BACKGROUND

Technical Field

[0001] The present disclosure relates generally to containers for storing fragile food products, and more particularly, to a cardboard molded container for storing potato chips, com based chips, cookies, and the like which is capable of adapting to changing environmental conditions while maintains its visual aesthetic appearance.

Description of Related Art

[0002] Currently, a great number of containers for containing fragile food products (snack chips, cookies, and the like) exists in the marketplace, and most of these containers are designed to withstand or adapt to different environmental conditions. Differences in environmental conditions (i.e., temperature, pressure and humidity) are natural consequences of the manufacturing process. For example, dry food products are typically manufactured at elevated temperature and thereafter sealed to protect the product from spoiling. Once sealed, a certain amount of gas is trapped within the container. As the contents of the sealed packaged cool to an ambient temperature, a vacuum or negative pressure condition is created which may cause the container to implode, distort, or destroy the seal.

[0003] Changes in atmospheric pressure also affect the volume of gas trapped within a container. This is normally not a problem for dry food products because they are typically packaged in flexible packages (e.g., bags and flexible film overwraps) that can adjust their shape to changing environmental conditions. However, flexible packages offer little, if any, protection from outside physical forces to the contained fragile food products. Thus, increasingly, a need to use more rigid containers has arisen.

[0004] Rigid containers constructed of paper are well known in the art, but their utilization in packaging fragile food products present many inherent drawbacks. The manufacturing costs of such rigid containers are relatively high. Moreover, in order to provide enough strength to resist forces induced by environmental change, the weight of such containers is relatively high. Additionally, changes in humidity can adversely affect the structural integrity of such containers.

[0005] Currently, paper containers for fragile food products are designed with the above principles in mind, and therefore most paper containers are designed as circular cylinders. When a vacuum forms inside container, the vacuum pulls at the walls of the container and with a circular cylinder, the force of the vacuum is equal on the walls of the container because the walls of the circular cylinder are all equal distance from the center. However, for paper containers that are not circular cylinders, the vacuum can deform the areas of the containers walls closest to the center of the container. These problems can also exist for containers made from other materials, such as plastic.

[0006] A need, therefore, exists for a container that is relatively simple to manufacture and strong enough to resist external compressive force, yet capable of adapting to changes in environmental conditions without adversely impacting the commercial presentation of the container.

SUMMARY

[0007] The present invention overcomes many of the shortcomings inherent in previous containers for packaging potato chips, com based chips, cookies and the like. The present invention is of a container comprising multiple layers that react to the formation of a vacuum inside the container. The interior of the container reacts to the vacuum by reducing the volume inside the container to provide vacuum relief.

[0008] In an exemplary embodiment, the invention provides a container with vacuum relief features used for fragile food products having a tubular body having a central longitudinal axis. The tubular body includes a sidewall positioned between a closed end and an open end having a hermetically sealable opening. The sidewall is formed by a first board layer attached to a liner layer. Prior to vacuum formation, the liner layer of the sidewall comprises a first cross-sectional shape corresponding to a second cross-sectional shape of the tubular body. After vacuum formation, the liner layer comprises a third cross-sectional shape different from the first cross-sectional shape reducing the volume inside the container providing vacuum relief.

[0009] Further, in an exemplary embodiment, prior to vacuum formation, the container comprises an initial interior volume, and after vacuum formation, the container comprises a second interior volume different from the initial interior volume.

[0010] In another exemplary embodiment, the first board layer comprises a second board layer.

[0011] Also, in an exemplary embodiment, the tubular body comprises an elliptical lateral cross-section along the central longitudinal axis. In another exemplary embodiment, the tubular body comprises a circular lateral cross-section along the central longitudinal axis. Other embodiments include a triangular, rectangular, and rounded rectangular lateral cross- sections along the central longitudinal axis. [0012] Additionally, after vacuum formation, the liner layer forms protrusions at areas unattached to the first board layer, wherein the protrusions extend toward the central longitudinal axis and decrease the volume inside the tubular body.

[0013] Further, the outer layer can comprise a fibrous material. The first board layer can comprise a cardboard material. The liner layer can comprise a material with low gas permeability. The liner layer can be selectively attached to the first board layer via at least one adhesive material, or can be selectively welded to the first board layer using ultrasonics.

