Abstract
There is provided an ovenable, fold-flat baking container assemblage from a flat unassembled form into an assembled form, the container comprising a flat base (1) and at least one side wall member (20). The base has a main base portion (2) and a number of base flaps (3-6) which are hingedly connected to the main base portion. The or each side wall member (20) has a main wall portion and which has along its bottom edge one or more tabs (21), each of said tabs being capable of folding outwards relative to the main wall portion. When the main wall portion has its bottom edge in contact with the main base portion with the tabs folded outwards, the base flaps are folded into an active position and the tabs (21) are sandwiched between the base flaps (3-6) and the main base portion (2). Retaining means are provided to secure the one or more base flaps in their active position, such that the main base portion and the one or more main wall portions form an open-topped enclosed cavity. There is also provided an ovenable, fold-flat baking container assemblage from a flat unassembled form into an assembled form, the container comprising a flat base (65) and at least three side wall portions (66) linked by gusset portions (69).
Claims
1. An ovenable fold-flat baking container assemblable from a flat unassembled form into an assembled form, the container comprising a flat base and at least one side wall member, wherein: the base comprises a main base portion and one or more base flaps which are hingedly connected to the main base portion, the or each base flap being foldable about its hinge connection between a first inactive position, in the unassembled form, in which the flap is substantially co-planar with the main base portion and a second active position, in the assembled form, in which it overlies the main base portion; the or each side wall member has a main wall portion and which has along its bottom edge one or more tabs, each of said tabs being capable of folding outwards relative to the main wall portion; such that, when the main wall portion of the side wall has its bottom edge in contact with the main base portion with the tabs folded outwards, and one or more base flaps are folded into an active position, the tabs are sandwiched between the base flaps and the main base portion with the main wall portion upstanding from the main base portion; retaining means being provided to secure the one or more base flaps in their active position, such that the main base portion and the one or more main wall portions form an open-topped enclosed cavity.
2. The container as claimed in claim 1, wherein the hinge connection for the or each base flap is defined by a crease or other line of weakness.
3. The container as claimed in claim 1, wherein the hinge connection for the or each base flap is defined by one or a combination of: i) a crease, ii) a pair of spaced creases or iii) an alternative type of line or lines of weakness.
4. The container as claimed in claim 3, wherein the pair of spaced creases or other lines of weakness is reduced to a single crease or other line of weakness at one or more points along its length.
5. The container as claimed in claim 1, wherein the inwardly facing edge of the base flap or of each base flap is shaped such that, when the main wall portion of the side wall has its bottom edge in contact with the main base portion with the tabs folded outwards, the one or more base flaps are folded into an active position, and the tabs are sandwiched between the base flaps and the main base portion, the inwardly facing edge of the base flap or flaps forms a substantially continuous abutment with the side wall.
6. The container as claimed in claim 1, wherein the retaining means comprises at least one hinged push through tab in the base which, when in the engaged position, extends from the base through a corresponding aligned aperture in the overlying base flap, the tab preferably having a bulbous shoulder or mushroom shape adjacent to the hinge.
7. The container as claimed in claim 1, wherein the base and the side walls are made from corrugated cardboard.
8. The container as claimed in claim 7, wherein the corrugated cardboard comprises an outer layer, a middle layer and an inner layer, said inner layer comprising greaseproof or vegetable parchment paper.
9. An ovenable, fold-flat baking container assemblable from a flat unassembled form into an assembled form, the container comprising a flat base and at least three side wall portions wherein: each side wall portion is hingedly attached to the base along a straight base fold line such that the side wall portion can be folded inwardly so as to be generally perpendicular to the base with the base fold lines forming a continuous folded edge and the side wall portions forming with the base an open-topped cavity when in said assembled form; an outwardly foldable gusset section being provided between the ends of adjacent side wall portions, each gusset section comprising a pair of gusset portions each hingedly connected to one of the adjacent side walls, the hinge connection of each gusset portion with its associated side wall portion being an outward fold extending perpendicular to the hinge connection of the associated side wall portion to the base; and retention means being provided to retain together the gusset portions of each gusset section in contact with each other in a position external to said cavity such that the container retains its assembled form with the side walls upstanding from the base.
10. The container as claimed in claim 9, wherein each pair of gusset portions is hingedly connected to each other with an inward fold.
11. The container as claimed in claim 9, wherein the base and the side walls are made from corrugated cardboard.
12. The container as claimed in claim 11, wherein the corrugated cardboard comprises an outer layer, a middle layer and an inner layer, said inner layer comprising greaseproof or vegetable parchment paper.
