Resealable Leak-Resistant Containers Having A Pressed Pulp Tray With A Thermoformed Plastic Lid

Abstract

A leak-resistant pulp container with a plastic lid is disclosed, including a tray formed of molded pulp and having a boom and a sidewall forming an interior volume. The tray has an edge extending peripherally outward from an upper edge of the sidewall, and the tray edge has an outer portion. The container further includes a plastic lid having an edge extending peripherally outward therefrom, and the lid edge having an outer portion.

What is claimed is: 
     
         1 . A leak-resistant pulp container with a plastic lid, comprising:
 a tray formed of molded pulp and having a bottom and a sidewall forming an interior volume, the tray further comprising an edge extending peripherally outward from an upper edge of the sidewall, the tray edge having an outer portion; and   a plastic lid having an edge extending peripherally outward therefrom, the lid edge having an outer portion,   wherein the lid edge and the tray edge each has a corresponding peripheral channel configured so that one of the peripheral channels is received in the other of the peripheral channels to secure the lid to the tray, each of the peripheral channels comprising an inner wall and an outer wall joined by a horizontal channel wall, and   wherein the outer wall of the peripheral channel of the lid edge has a protrusion which mates with the outer portion of the tray edge to create an interference fit between the lid edge and the tray edge to secure the lid to the tray.   
     
     
         2 . The leak-resistant pulp container of  claim 1 , wherein the inner wall of the peripheral channel of the tray edge has a sealing surface which presses against a corresponding sealing surface of the inner wall of the peripheral channel of the lid edge when the lid is secured to the tray, thereby forming a leak-resistant seal between the lid edge and the tray edge. 
     
     
         3 . The leak-resistant pulp container of  claim 2 , wherein the lid edge is configured so that the outer wall of the peripheral channel of the lid edge applies force to the outer portion of the tray edge to force the sealing surface of the tray edge against the sealing surface of the lid edge. 
     
     
         4 . The leak-resistant pulp container of  claim 2 , wherein sealing surfaces of the lid edge and the tray edge extend to include at least a portion of the horizontal channel walls of the lid edge and the tray edge. 
     
     
         5 . The leak-resistant pulp container of  claim 2 , wherein the inner wall of the peripheral channel of the lid edge and the inner wall of the peripheral channel of the tray edge are dimensioned to at least partially overlap in a cross-sectional plane, thereby forcing the sealing surface of the tray edge against the sealing surface of the lid edge when the lid is secured to the tray. 
     
     
         6 . The leak-resistant pulp container of  claim 1 , wherein the protrusion of the outer wall of the peripheral channel of the lid edge has a lower lip which extends inward to keep the outer portion of the tray edge in place in the protrusion, thereby acting to secure the lid to the tray. 
     
     
         7 . The leak-resistant pulp container of  claim 6 , wherein the lower lip of the protrusion of the outer wall of the peripheral channel of the lid edge is formed in separate peripheral segments around the periphery of the lid. 
     
     
         8 . The leak-resistant pulp container of  claim 1 , wherein inner wall of the peripheral channel of the tray edge forms a draft angle with respect to a vertical direction of the container, when upright, of between about 8 degrees and about 12 degrees. 
     
     
         9 . The leak-resistant pulp container of  claim 8 , wherein the draft angle of the inner wall of the peripheral channel of the tray edge is between about 10 degrees and about 12 degrees. 
     
     
         10 . The leak-resistant pulp container of  claim 1 , wherein the outer portion of the tray edge is substantially flat in a horizontal plane of the container when upright. 
     
     
         11 . The leak-resistant pulp container of  claim 1 , wherein a tab extends from the lid edge and beyond the tray edge. 
     
     
         12 . The leak-resistant pulp container of  claim 1 , wherein the tray and the lid each has a substantially oval shape. 
     
     
         13 . The leak-resistant pulp container of  claim 1 , wherein the lid is formed of any of the following plastic materials: high density polyethylene (HDPE), polyethylene terephthalate (PET), polypropylene (PP), polystyrene (PS), and polylactic acid (PLA). 
     
     
         14 . The leak-resistant pulp container of  claim 1 , wherein the lid is formed by a thermoforming process. 
     
     
         15 . The leak-resistant pulp container of  claim 1 , wherein the lid is formed by an injection molding process. 
     
     
         16 . A leak-resistant pulp container with a plastic lid, comprising:
 a tray formed of molded pulp and having a bottom and a sidewall forming an interior volume, the tray further comprising an edge extending peripherally outward from an upper edge of the sidewall, the tray edge having an outer portion; and   a plastic lid having an edge extending peripherally outward therefrom, the lid edge having an outer portion,   wherein the lid edge and the tray edge each has a corresponding lock portion configured so that one of the lock portions mates with the other of the lock portions to secure the lid to the tray, and   wherein the lid edge and the tray edge each has a corresponding seal portion configured so that one of the seal portions presses against the other of the seal portions when the lid is secured to the tray, thereby forming a leak-resistant seal between the lid edge and the tray edge.   
     
     
         17 . The leak-resistant pulp container of  claim 16 , wherein the seal portions of the lid edge and the tray edge are formed in an inner portion of the lid edge and the tray edge with respect to the lock portions of the lid edge and the tray edge. 
     
     
         18 . The leak-resistant pulp container of  claim 16 , wherein the lock portion of the lid edge comprises an outer wall having a protrusion which mates with the outer portion of the tray edge to create an interference fit between the lid edge and the tray edge to secure the lid to the tray. 
     
     
         19 . The leak-resistant pulp container of  claim 16 , wherein the lid edge is configured so that the outer wall of the lock portion applies force to the outer portion of the tray edge to force the seal portion of the tray edge against the seal portion of the lid edge.