BACKGROUND
Disposable or limited-use carry out food containers are used in a wide variety of environments and use cases, such as at self-service salad bars or hot-food bars at grocery stores and food courts, as take-out containers for restaurant take-out or delivery (e.g., from “ghost kitchens”), at temporary eateries such as pop-ups or food trucks, for dispensing bulk items such as at bulk-food stores or farmers markets, and a variety of home applications such as travel or picnics. These are just examples of dozens of common uses for disposable or limited use food containers (hereinafter, “carry out containers” or “food containers”). Many of these use cases involve initially receiving food to be consumed in the food container, temporarily enclosing the food in the food container, and transporting the food in the food container to another location such as a table, park, office, or home to be consumed. Although high-quality food containers are typically designed to be environmentally friendly through use of materials that are compostable or otherwise have minimal net environmental impact, eating directly out of such containers can be inconvenient or unwieldy. Accordingly, some consumers will use additional containers such as bowls or plates when consuming the food item, resulting in inconvenience and/or additional waste.
SUMMARY
In an embodiment of the present disclosure, a food container comprises a food compartment, which comprises a bottom surface and a plurality of sidewalls that extend from the bottom surface, wherein each of the plurality of sidewalls is fixed to at least one of another of the plurality of sidewalls to provide a volume for receiving a food item. The food container can further comprise a plurality of foldable wings, wherein each of the foldable wings is connected to one of the plurality of sidewalls at a base of the foldable wing, and a plurality of creases, wherein each respective crease of the plurality of creases is located at a respective base of each foldable wing, and wherein each of the foldable wings is configured to fold inwardly from the respective crease at the respective base of the foldable wing. The food container can further comprise a detachment feature located on a first sidewall of the plurality of sidewalls, wherein the detachment feature is located below a first crease of the plurality of creases that connects the first sidewall to a first foldable wing of the plurality of foldable wings, and wherein the detachment feature is configured to selectively separate the first foldable wing and a portion of the first sidewall from the food container.
In an embodiment of the present disclosure, a method for converting an enclosed food container into a bowl comprises releasing a first foldable wing of a plurality of foldable wings of a food container, wherein the food container includes a food compartment comprising a bottom surface and a plurality of sidewalls that extend from the bottom surface, wherein each of the plurality of sidewalls is fixed to at least one of another of the plurality of sidewalls to provide a volume for receiving a food item, wherein each of the foldable wings is connected to one of the plurality of sidewalls at a base of the foldable wing at a respective crease of a plurality of creases, wherein each respective crease of the plurality of creases is located at a respective base of each foldable wing, and wherein each of the foldable wings is configured to fold inwardly from the respective crease at the respective base of the foldable wing. The method can further comprise engaging a detachment feature located on a first sidewall of the plurality of sidewalls to selectively separate the first foldable wing and a portion of the first sidewall from the food container, wherein the detachment feature is located below a first crease of the plurality of creases that connects the first sidewall to a first foldable wing of the plurality of foldable wings.
In an embodiment of the present disclosure, a food container comprises a food compartment, wherein the food compartment comprises a bottom surface and a plurality of sidewalls that extend from the bottom surface, wherein each of the plurality of sidewalls is fixed to at least one of another of the plurality of sidewalls to provide a volume for receiving a food item. The food container may further comprise a plurality of foldable wings, wherein each of the foldable wings is connected to one of the plurality of sidewalls at a base of the foldable wing and a plurality of creases, wherein each respective crease of the plurality of creases is located at a respective base of each foldable wing, and wherein each of the foldable wings is configured to fold inwardly from the respective crease at the respective base of the foldable wing. The food container may further comprise a detachment feature located on a first foldable wing of the plurality of foldable wings, wherein the detachment feature is located above a first crease of the plurality of creases that connects a first sidewall of the plurality of sidewalls to the first foldable wing, and wherein the detachment feature is configured to selectively separate a portion of the first foldable wing from the food container.
BRIEF DESCRIPTION OF DRAWINGS
The above and other features of the present disclosure, its nature, and various advantages will be more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings in which:
FIG. 1 shows a perspective view of a food container in a closed configuration in accordance with an embodiment of the present disclosure;
FIG. 2 depicts a perspective view of the food container of FIG. 1 in an opened configuration in accordance with an embodiment of the present disclosure;
FIG. 3 depicts a perspective view of the food container of FIG. 1 in an open configuration with a foldable wing removed in accordance with an embodiment of the present disclosure;
FIG. 4 depicts a perspective view of the food container of FIG. 1 in an open configuration with all foldable wings removed in accordance with an embodiment of the present disclosure;
FIG. 5 depicts a top view of a flattened blank for the food container of FIG. 1 prior to assembly in accordance with an embodiment of the present disclosure;
FIG. 6 depicts a perspective view of another embodiment of a food container in an open configuration with one foldable wing removed and with folding sidewall connectors that run along the perforations of the detachment feature in accordance with an embodiment of the present disclosure;
FIG. 7 depicts a perspective view of the food container of FIG. 6 with all foldable wings removed in accordance with an embodiment of the present disclosure;
FIG. 8 depicts a perspective view of another embodiment of a food container in an open configuration with handle detachment guides and a handle in accordance with an embodiment of the present disclosure;
FIG. 9 depicts a perspective view of the food container of FIG. 8 with handles engaged in accordance with an embodiment of the present disclosure;
FIG. 10 depicts a top view of a flattened blank for the food container of FIG. 8 prior to assembly in accordance with an embodiment of the present disclosure;
FIG. 11 depicts a top view of an additional embodiment of a flattened blank for the food container of FIG. 10 prior to assembly that is similar to the embodiment of FIG. 10 but having differing perforation characteristics in different portions of the detachment feature in accordance with an embodiment of the present disclosure;
FIG. 12 depicts a top view of a flattened blank that is similar to the embodiment of FIG. 10 and also includes cuts or scoring to assist in accessing and engaging the handle of the food container in accordance with an embodiment of the present disclosure;
FIG. 13 depicts a top view of a flattened blank of another embodiment of a food container prior to assembly with downward and upward oriented rounded punch-out detachment guides with cuts or scoring in accordance with an embodiment of the present disclosure;
FIG. 14 depicts a top view of a flattened blank of another embodiment of a food container prior to assembly with downward oriented rounded punch-out detachment guides with cuts or scoring in accordance with an embodiment of the present disclosure;
FIG. 15 depicts a perspective view of another embodiment of a food container in an open configuration with detachment features located in the foldable wings in accordance with an embodiment of the present disclosure;
FIG. 16 depicts a perspective view of the food container of FIG. 15 with one the foldable wings removed in accordance with an embodiment of the present disclosure;
FIG. 17 depicts a perspective view of another embodiment of a food container in a closed configuration with a wave-shaped detachment feature in accordance with an embodiment of the present disclosure;
FIG. 18 depicts a perspective view of the food container of FIG. 17 in an open configuration in accordance with an embodiment of the present disclosure;
FIG. 19 depicts a perspective view of the food container of FIG. 17 with a foldable wing removed in accordance with an embodiment of the present disclosure;
FIG. 20 depicts a perspective view of the food container of FIG. 17 with all foldable wings removed in accordance with an embodiment of the present disclosure;
FIG. 21 depicts a top view of a flattened blank of another embodiment of a food container prior to assembly with the detachment features located in the foldable wings with handle detachment guides in accordance with an embodiment of the present disclosure;
FIG. 22 depicts a top view of a flattened blank of another embodiment of a food container prior to assembly with detachment features located in the sidewalls and the foldable wings in accordance with an embodiment of the present disclosure;
FIG. 23 depicts a top view of a flattened blank of another embodiment of a food container prior to assembly with a detachment strip in accordance with an embodiment of the present disclosure;
FIG. 24 depicts a top view of a flattened bank of another embodiment of a food container prior to assembly with a detachment feature that extends through the crease of the food container into the foldable wings in accordance with an embodiment of the present disclosure;
FIG. 25 depicts exemplary steps of manufacturing a convertible food container in accordance with an embodiment of the present disclosure; and
FIG. 26 depicts the exemplary steps of using a convertible food container in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
A disposable or limited use food container has a large variety of use cases and helps to facilitate many forms of commerce related to prepared or bulk food items. A food container must meet a variety of requirements to be acceptable for consumers, including case of access for loading food items into the food container, rigid construction of the food container walls or surfaces that hold and contain the food item, a simple and consistent closing mechanism that protects the food item from the external environment and prevents leaks, and resilience of the enclosure and closing mechanism to use or misuse by employees and consumers. At the same time, by design these food containers are not intended to be reusable (or in some cases, have only a limited number of uses) and thus raise concerns over waste. For reasons of convenience and/or waste reduction, many users eat directly out of these carry out food containers rather than using additional plates, bowls, and the like. However, the food container may not be convenient for consuming food directly from the internal volume of the food container, for example, based on interference from components that initially seal the food container and that have previously been folded to cover the food within the food containers. Users may attempt to remove such components, but doing so often results in inconstant tearing such as of the sidewalls of the food container. Attempts to integrate tear assist features into food containers have compromised the structural integrity and/or utility of the food container, for example, by integrating tear assist features at an active crease of the food container used for folding during closure of the food container, and thus decreasing the utility of the folding feature and resulting in inadvertent tearing at the crease during the food loading (e.g., when users are holding the food container in a manner that stressing the crease during loading) and enclosure (e.g., when users apply inconsistent forces to the crease during closure of the container) processes. Further, a tear assist feature such as perforations integrated into an active crease is prone to earlier damage or separation during multiple opening and closing cycles. Indeed, food containers are often used (and misused) during times where users such as food service employees or consumers are under stress or otherwise paying little attention to the food container. Accordingly, a food container is expected to encounter a substantial amount of misuse, and failure to appropriately account for such misuse can result in significant monetary loss and environmental waste from discarded containers, as well as customer complaints due to loss of food items.