13. The container as claimed in claim 9, wherein there are four side wall portions.
14. The container as claimed in claim 9, wherein the retention means comprises one or a combination of: i) foldable flaps and ii) push through tabs.
15. The container as claimed in claim 9, wherein each side wall portion has an outwardly foldable return or flange which, in assembled form, extends in a direction away from the cavity.
Description
[0055] The invention will now be described solely by way of example and with reference to the accompanying drawings (FIGS. 1 to 18 illustrate the first embodiment of this invention; while FIGS. 19 to 27 relate to the second embodiment) in which:—
[0056] FIG. 1 is a plan view of the base (unfolded) of a container for use in baking a round cake.
[0057] FIG. 2 is a side view of two side walls (unfolded) of a container for use in baking a round cake.
[0058] FIG. 3 is a perspective view of the base of a container for use in baking a round cake.
[0059] FIG. 4 is a perspective view of two side walls (unfolded) of a container for use in baking a round cake.
[0060] FIG. 5 is a perspective view of two side walls (folded) of a container for use in baking a round cake.
[0061] FIG. 6 is a perspective view of a container for use in baking a round cake (partially assembled with part cut away).
[0062] FIG. 7 is a perspective view of a container for use in baking a round cake (fully assembled in cross-section).
[0063] FIG. 8A is a perspective view of a container for use in baking a round cake (fully assembled); FIGS. 8B and 8C are cross-sections of part of that same container (fully assembled).
[0064] FIG. 9 is a perspective view of a container for use in baking a round cake with a freestanding core (partially assembled with part cut away).
[0065] FIG. 10 is a perspective view of a container for use in baking a round cake with a freestanding core (partially assembled with part cut away).
[0066] FIG. 11 is a perspective view of a container for use in baking a round cake with a freestanding core (fully assembled in cross-section).
[0067] FIG. 12 is a plan view of the base (unfolded) of a container for use in baking a cake in the shape of a heart.
[0068] FIG. 13 is a perspective view of the base of a container for use in baking a cake in the shape of a heart.
[0069] FIG. 14 is a perspective view of a container for use in baking a cake in the shape of a heart (partially assembled with part cut away).
[0070] FIG. 15 is a plan view of the base (unfolded) of a container for use in baking a cake in the shape of a Christmas tree.
[0071] FIG. 16 is a perspective view of the base of a container for use in baking a cake in the shape of a Christmas tree.
[0072] FIG. 17 is a perspective view of a container for use in baking a cake in the shape of a Christmas tree (partially assembled with part cut away).
[0073] FIG. 18 is a plan view of the base (unfolded) of another container for use in baking a round cake.
[0074] FIG. 19 is a plan view of the base and side walls (unfolded) of a container for use in baking a square cake.
[0075] FIG. 20 is a perspective view of the base and side walls (unfolded) of a container for use in baking a square cake.
[0076] FIGS. 21A, B and C are perspective views of the corner assembly (viewed from inside the container) of a container for use in baking a square cake; showing two of the side walls flat (A), half raised (B) and ¾ raised (C).
[0077] FIG. 22 is a perspective view of a container (partially assembled, with the sides fully raised) for use in baking a square cake.
[0078] FIG. 23 is a perspective view of a container (partially assembled, with the sides fully raised but the corner tabs unfolded) for use in baking a square cake.
[0079] FIG. 24 is a perspective view of a container (fully assembled) for use in baking a square cake.
[0080] FIG. 25 is a plan view of the base and side walls (unfolded) of another container for use in baking a square cake.
[0081] FIGS. 26A, B and C are perspective views of the corner assembly (viewed from inside the container) of the container of FIG. 25 for use in baking a square cake; showing two of the side walls flat (A), half raised (B) and ¾ raised (C).
[0082] FIG. 27 is a perspective view of the container of FIG. 25 (fully assembled) for use in baking a square cake.
[0083] FIGS. 28A (sectional elevation), B (plan view) and C (sectional elevation) show a hinged push through tab suitable for use in the first embodiment and in the second embodiment of the present invention.
[0084] Referring to FIG. 1, the base 1 for use in baking a round cake comprises a main base portion 2 and four base flaps 3, 4, 5 and 6, and which are shown in the unfolded state. Each of the said base flaps is connected to the main base portion by means of a hinge or fold 7, 8, 9 and 10 respectively, and each hinge or fold is defined by a pair of creases, 11 and 12, 13 and 14, 15 and 16, and 17 and 18 respectively. The creases are parallel, set 4 mm apart in this example; although this spacing may be different depending upon various factors, such as the thickness of the corrugated cardboard from which the base is made. Each pair is reduced at two sections along their length to a single crease 11a, 13a, 15a and 17a. Push through tabs 19 are provided on the main base portion and on each of the base flaps.
