Patent Application
20250033859
The present disclosure is directed to foldable containers formed of a single piece of corrugated cardboard, where said container is capable of maintaining a modified atmosphere environment.
Corrugated paper cartons (CPC), both waxed and unwaxed, and reusable plastic containers (RPC) have been used to transport produce, flowers, plants, and the like in ambient atmosphere conditions. CPC and RPC conventionally rely extensively on a porous construction (e.g., containers with slots and vents) to provide cooling of the goods housed therein. However, the continuous exposure to ambient conditions often leads to desiccation and oxidation of the products therein, as well as acceleration of said products' physiological processes therein, which may reduce the quality and shelf life of said products.
To reduce respiration rate and delay senescence, top-icing in waxed-CPC or RPC have been used for shipment of perishables (e.g., broccoli, watercress). The purpose is to ensure the produce remains cold and adequately hydrated. However, issues related to lack of recyclability and co-shipment of ice/water have driven a need to look at sustainable alternatives for product's shelf-life preservation.
Modified atmosphere packaging (MAP) is an alternative to CPC and RPC where the atmosphere inside the packaging is manipulated to delay product senescence. For the transport of perishables like produce (e.g., broccoli, green onions, brussels sprouts, watercress, and cilantro), flowers, and plants, MAP results in higher-quality, longer-shelf-life products after delivery. MAP exploits the dynamic relationship between fresh produce's respiration rate and mass transfer properties of the package materials to establish optimal reduced O2 and elevated CO2 concentrations in the headspace, aiming to decrease produce respiration rate, reduce production/sensitivity of ethylene, delay deterioration phenomena (e.g., microbial growth, ripening), and so on. For example, the use of MAP may actually extend the useful distribution and shelf life of produce by about 4 to 5 times as compared to conventional CPC and RPC.
Wrapping individual products or small groups of individual products in plastic with a modified atmosphere (e.g., via vacu-seal or with reduced oxygen concentration) is a common MAP practice. However, these MAP techniques increase the cost of packaging because the plastic wrapped products still need to be contained in larger containers (e.g., cardboard boxes) for transport). Further, for products like produce, flowers, plants, and the like, these techniques may not be available at the point of harvest, or to provide for said MAP technique on-site would be prohibitively expensive. Additionally, the wrapping itself, especially in vacu-seal techniques, may exert too much pressure on the produce, flowers, plants, and the like, causing physically damage. Besides, the generation of solid waste from these non-recyclable plastic wraps is an environmental issue.
Thus, there exists a need in the art to provide cardboard-based containers capable of implementing MAP techniques but having less additional packaging requirements, especially containers suitable for use when harvesting, transporting, and storing goods like produce, flowers, and plants.
The present disclosure is directed to foldable containers formed of a single piece of corrugated cardboard, where said container is capable of maintaining a modified atmosphere.
Disclosed herein is a container that may comprise: a single piece of corrugated cardboard that, in an assembled-closed configuration, comprises (i) four walls connected via gusset folds to form four corners, (ii) a bottom contiguous with the four walls, (iii) a top contiguous with one of the four walls and not contiguous with three of the four walls, (iv) three top flaps each contiguous with one of the three of the four walls not contiguous with the top such that each of the top flaps fold into the container and engage the top, and (v) a closing flap contiguous with the top such that the closing flap engages an opposing wall to the one of the four walls contiguous with the top; wherein each gusset fold comprises a first fold portion having a tab and a second fold portion having a notch, wherein the tab and notch of each gusset fold are configured to interlock in the assembled-closed configuration; and wherein the container is capable of maintaining a modified atmosphere in the assembled-closed configuration.
Disclosed herein is a method that comprises: transitioning a container from a folded-collapsed configuration to an assembled-open configuration, the container comprising: a single piece of corrugated cardboard that, in an assembled-closed configuration, comprises (i) four walls connected via gusset folds to form four corners, (ii) a bottom contiguous with the four walls, (iii) a top contiguous with one of the four walls and not contiguous with three of the four walls, (iv) three top flaps each contiguous with one of the three of the four walls not contiguous with the top such that each of the top flaps fold into the container and engage the top, and (v) a closing flap contiguous with the top such that the closing flap engages an opposing wall to the one of the four walls contiguous with the top; wherein each gusset fold comprises a first fold portion having a tab and a second fold portion having a notch, wherein the tab and notch of each gusset fold are configured to interlock in the assembled-closed configuration; wherein the container is capable of maintaining a modified atmosphere in the assembled-closed configuration; and wherein the four walls, the four corners, and the bottom define a cavity in the assembled-open configuration; adding a product to cavity; and transitioning the container from the assembled-open configuration to the assembled-closed configuration.
Disclosed herein is a method that comprises: transitioning a container from a folded-collapsed configuration to an assembled-open configuration at a first site, the container comprising: a single piece of corrugated cardboard that, in an assembled-closed configuration, comprises (i) four walls connected via gusset folds to form four corners, (ii) a bottom contiguous with the four walls, (iii) a top contiguous with one of the four walls and not contiguous with three of the four walls, (iv) three top flaps each contiguous with one of the three of the four walls not contiguous with the top such that each of the top flaps fold into the container and engage the top, and (v) a closing flap contiguous with the top such that the closing flap engages an opposing wall to the one of the four walls contiguous with the top; wherein each gusset fold comprises a first fold portion having a tab and a second fold portion having a notch, wherein the tab and notch of each gusset fold are configured to interlock in the assembled-closed configuration; wherein the container is capable of maintaining a modified atmosphere in the assembled-closed configuration; and wherein the four walls, the four corners, and the bottom define a cavity in the assembled-open configuration; adding a product to cavity at the first site; transitioning the container from the assembled-open configuration to the assembled-closed configuration at the first site; transporting the container having the product therein to a second site; and storing the product at the second site.
