Tearable leak-resistant container

Abstract

A tearable leak-resistant container is provided with creases, partial perforation along selected creases, adhesion of flaps, and a collapsed position to permit rapid reconfiguration to an expanded position. The expanded position of the container enables enhanced filling with food ingredients and transportation without spillage. The adhered flaps provide enhanced leak resistance, and the perforated creases permit disassembly of the container to improve access to the food contained within.

Claims

1. A tearable container comprising: a bottom spine, wherein the bottom spine comprises a first end and a second end; a first side foldably attached to the bottom spine by a first spine crease; a second side foldably attached to the bottom spine by a second spine crease, wherein said second spine crease is parallel to the first spine crease; an open end, wherein the first end of the bottom spine is located at the open end; a bottom flap foldably attached to the second end of the bottom spine by a bottom crease; a first end flap foldably attached to the first side by a first end crease; and a second end flap foldably attached to the second side by a second end crease, wherein the bottom spine is defined by the first end of the bottom spine, the second end of the bottom spine, the first spine crease, and the second spine crease, and wherein the first and second spine creases comprise perforated crease segments.

2. The tearable container of claim 1, wherein each perforated crease segment comprises a notch at the first end of the bottom spine, forming a center tab at the open end.

3. The tearable container of claim 2, wherein the size and shape of each notch and the center tab are modulated to facilitate a tearing mechanism along the perforated crease segments.

4. The tearable container of claim 1, wherein each side comprises a side crease, wherein a collapsed position is planar, and wherein the collapsed position comprises the pair of sides folded along the side creases, the bottom flap folded along the bottom crease, and the end flaps adhered to the bottom flap and fully overlapping and adhered to each other, forming a closed end and a corner of the container.

5. The tearable container of claim 4, wherein an expanded position comprises the pair of sides and the bottom flap folded substantially perpendicular relative to the bottom spine, the pair of end flaps folded substantially perpendicular relative to each side, and the pair of sides unfolded along each side crease, forming the open end and an interior cavity defined by the bottom spine, the closed end, and the sides.

6. The tearable container of claim 5, wherein the distance between spine creases is modulated to optimize the shapes of the bottom spine and the interior cavity.

7. The tearable container of claim 5, wherein the perforated crease segments extend at least one-fourth the length of each spine crease from the first end of the bottom spine.

8. The tearable container of claim 5, wherein the lengths and perforation parameters of the perforated crease segments are modulated to optimize a tearing mechanism along said perforated crease segments.

9. The tearable container of claim 5, wherein a disassembled position comprises the bottom spine and pair of sides bent away from the interior cavity at the open end, and wherein perforations along the pair of perforated crease segments are ruptured.

10. The tearable container of claim 1 wherein the container is made of paperboard that includes printed graphical or written descriptions of proper container usage.

11. A tearable container comprising: a bottom spine, wherein the bottom spine comprises a first end and a second end; a first side foldably attached to the bottom spine by a first spine crease; a second side foldably attached to the bottom spine by a second spine crease, wherein said second spine crease is parallel to the first spine crease; an open end, wherein the first end of the bottom spine is located at the open end; a bottom flap foldably attached to the second end of the bottom spine by a bottom crease; a first end flap foldably attached to the first side by a first end crease; and a second end flap foldably attached to the second side by a second end crease, wherein the bottom spine is defined by the first end of the bottom spine, the second end of the bottom spine, the first spine crease, and the second spine crease, wherein the first and second spine creases comprise perforated crease segments extending from the first end toward the second end of the bottom spine, wherein each perforated crease segment comprises a notch at the first end of the bottom spine forming a center tab at the open end, wherein the size and shape of each notch and said center tab and the perforation parameters of the perforated crease segments are modulated to optimize a tearing mechanism along said perforated crease segments.

12. The tearable container of claim 11, wherein each side comprises a side crease, wherein a collapsed position is planar, and wherein the collapsed position comprises the pair of sides folded along the side creases, the bottom flap folded along the bottom crease, and the end flaps adhered to the bottom flap and fully overlapping and adhered to each other so that a closed end and a corner of the container are formed.