[0085] In FIG. 2, each of the two side wall members 20 has a number of tabs 21 along its bottom edge. The side wall members have a flange 22 at each end. There is a push through tab 23 provided on each of the flanges to secure the flanges together when they overlie each other.
[0086] Turning to FIG. 3, the arrows indicate the direction in which the four base flaps 3, 4, 5 and 6 are folded about the hinges 7, 8, 9 and 10, respectively, when the base of the baking container is being assembled. The broken lines indicate the position of the base flaps once they have been folded so as to overlie the main base portion 2.
[0087] In FIG. 4, the two side wall members 20, the tabs 21 along their bottom edges, the flanges 22 and the push through tabs 23 are shown in the unfolded state.
[0088] FIG. 5 shows each of the two side wall members 20 folded into a semi-circular shape such that, when joined together, they would form the side walls of a container for use in baking a round cake. The tabs 21 along the bottom edges of the side wall members are shown folded outwards; and the flanges 22 at the ends of each side wall member, each with a push through tab 23, are also folded outwards.
[0089] In FIG. 6, the baking container for a round cake is shown partially assembled. The base flaps 3 and 4 have been folded inwards so as to overlie the main base portion 2, the side wall member 20 at the rear has been secured in position with the tabs along its bottom edge (not visible) sandwiched between the said base flaps 3 and 4 and the main base portion 2. The side wall member 20 at the front, shown with part cut away, has the tabs 21 along its bottom edge folded outwards. Once the base flaps 5 and 6 are folded inwards (in the direction indicated by the arrows), so as to overlie the main base portion 2, the tabs 21 along the bottom edge of that side wall member will be secured in position by becoming sandwiched between the said base flaps 5 and 6 and the main base portion 2.
[0090] FIG. 7 is a cross-section of a fully assembled baking container for a round cake. The side wall member 20 is secured in position with the tabs 21 along its bottom edge sandwiched between the base flaps 3, 4 and 5, and the underlying main base portion 2; the inside edges of the base flaps abutting and supporting the side walls; with the said base flaps being secured in that position by means of the push through tabs 19 (shown in the locked/engaged state); and the flanges 22 of the two side wall members are held together by the push through tab 23 (shown in the locked/engaged state).
[0091] FIG. 8A shows a fully assembled baking container for a round cake. The two side wall members 20 are secured in position with the tabs along its bottom edge (not visible) sandwiched between the base flaps 3, 4, 5 and 6, and the underlying main base portion, with the said base flaps being secured in that position by means of the push through tabs 19 (shown in the locked/engaged state); and the flanges 22 of the two side wall members are held together by the push through tab 23 (shown in the locked/engaged state). FIGS. 8B and 8C are cross-sections of part of that fully assembled baking container and show one of the base flaps, at a place where its hinge is defined by a pair of creases (FIG. 8B) and at a place where its hinge is reduced to a single crease (FIG. 8C), secured in position by means of a push through tab.
[0092] FIG. 9 shows a partially assembled baking container for a round cake with a hole at its centre. In addition to being an attractive shape in its own right, such a cake could be seen as resembling the numeral zero. It will be apparent that the container is constructed in the same manner as described for the preceding figures, except that it includes a freestanding core 24 (shown with part cut away) which defines the hole at the centre of the cake. The core 24 comprises a side wall 25 which has tabs 26 along its bottom edge that fold outwards relative to the said side wall. It is held in position by means of an upper core insert 27 that is placed on top of the outwardly folded tabs 26 and secured to the main base portion 2 by push through tabs 28.
[0093] FIG. 10 is a further view of the partially assembled baking container of FIG. 9. The side wall 25 of the freestanding core 24 (shown with part cut away) has a flange 29 at either end, which is folded outwards (i.e. such that it extends into the hole at the centre of the cake) so that the ends of the side wall can be secured together by means of a push through tab 30.
[0094] FIG. 11 is a cross-section of a fully assembled baking container for a round cake with a hole at its centre. The side wall member 20 is secured in position with the tabs 21 along its bottom edge sandwiched between the base flaps 3, 4 and 5, and the underlying main base portion 2, with the said base flaps being secured in that position by means of the push through tabs 19 (shown in the locked/engaged state); and the flanges 22 of the two side wall members are held together by the push through tab 23 (shown in the locked/engaged state). The side wall 25 of the freestanding core is held in position by means of an upper core insert 27 placed on top of the outwardly folded tabs 26 and secured to the main base portion 2 by push through tabs 28 (shown in the locked/engaged state).
