Patent Application
20120024859
The described embodiments relate generally to a container and more particularly to a portable and nestable container that is environmentally friendly.
Containers are used widely throughout many applications including the storage and transport of items. Containers are constructed in a wide array of sizes and shapes to contain a variety of items. Containers are constructed from various materials including plastics that provide the necessary support to contain an item, while still being economically feasible. However, as environmental concerns have increased over the years, the demand for a container that is constructed from an environmentally friendly material has risen. Furthermore, due to such environmental concerns, and in order to reduce the amount of consumption of materials, what is needed is a container that is adaptable for use in a wide variety of applications.
Therefore, what is needed is a container that is structurally stable enough for containing an item in a variety of applications and is also environmentally friendly.
A molded fiber container suitable for containing a food item includes a base having a plurality of ridges integrated with an interior surface of the base. When the food item is placed on at least some of the plurality of ridges, a gap is formed between the food item and the interior surface of the base, the gap assisting in thermally isolating the food item and allowing moisture expelled from the food item to be transported away from the food item. The container also includes a lid having a plurality of openings arranged in accordance with at least some of the plurality of ridges. The lid also including a moisture channeling feature integrally formed in the lid, the moisture channeling feature cooperating with at least some of the plurality of openings and the gap to provide a path by which at least some of the moisture expelled from the food item is transported out of the container and into an external environment.
A container includes at least a base portion. The base portion includes a a bottom surface that includes concentric ridges that provide structural support for the container and elevates a food item from the bottom surface forming a gap. The base portion also includes a sidewall integrally formed with the bottom surface, the sidewall including an integrated sidewall feature arranged to provide structural support for the container. The container includes a lid portion. The lid portion including a top surface that includes first integrated top feature co-operating with the integrated bottom feature and the integrated support feature to provide structural support for the container. The lid further includes a second integrated top feature that includes apertures that allow an outflow of air from within the container to the external environment. A hinge assembly integrally formed with a first section of the sidewall for pivotally connecting the base portion to the lid portion includes a first hinge portion integrally formed with the base portion, a second hinge portion integrally formed with the lid portion, and a flexure between first and second hinge portion that allows pivoting of the second hinge portion about the first hinge portion. A locking mechanism that includes a first portion integrally formed with a second section of the sidewall different from the first section, and a second portion integrally formed with a section of the lid portion. The first and second portions of the locking mechanism are co-operatively shaped so that they interlock wherein in a locking configuration, the locking mechanism secures the lid and the base portion.
A method of forming a molded fiber container suitable for containing a food item can be performed by providing a fiber slurry, providing a mold having a shape in the form of the container, conformally applying the fiber slurry to the mold, wherein the conformally applied fiber slurry takes on essentially the shape of the container, curing the fiber slurry, and obtaining the molded fiber container by separating the mold and the cured fiber slurry. In the described embodiment, the molded fiber container includes a base portion, the base portion a bottom surface, the bottom surface including concentric ridges, the concentric ridges providing structural support and elevating an item placed on at least some of the ridges a sidewall integrally formed with the bottom surface, the sidewall including an integrated sidewall feature, the integrated sidewall feature arranged to provide structural support for the container; a lid a plurality of openings arranged in accordance with at least some of the plurality of ridges, and a moisture channeling feature integrally formed in the lid, the moisture channeling feature cooperating with at least some of the plurality of openings and the gap to provide a path by which at least some of the moisture expelled from the food item is transported out of the container and into an external environment.
The invention and the advantages thereof may best be understood by reference to the following description taken in conjunction with the accompanying drawings.
a-9c shows a close up step by step view of the locking mechanism and the associated locking method
In the following description, numerous specific details are set forth to provide a thorough understanding of the concepts underlying the described embodiments. It will be apparent, however, to one skilled in the art that the described embodiments may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the underlying concepts.
The embodiments herein describe a cost effective, environmentally friendly container. The container can have an aesthetically pleasing appearance and can also be used to store and transport an item. The shape and size of the container can be widely varied to contain any type of item. For example, the container can be used to contain computer hardware components, office supplies or food items of varying shapes and sizes. The container can also be used to display an item. The container can also be used to contain an item during any preparation or process steps associated with such item. Alternatively, the container can be used to contain and subsequently protect an item incorporated with other items in a bundled shipping configuration. The container can include indicia to convey a message or further add to the aesthetic appeal of the container.
The container can be formed of many types of material. The container can be formed of environmentally friendly materials such as bamboo, Begasse, rice hull, PLA, etc. In a particular embodiment, however, the container can be formed from a single, continuous piece of molded fiber. The use of molded fiber has many advantages. One advantage to using molded fiber is that since molded fiber is derived from recycled paper, molded fiber is considered an environmentally sustainable material. Another advantage to using molded fiber is that molded fiber can be easily formed into any desired shape. Moreover, molded fiber also resists moisture absorption. In this way, any moisture and liquids that are emitted from the item from within the container or present in the area surrounding the container are not generally absorbed into the molded fiber thereby helping the molded fiber container to retain its structural integrity.