[0014] In another exemplary embodiment, the invention provides a container with vacuum relief features, where the container has a tubular body having a central longitudinal axis. The tubular body includes a sidewall positioned between a closed end and an open end having a hermetically sealable opening. Prior to vacuum formation, the closed end comprises a protrusion extending in a first direction, and after vacuum formation, the protrusion extends in a second direction opposite the first direction.

[0015] Thus, numerous embodiments of containers that are capable of adapting to changing environmental conditions while maintaining their visual aesthetic appearance are disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood from the Detailed Description, here below, with reference to the following illustrations of exemplary non-limiting embodiments wherein:

[0017] Figure 1A illustrates a perspective view of one exemplary embodiment of a fragile food products container made of a several layers of material.

[0018] Figure IB illustrates a cutaway cross-sectional view of one exemplary embodiment of the fragile food products container made with several layers of material.

[0019] Figure 1C illustrates a top view of one exemplary embodiment of a fragile food products container made of several layers of material, with an axis superimposed on top.

[0020] Figure 2A illustrates a top view of one exemplary embodiment of a fragile food products container prior to construction.

[0021] Figure 2B illustrates a top view of one exemplary embodiment of a fragile food products container.

[0022] Figure 2C illustrates a top view of one exemplary embodiment of a fragile food products container after a vacuum has formed inside the container.

[0023] Figure 3A illustrates a top view of one exemplary embodiment of a fragile food products container prior to construction.

[0024] Figure 3B illustrates a top view of one exemplary embodiment of a fragile food products container.

[0025] Figure 3C illustrates a top view of one exemplary embodiment of a fragile food products container after a vacuum has formed inside the container. [0026] Figure 4A illustrates a top view of one exemplary embodiment of a fragile food products container prior to construction.

[0027] Figure 4B illustrates a top view of one exemplary embodiment of a fragile food products container.

[0028] Figure 4C illustrates a top view of one exemplary embodiment of a fragile food products container after a vacuum has formed inside the container.

[0029] Figure 5A illustrates a cutaway cross-sectional view of one exemplary embodiment of a fragile food products container.

[0030] Figure 5B illustrates a cutaway cross-sectional view of one exemplary embodiment of a fragile food products container after a vacuum has formed inside the container.

[0031] Figure 6A illustrates a cutaway cross-sectional view of one exemplary embodiment of a fragile food products container.

[0032] Figure 6B illustrates a cutaway cross-sectional view of one exemplary embodiment of a fragile food products container after a vacuum has formed inside the container.

[0033] The above figures are provided for the purpose of illustration and description only, and are not intended to define the limits of the disclosed invention. Use of the same reference number in multiple figures is intended to designate the same or similar parts. Furthermore, when the terms“top,”“bottom,”“first,”“second,”“uppe r,”“lower,”“height,” “width,”“length,”“end,”“side,”“horizontal, ”“vertical,” and similar terms are used herein, it should be understood that these terms have reference only to the structure shown in the drawing and are utilized only to facilitate describing the particular embodiment. The extension of the figures with respect to number, position, relationship, and dimensions of the parts to form the preferred embodiment will be explained or will be within the skill of the art after the following teachings of the present invention have been read and understood. DETAILED DESCRIPTION

[0034] In view of the foregoing, through one or more various aspects, embodiments and/or specific features or sub-components, the present disclosure is thus intended to bring out one or more of the advantages that will be evident from the description. The present disclosure makes reference to one or more specific embodiments by way of illustration and example. It is understood, therefore, that the terminology, examples, drawings and embodiments are illustrative and are not intended to limit the scope of the disclosure.

[0035] The multi-layered containers and methods described herein provide many advantages over the prior art. As will become clear, the embodiments utilize less materials for a multi-layered container of comparable size, while also allowing the flexibility of shaping the container in any number of shapes. The exemplary embodiment comprises a container 100 made of multiple layers that reacts to changes in environmental conditions. Because of environmental conditions and changes thereto, a vacuum can form inside the container 100 and to prevent the pressure of the vacuum from deforming the container 100, the innermost layer starts protruding inwardly from its initial configuration to reduce the volume inside the container 100. By reducing the volume inside the container, the negative pressure resulting in the vacuum decreases and thereby preventing the container 100 from imploding or deforming.

