and other eye-catching visual features on the containerthat significantly improves its presences on a display shelf. In addition, the side-by-side arrangement of productprovides a slim profile of the containerdespite housing larger amounts of the product.

In the arrangement shown, the productis disposed in both the first shell portionand the second shell portionwhen the containeris in the open configuration. In some such arrangements, different types or varieties of the productmay be separately housed in the first shell portionand the second shell portion, for example different flavors of comestible products may be arranged in each shell portion. However, in other arrangements, the productmay be disposed in either the first shell portiononly or the second shell portiononly when the containeris in the open configuration. In the arrangement shown in, the productis housed in only the second shell portionwhile the containeris in the open configuration, and further includes a stadium membersuch as a shelf configured to stagger an arrangement the product, for example such that the productis attractively displayed at different heights. In arrangements as that shown here where the productis a plurality of articles, the stadium memberstaggers the height of some of the articles relative to other articles such that multiple rows of the productare shown at different heights. As one skilled in the art would appreciate, the stadium membermay be present in both shell portions,in embodiments where the productis disposed in both shell portions,.

Returning to, in some arrangements, the containerincludes a securing member that releasably couples the first shell portionand the second shell portiontogether such that in a closed configuration product is safely housed in the product chamber, and in an open configuration the product is accessible to a user. Such features may be embodied as one or more undercuts, tabs and slots, ribs, interlocking protrusions, or other complementary components configured for releasable engagement. In the arrangement shown, the securing member is embodied as a first set of ribsand a complementary second set of ribsdisposed on the first shell portionand the second shell portionrespectively. In this arrangement, the first set of ribsis disposed on internal faces of an internally facing recessed lip at the rim of either lateral side of the first shell portion, and the second set of ribsis disposed on exterior faces of an exterior facing recessed lip at the rim of either lateral side of the second shell portion. The recessed lips on the shell portions,are configured to complement and engage each other when the containeris in the closed configuration. In the arrangement shown, the ribs of the sets of ribs,are disposed parallel to the rim of each respective shell portion,. In operation, as the containeris transitioned from the open configuration to the closed configuration, the first set of ribsinterlocks with the second set of ribsas the first shell portionengages the second shell portion, thereby releasably securing the container in the closed configuration. In some arrangements, the securing member is configured for audible engagement such as a pleasing “click” or other sound when the first shell portionis secured to the second shell portion. For example, the first set of ribsand the second set of ribsmay be configured to “click” when the ribs interlock in the closed configuration.

In some arrangements, the containermay include either or both of a first branding areaand a second branding areadisposed on interior faces (i.e., facing into the product cavity) of the first shell portionor the second shell portionrespectively. The first branding areaand the second branding areaare portions of these interior faces upon which graphics, logos, decorations, slogans, or other visual components are disposed, for example as stickers, prints, dye, paint, embossed or debossed digits or designs, etched digits or designs, and so on. In some such arrangements like the arrangement shown in, at least a portion of the first branding areaand the second branding areais visible even while the productis disposed in the container. In other arrangements, either or both of the first branding areaand the second branding areabecome visible as or after productis removed from the container.

In some arrangements, the branding areas,as well as the exterior faces of the containermay be used for any of a variety of highly customizable branding, personalization, or messaging purposes. Each of these areas and faces may be customized independently of any molding or casting processes used to make the containeritself, and as a result, the same stockpile of containersmay be used for different products, different brands, different varieties of product, and even for specific customers, by simply customizing the branding areas,or exterior faces of each container. For example, in an embodiment, the exterior faces of a given containerpresent the logos, colors, and branding of a specific brand of chewing gum as determined by the chewing gum manufacturer, while the first branding areaand the second branding areainclude images and text customized for a specific user. Any combination of such branding, personalization, and messaging across the exterior faces of the containerand the branding areas,are contemplated by this disclosure.

In yet more arrangements, the containermay be formed such that it is entirely or partially transparent, so that one or more components inside are visible even when the containeris closed. As such, various components inside the containermay be used as branding surfaces. For example, in one such arrangement, the article stack organizing membermay include visual elements (e.g., any such elements that may be disposed on a branding area,) disposed on externally facing surfaces that would be visible through a transparent embodiment of the container. Visual elements may similarly be applied to the article organizing memberor individual wrappers of the product.

A bridging portionis disposed between the first shell portionand the second shell portion. A first hingeand a second hingecouples opposing ends of the bridging portionto the first shell portionand the second shell portionof the container respectively. Each hinge,is a component capable of enabling a pivoting or hinging movement, such as a living hinge, a line of weakening, and so on. As a result, each of the first shell portionand the second shell portioncan pivot relative to the bridging portion. The bridging portionis sized and shaped to be received by either of the first shell portionand the second shell portionwhen the containeris in an assembled configuration (e.g., as shown in). In the arrangement shown in the figures, the bridging portionspans less than the full width of the second shell portion, and the second shell portionhas a cutout sized and shaped to receive the bridging portion. In other arrangements, the bridging portionmay be received by either or both of the first shell portionand the second shell portion.

As may be appreciated particularly in, the bridging portioneffectively increases the distance between the first clamshell portionand the second clamshell portionwhen the container is molded in the unassembled configuration. As a result, a larger mold segment can be disposed between the first shell portionand the second shell portion, thereby substantially reducing or eliminating thin steel conditions when the container is being manufactured.

