FOLDABLE CONTAINER

BACKGROUND

1. Field of the Invention

The invention relates to containers. More specifically, the systems and methods relate to containers that may be folded to have a low profile after construction and then unfolded for use.

2. Description of the Related Technology

Food is increasingly being purchased pre-prepared instead of being cooked at home. Accordingly, there is an increasing demand for food containers that can be used for storing and transporting food. It is desirable for such food containers to be sturdy, leak-proof and re-closable so that they may be used to transport and store food easily and reliably. A common example of such a container is the classic Chinese food box.

So called “take-out” containers are typically pre-cut and pre-scored pieces of cardboard or the like, which may be referred to generally as blanks. After a blank has been pre-cut and pre-scored, it may be constructed by folding, tucking and gluing or otherwise joining different panels together to form a container.

To keep take-out food containers cost competitive, it is desirable to use a design which is simple to construct as well as simple to package and ship to end users, such as food providers. Existing designs, such as those disclosed in U.S. Pat. No. 5,411,204, are designed so that after they are constructed, they may be stacked together before being shipped to an end user. Because it is not practical to construct each container at the point of sale, typically such designs are constructed in a manufacturing environment, stacked one within another and then shipped to an end user. While stacking in this fashion is simple, it is not space efficient due to the open volume of the container and the flaps which extend the three dimensional space required by each container during shipping to the end user or while being stored before use. Furthermore, such designs may be easily damaged during shipment or while being stored because they are stacked in an open configuration which leaves the exterior walls exposed to possible damage prior to use.

Accordingly, there is a need for containers that may be folded to have a low profile after construction and then unfolded for use.

SUMMARY OF THE INVENTION

The devices and methods of the present invention have several features, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of this invention as expressed by the claims which follow, its more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled “Detailed Description,” one will understand how the features of this invention provide several advantages over existing containers.

An aspect of the invention includes a container having a base and four sidewalls with each sidewall being connected to the base. The container further includes four webs with each web connecting one of the four sidewalls to another one of the four sidewalls. The container further includes four flaps with each flap being connected to an upper edge of one of the four sidewalls by a hinge fold-line. The container further includes four triangular fold-lines with each triangular fold-line extending across a portion of the base and across at least one of the four webs. The container further includes an end-to-end fold-line extending across two of the four flaps, the base, and two of the four sidewalls. The container is configured to be foldable to a low profile arrangement from a high profile constructed arrangement.

Another aspect is a container having a base, at least two webs, and at least two triangular fold-lines with each triangular fold-line extending across a portion of the base and across at least one of the two webs. The container is configured to be foldable to a low profile arrangement from a high profile constructed arrangement.

Another aspect is a folding template for a container. The template includes a planar member having an upper surface, a lower surface, and a plurality of fold-lines with each of the plurality of fold-lines being disposed on one of the upper and lower surfaces. The plurality of fold-lines defines a base having a rectangular shape, four sidewalls, four webs, and four flaps. At least two of the sidewalls have a trapezoidal shape. At least one of the plurality of fold-lines extends across a portion of the defined base and across one of the four defined webs. At least another one of the plurality of fold-lines extends across two of the four defined flaps, the defined base, and two of the four defined sidewalls.

Another aspect is a container having a base, at least two sidewalls, and at least two sidewall fold-lines with each sidewall fold-line extending across a portion of one of the sidewalls. The container is configured to be foldable to a low profile arrangement from a high'profile constructed arrangement.

Another aspect is a folding template for a container. The template includes a planar member having an upper surface, a lower surface, and a plurality of fold-lines with each of the plurality of fold-lines being disposed on one of the upper and lower surfaces. The plurality of fold-lines defines at least a base having a rectangular shape, four sidewalls, four webs, and four flaps. At least two of the sidewalls have a trapezoidal shape. At least one of the plurality of fold-lines extends across a portion of one of the four sidewalls. At least another one of the plurality of fold-lines extends across a portion of one of the four flaps.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view depicting a prior art food container.

FIG. 2 is an isometric view depicting a plurality of the food containers from FIG. 1 in a stacked or storage configuration.

