Stackable Container with Lid

Abstract

An enclosable and stackable container comprising a tray and lid is provided with structural elements to permit rapid covering and uncovering of the tray, efficient stacking of containers, and safe transportation. At least one catching mechanism may be engaged quickly to securely cover the tray and its food contents and disengaged quickly to uncover the tray and its food contents, improving food hygiene practices. Foldable flange flaps enhance stacking strength to permit safe transportation of stacked containers and their food contents.

Claims

1. A stackable container comprising: a tray; and a lid, wherein the lid comprises a pair of flange flaps foldably attached to a center panel and a pair of catch tabs foldably attached to the center panel, wherein each catch tab comprises a pair of wing slits, wherein the tray comprises a pair of side panels foldably attached to a bottom panel and a pair of end panels foldably attached to the bottom panel, wherein each end panel comprises a pair of friction tabs.

2. The stackable container of claim 1, wherein the friction tabs secure within the wing slits in a stackable position.

3. The stackable container of claim 2, wherein the stackable position comprises the pair of side panels folded substantially perpendicular relative to the bottom panel, and the pair of end panels folded substantially perpendicular relative to the bottom panel.

4. The stackable container of claim 3, wherein each catch tab is folded along a catch tab crease.

5. The stackable container of claim 4, wherein each end panel comprises a pair of glue flaps securing each end panel to adjacent side panels.

6. The stackable container of claim 5, wherein a catch tab gap is located between the friction tabs of each pair of friction tabs.

7. The stackable container of claim 6, wherein each side panel comprises a side panel edge, wherein each end panel comprises an end panel edge, and wherein each friction tab comprises a friction tab edge.

8. The stackable container of claim 7, wherein each catch tab comprises a pair of wings and a pair of wing shoulders.

9. The stackable container of claim 8, wherein the stackable position comprises the friction tabs extending through the wing slits, the catch tabs interlocking with the catch tab gaps, the wings compressed against the glue flaps, and the wing shoulders compressed against the friction tabs.

10. The stackable container of claim 9, wherein engagement of at least one wing against at least one glue flap comprises a catching mechanism that secures the lid to the tray.

11. The stackable container of claim 10, wherein the container is made of paperboard and the center panel comprises at least one window.

12. A stackable container comprising: a tray; and a lid, wherein the lid comprises a pair of flange flaps foldably attached to a center panel and a pair of catch tabs foldably attached to the center panel, wherein each catch tab comprises a pair of wing slits, wherein the tray comprises a pair of side panels foldably attached to a bottom panel and a pair of end panels foldably attached to the bottom panel, wherein each end panel comprises a pair of friction tabs and a pair of glue flaps securing each end panel to the adjacent side panels, wherein engagement of at least one wing against at least one glue flap comprises a catching mechanism that secures the lid to the tray.

13. The stackable container of claim 12, wherein the friction tabs secure within the wing slits in a stackable position.

14. The stackable container of claim 13, wherein the stackable position comprises the pair of side panels folded substantially perpendicular relative to the bottom panel, the pair of end panels folded substantially perpendicular relative to the bottom panel, the pair of flange flaps folded substantially perpendicular relative to the center panel, and the pair of catch tabs folded substantially perpendicular relative to the center panel.

15. The stackable container of claim 14, wherein each catch tab is folded along a catch tab crease and each flange flap is folded along a flange flap crease.

16. The stackable container of claim 15, wherein a catch tab gap is located between the friction tabs of each pair of friction tabs.

17. The stackable container of claim 16, wherein each side panel comprises a side panel edge, wherein each end panel comprises an end panel edge, and wherein each friction tab comprises a friction tab edge.

18. The stackable container of claim 17, wherein each catch tab comprises a pair of wings and a pair of wing shoulders, and each flange flap comprises a pair of flange flap tabs and a pair of flange flap shoulders.