A food container in accordance with the present disclosure provides significant added utility to users without sacrificing core functionality such as the structural integrity of the container or the ability to withstand substantial forces (e.g., including misuse) during the multiple stages of use of a carry out food container. A food container includes detachment features that are primarily located on non-active portions of the food container, such as in an upper portion of the food container sidewall below the active crease that is utilized for folding the foldable wings (also referred to as closure flaps) that enclose the food item (e.g., by temporary attachment of a tab within a tab slot). The detachment feature includes perforations that have appropriate specifications (e.g., tie and ties-per-inch (“TPI”)) to facilitate separation of upper portions of the food container (e.g., a portion of each of the sidewalls and the entirety of the foldable wing(s) attached to each sidewall) from the lower portion enclosing the food item. In one example, the detachment feature may run from opposite upper corners at the sidewall/crease intersection of the food container downward into the sidewall, forming a “smile” or upward curving arc shape on each sidewall that follows a more natural (e.g., partially downward removal motion) from the user that is more convenient than a linear removal motion, and also providing for better access to the food item for consumption. It will be understood that other shapes (e.g., a “sine wave” shape) may be utilized for the sidewall perforations, or that perforations may also extend through the crease partially into the foldable wings in some embodiments for case in separation.
A variety of additional features may also be used to separate the upper portions of the food container. For example, sidewall connectors can connect adjacent sidewalls to each other, such as by using adhesive to fix sidewall connectors to sidewalls. The upper surfaces of the sidewall connectors may be designed to run along the perforations in a manner that provides backing and support for the initial portion of the separation, for example, from the intersection of the perforation with an upper end of the crease that connects the sidewall to the foldable wing. As another example, perforations may be provided for handles or punch-outs that intersect with the detachment feature and that can be used to start the removal process from a central location rather than or in addition to at an end of the detachment portion. Scoring or cuts (e.g., via laser or other cutting) may also be provided to facilitate the starting of the removal at particular locations. In addition, different types of perforations (e.g., having different TPI and tie values) may be utilized at different portions of a single perforation pattern, for example, to facilitate initiation of removal at a first location while other portions must merely support continuation of an initiated removal. In some instances, rather than a single perforation pattern the detachment feature may be implemented with multiple perforation patterns on a single sidewall, such as parallel perforations forming a detachment strip or zipper tear.
FIG. 1 shows a perspective view of a food container 100 in a closed configuration in accordance with an embodiment of the present disclosure. Although food container 100 may include a variety of components, and one or more components may be added, removed, or modified in different embodiments, in the exemplary embodiment of FIG. 1, components of the food container 100 can include a food compartment, a bottom surface 103 (not depicted in FIG. 1), a plurality of sidewalls 102, a plurality of foldable wings 104, a plurality of creases 110, and a detachment feature 108. In addition, the components of food container 100 may include a tab slot 106b, structural ribs 112, and folding sidewall connectors 114 (not depicted in FIG. 1). It will be understood that the specific depicted relative dimensions and proportions are exemplary only, and that the present disclosure applies to a variety of food container shapes. These shapes can include squares, rectangles, circles, ovals, polygons, or irregular shapes, as may suit a particular end use application (e.g., customized shapes for particular food items). The sizes of the food container 100 can also vary from small enough to carry a single food serving to carrying multiple food portions for serving multiple people, and may include multiple internal sub-compartments and/or externally attached sub-compartments. The container 100 can be made from various types of materials including paper, paperboard, cardboard, molded fibers, pulp, light metal (e.g., light aluminum), plastics/polymers, bioplastics, styrofoam, and combinations of materials (e.g., a cardboard container having plastic “windows” on one or more sides). The container material can include various treatments or coatings suitable for particular applications, such as to prevent leakage of liquid or viscous portions of the food items, to absorb moisture, to insulate to retain temperature, etc.
The food container 100 as shown in FIG. 1 is rectangular in shape with four sidewalls 102a, 102b, 102c, and 102d (102b and 102c not depicted in FIG. 1). In the embodiment of FIG. 1, each sidewall 102a/102b/102c/102d is connected to two adjacent sidewalls via sidewall connectors (e.g., sidewall 102a is connected to sidewalls 102b and 102d, sidewall 102b is connected to sidewalls 102a and 102c, sidewall 102c is connected to sidewalls 102b and 102d, and sidewall 102d is connected to sidewalls 102c and 102a), to one of foldable wings 104a, 104b, 104c and 104d via a respective crease 110a, 110b, 110c, and 110d (e.g., sidewall 102a is connected to foldable wing 104a via crease 110a, sidewall 102b is connected to foldable wing 104b via crease 110b, sidewall 102c is connected to foldable wing 104c via crease 110c, and sidewall 102d is connected to foldable wing 104d via crease 110d), and to the bottom surface 103. It will understood that different combinations of connections may be utilized for different container shapes, or for the depicted rectangular shape. For example, a single sidewall may attach to multiple foldable wings for different attachment and closure scenarios. In an embodiment, all of the components are constructed of a single blank as described herein, with certain components being attached such as by adhesives or features (e.g., tabs) of the blank when the blank is folded into the operably functional food container. For example, the sidewalls 102 and the bottom surface 103 can be one piece of material where there is a bottom crease between the sidewalls 102a-d and the bottom surface 103. In another embodiment, the sidewalls 102a-d can be a separate material from the bottom surface 103 and attached by a bottom sidewall connector. In another embodiment, there can be a bottom connector that connects to the sidewalls 102. Both the sidewalls 102a/102b/102c/102d and the bottom connectors can either attach on the inside or the outside of the container 100.
In the embodiment of FIG. 1, a foldable wing 104a/104b/104c/104d is connected to a respective sidewall 102a/102b/102c/102d via a respective crease 110a/110b/110c/110d of the food container 100. In the example of FIG. 1, The foldable wings 104a/104b/104c/104d and the sidewalls 102a/102b/102c/102d are continuous portions of the blank material connected via the crease 110a/110b/110c/110d between the foldable wings 104a/104b/104c/104d and the sidewalls 102a/102b/102c/102d. In another embodiment, the sidewalls 102a/102b/102c/102d can be a separate piece of material or material type than the foldable wings 104a/104b/104c/104d, for example, connected by an adhesive with the crease 110a/110b/110c/110d being integrated in one of the connected pieces. While the bottom surface 103 (not depicted in FIG. 1) and the sidewalls 102a/102b/102c/102b provide a defined food storage volume for holding the food items, the foldable wings 104a/104b/104c/104d allow for the selective enclosure of the food storage volume, such as via a tab slot 106b (corresponding tab 106a not depicted in FIG. 1).
While the foldable wings 104a/104b/104c/104d provide an effective method for providing initial access for initially storing food within the food container, once the food container is accessed the foldable wings 104a/104b/104c/104d provide an obstruction to accessing the food (e.g., as depicted in FIG. 2), particularly if an individual wishes to cat food directly from the food container. If a user attempts to remove one or more of the foldable wings 104a/104b/104c/104d at its corresponding crease 110a/110b/110c/110d, there is likelihood of an uneven tear that is likely to damage the food container as a whole (e.g., a vertical tear), and even if not damaged, the resulting exposed surface at the tear may be physically uncomfortable due to the tearing or the fact that the resulting surface is a flat, horizontal surface. Further, if the crease 110a/110b/110c/110d is weakened to facilitate tearing, the strength and functionality of the crease may be compromised, resulting in inadvertent tearing off of foldable wings 104a/104b/104c/104d during packing, storage or transportation of the food item, and reducing the overall structural integrity of the food container where the contents of the food container 100 can fall out.
In order to easily remove one of the foldable wings 104a/104b/104c/104d for easier access to the contents in the food container 100, the food container 100 has four detachment features 108a, 108b, 108c, and 108d (108b and 108c not depicted in FIG. 1). Each sidewall 102a/102b/102c/102d has a detachment feature 108a/108b/108c/108d that runs between the left corner of its respective top crease 110a/110b/110c/110d and right corner of its respective top crease. (e.g., sidewall 102a has a detachment feature 108a that extends from the left corner of 110a to the right corner of 110a, sidewall 102b has a detachment feature 108b that extends from the left corner of 110b to the right corner of 110b, sidewall 102c has a detachment feature 108c that extends from the left corner of 110c to the right corner of 110c, and sidewall 102d has a detachment feature 108d that extends from the left corner of 110d to the right corner of 110d).
In FIG. 1 the detachment features 108a/108b/108c/108d are located below its respective crease 110a/110b/110c/110d and is curved in a “smiling” pattern, with the greatest distance from the corresponding crease being at a middle or center point of the crease and sidewall, although in other embodiments, the detachment feature may have different shapes and patterns (e.g., with a greatest distance at one side to facilitate tearing from one side to another). In some examples, the middle or center point is about 1% to about 30% of the height of the corresponding sidewall, such as from about 5% to about 30%, such as from about 10% to about 30%, from about 15% to about 30%, from about 20% to about 30%, or from about 20% to about 25% of the height the respective sidewall. The detachment feature 108a/108b/108c/108d can be a weakened (e.g., perforated such as by cutting or scoring) to assist the user in tearing along the detachment feature 108a/108b/108c/108d and thus easily removing its respective foldable wing 104a/104b/104c/104d while maintaining the integrity of the food container 100. The parameters for the perforations (e.g., TPI and tie) will be dependent on the design and materials of the food container. As an example, when using 18 pt paperboard, an exemplary configuration may use an 8 TPI× 1/16″ Tie formulation. For a thicker material, this may be changed such as to an 12 TPI× 1/32″ Tie formulation. In an example of a thinner paperboard, this may be changed to a 6 TPI× 3/32″ Tie formulation.
The perforation can be configured in a variety of manners, for example, with different cut depths and cut distributions corresponding to different sidewall thicknesses, end uses, and the like. Further, the perforations may be patterned such that some portions (e.g., at handles, edges, and the like) are more easily separated from the sidewall while other portions have less cut depth or density, and thus, improved structural integrity. In an example embodiment, different perforation types may be interspersed along each detachment feature, providing for regions that facilitate removal while maintaining better overall structural integrity. In the exemplary embodiment of FIG. 1, the perforations of each of the detachment features are uniform.
The sidewalls 102a/102b/102c/102d are constructed with a strong enough material so that when a foldable wing 104a/104b/104c/104d is removed by tearing along the detachment feature 108a/108b/108c/108d, the food container 100 can maintain its integrity and properly contain any food item. The detachment features 108a/108b/108c/108d may have various shapes. For example, they can be waves or have punched tabs. The type of perforation can also vary in length and depth of cut into the container. Further, in other embodiments the detachment features 108a/108b/108c/108d can be located in various locations including on the foldable wings 104a/104b/104c/104d or on both the foldable wings 104a/104b/104c/104d and the sidewalls 102a/102b/102c/102d at the same time, as described herein.