FIG. 3 is an isometric view depicting another prior art food container.

FIG. 4 is an isometric view depicting a plurality of the food containers from FIG. 3 in a stacked or storage configuration.

FIG. 5A is a plan view of a container in an unconstructed arrangement according to one embodiment of the present invention.

FIG. 5B is an isometric view of the container from FIG. 5A in a constructed arrangement which has a high profile.

FIG. 5C is an isometric view of the container from FIG. 5B in a partially folded arrangement.

FIG. 5D is an isometric view of five of the containers from FIG. 5C after each container has been further folded or compressed to achieve a lower profile advantageous for shipping and storage.

FIG. 5E is a side view of five of the containers from FIG. 5D illustrating their low profile arrangement.

FIG. 6A is a plan view of a container in an unconstructed arrangement according to another embodiment.

FIG. 6B is an isometric view of the container from FIG. 6A in a constructed arrangement which has a high profile.

FIG. 6C is an isometric view of the container from FIG. 6B in a partially folded arrangement.

FIG. 6D is an isometric view of five of the containers from FIG. 6C after each container has been further folded or compressed to achieve a lower profile advantageous for shipping and storage.

FIG. 6E is a side view of five of the containers from FIG. 6D illustrating their lower profile.

FIG. 7A is a plan view of a container in an unconstructed arrangement according to another embodiment.

FIG. 7B is an isometric view of the container from FIG. 7A in a constructed arrangement which has a high profile.

FIG. 7C is an isometric view of the container from FIG. 7B in a partially folded arrangement.

FIG. 7D is an isometric view of five of the containers from FIG. 7C after each container has been further folded or compressed to achieve a lower profile advantageous for shipping and storage.

FIG. 7E is a side view of five of the containers from FIG. 7D illustrating their lower profile.

DETAILED DESCRIPTION

The following detailed description is directed to certain specific embodiments of the invention. However, the invention can be embodied in a multitude of different ways. In this description, reference is made to the drawings wherein like parts are designated with like numerals throughout.

The following description is provided in the context of a container for food. However, the invention is not limited to containers for food. The containers described herein may be used for food, clothing, toys, gifts, or any other article. In addition, the containers may be used with solids and/or liquids. Thus, the inventive containers described herein are independent of the type of article(s) placed or stored in the container and may have a different appearance than the embodiments illustrated herein. For example, containers, such as “take-out” food containers, may include interior and exterior walls, interior and exterior surfaces, panels, folds, flaps, seams, cuts, scores, hinges and other structures of various shapes and sizes. Containers may be made from paper, paperboard, SBS board, food grade paper, white board paper, duplex paper, cardboard, plastic and other materials as are known in the art.

Containers may be made by cutting a blank, which is a “raw” piece of material, such as cardboard stock, into a preconfigured shape, which may also be referred to as a template. A template may be generally planar and include an upper surface, a lower surface, and a plurality of fold-lines. Subsequently, the preconfigured shape may be scored, perforated, cut or additionally processed so that the preconfigured shape has folds and seams necessary to create the finished container. Once the processing of the preconfigured shape is completed, the container may be constructed by bending or folding along preprocessed lines to create a three dimensional shape. The three dimensional shape may be held in place by structures built into the preconfigured shape, such as slots in a panel that interface with hooks in another panel, or by using attachment means such as adhesives. Other means of attachment are well known in the art.

Typically the construction of a container, such as a take-out food container, is completed in an automated manufacturing environment and therefore is completed in a cost efficient manner. It would not be practical or desirable to ship blanks or even preconfigured shapes to food providers to be constructed later before use. Consequently, food containers are typically formed completely before being shipped to end users, such as food providers, and stored thereafter in the same or similar configuration.

Because these containers are often fully constructed before being shipped, they are often designed to be stacked within each other, that is: one within another within another and so on. This is convenient; however it is neither space efficient nor particularly damage resistant during shipping or subsequent storage before use by the end user. Due to the ever rising cost of shipping, and the desire to be space efficient in general, it is desirable to create a food container that can be fully preprocessed and constructed such that it is ready to use by end users, but that is also capable of being packaged and stored in a space efficient configuration, such as in a low profile arrangement or even as a flat stack. Additionally, packaging in a space efficient configuration, such as a flat stack, creates a more damage resistant shipping and storage configuration. These two advantages may reduce shipping cost as well as propensity for damage during shipping or storing alike.