19. The stackable container of claim 18, wherein the stackable position comprises the friction tabs extending through the wing slits, the catch tabs interlocking with the catch tab gaps, the wings compressed against the glue flaps, and the wing shoulders compressed against the friction tabs.

20. The stackable container of claim 19, wherein the pair of flange flaps secures within an interior of the tray in a stackable position.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The unique attributes of the stackable container with lid are presented in a detailed exemplary embodiment below. Chiefly, the apparatus described in this application is designed for optimal manufacturing, storage, assembly, and usage, including enhanced food hygiene, storage, and transportation and container stacking strength. 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 present teachings are within the scope of this disclosure.

[0017] Embodiments of the present invention are better understood from the following detailed description with reference to the following drawings:

[0018] FIG. 1A is a perspective view of an exemplary flat lid of the present invention.

[0019] FIG. 1B is a perspective view of an exemplary tray of the present invention.

[0020] FIG. 2A is a perspective view of a plurality of flat lids of FIG. 1A stacked for storage or shipping.

[0021] FIG. 2B is a perspective view of a plurality of trays of FIG. 1B stacked for storage or shipping.

[0022] FIG. 3A is a perspective view of a flat lid of FIG. 1A aligned in an orientation for assembly with a tray of FIG. 1B.

[0023] FIG. 3B is a perspective view of the lid and tray of FIG. 3A showing the lid partially folded along the catch tab crease and lid catch tabs partially interlocking with the tray catch tab gaps.

[0024] FIG. 3C is a perspective view of the lid and tray of FIG. 3A showing the lid fully folded along the catch tab crease and lid catch tabs interlocking with the tray catch tab gaps to form a container in a stackable position.

[0025] FIG. 4A is a perspective view of a lid of FIG. 1A aligned in an orientation for assembly with a tray of FIG. 1B wherein the lid flange flaps are in a folded position.

[0026] FIG. 4B is a perspective view of the lid and tray of FIG. 4A showing the folded lid flange flaps secured within the interior of the tray and showing the lid partially folded along the catch tab crease and lid catch tabs partially interlocking with the tray catch tab gaps.

[0027] FIG. 4C is a perspective view of the lid and tray of FIG. 4A showing folded lid flange flaps secured within the interior of the tray and the lid fully folded along the catch tab crease and lid catch tabs fully interlocking with the tray catch tab gaps to form a container in a stackable position.

[0028] FIG. 5A is an isolation exterior perspective view of a corner of the lid and tray of

[0029] FIG. 4C showing a catch tab fully folded along the catch tab crease, a wing compressed against a glue flap, and a wing shoulder compressed against a friction tab as a catching mechanism.

[0030] FIG. 5B is an isolation exterior perspective view of the corner of FIG. 5A showing the catching mechanism.

[0031] FIG. 5C is an isolation exterior perspective view of the corner of FIG. 5A showing the catching mechanism and a flange flap secured within the interior of the tray.

[0032] FIG. 6 is a perspective view of a stack of containers of FIG. 4C.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

[0033] As depicted in FIGS. 1A and 1B, an exemplary rectangular embodiment of the novel container is aligned in an orientation of assembly with separate lid 20 shown in FIG. 1A and tray 22 shown in FIG. 1B.

[0034] Referring now to FIG. 1A, an exemplary lid 20 is formed from a unitary paperboard blank that is cut, creased, and slitted to form elements that engage with elements of the tray to cover and enclose the tray and enhance container stacking strength. The lid 20 may have four sides, namely catch tab sides 19a and 19b and flange flap sides 18a and 18b. The lid may comprise a pair of flange flaps, namely flange flaps 29a and 29b on flange flap sides 18a and 18b, respectively, wherein the pair of flange flaps is foldably attached to the center panel 21 by flange flap creases 30a and 30b, respectively, running the lengths of each parallel side. The lid may comprise a pair of catch tabs, namely catch tabs 23a and 23b on catch tab sides 19a and 19b, respectively, wherein the pair of catch tabs is foldably attached to the center panel 21 by catch tab creases 24a and 24b, respectively, running the lengths of each parallel side. In this exemplary embodiment, catch tab creases 24a and 24b and flange flap creases 30a and 30b are straight lines and center panel 21 is rectangular.