Disclosed herein is a container that comprises: a single piece of corrugated cardboard having a first side and a second side that, in an assembled-closed configuration, comprises four walls, a bottom, a top, two bottom flaps, two wall flaps, two wall fold overs, and a closing flap, wherein each of the foregoing have a first side corresponding to the first side of the corrugated cardboard and a second side corresponding to the second side of the corrugated cardboard; wherein a fourth wall is continuous with a first wall, a bottom, a third wall, and a top, wherein in a first direction and in order the following are contiguously connected: the closing flap, the top, the fourth wall, the bottom, and a second wall, wherein in a second direction perpendicular to the first direction and in order the following are contiguously connected: the third wall, the fourth wall, and the first wall, wherein the second side of each of the two bottom flaps engages the first side of the bottom, wherein the second side of a first of the two side flaps engages the first side of a first wall and the second side of a second side of the two side flaps engages the first side of a third wall, wherein the first side of a first of the two wall fold overs engages the first side of the first of the two sidewall flaps and the first side of a second of the two wall fold overs engages the first side of the second of the two sidewall flaps, and wherein the closing flap engages the second wall; and wherein the container is capable of maintaining a modified atmosphere in the assembled-closed configuration.
Disclosed herein is a method that comprises: transitioning a container from a single-layer configuration to an assembled-open configuration, the container comprising: a single piece of corrugated cardboard having a first side and a second side that, in an assembled-closed configuration, comprises four walls, a bottom, a top, two bottom flaps, two wall flaps, two wall fold overs, and a closing flap, wherein each of the foregoing have a first side corresponding to the first side of the corrugated cardboard and a second side corresponding to the second side of the corrugated cardboard; wherein a fourth wall is continuous with a first wall, a bottom, a third wall, and a top, wherein in a first direction and in order the following are contiguously connected: the closing flap, the top, the fourth wall, the bottom, and a second wall, wherein in a second direction perpendicular to the first direction and in order the following are contiguously connected: the third wall, the fourth wall, and the first wall, wherein the second side of each of the two bottom flaps engages the first side of the bottom, wherein the second side of a first of the two side flaps engages the first side of a first wall and the second side of a second side of the two side flaps engages the first side of a third wall, and wherein the first side of a first of the two wall fold overs engages the first side of the first of the two sidewall flaps and the first side of a second of the two wall fold overs engages the first side of the second of the two sidewall flaps; and wherein the container is capable of maintaining a modified atmosphere in the assembled-closed configuration; and wherein a cavity in the container in the assembled-open configuration is defined by at least the first side of the two bottom flaps, the second side of the two fold overs, the second wall, and the fourth wall; adding a product to cavity; and transitioning the container from the assembled-open configuration to the assembled-closed configuration by engaging the closing flap and the second wall.
Disclosed herein is a method that comprises: transitioning a container from a single-layer configuration to an assembled-open configuration, the container comprising: a single piece of corrugated cardboard having a first side and a second side that, in an assembled-closed configuration, comprises four walls, a bottom, a top, two bottom flaps, two wall flaps, two wall fold overs, and a closing flap, wherein each of the foregoing have a first side corresponding to the first side of the corrugated cardboard and a second side corresponding to the second side of the corrugated cardboard; wherein a fourth wall is continuous with a first wall, a bottom, a third wall, and a top, wherein in a first direction and in order the following are contiguously connected: the closing flap, the top, the fourth wall, the bottom, and a second wall, wherein in a second direction perpendicular to the first direction and in order the following are contiguously connected: the third wall, the fourth wall, and the first wall, wherein the second side of each of the two bottom flaps engages the first side of the bottom, wherein the second side of a first of the two side flaps engages the first side of a first wall and the second side of a second side of the two side flaps engages the first side of a third wall, and wherein the first side of a first of the two wall fold overs engages the first side of the first of the two sidewall flaps and the first side of a second of the two wall fold overs engages the first side of the second of the two sidewall flaps; and wherein the container is capable of maintaining a modified atmosphere in the assembled-closed configuration; and wherein a cavity in the container in the assembled-open configuration is defined by at least the first side of the two bottom flaps, the second side of the two fold overs, the second wall, and the fourth wall; adding a product to cavity at the first site; transitioning the container from the assembled-open configuration to the assembled-closed configuration at the first site; transporting the container having the product therein to a second site; and storing the product at the second site.
These and other aspects of the present invention may be realized in an improved foldable container as shown and described in the following figures and related description.
It will be appreciated that the drawings are illustrative and not limiting of the scope of the invention, which is defined by the appended claims. The embodiments shown accomplish various aspects and objects of the invention. It is appreciated that it is not possible to clearly show each element and aspect of the invention in a single figure, and as such, multiple figures are presented to separately illustrate the various details of the invention in greater clarity. Similarly, not every embodiment need accomplish all advantages of the present invention. Elements and acts in the figures are illustrated for simplicity and have not necessarily been rendered according to any particular sequence or embodiment.
The present disclosure is directed to foldable containers formed of a single piece of corrugated cardboard, where said container is capable of maintaining a modified atmosphere. Because the container is formed by a single piece of corrugated cardboard, the container may be shipped and stored before use in a flat configuration (e.g., a single-layer configuration or a folded-collapsed configuration discussed in detail herein) that is one to a few layers thick of corrugated cardboard. Further, because of the folding mechanism, the container is easily transitioned from one of the flat configurations to a 3-dimensional, assembled configuration with a cavity (e.g., an assembled-open configuration) ready to receive products and be closed (e.g., to an assembled-closed configuration). Once closed, the folding mechanism and, optionally, the inclusion of adhesive and/or coating, enable the container to be sufficiently sealed to be able to maintain a modified atmosphere therein during transport and storage of the products. As such, the containers of the present disclosure are especially advantageous for the harvesting and transport of perishable products like produce, flowers, and plants.
Further, because the container is primarily, if not completely, cardboard, the container may advantageously be paper recycle compatible. When adhesives and/or coatings are included, paper recycle compatible adhesives and coating are preferred to maintain the paper recycle compatibility of the container.
The foldable containers of the present disclosure formed of a single piece of corrugated cardboard may have configurations that include a single-layer configuration, a folded-collapsed configuration, an assembled configuration, and configurations therebetween. As used herein, a “single-layer configuration” refers to a configuration where the corrugated cardboard is not folded and lying as a flat, single-layer of cardboard. As used herein, a “folded-collapsed configuration” refers to a configuration where the corrugated cardboard is folded along some of the fold lines such that portions of the cardboard overlap but a flat configuration is maintained with a maximum thickness of no more than three layers of cardboard (illustrated in
In
The container 100 comprises a single piece of corrugated cardboard 106 having a first side 106a (illustrated as white) and a second side 106b (illustrated with hatching). As illustrated, the first side 106a forms most of the inner surfaces of the container 100 in the assembled-closed configuration 105 while the second side 106b forms most of the outer surfaces in the assembled-closed configuration 105.