FIG. 1 is an isometric view depicting a prior art container 100 typically used for food. The container 100 includes sidewalls 102, 104, 106 and 108, which each have interior and exterior surfaces. Container 100 also includes flaps 110, 112, 114 and 116, which each have interior and exterior surfaces. Flap 114 includes a hook structure 118 which is configured to fit within slot 120 in flap 110 such that the food container 100 can be held closed. Container 100 also includes base 122, which has an interior and exterior surface. The sidewalls 102, 104, 106 and 108 and the base 122 form a cavity 124, wherein food or other articles may be stored. In a typical configuration, the flaps 112 and 116 are first folded down and toward the cavity 124 and then the flaps 110 and 114 are folded down and toward the cavity 124 and the top of the flaps 112 and 116 are then engaged or joined via structures 118 and 120. When all of the flaps are folded down, the cavity 124 becomes a closed container suitable for storing and transporting food or other articles. Container 100 may be opened and the contents stored within the cavity 124 accessed by de-coupling the hook structure 118 and the slot structure 120 and then folding back one or more of the flaps 110, 112, 114 and 116.

Once fully constructed, the container illustrated in FIG. 1 cannot be subsequently folded into a flat arrangement or even into a configuration that has a lower profile than a closed container without deconstructing the container. For example, if a seam is glued or otherwise fastened together, it must be unfastened before being able to take on a low profile or flat arrangement. However, such an arrangement would require reconstructing the deconstructed container prior to use. Furthermore, such deconstruction can harm the aesthetic and structural quality of the container. Therefore, once constructed, it is preferred that a container such as that shown in FIG. 1 remains in its constructed or full-sized arrangement.

FIG. 2 is an isometric view depicting a stack of prior art containers in a typical shipping or storage configuration. In FIG. 2, food containers 202, 204, 206, 208 and 210, each the same as that described with reference to FIG. 1, are stacked one within another. Notably, even when stacked together, the cavity 224 is left empty in the shipping or storage configuration. The unused volume (e.g. cavity 224) increases the amount of space the food containers require for shipping and storage. Also, the flaps of each of the food containers 202, 204, 206, 208 and 210 extend upward and further increase the unused volume when in the shipping or storage configuration. Finally, in this configuration, the food containers 202, 204, 206, 208 and 210 are prone to damage such as crushing, bending, impalement and other types of damage possibly sustained during shipping or storage. Accordingly, when received by, for example, an end user food provider, one or more of the stacked food containers may be damaged and not suitable for use. This may lead to inconvenience on the part of the end user of the containers as well as financial loss on the part of the provider of the containers.

FIG. 3 is an isometric view depicting another prior art food container 300. The food container 300 includes sidewalls 302, 304, 306 and 308, which each have interior and exterior surfaces. Food container 300 also includes flaps 310, 312, 314 and 316, which each have interior and exterior surfaces. Flap 316 includes a hook structure 318 which is configured to fit within slot 320 in flap 312 such that the food container 300 can be held closed. Food container 300 also includes base 322, which has an interior and exterior surface. The sidewalls 302, 304, 306 and 308 and the base 322 form a cavity 324, wherein food or other articles may be stored. In a typical configuration, the flaps 310 and 314 would first be folded down and toward the cavity 324 and then the flaps 318 and 320 would be folded down and toward the cavity 324 and the top of the flaps 318 and 320 would be engaged or joined via structures 318 and 320. When all of the flaps are folded down, the cavity 324 becomes a closed food container suitable for storing and transporting food. Food container 300 may be opened and the contents stored within the cavity 324 may be accessed by de-coupling the hook structure 318 and the slot structure 320 and folding back the flaps 310, 312, 314 and 316.

Once fully constructed, the food container illustrated in FIG. 3, like the food container illustrated in FIG. 1, cannot be subsequently folded into a flat arrangement without deconstructing the container. Once constructed, a food container such as that shown with reference to FIG. 3 remains in its full-sized arrangement.