The food container 100 as shown in FIG. 1 has structural ribs 112a, 112b, 112c and 112d (112b and 112c not depicted in FIG. 1) on each sidewall 102a/102b/102c/102d respectively perpendicular to each sidewall's respective top crease 110a/110b/110c/110d (e.g., sidewall 102a has structural ribs 112a located perpendicular to the top crease 110a, sidewall 102b has structural ribs 112b located perpendicular to the top crease 110b, sidewall 102c has structural ribs 112c located perpendicular to the top crease 110c and sidewall 102d has structural ribs 112d located perpendicular to the top crease 110d). In an example of structural ribs within a paperboard material, the structural ribs are manufactured via indenting the paperboard with a blunt blade that is mated to a corresponding channel in the cutting surface. This leaves a “U” shaped indent in the paperboard, which provides structural integrity due to the fact that it is running perpendicular to the pulling forces along the detachment features that the structural ribs are intended to counteract.
Although FIG. 1 depicts three vertical structural ribs 112a/112b/112c/112d that are perpendicular to their respective top crease 110a/110b/102c/110d, it will be understood that the structural ribs 112a/112b/112c/112d can vary in shape, size, number, location, and orientation and still provide the required stability for the food container 100. These structural ribs 112a/112b/112c/112d provide strength to the food container 100 and assist in maintaining its integrity both when the food container 100 is closed and has food items within it and also when one or more foldable wings 104a/104b/104c/104d are removed with assistance from their corresponding detachment features 108a/108b/108c/108d. One way the structural ribs 112a/112b/112c/112d provide support to the food container 100 is by being thicker than the rest of the food container 100. In some examples, the structural ribs 112a/112b/112c/112d can be reinforced with a different material than the food container 100 such as with a wire or a plastic insert.
FIG. 2 depicts a perspective view of the food container 100 of FIG. 1 in an opened configuration in accordance with an embodiment of the present disclosure. In this open configuration, the foldable wing 104c is shown connected to its respective sidewall 102c via its respective crease 110c of the food container 100. Further, in this open configuration, there is a tab 106a on the end of the foldable wing 104c. Although a particular tab configuration is depicted herein, other tab types and configurations may be utilized with the present disclosure as well (e.g., a hook tab, right hook tab, a left hook tab, double hook tab, or a tuck tab). When the food container 100 is closed as shown in FIG. 1, the tab 106a can insert into the tab slot 106b to securely close the food container 100. Other tab configurations, multiple tabs, or different attachment mechanisms such as an adhesive on the wing 104c could also be used to securely close the food container 100. For example, the tab slot 106b can be a single cut line having a suitable shape and size to receive the corresponding tab, such as a curved cut line (convex or concave), a straight cut line, or other suitable shapes to receive the corresponding tab. Optionally, one or more additional cut lines are arranged perpendicularly to the tab slot 106b, such as located on each side of the slit, in the middle of the slit, or on each side and the middle of the slit. The additional cut lines are configured to facilitate the insertion and removal of the tab from the slit.
In a scenario of adhesive, the wing 104c would not need a tab 106a, but rather an adhesive on the underside of the wing 104c and the opposite side wing 104a would also not need a tab slot 106b. In the open configuration as depicted in FIG. 2, a food item may be dispensed into the receiving volume of food container defined by the sidewalls 102a/102b/102c/102d and the bottom surface 103, and the foldable wings 104a/104b/104c/104d may assist in dispensing the food item into the volume, for example, by providing a “ramp” or “slide” for accidentally misplaced food items to be steered into the volume of the food container. However, in this open configuration the foldable 104a/104b/104c/104d interfere with attempts to access the food item within the volume, such as with a fork, spoon, chopsticks, or the like.
FIG. 3 depicts a perspective view of the food container 100 of FIG. 1 in an open configuration with the foldable wing 104a removed in accordance with an embodiment of the present disclosure. The foldable wing 104a is removed along the detachment feature 108a thereby creating a sidewall 102a curved in a “smiling” pattern, with the greatest distance from the corresponding crease being at a middle or center point of the crease and sidewall, although in other embodiments the detachment feature may have different shapes and patterns (e.g., with a greatest distance at one side to facilitate tearing from one side to another). FIG. 3 also depicts that the structural ribs 112b/112c are visible on the inside of the food container 100. In addition, sidewall connectors (also referred to as gussets) 114a/114b/114c/114d are visible in FIG. 3. Each of the sidewall connectors rigidly physically attaches adjacent sidewalls to each other (e.g., by being folded along one or both sidewalls and attached such as with an adhesive or tab (not shown), with sidewall connector 114a attaching sidewall 102a to sidewall 102b, sidewall connector 114b attaching sidewall 102b to sidewall 102c, sidewall connector 114c attaching sidewall 102c to sidewall 102d, and sidewall connector 114d attaching sidewall 102d to sidewall 102a.
Removal of the of the removed portion of the food container (e.g., including the foldable wing 104a and a portion of the sidewall 102a) is facilitated by the structural ribs 112a, which provide structural support at locations within the sidewall 102a where the detachment feature 108a might otherwise have less support. For example, the structural ribs provide structural support by preventing inadvertent folding at the tear line during the foldable wing folding action when closing the container. Thus, the user can begin the removal process at one or the other side of the detachment feature 108a (e.g., typically based on whether the user is left or right handed) which provides structural support for the detachment feature 108a by virtue of being at a reinforced location where sidewalls connect to each other, while the ribs provide structural support at strategic locations within the sidewall of the detachment feature and prevent tearing at or from the crease. In this manner, the removed portion is removed without inadvertent tearing of the sidewall 102a or crease. Once removed, the removed portion can be easily discarded or temporarily stored until the user is at an appropriate disposal location (e.g., for a recyclable or compostable material). The curvature of the remaining portion of the sidewall 102a facilitates access to food items within the food container, with the curved shape providing superior access to the interior volume and comfort to the user as compared to simply removing the foldable wing along the crease 110a.
FIG. 4 depicts a perspective view of the food container 100 of FIG. 1 in an open configuration with all foldable wings 104a/104b/104c/104d (not shown in FIG. 4) removed in accordance with an embodiment of the present disclosure. In FIG. 4, each foldable wing 104a/104b/104c/104d (not shown in FIG. 4) and a portion of each sidewall 102a/102b/102c/102d is removed along their respective detachment features 108a/108b/108c/108d. This creates respective sidewalls 102a/102b/102c/102d curved in a “smiling” pattern, with the greatest distance from the corresponding crease 110a/110b/110c/110d (not shown in FIG. 4) being at a middle or center point of the crease and sidewall. FIG. 4 depicts a food container 100 that is user friendly in that there are no foldable wings 104a/104b/104c/104d that will get in the way of a user to trying to access the contents of the food container 100, and access to the interior volume is improved by removal of a portion of the sidewalls 102a/102b/102c/102d.
FIG. 5 depicts a top view of a flattened blank for the food container 100 of FIG. 1 prior to assembly in accordance with an embodiment of the present disclosure. In FIG. 5, the structural ribs 112a/112b/112c/112d are shown on the inside of the food container 100. As depicted in FIG. 5, all of the features described in FIGS. 1-4 can be manufactured in a single-piece blank. Preparing a single-piece blank can improve the structural rigidity of the food container when assembled compared to multi-piece configurations. Further, in some instances, a single-piece blank facilitates bulk shipment of food containers to customers or distributors, while in other instances the folded and assembled blank is sent to customers or distributors. In order to prepare the food container, the blank is folded upward and inward to cause the sidewall connectors 114a/114b/114c/114d to contact the sidewalls (e.g., in the context of a blank, also referred to as a tray panel) 102a/102b/102c/102d (e.g., on an interior surface of the sidewall) with the attachment being secured such as by an adhesive (e.g., that is placed on the sidewall connectors, not shown) or an attachment feature integral to the sidewall connectors (not shown).
The blank may be formed from a foldable material such as paper-based material such as paperboard or corrugated sheet material, although other materials may be used if desired. In embodiments utilizing paperboard, the paperboard may be virgin or recycled material, may be coated or uncoated, and may be single-ply or laminated paperboard. The foldable material may be Folding Box Board (FBB). FBB is a chemically and mechanically generated multiply pulp material making it strong and durable. FBB generally includes a bleached chemical layer. The foldable material may be Solid Bleached Sulfate (SBS) Board. This type of board is formed by chemically pulping fibers and then bleaching it. The bleached pulp is refined and formed into boxes. SBS boxes generally contain white surfaces on the inside and outside of the box. SBS can be coated on only one side (C1S) or on both sides (C2S). FBB and SBS board are produced from virgin fibers and are generally suitable for all types of product packaging. SBS board quality also allows special processes such as embossing & debossing, hot foil stamping or spot UV printing due to its grade quality.
The foldable material may be Natural Kraft or Coated Unbleached Kraft (SUS or CUK). This type of board is made from 100% recyclable materials, and is often used for Kraft packaging. When coated with polyethylene (PE) resin, this board can be used to make food packaging of wet strength. At least 80% of virgin unbleached wood pulp is used to make CUK. This type of board is strong and durable; the stiffness leads to high resistance to tearing making the board long-lasting. The printing quality of the board can be improved by coating the surface with a thin layer of kaolin clay.
The foldable material may be from about 0.012 inch to about 0.024 inch thick, although it may have any suitable thickness. In some embodiments, the foldable material may be solid bleached sulfate (SBS) with ½ mil low density polyethylene (LDPE), while in other embodiments the foldable material may be SBS with ¾ mil LDPE, while in still yet other embodiments, any other suitable foldable material may be used. Different types of food grade paperboard may be used to form the blank and ultimately the container. The paperboard is optionally ovenable paperboard suitable for use in conventional and microwave ovens.
The paperboard may be coated with a suitable food grade material to reduce leakage, such as a polyester resin film. Optionally, the side of the paperboard blank that forms the interior surface of the resulting tray is coated with a liquid impervious polymer film. Optionally, the blank is coated on one side, which will serve as the inside surface of the resulting container, with a clay-coat, which is cured with a UV or electron beam varnish.
Each of the sidewall connectors 114a/114b/114c/114d can have two or more foldable regions or panels. The sidewalls and their foldable regions can have different sizes to facilitate attachment of the sidewalls when the sidewall connector is folded. The first and second sidewall connector panels may have the same shape and/or size or different shapes and/or sizes. For example, the first sidewall connector panel has a shape and/or size that is different from the second sidewall connector panel. In some embodiments, the surface area of the first sidewall connector panel is smaller than the surface area of the second sidewall connector panel. For example, as depicted in FIG. 1, the first sidewall connector region is smaller (has a larger surface area) than the second sidewall connector region. In embodiments where the first sidewall connector panel has a shape and/or size that is different from the second sidewall connector panel and the overall size of the first sidewall connector panel is smaller than the second sidewall connector panel, when folded, the interior surface of a first sidewall connector panel contacts and attaches to a sidewall connector contacting portion of the interior surface of the adjacent opposing sidewall. Additionally, when folded, the second sidewall connector panel covers the surface of the first sidewall connector panel. The exterior surface of the portion of the second sidewall connector panel that is larger than the first sidewall connector panel contacts and adheres to the sidewall connector contacting portion of the interior surface of the adjacent opposing sidewall, third sidewall, or partition wall.
