Note: Descriptions are shown in the official language in which they were submitted.
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FOLDABLE CONTAINER INCLUDING HORIZONTALLY HINGED SIDE WALL SECTIONS
FIELD OF THE NVENTION
The present invention relates to erectable containers, and more particularly,
to such
containers wherein the container is erectable from a generally flat collapsed
configuration to a
generally three-dimensional configuration in response to forces applied to
opposing walls of the
container.
BACKGROUND OF THE INVENTION
The use of storage bags for containing and protecting items, including
preservation of
perishable materials such as food items, is generally known in the art. Such
storage bags include
bags formed of opposing sheets of film material joined together along
peripheral edges to form a
semi-enclosed container having three sealed or folded edges and one open edge.
The open edge is
typically provided with a closure, such as a reclosable or reusable seal
formed integrally, as may
be provided by an integrally formed interlocking seal. Storage bags may be
conveniently stored
in a flat configuration prior to use and expanded to accommodate the contents
placed in the bag.
With regard to rigid or semi-rigid containers, it is well recognized that such
containers
have also realized a fair degree of commercial success in providing a means
for storing a wide
variety of contents. Such containers typically have an opening which maintains
an open condition
for filling and/or removal of contents. Such containers also are frequently
provided with flat
bottoms and tops to provide stackability. However, such containers typically
use more material
than bags such that disposability may be limited. At the same time, the useful
life of such
containers may be limited by damage, soiling, or other degradation naturally
occurring in use.
Such three-dimensional, rigid or semi-rigid containers may also require
greater storage area than
other, more flexible containers, since they generally occupy as much volume
empty as they do in
a filled condition.
Accordingly, it would be desirable to provide a container combining the
desirable
qualities of both flexible bags and rigid or semi-rigid storage containers. It
would also be
desirable to provide such a container which is capable of being self-
supporting in an open
condition for filling purposes, yet stores easily by folding into a compact
form.
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SUMMARY OF THE INVENTION
In accordance with one aspect of the invention, an erectable and collapsible
container is
provided comprising a structure comprising a bottom wall and at least a pair
of end walls
pivotably attached to the bottom wall. The end walls each comprise a plurality
of end wall
sections having an end wall hinge disposed therebetween. An upper portion
comprising a sheet of
material is attached to the structure, the upper portion comprising engageable
sides defining a
closable opening for the container. The end walls are articulable about the
end wall hinges when
the pair of end walls moves from a first position relative to the bottom wall
to a second position
relative to the bottom wall.
In accordance with another aspect of the invention, an erectable and
collapsible container
is provided comprising a structure comprising a bottom wall and at least a
pair of end walls
pivotably attached to the bottom wall. The end walls each comprise a plurality
of end wall
sections having an end wall hinge disposed therebetween. Side walls are
pivotably attached to the
bottom wall and extend between the end walls, the side walls each comprising a
plurality of side
wall sections having a side wall hinge disposed therebetween. An upper portion
is attached to the
structure. The end walls are articulable about the end wall hinges when the
pair of end walls
moves from a first position relative to the bottom wall to a second position
relative to the bottom
wall.
In accordance with a further aspect of the invention, an erectable and
collapsible
container is provided comprising a structure comprising a bottom wall and at
least a pair of end
walls pivotably attached to the bottom wall. The end walls each comprise a
plurality of end wall
sections having an end wall hinge disposed therebetween. Side walls are
pivotably attached to the
bottom wall and extend between the end walls, and including gusset portions
extending between
the side walls and adjacent end walls, each gusset portion including a gusset
hinge articulable
relative an adjacent end wall hinge of an adjacent end wall. The end walls are
articulable about
the end wall hinges and the gusset hinges are articulable relative to the
adjacent end wall hinges
when the pair of end walls moves from a first position relative to the bottom
wall to a second
position relative to the bottom wall.