FIG. 4 is an isometric view depicting a stack of prior art food containers in a typical shipping configuration. In FIG. 4, food containers 402, 404, 406, 408 and 410, each the same as that described with reference to FIG. 3, are stacked one within another. Notably, even when stacked together, the cavity 424 is left empty in the shipping or storage configuration. This unused area increases the amount of space the food containers require for shipping or storage. Also, the flaps of each of the food containers 402, 404, 406, 408 and 410 extend upward and further increase the unused area when in the shipping or storage configuration. As described above, in this configuration, the food containers 402, 404, 406, 408 and 410 are more prone to damage during shipping or storage, which may lead to inconvenience on or financial loss.

FIG. 5A is a plan view of a container 500 in an unconstructed arrangement according to one embodiment. In this arrangement, a variety of fold-lines are shown in broken lines as well as other structures of the container 500. Each fold-line may be created by a variety of means, including scoring, perforating or other means of processing known in the art. FIG. 5A includes: an end-to-end fold-line 502; long fold-lines 506, 510, 514 and 520; triangular fold-lines 508, 516, 522 and 526; and hinge fold-lines 504, 512, 518 and 524. The various fold-lines may intersect to define or form regions or structures of the container 500. These regions may include a base, one or more sidewalls and/or one or more webs.

The following description is of an exemplary combination of regions or structures defined by an exemplary combination of fold-lines. For example, base 548 is defined by the intersection of long fold-lines 510 and 514 with long fold-lines 506 and 520. In this embodiment, the base 548 has a rectangular shape. Of course the base 548 is not limited to any specific shape.

Sidewall 540 is formed by the intersection of long fold-lines 506 and 520 with long fold-line 514 and hinge fold-line 518. Sidewall 542 is formed by the intersection of long fold-lines 510 and 514 with long fold-line 506 and hinge fold-line 512. Sidewall 544 is formed by the intersection of long fold-lines 506 and 520 with long fold-line 510 and hinge fold-line 504. Sidewall 546 is formed by the intersection of long fold-lines 510 and 514 with long fold-line 520 and hinge fold-line 524. In this embodiment, sidewalls 540, 542, 544 and 546 have a trapezoidal shape. In other embodiments, one or more of the sidewalls may have a different shape including rectangular, square, and other polygonal shapes. For example, an embodiment may include two trapezoidal sidewalls and two rectangular sidewalls. In such an embodiment, preferably the two trapezoidal sidewalls are on opposite sides of the base 548. Further, any portion of a region formed by the intersection of fold-lines which also defines a portion of the outer perimeter of the container 500 may include curved surfaces.

Web 570 is formed by the intersection of long fold-lines 506 and 510. A portion of the web 570 is defined by the outer perimeter of the container 500. Web 572 is formed by the intersection of long fold-lines 506 and 514. Web 574 is formed by the intersection of long fold-lines 520 and 514. Web 576 is formed by the intersection of long fold-lines 510 and 520.

The container 500 may further include flaps 528, 530, 532 and 534. The flap 530 includes a slot 536, which may be used as a means of closing the container 500 once constructed. The flap 534 includes the corresponding means for closing: hook structure 538. When fully constructed, the hook structure 538 may be inserted into the slot structure 536 to keep the container closed. Other means of holding the flaps closed may also be used, such as alternate hook structures, reusable adhesives, velcro, or others as are known in the art.

FIG. 5B is an isometric view of the container 500 from FIG. 5A in a constructed arrangement which has a high profile. The container 500 includes sidewalls 540, 542, 544 and 546; flaps 528, 530, 532, and 534; webs 570, 572, 574 and 576; and a base 548.

Each of the sidewalls and the base has an interior and exterior surface. In the embodiment illustrated in FIG. 5B, the sidewalls 540, 542, 544 and 546 are each at an obtuse angle with respect to the base 548. That is, each sidewall leans outward and the cavity 550 increases in cross-section from bottom to top along the z-axis. Such an arrangement may facilitate stacking multiple containers 500 in the constructed arrangement. However, other embodiments may include sidewalls perpendicular to the base, or even at acute angles with respect to the base.