For example, FIGS. 3-4 (and other FIGS. herein) show the exterior surfaces of the sidewall connector panels when they are folded to form folded sidewall connectors 114a, 114b, 114c, and 114d. As illustrated in FIG. 5, the second sidewall connector panel has a shape and/or size that is different from the first sidewall connector panel, and the overall size of the second sidewall connector panel is larger than the first sidewall connector panel. For embodiments in which one sidewall connector panel is large than the other, the larger sidewall connector panel (referred to herein as the second sidewall connector panel) is typically adhered to the surface of a side wall. Optionally the second sidewall connector panel contains at least one and optionally two or more glue locations. As an example, the second sidewall connector panel can have two glue locations, optionally as a a top glue location that is configured to adhere to the sidewall and a bottom glue location that is configured to adhere to the first sidewall connector panel.
When folded, the interior surface of the first sidewall connector panel contacts and attaches the sidewall connector to the interior surface of the adjacent opposing sidewall. Additionally, when folded, the exterior surface of the second sidewall connector panel of the sidewall connector covers the exterior surface of the first sidewall connector panel. The exterior surface of the portion of the second sidewall connector panel that is larger than the first sidewall connector panel contacts and adheres the interior surface of the adjacent opposing sidewall. In this manner, when folded, the interior surface (not shown) of the second sidewall connector panel is exposed and attaches to the interior of the compartment of the container, while the first sidewall connector panel is covered by the second sidewall connector panel.
Alternatively, in embodiments where the container is not leak resistant, the blank can be folded such that one or more of the sets of sidewall connector panels, optionally each set of sidewall connector panels, folds outwardly along the dividing fold line. In these embodiments, a surface of either one or both of the first and second sidewall connector panels contacts a sidewall connector contacting portion of the exterior surface of the adjacent side sidewall (either an opposing side sidewall). When the first and second sidewall connector panels are folded, the exterior surface of a first sidewall connector panel contacts and attaches to a sidewall connector contacting portion of the exterior surface of the adjacent opposing sidewall. Additionally, when folded, the second sidewall connector panel covers the surface of the first sidewall connector panel. The interior surface of the portion of the second sidewall connector panel that is larger than the first sidewall connector panel contacts and adheres to the sidewall connector contacting portion of the exterior surface of the adjacent opposing sidewall or third sidewall.
Regarding their attachment, the sidewall connectors 114a, 114b, 114c, and 114d can be secured to the inside surface of respective sidewalls. Alternatively, each sidewall connector can be folded and secured to the outside surface of the sidewalls. The second sidewall connector panel contains an adhesive or other material to attach the sidewall connector to the sidewall connector contacting portion of the interior surface of the adjacent opposing sidewall. In some embodiments, the second sidewall connector panel contains one or more marked glue location(s), optionally a printed or embossed area, which identifies the locations for placement of the adhesive. For example, as shown in FIG. 5, a first glue location and a second glue location are on the second sidewall connector panels. In use, the first sidewall connector panel is folded so that it contacts the exterior of sidewall, and the second sidewall connector is folded to overlap with the first sidewall connector panel and adheres the first sidewall connector panel to the second sidewall connector panel. The adhesive on the second sidewall connector panel also adheres to the exterior surface of the sidewall when the first and second sidewall connector panel are folded to form the sidewall connector. Additionally, an adhesive located in the first glue location on second sidewall connector panel adheres the sidewall connector to the sidewall.
FIG. 6 depicts a perspective view of another embodiment of a food container 100 in an open configuration with one foldable wing 104a (not shown) removed. As depicted in FIG. 6, certain components and structure (e.g., components 102, 104, 108, 110, 112, and 106b) are similar and function in a similar manner to those previously described in FIG. 1. It will be understood that similar modifications, substitutions, changes, and alternatives as described with respect to those components can be similarly implemented in the context of the embodiment of FIG. 6. As compared to FIG. 1, FIG. 6 includes a plurality of folding sidewall connectors (also referred to as gussets) 114a/114b/114c/114d located along the detachment features that are configured to provide an initial removal support surface for the detachment features 108a/108b/108c/108d.
The food container 100 as shown in FIG. 6 is rectangular in shape with four sidewalls 102a, 102b, 102c, and 102d. In the embodiment of FIG. 6, each sidewall 102a/102b/102c/102d is connected to two adjacent sidewalls via folding sidewall connectors 114a, 114b, 114c, and 114d (e.g., sidewall 102a is connected to sidewall 102b via sidewall connector 114a, sidewall 102a is connected to sidewall 102d via folding sidewall connector 114d, sidewall 102b is connected to sidewall 102c via sidewall connector 114b, and sidewall 102c is connected to sidewall 102d via folding sidewall connector 114c. These folding sidewall connectors 114a/114b/114d/114c run along the detachment features 108a/108b/108c/108d of the food container 100 (e.g. sidewall connector 114a runs along the right side of detachment feature 108a, sidewall connector 114d runs along the left side of detachment feature 108a, sidewall connector 114b runs along the right side of detachment feature 108c and sidewall connector 114c runs along the left side of detachment feature 108c)
The folding sidewall connectors 114a/114b/114c/114d can provide additional support and structure to food container 100. They also can facilitate the tearing off of the detachment features 108a/108b/108c/108d and help maintain the integrity of the sidewall 102a/102b/102c/102d when tearing off the foldable wing 104a/104b/104c/104d at the detachment feature 108a/108b/108c/108d. For example, a user may start the removal along each detachment feature at the intersection of the detachment feature with the adjacent sidewall, and tear inwardly towards the folding sidewall connectors, with the contours of the sidewall connectors supporting the removal along the detachment feature.
FIG. 7 depicts a perspective view of the food container 100 of FIG. 6 with all foldable wings (not shown) 104a/104b/104c/104d removed in accordance with an embodiment of the present disclosure. FIG. 7 shows the folding sidewall connectors 114a/114b/114c/114d run along the detachment features 108a/108b/108c/108d of the food container (e.g., folding sidewall connector 114a runs along the right side of detachment feature 108a, folding sidewall connector 114d runs along the left side of detachment feature 108a, folding sidewall connector 114c runs along the right side of detachment feature 108c, and folding sidewall connector 114d runs along the left side of detachment feature 108c).
FIG. 8 depicts a perspective view of another embodiment of a food container 100 in an open configuration with left side handle detachment guides 120, right side handle detachment guides 122, and a handle 124 in accordance with an embodiment of the present disclosure. As depicted in FIG. 8, certain components and structure (e.g., components 102, 104, 108, 110, 106a, and 106b) are similar and function in a similar manner to those previously described in FIG. 1. It will be understood that similar modifications, substitutions, changes, and alternatives as described with respect to those components can be similarly implemented in the context of the embodiment of FIG. 8. As compared to FIG. 1, FIG. 8 includes a plurality of right side handle detachment guides 122, a plurality of left side handle detachment guides 120 and a plurality of handles 124 formed with those guides and their respective detachment features 108 for detachment, and hinged along the creases 110.
The food container 100 of FIG. 8 is rectangular in shape with four sidewalls 102a, 102b (not shown), 102c, and 102d. Each sidewall 102a/102b (not shown)/102c (not shown)/102d has a detachment feature 108a/108b (not shown)/108c/108d that runs between the left corner of its respective top crease 110a/110b (not shown)/110c/110d and right corner of its respective top crease (e.g., sidewall 102a has a detachment feature 108a that extends from the left corner of crease 110a to the right corner of crease 110a, sidewall 102b (not shown) has a detachment feature 108b (not shown) that extends from the left corner of crease 110b (not shown) to the right corner of crease 110b (not shown), sidewall 102c has a detachment feature 108c that extends from the left corner of crease 110c (not shown) to the right corner of crease 110c (not shown), and sidewall 110d has a detachment feature 108d that extends from the left corner of crease 110d to the right corner of crease 110d). On each sidewall 102a/102b (not shown)/102c/102d there is a left side handle detachment guide 120a, 120b (not shown), 120c (not shown), and 120d and a right side handle detachment guide 122a, 122b (not shown), 122c (not shown) and 122d. The left side handle detachment guide 120a/120b (not shown)/120c/120d is perforated and starts at its respective detachment feature 108a/108b (not shown)/108c/108d and ends perpendicularly at its respective crease 110a/110b (not shown)/110c/110d (e.g., left side handle detachment guide 120a starts at detachment feature 108a and ends perpendicularly at crease 110a, left side handle detachment guide 120b (not shown) starts at detachment feature 108b (not shown) and ends perpendicularly at crease 110b (not shown), left side detachment guide 120c (not shown) starts at detachment feature 108c (not shown) and ends perpendicularly at crease 110c (not shown), left side handle detachment guide 120d starts at detachment feature 108d and ends perpendicularly at crease 110d). FIG. 8 shows the left side handle detachment guide 120a/120b/120c/120d as a straight line, but can be other shapes.
The right side handle detachment guide 122a/122b (not shown)/122c (not shown)/122d is perforated and starts at its respective detachment feature 108a/108b (not shown)/108c/108d and ends perpendicularly at its respective crease 110a/110b (not shown)/110c/110d (e.g., right side handle detachment guide 122a starts at detachment feature 108a and ends perpendicularly at crease 110a, right side handle detachment guide 122b (not shown) starts at detachment feature 108b (not shown) and ends perpendicularly at crease 110b (not shown), right side detachment guide 122c (not shown) starts at detachment feature 108c (not shown) and ends perpendicularly at crease 110c (not shown), right side handle detachment guide 122d starts at detachment feature 108d and ends perpendicularly at crease 110d). FIG. 8 shows the right side handle detachment guide 122a/122b/122c/122d as a straight line, but can be other shapes.