The container 100 includes four walls (illustrated as first wall 107, second wall 108, third wall 109, and fourth wall 110) connected via (illustrated as first gusset fold 111, second gusset fold 112, third gusset fold 113, and fourth gusset fold 114). That is, each of the four walls is contiguous with two of the four gusset folds 111, 112, 113, 114. A fold line is present where a wall is contiguous with a gusset fold. As illustrated, the first wall 107 is contiguous with the first gusset fold 111 at fold line 115 and the fourth gusset fold 114 at fold line 116. The second wall 108 is contiguous with the first gusset fold 111 at fold line 117 and the second gusset fold 112 at fold line 118. The third wall 109 is contiguous with the second gusset fold 112 at fold line 119 and the third gusset fold 113 at fold line 120. The fourth wall 110 is contiguous with the third gusset fold 113 at fold line 121 and the fourth gusset fold 114 at fold line 122. The first gusset fold 111 connects the first wall 107 and the second wall 108. The second gusset fold 112 connects the second wall 108 and the third wall 109. The third gusset fold 113 connects the third wall 109 and the fourth wall 110. The fourth gusset fold 114 connects the first wall 107 and the fourth wall 110.
Each of the four gusset folds 111, 112, 113, 114 comprises a first fold portion 11a, 112a, 113a, 114a and a second fold portion 111b, 112b, 113b, 114b. As illustrated in
Each of the first fold portions 11a, 112a, 113a, 114a has a tab 111c, 112c, 113c, 114c, and each second fold portion 111b, 112b, 113b, 114b had a notch 111d, 112d, 113d, 114d. As illustrated in
Each of the four gusset folds 111, 112, 113, 114 engages one of the walls 107, 108, 109, 110 to which it is contiguous. In the illustrated container, the first gusset fold 111 (specifically, the first side 106a portion of the first portion 11a) engages the second wall 108 (specifically, the first side 106a portion of the second wall 108), the second gusset fold 112 (specifically, the first side 106a portion of the second portion 112a) engages the second wall 108 (specifically, the first side 106a portion of the second wall 108), the third gusset fold 113 (specifically, the first side 106a portion of the third portion 113a) engages the fourth wall 110 (specifically, the first side 106a portion of the fourth wall 110), and the fourth gusset fold 114 (specifically, the first side 106a portion of the fourth portion 114a) engages the fourth wall 110 (specifically, the first side 106a portion of the fourth wall 110). Other configurations are contemplated.
Each of the four walls 107, 108, 109, 110 are contiguous with a bottom 123 along a corresponding fold line 124, 125, 126, 127.
One of the four walls (illustrated as fourth wall 110) is contiguous with a top 128 at fold line 129. The top 128 is contiguous with a closing flap 130 at fold line 131 where fold line 129 and fold line 131 are opposing edges of the top 128. In the assembled-closed configuration 105 (
The remaining three of the four walls (illustrated as the first, second, and third walls 107,108, 109) are contiguous with a respective top flap 133, 134, 135 at respective fold lines 136, 137, 138. In the assembled-closed configuration 105 (
Assembling the container 100 may include folding along fold lines 118, 126, 121 so that the second gusset fold 112, the third wall 109, and the third gusset fold 113 are above the second wall 108, the bottom 123, and the fourth wall 110, respectively, and folding along fold lines 117, 124, 122 so that the first gusset fold 111, the first wall 107, and the fourth gusset fold 114 are above the second wall 108, the bottom 123, and the fourth wall 110. Depending on the dimensions, the first and second gusset folds 111, 112 may overlap, the first and third walls 107, 109 may overlap, and the third and fourth gusset folds 113, 114 may overlap. As illustrated in
The first and third walls 107, 109 are then moved upward and outward while folding the gusset folds 111, 112, 113, 114 and the second and fourth walls 108, 110 upward and inward (see
In the assembled-open configuration 104, the four walls 107, 108, 109, 110, the four corners 139, 140, 141, 142, and the bottom 123 define a cavity 143. The cavity 143 can be used to hold products (perishable or otherwise). Once filled with a desired amount of product, the container 100 may be closed (or transitioned to the assembled-closed configuration 105) by (i) folding the top flaps 133, 134, 135 and the top 128 so that the top 128 (specifically, the first side 106a portion of the top 128) engages the top flaps 133, 134, 135 (specifically, the second side 106b portion of the top flaps 133, 134, 135) and (ii) folding the closing flap 132 to engage the second wall 108 (specifically, engaging the first side 106a of the closing flap 132 with the second side 106b of the second wall 108).
In the assembled-closed configuration 105, the container 100 may be capable of maintaining a modified atmosphere (e.g., an atmosphere having a different gas composition compared to ambient conditions at the point of closing). A container capable of maintaining a modified atmosphere may be assessed by modifying the gas composition in the cavity 143 to air with 2 vol % CO2, closing the container with the modified atmosphere and not products in the cavity 143, storing the closed container at room temperature (21° C.) in air (unmodified CO2 concentration) at atmospheric pressure for 24 hours, and measuring the composition of the atmosphere inside the container after said storing. If the atmosphere inside the container has maintained a CO2 concentration of 1.8 vol % to 2 vol %, the container is considered capable of maintaining a modified atmosphere. The CO2 concentration can be measured with non-dispersive infrared (NDIR) spectroscopy.
In
The container 200 comprises a single piece of corrugated cardboard 250 having a first side 250a (illustrated as white) and a second side 250b (illustrated with hatching). As illustrated, the first side 250a forms most of the inner surfaces of the container 200 in the assembled-closed configuration 204 while the second side 250b forms all of the outer surfaces in the assembled-closed configuration 204.
The container 200 includes four walls (illustrated as first wall 251, second wall 252, third wall 253, and fourth wall 254), a bottom 255, and a top 256. In the single-layer configuration 201, the top 256, the fourth wall 254, the bottom 255, and the second wall 252 are, in that order, linearly contiguous in a first direction 257. In the single-layer configuration 201, the third wall 253, the fourth wall 254, and the first wall 251 are, in that order, linearly contiguous in a second direction 258 that is perpendicular to the first direction 257. The fourth wall 254 is a rectangle that is contiguous with the top 256 and the bottom 255 at opposing long sides along fold lines 259 and 260, respectively and contiguous with the first wall 251 and the third wall 253 at opposing short sides along fold lines 261 and 262, respectively.