The molded fiber container can be formed through any suitable technique including but not limited to the transfer molding process. In the transfer molding process, a fine mesh mold is positioned within a vacuum chamber and fiber slurry containing fiber pulp is then sprayed onto the mold using airflow. The fiber pulp on the mold is then dried ultimately taking on the shape of the mold. In addition to transfer molding the molded fiber container can be created using other molded pulp manufacturing processes. For example, a thick wall molding process can be used to create thicker more rugged containers whereas a thermoformed fiber process can create molded fiber products that are denser and more resistant to the environment.
In a particularly useful embodiment, the molded fiber container can be used to store a food item that can come in any shape and size such as, for example, eggs, fruits, and meat products. Accordingly, the size and shape of the container can be widely varied. For example, the container can have a size that is small enough to contain a single serving of food. On the other hand, the molded fiber container can be fabricated to have a size that is large enough to contain multiple servings of food. Containers of this size are especially useful in situations where food needs to be stored and transported in large quantities, such as at catered events. For the remainder of this discussion, however, and without loss of generality, the container will be discussed in terms of a single item food container. More specifically, the food container can be used to store and transport a hot food product such as pizza. Accordingly, the pizza container can have a size and shape (i.e., circular or rectangular) in accordance with the shape of the pizza contained within.
In order to preserve and enhance the overall culinary experience, the container can be formed to include a number of features that can be integrated into the structure of the container. For example, in order to prevent moisture from being trapped beneath the pizza rendering the pizza soggy, selected portions of an interior surface of a base of the container can be elevated to provide a support platform. In one embodiment, the elevated portion can take the form of concentric rings that elevate the pizza from the bottom surface of the container. Elevating the pizza from the bottom surface ensures that any steam that is emitted from the bottom of the pizza can flow away from the bottom of the pizza. Allowing such steam to flow away from the bottom of the pizza prevents moisture from becoming trapped between the pizza and the bottom surface of the container and subsequently reabsorbed by the pizza causing it to get soggy. The container can also include openings in the lid that allow steam to escape from the pizza. Allowing such steam to escape from within the container further ensuring that the pizza does not become soggy through the re-absorption of moisture.
These and other embodiments are discussed below with reference to
Container 10 can include base portion 12 having bottom surface 14. Bottom surface 14 can include bottom feature 16 integrated with base portion 12. In the described embodiment, bottom feature 16 can be formed of concentric ridges 18 each extending above bottom surface 14. Ridges 18 can provide structural support for container 10 by distributing an applied load helping to prevent excessive bending and flexing of container 10. In this way, even though fully loaded and in the first open configuration, pizza container 10 can be picked up and transported without undue risk of deforming. Moreover, when a pizza is placed upon ridges 18, an air gap between bottom surface 14 and the pizza can be formed allowing excess moisture to escape from the pizza. The air gap can also act as a thermal barrier preventing excess heat transfer away from the pizza. In this way, while enclosed within pizza container 10, the pizza can remain fresh and crisp and hot for an extended period of time. Base portion 12 can also include sidewalls 20 integrally formed with bottom surface 18. Sidewalls 20 can include integrated sidewall feature 22. Integrated sidewall feature 22 can be recessed into sidewalls 20 having a shape that can help prevent flexing of base portion 12.
Container 10 can also include lid portion 24 having a size and shape in accordance with base portion 12. In this way, in a closed configuration, lid portion 24 and base portion 12 can come together to form an enclosed space well suited for accommodating the pizza. Lid portion 24 can include top surface 26 onto which can be formed first top feature 28 and second top feature 30. In one embodiment, first top feature 28 can be an elevated region integrally formed with lid portion 24 in such a way as to provide structural support for lid portion 24. Furthermore, in a closed configuration, integrated first top feature 28 can align and cooperate with sidewalls 20 and integrated side wall features 22 to provide additional structural support for pizza container 10. In addition to first top feature 28, second top feature 30 can have a raised shape suitable for providing structural support for lid portion 24. In addition to providing structural support for container 10, second top feature 30 can aid in the transport of excess moisture from the pizza through vents 32. In one embodiment, for example, second top feature 30 can form channel 34 that can cooperate with central platform 36 to create a “chimney effect” that can help to draw excess moisture from the pizza that can be channeled to vents 32 for transport to the external environment. In this way, ridges 18, second top feature 30 and vents 32 can work together to form a mechanism by which a proper moisture level within container 10 can be maintained thereby assuring that the pizza does not absorb excess moisture and become soggy.