[0035] Alternative embodiments anticipated herein may exhibit alternative crease geometries for some or all creases, including curved or multi-segmented geometries, or any other geometry. Center panel 21 may exhibit alternative shapes, including rectilinear (e.g., rectangular or square), rounded rectangular, bulging rectangular, curved rectangular, or any other shape. Center panel 21, side panels 37a and 37b, and end panels 39a and 39b may also include windows and window films of diverse sizes, shapes, and materials. For example, alternative embodiments anticipated herein may include windows of various shapes, including circles, triangles, rectangles, stars, diamonds, ovals, semicircles, hearts, hexagons, pentagons, trapezoids, crosses, crescents, parallelograms, octagons, and combinations thereof. Windows may be made of clear, colored, opaque, and/or translucent materials and combinations thereof, including cellophane and other suitable thin films.

[0036] Each catch tab comprises a pair of wing slits and wings, wherein each wing comprises a wing shoulder and a wing end. For example, catch tab 23a comprises wing slits 26a and 26b and wings 25a and 25b. Wings 25a and 25b comprise wing shoulders 27a and 27b, respectively, and wing ends 28a and 28b, respectively. Similarly, catch tab 23b comprises wing slits 26c and 26d and wings 25c and 25d. Wings 25c and 25d comprise wing shoulders 27c and 27d, respectively, and wing ends 28c and 28d, respectively.

[0037] The curvatures of wing slits 26a, 26b, 26c, and 26d delineate the shapes of wing shoulders 27a, 27b, 27c, and 27d, respectively, and thus the wing slit curvatures define the overall shape of wings 25a, 25b, 25c, and 25d. The shapes of wings 25a and 25b define the overall shape of catch tab 23a, and the shapes of wings 25c and 25d define the overall shape of catch tab 23b.

[0038] In an exemplary embodiment, wing slits 26a, 26b, 26c, and 26d are curved. Wing slits 26a, 26b, 26c, and 26d are separated from center panel 21 by narrow, Bézier curve-shaped cuts such that wing shoulders 27a, 27b, 27c, and 27d are separated from center panel 21 only by narrow slits. Herein, the angle between each wing end and its corresponding wing shoulder is about perpendicular. From the point where each wing end meets its corresponding wing shoulder, each wing slit curves toward the center of center panel 21, then each wing slit curves back away from center panel 21 in a semi-circular shape at each corresponding catch tab crease to terminate pointing toward the wing end. Thus, in this exemplary embodiment wing shoulders 27a, 27b, 27c, and 27d exhibit rounded edges due to the curvatures of wing slits 26a, 26b, 26c, and 26d, respectively.

[0039] Alternative embodiments anticipated herein may exhibit alternative catch tab lengths, widths, and creasing patterns, alternative catch tab crease curvatures and lengths, alternative wing slit lengths and widths, alternative wing shoulder angles, curvatures, and shapes, and alternative wing lengths and widths within a range in order to modulate the properties of the catching mechanisms. Herein, the lengths of the catch tab sides of the lid are about equal to the lengths of the catch tabs themselves, and widths of the catch tabs measure about one tenth the lengths of the catch tab sides. Alternative embodiments anticipated herein include lengths of catch tabs less than lengths of the catch tab sides, and widths of catch tabs greater or less than one tenth the length of the catch tab sides in order to modulate properties of the catching mechanisms. Alternative embodiments may also include linear and non-linear catch tab creases and longer or shorter catch tab creases. Alternative embodiments anticipated herein may also exhibit different creasing patterns on the wings to further modulate properties of the catching mechanisms, including linear and nonlinear creases. Herein, narrow slits separate wings from the center panel and delineate wing shoulder shape. Alternative embodiments anticipated herein include greater wing slit widths, including slots made by removing narrow strips of substrate, longer or shorter wing and wing slit lengths, and various wing slit curvatures, including linear and non-linear curves. These alternative embodiments enable modulation of properties of the catching mechanisms that engage the lid with the tray and permit optimization of engagement and disengagement depending on the materials used to fabricate the lid and tray and the intended container use.