[0036] Figure 1A, IB, and 1C illustrates a container 100 in the form of an elliptical cylinder of one embodiment of the present invention. Figure 1A starts with an illustration showing a perspective view of a fragile food products container 100 shaped into an elliptic cylinder, where the cross-section of the container 100 is an ellipse. As herein used, the container 100 of the exemplary embodiment comprises a sidewall 102 positioned between a closed end 104 and an open end 106. The open end 106 is a hermetically sealable opening. In the exemplary embodiment, the sidewall 102 comprises multiple layers to provide the structural integrity needed to maintain the shape of the container 100. The container 100 can have any size or shape suitable for fragile food products.

[0037] Figure IB is a cutaway cross-sectional view of the container 100 of Figure 1A showing the multiple layers of the sidewall 102 and snack products 108 inside the container 100. The sidewall 102 of the exemplary embodiment comprises five layers: an outer layer 110, a first adhesive layer 112, a first paperboard layer 114, a second paperboard layer 116, a second adhesive layer 118, and a liner layer 120. The outer layer 110 can be a decorative coated paper outer wrapping for protecting the other layers of the sidewall 102 and is attached to the first paperboard layer 114 by the first adhesive layer 112. The first paperboard layer 114 and the second paperboard layer 116 provide the structural integrity of the container 100. The second adhesive layer 118 attaches the liner layer 120 to the second paperboard layer 114 at selected areas. Figure IB illustrates the second adhesive layer 118 attaching the second paper layer to the liner layer 120, and later illustrates demonstrate how the second adhesive layer 118 is a selective layer of adhesive. The thickness of each of the layers of the sidewall 102 can vary based on the material used for each layer; therefore, the sidewall 102 can have any thickness corresponding to the thickness of the layers of the sidewall 102.

[0038] Figure 1C is a top view of the container 100 with a major axis 103 and minor axis 105 superimposed on top of the container 100, with the major axis 103 and minor axis 105 intersecting at the center 107. In the exemplary embodiment, the container 100 has a uniform elliptic lateral cross-section, and in other embodiments, the container can have non-uniform lateral cross-sections of different shapes, such as a circle, square, rectangle, rounded rectangle, triangle, etc. A container 100 with an elliptic lateral cross-section provides an aesthetically pleasing appearance, and it reduces the excess volume inside the container 100, thereby reducing the amount of material needed to construct the container 100. [0039] Figures 2A, 2B, and 2C illustrate a top view of a container 200 of one exemplary embodiment. Figure 2A illustrates a top view of one exemplary embodiment of a fragile food products container prior to construction. The container 200, as mentioned with Figures 1A-1C, comprises six layers for the sidewall 202: an outer layer 210, a first adhesive layer 212, a first paperboard layer 214, a second paperboard layer 216, a second adhesive layer 218, and a liner layer 220. The container 200 can contain any number of layers to accommodate the features described herein. In the exemplary embodiment, the six layers of the container 200 are separated for the purposes of distinctly showing the different layers, and when pressed together, the layers form a composite 222 for use with a forming mandrel 224 to shape the composite 222 into a container 200. The forming mandrel 224 may comprise any size and shape to facilitate the formation of the container 200 from the composite 222. In Figure 2A, the forming mandrel 224 comprises an elliptic cylinder shape to shape the composite 222 into an elliptic cylinder container 200.

[0040] In another embodiment, the composite 222 may comprise a subset of the layers of the exemplary embodiment, such as the first paperboard layer 214, the second paperboard layer 216, the second adhesive layer 218, and the liner layer 220. In this alternative embodiment, the first adhesive layer 212 and the outer layer 210 may be added after the container 200 has been shaped from the composite 222 via the forming mandrel 224. One of ordinary skill in the art would understand how to add the first adhesive layer 212 and the outer layer 210 to the container 200 after it has been formed.