Webs 570 and 572 are folded and affixed to the exterior surface of sidewall 542 during the construction process. An adhesive may be used to affix the webs to the sidewalls. Similarly, webs 574 and 576 are folded and affixed to the exterior surface of sidewall 546 during the construction process. In other embodiments, the webs may be folded and affixed to an interior surface of the sidewalls. Preferably, the webs are affixed to the sidewalls that do not include the end-to-end fold-line 502 so as to avoid interfering with folding of the container 500. However, in other embodiments, the webs may be folded and affixed to the sidewalls that include the end-to-end fold lines. In such embodiments, it is preferable that a width of the webs be less than half the width of the sidewall so as to avoid interfering with the end-to-end fold line when folding the container.

The container 500 is shown with flaps 528, 530, 532 and 534 in an open configuration such that food or other articles may be placed within a cavity 550 of the container 500 formed by the sidewalls 540, 542, 544 and 546 and the base 548.

Also shown are a slot structure 536 and a hook structure 538, which allow the flaps 530 and 534 to be engaged or joined together to keep the container 500 in a closed configuration. Note that the hook structure 538 and the slot structure 536 are on opposing flaps 530 and 534 such that opposing flaps 528 and 532 can first be folded toward each other and across the cavity 550, and then opposing flaps 530 and 534 can be folded toward each other, across the cavity 550 and on top of flaps 528 and 532, and then engaged or joined via the hook structure 538 and the slot structure 536 to close the container 500. The container 500 may be opened by completing the preceding procedure in reverse i.e. disengaging the hook structure 538 from the slot structure 536 and then folding each of the flaps 528, 530, 532 and 534 up and away from the cavity 550. Thus, the container 500 may be in a closed or open arrangement i.e. the container is reclosable.

FIG. 5C is an isometric view of the container 500 from FIG. 5B in a partially folded arrangement. Arrows 560 and 564 indicate the general direction in which the container 500 collapses on itself to achieve a lower profile. That is, as container 500 is folded, walls 546 and 542 move towards each other until they are adjacent (as shown in FIG. 5D). Likewise, arrow 562 shows the direction in which end-to-end fold-line 502 allows flap 532 and sidewall 540 to fold inward. The flap 528 and the side wall 544 fold in a similar manner when the container 500 is folded.

FIG. 5D is an isometric view of five of the containers 500 from FIG. 5C after each container 500 has been further folded or compressed to achieve a lower profile advantageous for shipping and storage. As can be seen, containers 580, 582, 584, 586 and 588, which are each the same as the container 500 described with respect to FIGS. 5A-5C, are fully folded and stacked one on top of another. In this configuration, the containers are stacked very space efficiently as compared to FIG. 2. Additionally, in this configuration the containers are much less likely to be damaged while being shipped or stored because they are in a strong, flat position where all walls are adjacent and no cavity exists.

FIG. 5E is a side view of five of the containers 500 from FIG. 5D illustrating their low profile arrangement. As can be seen, containers 580, 582, 584, 586 and 588 are stacked to height 598. This arrangement, which can be used for shipping or for storage, is significantly more space efficient as compared to FIG. 2. Further, as mentioned above, this configuration is less prone to damage any of the individual containers.

FIG. 6A is a plan view of a container 600 in an unconstructed arrangement according to another embodiment. In this arrangement, a variety of fold-lines are shown in broken lines as well as other structures. As discussed above, each fold-line may be created by a variety of means, including scoring, perforating or other means of processing known in the art. FIG. 6A includes: long fold-lines 606, 610, 614 and 620; triangular fold-lines 608, 616, 622 and 626; sidewall fold-lines 633, 635, 645 and 647; flap fold-lines 637, 639, 641 and 643; and hinge fold-lines 604, 612, 618 and 624. The various fold-lines may intersect to define or form regions or structures of the container 600. These regions may include a base, one or more sidewalls and/or one or more webs.

The following description is of an exemplary combination of regions or structures defined by an exemplary combination of fold-lines. For example, base 648 is defined by the intersection of long fold-lines 606 and 620 with long fold-lines 610 and 614. In this embodiment, the base 648 has a rectangular shape. Of course the base 648 is not limited to any specific shape.