Base portion 12 and lid portion 24 can be pivotally connected to one another by way of hinge assembly 38. Hinge assembly 38 can be integrally formed with both lid portion 24 and base portion 12. Hinge assembly 38 can include first hinge portion 40 as part of base portion 12 and second hinge portion 42 as part of lid portion 24. Flexure 44 can pivotally connect first hinge portion 40 and second hinge portion 42. First hinge portion 40 and second hinge portion 42 can be formed of stiff molded fiber whereas flexure 44 can be formed of bendable molded fiber. In this way, flexure 44 can facilitate a folding over of first hinge portion 40 and second hinge portion 44 when container 10 transitions to the closed configuration. Alternatively, when transitioning to an open configuration, flexure 44 can facilitate the unfolding of first hinge portion 40 and second hinge portion 42.
Container 10 can also include locking mechanism 46. Locking mechanism 46 can include first portion 48 integrally formed with base portion 12 and second portion 50 integrally formed with lid portion 24. Locking mechanism 46 can be used to secure base portion 12 and lid portion 24 when container 10 is placed in the closed configuration. By securing it is meant that in the locked configuration, locking mechanism 46 can exert a securing force sufficiently strong to prevent base portion 12 and lid portion 24 from separating from each other when, for example, container 10 is being transported. For example, when locking mechanism 46 is engaged, lid portion 24 remains securely attached to base portion 12. However, when a user desires to open pizza container 10 by disengaging locking mechanism 46, lip 52 on second portion 50 can be easily accessed by the user inserting a finger, or other object, within recess portion 54 of first portion 48. Recess portion 54 can be sized and positioned relative to lip 52 to provide easy access to lip 52. In this way, a simple lifting action on lip 52 can easily overcome the securing force provided by locking mechanism 46 to separate lid portion 24 and base portion 12. By overcoming the securing force provided by locking mechanism 46, the user can easily cause container 10 to transition from a closed configuration to an open configuration. It should also be noted that container 10 can be used to dispose of any eating utensils, napkins, cups, and so forth in an environmentally friendly manner. For example, all used eating utensils and other paraphernalia can be placed inside of container 10 when the meal is finished, closed, sealed and disposed of as a single unit making disposal easy and efficient.
In the first open configuration, lid portion 24 and base portion 12 are positioned approximately 180° relative to each other such that any item (such as the pizza) on bottom surface 14 is easily viewed and accessible. However, in some situations, it may not be convenient to place container 10 in the first open configuration due to the large footprint presented by the relative positioning of base portion 12 and lid portion 24. For example, if available space is limited due to, for example, a small dining table or area, it may not be convenient or even possible to position base portion 12 and lid portion 24 in the first open configuration. Accordingly, one of the advantages provided by container 10 is the ability of container 10 to be placed in a second open configuration, also referred to in some embodiments as a food server configuration. As shown in
Top feature 30 integrated within lid portion 24 increases the surface area along exterior surface of lid portion 24, thereby serving to create a lower outside pressure along the exterior surface. Top surface airflow 90 can have a higher pressure than the outside pressure along the exterior surface of lid portion 24, thereby creating a chimney effect. Such chimney effect causes top surface airflow 90 to move along top surface 26, whereby airflow can subsequently exit container 10 through vents 32. Vents 32 can be formed within top surface 26 and extend through lid portion 24. Vents 32 can be positioned in an annular pattern concentric with the center of lid portion 24, helping to ensure that a maximum amount of contained hot air, including air from bottom airflow 84, can exit container 10. In turn, such moisture air expelling process ensures that the hot air that is generated from pizza 82 can be discharged from within container 10. Expelling the hot air generated by pizza 82, prevents pizza 82 from reabsorbing the moisture within such hot air and subsequently becoming soggy.
a-9c shows a close up step by step view of the locking mechanism 46 and the associated locking method. Locking mechanism 46 can be a press fit lock with first portion 48 that is integrally formed with base portion 12 and second portion 50 that is integrally formed with lid portion 24. Second portion 50 can include protrusion 802 that extends out from second portion 50. First portion 48 can include cavity 804 that is integrally formed within first portion 50. Cavity 804 can receive protrusion 802 when an external force pushes first portion 48 and second portion 50 together while container 10 is in a closed configuration. In receiving protrusion 802, cavity 804 generates a locking mechanism force, which serves to hold locking mechanism 46 and subsequently lid portion 24 and base portion 12 in closed configuration. Such locking mechanism force resists external forces applied to container 10, so that container 10 remains closed, throughout storage, transportation, and any other functioning of container 10. Locking mechanism 46 can include recessed portion 54 within first portion 48, which allows the user to contact second portion 50 such that the second portion 50 can be separated from the first portion 48.
Container 10 can also include indicia 80 as shown in
In a specific embodiment, the container can be reusable. Specifically, the container can be reused in the containment of an item in any of the previously mentioned applications. The reuse of the container is environmentally friendly as it reduces the amount of materials that are consumed by society through the construction of single use containers. Furthermore, the ability to reuse containers reduces the amount of waste that is generated by single use containers. In a further specific embodiment, the container can be formed of material that allows the container to be washed or cleaned before such subsequent reuse.
The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the invention. Thus, the foregoing descriptions of specific embodiments of the present invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.
The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