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BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and
distinctly
claiming the present invention, it is believed that the present invention will
be better understood
from the following description in conjunction with the accompanying Drawing
Figures, in which
like reference numerals identify like elements, and wherein:
Fig. I is a perspective view of a front side of a container illustrating the
present invention
in an erected configuration;
Fig. 2 is a perspective view of a rear side of the container shown in Fig. 1;
Fig. 3 is a perspective view of the container illustrating the present
invention in a
collapsed configuration;
Fig. 4 is a perspective view of the container illustrating the present
invention in a partially
erected configuration;
Fig. 5 is a cross-sectional view taken along line 5-5 in Fig 4;
Fig. 6 is a cross-sectional view taken along line 6-6 in Fig. 4;
Figs. 7 and 8 are perspective views illustrating steps of folding a side panel
and
implementing an interlocking structure to hold the side panel in a folded
position;
Figs. 9 and 10 are perspective views illustrating steps of folding a side
panel and
implementing a pocket structure to hold the side panel in a folded position;
Fig. I 1 is a perspective view of a step of separating the side panels along
separation lines
extending along an edge of the side panels;
Fig. 12 is a perspective view of the support portion of the container after
separation of the
side panels along a separation line extending along a connection between the
side panels and the
support structure; and
Fig. 13 is perspective view of the container of Fig. I with the side panels
joined together
in a sealed configuration.
DETAILED DESCRIPTION OF THE INVENTION
Referring to Figs. I and 2, a container 10 in accordance with the teachings of
the present
invention is shown. The container 10 generally includes a support structure 12
movable between
a configuration defining a flexi-resilient structure and a configuration
defining a rigid or semi-
rigid structure. The support structure 12 comprises a bottom wall 14 including
opposing side
edges 16, 18 and opposing end edges 20, 22 connecting the side edges 16, 18.
First and second
opposing end walls 24, 26 are attached to the bottom wall 14 at respective
hinges 28, 30 defined
at the end edges 20, 22; and a front or first longitudinal side wall 32 is
attached to the bottom wall
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at a hinge 36 defined at side edge 16, and a rear or second longitudinal side
wall 34 is attached to
the bottom wall at a hinge 38 defined at the side edge 18. The first and
second end walls 24, 26
and front and rear side walls 32, 34 extend generally perpendicular relative
to the bottom wall 14
and circumscribe a generally rectangular area when the container 10 is in an
erected three-
dimensional configuration.
It should be noted that although the present invention is described with
reference to a
four-sided or rectangular container, the structure and operation of the
present invention is not
limited to four-sided containers, and the principles of the present invention
may be applicable to
other polygon-sided container configurations, for example, such that the
bottom wall 14 may
comprise three or more edges.
The first end wall 24 comprises first and second sections 40, 42 connected for
articulation
relative to each other at a first end wall hinge 44. The first section 40 of
the first end wall 24
comprises opposing front and rear edges 46, 48, and opposing inner and outer
faces 50, 52; and
the second section 42 of the first end wall 24 comprises opposing front and
rear edges 54, 56, and
opposing inner and outer faces 58, 60. The first and second sections 40, 42
are illustrated as
preferably having substantially similar dimensions in both the width
direction, i.e. extending
between the front edges 46, 54 and rear edges 48, 56, and the height
direction, i.e., extending
generally perpendicular to the width direction in a direction extending from
the bottom wall 14.
Although preferred dimensional relationships between the components of the
container 10 are
described herein, those skilled in the art will recognize that the relative
dimensions of the
components, as well as the degree of displacement of the components relative
to each other, the
number of components that comprise a wall, the consistency or inconsistency of
the dimensions
of the components with each other, may vary and still remain functional within
the scope of the
invention.