[0095] Referring to FIG. 12, the base 31 for use in baking a cake in the shape of a heart comprises a main base portion 32 and four base flaps 33, 34, 35 and 36, and which are shown in the unfolded state. Each of the said base flaps is connected to the main base portion by means of a hinge or fold 37, 38, 39 and 40 respectively, and each hinge or fold is defined by a pair of creases, 41 and 42, 43 and 44, 45 and 46, and 47 and 48 respectively. The creases are parallel, and each pair is reduced at two sections along their length to a single crease 41a, 43a, 45a and 47a. Push through tabs 49 are provided on the main base portion and on each of the base flaps.
[0096] Turning to FIG. 13, the arrows indicate the direction in which the four base flaps 33, 34, 35 and 36 are folded about the hinges 37, 38, 39 and 40, respectively, when the base of the baking container is being assembled. The broken lines indicate the position of the base flaps once they have been folded so as to overlie the main base portion 32.
[0097] In FIG. 14, the baking container for a cake in the shape of a heart is shown partially assembled. The base flaps 33 and 34 have been folded inwards so as to overlie the main base portion 32, the side wall member 50 at the rear has been secured in position with the tabs along its bottom edge (not visible) sandwiched between the said base flaps 33 and 34 and the main base portion 32. The side wall member 50 at the front, shown with part cut away, has the tabs 51 along its bottom edge folded outwards. Once the base flaps 35 and 36 are folded inwards (in the direction indicated by the arrows), so as to overlie the main base portion 32, the tabs 51 along the bottom edge of that side wall member will be secured in position by becoming sandwiched between the said base flaps 35 and 36 and the main base portion 32.
[0098] Referring to FIG. 15, the base 52 for use in baking a cake in the shape of a Christmas tree comprises a main base portion 53 and two base flaps 54 and 55, and which are shown in the unfolded state. Each of the said base flaps is connected to the main base portion by means of a hinge or fold 56 and 57 respectively, and each hinge or fold is defined by a pair of creases, 58 and 59, and 60 and 61 respectively. The creases are parallel, and each pair is reduced at two sections along their length to a single crease 58a and 60a. Push through tabs 62 are provided on the main base portion and on each of the base flaps.
[0099] Turning to FIG. 16, the arrows indicate the direction in which the two base flaps 54 and 55 are folded about the hinges 56 and 57, respectively, when the base of the baking container is being assembled. The broken lines indicate the position of the base flaps once they have been folded so as to overlie the main base portion 53.
[0100] In FIG. 17, the baking container for a cake in the shape of a Christmas tree is shown partially assembled. The base flap 54 has been folded inwards so as to overlie the main base portion 53, the side wall member 63 on the left has been secured in position with the tabs along its bottom edge (not visible) sandwiched between the said base flap 54 and the main base portion 53. The side wall member 63 on the right, shown with part cut away, has the tabs 64 along its bottom edge folded outwards. Once the base flap 55 is folded inwards (in the direction indicated by the arrow), so as to overlie the main base portion 53, the tabs 64 along the bottom edge of that side wall member will be secured in position by becoming sandwiched between the said base flap 55 and the main base portion 53.
[0101] FIG. 18 shows the base of another container according to the first embodiment of this invention for use in baking a round cake. The base 1 comprises a main base portion 2 and four base flaps 3, 4, 5 and 6, and which are shown in the unfolded state. Each of the said base flaps is connected to the main base portion by means of a hinge or fold 7, 8, 9 and 10 respectively, and each hinge or fold is defined by a pair of creases, 11 and 12, 13 and 14, 15 and 16, and 17 and 18 respectively. The creases 11 and 12 are parallel, set 4 mm apart, such that the resulting hinge 7 is of a constant thickness; the creases 13 and 14 are also parallel but are set a greater distance apart (6 mm), such that the resulting hinge 8 is thicker than the aforementioned hinge 7. The creases 15 and 16 are not parallel, such that the resulting hinge 9 varies in thickness along its length from 6 mm to 4 mm and then back to 6 mm (i.e. it is thinner in the middle than at either end); the creases 17 and 18 are also not parallel such that the resulting hinge 10 varies in thickness along its length from 8 mm to 3 mm and then back to 8 mm (i.e. it is thinner in the middle than at either end). Push through tabs 19 are provided on the main base portion and on each of the base. When this base is used together with the side walls shown in FIG. 2, the container can be assembled in a similar manner to that shown in FIGS. 5 to 8.
