Foldable sealing container

Abstract

A foldable sealing container is provided with cuts, creases, adhesion of some elements, and a planar collapsed position to permit rapid reconfiguration to an expanded position. A plurality of catching mechanisms comprises friction tabs partially folded along friction tab creases to engage friction tab edges with side panels and hold the bottom side panels substantially perpendicular relative to the bottom panel. The plurality of catching mechanisms holds bottom side panels in a substantially upright position to form leak-proof seals at the lower corners. Engagement of the friction tab catching mechanisms provides enhanced leak resistance, improving storage and transportation of liquids and liquid-containing foods.

Claims

1. A container comprising: a container bottom, wherein the container bottom comprises a bottom panel, a bottom front panel, a bottom back panel, a pair of bottom side panels, and a plurality of catching mechanisms, wherein engagement of the plurality of catching mechanisms holds the bottom side panels substantially perpendicular relative to the bottom panel.

2. The container of claim 1, wherein each of the plurality of catching mechanisms comprises a friction tab, a friction tab crease, and a friction tab edge.

3. The container of claim 2, wherein an expanded position comprises each of the friction tabs folded along each of the friction tab creases and each of the friction tab edges engaged with the bottom side panels, holding the bottom side panels substantially perpendicular relative to the bottom panel and in a substantially upright position.

4. The container of claim 3, wherein the bottom front panel comprises a pair of friction tabs.

5. The container of claim 4, wherein the bottom back panel comprises a pair of friction tabs.

6. The container of claim 5, wherein the container bottom comprises a pair of front foldable corner panels and a pair of back foldable corner panels.

7. A container comprising: a container bottom; and a lid, wherein the container bottom comprises a bottom panel, a bottom front panel, a bottom back panel, a pair of bottom side panels, and a plurality of catching mechanisms, wherein engagement of the plurality of catching mechanisms holds the bottom side panels substantially perpendicular relative to the bottom panel.

8. The container of claim 7, wherein the lid comprises a lid top panel, a lid front panel, a pair of lid side panels, a pair of lid foldable corner panels, and a pair of lid front panel flaps, and the container bottom comprises a pair of front foldable corner panels and a pair of back foldable corner panels.

9. The container of claim 8, wherein the lid is hingedly attached to the container bottom.

10. The container of claim 9, wherein the lid comprises a lid top panel window.

11. The container of claim 10, wherein each of the plurality of catching mechanisms comprises a friction tab, a friction tab crease, and a friction tab edge.

12. The container of claim 11, wherein an expanded position comprises each of the friction tabs folded along each of the friction tab creases and each of the friction tab edges engaged with the bottom side panels, holding the bottom side panels substantially perpendicular relative to the bottom panel and in a substantially upright position.

13. The container of claim 12, wherein the bottom front panel comprises a pair of friction tabs.

14. The container of claim 13, wherein the bottom back panel comprises a pair of friction tabs.

15. A method comprising: providing a pre-creased blank made of a foldable substrate, the blank being of the type having: a container bottom, wherein the container bottom comprises a bottom panel, a bottom front panel, a bottom back panel, a pair of bottom side panels, and a plurality of catching mechanisms, wherein engagement of the plurality of catching mechanisms holds the bottom side panels substantially perpendicular relative to the bottom panel; and folding the blank into a container in a collapsed position by folding and adhering some elements.

16. The method of claim 15, wherein the blank comprises a lid hingedly attached to the container bottom.

17. The method of claim 16 further comprising reconfiguring the planar collapsed container into an expanded position by unfolding the pair of bottom side panels, unfolding the bottom front panel, and unfolding the bottom back panel to reconfigure them to be substantially perpendicular relative to the bottom panel, and engaging the plurality of catching mechanisms.

18. The method of claim 17, wherein engaging the plurality of catching mechanisms comprises folding along each of the friction tab creases and engaging each of the friction tab edges with bottom side panels to hold the bottom side panels substantially perpendicular relative to the bottom panel and in a substantially upright position.

19. The method of claim 18 further comprising filling the container in its expanded position with food.

20. The method of claim 19 further comprising reconfiguring the filled container to an expanded closed position by lowering the lid using a hinging mechanism.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The unique attributes of the foldable, sealing container are presented in a detailed exemplary embodiment below. Chiefly, the apparatus described in this application is designed to contain liquids and liquid-containing foods and enable rapid reconfiguration from the planar collapsed position to the expanded position. 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. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the apparatus and methods described herein. In these drawings, like reference numerals identify corresponding elements.