Each of the first wall 251 and third wall 253 are continuous on opposing sides in the first direction 257 with a corresponding flap and fold over. The first wall 251 is contiguous with a first wall fold over 263 at double fold line 264a,b and contiguous with a first bottom flap 265 at fold line 266 where the double fold line 264a,b is at an opposing side of the first wall 251 from the fold line 266. The third wall 253 is contiguous with a third wall fold over 267 at double fold line 268a,b and contiguous with the second bottom flap 269 at fold line 270 where the double fold line 268a,b is at an opposing side of the third wall 253 from the fold line 270.
Each of the corresponding flaps and fold overs have a notch and a tab that are configured to engage during folding and be engaged in the assembled-open configuration 203 and the assembled-closed configuration 204. More specifically, the first bottom flap 265 has a notch 271a, which is a hole with a length (or longest dimension) extending in the second direction along fold line 266, that is configured to engage with a tab 271b extending from the first wall fold over 263. The tab 271b extends from the side of the first wall fold over 263 that opposes the double fold line 264a,b. The second bottom flap 269 has a notch 272a, which is a hole with a length (or longest dimension) extending in the second direction along fold line 266, along fold line 270 that is configured to engage with a tab 272b extending from the third wall fold over 267. The tab 272b extends from the side of the third wall fold over 267 that opposes the double fold line 268a,b.
Each of the fold overs also have a notch in a side perpendicular to the sides with the tabs and along that side proximal to but not at the double fold lines. The first wall fold over 263 has notch 273a in the side furthest from the top 256 and proximal to the double fold line 264a,b along that side. The third wall fold over 267 has notch 274a in the side furthest from the top 256 and proximal to the double fold line 274a,b along that side. The notches 273a,274a are configured to mate with latching flaps 273b,274b (described in more detail below) in the assembled-closed configuration 204.
The second wall 252 is contiguous in the second direction 258 on opposing sides with a first wall flap 275 at fold line 276 and a third wall flap 277 at fold line 278. The second wall 252 is continuous with the bottom at fold line 279.
In the first direction, the top 256 is contiguous with the closing flap 280 at fold line 281, which is at the side of the top 256 opposite the fold line 259. At the side of the closing flap 280 opposite fold line 281, the closing flap 280 is wider in the first direction than the side of the closing flap 280 opposite the fold line 281 because latching flaps 273b,274b extend from opposing sides of the closing flap 280 in the second direction. Each of the latching flaps 273b,274b may extend 0.1 inches to 0.5 inches, preferably 0.2 inches to 0.4 inches, beyond the width of the fold line 281. Each of the latching flaps 273b,274b may extend 0.5 inches to 2 inches, preferably 0.5 inches to 1.5 inches, in the second direction along the opposing sides of the closing flap 280. Each of the latching flaps 273b,274b may be dimensioned to correspond to 75% or less, preferably 10% to 60%, more preferably 30% to 60%, of the total height of the closing flap in the first direction.
Assembling the container 200 may include folding along fold lines 266 and 270, then along fold lines 261 and 262, and finally along fold line 255 so that the second side 250a of the first and second bottom flaps 265,269 engage the first side 250a of the bottom 255 (shown in the intermediate configuration 202 of
Other methods of transitioning from the single-layer configuration 201 to the assembled-open configuration 203 can also be used. One of ordinary skill in the art with the benefit of this disclosure will recognize other methods for folding the cardboard 250 to achieve assembled-open configuration 203.
Transitioning from the assembled-open configuration 203 (
In the assembled-closed configuration 203, the container 200 may be capable of maintaining a modified atmosphere (e.g., an atmosphere having a different gas composition compared to ambient conditions at the point of closing). A container capable of maintaining a modified atmosphere may be assessed by modifying the gas composition in the cavity 282 to air with 2 vol % CO2, closing the container with the modified atmosphere and not products in the cavity 282, storing the closed container at room temperature (21° C.) in air (unmodified CO2 concentration) at atmospheric pressure for 24 hours, and measuring the composition of the atmosphere inside the container after said storing. If the atmosphere inside the container has maintained a CO2 concentration of 1.8 vol % to 2 vol %, the container is considered capable of maintaining a modified atmosphere. The CO2 concentration can be measured with non-dispersive infrared (NDIR) spectroscopy.
The containers of the present disclosure may be capable of maintaining a CO2 concentration of 2 vol % to 50 vol % (or 2 vol % to 20 vol %, or 10 vol % to 35 vol %, or 20 vol % to 40 vol %, or 35 vol % to 50 vol %) in air for 6 hours to 50 days or more (or 6 hours to 24 hours, or 12 hours to 48 hours, or 1 day to 10 days, or 5 days to 25 days, or 15 days to 30 days, or 25 days to 50 days, or more) with a CO2 concentration change of ±10% at temperatures of −10° C. to 50° C. (e.g., cold storage temperatures (2° C. to 8° C.)) regardless of the CO2 concentration in the surrounding environment. The container of the present disclosure may be capable of maintaining an O2 concentration of 0.5 vol % to 30 vol % (or 0.5 vol % to 10 vol %, or 5 vol % to 20 vol %, or 10 vol % to 30 vol %) in air for 6 hours to 50 days or more (or 6 hours to 24 hours, or 12 hours to 48 hours, or 1 day to 10 days, or 5 days to 25 days, or 15 days to 30 days, or 25 days to 50 days, or more) with a O2 concentration change of ±10% at temperatures of −10° C. to 50° C. regardless of the O2 concentration in the surrounding environment. The containers of the present disclosure may be capable of maintaining a relative humidity of 10% to 95% (or 10% to 50%, or 25% to 60%, or 50% to 85%, or 60% to 95%, or 85% to 90%) in air for 6 hours to 50 days or more (or 6 hours to 24 hours, or 12 hours to 48 hours, or 1 day to 10 days, or 5 days to 25 days, or 15 days to 30 days, or 25 days to 50 days, or more) with a relative humidity change of ±10% at temperatures of −10° C. to 50° C. regardless of the relative humidity in the surrounding environment. Therefore, in the assembled-closed configuration 105, the atmosphere in the containers may be established and maintained with optimal reduced O2 and elevated CO2 concentrations as well as optimal humidity (e.g., via active or passible gas composition modification) to the packed products like produce, flowers, and plants during the storage, shipping, and distribution for periods of 50 days or more.