[0041] As mentioned previously, the outer layer 210 can be a decorative coated layer for protecting the other layers. The outer layer 210 can have any shape or size and can constructed from any material for protecting the other layers of the composite 222 or the container 200. [0042] The first adhesive layer 212 attaches the outer layer 210 to the first paperboard layer 214. The adhesive layer can have any shape or size and can be made from any material for adhering the outer layer 210 to the first paperboard layer 214.

[0043] The first paperboard layer 214 and second paperboard layer 216 are designed to attach to each other in the exemplary embodiment, and provide the structural integrity of the container 200. One of ordinary skill in the art would understand how to attach the first paperboard layer 214 to the second paperboard layer 216. The first paperboard layer 214 and the second paperboard layer 216 can have any shape or size and can be made from any material for providing structure to a container 200, such as cardboard. The first paperboard layer 214 and the second paperboard layer 216 are made from paperboard or cardboard in the exemplary embodiment. In another embodiment, the first paperboard layer 214 and the second paperboard layer may be a single layer corresponding to the shape and design of the paperboard layers 214 and 216 when attached.

[0044] The exemplary embodiment also illustrates the first paperboard layer 214 positioned offset from the second paperboard layer 216. This arrangement allows for the first paperboard layer 214 to surround the second paperboard layer 216 upon being formed while also offsetting the crease that forms where the ends of the first paperboard layer 214 meet from the crease that forms where the ends of the second paperboard layer 216. Offsetting the creases of the paperboard layers 214 and 216 increases the structural integrity of the container 200

[0045] The second adhesive layer 218 attaches the second paperboard layer 216 to the liner layer 220. The second adhesive layer 218 can have any shape or size and can be made from any material for adhering the liner layer 220 to the second paperboard layer 216. In the exemplary embodiment, the second adhesive layer 218 is a layer where adhesive is positioned selectively. As shown in Figure 2A, the second adhesive layer 218 comprises multiple adhesive sections and these adhesive sections are placed to attach the liner layer 220 to the second paperboard layer 216 while leaving other areas of the liner layer 220 and the second paperboard layer 216 unattached. The arrangement of the adhesive sections of the second adhesive layer 218 as shown in Figure 2A allows for the reduction of volume inside the container 200 when a vacuum forms inside the container 200, which is shown in Figure 2B and 2C.

[0046] The liner layer 220 is the innermost layer of the container sidewall 202. The liner layer can comprise any size or shape and can be made from any material for protecting the contents of the container 200, such as a material with low gas permeability. Because of the arrangement of adhesive sections of the second adhesive layer 218, the liner layer 220 provides for the reduction of volume inside the container 200 when a vacuum forms inside the container 200, which is discussed below. In another embodiment, the liner layer 220 is attached or welded to the second paperboard layer 216 at selected locations using ultrasonics.

[0047] Figure 2B illustrates a top view of one exemplary embodiment of a fragile food products container 200 after the composite 22 of Figure 2A has been shaped into the container 200. Similar to Figure 1C, Figure 2B shows the layers 210, 212, 214, 216, 218, and 220 of the container 200. As shown with Figure 2A, the second adhesive layer 218 attaches the liner layer 220 with the second paperboard layer 216 at selected areas.

[0048] Figure 2C illustrates a top view of one exemplary embodiment of a fragile food products container 200 after a vacuum has formed inside the container 200. As mentioned, because fragile food products are packaged in the container 200 while warm, the natural decrease in temperature or other changes in environmental conditions can create a vacuum inside the container 200. To alleviate the pressure caused by the vacuum on the container 200, the liner layer 220 shifts from its initial configuration with an elliptic cross-sectional shape to a reduced volume configuration while also accommodating the food products 208 inside the container 200. The reduced volume configuration of the liner layer 220 after the vacuum forms inside the container 200 is shown in Figure 2C. [0049] The reduced volume configuration of the liner layer 220 comprises protrusions extending towards the food product 208. The number of protrusions of the reduced volume configuration of the liner layer 220 depends on the number of adhesive sections of the second adhesive layer 218. In the exemplary embodiment, four adhesive sections of the second adhesive layer 218 attach the liner layer 220 to the second paperboard layer 216, so when the vacuum forms inside the container 200, the liner layer 220 protrudes inwardly due to the negative pressure of the vacuum. The reduced volume configuration can comprise any number of protrusion corresponding to the number of adhesive sections of the second adhesive layer 218, and the shape of the protrusions is based on the size and shape of the adhesive sections of the second adhesive layer 218. In alternate embodiments, the second adhesive layer 218 can comprise multiple adhesive sections that vary in number, size, and arrangement along the length of the container 200 going from the open end (not illustrated) to the closed end (not illustrated) of the container 200.