Sidewall 640 is formed by the intersection of long fold-lines 610 and 614 with long fold-line 606 and hinge fold-line 612. Sidewall 642 is formed by the intersection of long fold-lines 606 and 620 with long fold-line 610 and hinge fold-line 604. Sidewall 644 is formed by the intersection of long fold-lines 610 and 614 with long fold-line 620 and hinge fold-line 624. Sidewall 646 is formed by the intersection of long fold-lines 606 and 620 with long fold-line 614 and hinge fold-line 618. In this embodiment, sidewalls 640, 642, 644 and 646 have a trapezoidal shape. In other embodiments, one or more of the sidewalls may have a different shape including rectangular, square, and other polygonal shapes. For example, an embodiment may include two trapezoidal sidewalls and two rectangular sidewalls. In such an embodiment, preferably the two trapezoidal sidewalls are on opposite sides of the base 648. Further, any portion of a region formed by the intersection of fold-lines which also defines a portion of the outer perimeter of the container 600 may include curved surfaces.

Web 670 is formed by the intersection of long fold-lines 606 and 610. A portion of the web 670 is defined by the outer perimeter of the container 600. Web 672 is formed by the intersection of long fold-lines 610 and 620. Web 674 is formed by the intersection of long fold-lines 620 and 614. Web 676 is formed by the intersection of long fold-lines 606 and 614.

The container 600 may further include flaps 628, 630, 632 and 634. The flap 630 includes a slot 636, which may be used as a means of closing the container 600 once constructed. The flap 634 includes the corresponding means for closing: hook structure 638. When fully constructed, the hook structure 638 may be inserted into the slot structure 636 to keep the container closed. Other means of holding the flaps closed may also be used, such as alternate hook structures, reusable adhesives, velcro, or others as are known in the art.

FIG. 6B is an isometric view of the container 600 from FIG. 6A in a constructed arrangement which has a high profile. The container 600 includes sidewalls 640, 642, 644 and 646; webs 670, 672, 674 and 676; flaps 628, 630, 632 and 634; and a base 648.

Each of the sidewalls and the base has an interior and exterior surface. In the embodiment illustrated in FIG. 6B, the sidewalls 640, 642, 644 and 646 are each at an obtuse angle with respect to the base 648. That is, each sidewall leans outward and the cavity 650 increases in cross-section from bottom to top along the z-axis. Such an arrangement may facilitate stacking container 600 in the constructed arrangement. However, other embodiments may include sidewalls perpendicular to the base, or even at acute angles with respect to the base.

Webs 670 and 676 are folded and affixed to the interior surface of sidewall 640 during the construction process. An adhesive may be used to affix the webs to the sidewalls. Similarly, webs 672 and 674 are folded and affixed to the interior surface of sidewall 644 during the construction process. In other embodiments, the webs may be folded and affixed to an exterior surface of the sidewalls. Preferably, the webs are affixed to the sidewalls so as to avoid interfering with the sidewall fold-lines.

The container 600 is shown with flaps 628, 630, 632 and 634 in an open configuration such that food or other articles may be placed within a cavity 650 of the container 600 formed by the sidewalls and the base.

Also shown are a slot structure 636 and a hook structure 638, which allow the flaps 630 and 634 to be engaged or joined together to keep the container 600 closed. Note that the hook structure 638 and the slot structure 636 are on opposing flaps 630 and 634 such that opposing flaps 628 and 632 can first be folded toward each other and across the cavity 650, and then opposing flaps 630 and 634 can be folded toward each other, across the cavity 650 and on top of flaps 628 and 632, and then engaged or joined via the hook structure 638 and the slot structure 636 to close the container 600. The container 600 may be opened by completing the preceding procedure in reverse i.e. unjoining or disengaging the hook structure 638 from the slot structure 636 and then folding each of flaps 628, 630, 632 and 634 up and away from the cavity 650. Thus, the container 600 may be in a closed or open arrangement i.e. the container is reclosable.