The atmosphere in the assembled-closed configuration may be (i) the ambient gas composition at the point of closing, (ii) a passively modified gas composition where the ambient gas composition at the point of closing is passively modified (e.g., reduced O2 concentration and elevated CO2 and H2O concentrations) due to respiration of the packed products, or (iii) an actively modified gas composition where a gas (e.g., nitrogen, argon, carbon dioxide, the like, and any combination thereof) is added to the cavity before, during, and/or after, adding product to the cavity.
The atmosphere in the assembled-closed configuration may change over time during storage, shipping, and distribution. For example, at closing, the atmosphere in the assembled-closed configuration may be the ambient gas composition. Then, passive modification of the gas composition may occur during storage, shipping, and/or distribution so that at the point of unpacking the product therein, the gas composition is different than the gas composition at the time of closing. In another example, at closing, the gas composition in the assembled-closed configuration may be actively modified (e.g., by adding nitrogen, argon, carbon dioxide, the like, and any combination thereof). Then, modification of the gas composition may occur during storage, shipping, and/or distribution so that at the point of unpacking the product therein, the gas composition is different than the actively modified gas composition at the time of closing.
When modifying the gas composition in the container, the type and amount of gas added may be chosen to achieve a modified atmosphere with preferred ranges of oxygen and carbon dioxide. The preferred ranges may vary based on the type of product and the temperature expected to be encountered during storage, shipping, and/or distribution. Table 1 provides nonlimiting examples of preferred ranges of oxygen and carbon dioxide for different products being stored, shipped, and/or distributed at room temperature.
Without being limited by theory it is believed that the modified atmosphere in the container along will extend the shelf life of the product therein during storage, shipping, and/or distribution. Table 3 are prophetic examples of the shelf life of various products without and with MAP like that described herein.
Optionally, adhesives may be used in conjunction with the containers. That is, the container may further comprise adhesive in at least one location on the first side and/or in at least one location on the second side of the corrugated cardboard. Alternatively, the container may be devoid of adhesive.
The adhesive may provide sealing and/or improve structural strength for the containers. Adhesive may be located between any two surfaces that are described herein as engaging. For example, the first fold portions 111a, 112a, 113a, 114a of the gusset folds 111, 112, 113, 114 may be adhered to wall to which each engages (see above description regarding engagement). In another example, the top flaps 133, 134, 135 may be adhered to the top 128. In another example, the closing flap 132 may be adhered to the second wall 108. In yet another example, the tabs 111c, 112c, 113c, 114c may be adhered to the second fold portions 111b, 112b, 113b, 114b of the gusset folds 111, 112, 113, 114. Further, the first fold portions 111a, 112a, 113a, 114a of the gusset folds 111, 112, 113, 114 may be adhered to the second fold portions 111b, 112b, 113b, 114b of the gusset folds 111, 112, 113, 114. Any combination of the foregoing may be implemented.
The adhesive may be applied during assembly. Alternatively, the adhesive may be applied before assembly (e.g., using a pressure sensitive adhesive or an adhesive having a removable, barrier film thereon that can be removed to access the adhesive). A combination of the foregoing may be used.
Examples of adhesives may include, but are not limited to, polyvinyl acetate-based adhesives, vinyl acetate ethylene copolymer-based adhesives, cellulose ester-based adhesives, acrylic-based adhesives, polyvinyl alcohol-based adhesives, polyolefin-based adhesives, polyester-based adhesives, the like, and any combination thereof. Preferably, the composition of the adhesive is paper recycle compatible (e.g., polyvinyl acetate-based adhesives, vinyl acetate-based ethylene copolymer adhesives, cellulose ester-based adhesives, and polyester-based adhesives).
The first side and/or the second side of the corrugated cardboard may have one or more layers disposed thereon. The layers may, for example, be coatings or laminates. The layers may be on all or portions of the corrugated cardboard. The layers coatings/laminates may adjust permeability of gases through the corrugated cardboard, improve mechanical properties of corrugated cardboard, allow for printing on corrugated cardboard, improve the antimicrobial and/or antibacterial properties of the containers, the like, and any combination thereof. Examples of materials that may be present in said layers may include, but are not limited to, wax, polyvinyl acetate, vinyl acetate ethylene copolymers, cellulose esters, acrylics, polyvinyl alcohols, polyolefins, polyesters (e.g., polylactic acid, poly(butylene adipate terephthalate), polyhydroxybutyrate, polyhydroxybutyrate-valerate, and polybutylene succinate), the like, and any combination thereof. Preferably, the composition of each of the layers is paper recycle compatible (e.g., polyvinyl acetate, vinyl acetate-based ethylene copolymers, cellulose esters, and polyesters).
In full, that is, with any coatings, laminates, adhesives, print, and the like applied, at least 98 wt % (or 98 wt % to 100 wt %, or 98 wt % to 99.5 wt %, or 99 wt % to 100 wt %, or 99.5 wt % to 100 wt %) the containers may be paper recycle compatible.
In the assembled-closed configuration, the container may be characterized by a height (distance from bottom to top), a width (largest distance between two opposing walls), and a depth (smallest distance between two opposing walls). For applications containing perishables like produce, flowers, and plants, preferred dimensions may include a height of 25 cm to 50 cm (or 25 cm to 40 cm, or 30 cm to 45 cm, or 35 cm to 50 cm), a width of 25 cm to 75 cm (or 25 cm to 50 cm, or 35 cm to 60 cm, or 50 cm to 75 cm), and a depth of 25 cm to 50 cm (or 25 cm to 40 cm, or 30 cm to 45 cm, or 35 cm to 50 cm). Larger and smaller dimensions are contemplated.