Similarly, the second end wall 26 comprises first and second sections 62, 64
connected
for articulation relative to each other at a second end wall hinge 66. The
first section 62 of the
second end wall 26 comprises opposing front and rear edges 68, 70, and
opposing inner and outer
faces 72, 74; and the second section 64 of the second end wall 26 comprises
opposing front and
rear edges 76, 78, and opposing inner and outer faces 80, 82. The first and
second sections 62, 64
of the second end wall 26 are illustrated as having width and height
dimensions preferably
substantially similar to the width and height dimensions of the first and
second sections 40, 42 of
the first end wall 24.
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The front side wall 32 comprises first and second sections 84, 86 pivotably
connected to
each other at a front side wall hinge 88, and first and second front gusset
structures 90, 92
extending from opposing ends 94, 96 of the front side wall hinge 88. The first
front gusset
5 structure 90 extends from the hinge end 94 to the front edges 46, 54 of the
first end wall 24, and
the second front gusset structure 92 extends from the hinge end 96 to the
front edges 68, 76 of the
second end wall 26.
The rear side wall 34 comprises first and second sections 98, 100 pivotably
connected to
each other at a rear side wall hinge 102, and first and second rear gusset
structures 104, 106
extending from opposing ends 108, 110 of the rear side wall hinge 102. The
first rear gusset
structure 104 extends from the hinge end 108 to the rear edges 48, 56 of the
first end wall 24, and
the second rear gusset structure 106 extends from the hinge end 110 to the
rear edges 70, 78 of the
second end wall 26. The first and second sections 98, 100 of the rear side
wall 34 and the first
and second sections 84, 86 of the front side wall 32 are illustrated as
preferably having
substantially similar width and height dimensions, where the height dimension
of the sections 84,
86, 98, 100 comprising the front and rear side walls 32, 34 is preferably
substantially similar to
the height dimension of the sections 40, 42, 62, 64 comprising the first and
second end walls 24,
26. Further, the height and width dimensions of sections 84, 86, 98, 100 may
comprise different
dimensions from. each other and from those of sections 40, 42, 62, 64.
In accordance with a further aspect of the invention, the container 10
includes two
generally planar opposing side panels 112, 114 extending from the end walls
24, 26 and side walls
32, 34 to define a flexible bag-like upper portion 116 for the container 10.
The side panel 112
extends from the front side wall 32 and from a front half of each of the end
walls 24, 26, and the
side panel 114 extends from the rear side wall 34 and from a rear half of each
of the end walls 24,
26. The side panels 112, 114 are attached together along elongated edge seams
118, 120 where
the edge seams 118, 120 may be formed by ultasonic welding, heat sealing, an
adhesive or other
conventional attachment means, joined in a butt joint, lap seam, a fin seal or
other configuration.
An upper end of the side panels 112, 114 distal from the bottom wall 14
defines an open
mouth 122 for the container 10 for passage of contents into and/or out of the
container 10. An
optional, reusable closure 124 is shown located at the mouth 122 of the
container 10 and is
illustrated as complementary mating elements 126, 128 attached to the interior
of the side panels
112, 114 for reclosably sealing the mouth 122 of the container 10. For
example, the reusable
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closure 124 may comprise an interlocking seal type closure, and which may or
may not include a
slider for manipulating opening and closing of the container 10. The present
invention is not
limited to the illustrated reusable closure, and non-limiting examples of
reusable closures which
may be employed, and information on their manufacture, are described in U.S.
Patent Nos.
4,186,786; 4,285,105; 4,363,345; 4,561,109; 5,804,265 and 5,851,070.
Additional closure
structures may be incorporated for closing the mouth 122 of the container 10
including, without
limitation, mechanical fasteners such as hook-and-loop fasteners, snap
closures, grips, clips, and
clamps, flap closures, tie flaps, drawstring closures, twist-tie closures, and
adhesion closures such
as pressure sensitive adhesive tapes or strips, mating cohesives, epoxy-resin
reactive adhesives,
and pressure sensitive adhesive embedded activated films. Non-limiting
examples of pressure
sensitive adhesive embedded activated films which may be used, and information
on their
manufacture may be found in U.S. Patent Nos. 5,662,758 and 6,489,022. Although
reusable
closures have been mentioned as a preferred closure, a more permanent closure
may be preferred
in certain applications of the invention. Full or partial closures, or absence
of closures, other than
those specifically mentioned herein may also be provided within the scope of
the described
invention.