13. The tearable container of claim 12, wherein an expanded position comprises the pair of sides and the bottom flap folded substantially perpendicular relative to the bottom spine, the pair of end flaps folded substantially perpendicular relative to each side, and the pair of sides unfolded along each side crease, forming the open end and an interior cavity defined by the bottom spine, the closed end, and the sides.

14. The tearable container of claim 13, wherein the distance between spine creases is modulated to optimize the shapes of the bottom spine and interior cavity.

15. The tearable container of claim 13, wherein the size and shape of the sides and bottom spine are modulated at the open end to optimize the tearing mechanism.

16. The tearable container of claim 13, wherein a disassembled position comprises the bottom spine and pair of sides bent away from the interior cavity at the open end, and wherein perforations along the pair of perforated crease segments are ruptured.

17. A method comprising: providing a perforated and pre-creased blank made of a foldable substrate, the blank being of the type having: a bottom spine, wherein the bottom spine comprises a first end and a second end; a first side foldably attached to the bottom spine by a first spine crease and comprising a first side crease; a second side foldably attached to the bottom spine by a second spine crease and comprising a second side crease, wherein said second spine crease is parallel to the first spine crease; an open end, wherein the first end of the bottom spine is located at the open end; a bottom flap foldably attached to the second end of the bottom spine by a bottom crease; a first end flap foldably attached to the second end of the bottom spine by a bottom crease; a first end flap foldably attached to the first side by a first end crease; and a second end flap foldably attached to the second side by a second end crease, wherein the bottom spine is defined by the first end of the bottom spine, the second end of the bottom spine, the first spine crease, and the second spine crease, wherein the first and second spine creases comprise perforated crease segments extending from the first end toward the second end of the bottom spine, wherein each perforated crease segment comprises a notch at the first end of the bottom spine forming a center tab at the open end, wherein the size and shape of each notch and said center tab and the perforation parameters of the perforated crease segments are modulated to optimize a tearing mechanism along said perforated crease segments; and folding the blank into a container in a planar collapsed position by folding the pair of sides along the side creases, folding the bottom flap along the bottom crease, adhering overlapping end flaps to each other, and adhering the bottom flap to the overlapping end flaps so that a closed end and a corner of the container are formed.

18. The method of claim 17 wherein the substrate is paperboard.

19. The method of claim 17 further comprising reconfiguring the planar collapsed container into an expanded position by folding the pair of sides and the bottom flap substantially perpendicular relative to the bottom spine, folding the pair of end flaps substantially perpendicular relative to each side, and unfolding the pair of sides along each side crease to form the open end and an interior cavity defined by the bottom spine, closed end, and sides.

20. The method of claim 19 further comprising filling the container in its expanded position with food.

21. The method of claim 20 further comprising: disassembling the filled container by bending the bottom spine and pair of sides away from the interior cavity at the open end, rupturing perforations along the pair of perforated crease segments; and accessing food contained within the interior activity.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The unique attributes of the tearable container are presented in a detailed exemplary embodiment below. Chiefly, the apparatus described in this application is designed for optimal manufacturing, storage, and usage, including enhanced leak resistance and touchless access to food contents within the container. The present invention is not intended to be limited to the subject matter and exemplary embodiments presently disclosed, and modifications and other embodiments that will come to mind to one skilled in the art having the benefit of the teachings presently disclosed are within the scope of this disclosure.

(2) Embodiments of the present invention are better understood from the following detailed description with reference to the following drawings:

(3) FIG. 1 is a perspective view of an exemplary container in its unfolded planar position.

(4) FIG. 2 is a perspective view of the container of FIG. 1 in its collapsed position where some elements have been folded and adhered.

(5) FIG. 3A is a perspective view of the container of FIG. 2 showing partial folding and unfolding along various creases to expand the container from the collapsed position.

(6) FIG. 3B is a perspective view of the container of FIG. 3A showing further partial folding and unfolding along various creases to further expand the container from the collapsed position.

(7) FIG. 3C is a perspective view of the container of FIG. 3B after it has been optimally unfolded and folded to expand the container from its collapsed position depicted in FIG. 2 to its expanded position ready for use.