[0040] Referring to FIG. 1A, the lid 20 may comprise a pair of flange flaps 29a and 29b foldably attached to center panel 21, wherein each flange flap comprises a pair of flange flap tabs and a pair of flange flap shoulders. Flange flap 29a on flange flap side 18a comprises flange flap tab 31a and flange flap shoulders 33a and 33c. Flange flap 29b on flange flap side 18b comprises flange flap tab 31b and flange flap shoulders 33b and 33d. Alternative embodiments anticipated herein may exhibit alternative flange flap lengths, widths and creasing patterns, alternative flange flap tab lengths, widths and curvatures, and alternative flange flap shoulder curvatures and shapes. Herein, the lengths of the flange flap sides are about equal to the lengths of the flange flaps themselves, and the widths of the flange flaps are about one tenth the length of the flange flap sides. Alternative embodiments anticipated herein include lengths of flange flaps less than lengths of flange flap sides, and widths of flange flaps greater than or less than one tenth the length of the flange flap sides in order to modulate properties of container stacking strength. Alternative embodiments may also include linear or non-linear flange flap creases, which may delineate alternative center panel 21 shapes, including rectilinear (e.g., rectangular or square), rounded rectangular, bulging rectangular, curved rectangular, or any other shape.

[0041] Referring to FIG. 1B, the tray 22 may be assembled by folding and adhering some elements. The tray 22 comprises sides 36a and 36b and ends 44a and 44b. Side panels 37a and 37b, end panels 39a and 39b, and bottom panel 35 delineate the interior 34 of tray 22. In this configuration, the top of tray 22 is open to the surrounding environment and its rectilinear shape is delineated by side panel edges 38a and 38b and end panel edges 40a and 40b. Alternative embodiments anticipated herein may exhibit alternative top shapes, including rectilinear (e.g., rectangular or square), rounded rectangular, bulging rectangular, curved rectangular, or any other shape.

[0042] Each end panel comprises a pair of glue flaps securing each end panel to the adjacent side panels; each corner of tray 22 is strengthened by a glue flap. Glue flaps 41a and 41b are adhered to end panel 39a, securing end panel 39a to adjacent side panels 37a and 37b at end 44a. Similarly, glue flaps 41c and 41d are adhered to end panel 39b, securing end panel 39b to adjacent side panels 37a and 37b at end 44b.

[0043] Each end panel comprises a pair of friction tabs. Friction tabs 42a, 42b, 42c, and 42d protrude above the tray top from glue flaps 41a, 41b, 41c, and 41d, respectively, and terminate with friction tab edges 43a, 43b, 43c, and 43d, respectively. Catch tab gaps are located between the friction tabs of each pair of friction tabs. Thus, catch tab gap 45a is located between friction tabs 42a and 42b, and catch tab gap 45a is further delineated by end panel edge 40a. Similarly, catch tab gap 45b is located between friction tabs 42c and 42d, and catch tab gap 45b is further delineated by end panel edge 4b.

[0044] Alternative embodiments anticipated herein may exhibit alternative tray dimensions, including alternative end, side, and bottom panel lengths and widths, alternative glue flap geometries, alternative friction tab lengths and widths, alternative friction tab edge curvatures, and alternative catch tab gap lengths and widths. Herein, friction tab lengths are about two fifths the length of the end lengths at the tray top and friction tab widths are about one seventh the height of the tray. Alternative embodiments include greater or lesser friction tab lengths and widths. Herein, catch tab gaps are about three tenths the length of the end lengths at the tray top and catch tab gaps are about one seventh the height of the tray. Alternative embodiments include greater or lesser catch tab gap lengths and widths.