[0014] Embodiments of the present invention are better understood from the following detailed description with reference to the following drawings:

[0015] FIG. 1A is a perspective view of an exemplary container in its unfolded planar position.

[0016] FIG. 1B is a perspective view of the container of FIG. 1B in the expanded closed position after it has been fully reconfigured into a three-dimensional container.

[0017] FIG. 2A is a perspective view of the container of FIG. 1A in its planar collapsed position where some elements have been folded and adhered.

[0018] FIG. 2B is a perspective view of the container of FIG. 2A showing partial folding and unfolding along various creases to expand the container from the planar collapsed position.

[0019] FIG. 2C is a perspective view of the container of FIG. 2B showing further partial folding and unfolding along various creases to further expand the container from the collapsed position.

[0020] FIG. 2D is a perspective view of the container of FIG. 2C showing further partial folding and unfolding along various creases to further expand the container from the planar collapsed position.

[0021] FIG. 2E is a perspective view of the container of FIG. 2D after it has been optimally unfolded and folded to expand the container from its planar collapsed position depicted in FIG. 2A to its expanded open position ready for receiving food contents.

[0022] FIG. 3A is an isolation exterior perspective view of a first corner of the container of FIG. 2E showing a first friction tab fully unfolded along a first friction tab crease.

[0023] FIG. 3B is an isolation exterior perspective view of the corner of FIG. 3A of the container of FIG. 2E showing a first catching mechanism wherein the first friction tab is partially folded along the first friction tab crease to engage a side panel with a first friction tab edge.

[0024] FIG. 4A is an isolation exterior perspective view of second corner of the container of FIG. 2E showing a second friction tab fully unfolded along a second friction tab crease.

[0025] FIG. 4B is an isolation exterior perspective view of the second corner of FIG. 4A of the container of FIG. 2E showing a second catching mechanism wherein the second friction tab is partially folded along the second friction tab crease to engage a side panel with a second friction tab edge.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

[0026] As depicted in FIG. 1A, in an exemplary embodiment the container is in an unfolded planar position. The container is formed from a unitary paperboard blank that is cut, creased, and slitted to form elements that facilitate reconfiguration to a planar collapsed position, an expanded open position, and an expanded closed position. Creases join bottom panel 11 to bottom side panels 19a and 19b, and creases join bottom panel 11 to bottom front panel 17 and to bottom back panel 21.

[0027] Front foldable corner panel 14a connects bottom side panel 19a to bottom front panel 17, and front foldable corner panel 14b connects bottom side panel 19b to bottom front panel 17. Creases join front foldable corner panels 14a and 14b to bottom side panels 19a and 19b, respectively, and creases join front foldable corner panels 14a and 14b to bottom front panel 17. Back foldable corner panel 16a connects bottom side panel 19a to bottom back panel 21, and back foldable corner panel 16b connects bottom side panel 19b to bottom back panel 21. Creases join back foldable corner panels 16a and 16b to bottom side panels 19a and 19b, respectively, and creases join back foldable corner panels 16a and 16b to bottom back panel 21. The container bottom comprises bottom panel 11, bottom front panel 17, bottom back panel 21, a pair of bottom side panels, namely bottom side panels 19a and 19b, a pair of front foldable corner panels, namely front foldable corner panels 14a and 14b, and a pair of back foldable corner panels, namely back foldable corner panels 16a and 16b.

[0028] In this exemplary embodiment of the present invention, a lid is also formed from the unitary paperboard blank and connected to the container bottom. Creases join lid top panel 13 to lid side panels 23a and 23b, and creases join lid panel 13 to lid front panel 25 and bottom back panel 21. Lid side panels 23a and 23b comprise lid foldable corner panels 18a and 18b, respectively. Creases join lid front panel 25 to lid front panel flaps 27a and 27b, which are separated from lid foldable corner panels 18a and 18b, respectively. The lid comprises lid top panel 13, lid front panel 25, a pair of lid side panels, namely lid side panels 23a and 23b, a pair of lid foldable corner panels, namely lid foldable corner panels 18a and 18b, and a pair of lid front panel flaps, namely lid front panel flaps 27a and 27b. The lid may also comprise lid top panel window 15.