[0102] FIG. 19 shows in the unfolded state a container for use in baking a square cake. It comprises a base 65 and four side wall portions 66; the said side wall portions being hingedly attached to the said base along straight fold lines 67. A return or flange 68, which can be folded outwards relative to the said side wall, runs along the top edge of each of the side walls. An outwardly foldable gusset comprising a pair of gusset portions 69 is provided between the ends of the adjacent side wall portions 66. Retention means comprising a long tab 70, a short tab 71 and two corner tabs 72 are provided for securing the said gusset portions in contact with each other when the container is in the assembled state.
[0103] In FIG. 20, the container for use in baking a square cake is again shown in the unfolded state.
[0104] FIG. 21 shows three stages in the assembly of the corner of the container for baking a square cake. In FIG. 20A, the base 65, two side wall portions 66, gusset portions 69 and long tab 70, short tab 71 and two corner tabs 72 are shown in the unfolded state. In FIG. 20B, the side wall portions 66 are half raised and, in consequence, the gusset portions 69 between them are partially folded outwards. In FIG. 20C, the side wall portions are ¾ raised and, in consequence, the gusset portions 69 between them are folded outwards to a greater extent (than in FIG. 20B), the returns or flanges 68 are folded outwards and the long tab 70 overlies the short tab 71.
[0105] In FIG. 22, the four side wall portions 66 are fully raised into a vertical position, the returns or flanges 68 are folded outwards so as to be horizontal relative to the side walls, the gusset portions 69 are fully folded outwards and, at each corner, the long tab 70 overlies the short tab 71.
[0106] Turning to FIG. 23, it will be seen that, at each corner, the ends of the long tab 70 and of the short tab 71 have been folded downwards so as to lie against the side wall portions. The corner tabs 72 are still unfolded.
[0107] FIG. 24 shows the fully assembled container for use in baking a square cake. The corner tabs 72 are folded outwards so as to secure/lock the underlying long tab 70 and short tab 71 in position at each of the four corners.
[0108] FIG. 25 shows in the unfolded state another container according to the second embodiment of this invention for use in baking a square cake. It comprises a base 80 and four side wall portions 81; the said side wall portions being hingedly attached to the said base along straight fold lines 82. A return or flange 83, which can be folded outwards relative to the said side wall, runs along the top edge of each of the side walls. An outwardly foldable gusset comprising a pair of gusset portions 84 is provided between the ends of the adjacent side wall portions 81. Retention means comprising push through tabs 85 are provided for securing the said gusset portions in contact with each other when the container is in the assembled state.
[0109] FIG. 26 shows three stages in the assembly of the corner of the container for baking a square cake. In FIG. 26A, the base 80, two side wall portions 81, gusset portions 84 and push through tabs 85 are shown in the unfolded state. In FIG. 26B, the side wall portions 81 are half raised and, in consequence, the gusset portions 84 between them are partially folded outwards. In FIG. 26C, the side wall portions are ¾ raised and, in consequence, the gusset portions 84 between them are folded outwards to a greater extent (than in FIG. 26B), and the returns or flanges 83 are folded outwards.
[0110] FIG. 27 shows the fully assembled container for use in baking a square cake. The push through tabs 85 are engaged so as to secure/lock the gusset portions and the four corners in position.
[0111] FIG. 28 shows three views of a hinged push through tab, suitable for use in both the first and the second embodiments of the present invention, and which is formed from two layers of corrugated cardboard (or other suitable material from which the baking containers are made) that overlie one another. The function of the tab 73 in the upper layer 74 is essentially to provide a hole or aperture 75 through which the tab 76 in the lower layer 77 is pushed. The tab 76 has a bulbous shoulder or mushroom shape 78 adjacent to the hinge (fold line) 79 and which is wider than the corresponding part of the aligned hole or aperture 75 in the upper layer. In FIGS. 28A and 28C (both sectional elevations), the push through tab is in the engaged (locked) position. FIG. 28B (a plan view) shows the tab 73 in the upper layer with the outline of the tab 76 in the lower layer shown in a broken line (since it is hidden from view). The act of folding the tab 76 in the lower layer from the horizontal into the vertical (upright) position causes the extra width of the shoulder 78 to project over the edge of the hole or aperture 75 in the upper layer and so lock the two layers together. The arced edge of the tab 76 at the point of the shoulder is smaller than the corresponding arc on the tab 73 in the upper layer. This avoids unnecessary interference/resistance with the edges of the tab holes when rotating the tabs into the vertical position apart from in the area of the shoulder 78 of the tab 76 that exceeds in width the edge of the hole or aperture 75 in the upper layer 74.
[0112] As will be apparent from the above, it is the lower tab 76 that does the work of locking the two layers or sheets of corrugated cardboard together. In this regard, provided that there is a suitably sized aperture in the upper layer it would be possible for the tab in the upper layer to be omitted or removed.