The corrugated cardboard may be a single-wall corrugated cardboard, a double-wall corrugated cardboard, or a triple-wall corrugated cardboard. The corrugated cardboard layers may have any flute structure one or more of: A flute, B flute, C flute, D flute, E flute, and F flute. Combinations of flutes may be used including, but not limited to F/E flute, E/B flute, E/C flute, and B/C flute. Individual flutes within the corrugated cardboard may be water repellant.
The corrugated cardboard may be characterized by a thickness of 1 mm to 5 mm (or 1 mm to 3 mm, or 2 mm to 4 mm, or 3 mm to 5 mm). Accordingly, in the folded-collapsed configuration, the container may be characterized by a thickness (or maximum thickness since the thickness will vary in said configuration) of 3 mm to 20 mm (or 3 mm to 10 mm, or 7 mm to 15 mm, or 10 mm to 20 mm).
The corrugated cardboard may be characterized by a weight of 350 g/m2 to 650 g/m2 (or 350 g/m2 to 450 g/m2, or 400 g/m2 to 550 g/m2, or 500 g/m2 to 650 g/m2).
Methods of the present disclosure may include assembling the container described herein to the assembled-open configuration, adding product to the cavity of the assembled-open configuration, and closing the container (or transitioning the container to the assembled-closed configuration).
Assembling the container to the assembled-open configuration may include (i) transitioning the container from the folded-collapsed configuration to the assembled-open configuration and/or (ii) transitioning the container from the single-layer configuration the folded-collapsed configuration, then transitioning from the folded-collapsed configuration to the assembled-open configuration. Further, assembling the container to the assembled-open configuration may include applying adhesive to one or more locations on the first side and/or the second side of the container.
Optionally, before closing the container, the method may include adding a gas to the cavity (described in more detail above).
The steps of assembling the container to the assembled-open configuration, adding product to the cavity of the assembled-open configuration, closing the container, and adding the gas to the cavity (if included) may occur at a first site. The method may then include transporting the container having the product therein to a second site. The first site may be a harvesting location (e.g., a farm or orchard where produce is harvested and packaged before shipping), a production location (e.g., a location with an assembly line that packages several assembled products in a single package), a packaging location (e.g., a location that combines receives, stores, and/or sorts products into a single packages based on orders like an e-commerce packaging location), or the like. The second site may be a storage facility, a consumer's location, a store or other commerce location, or the like. The first and second sites may be any distance apart (e.g., 1 mile to 10,000 miles or more). The container having the product therein may be further transported to any number of sites.
The amount of time from closing the container to reopening the container may be any amount of time (e.g., 8 hours to 1 month or longer).
Embodiment 1. A container comprising: a single piece of corrugated cardboard that, in an assembled-closed configuration, comprises (i) four walls connected via gusset folds to form four corners, (ii) a bottom contiguous with the four walls, (iii) a top contiguous with one of the four walls and not contiguous with three of the four walls, (iv) three top flaps each contiguous with one of the three of the four walls not contiguous with the top such that each of the top flaps fold into the container and engage the top, and (v) a closing flap contiguous with the top such that the closing flap engages an opposing wall to the one of the four walls contiguous with the top; wherein each gusset fold comprises a first fold portion having a tab and a second fold portion having a notch, wherein the tab and notch of each gusset fold are configured to interlock in the assembled-closed configuration; and wherein the container is capable of maintaining a modified atmosphere in the assembled-closed configuration.
Embodiment 2. The container of Embodiment 1, wherein one or both sides of the corrugated cardboard has one or more layers disposed thereon.
Embodiment 3. The container of Embodiment 1 or 2, wherein an adhesive is present at one or more locations on the corrugated cardboard.
Embodiment 4. The container of Embodiment 1 or 2 further comprising: an adhesive located so that, in the assembled-closed configuration, (i) the first fold portion of each of the gusset folds is adhered to one of the four walls, (ii) the first fold portion is adhered to the second fold portion for each of the gusset folds, (iii) each of the three top flaps are adhered to the top, and/or (iv) the closing flap is adhered to the one of the four walls not contiguous with the top.
Embodiment 5. The container of Embodiment 1 or 2, wherein the container is devoid of adhesive.
Embodiment 6. The container of any preceding Embodiment, wherein at least 98 wt % of the container is paper recycle compatible.
Embodiment 7. The container of any preceding Embodiment, wherein the corrugated cardboard comprises one or more of: A flute, B flute, C flute, D flute, E flute, and F flute.
Embodiment 8. The container of any preceding Embodiment, wherein the corrugated cardboard is a single-wall corrugated cardboard or a double-wall corrugated cardboard.
Embodiment 9. The container of any preceding Embodiment, wherein the corrugated cardboard has a weight of 350 g/m2 to 650 g/m2.
Embodiment 10. The container of any preceding Embodiment, wherein the corrugated cardboard has a thickness of 1 mm to 5 mm.
Embodiment 11. The container of any preceding Embodiment, wherein the single piece of the corrugated cardboard, in a collapsed configuration, has at maximum thickness of 3 mm to 20 mm.
Embodiment 12. The container of any preceding Embodiment, wherein, in the assembled-closed configuration, the container has a height of 25 cm to 50 cm, a width of 25 cm to 75 cm, and a depth of 25 cm to 50 cm.
Embodiment 13. A method comprising: transitioning a container from a folded-collapsed configuration to an assembled-open configuration, the container comprising: a single piece of corrugated cardboard that, in an assembled-closed configuration, comprises (i) four walls connected via gusset folds to form four corners, (ii) a bottom contiguous with the four walls, (iii) a top contiguous with one of the four walls and not contiguous with three of the four walls, (iv) three top flaps each contiguous with one of the three of the four walls not contiguous with the top such that each of the top flaps fold into the container and engage the top, and (v) a closing flap contiguous with the top such that the closing flap engages an opposing wall to the one of the four walls contiguous with the top; wherein each gusset fold comprises a first fold portion having a tab and a second fold portion having a notch, wherein the tab and notch of each gusset fold are configured to interlock in the assembled-closed configuration; wherein the container is capable of maintaining a modified atmosphere in the assembled-closed configuration; and wherein the four walls, the four corners, and the bottom define a cavity in the assembled-open configuration; adding a product to cavity; and transitioning the container from the assembled-open configuration to the assembled-closed configuration.