FIG. 8 also shows a handle 124 in each respective side 102. This handle 124a, 124b (not shown), 124c (not shown) and 124d is created when the left side handle detachment guide 120a/120b (not shown)/120c (not shown)/120d, the right side handle detachment guide 122a/122b (not shown)/122c (not shown)/122d and the portion of the respective detachment feature 108a/108b (not shown)/108c (not shown)/108d located between the left side handle detachment guide 120a/120b/120c/120d and the right side detachment guide 122a/122b/122c/122d is punched open along the perforation (e.g., the left side handle detachment guide 120a, the right side handle detachment guide 122a and the portion of the detachment feature 108a between these two guides is punched out and creates handle 124a, the left side handle detachment guide 120b (not shown), the right side handle detachment guide 122b (not shown) and the portion of the detachment feature 108b (not shown) between these two guides is punched out and creates handle 124b, the left side handle detachment guide 120c (not shown), the right side handle detachment guide 122c (not shown) and the portion of the detachment feature 108c (not shown) between these two guides is punched out and creates handle 124c (not shown) and the left side handle detachment guide 120d, the right side handle detachment guide 122d and the portion of the detachment feature 108d between these two guides is punched out and creates handle 124d).
The right and left handle detachment guides 120/122 can be in various orientations and lengths located in any position across the detachment feature 108 and can include more than one of each (e.g., there could be two or more handle detachment guides). For example, although in FIG. 8 the right and left hand detachment guides 120/122 intersect the detachment feature and the respective crease 110 at a right angle, the right and left hand detachment guides 120/122 can intersect the detachment feature 108 and the crease 110 at any angle. Further, although FIG. 8 shows the right and left hand detachment guides 120/122 equidistant from the center of the food container 100, they can be located in any distance along the detachment guide 108. Also, the right and left hand detachment guides 120/122 can be a variety of perforations or cuts.
FIG. 9 depicts a perspective view of the food container 100 of FIG. 8 with a created handle 124 in the side in accordance with an embodiment of the present disclosure. There is a handle 124a/124b (not shown)/124c (not shown)/124d in each respective sidewall 102a/102b (not shown)/102c (not shown)/102d which provide an alternative way for the user to securely hold the food container 100 and to allow steam to escape from the food container 100 if necessary. Accordingly, the user can punch the handle 124 inwardly to effect a portion of the removal process, and use a variety of methods as appropriate to complete the removal of the respective foldable wing 104 and removed portion of the sidewall 102 (e.g., simultaneously pulling from the sides of the detachment features 108 while engaging the handles 124).
FIG. 10 depicts a top view of a flattened blank for the food container 100 of FIG. 8 prior to assembly in accordance with an embodiment of the present disclosure. Similar to the blank of FIG. 5, the use of a single-piece blank in manufacturing may provide advantages in manufacturing, assembly, and handling during production and distribution.
FIG. 11 depicts a top view of an additional embodiment of a flattened blank for the food container 100 of FIG. 10 prior to assembly that is similar to the embodiment of FIG. 10 but having differing perforation characteristics in different portions of the detachment feature 108.1 and 108.2 in accordance with an embodiment of the present disclosure. As shown in FIG. 11, the detachment feature 108 is divided into different sections 108.1 and 108.2. There is a section 108a.1, 108b.1, 108c.1, and 108d.1 which is located between the left side handle detachment guides 120a, 120b, 120c, and 120d and the right side handle detachment guides 122a, 122b, 122c, and 122d. There is also sections 108a.2, 108b.2, 108c.2, and 108d.2 located to the right of the right handle detachment guides 122a, 122b, 122c, and 122d, and to the left of the left handle detachment guides 120a, 120b, 120c, and 120d.
Section 108a.1/108b.1/108c.1/108d.1 has a different perforation characteristic than the rest of the detachment feature 108a.2, 108b.2, 108c.2 and 108d.2 (e.g., on sidewall 102a, detachment feature 108a.1 which is located between the left side handle detachment guide 120a and the right side handle detachment guide 122a has a different perforation characteristic than detachment guide 108a.2 which is located to the left of the left side handle detachment guide 120a and to the right of the right side handle detachment guide 122a, on sidewall 102b, detachment feature 108b.1 which is located between the left side handle detachment guide 120b and the right side handle detachment guide 122b has a different perforation characteristic than detachment guide 108b.2 which is located to the left of the left side handle detachment guide 120b and to the right of the right side handle detachment guide 122b, on sidewall 102c, detachment feature 108c.1 which is located between the left side handle detachment guide 120c and the right side handle detachment guide 122c has a different perforation characteristic than detachment guide 108c.2 which is located to the left of the left side handle detachment guide 120c and to the right of the right side handle detachment guide 122c, and on sidewall 102d, detachment feature 108d.1 which is located between the left side handle detachment guide 120d and the right side handle detachment guide 122d has a different perforation characteristic than detachment guide 108d.2 which is located to the left of the left side handle detachment guide 120d and to the right of the right side handle detachment guide 122d). These differences in perforations enable one section of the handle 124a/124b/124c/124d to be easier to open than other sections on the detachment feature 108a.2/108b.2/108c.2/108d.2.
FIG. 12 depicts a top view of a flattened blank for the food container 100 prior to assembly that is similar to the embodiment of FIG. 10 prior to assembly with vertical cut guides 226 in accordance with an embodiment of the present disclosure. The vertical cut guides, and other cut guides described herein, may be implemented as thin through cuts or as scoring or laser cutting of the sidewall, as is appropriate for different materials and end use cases. FIG. 12 includes vertical cut guides 226a, 226b, 226c and 226d which intersect perpendicularly to their respective detachment feature 108a, 108b, 108c, and 108d and are centered in the middle of their respective detachment feature 108a/108b/108c/108d between the right side handle detachment guide 122a/122b/122c/122d and the left side handle detachment guide 120a/120b/120c/120d (e.g., vertical cut guides 226a intersect perpendicularly to detachment feature 108a and are located between right side handle detachment guide 122a and left side handle detachment guide 120a, vertical cut guides 226b intersect perpendicularly to detachment feature 108b and are located between right side handle detachment guide 122b and left side handle detachment guide 120b, vertical cut guides are 226c intersect perpendicularly to detachment feature 108c and are located between right side handle detachment guide 122c and left side handle detachment guide 120c and vertical cut guides 226d intersect perpendicularly to detachment feature 108d and are located between right side handle detachment guide 122d and left side handle detachment guide 120d), although such cut guides may be at different locations and orientations in different embodiments. The use of the vertical cut guides 226a/226b/226c/226d facilitate the user in removing the respective handle 124a, 124b, 124c and 124d (or initiating removal from other locations in other embodiments) from their respective sidewalls 102a, 102b, 102c, 102d. Although FIG. 12 shows vertical cut guides 226a/226b/226c/226d as three vertical cut guides intersecting perpendicularly to the detachment feature 108a/108b/108c/108d, it should be noted that any number of vertical cuts can be used.
FIG. 13 depicts a top view of a flattened blank of another embodiment of a food container 100 prior to assembly with downward and upward oriented rounded punch-out detachment guides 230 with vertical scoring 232 in accordance with an embodiment of the present disclosure. As depicted in FIG. 13, certain components and structure (e.g., components 102, 104, 108, 110, and 106b) are similar and function in a similar manner to those previously described in FIG. 1. It will be understood that similar modifications, substitutions, changes, and alternatives as described with respect to those components can be similarly implemented in the context of the embodiment of FIG. 13. As compared to FIG. 1, FIG. 13 includes upward oriented punch-out detachment guides 230a and 230d, and downward oriented punch-out detachment guides, 230b and 230c. The upward oriented punch-out detachment guides 230a/230d are located in the center of their respective detachment feature 108a and 108d with the apex of the punch-out touching their respective crease 110a/110d of their respective sidewall 102a/102d (e.g., sidewall 102a has an upward oriented punch-out detachment guide 230a that is located in the center of detachment feature 108a with its apex touching crease 110a and sidewall 102d has an upward oriented punch-out detachment guide 230d that is located in the center of detachment feature 108d with its apex touching crease 110d). There are small vertical cut guides 233a and 233d on their respective detachment features 108a/108d below the upward oriented punch-out detachment guides 230a/230d (e.g., small vertical cuts 233a are located on detachment feature 108a below the upward oriented punch-out detachment guide 230a and small vertical cuts 233d are located on detachment feature 108d below the upward oriented punch-out detachment guide 230d).
The downward oriented punch-out detachment guides 230b/230c are located in the center of their respective detachment feature 108b and 108c with each end of the downward oriented punch-out detachment guide 230b/230c touching their respective detachment guide 108b/108c and the apex facing the bottom of their respective sidewall 102b and 102c (e.g., sidewall 102b has a downward oriented punch-out detachment guide 230b that is located in the center of detachment feature 108b with the punch-out detachment guide 230b ends touching the detachment feature 108b and the apex facing towards the bottom of sidewall 102b, and sidewall 102c has a downward oriented punch-out detachment guide 230c that is located in the center of detachment feature 108c with the punch-out detachment guide 230c ends touching the detachment feature 108c and the apex facing towards the bottom of sidewall 102c). There are vertical cut guides 232b and 232c intersecting perpendicularly along the curvature of the downward oriented punch-out detachment guides 230b/230c (e.g., vertical cuts 232b intersect perpendicularly along the curvature of the downward oriented punch-out detachment guide 230b and vertical cuts 232c intersect perpendicularly along the curvature of the downward oriented punch-out detachment guide 230c). Although three cuts are shown in each punch-out detachment guide, any number of cuts can used and be placed in various locations along the punch-out detachment guide 230a/230b/230c/230d or the detachment feature 108a/108b/108c/108d. The punch-out detachment guides 230a/230b/230c/230d facilitate removing their respective foldable wings 104a/104b/104c/104d.
FIG. 14 depicts a top view of a flattened blank for the food container 100 prior to assembly with downward oriented rounded punch-out detachment guides with vertical scoring in accordance with an embodiment of the present disclosure. As depicted in FIG. 14, certain components and structure (e.g., components 102, 104, 108, 110, and 106b) are similar and function in a similar manner to those previously described in FIG. 1. It will be understood that similar modifications, substitutions, changes, and alternatives as described with respect to those components can be similarly implemented in the context of the embodiment of FIG. 14. As compared to FIG. 1, FIG. 14 includes downward oriented punch-out detachment guides 230a, 230b, and 230c and 230d on all four sidewalls 102a, 102b, 102c, 102d, whereas FIG. 13 only has downward oriented punch-out detachment guides 230b/230c on sidewalls 102b and 102c.