FIG. 6C is an isometric view of the container 600 from FIG. 6B in a partially folded arrangement. Arrows 660 and 664 indicate the general direction in which the walls 640 and 644 fold in. Likewise, arrows 662 and 666 indicate the direction in which the flaps 630 and 634 fold when folding container 600 flat. Once folded, the flaps 630 and 634 will sit adjacent to and partially on top of the flaps 628 and 632 (as shown in FIG. 6D).

FIG. 6D is an isometric view of five of the containers 600 from FIG. 6C after each container 600 has been further folded or compressed to achieve a lower profile advantageous for shipping and storage. As can be seen, containers 680, 682, 684, 686 and 688, which are each the same as the container 600 described with respect to FIGS. 6A-6C, are fully folded and stacked one on top of another. In this configuration, the containers are stacked very space efficiently as compared to FIG. 4. Additionally, in this configuration the containers are much less likely to be damaged while being shipped or stored because they are in a strong, flat position where all walls are adjacent and no cavity exists.

FIG. 6E is a side view of the five containers 600 from FIG. 6D illustrating their lower profile. As can be seen, containers 680, 682, 684, 686 and 688 are stacked to height 698. This arrangement, which can be used for shipping or for storage, is significantly more space efficient as compared to FIG. 4. Further, as mentioned above, this configuration is less prone to damage any of the individual containers.

FIG. 7A is a plan view of a container 700 in an unconstructed arrangement according to another embodiment. In this arrangement, a variety of fold-lines are shown in broken lines as well as other structures. As discussed above, each fold-line may be created by a variety of means, including scoring, perforating or other means of processing known in the art. FIG. 7A includes: long fold-lines 706, 710, 714 and 720; triangular fold-lines 708, 716, 722 and 726; sidewall fold-lines 725, 727, 735 and 737; flap fold-lines 721, 723, 731 and 733; and hinge fold-lines 704, 712, 718 and 724.

As described above, the various fold-lines may intersect to define or form regions or structures of the container 700. These regions may include a base, one or more sidewalls and/or one or more webs.

The following description is of an exemplary combination of regions or structures defined by an exemplary combination of fold-lines. For example, base 748 is defined by the intersection of long fold-lines 706 and 720 with long fold-lines 710 and 714. In this embodiment, the base 748 has a rectangular shape. Of course the base 748 is not limited to any specific shape.

Sidewall 740 is formed by the intersection of long fold-lines 710 and 714 with long fold-line 706 and hinge fold-line 712. Sidewall 742 is formed by the intersection of long fold-lines 706 and 720 with long fold-line 710 and hinge fold-line 704. Sidewall 744 is formed by the intersection of long fold-lines 710 and 714 with long fold-line 720 and hinge fold-line 724. Sidewall 746 is formed by the intersection of long fold-lines 706 and 720 with long fold-line 714 and hinge fold-line 718. In this embodiment, sidewalls 740, 742, 744 and 746 have a trapezoidal shape. In other embodiments, one or more of the sidewalls may have a different shape including rectangular, square, and other polygonal shapes. For example, an embodiment may include two trapezoidal sidewalls and two rectangular sidewalls. In such an embodiment, preferably the two trapezoidal sidewalls are on opposite sides of the base 748. Further, any portion of a region formed by the intersection of fold-lines which also defines a portion of the outer perimeter of the container 700 may include curved surfaces.

Web 770 is formed by the intersection of long fold-lines 706 and 710. A portion of the web 770 is defined by the outer perimeter of the container 700. Web 772 is formed by the intersection of long fold-lines 710 and 720. Web 774 is formed by the intersection of long fold-lines 720 and 714. Web 776 is formed by the intersection of long fold-lines 706 and 714.

The container 700 may further include flaps 728, 730, 732 and 734. The flap 730 includes a slot 736, which may be used as a means of closing the container 700 once constructed. The flap 734 includes the corresponding means for closing: hook structure 738. When fully constructed, the hook structure 738 may be inserted into the slot structure 736 to keep the container closed. Other means of holding the flaps closed may also be used, such as alternate hook structures, reusable adhesives, velcro, or others as are known in the art.