The illustrated embodiment of the container 10 is constructed from a sheet or
sheets of
the flexible material 130 (see Figs. 5 and 6), where the term "flexible" is
utilized to refer to
materials which are capable of being flexed or bent, especially repeatedly,
such that they are
pliant and yieldable in response to externally applied forces. Accordingly,
"flexible" is
substantially opposite in meaning to the terms inflexible, rigid, or
unyielding. Materials and
structures which are flexible, therefore, may be altered in shape and
structure to accommodate
external forces and to conform to the shape of objects brought into contact
with them without
losing their integrity. The sheet material 130 for forming the container 10
may comprise a
flexible film material including a polymeric film, such as polypropylene or
comparable material,
where a polypropylene material may be provided in a thickness of from 1 to 4
mils, for example.
The sheet or sheets of flexible material 130 forming the container 10 may form
the end
walls 24, 26, the side walls 32, 34, the bottom wall 14 and the side panels
112, 114 as a
continuous flexible containment material. Alternatively, the flexible material
130 can comprise a
bag-like or tube-like structure. Further, the end wall sections 40, 42, 62, 64
and bottom wall 14
define semi-rigid, resilient surfaces of the container 10 capable of pivoting
relative to each other
at the hinges 28, 30, 44, 66 where the hinges may be formed by the flexible
material 130. In the
illustrated embodiment of the container 10, each of the end wall sections 40,
42, 62, 64 and
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bottom wall 14 are defined by a layered structure comprising the flexible
material 130 and a panel
of resilient semi-rigid structural material 132 that is attached to the
exterior surface of the flexible
material 130 as shown, for example, in Figs. 5 and 6. In a non-limiting
example of the invention,
the panel of structural material 132 may comprise a material having a flexural
modulus in the
range of between 170,000 and 250,000 psi and a thickness of between 0.01 and
0.50 inches, as
compared to the flexible material 130 which has a flexural modulus of between
170,000 and
250,000 psi and a thickness of between 0.0005 and 0.01 inches. The structural
material 132 is
preferably stiffer than the flexible material 130 and is preferably capable of
resiliently flexing
from and returning to a predetermined initial shape, such as a generally
planar shape. As used
herein, the term "flexural modulus" means the flexural modulus as determined
according to
ASTM Test Method D 790. In one embodiment the structural material 132 may
preferably
comprise a polypropylene material. However, additional or other materials may
be used for the
structural material 132 including, without limitation, any known polymeric
material including
extruded corrugate polymeric materials, carded fibrous materials, and fine
fluted corrugates.
Those skilled in the art will recognize that the particular stiffness for
either the flexible material
130 or the structural material 132 may be adjusted in accordance with a
desired end use or
application for the container 10.
The structural material 132 may be attached to the flexible material 130 by
means of a
mechanical connection forming a molecular level bond between the structural
material 132 and
the flexible material 130, such as by ultrasonic welding, or a thermal bond,
e.g., heat sealing.
Alternatively, the structural material 132 and flexible material 130 may be
joined by adhesives or
cohesives including without limitation contact adhesives, or by mechanical
connections such as a
snap fit, clips, rubber bands, mechanical fasteners, staples, grips, clamps,
and/or an interference fit
connection between the two materials, i.e., a tolerance fit such as by
locating the structural
material 132 in a tight fit within the flexible material 130, or a mechanical
punching of the
material together, Such attachment may be continuous or discontinuous as in,
for example, a
series of two or more points of attachment.
