Tear-away container top

[0002] This application is a continuation of application Ser. No. 09/537,465, filed Mar. 27, 2000, now U.S. Pat. No. 6,419,152, which is a continuation of application Ser. No. 09/020,440, filed Feb. 9, 1998, now U.S. Pat. No. 6,098,874, entitled Tear-Away Container Top. Each reference is hereby incorporated by reference in its entirety.

[0003] The present invention relates generally to food and beverage containers, and more particularly, to a tear-away top for a sealed aseptic container. Sealed aseptic containers do not support the growth of living microorganisms. As a result, sealed aseptic containers may provide a shelf life of greater than one year without the use of preservatives or refrigeration.

[0004] Sealed aseptic packages are commonly used for packaging and transporting products that are sensitive to oxygen and/or light. Accordingly, sealed aseptic packages may be used for beverages and foods such as juice, wine, gravies, and other liquid or semi-liquid foodstuffs that quickly deteriorate after exposure to oxygen or light. However, the opening facilitators of known sealed aseptic packages are designed primarily for use only with liquid foodstuffs such as juice and wine.

[0005] Known opening facilitators include caps, flip-top lids, depressable push tabs, and straw holes. While suitable for use with liquid foodstuffs, these opening facilitators may not be adapted for use with semi-liquid or viscous foodstuffs like gravy. In addition, these opening facilitators may require extraneous components that must be attached to the container by means such as adhesives. Consequently, a need exists for an opening facilitator that may be easily and efficiently used with semi-liquid and viscous foodstuffs. A need also exists for an opening facilitator that does not require extraneous components.

[0006] The present invention is designed to meet these objectives. The present invention includes a container having a tear-away top. In general, the container comprises an outer substrate layer which may include a paperboard layer, an inner aseptic layer secured to the outer substrate layer, and a cut in the outer substrate layer. In order to preserve the product in the container, the cut is of a predetermined depth such that the cut does not puncture the inner aseptic layer. The cut, however, is sufficiently deep so that a predetermined portion of the top may be torn away from the container at the cut.

[0007] The inner aseptic layer may include an oxygen barrier layer which substantially prevents the transmission of oxygen through the container. In addition, the inner aseptic layer may include a photic barrier layer which substantially controls light transmission through the container. Since the cut does not puncture the inner aseptic layer, it is preferred that the cut does not compromise the aseptic quality of the inner aseptic layer.

[0008] The cut is preferably made by a laser. The cut may have a predetermined shape such that a pouring spout is created when a predetermined portion of the top is torn away from the container. In addition, the cut may be a perforated cut or a scored cut.

[0009] The present invention also includes a method for manufacturing a container that has a tear-away top. The method generally includes the steps of providing an outer substrate layer, securing an inner aseptic layer to the outer substrate layer, making a cut of predetermined depth in the outer substrate layer such that the cut does not puncture the inner aseptic layer, and then forming a container. After the container has been formed, a predetermined portion of the top may be torn away from the container at the cut.

[0010] The present invention is primarily designed for use with semi-liquid or viscous foodstuffs such as gravies. However, the present invention may also be used in conjunction with liquid foodstuffs such as juice and wine. In addition, other objects and advantages of the present invention will be readily apparent from the following descriptions of the drawings and preferred embodiments.

[0011] FIG. 1 is a perspective view of a preferred embodiment of the container of the present invention;

[0012] FIG. 2 is a perspective view of the container shown in FIG. 1 with the top torn off;

[0013] FIG. 3 is a perspective view of a preferred embodiment of the container of the present invention;

[0014] FIG. 4 is a perspective view of the container shown in FIG. 3 with the top torn off;

[0015] FIG. 5 is a perspective view of a preferred embodiment of the container of the present invention;

[0016] FIG. 6 is a perspective view of the container shown in FIG. 5 with a portion of the top torn off;

[0017] FIG. 7 is a perspective view of a preferred embodiment of the container of the present invention;

[0018] FIG. 8 is an outer plan view of a preferred embodiment of a flat card of the present invention; and

[0019] FIG. 9 is a schematic view of a preferred embodiment of a laser system which may be used to make the cut in the outer substrate layer.

[0020] The present invention is directed to a tear-away top for a sealed aseptic container. In general, the container of the present invention includes an outer substrate layer, an- inner aseptic layer, a cut, and a top. In addition, the container preferably includes other layers such as those taught by U.S. Pat. No. 5,306,533, the disclosure of which is hereby incorporated by reference. However, the other layers are not pertinent to the description of the container of the present invention. Therefore, the other layers are not described or shown in the Figures

[0021] The outer substrate layer includes a substrate such as a layer of paperboard. However, it should be recognized that other suitable substrate materials may be used in the present invention. In addition, the thickness of the substrate may vary depending on the application for the container.

[0022] The inner aseptic layer is secured to the outer substrate layer. The inner aseptic layer may include any material that impedes the deterioration of the product in the container. Since exposure to oxygen may accelerate the deterioration of the product, the inner aseptic layer preferably includes an oxygen barrier layer which substantially prevents the transmission of oxygen through the container. Similarly, a product may be sensitive to exposure to light. Accordingly, the inner aseptic layer may also include a photic barrier layer which substantially controls light transmission through the container.

[0023] The cut is of a predetermined depth in the outer substrate layer so that the cut does not puncture the inner aseptic layer. In addition, it is preferred that the cut does not compromise the aseptic quality of the inner aseptic layer. However, the cut is sufficiently deep so that a predetermined portion of the top may be torn away from the container at the cut.