Embodiment 14. The method of Embodiment 13 further comprising: adhering (i) the first fold portion of each of the gusset folds to one of the four walls, (ii) the first fold portion to the second fold portion for each of the gusset folds, (iii) each of the three top flaps to the top, and/or (iv) the closing flap to the one of the four walls not contiguous with the top.
Embodiment 15. The method of Embodiment 14 further comprising: applying an adhesive in a location on the corrugated cardboard to accomplish the adhering.
Embodiment 16. The method of any of Embodiments 13-15 further comprising: adding a gas to the cavity before the transitioning of the container from the assembled-open configuration to the assembled-closed configuration, wherein the gas comprises nitrogen, argon, carbon dioxide, or any combination thereof.
Embodiment 17. The method of any of Embodiments 13-16 further comprising: allowing the product in the cavity of the container in the assembled-closed configuration to respirate and passively modify a gas composition in the cavity; and maintaining the modified gas composition for at least 8 hours.
Embodiment 18. The method of any of Embodiments 13-17, wherein (i) the transitioning of the container from the folded-collapsed configuration to the assembled-open configuration, (ii) adding the product to the cavity, and (iii) the transitioning of the container from the assembled-open configuration to the assembled-closed configuration all occur at a first site; and wherein the method further comprises transporting the container having the product therein to a second site.
Embodiment 19. The method of any of Embodiments 13-18, wherein the product is a perishable product.
Embodiment 20. The method of any of Embodiments 13-19, wherein the product comprises produce, a flower, a plant, or any combination thereof.
Embodiment 21. A method comprising: transitioning a container from a folded-collapsed configuration to an assembled-open configuration at a first site, the container comprising: a single piece of corrugated cardboard that, in an assembled-closed configuration, comprises (i) four walls connected via gusset folds to form four corners, (ii) a bottom contiguous with the four walls, (iii) a top contiguous with one of the four walls and not contiguous with three of the four walls, (iv) three top flaps each contiguous with one of the three of the four walls not contiguous with the top such that each of the top flaps fold into the container and engage the top, and (v) a closing flap contiguous with the top such that the closing flap engages an opposing wall to the one of the four walls contiguous with the top; wherein each gusset fold comprises a first fold portion having a tab and a second fold portion having a notch, wherein the tab and notch of each gusset fold are configured to interlock in the assembled-closed configuration; wherein the container is capable of maintaining a modified atmosphere in the assembled-closed configuration; and wherein the four walls, the four corners, and the bottom define a cavity in the assembled-open configuration; adding a product to cavity at the first site; transitioning the container from the assembled-open configuration to the assembled-closed configuration at the first site; transporting the container having the product therein to a second site; and storing the product at the second site.
Embodiment 22. A container comprising: a single piece of corrugated cardboard having a first side and a second side that, in an assembled-closed configuration, comprises four walls, a bottom, a top, two bottom flaps, two wall flaps, two wall fold overs, and a closing flap, wherein each of the foregoing have a first side corresponding to the first side of the corrugated cardboard and a second side corresponding to the second side of the corrugated cardboard; wherein a fourth wall is continuous with a first wall, a bottom, a third wall, and a top, wherein in a first direction and in order the following are contiguously connected: the closing flap, the top, the fourth wall, the bottom, and a second wall, wherein in a second direction perpendicular to the first direction and in order the following are contiguously connected: the third wall, the fourth wall, and the first wall, wherein the second side of each of the two bottom flaps engages the first side of the bottom, wherein the second side of a first of the two side flaps engages the first side of a first wall and the second side of a second side of the two side flaps engages the first side of a third wall, wherein the first side of a first of the two wall fold overs engages the first side of the first of the two sidewall flaps and the first side of a second of the two wall fold overs engages the first side of the second of the two sidewall flaps, and wherein the closing flap engages the second wall; and wherein the container is capable of maintaining a modified atmosphere in the assembled-closed configuration.
Embodiment 23. The container of Embodiment 22, wherein the single piece of corrugated cardboard further comprises two latching flaps contiguous with the closing flap in the second direction such that in the second direction and in order is a first of the two latching flaps, the closing flap, and a second of the two latching flaps are contiguous, and wherein each of the two wall fold overs have a notch therein each capable of mating with a corresponding one of the two latching flaps in the assembled-closed position.
Embodiment 24. The container of any of Embodiments 22-23, wherein each of the two bottom flaps have a notch and each of the two wall fold overs have a tab configured to mate with the notch corresponding thereto.
Embodiment 25. The container of any of Embodiments 22-24, wherein the second side of the closing flap engages the second side of the second wall
Embodiment 26. The container of any of Embodiments 22-25, wherein one or both sides of the corrugated cardboard has one or more layers disposed thereon.
Embodiment 27. The container of any of Embodiments 22-26, wherein an adhesive is present at one or more locations on the corrugated cardboard.
Embodiment 28. The container of any of Embodiments 22-26, wherein the container is devoid of adhesive.
Embodiment 29. The container of any of Embodiments 22-28, wherein at least 98 wt % of the container is paper recycle compatible.
Embodiment 30. The container of any of Embodiments 22-29, wherein the corrugated cardboard comprises one or more of: A flute, B flute, C flute, D flute, E flute, and F flute.
Embodiment 31. The container of any of Embodiments 22-30, wherein the corrugated cardboard is a single-wall corrugated cardboard or a double-wall corrugated cardboard.
Embodiment 32. The container of any of Embodiments 22-31, wherein the corrugated cardboard has a weight of 350 g/m2 to 650 g/m2.
Embodiment 33. The container of any of Embodiments 22-32, wherein the corrugated cardboard has a thickness of 1 mm to 5 mm.
Embodiment 34. The container of any of Embodiments 22-33, wherein, in the assembled-closed configuration, the container has a height of 25 cm to 50 cm, a width of 25 cm to 75 cm, and a depth of 25 cm to 50 cm.