It should be noted that structural material 132 comprising the bottom wall 14
may
optionally be unattached to the flexible material 130, In such a case, the
structural material 132 of
the bottom wall 14 may be attached to other structure, for example, one or
more of the end walls,
32, 34. Further, although the illustrated construction locates the structural
material 132 on the
exterior surface of the flexible material 130, some or all portions of the
structural material 132
may be located on the inside surface of the flexible material 130.
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Alternatively, the end wall sections 40, 42, 62, 64 and/or bottom wall 14 may
be formed
with less than the full area of the end wall sections 40, 42, 62, 64 and/or
bottom wall 14 covered
with the structural material 132. For example, the end wall sections 40, 42,
62, 64 and/or bottom
wall 14 may include frame members (not shown) located so as to maintain the
structural integrity
or shape of the end wall sections 40, 42, 62, 64 and/or bottom wall 14 during
movement between
a generally flat collapsed configuration and the erected configuration and/or
during use of the
container 10. It should be understood that any construction capable of
providing a stiffness to the
end wall sections 40, 42, 62, 64 and/or bottom wall 14 greater than the
stiffness of the flexible
material 130 may be used, whether solid or perforated sheets or frames or
other structural
elements are employed, which construction need not necessarily include
providing separate or
attached rigidifying structure to the end wall sections 40, 42, 62, 64 and/or
bottom wall 14. For
example, the end wall sections 40, 42, 62, 64 and/or bottom wall 14 may be
formed of the same
sheet of material comprising the side panels 112, 114, but formed with a
different material
characteristic, such as may be provided by a different material caliper or by
increased cross-
linking or crystallization of the material in the end wall sections 40, 42,
62, 64 and/or bottom wall
14, or by mechanical means such as by forming folds, creases or corrugations
in the material.
Although the flexible material 130 has been described as flexible
polypropylene film
material, other materials exhibiting flexible characteristics may be
incorporated as the flexible
material 130 including without limitation, substantially impermeable polymeric
materials,
cellulose materials, aluminum foil, coated (waxed, etc.) and uncoated paper,
coated nonwovens
etc., and substantially permeable materials such as scrims, meshes, wovens,
nonwovens, open or
closed cell foams, or perforated or porous films, whether predominantly two-
dimensional in
nature or formed into three-dimensional structures. Such materials may
comprise a single
composition or layer or may be a composite or laminate structure of multiple
materials, including
a substrate material utilized as a carrier for a substance. Further, those
skilled in the art will
recognize that any material that provides the desired stiffness
characteristics for the flexible
material 130 may be incorporated within the scope of the present invention.
The flexible material 130 is not limited to constructions formed from sheet
materials, and
the flexible material portion of the container 10 may be constructed in any
known and suitable
fashion such as those known in the art for making bags or storage containers
in commercially
available form. Heat or adhesive sealing technologies may be utilized to join
various components
or elements of the flexible material 130 to themselves or to each other. In
addition, the flexible
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material portion of the container 10 may be thermoformed, blown, or otherwise
formed or molded
as an alternative to reliance upon folding and bonding techniques to construct
the flexible material
portion from a web or sheet of material.
The materials selected for either or both the flexible material 130 and the
structural
material 132 may exhibit any degree of transparency, translucency and/or
opacity, such as may be
selected to provide a desired degree of visual identification of contents and
may include colored
transparent, translucent and/or opaque materials. The degree of transparency,
translucency and/or
opacity may additionally be selected to facilitate writing and/or reading
textual messages, i.e.,
container contents and/or directions, on the container 10.
Also included among materials acceptable for forming the flexible material 130
and the
structural material 132 are microwaveable materials. Further, the flexible
material 130 and the
structural material 132 may comprise materials and constructs or structures
providing insulative
properties for limiting flow of heat between exterior and interior surfaces of
the container 10, such
as may be provided to the bottom wall 14 or other contacted surfaces to limit
heat transfer to a
user's hand or a supporting surface. Such materials may include those
materials which generally
have a lower heat conductivity, lower heat/cold capacity, less mass and/or
material structures
influencing the thermal conductivity and/or thermal capacity, such as
materials including void
spaces for either partially or fully enveloping or enclosing a fluid, such as
air, within the material.