[0050] The functionality described above regarding the configuration of the multiple layers of the container sidewall 202 is further illustrated in Figures 3A-3C and 4A-4C, which are discussed in detail below.

[0051] Figures 3A, 3B, and 3C illustrate top views of a container 300 of one exemplary embodiment. The container 300 of Figures 3A, 3B, and 3C comprise similar layers as those shown in Figures 2A-2C and is illustrated in accordance to the above disclosed principles, and the exemplary embodiment of Figure 3A-3C provide a different arrangement of adhesive sections of the second adhesive layer 318. Figure 3A illustrates a top view of one exemplary embodiment of a fragile food products container 300 prior to construction and shows eight adhesive sections to attach the liner layer 320 to the second paperboard layer 316.

[0052] As with Figure 2A, the container 300 is formed via a forming mandrel 324 from a composite 322 comprising six layers: an outer layer 310, a first adhesive layer 312, a first paperboard layer 314, a second paperboard layer 316, a second adhesive layer 318, and a liner layer 320. The six layers of the container 300 are separated for the purposes of distinctly showing the different layers, and when pressed together, the layers form a composite 322 for use with a forming mandrel 324 to shape the composite 322 into the container 300. The forming mandrel 324 may comprise any size and shape to facilitate the formation of the container from the composite 322, and in the exemplary embodiment, the forming mandrel 324 comprises an elliptic cylinder shape to shape the composite 322 into an elliptic cylinder container 300.

[0053] In the exemplary embodiment, the second adhesive layer 318 comprises eight adhesive sections that are equally spaced from each other. Alternative embodiments can have different amounts of adhesive sections and different arrangements thereof, as shown in

Figures 2A-2C.

[0054] Figure 3B illustrates a top view of one exemplary embodiment of a fragile food products container 300 after the composite 322 of Figure 3A has been shaped into the container 300. Similar to Figure 1C and 2B, Figure 3B shows the layers 310, 312, 314, 316, 318, and 320 of the container 300. As shown with Figure 3A, the second adhesive layer 318 attaches the liner layer 320 with the second paperboard layer 316 at selected areas. In another embodiment, the liner layer 320 is attached or welded to the second paperboard layer 316 at selected locations using ultrasonics.

[0055] Figure 3C illustrates a top view of one exemplary embodiment of a fragile food products container 300 after a vacuum has formed inside the container 300. In accordance to the disclosed principles, the liner layer 320 shifts from its initial configuration as shown in Figure 3B to create a reduced volume configuration while also accommodating the food products 308 inside the container 300. As mentioned with Figure 2C, the reduced volume configuration of the liner layer 320 comprises protrusions extending towards the food products 308, and the number of protrusions depends on the number of adhesive sections of the second adhesive layer 318. In the exemplary embodiment, because the second adhesive layer 318 has eight adhesive sections, the reduced volume configuration comprises eight protrusions of the liner layer 320. The size and shape of the protrusions of the liner layer 320 correspond the area of the liner layer 320 unattached to the second paperboard layer 316.

[0056] Figures 4A, 4B, and 4C illustrate top views of a container 400 of one exemplary embodiment. The container 400 of Figures 4A-4C comprise similar layers as those shown in Figures 2A-2C and 3A-3C and in accordance to the above disclosed principles. The exemplary embodiment of Figures 4A-4C provide a different arrangement of adhesive sections of the second adhesive layer 418 as compared to Figures 2A-2C and 3A-3C. Figure 4A illustrates a top view of one exemplary embodiment of a fragile food products container 400 prior to construction and shows six adhesive sections to attach the liner layer 420 to the second paperboard layer 416.