(8) FIG. 4 is a perspective view of the container of FIG. 3C showing the sides and bottom spine designed for ease of disassembly along perforated creases.

(9) FIG. 5 is a perspective view of the container of FIG. 4 showing the sides and bottom spine in a partially disassembled position for enhanced accessibility.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

(10) As depicted in FIG. 1, in an exemplary embodiment the container is in its unfolded planar position. Parallel spine creases 20a and 20b join bottom spine 23 with sides 27a and 27b, respectively. Bottom spine 23 includes first end 18 and second end 19. Spine crease 20a includes perforated crease segment 30a and spine crease 20b includes perforated crease segment 30b.

(11) Sides 27a and 27b are bisected by side creases 28a and 28b. In this embodiment, sides 27a and 27b exhibit rounded edges 32a and 32b between their respective perforated crease segments 30a and 30b and side creases 28a and 28b. Alternative embodiments anticipated herein may exhibit alternative geometries of edges 32a and 32b, including square, zigzag, sinusoidal, irregularly fluctuating, some combination of these, or any other geometry.

(12) In this embodiment, perforated crease segments 30a and 30b extend from first end 18 approximately four-fifths the length of spine creases 20a and 20b, respectively, leaving one-fifth the length of spine creases 20a and 20b unperforated toward second end 19. Alternative embodiments anticipated herein include perforated crease segments of various lengths and perforations that are effectively and efficiently designed to modulate tear strength, or resistance to tearing at the perforation when external force is applied beginning at first end 18 to rupture the perforation. Alternative embodiments include perforated crease segments longer than and shorter than four-fifths the length of their respective spine creases, including a range of lengths of perforated crease segments from at least one-fourth the length of their respective spine creases to a length equivalent to the length of their respective spine creases. Alternative embodiments anticipated herein include perforated crease segments 30a and 30b exhibiting perforations of any dimension or pattern compatible with the preferred substrate, including micro or coarse perforations with alternative ties per inch, cut/tie sizes, tooth sizes, or any other arrangements and geometries to modulate burst and tear strengths.

(13) Herein, perforated crease segments 30a and 30b are depicted approximately one inch apart. Alternative embodiments anticipated herein include distances between perforated crease segments 30a and 30b greater than or less than one inch in order to modulate ease of container expansion, shape of the expanded position, efficiency of disassembly/tearing, intended use, or any combination of these.

(14) End creases 26a and 26b join end flaps 24a and 24b, respectively, with sides 27a and 27b, respectively. Bottom crease 22 joins bottom flap 21 with bottom spine 23. In this embodiment, side crease 28a bisects side 27a to form a 45-degree angle between side crease 28a and spine crease 20a and a 45-degree angle between side crease 28a and end crease 26a. Similarly, side crease 28b bisects side 27b to form a 45-degree angle between side crease 28b and spine crease 20b and a 45-degree angle between side crease 28b and end crease 26b. Alternative embodiments anticipated herein may feature different angles between creases 28a and 28b and the other creases along their respective sides 27a and 27b. In this embodiment, creases are deep and narrow, resulting in low folding resistance and accurate folding operations. Alternative embodiments of the present invention anticipated herein include creases of varying width, depth, patterning, orientation to the paperboard fiber direction, and combinations thereof to optimize the creasing operation to facilitate folding operations. Alternative embodiments anticipated herein may feature diverse bottom flap sizes, shapes, and geometries, including wings or tabs.

(15) In FIG. 2, the embodiment of FIG. 1 has been reconfigured to its collapsed position by folding and adhering some elements. All elements of the container remain coplanar with the container bottom spine 23 and the container remains collapsed. Sides 27a and 27b are folded along the side creases 28a and 28b, respectively, such that end flap 24a overlaps and is adhered to end flap 24b with any bonding agent demonstrated effective in the food container industry. The overlapping of end flap 24b with 24a and subsequent adhering of the same forms closed end 25, and bottom flap 21 is folded along crease 22 to overlap and adhere to closed end 25 with a bonding agent. The joining and adhering of end flaps 24a and 24b and bottom flap 21 generate corner 29, a region of the container designed for leak resistance. Alternative embodiments of the present invention anticipated herein may exhibit varied ordering of layering and adhering overlapping end flaps 24a, 24b, and bottom flap 21 to generate corner 29.