In FIG. 14, the downward oriented punch-out detachment guides 230a/230b/230c/230d are located in the center of their respective detachment feature 108a, 108b, 108c, and 108d with each end of the downward oriented punch-out detachment guide 230a/230b/230c/230d touching their respective detachment guide 108a/108b/108c/108d and the apex facing the bottom of their respective sidewall 102a/102b/102c/102d (e.g., sidewall 102a has a downward oriented punch-out detachment guide 230a that is located in the center of detachment feature 108a with the punch-out detachment guide 230a ends touching the detachment feature 108a and the apex facing towards the bottom of sidewall 102a, sidewall 102b has a downward oriented punch-out detachment guide 230b that is located in the center of detachment feature 108b with the punch-out detachment guide 230b ends touching the detachment feature 108b and the apex facing towards the bottom of sidewall 102b, sidewall 102c has a downward oriented punch-out detachment guide 230c that is located in the center of detachment feature 108c with the punch-out detachment guide 230c ends touching the detachment feature 108c and the apex facing towards the bottom of sidewall 102c and sidewall 102d has a downward oriented punch-out detachment guide 230d that is located in the center of detachment feature 108d with the punch-out detachment guide 230d ends touching the detachment feature 108d and the apex facing towards the bottom of sidewall 102d). Vertical cut guides 232a, 232b, 232c, and 232d intersect perpendicularly along the curvature of the downward oriented punch-out detachment guides 230a/230b/230c/230d (e.g., vertical cuts 232a intersect perpendicularly along the curvature of the downward oriented punch-out detachment guide 230a, vertical cuts 232b intersect perpendicularly along the curvature of the downward oriented punch-out detachment guide 230b, vertical cuts 232c intersect perpendicularly along the curvature of the downward oriented punch-out detachment guide 230c, and vertical cuts 232d intersect perpendicularly along the curvature of the downward oriented punch-out detachment guide 230d). Although three cuts are shown in each punch-out detachment guide, any number of cuts can used and be placed in various locations along the punch-out detachment guide 230a/230b/230c/230d or the detachment feature 108a/108b/108c/108d. The punch-out detachment guides 230a/230b/230c/230d facilitate removing their respective foldable wings 104a/104b/104c/104d.
FIG. 15 depicts a perspective view of another embodiment of a food container 100 in an open configuration with detachment features 108 located in the foldable wings 104 in accordance with an embodiment of the present disclosure. In some end-use applications it may not be desired to have ready access to eat out of the food container, but rather to perform other actions such as providing a container that is convenient for accessing food items (e.g., popcorn, small fruit, etc.). Accordingly, the detachment feature 108 may be located within the foldable wing 104. As depicted in FIG. 15, certain components and structure (e.g., components 102, 104, 108, 110, and 106b) are similar and function in a similar manner to those previously described in FIG. 1. It will be understood that similar modifications, substitutions, changes, and alternatives as described with respect to those components can be similarly implemented in the context of the embodiment of FIG. 15. As compared to FIG. 1, FIG. 15 shows its detachment feature 108a, 108b, 108c, and 108d located in their respective foldable wings 104a, 104b, 104c, and 104d of the food container 100. Although not depicted in FIG. 15, detachment aids such as structural ribs, handles, or punch-outs may be utilized with the embodiment of FIG. 15.
The detachment feature 108a/108b/108c/108d spans from corner to corner of their respective crease 110a, 110b, 110c, and 110d in and curves upward into their respective foldable wing 104a/104b/104c/104d (e.g., detachment feature 108a spans from the left corner of crease 110a to the right corner of crease 110a and curves upward into foldable wing 104a, detachment feature 108b spans from the left corner of crease 110b to the right corner of 110b and curves upward into the foldable wing 104b, detachment feature 108c spans from the left corner of crease 110c to the right corner of 110c and curves upward into foldable wing 104c, and detachment feature 108d spans from the left corner of the crease 110d to the right corner of the crease 110d and curves upward into foldable wing 104d). The detachment feature 108a/108b/108c/108d curves downward in a downward curving arc or a “frowning” pattern with the greatest distance from the corresponding crease 110a/110b/110c/110d being at the middle or center point of respective crease 110a/110b/110c/110d and respective foldable wing 104a/104b/104c/104d. Although in other embodiments, the detachment feature 108a/108b/108c/108d may have different shapes and patterns (e.g., with a greatest distance at one side to facilitate tearing from one side to another). This embodiment would be useful to prevent an overpacked food container 100 from overflowing when the foldable wings 104a/104b/104c/104d were removed.
FIG. 16 depicts a perspective view of the food container 100 of FIG. 15 with a portion of the foldable wing 104a removed above the detachment feature 108a in accordance with an embodiment of the present disclosure. As is depicted in FIG. 16, a portion of the foldable wing 104a remains above the crease 110a after removal. In this manner, the remaining portion of the foldable wing 104a (and other foldable wings 102b/102c/102d after removal) provides a flexible surface above and about crease 110a that provides a barrier to spillage of food items but is less obstructive than a complete foldable wing.
FIG. 17 depicts a perspective view of another embodiment of a food container 100 in a closed configuration with a wave-shaped detachment feature 302 in accordance with an embodiment of the present disclosure. As depicted in FIG. 17, certain components and structure (e.g., components 102, 104, 110, 112, and 106b) are similar and function in a similar manner to those previously described in FIG. 1. It will be understood that similar modifications, substitutions, changes, and alternatives as described with respect to those components can be similarly implemented in the context of the embodiment of FIG. 17. In some embodiments, the shape of the detachment feature may be modified in a manner that assists in removal or provides desired aesthetic characteristics. For example, detachment features may be configured in a variety of shapes such as multiple curves, angles, company logos or portions thereof, or combinations thereof. In the embodiment of FIG. 17, the detachment features 302a, 302b, 302c, and 302d are wave-shaped.
FIG. 18 depicts a perspective view of the food container 100 of FIG. 17 in an open configuration in accordance with an embodiment of the present disclosure. In this open configuration, the food container FIG. 17 functions identically to the food container of FIG. 2.
FIG. 19 depicts a perspective view of the food container 100 of FIG. 17 with a foldable wing 104a (not shown) and a portion of sidewall 102a removed in accordance with an embodiment of the present disclosure. The foldable wing 104a (not shown) is removed along the detachment feature 302a thereby creating a sidewall 102a with a wave-shaped edge. FIG. 19 also depicts that the structural ribs 112b/112c are visible on both the outside and the inside of the food container 100. (Although all structural ribs 112a/112b/112c/112d are visible on both the inside and outside of the food container 100, FIGS. 17 and 18 do not show the structural ribs 112d and 112a on the inside.)
FIG. 20 depicts a perspective view of the food container of FIG. 17 with all foldable wings 104a/104b/104c/104d removed in accordance with an embodiment of the present disclosure. In FIG. 20, each foldable wing 104a/104b/104c/104d (not shown in FIG. 20) is removed along their respective detachment features 302a/302b/302c/302d. This creates respective sidewalls 102a/102b/102c/102d with wave-shaped edges. FIG. 20 depicts a food container 100 that is user friendly in that there are no foldable wings 104a/104b/104c/104d that will get in the way of a user to trying to access the contents of the food container 100, while the wave shape provides a variety of locations for accessing the food items, supporting utensils, and the like.
FIG. 21 depicts a top view of a flattened blank of another embodiment of a food container 100 prior to assembly with the detachment features 108 located in the foldable wings 104 and with right side handle detachment guides 122, left side handle detachment guides 120, and handles 124 located in their respective foldable wings 104 in accordance with an embodiment of the present disclosure. As depicted in FIG. 21, certain components and structure (e.g., components 102, 104, 108, 110, and 106b) are similar and function in a similar manner to those previously described in FIGS. 15 and 16. It will be understood that similar modifications, substitutions, changes, and alternatives as described with respect to those components can be similarly implemented in the context of the embodiment of FIG. 21.
FIG. 21 shows detachment feature 108a, 108b, 108c, and 108d located in their respective foldable wing 104a, 104b, 104c, and 104d above their respective crease 110a, 110b, 110c, and 110d of their respective sidewall 102a, 102b, 102c, and 102d and the detachment feature 108a/108b/108c/108d runs between the left corner and right corner of its respective top crease 110a/110b/110c/110d (e.g., detachment feature 108a is located in foldable wing 104a above crease 110a and runs from the left corner to the right corner of crease 110a, detachment feature 108b is located in foldable wing 104b above crease 110b and runs from the left corner to the right corner of crease 110b, detachment feature 108c is located in foldable wing 104c above crease 110c and runs from the left corner to the right corner of crease 110c, and detachment feature 108d is located in foldable wing 104d above crease 110d and runs from the left corner to the right corner of crease 110d). Each detachment feature 108a/108b/108c/108d is located above its respective crease 110a/110b/110c/110d and is curved in a “frowning” pattern, with the greatest distance from the corresponding crease 110a/110b/110c/110d being at a middle or center point of the crease 110a/110b/110c/110d and foldable wing 104a/104b/104c/104d, although in other embodiments the detachment feature 108a/108b/108c/108d may have different shapes and patterns (e.g., with a greatest distance at one side to facilitate tearing from one side to another).
On each foldable wing 104a/102b/102c/102d there is a left side handle detachment guide 120a, 120b, 120c, and 120d and a right side handle detachment guide 122a, 122b, 122c and 122d. This left side handle detachment guide 120a/120b/120c/120d is perforated and starts perpendicularly at its respective crease 110a/110b/110c/110d and ends at its respective detachment feature 108a/108b/108c/108d. (e.g., left side handle detachment guide 120a starts perpendicularly at crease 110a and ends at detachment feature 108a, left side handle detachment guide 120b starts perpendicularly at crease 110b and ends at detachment feature 108b, left side detachment guide 120c starts perpendicularly at crease 110c and ends at detachment feature 110c, left side handle detachment guide 120d starts perpendicularly at crease 110d and ends at detachment feature 108d).
The right side handle detachment guide 122a/122b/122c/122d is perforated and starts perpendicularly to its respective crease 110a, 110b, 110c, and 110d and its respective detachment feature 108a/108b/108c/108d (e.g., right side handle detachment guide 122a starts perpendicularly at crease 110a and ends at detachment feature 108a, right side handle detachment guide 122b starts perpendicularly at crease 110b and ends at detachment feature 108b, right side detachment guide 122c starts perpendicularly at crease 110c and ends at detachment feature 108c, and right side handle detachment guide 122d starts perpendicularly at crease 110d and ends at detachment feature 108d runs perpendicular to the crease 110d). Both the left side handle detachment guides 120a/120b/120c/120d and the right side handle detachment guides 122a/122b/122c/122d are shown as a straight line in FIG. 21, but can be other shapes as well.