[0057] As with Figures 2A and 3A, the container 400 is formed via a forming mandrel 424 from a composite 422 comprising six layers: an outer layer 410, a first adhesive layer 412, a first paperboard layer 414, a second paperboard layer 416, a second adhesive layer 418, and a liner layer 420. The six layers of the container 400 are separated for the purposes of distinctly showing the different layers, and when pressed together, the layers form a composite 422 for use with a forming mandrel 424 to shape the composite 422 into a container 400. The forming mandrel 424 may comprise any size and shape to facilitate the formation of the container 400 from the composite 422, and in the exemplary embodiment, the forming mandrel 424 comprises an elliptic cylinder shape to shape the composite 422 into an elliptic cylinder container 400.

[0058] In the exemplary embodiment, the second adhesive layer 418 comprises six adhesive sections of the second adhesive layer 418 that are equally spaced from each other. It is understood that the size and shape of the adhesive sections of the second adhesive layer 418 can vary. Alternative embodiments can have different amounts of adhesive sections and different arrangements thereof, as shown in Figures 2A-2C and 3A-3C. [0059] Figure 4B illustrates a top view of one exemplary embodiment of a fragile food products container after the composite 422 of Figure 4A has been shaped into the container 400. Figure 4B shows the layers 410, 412, 414, 416, 418, and 420 of the container 400. As shown with Figure 4A, the second adhesive layer 418 attaches the liner layer 420 with the second paperboard layer 416 at selected areas. In another embodiment, the liner layer 420 is attached or welded to the second paperboard layer 416 at selected locations using ultrasonics.

[0060] Figure 4C illustrates a top view of one exemplary embodiment of a fragile food products container after a vacuum has formed inside the container 400. In accordance to the disclosed principles, the liner layer 420 shifts from its initial configuration as shown in Figure 4B to create a reduced volume configuration while also accommodating the food products 408 inside the container 400. As mentioned with Figures 2C and 3C, the reduced volume configuration of the liner layer 420 comprises protrusions extending towards the food products 408, and the number of protrusions depends on the number of adhesive sections of the second adhesive layer 418. In the exemplary embodiment, because the second adhesive layer 418 has six adhesive sections, the reduced volume configuration comprises eight protrusions of the liner layer 420. The size and shape of the protrusions of the liner layer 420 correspond the area of the liner layer 420 unattached to the second paperboard layer 416.

[0061] Figures 5A and 5B illustrate cutaway cross-sectional view of one exemplary embodiment of a fragile food products container 500. The closed end 504 of the container 500 can be constructed to embody the above disclosed principles to reduce the volume inside the container 500 and therefore reduce pressure inside the container 500. The closed end 504 of the container 500 can be constructed from a material that can react to changes in environmental conditions and to conditions applied to the container 500. For example, the closed end 504 reacts when a vacuum forms inside the container 500 and reduces the volume inside the container to prevent deformation or implosion of the container 500. In the exemplary embodiment, the closed end 504 can be any shape or size corresponding to the shape of the container 500. Figures 5A and 5B also show the container 500 with multiple layers of the sidewall 502 to illustrate the combination of the use of the multiple layers of Figures 1-4 with the use of the vacuum relief closed end 504. Alternate embodiments may include the vacuum relief closed end 504 without the use of the multiple layers of the sidewall 502.

[0062] Figure 5A illustrates a cutaway cross-sectional view of the exemplary embodiment of the fragile food products container 500 before a vacuum forms inside the container 500. The closed end 504 comprises an endplate 530 protruding outward away from the food products 508 inside the container 500. It is understood that the curvature of the endplate 530 can vary, as shown in Figures 6A-6B, and the endplate 530 can comprise any shape or size corresponding to the closed end 504.

[0063] Figure 5B illustrates a cutaway cross-sectional view of the exemplary embodiment of the fragile food products container 500 after a vacuum forms inside the container 500. The vacuum creates a negative pressure and force that pulls at the structure of the container, and in response, the endplate 530 of the closed end 504 inverts so that the endplate 530 is protruding inward toward the food products 508 inside the container 500. As with the use of the protruding sections of the liner layer 420 of Figures 2A-C, the inversion of the protrusion of the endplate 530 reduces the volume inside the container 500 and thereby reduces the vacuum inside the container.