FIG. 7B is an isometric view of the container 700 from FIG. 7A in a constructed arrangement which has a high profile. The container 700 includes sidewalls 740, 742, 744 and 746; webs 770, 772, 774 and 776; flaps 728, 730, 732 and 734; and a base 748.

Each of the sidewalls and the base has an interior and exterior surface. In the embodiment illustrated in FIG. 7B, the sidewalls 740, 742, 744 and 746 are each at an obtuse angle with respect to the base 748. That is, each sidewall leans outward and the cavity 750 increases in cross-section from bottom to top along the z-axis. Such an arrangement may facilitate stacking multiple containers 700 in the constructed arrangement. However, other embodiments may include sidewalls perpendicular to the base, or even at acute angles with respect to the base.

Webs 770 and 776 are folded and affixed to the exterior surface of sidewall 740 during the construction process. An adhesive may be used to affix the webs to the sidewalls. Similarly, webs 772 and 774 are folded and affixed to the exterior surface of sidewall 744 during the construction process. In other embodiments, the webs may be folded and affixed to an interior surface of the sidewalls. Preferably, the webs are affixed to the sidewalls so as to avoid interfering with the sidewall fold-lines.

The container 700 is shown with flaps 728, 730, 732 and 734 in an open configuration such that food or other articles may be placed within a cavity 750 of the container 700 formed by the sidewalls and the base.

Also shown are a slot structure 736 and a hook structure 738, which allow the flaps 730 and 734 to be engaged or joined together to keep container 700 closed. Note that the hook structure 738 and the slot structure 736 are on opposing flaps 730 and 734 such that opposing flaps 728 and 732 can first be folded toward each other and across the cavity 750, and then opposing flaps 730 and 734 can be folded toward each other, across the cavity 750 and on top of flaps 728 and 732, and then engaged or joined via the hook structure 738 and the slot structure 736 to close the container 700. The container 700 may be opened by completing the preceding procedure in reverse i.e. unjoining or disengaging the hook structure 738 from the slot structure 736 and then folding each of flaps 728, 730, 732 and 734 up and away from the cavity 750. Thus, the container 700 may be in a closed or open arrangement i.e. the container is reclosable.

FIG. 7C is an isometric view of the container 700 from FIG. 7B in a partially folded arrangement. Arrows 760 and 764 indicate the general direction in which the walls 740 and 744 fold in. Likewise, arrows 762 and 768 indicate the direction in which the flaps 728 and 732 fold when folding container 700 flat. Once folded, the flaps 728 and 732 will sit adjacent to and partially on top of the flaps 734 and 730 (as shown in FIG. 7D).

FIG. 7D is an isometric view of five of the containers 700 from FIG. 7C after each container 700 has been further folded or compressed to achieve a lower profile advantageous for shipping and storage. As can be seen, containers 780, 782, 784, 786 and 788, which are each the same as the container 700 described with respect to FIGS. 6A-6C, are fully folded and stacked one on top of another. In this configuration, the containers are stacked very space efficiently as compared to FIG. 4. Additionally, in this configuration the containers are much less likely to be damaged while being shipped or stored because they are in a strong, flat position where all walls are adjacent and no cavity exists.

FIG. 7E is a side view of the five containers 700 from FIG. 7D illustrating their lower profile. As can be seen, containers 780, 782, 784, 786 and 788 are stacked to height 798. This arrangement, which can be used for shipping or for storage, is significantly more space efficient as compared to FIG. 4. Further, as mentioned above, this configuration is less prone to damage any of the individual containers.

The embodiments described above are exemplary and are not intended to limit the scope of possible light guide configurations that provide the advantageous functions described herein. A wide variety of variations in design, and configuration, and use are possible. For example, the container need not have any top flaps and may only included side walls and a bottom and still fall within the scope of the disclosure.

The foregoing description details certain embodiments of the invention. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the invention can be practiced in many ways. As is also stated above, it should be noted that the use of particular terminology when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to including any specific characteristics of the features or aspects of the invention with which that terminology is associated. The scope of the invention should therefore be construed in accordance with the appended claims and any equivalents thereof.

FOLDABLE CONTAINER

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