Examples of materials for providing desirable thermal properties to the
container 10 include,
without limitation, open or closed cell foamed materials, small air entrapping
materials, e.g.,
fibers, down, spaced particles, etc., dispersed through, on or between the
flexible material 130
and/or structural material 132, low mass portions defined in the flexible
material 130 and/or
structural material 132, e.g., thinned portions of the flexible material 130
and/or structural
material 132, and/or provision of a low heat transference insulative layer or
coating between the
flexible material 130 and structural material 132. Such materials may be in
the form of a
corrugated paper or polymer material structure formed of one or two or more
layers having offset
areas, such as may be formed by thermoforming, embossing, folding, etc. For
example, a multi-
layered structure formed of two layers, at least one of which includes areas
offset from the plane
of the other layer, or a single layer material where selected areas of the
material are offset from
other areas of the material to provide a volume of insulative air between
exterior and interior
surfaces of the container. Alternatively, a thermal barrier may be formed by
two or more layers of
flexible polymeric material selectively sealed or bonded together to produce
areas of entrapped
air.
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As seen in Figs. 1-2 and 4, the container 10 in the illustrated embodiment
includes a
bottom 14 formed with a corrugated construction. Referring further to Fig. 6,
the corrugated
construction includes a layer of formed structural material 132 including
corrugation portions
5 134, and a flexible material layer 130 attached to the structural material
132. An air space is
defined between the structural material 132 and the flexible material 130 at
the corrugation
portions 134 which may entrap air to provide a thermal barrier at the bottom
wall 14. In addition,
the corrugation portions 134 may provide additional structural rigidity to
stiffen the bottom wall
14.
Fig. 3 illustrates the container 10 in the generally flat collapsed
configuration where the
end walls 24, 26 are folded substantially flat. Specifically, the first
sections 40 and 62 of the end
walls 24, 26 may pivot toward the bottom wall 14 to locate the respective
inner surfaces 50 and
72 adjacent and generally parallel to the bottom wall 14. The second sections
42 and 64 of the
end walls 24, 26 may pivot about the respective end wall hinges 44, 66 to
locate the first and
second sections 40, 42 of the first end wall 24 generally parallel and
adjacent to one another with
the outer faces 52, 60 thereof in substantially facing relationship to one
another, and to locate the
first and second sections 62, 64 of the second end wall 26 generally parallel
and adjacent to one
another with the outer faces 74, 82 thereof in substantially facing
relationship to one another. The
pivoting of the second sections 42 and 64 of the end walls 24, 26 may occur
substantially
simultaneously with and in the opposite pivoting direction of the respective
first sections 40 and
62 of the end walls 24, 26. In addition, hinges 136, 138 may be provided
adjacent a junction
between upper edges of the second end wall sections 42, 64 and the upper
portion 116 of the
container 10 to facilitate pivoting movement of the second end wall sections
42, 64 relative to the
upper portion 116.
The flexible material 130 forming the front and rear side walls 32, 34 is
folded in a
substantially predetermined configuration when the container 10 is in the
collapsed configuration,
where the first sections 84 and 98 of the front and rear side walls 32, 34 may
pivot about
respective hinges 36 and 38 toward the bottom wall 14 to locate the first
sections 84, 98 generally
parallel and adjacent to the bottom wall 14. The second sections 86 and 100 of
the front and rear
side walls 32, 34 may pivot about the side wall hinges 88, 102 to locate the
first and second
sections 84, 86 of the front side wall 32 generally parallel and adjacent to
one another, and to
locate the first and second sections 98, 100 of the rear side wall 34
generally parallel and adjacent
to one another. The pivoting of the second sections 86 and 100 of the front
and rear side walls 32,
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34 may occur substantially simultaneously with and in the opposite pivoting
direction of the
respective first sections 84 and 98 of the front and rear side walls 32, 34.
