Sealable snack container

A method of making a container comprising the steps of:

• providing a thermoforming mold comprising a first cavity for forming a cup portion of the container and a second cavity for forming a mating lid of the container, the second cavity disposed in proximity to the first cavity, the first cavity shaped to form the cup portion comprising a bottom panel, a sidewall, and a sealing brim defining an annular cup sealing surface, the second cavity shaped to form the lid comprising a sealing rim defining an annular lid sealing surface;
• feeding thermoplastic sheet stock having a maximum gauge of less than 35 mils to the mold;
• concurrently thermoforming the cup portion and the lid in the mold in proximity to one another from proximate areas of the thermoplastic sheet stock such that the cup portion is connected to the lid by a hinge portion, wherein the thermoforming is controlled, the sheet stock is selected, and the first cavity and the second cavity are shaped such that upon assembly of the container the annular cup sealing surface and the annular lid sealing surface cooperate to form a seal extending around the container;
• coining the hinge portion such that the hinge portion comprises a coined region extending longitudinally along an axis of rotation of the hinge portion;
• and
• removing material from the hinge portion such that the hinge portion comprises a cut-away portion disposed along the axis of rotation of the hinge portion.

A thermoformed sealable container comprising:

• a cup portion comprising a sidewall, a bottom, and a sealing brim defining an interior volume, the sealing brim having a U-shaped profile;
• a lid comprising a sealing rim having a U-shaped profile;
• and
• a hinge portion integrally formed with and connecting the cup portion and the lid, the hinge portion comprising a coined region extending longitudinally along an axis of rotation of the hinge portion and a cut-away portion disposed along the axis of rotation of the hinge portion;
• wherein the cup portion, the lid, and the hinge portion are thermoformed from proximate areas of a thermoplastic sheet stock, and wherein the sealing brim of the cup portion and the sealing rim of the lid are configured to cooperate to form a seal therebetween along an interior wall of the sealing brim of the cup portion and to define a clearance therebetween along an exterior wall of the sealing brim of the cup portion upon assembly to the container.

A thermoformed sealable container comprising:

• a cup portion comprising a sidewall, a bottom, and a sealing brim defining an interior volume;
• a lid comprising a sealing rim;
• and
• a hinge portion integrally formed with and connecting the cup portion and the lid, wherein the hinge portion has an arched hinge profile so that the hinge portion is substantially elastic and relatively pliant, and wherein the hinge portion is incapable of sustaining a hinge torque sufficient to tilt the cup portion when the cup portion is empty and disposed on a countertop.

A thermoformed sealable container comprising:

• a cup portion comprising a sidewall, a bottom, and a sealing brim defining an interior volume;
• a lid comprising a sealing rim;
• and
• a hinge portion integrally formed with and connecting the cup portion and the lid, wherein the hinge portion has an arched hinge profile, and wherein a maximum moment the hinge portion is capable of sustaining is:
• less than mcrc, or
• less than
• m
• l
• ⁢
• w
• l
• 2
• -
• h
• c
• 2
• 2
• where mc is a mass of the cup portion, rc is a horizontal distance to a center of mass of the cup portion from the hinge portion, ml is a mass of the lid, wl is a length of the lid perpendicular to an axis of rotation of the hinge portion, and hc is a height of the hinge portion above a countertop upon which the cup portion rests.

A method of making a sealable container by thermoforming comprising:

• providing a thermoforming mold comprising a first cavity for forming a cup portion of the container and a second cavity for forming a mating lid of the container, the second cavity disposed in proximity to the first cavity, the first cavity shaped to form the cup portion comprising a sidewall, a bottom, and a sealing brim defining an interior volume, the second cavity shaped to form the lid comprising a sealing rim;
• feeding thermoplastic sheet stock having a maximum gauge of less than 35 mils to the mold;
• concurrently thermoforming the cup portion and the lid in the mold in proximity to one another from proximate areas of the thermoplastic sheet stock such that the lid is connected to the cup portion by a hinge portion;
• and
• coining the hinged portion to provide an arched profile thereto so that the hinge portion is substantially elastic and relatively pliant, wherein the hinge portion is incapable of sustaining a hinge torque sufficient to tilt the cup portion when the cup portion is empty and disposed on a countertop.

A lightweight, thermoformed sealable container comprising:

• a frusto-pyramidal cup portion having a maximum gauge of less than 35 mils, the cup portion comprising four sidewall panels, a bottom panel, four chamfered lower corner panels bridging the sidewall panels and the bottom panel, and a sealing brim defining an annular cup sealing surface;
• a lid having a maximum gauge of less than 35 mils, the lid comprising a sealing rim defining an annular lid sealing surface;
• and
• a hinge portion integrally formed with and connecting the cup portion and the lid, the hinge portion comprising a coined region extending longitudinally along an axis of rotation of the hinge portion and a cut-away portion disposed along the axis of rotation of the hinge portion;
• wherein the cup portion, the lid, and the hinge portion are thermoformed from proximate areas of a thermoplastic sheet stock, and wherein the annular cup sealing surface and the annular lid sealing surface are configured to cooperate to form a seal therebetween extending around the container upon assembly.

A packaged ensemble comprising:

• at least five sealable containers, each of the sealable containers comprising:
• a cup portion having a maximum gauge of less than 35 mils, the cup portion comprising a bottom panel, a sidewall, and a sealing brim defining an annular cup sealing surface;
• a mating lid having a maximum gauge of less than 35 mils, the lid comprising a sealing rim defining an annular lid sealing surface;
• and
• a hinge portion integrally formed with and connecting the cup portion and the lid, the hinge portion comprising a coined region extending longitudinally along an axis of rotation of the hinge portion and a cut-away portion disposed along the axis of rotation of the hinge portion;
• wherein the cup portion, the lid, and the hinge portion are thermoformed from proximate areas of a thermoplastic sheet stock, and wherein the annular cup sealing surfaces and the annular lid sealing surfaces are configured to cooperate to form seals therebetween extending around the containers upon assembly.

A lightweight, thermoformed sealable container comprising:

• a cup portion having a maximum gauge of less than 35 mils, the cup portion comprising a bottom panel, a sidewall, and a sealing brim defining an annular cup sealing surface;
• and
• a lid having a maximum gauge of less than 35 mils, the lid comprising a sealing rim defining an annular lid sealing surface;
• wherein the cup portion and the lid are thermoformed from proximate areas of a thermoplastic sheet stock, wherein the annular cup sealing surface and the annular lid sealing surface are configured to cooperate to form a seal therebetween extending around the container upon assembly, and wherein the container exhibits a Crush Force/Capping Force ratio of from 5 to 1.5, and a Capping Force of at least 0.4 lbs/lineal inch of seal perimeter.