[0029] Creases may be deep and narrow, enabling foldable connections between elements and resulting in low folding resistance and accurate folding operations. Alternative embodiments of the present invention anticipated herein include creases of varying width and depth, and may include creases, score lines, or combinations thereof, where the score lines may have ratios of penetration between about 0.1 and 0.9. Alternative embodiments may include creases of varying patterning, orientation to the paperboard fiber direction, and combinations thereof to optimize the creasing operation to facilitate folding operations.

[0030] The container bottom comprises a plurality of catching mechanisms. Each of the plurality of catching mechanisms comprises a friction tab, a friction tab crease, and a friction tab edge. In an exemplary embodiment, the bottom front panel comprises a pair of friction tabs. A top edge 22 of bottom front panel 17 includes friction tabs 10a and 10b, where friction tab 10a is adjacent to and separated from front foldable corner panel 14a, and friction tab 10b is adjacent to and separated from front foldable corner panel 14b. Friction tab creases 12a and 12b join friction tab 10a and 10b, respectively, to bottom front panel 17. Friction tab edges 20a and 20b separate friction tabs from bottom front panel 17 and are formed by cuts in the paperboard blank. Friction tab edge 20a separates friction tab 10a from bottom front panel 17 and front foldable corner panel 14a, and friction tab edge 20b separates friction tab 10b from bottom front panel 17 and front foldable corner panel 14b.

[0031] In this embodiment, friction tabs 10a and 10b are triangular. Alternative embodiments of the present invention may exhibit friction tabs of varying shape, including triangles of varying interior angles. Alternative embodiments of the present invention may exhibit friction tab creases and friction tab edges of varying curvature and length, including linear and non-linear curves.

[0032] As depicted in FIG. 1A, an exemplary embodiment includes lid top panel window 15 within lid top panel 13. In this embodiment, lid top panel window 15 is a square with rounded corners and is centered within lid top panel 13. In embodiments of the present invention, a window film is installed on the surface of lid top panel 13 that is proximal to the interior of the three-dimensional container when it is in the expanded position. In alternative embodiments, a window film is installed on the surface of lid top panel 13 that is distal to the interior of the three-dimensional container when it is in the expanded position. The window film may be made of polypropylene, acetate, polyester, or any other material reasonably anticipated by one skilled in the art. The window film may be installed using staples, adhesives, including polyvinyl acetate and hot melt adhesives, or any bonding agent demonstrated effective in the container industry. Alternative embodiments anticipated herein may include one or more top windows and window films of varying sizes, shapes, and materials, including custom designs, circles, triangles, rectangles, stars, diamonds, ovals, semicircles, hearts, hexagons, pentagons, trapezoids, crosses, crescents, parallelograms, octagons, and combinations thereof. Alternative embodiments may include one or more top windows in a symmetrical, asymmetrical, or off-center configuration. Alternative embodiments may include a lid top panel 13 in which no window is present.

[0033] In FIG. 1B, the embodiment of FIG. 1A is depicted in its expanded closed position as a fully assembled, three-dimensional container wherein internal cavity 29 is formed. The expanded closed position is formed when the container in the unfolded planar position is reconfigured to its planar collapsed position by folding and adhering some elements, then the planar collapsed position is reconfigured to its expanded closed position. Internal cavity 29 is defined by bottom panel 11, bottom back panel 21, lid top panel 13, front panels (both bottom front panel 17 and lid front panel 25), and side panels (both bottom side panels 19a and 19b and lid side panels 23a and 23b).

[0034] In FIG. 2A, the embodiment of FIG. 1A has been reconfigured to its planar collapsed position by folding and adhering some elements. The planar collapsed position achieves desirable transportation and storage economies, and may be expanded rapidly, filled with food items, and transferred to consumers either in a food service location or by a delivery service with minimal space requirements and maximal protection of food contents. As depicted in FIG. 2A, bottom back panel 21 connects lid top panel 13 to bottom panel 11, and adhered and folded elements are located between lid top panel 13 and bottom panel 11. Lid top panel 13 is hingedly attached to bottom back panel 21.