(16) Referring now to FIGS. 3A and 3B, the embodiment of FIG. 2 is compressed along sides 27a and 27b to reconfigure the container from the collapsed position to the expanded position. As force is applied, the container folds along spine creases 20a and 20b as well as end creases 26a and 26b, while the container unfolds along bottom crease 22 and side creases 28a and 28b. Bottom spine 23 is the only element remaining in its original plane as all other elements are reconfigured to generate interior cavity 31.

(17) As depicted in FIG. 3C, the embodiment of FIG. 2 is configured in its expanded position upon completion of the reconfiguration shown in FIGS. 3A and 3B, generating interior cavity 31. Spine creases 20a and 20b as well as side creases 26a and 26b are folded optimally while bottom crease 22 and side creases 28a and 28b are unfolded optimally. Sides 27a and 27b and bottom flap 21 are folded substantially perpendicular relative to bottom spine 23, end flaps 24a and 24b are folded substantially perpendicular relative to sides 27a and 27b, and sides 27a and 27b are unfolded along the side creases 28a and 28b, respectively, forming open end 36 and interior cavity 31.

(18) Referring now to FIGS. 4 and 5, the embodiment depicted in FIG. 3C is rotated to show open end 36 and the function of perforated crease segments 30a and 30b along spine creases 20a and 20b, respectively, to increase access to interior cavity 31. Consumers of food products packaged by this embodiment of the invention may grip side 27a, side 27b, bottom spine 23 at center tab 35, or some combination of these to exert bending force that facilitates a tearing mechanism of perforated crease segments 30a and 30b initiating at the first end 18 of the bottom spine. In this exemplary embodiment, perforated crease segments 30a and 30b include notches 34a and 34b, respectively, forming center tab 35 for easier grip that facilitates tearing of the perforations beginning at first end 18. Alternative embodiments may include notches, tabs, flaps, textured contact points, indentations, grooves, some combination of these, or other features on the spine or sides at first end 18 or open end 36 to contribute to rupture of perforations and tearing along spine creases.

(19) Referring to FIG. 5, as bending force away from interior cavity 31 is applied to side 27a, side 27b, bottom spine 23, or a combination of these, perforated crease segment 30a, perforated crease segment 30b, or both perforated crease segments 30a and 30b tear along their perforations. In particular, when external bending force is applied in order to separate side 27a from bottom spine 23, rupturing perforations 33a along perforated crease segment 30a facilitate tearing along spine crease 20a to the point where perforated crease segment 30a ends. Similarly, when external bending force is applied in order to separate side 27b from bottom spine 23, rupturing perforations 33b along perforated crease segment 30b facilitate tearing along spine crease 20b to the point where perforated crease segment 30b ends. These bending and tearing operations allow separation of side 27a from bottom spine 23, separation of side 27b from bottom spine 23, or separation of both sides 27a and 27b from bottom spine 23, disassembling the container to permit easier access to interior cavity 31. Tearing of perforated crease segments 30a and 30b along spine creases 20a and 20b, respectively, to the point where perforated crease segments 30a and 30b end results in a disassembled position, and partial tearing up to the point where perforated crease segments 30a and 30b end results in a partially disassembled position.

(20) In alternative embodiments of the present invention, a method may include providing a perforated and pre-creased blank made of a foldable substrate as depicted in FIG. 1, folding the blank into a container in a collapsed position as depicted in FIG. 2, and compressing and drying the collapsed container. The method may include reconfiguring the collapsed container into an expanded position as depicted in FIGS. 3A-3C or filling the container in its expanded position with food. The method may also include disassembling the filled container as depicted in FIG. 5 and accessing food contained within the interior cavity.

(21) The representative embodiments described in detail herein have been presented by way of example and not by way of limitation. It will be understood by those skilled in the art that changes may be made in the form and details of the described embodiments resulting in equivalent embodiments that remain within the scope of the appended claims.