[0064] Figures 6A and 6B illustrate cutaway cross-sectional view of one exemplary embodiment of a fragile food products container, with Figure 6A showing the container 600 prior to vacuum formation and Figure 6B showing the container 600 after vacuum formation. The container 600 of the exemplary embodiment comprises similar features as those shown in Figures 5A-5B and are illustrated in accordance with the above disclosed principles. The exemplary embodiment of Figures 6A-6B provide a different curvature of the endplate 630 of the closed end 604 of the container 600 to illustrate that any degree of curvature of the protrusion of the endplate 630 can facilitate vacuum relief. Figures 6A and 6B also show the container 600 with multiple layers of the sidewall 602 to illustrate the combination of the use of the multiple layers of Figures 1-4 with the use of the vacuum relief closed end 604. Alternate embodiments may include the vacuum relief closed end 604 without the use of the multiple layers of the sidewall 602.

[0065] It can be understood that the flexibility of the vacuum relief features provides for a larger variety of configurations that accommodate any food product. The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive. Accordingly, the scope of the invention is established by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Further, the recitation of method steps does not denote a particular sequence for execution of the steps. Such method steps may therefore be performed in a sequence other than recited unless the particular claim expressly states otherwise.

ADDITIONAL DESCRIPTION

[0066] The following paragraphs are offered as further description of the various embodiments of the disclosed invention.

[0067] In a first embodiment, novel aspects of the present disclosure describe a container with vacuum relief features used for fragile articles, comprising: a tubular body having a central longitudinal axis, said body comprising a sidewall positioned between a closed end and an open end having a hermetically sealable opening; wherein the sidewall is formed by a first board layer selectively attached to a liner layer; wherein prior to vacuum formation, the liner layer comprises a first cross-sectional shape corresponding to a second cross-sectional shape of the tubular body, and after vacuum formation, the liner layer comprises a third cross-sectional shape different from the first cross-sectional shape.

[0068] In another aspect of the first embodiment, novel aspects of the present disclosure describe a container with vacuum relief features used for a single stack of fragile articles, comprising: a tubular body having a central longitudinal axis, said body comprising a sidewall positioned between a closed end and an open end having a hermetically sealable opening; wherein the sidewall is formed by a first board layer selectively attached to a liner layer; wherein prior to vacuum formation, the liner layer comprises a first cross-sectional shape corresponding to a second cross-sectional shape of the tubular body, and after vacuum formation, the liner layer comprises a third cross-sectional shape different from the first cross-sectional shape; and one or more limitations selected from the following list:

[0069] wherein prior to vacuum formation, the container comprises an initial interior volume, and after vacuum formation, the container comprises a second interior volume different from the initial interior volume;

[0070] wherein the first board layer comprises a second board layer; [0071] wherein the tubular body comprises an elliptical lateral cross-section along the central longitudinal axis;

[0072] wherein the tubular body comprises a circular lateral cross-section along the central longitudinal axis;

[0073] wherein the tubular body comprises a circular triangular cross-section along the central longitudinal axis;

[0074] wherein the tubular body comprises a rectangular lateral cross-section along the central longitudinal axis;

[0075] wherein the tubular body comprises a rounded rectangular lateral cross-section along the central longitudinal axis;

[0076] wherein after vacuum formation, the liner layer forms protrusions at areas unattached to the first board layer, wherein the protrusions extend toward the central longitudinal axis and decrease the volume inside the tubular body;

[0077] further comprising an outer layer attached to the first board layer;

[0078] wherein the outer layer comprises a fibrous material;

[0079] wherein the first board layer comprises a cardboard material;

[0080] wherein the liner layer comprises a material with low gas permeability;

[0081] wherein the liner layer is selectively attached to the first board layer via at least one adhesive material; and

[0082] wherein the liner layer is selectively welded to the first board layer using ultrasonics.

[0083] In a second embodiment, novel aspects of the present disclosure describe a container with vacuum relief features used for fragile articles, comprising: a tubular body having a central longitudinal axis, said body comprising a sidewall positioned between a closed end and an open end having a hermetically sealable opening; wherein, prior to vacuum formation, the closed end comprising a protrusion extending in a first direction, and after vacuum formation, the protrusion extends in a second direction opposite the first direction.