[0024] The cut is preferably made by a laser. A preferred process for laser treating material is disclosed in U.S. Pat. No. 5,688,463, the disclosure of which is hereby incorporated by reference. The cut may be of any type that enables a user to tear a predetermined portion of the top off of the container. However, it is preferred that the cut is a perforated cut or a scored cut. In addition, it is preferred that the cut has a predetermined shape such that a pouring spout is created when a predetermined portion of the top is torn away from the container. The pouring spout is preferably created on one of the sides of the container.

[0025] A user may tear off a predetermined portion of the top by first severing a portion of the outer substrate layer and the inner aseptic layer at the cut. It is preferred that a user be able to sever a portion of these layers by simply depressing the container with a finger at or near the cut. Once the user severs a portion of the outer substrate layer and the inner aseptic layer at the cut, the user may then grasp the top and pull a predetermined portion of the top away from the container at the cut.

[0026] A preferred method of manufacturing the container of the present invention involves a flat card. The flat card is formed by providing an outer substrate layer and then securing an inner aseptic layer to the outer substrate layer. After the flat card is formed, a cut of predetermined depth is made in the outer substrate layer so that the cut does not puncture the inner aseptic layer. The flat card may have creases which facilitate its transition into a container. While the cut may intersect the creases, it is preferred that the path of the cut does not run directly on any of the creases.

[0027] After the cut is made in the outer substrate layer, the flat card is folded into a container. In one preferred method of folding a flat card into a container, the flat card is first formed into a sleeve. An end of the sleeve is then folded to form the bottom of the container. After the bottom of the container is formed, the interior of the container is preferably sterilized. A product which is preferably sterilized may then be deposited in the container through the open end of the sleeve. Once the product has been deposited, the open end of the sleeve may be folded to form the top of the container. It should be noted that a predetermined amount of product should be deposited in the container so that a user does not unintentionally contact the product when tearing a predetermined portion of the top off of the container.

[0028] FIGS. 1 and 2 illustrate a preferred embodiment of the container of the present invention. The container 10aincludes an outer substrate layer 20a, an inner aseptic layer 30a, a cut 40a, and a top 50a. FIG. 1 shows the container 10awith the top 50astill attached, whereas FIG. 2 shows the container 10aafter a predetermined portion of top 50ahas been torn off.

[0029] FIGS. 3 and 4 depict another preferred embodiment of the container of the present invention in which the path of the cut is different. The container 10bincludes an outer substrate layer 20b, an inner aseptic layer 30b, a cut 40b, and a top 50b. FIG. 3 shows the container 10bwith the top 50bstill attached, whereas FIG. 4 shows the container 10bafter a predetermined portion of the top 50bhas been torn off.

[0030] While FIGS. 2 and 4 depict embodiments in which all or substantially all of the top has been torn off of the container, it should be recognized that a predetermined portion of the top includes any portion of the top. It should also be noted that a portion of any of the sides of the container may be torn away along with a predetermined portion of the top. For instance, the creation of a pouring spout may require that a portion of a side of the container be torn away along with a predetermined portion of the top.

[0031] FIGS. 5 and 6 illustrate a preferred embodiment of the container of the present invention in which an end portion of the top may be torn away from the container at the cut. The container 10cincludes an outer substrate layer 20c, an inner aseptic layer 30c, a cut 40c, and a top 50c. FIG. 5 shows the container 10cwith the top 50cstill attached, whereas FIG. 6 shows the container 10cafter a predetermined portion of the top 50chas been torn off at the cut 40c.

[0032] FIG. 7 shows another preferred embodiment of the container of the present invention in which a predetermined portion of the top may be torn away from the container at the cut. The container 10dincludes an outer substrate layer 20d, a cut 40d, and a top 50d. It should be noted that the container 10dalso has a flap. In this type of embodiment, at least a portion of the flap may be torn away along with a predetermined portion of the top 50d.

[0033] FIG. 8 illustrates a preferred embodiment of a flat card 60ewhich may be folded into a preferred embodiment of the container of the present invention. As shown, the cut 40eis preferably made in the outer substrate layer 20eof the flat card 60e. In this embodiment, it should be noted that the cut 40edoes not run directly on any of the creases of the flat card 60e.

[0034] The cut is preferably made in the flat card before the flat card is folded into the container. The cut is preferably made by a laser. The cut may be made by any laser system which may cause the local evaporation of material from the flat card. As opposed to mechanical cutting means, a laser can typically make tear lines which are more precise, which are easier to sever, and which require less force to sever. In particular, a benefit of using a laser system is that precise right angle cuts or incisions may be made without rotating the flat card. Conversely, mechanical cutting means typically can only make curved corners. Depending on the type of force applied to the predetermined portion of the top, a cut having right angles may facilitate the removal of a predetermined portion of the top.

[0035] FIG. 9 illustrates a preferred embodiment of a laser system which may be used to make the cut. As shown in FIG. 9, the laser 70fmay generate a laser beam and supply it to a z-axis focus 72f. The laser beam may then travel through a two-axis laser galvo 74fwhich may comprise X and Y-axis positioning mirrors. The laser beam may then be guided through its desired pattern on the flat card 60f.

[0036] The preferred embodiments herein disclosed are not intended to be exhaustive or to unnecessarily limit the scope of the invention. The preferred embodiments were chosen and described in order to explain the principles of the present invention so that others skilled in the art may practice the invention. Having shown and described preferred embodiments of the present invention, those skilled in the art will realize that many variations and modifications may be made to affect the described invention. Many of those variations and modifications will provide the same result and fall within the spirit of the claimed invention. It is the intention, therefore, to limit the invention only as indicated by the scope of the claims.