[0045] In FIG. 2A, a plurality of lids 20 of FIG. 1A is depicted stacked for storage or shipping, and in FIG. 2B, a plurality of trays 22 of FIG. 1B is depicted stacked for storage or shipping. Trays may be stacked wherein each tray is nested within the interior of the tray immediately below it.

[0046] Referring now to FIGS. 3A, 3B, and 3C, the embodiments of FIG. 1A and FIG. 1B are aligned in an orientation of assembly to form container 55. In FIG. 3A, lid 20 is aligned with tray 22 so that catch tabs 23a and 23b align with catch tab gaps 45a and 45b, respectively. This orientation also aligns flange flaps 29a and 29b with side panels 37a and 37b, respectively. Alignment of catch tabs with catch tab gaps and flange flaps with side panels orients lid 20 with respect to tray 22 to cover interior 34 with center panel 21 and align the catching mechanisms. In alternative embodiments anticipated herein, the catching mechanisms may be engaged when elements are not perfectly aligned and across a wide range of alternative catch tab lengths, widths, and creasing patterns, alternative catch tab crease curvatures and lengths, alternative wing slit lengths and widths, alternative wing shoulder curvatures and shapes, and alternative wing lengths and widths.

[0047] Now referring to end 44a of FIG. 3A as an exemplary depiction of catching mechanisms that secure lid 20 to tray 22, elements are aligned to engage at least one wing against at least one glue flap. Namely, end panel edge 40a is aligned with catch tab crease 24a; glue flap 41a, friction tab 42a, and friction tab edge 43a are aligned with wing slit 26a; and glue flap 41b, friction tab 42b, and friction tab edge 43b are aligned with wing slit 26b. Similar alignments at end 44b ensure that elements are aligned to engage at least one wing against at least one glue flap.

[0048] In FIG. 3B, lid 20 is aligned with and on top of tray 22. Downward pressure is applied to catch tabs 23a and 23b to begin engaging the catching mechanisms at ends 44a and 44b. Lid 20 is partially folded along catch tab creases 24a and 24b so that catch tabs 23a and 23b, respectively, interlock with catch tab gaps 45a and 45b, respectively.

[0049] Now referring to end 44a of FIG. 3B as an exemplary depiction of catching mechanisms that secure lid 20 to tray 22, engagement of at least one wing against at least one glue flap comprises a catching mechanism. For example, when catch tab 23a interlocks with catch tab gap 45a, friction tabs 42a and 42b extend through wing slits 26a and 26b, respectively, separating wings 25a and 25b, respectively, from center panel 21. Friction tabs 42a and 42b secure within wing slits 26a and 26b, respectively. Wing shoulders 27a and 27b are compressed against friction tabs 42a and 42b, respectively, creating the friction integral to the catching mechanisms. Similar engagements at end 44b create the friction integral to the catching mechanisms.

[0050] Referring to the depiction of a catching mechanism of FIGS. 5A, 5B, and 5C, engagement of wing 25b against glue flap 41b comprises a catching mechanism that secures the lid to the tray. In this exemplary embodiment, folding catch tab 23a down and inward toward the interior of the container and compressing wing 25b against glue flap 41b engages a catching mechanism at end 44a. Engagement of both catching mechanisms at end 44a results in friction tabs 42a and 42b protruding above center panel 21 through wing slits 26a and 26b, respectively. Similarly, engagement of both catching mechanisms at end 44b results in friction tabs 42c and 42d protruding above center panel 21 through wing slits 26c and 26d, respectively.