[0084] In another aspect of the second embodiment, novel aspects of the present disclosure describe a container with vacuum relief features used for a single stack of fragile articles, comprising A tubular body having a central longitudinal axis, said body comprising a sidewall positioned between a closed end and an open end having a hermetically sealable opening; wherein, prior to vacuum formation, the closed end comprising a protrusion extending in a first direction, and after vacuum formation, the protrusion extends in a second direction opposite the first direction, and one or more limitations selected from the following list:

[0085] wherein the tubular body comprises an elliptical lateral cross-section along the central longitudinal axis;

[0086] wherein the tubular body comprises a circular lateral cross-section along the central longitudinal axis;

[0087] wherein the tubular body comprises a circular triangular cross-section along the central longitudinal axis;

[0088] wherein the tubular body comprises a rectangular lateral cross-section along the central longitudinal axis;

[0089] wherein the tubular body comprises a rounded rectangular lateral cross-section along the central longitudinal axis;

[0090] wherein prior to vacuum formation, the container comprises an initial interior volume, and after vacuum formation, the container comprises a second interior volume different from the initial interior volume;

[0091] wherein prior to vacuum formation, the container comprises an initial interior volume, and after vacuum formation, the container comprises a second interior volume different from the initial interior volume; [0092] wherein a first amount of curvature of the protrusion prior to vacuum formation matches the second amount of curvature of the protrusion after vacuum formation;

[0093] wherein the sidewall comprises a fibrous material;

[0094] wherein the closed end comprises a fibrous material;

[0095] wherein the closed end comprises metal; and

[0096] wherein the closed end comprises at least one of paper, metal, and plastic;

[0097] In a third embodiment, novel aspects of the present disclosure describe a method for forming a container with vacuum relief features used for fragile articles, comprising: providing a sidewall comprising a first board layer selectively attached to a liner layer; forming a tubular body from the sidewall using a forming mandrel; wherein after the tubular body is formed, prior to vacuum formation, the liner layer comprises a first cross-sectional shape corresponding to a second cross-sectional shape of the tubular body, and after vacuum formation, the liner layer comprises a third cross-sectional shape different from the first cross-sectional shape.

[0098] In another aspect of the third embodiment, novel aspects of the present disclosure describe a method for forming a container with vacuum relief features used for a single stack of fragile articles, comprising: providing a sidewall comprising a first board layer selectively attached to a liner layer; forming a tubular body from the sidewall using a forming mandrel; wherein after the tubular body is formed, prior to vacuum formation, the liner layer comprises a first cross-sectional shape corresponding to a second cross-sectional shape of the tubular body, and after vacuum formation, the liner layer comprises a third cross-sectional shape different from the first cross-sectional shape, and one or more limitations selected from the following list:

[0099] wherein prior to vacuum formation, the container comprises an initial interior volume, and after vacuum formation, the container comprises a second interior volume different from the initial interior volume; [0100] wherein the first board layer comprises a second board layer;

[0101] wherein the tubular body comprises an elliptical lateral cross-section along the central longitudinal axis;

[0102] wherein the tubular body comprises a circular lateral cross-section along the central longitudinal axis;

[0103] wherein the tubular body comprises a circular triangular cross-section along the central longitudinal axis;

[0104] wherein the tubular body comprises a rectangular lateral cross-section along the central longitudinal axis;

[0105] wherein the tubular body comprises a rounded rectangular lateral cross-section along the central longitudinal axis;

[0106] wherein after vacuum formation, the liner layer forms protrusions at areas unattached to the board layer, wherein the protrusion extend toward the central longitudinal axis and decrease the volume inside the tubular body;

[0107] further comprising an outer layer attached to the first board layer;

[0108] wherein the outer layer comprises a fibrous material;

[0109] wherein the board layer comprises a cardboard material;

[0110] wherein the liner layer comprises a material with low gas permeability;

[0111] wherein the liner layer is selectively attached to the first board layer via at least one adhesive material; and

[0112] wherein the liner layer is selectively welded to the first board layer via ultrasonics.