[0035] Referring now to FIGS. 2B, 2C, 2D, and 2E, a user may unfold the planar collapsed container by lifting the lid and unfolding certain folded elements to reconfigure the container from the planar collapsed position to the expanded open position.

[0036] As depicted in FIGS. 2C and 2D, lid side panels 23a and 23b and lid front panel 25 unfold from lid top panel 13, and lid foldable corner panels 18a and 18b unfold and connect each lid side panel-lid front panel pair so that top foldable corner panels and adhered lid front panel flaps 27a and 27b form gussets to strengthen each lid corner. Bottom side panels 19a and 19b, bottom back panel 21, and bottom front panel 17 unfold from bottom panel 11. Front foldable corner panels 14a and 14b unfold and connect each bottom side panel-bottom front panel pair so that front foldable corner panels form gussets to strengthen each bottom front corner. Back foldable corner panels 16a and 16b unfold and connect each bottom side panel-bottom back panel pair so that back foldable corner panels form gussets to strengthen each bottom back corner.

[0037] As depicted in FIG. 2E, the container is in the expanded open position wherein each of the friction tabs is folded along each of the friction tab creases and each of the friction tab edges is engaged with the bottom side panels, holding the bottom side panels substantially perpendicular relative to the bottom panel and in a substantially upright position. Internal cavity 29 is formed and may receive one or more objects, including liquids or liquid-containing foods, for storage, transportation, or a combination thereof. Friction tabs 10a and 10b are partially folded along friction tab creases 12a and 12b, respectively, inward toward internal cavity 29. Catching mechanisms at bottom front upper corners 31a and 31b comprise engagement of friction tab edges 20a and 20b, respectively, with bottom side panels 19a and 19b, respectively. The catching mechanisms hold bottom side panels 19a and 19b substantially perpendicular relative to bottom panel 11 and in a substantially upright position. In this position, bottom front lower corners 33a and 33b and bottom back lower corners 35a and 35b are sealed, preventing leakage of liquid contents from internal cavity 29.

[0038] A user may reconfigure the container from the expanded open position depicted in FIG. 2E to the expanded closed position depicted in FIG. 1B by lowering the lid using a hinging mechanism along the crease connecting lid top panel 13 to bottom back panel 21. In this exemplary embodiment, when the lid is lowered fully and the container is in the expanded closed position, the lid front panel 25 is adjacent to bottom front panel 17, the lid side panel 23a is adjacent to bottom side panel 19a, and the lid side panel 23b is adjacent to bottom side panel 19b. Bottom front panel 17, bottom side panel 19a, and bottom side panel 19b are proximal to internal cavity 29, and lid front panel 25, lid side panel 23a, and lid side panel 23b are distal to internal cavity 29.

[0039] In the exemplary embodiment depicted in FIG. 1B, lid top panel 13 and bottom panel 11 are square shaped and bottom front panel 17, bottom back panel 21, lid front panel 25, bottom side panels 19a and 19b, and lid side panels 23a and 23b are rectangular. In alternative embodiments anticipated herein, all panels may be varying sizes and shapes, including square and rectangular, and the container may be varying sizes and shapes.

[0040] In an alternative embodiment, the container may function as a leak-proof tray without an attached lid. In this alternative embodiment, the lid is not attached, and lid top panel 13, lid side panels 23a and 23b, lid front panel 25, lid foldable corner panels 18a and 18b, and lid front panel flaps 27a and 27b are omitted. In this alternative embodiment, separate, unattached lids of varying sizes and shapes may be paired with the leak-proof tray for enhanced portability and stacking.

[0041] In alternative embodiments anticipated herein, bottom back panel 21 may also include catching mechanisms, including a pair of friction tabs with friction tab creases and friction tab edges to further engage bottom side panels 19a and 19b and hold them in a substantially upright position. These back panel friction tabs may further hold side panels 19a and 19b substantially perpendicular relative to bottom panel 11 and in a substantially upright position so that bottom front lower corners 33a and 33b and bottom back lower corners 35a and 35b are sealed, preventing leakage of liquid contents from internal cavity 29.