Embodiment 35. A method comprising: transitioning a container from a single-layer configuration to an assembled-open configuration, the container comprising: a single piece of corrugated cardboard having a first side and a second side that, in an assembled-closed configuration, comprises four walls, a bottom, a top, two bottom flaps, two wall flaps, two wall fold overs, and a closing flap, wherein each of the foregoing have a first side corresponding to the first side of the corrugated cardboard and a second side corresponding to the second side of the corrugated cardboard; wherein a fourth wall is continuous with a first wall, a bottom, a third wall, and a top, wherein in a first direction and in order the following are contiguously connected: the closing flap, the top, the fourth wall, the bottom, and a second wall, wherein in a second direction perpendicular to the first direction and in order the following are contiguously connected: the third wall, the fourth wall, and the first wall, wherein the second side of each of the two bottom flaps engages the first side of the bottom, wherein the second side of a first of the two side flaps engages the first side of a first wall and the second side of a second side of the two side flaps engages the first side of a third wall, and wherein the first side of a first of the two wall fold overs engages the first side of the first of the two sidewall flaps and the first side of a second of the two wall fold overs engages the first side of the second of the two sidewall flaps; and wherein the container is capable of maintaining a modified atmosphere in the assembled-closed configuration; and wherein a cavity in the container in the assembled-open configuration is defined by at least the first side of the two bottom flaps, the second side of the two fold overs, the second wall, and the fourth wall; adding a product to cavity; and transitioning the container from the assembled-open configuration to the assembled-closed configuration by engaging the closing flap and the second wall.
Embodiment 36. The method of Embodiment 35 further comprising: applying an adhesive in a location on the corrugated cardboard to accomplish the adhering of two engaged surfaces.
Embodiment 37. The method of any of Embodiments 35-36 further comprising: adding a gas to the cavity before the transitioning of the container from the assembled-open configuration to the assembled-closed configuration, wherein the gas comprises nitrogen, argon, carbon dioxide, or any combination thereof.
Embodiment 38. The method of any of Embodiments 35-37 further comprising: allowing the product in the cavity of the container in the assembled-closed configuration to respirate and passively modify a gas composition in the cavity; and maintaining the modified gas composition for at least 8 hours.
Embodiment 39. The method of any of Embodiments 35-38, wherein (i) the transitioning of the container from the single-layer configuration to the assembled-open configuration, (ii) the adding of the product to the cavity, and (iii) the transitioning of the container from the assembled-open configuration to the assembled-closed configuration all occur at a first site; and wherein the method further comprises transporting the container having the product therein to a second site.
Embodiment 40. The method of any of Embodiments 35-39, wherein the product comprises produce, a flower, a plant, or any combination thereof.
Embodiment 41. A method comprising: transitioning a container from a single-layer configuration to an assembled-open configuration, the container comprising: a single piece of corrugated cardboard having a first side and a second side that, in an assembled-closed configuration, comprises four walls, a bottom, a top, two bottom flaps, two wall flaps, two wall fold overs, and a closing flap, wherein each of the foregoing have a first side corresponding to the first side of the corrugated cardboard and a second side corresponding to the second side of the corrugated cardboard; wherein a fourth wall is continuous with a first wall, a bottom, a third wall, and a top, wherein in a first direction and in order the following are contiguously connected: the closing flap, the top, the fourth wall, the bottom, and a second wall, wherein in a second direction perpendicular to the first direction and in order the following are contiguously connected: the third wall, the fourth wall, and the first wall, wherein the second side of each of the two bottom flaps engages the first side of the bottom, wherein the second side of a first of the two side flaps engages the first side of a first wall and the second side of a second side of the two side flaps engages the first side of a third wall, and wherein the first side of a first of the two wall fold overs engages the first side of the first of the two sidewall flaps and the first side of a second of the two wall fold overs engages the first side of the second of the two sidewall flaps; and wherein the container is capable of maintaining a modified atmosphere in the assembled-closed configuration; and wherein a cavity in the container in the assembled-open configuration is defined by at least the first side of the two bottom flaps, the second side of the two fold overs, the second wall, and the fourth wall; adding a product to cavity at the first site; transitioning the container from the assembled-open configuration to the assembled-closed configuration at the first site; transporting the container having the product therein to a second site; and storing the product at the second site.
There is thus disclosed an improved corrugated container and method of manufacturing the container. In the foregoing specification, the present invention has been described with reference to specific exemplary embodiments. Various modifications and changes may be made, however, without departing from the spirit and scope of the present invention as set forth in the claims, including combinations of elements of the various illustrated embodiments. The specification and figures are illustrative, not restrictive, and modifications are intended to be included within the scope of the present invention. Accordingly, the scope of the present invention should be determined by the claims and their legal equivalents rather than by merely the examples described.
For example, the steps recited in any method or process claims may be executed in any order and are not limited to the specific order presented in the claims. Additionally, the components and/or elements recited in any apparatus claims may be assembled or otherwise operationally configured in a variety of permutations and are accordingly not limited to the specific configuration recited in the claims.
Benefits, other advantages, and solutions to problems have been described above with regard to particular embodiments. Any benefit, advantage, solution to problem, or any element that may cause any particular benefit, advantage, or solution to occur or to become more pronounced are not to be construed as critical, required, or essential features or components of any or all the claims.
Unless otherwise indicated, all numbers expressing quantities of ingredients, properties (e.g., molecular weight), reaction conditions, and the like, used in the present disclosure and associated claims, are to be understood as being modified in all instances by the term “about.” At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claim, the term “about” relative to each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
As used herein, the meaning of “a,” “an,” or “the” includes singular and plural references unless the context clearly dictates otherwise.
The phrase “consisting essentially of” as used herein is intended to cover additional elements or functions that do not materially affect the basic and novel characteristics of the claimed invention. Thus, “consisting essentially of” is intended to encompass not only those components specifically listed, but also separate or additional components that do not materially alter the specifically recited functions or elements.
The terms “comprise”, “comprises”, “comprising”, “having”, “including”, “includes” or any variations of such terms, are intended to reference a non-exclusive inclusion, such that a process, method, article, composition or apparatus that comprises a list of elements does not include only those elements recited, but may also include other elements not expressly listed or inherent to such process, method, article, composition or apparatus. Other combinations and/or modifications of the above-described structures, arrangements, applications, proportions, elements, materials, or components used in the practice of the present invention, in addition to those not specifically recited, may be varied or otherwise particularly adapted to specific environments, manufacturing specifications, design parameters, or other operating requirements without departing from the general principles of the same.
The present application claims priority to U.S. Provisional Application No. 63/515,167 filed Jul. 24, 2024, the full disclosure of which is incorporated by reference in its entirety for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 63515167 | Jul 2023 | US |