Turning to, the containeris shown in an assembled, open configuration. The containerincludes one or more fastenersthat permanently couple the bridging portionto either of the first shell portionor the second shell portion. The fastenerscouple the bridging portionto the second shell portionin the embodiment shown in. In contrast to the securing member, the coupling function of the fastenersare not releasable, and as such, once the bridging portionis coupled to one of the shell portions,, it cannot be readily uncoupled without a significant application of force or damaging the fastenersor the corresponding shell or bridging portions,,. In various arrangements, the fastenersmay be embodied as one-way (i.e., irreversible) tabs or ribs, adhesives, welded or fused portions of the container, or other mechanical components intended for permanent engagement. As such, once the bridging portionis coupled to a shell portion,, decoupling the bridging portionwould result in deforming tabs or ribs, or tearing adhesives or welds, and so on depending on the manner of fastenerused. In the arrangement of, the fastenersare embodied as laterally protruding tabs on opposing sides of the bridging portionthat clip to the second shell portionas the second shell portionreceives the bridging portion. In other arrangements using laterally protruding tabs, the fastenersmay be disposed on the first or second shell portion,and clip onto the bridging portion.

The containeris shown in an assembled, closed configuration in. As a result of the bridging portionbeing permanently coupled to the second shell portion, the first shell portioncan only pivot relative to the second shell portionat the first hingeto open and close the container. In arrangements where the bridging componentis instead permanently coupled to the first shell portion, the first shell portion can only pivot relative to the second shell portionat the second hinge.

The advantage provided by taking the extra step of permanently coupling the bridging portionto either of the first shell portionand the second shell portionafter the containeris created is that the reduction or elimination of thin steel conditions in manufacturing is preserved while providing a single piece clamshell container (i.e., where the container is molded as a single piece not requiring the coupling together of separate pieces) with a strong, tightened pivoting action for opening and closing at a single hinge. In addition, the overall profile of the containerwhile in the open configuration is slimmer and more attractive, for example as shown in. Maintaining a wider hinge for example by not permanently coupling the bridging portionto one of the first shell portionand second shell portion, or having a larger hinge altogether results in a weaker, flimsy hinge that disposes the first shell portionat a greater distance from the second shell portionwhen the containeris in the open configuration, for example as shown in. As such, the costs of taking the additional step of permanently coupling the bridging portionto a shell portion,that renders one of the hinges,inoperable are well justified by the advantages both in manufacturing and consumer use.

In operation, an end user receives the containerhousing productin the closed configuration shown in. When the user wishes to access the product, the first shell portionis urged away from the second shell portion, causing a pivoting action at the first hingewhen resistance provided by the interlocked first set of ribsand second set of ribsis overcome. The containeris then transitioned to the open configuration shown in, exposing the productheld within. The user selects one of the productand observes the first branding areaand the second branding areabefore returning the containerto the closed configuration as shown in. Throughout this operation, the bridging componentremains coupled to the second shell portion.

illustrates a flow diagram showing a methodof making a clamshell container (e.g., container) containing consumer packaged goods (e.g., product) in accordance with example embodiments.

At, a container mold is provided. The container mold is shaped to define the container and includes a first shell portion (e.g., the first shell portion), a second shell portion (e.g., the second shell portion), and a bridging portion (e.g., the bridging portion). In various arrangements, the container mold may further define fasteners (e.g., fasteners), securing members (e.g., the first set of ribsand the second set of ribs), stadium members (e.g., the stadium member).

At, a container (e.g., the container) is formed. The container is formed using the mold provided atand may be made by any of various known processes such as injection molding or casting.

In some arrangements, branding areas (e.g., branding areas,) are applied to either or both of the first shell portion and the second shell portion of the container at. Branding areas may be applied by way of prints, dyes, stickers, or any of a variety of visual application methods.

At, the container is filled with product (e.g., the product). The product may be disposed at either or both of the first shell portion and the second shell portion of the container.

At, the bridging portion is coupled to either or both of the first shell portion and the second shell portion of the container. Fasteners (e.g., fasteners) are used to permanently couple the bridging portion to at least one of the first shell portion and the second shell portion of the container.

At, the container is moved to a closed configuration (e.g., as shown in). The first shell portion is pivoted at a hinge (e.g., the first hinge) of the bridging portion to releasably engage the second shell portion to arrive at the closed configuration. In some arrangements, additional graphics are disposed on exterior faces of the container (e.g., stickers, prints, dyes, etc.) and an overwrap is applied. Further, in some such arrangements, yet more graphics are applied on top of the overwrap (e.g., stickers, prints, etc.).

For the purpose of this disclosure, the term(s) “coupled” means the joining of two members directly or indirectly to one another. Such joining may be stationary or moveable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature.

It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure. It is recognized that features of the disclosed embodiments can be incorporated into other disclosed embodiments.

It is important to note that the constructions and arrangements of apparatuses or the components thereof as shown in the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter disclosed. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present disclosure.

While various inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other mechanisms and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that, unless otherwise noted, any parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the inventive teachings is/are used. Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the inventive scope of the present disclosure.

Also, the technology described herein may be embodied as a method, of which at least one example has been provided. The acts performed as part of the method may be ordered in any suitable way unless otherwise specifically noted. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments.

The claims should not be read as limited to the described order or elements unless stated to that effect. Various changes in form and detail may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims. All embodiments that come within the spirit and scope of the following claims and equivalents thereto are claimed.