[0042] Referring now to FIGS. 3A and 3B, a first corner of an exemplary embodiment of the present invention is depicted. In FIG. 3A, friction tab 10a is not folded along friction tab crease 12a and top edge 22 maintains an unbroken, linear configuration at the first corner. In this configuration, the catching mechanism at bottom front upper corner 31a is not engaged, bottom side panel 19a falls slightly inward toward internal cavity 29, and bottom side panel 19a is not substantially perpendicular relative to bottom panel 11. In this configuration, bottom front lower corner 33a and bottom back lower corner 35a are not fully sealed.

[0043] In FIG. 3B, friction tab 10a is partially folded along friction tab crease 12a, engaging friction tab edge 20a with bottom side panel 19a at bottom front upper corner 31a, and bottom side panel 19a is held substantially perpendicular relative to bottom panel 11 and in a substantially upright position. In this configuration, bottom front lower corner 33a and bottom back lower corner 35a are sealed, preventing leakage of liquid contents from the internal cavity.

[0044] Referring now to FIGS. 4A and 4B, a second corner of an exemplary embodiment of the present invention is depicted. In FIG. 4A, friction tab 10b is not folded along friction tab crease 12b and top edge 22 maintains an unbroken, linear configuration at the second corner. In this configuration, the catching mechanism at bottom front upper corner 31b is not engaged, bottom side panel 19b falls slightly inward toward internal cavity 29, and bottom side panel 19b is not substantially perpendicular relative to bottom panel 11. In this configuration, bottom front lower corner 33b and bottom back lower corner 35b are not fully sealed.

[0045] In FIG. 4B, friction tab 10b is partially folded along friction tab crease 12b, engaging friction tab edge 20b with the bottom side panel 19b at bottom front upper corner 31b, and bottom side panel 19b is held substantially perpendicular relative to bottom panel 11 and in a substantially upright position. In this configuration, bottom front lower corner 33b and bottom back lower corner 35b are sealed, preventing leakage of liquid contents from the internal cavity.

[0046] In the configurations depicted in FIGS. 3B and 4B, bottom front lower corners 33a and 33b and bottom back lower corners 35a and 35b are sealed, enabling a user to store or transport liquids or liquid-containing foods without leakage from the internal cavity. These seals are formed when a plurality of catching mechanisms, namely the catching mechanisms at bottom front upper corners 31a and 31b, are engaged. Engagement of these catching mechanisms comprises a user partially folding friction tabs 10a and 10b, respectively, along friction tab creases 12a and 12b, respectively, so that friction tab edges 20a and 20b, respectively, engage bottom side panels 19a and 19b, respectively.

[0047] In alternative embodiments of the present invention, a method may include providing a pre-creased blank made of a foldable substrate as depicted in FIG. 1A, folding the blank and adhering elements into a container in a planar collapsed position as depicted in FIG. 2A, and compressing and drying the planar collapsed container. The blank may be of the type having a container bottom, wherein the container bottom comprises a bottom panel, a bottom front panel, a bottom back panel, a pair of bottom side panels, and a plurality of catching mechanisms. The container bottom may comprise front foldable corner panels and back foldable corner panels. The blank may be of the type having a lid hingedly attached to the container bottom. In this embodiment, engagement of the plurality of catching mechanisms holds the bottom side panels substantially perpendicular relative to the bottom panel.

[0048] The method may include reconfiguring the planar collapsed container into an expanded open position as depicted in FIGS. 2B, 2C, 2D, and 2E, by unfolding the pair of bottom side panels, unfolding the bottom front panel, and unfolding the bottom back panel so they are substantially perpendicular relative to the bottom panel, engaging the plurality of catching mechanisms, and raising the lid using a hinging mechanism. In this embodiment, engaging the plurality of catching mechanisms comprises folding along each of the friction tab creases and engaging each of the friction tab edges with bottom side panels to hold the bottom side panels substantially perpendicular relative to the bottom panel and in a substantially upright position. The method may include filling the container in its expanded open position with food. The method may also include reconfiguring the filled container from the expanded open position depicted in FIG. 2E to the expanded closed position depicted in FIG. 1B for storage or transportation by lowering the lid using a hinging mechanism.

[0049] In general, a method of using the apparatus may include partially folding one or more friction tabs to form catching mechanisms, sealing the internal cavity to prevent fluid leakage.

[0050] It will be appreciated that the apparatus and methods described above, and the various representative embodiments which have been described in detail herein, are set forth by way of example and not 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 present invention. The order or presentation of method steps above is not intended to require this order of performing the recited steps.