[0051] In FIG. 3C, the catching mechanisms at ends 44a and 44b are fully engaged so lid 20 and tray 22 form container 55 in a stackable position. Lid 20 is fully folded along catch tab creases 24a and 24b so that catch tabs 23a and 23b, respectively, fully interlock with catch tab gaps 45a and 45b, respectively, and are fully compressed against ends 44a and 44b, respectively.

[0052] Now referring to end 44a of FIG. 3C as an exemplary depiction of catching mechanisms, wings 25a and 25b are compressed against glue flaps 41a and 41b, respectively and wing shoulders 27a and 27b are compressed against friction tabs 42a and 42b, respectively. The plane of wing 25a is adjacent to the plane of glue flap 41a and the plane of wing 25b is adjacent to the plane of glue flap 41b. The friction from engagement of the wings against the glue flaps comprises the catching mechanisms at end 44a. Similarly, the plane of wing 25c is adjacent to the plane of glue flap 41c and the plane of wing 25d is adjacent to the plane of glue flap 41d. The friction from engagement of the wings against the glue flaps comprises the catching mechanisms at end 44b.

[0053] As depicted in FIG. 3C, an exemplary embodiment container 55 may exhibit unfolded flange flaps, requiring fewer folding steps to assemble. In this configuration, the flange flap creases 30a and 30b are not folded such that flange flaps 29a and 29b are coplanar with center panel 21. This configuration may be simpler and faster for food preparers, distributers, transporters, and consumers to use.

[0054] Referring now to FIGS. 4A, 4B, and 4C, the embodiments of FIG. 1A and FIG. 1B are aligned in an orientation of assembly and flange flaps are in a folded position to form container 65. In FIG. 4A, lid 20 is aligned with tray 22 as described above so that at least one catching mechanism is aligned. Flange flap creases 30a and 30b are folded so that flange flaps 29a and 29b, respectively, are angled toward the interior 34 of tray 22. In FIG. 4B, lid 20 is aligned with and on top of tray 22 and downward pressure is applied to begin engaging the catching mechanisms at ends 44a and 44b as described above. Flange flaps 29a and 29b are contained within interior 34, and flange flap creases 30a and 30b are adjacent to side panel edges 38a and 38b, respectively. In FIG. 4C, the catching mechanisms at ends 44a and 44b are fully engaged as described above so lid 20 and tray 22 form container 65 in a stackable position. Container stacking strength and engagement of the lid with the tray are both enhanced by flange flaps contained within interior 34 of container 65.

[0055] Referring now to FIGS. 5A, 5B, and 5C, the catching mechanism 51 of one corner of the embodiment of FIG. 4C is depicted in greater detail. Lid 20 is fully folded along catch tab crease 24a and friction tab 42b extends through wing slit 26b, separating wing 25b from center panel 21. Catch tab 23a fully interlocks with catch tab gap 45a and catch tab 23a is fully compressed against end 44a. Wing 25b is compressed against glue flap 41b and wing shoulder 27b is compressed against friction tab 42b such that the plane of wing 25b is adjacent to the plane of glue flap 41b. The friction from engagement of the wing against the glue flap comprises a catching mechanism at end 44a. Engagement of this catching mechanism at end 44a results in friction tab 42b protruding above center panel 21 through wing slit 26b.

[0056] In FIG. 6, a plurality of containers 65 of FIG. 4C are in stackable positions and are stacked for storage or transportation. Each container of this plurality of containers comprises catching mechanisms that secure each lid to each tray and flange flaps that are located inside each container interior. These enclosable, stackable, leak-resistant containers improve food hygiene practices and container stacking strength.

[0057] As used herein, the term “about” when referring to a measurable value such as angle, length, height, and the like, encompasses ±20%, ±10%, ±5%, ±1%, ±0.5%, or ±0.1% of the specified amount. As used herein, the term “substantially” when referring to a measurable value such as angle encompasses ±20%, ±10%, ±5%, ±1%, ±0.5%, or ±0.1% of the specified amount.