FIG. 21 also shows a handle 124 in each respective side 102. This handle 124a, 124b, 124c and 124d is created when the left side handle detachment guide 120a/120b/120c/120d, the right side handle detachment guide 122a/122b/122c/122d and the portion of the respective detachment feature 108a/108b/108c/108d located between the left side handle detachment guide 120 and the right side detachment guide 122 is punched open along the perforation (e.g., the left side handle detachment guide 120a, the right side handle detachment guide 122a and the portion of the detachment feature 108a between these two guides is punched out and creates handle 124a, the left side handle detachment guide 120b, the right side handle detachment guide 122b and the portion of the detachment feature 108b between these two guides is punched out and creates handle 124b, the left side handle detachment guide 120c, the right side handle detachment guide 122c and the portion of the detachment feature 108c between these two guides is punched out and creates handle 124c and the left side handle detachment guide 120d, the right side handle detachment guide 122d and the portion of the detachment feature 108d between these two guides is punched out and creates handle 124d).
FIG. 22 depicts a top view of a flattened blank of another embodiment of a food container 100 prior to assembly with detachment features 208 located in both the sidewalls 102 and the foldable wings 104 and with right side handle detachment guides 122, left side handle detachment guides 120, and handles 124 running from their respective upper detachment feature 208 in their respective foldable wings 104 to their respective lower detachment feature 2081.1 in their respective sidewalls 102 in accordance with an embodiment of the present disclosure. As depicted in FIG. 22, certain components and structure (e.g., components 102, 104, 108, 110, and 106b) are similar and function in a similar manner to those previously described in FIGS. 1, 815, and 21. It will be understood that similar modifications, substitutions, changes, and alternatives as described with respect to those components can be similarly implemented in the context of the embodiment of FIG. 22.
In the embodiment of FIG. 22, detachment features 208 are located in both the sidewalls 102 and the foldable wings 104, providing the user with optionality as to a configuration of the food container. For example, a user could detach along the detachment features 208 within the sidewalls 102 for some portions of the food container 100 and along the detachment features 208 within the foldable wings 104 for other portions of the food container, providing some areas for accessing the food item (e.g., facing the use) and other areas for retaining the food item and preventing spillage (e.g., opposite the user). Although handles 124 are depicted in FIG. 22, it will be understood that FIG. 22 can be implemented without handles and that other detachment aids (e.g., cut guides, punch-outs, contoured sidewall connectors, etc.) may be combined or substituted for the depicted handles.
FIG. 22 shows a lower detachment feature 208a.1, 208b.1, 208c.1, and 208d.1 located in their respective sidewalls 102a, 102b, 102c, and 102d and an upper detachment feature 208a.2, 208b.2, 208c.2 and 208d.2 located in their respective foldable wing 104a, 104b, 104c, and 104d above their respective crease 110a, 110b, 110c, and 110d of their respective sidewall 102a, 102b, 102c, and 102d. The lower detachment feature 208a.1/208b. 1/208c. 1/208d. 1 runs between the left corner and right corner of its respective top crease 110a/110b/110c/110d (e.g., lower detachment feature 208a.1 is located in sidewall 102a below crease 110a and runs from the left corner to the right corner of crease 110a, lower detachment feature 208b. 1 is located in sidewall 102b below crease 110b and runs from the left corner to the right corner of crease 110b, lower detachment feature 208c.1 is located in sidewall 102c below crease 110c and runs from the left corner to the right corner of crease 110c, and lower detachment feature 208d.1 is located in sidewall 102d below crease 110d and runs from the left corner to the right corner of crease 110d). The lower detachment feature 208a.1/208b.1/208c.1/208d.1 is located below its respective crease 110a/110b/110c/110d and is curved in a “smiling” pattern, with the greatest distance from the corresponding crease being at a middle or center point of the crease and sidewall, although in other embodiments the lower detachment feature 208a.1/208b.1/208c.1/208d.1 may have different shapes and patterns (e.g., with a greatest distance at one side to facilitate tearing from one side to another).
The upper detachment feature 208a.2/208b.2/208c.2/208d.2 runs between the left corner and right corner of its respective top crease 110a/110b/110c/110d and is located in its respective foldable wing 104a/104b/104c/104d (e.g., upper detachment feature 208a.2 is located in foldable wing 104a above crease 110a and runs from the left corner to the right corner of crease 110a, upper detachment feature 208b.2 is located in foldable wing 104b above crease 110b and runs from the left corner to the right corner of crease 110b, upper detachment feature 208c.2 is located in foldable wing 104c above crease 110c and runs from the left corner to the right corner of crease 110c, and upper detachment feature 208d.2 is located in foldable wing 104d above crease 110d and runs from the left corner to the right corner of crease 110d). The upper detachment feature 208a.2/208b.2/208c.2/208d.2 is located above its respective crease 110a/110b/110c/110d and is curved in a “frowning” pattern, with the greatest distance from the corresponding crease being at a middle or center point of the crease and foldable wing, although in other embodiments the detachment feature may have different shapes and patterns (e.g., with a greatest distance at one side to facilitate tearing from one side to another).
In FIG. 22, there is a left side handle detachment guide 120a, 120b, 120c, and 120d and a right side handle detachment guide 122a, 122b, 122c and 122d that runs from the upper detachment feature 208a.2/208b.2/208c.2/208d.2 intersecting perpendicularly its respective crease 110a/110b/110c/110d and ending at its respective lower detachment feature 208a.1/208b.1/208c.1/208d.1. The left side handle detachment guide 120a/120b/120c/120d is perforated and starts at its respective upper detachment feature 208a.2/208b.2/208c.2/208d.2 and runs from the respective upper detachment feature 208a.2/208b.2/208c.2/208d.2, intersects perpendicularly its respective crease 110a/110b/110c/110d and ends at its respective lower detachment feature 208a.1/208b. 1/208c. 1/208d.1 (e.g., left side handle detachment guide 120a starts at upper detachment feature 208a.2, runs perpendicularly through crease 110a and ends at lower detachment feature 208a.1, left side handle detachment guide 120b starts at upper detachment feature 208b.2, runs perpendicularly through crease 110b and ends at lower detachment feature 208b.1, left side detachment guide 120c starts at upper detachment feature 208c.2, runs perpendicularly through crease 110c and ends at lower detachment feature 208c.1, left side handle detachment guide 120d starts at upper detachment feature 208d.2, runs perpendicularly through crease 110d and ends at lower detachment feature 208d. 1).
The right side handle detachment guide 122a/122b/122c/122d is perforated and starts at its respective upper detachment feature 208a.2/208b.2/208c.2/208d.2 and runs from the respective upper detachment feature 208a.2/208b.2/208c.2/208d.2, intersects perpendicularly its respective crease 110a/110b/110c/110d and ends at its respective lower detachment feature 208a.1/208b.1/208c.1/208d.1 (e.g., right side handle detachment guide 122a starts at upper detachment feature 208a.2, runs perpendicularly through crease 110a and ends at lower detachment feature 208a.1, right side handle detachment guide 122b starts at upper detachment feature 208b.2, runs perpendicularly through crease 110b and ends at lower detachment feature 208b. 1, right side detachment guide 122c starts at upper detachment feature 208c.2, runs perpendicularly through crease 110c and ends at lower detachment feature 208c.1, right side handle detachment guide 122d starts at upper detachment feature 208d.2, runs perpendicularly through crease 110d and ends at lower detachment feature 208d.1).
FIG. 22 also shows a handle 124 in each respective side 102 and respective foldable wing. This handle 124a, 124b, 124c and 124d is created when the left side handle detachment guide 120a/120b/120c/120d, the right side handle detachment guide 122a/122b/122c/122d and the portion of the respective lower detachment feature 208a.1/208b.1/208c. 1/208d. 1 and the portion of the respective upper detachment feature 208a.2/208b.2/208c.2/208d.2 both located between the left side handle detachment guide 120a/120b/120c/120d and the right side detachment guide 122a/122b/122c/122d is punched open along the perforation (e.g., the left side handle detachment guide 120a, the right side handle detachment guide 122a and the portion of the lower detachment feature 208a.1 and the portion of the upper detachment feature 208a.2 between these two guides is punched out and creates handle 124a, the left side handle detachment guide 120b, the right side handle detachment guide 122b and the portion of the lower detachment feature 208b.1 and the portion of the upper detachment feature 208b.2 between these two guides is punched out and creates handle 124b, the left side handle detachment guide 120c, the right side handle detachment guide 122c and the portion of the lower detachment feature 208c.1 and portion upper detachment feature 208c.2 between these two guides is punched out and creates handle 124c and the left side handle detachment guide 120d, the right side handle detachment guide 122d and the portion of the lower detachment feature 208d. 1 and the portion of the upper detachment feature 208d.2 between these two guides is punched out and creates handle 124d). In this embodiment, a larger handle 124a/124b/124c/124d is created.
FIG. 23 depicts a top view of a flattened blank of another embodiment of a food container 100 prior to assembly with a detachment strip 310 in accordance with an embodiment of the present disclosure. The detachment strip 310 are two parallel perforated curved lines curved in a “smiling” pattern, with the greatest distance from the corresponding crease being at a middle or center point of the crease and sidewall, although in other embodiments the detachment feature may have different shapes and patterns (e.g., with a greatest distance at one side to facilitate tearing from one side to another). Further, the detachment strip 310 starts on the left side of its respective foldable wing 104, extends down through the left side of its respective crease 110 in the “smiling” pattern and then curves back upward through the right side of its respective crease 110 ending on the right side of it respective foldable wing 104.
As depicted in FIG. 23, certain components and structure (e.g., components 102, 104, 110, and 106b) are similar and function in a similar manner to those previously described in FIG. 1. It will be understood that similar modifications, substitutions, changes, and alternatives as described with respect to those components can be similarly implemented in the context of the embodiment of FIG. 23.
As compared to FIG. 1, FIG. 23 shows a detachment strip 310 that starts on the left side of its respective foldable wing 104, above the left corner of its respective crease 110, extends down through the left side of its respective crease 110 into its respective sidewall 102 and then curves upward back through the right side of its respective crease 110 and ends above the right corner of its respective crease 110 on the right side of its respective foldable wing 104 (e.g., detachment strip 310a begins above the left corner of crease 110a in foldable wing 104a and extends down through the left side of crease 110a into sidewall 102a and then curves upward back through the right side of crease 110a and ends above the right corner of crease 110a in foldable wing 104a, detachment strip 310b begins above the left corner of crease 110b in foldable wing 104b and extends down through the left side of crease 110b into sidewall 102b and then curves upward back through the right side of crease 110b and ends above the right corner of crease 110b in foldable wing 104b, detachment strip 310c begins above the left corner of crease 110c in foldable wing 104c and extends down through the left side of crease 110c into sidewall 102c and then curves upward back through the right side of crease 110c and ends above the right corner of crease 110c in foldable wing 104c, and detachment strip 310d begins above the left corner of crease 110d in foldable wing 104d and extends down through the left side of crease 110d into sidewall 102d and then curves upward back through the right side of crease 110d and ends above the right corner of crease 110d in foldable wing 104d). Detachment feature 310a/310b/310c/310d is curved upward in a “smiling” pattern with the greatest distance from the corresponding crease being at a middle or center point of the crease, sidewall, and foldable wing, although in other embodiments, the detachment feature may have different shapes and patterns (e.g., with a greatest distance at one side to facilitate caring from one side to another).
FIG. 24 depicts a top view of a flattened blank of another embodiment of a food container 100 prior to assembly with a detachment feature 108 that intersects the crease 110 of the food container 100 in accordance with an embodiment of the present disclosure. As depicted in FIG. 24, certain components and structure (e.g., components 102, 104, 108, 110, and 106b) are similar and function in a similar manner to those previously described in FIG. 1. It will be understood that similar modifications, substitutions, changes, and alternatives as described with respect to those components can be similarly implemented in the context of the embodiment of FIG. 24.
As compared to FIG. 1, FIG. 24 shows a detachment feature 108 that starts on the left side of its respective foldable wing 104, above the left corner of its respective crease 110, extends down through the left side of its respective crease 110 into its respective sidewall 102 and then curves upward back through the right side of its respective crease 110 and ends above the right corner of its respective crease 110 on the right side of its respective foldable wing 104 (e.g., detachment feature 108a begins above the left corner of crease 110a in foldable wing 104a and extends down through the left side of crease 110a into sidewall 102a and then curves upward back through the right side of crease 110a and ends above the right corner of crease 110a in foldable wing 104a, detachment feature 108b begins above the left corner of crease 110b in foldable wing 104b and extends down through the left side of crease 110b into sidewall 102b and then curves upward back through the right side of crease 110b and ends above the right corner of crease 110b in foldable wing 104b, detachment feature 108c begins above the left corner of crease 110c in foldable wing 104c and extends down through the left side of crease 110c into sidewall 102c and then curves upward back through the right side of crease 110c and ends above the right corner of crease 110c in foldable wing 104c, and detachment feature 108d begins above the left corner of crease 110d in foldable wing 104d and extends down through the left side of crease 110d into sidewall 102d and then curves upward back through the right side of crease 110d and ends above the right corner of crease 110d in foldable wing 104d).
Detachment feature 108a/108b/108c/108d is curved upward in a “smiling” pattern with the greatest distance from the corresponding crease being at a middle or center point of the crease, sidewall, and foldable wing, although in other embodiments, the detachment feature may have different shapes and patterns (e.g., with a greatest distance at one side to facilitate caring from one side to another).
As the detachment feature 108a/108b/108c/108d crosses through its respective crease 110a/110b/110c/110d on both the left side and the right side, a handle 124a, 124b, 124c, 124d is created if the user chooses to punch out the perforation of the detachment feature 108a/108b/108c/108d below its respective crease 110a/110b/110c/110d and thus leaving the right side and the left side of the detachment feature 108a/108b/108c/108d above the respective crease 110a/110b/110c/110d intact (e.g., punching out detachment feature 108a only below crease 110a creates handle 124a, punching out detachment feature 108b only below crease 110b creates handle 124b, punching out detachment feature 108c only below crease 110c creates handle 124c, and punching out detachment feature 108c only below crease 110d creates handle 124d).
FIG. 25 depicts exemplary steps of manufacturing a flattened bank of a convertible food container 100 in accordance with an embodiment of the present disclosure. At step 2502 a blank is prepared for the food container 100. The blank is made from a material that is sturdy enough to be an assembled container. The blank can made from a variety of materials including paper, cardboard, fibers, light metal (e.g., light aluminum), plastics/polymers, foam, and combinations of materials (e.g., a cardboard container having plastic “windows” on one or more sides). The blank material can include various treatments or coatings suitable for particular applications, such as to prevent leakage of liquid or viscous portions of the food items, to absorb moisture, to insulate to retain temperature, etc. Further, the blank can be various sizes depending on the desired end use of the food container 100. The blank size can vary from small enough to carry a single food serving when assembled into a food container 100 to carrying multiple food portions for serving multiple people when assembled into a food container 100. The blank can also have various shapes such as squares, rectangles, circles, ovals, polygons, or irregular shapes, as may suit a particular end use application (e.g., customized shapes for particular food items). Further, more than one blank can be combined to manufacture a food container 100.
Once the blank is prepared in step 2502, the detachment feature locations and parameters are determined in step 2504. The detachment features 108 can include perforations along parts of the blank, handles, punch-out tabs, detachment strips, etc. These detachment features may be located in various locations such as above or below the crease 110 of the sidewall 102, i.e., the detachment features 108 can be located solely above the foldable wings 104 or solely in the sidewalls 102 or in a combination of both the foldable wings 104 and the sidewalls 102 in various proportions. The detachment features 108 can also be various shapes. The detachment features 108 can have can be curved upwards, curved downwards, be straight, be wave-patterned or have one or more parallel lines. In some instances, the detachment feature can release such that a brand symbol or icon is displayed. Once the detachment feature and locations parameters are determined in step 2504, step 2506 determines whether or not structural ribs 112 are to be added to the blank.
In step 2506, if structural ribs 112 are to be added, processing continues to step 2508 to determine the structural rib 112 locations and parameters. The structural ribs 112 may be manufactured such that the portion of the blank that makes up the rib is thicker than rest of the food container 100. In another example, the structural ribs 112 can be reinforced with a different material than the food container 100 such as with a wire or a plastic frame. The structural ribs 112 may be vertical and oriented perpendicular to their respective top crease 110, or can vary in shape, size, number, and orientation and still provide the required stability for the intended use of the food container 100. Once the rib locations and parameters are determined, the process continues to step 2510. Or if it if determined that structural ribs 112 will not be added, the process continues directly to step 2510 from step 2506.
Step 2510 determines whether detachment guides 120, 122, 230 will be placed on the blank. If detachment guides 120/122/230 are to be added, the process proceeds to step 2512. In step 2512, the process determines the detachment guide locations and parameters. The detachment guides 120/122/230 can be lines or punch out tabs 230. The detachment guides 120/122/230 can be located in various parts of the food container 100. The detachment guides can be perforated lines or cut lines which often intersect the detachment feature 108/208. The detachment guides 120/122/230 can be in various orientations and lengths and shapes located in any position across the detachment feature 108/208 and can include more than one of each (e.g., there could be a two or more handle detachment guides). For example, the right and left side handle detachment guides 120/122 intersect the detachment feature 108 and their respective crease 110 at a right angle, the right and left side handle detachment guides 120/122 can intersect the detachment feature and the crease at any angle. Further, the right and left side handle detachment guides 120/122 can be various distances along the detachment guides 108/208. For example, the right and left side handle detachment guides 120/122 can be equidistant from the center of the food container 100, or they can be located in any distance along the detachment guide 108/208. Also, the right and left side handle detachment guides can be a variety of perforations or cuts. Once the process determines the guide locations and parameters in step 2512, the process moves on to step 2514. Or if it is determined in step 2510 that no detachment guides are to be added, the process moves directly to step 2514.
In step 2514, it is determined if guided tabs 106 are to be added to the blank. If guided tabs 106 are to be added, the process moves to step 2516 to determine tab locations and parameters. The tab 106a and tab slot 106b are located on opposing sidewalls 102. There can be multiple tabs 106a and tab slots 106b. Instead of tabs 106a and tab slots 106b, an adhesive could also be placed on a wing of the food container 100 blank to allow the user to securely close the food container 100. In that scenario, the adhesive would likely be placed on the underside of the wing. Once the tab locations and parameters are determined in step 2516, the process proceed to step 2518. Or if it is determined in step 2514 that no guided tabs are to be placed on the blank, the process moves directly to step 2518.
In step 2518, the blank is modified according to features determined to be added during the process. Once the blank is modified, the process ends.
FIG. 26 depicts the exemplary steps of using a convertible food container in accordance with an embodiment of the present disclosure. Starting with step 2602, the user obtains a food container 100. A user can include the actual consumer of the food or a food service worker. In step 2604, the user can then place food item(s) in the food compartment. The user can be using it to put food items in it to take them “to go”, they can be using the container to put left over food items after their meal is complete as in a “doggy bag” or a food service worker can be placing food items in the container for the customer.
Once the food item(s) are in the food container, in step 2606, the user seals the food container 100. The user folds the foldable wings 104. If the food container 100 has a tab 106a and a tab slot 106b, once the foldable wings 104 are folded, the user inserts the tab 106a and into tab slot 106b to secure the food item(s) in the food container 100. If there is no tab 106a and tab slot 106, the food container may have an adhesive on the underside of one of the foldable wings to secure the food container 100. Or the user may use an auxiliary adhesive, string or rubber band to secure the container.
In step 2608, the user transports the food container 100 to their desired location. When the user is ready to consume the contents in the food container 100, they will release the foldable wings 104 in step 2610.
Once the foldable wings 104 are released, the user proceeds to step 2612. In step 2612, the user can decide to engage a portion or all of the detachment feature 108 in order to more easily consume the food item(s). In step 2614, the user will then dispose of the removed portion. The user will then consumer the food item(s) within the non-removed portions in step 2616. As the detachment feature and/or features 108 are removed, the enables the user to more easy access the food item(s) in the food container 100. Once the user has completed consuming the food item(s) they desire in the food container 100 and decide they no longer want any more of the food item(s), the user will dispose of the non-used food item(s) and the used food container in step 2618, thus ending the process.
The foregoing description includes exemplary embodiments in accordance with the present disclosure. These examples are provided for purposes of illustration only, and not for purposes of limitation. It will be understood that the present disclosure may be implemented in forms different from those explicitly described and depicted herein and that various modifications, optimizations, and variations may be implemented by a person of ordinary skill in the present art, consistent with the following claims.
Patent Application
20250042602