In addition, hinges 140,
142 may be provided adjacent a junction between upper edges of the second
sections 86, 100 of
the front and rear side walls 32, 34 and the upper portion 116 of the
container 10 to facilitate
pivoting movement of the second sections 86, 100 relative to the upper portion
116.
Movement and orientation of the gusset structures 90, 92, 104, 106 relative to
the
articulated movement of the sections 40, 42, 62, 64 of the end walls 24, 26 is
described with
reference to Figs. 4-6, where Fig. 4 illustrates the container 10 in a
partially erected configuration.
The gusset structures 90, 92, 104, 106 may each undergo substantially similar
movement, as will
be described below with reference to the first gusset structure 90 of the
front side wall 32. The
gusset structure 90 is foldable about a gusset hinge 144 extending generally
collinear with the side
wall hinge 88, where folding of the gusset structure 90 about the gusset hinge
144 defines a first
gusset portion 146 and a second gusset portion 148 (see also Fig. 1) on either
side of the gusset
hinge 144. By way of illustration, during movement of the support structure 12
of the container
10 from the erected configuration to the collapsed configuration, an inner
surface 150 (Fig. 5) of
the gusset structure 90 may move from an orientation generally perpendicular
to the end wall
sections 40, 42 to an orientation where the portions of the inner surface 150
defined on the first
and second gusset portions 146, 148 may be substantially parallel and facing
toward the
respective inner faces 50, 58 of the end wall sections 40, 42. The gusset
hinge 144 also may
move from an orientation generally perpendicular to the end wall hinge 44 in
the erected
configuration to an orientation where the gusset hinge 144 may extend
generally parallel to the
end wall hinge 44 in the collapsed configuration. As the end wall sections 40,
42 pivot to the
collapsed configuration, the gusset structure 90 folds or wraps around the
inner faces 50, 58
substantially progressively in a direction from the front edges 46, 54 toward
the rear edges 48, 56,
as illustrated in Fig. 5 in which a folded portion 152 of the gusset structure
90 is shown extending
substantially parallel to the end wall section 40, and a remaining portion 154
of the gusset
structure 90 may extend between the folded portion 152 and the side wall
section 84. As noted
above, each of the remaining gusset structures 92, 104, 106 may move in a
manner substantially
similar to the described movement of the gusset structure 90 during
articulated movement of the
end wall sections 40, 42 and 62, 64 relative to each other.
In the collapsed configuration of the container 10, as illustrated in Fig. 3,
the ends 94, 96
and 108, 110 of the front and rear side wall hinges 88, 102 are located
adjacent the end wall
hinges 44, 66, locating the side wall hinges 88, 102 at an innermost position.
Similarly, the end
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wall hinges 44, 66 are located at an innermost position, such that the support
structure 12 is
configured as a substantially compact folded structure in the collapsed
configuration of the
container 10. As the container moves form the collapsed toward the erected
configurations, the
end wall hinges 44, 46 move away from each other and the side wall hinges 88,
102 move away
from each other.
The upper portion 116 of the container 10 may include extended end portions
154, 156
(Fig. 3) that may extend outwardly beyond a location adjacent the hinges 136,
138 at the upper
edges of the second sections 42, 64 of the end walls 24, 26 when the upper
edges of the side
panels 112, 114 are located adjacent each other, i.e., when the opening 122 is
substantially closed.
The extended end portions 154, 156 may comprise gusset portions 158, 160
(Figs. I and 2)
located between upper edges of the second sections 42, 62 of the end walls 24,
26 and respective
angled hinges 162, 164 and 166, 168 positioned on either side of the edge
seams 118, 120,
respectively. The angled hinges 162, 164, 166, 168 may comprise, without
limitation, score lines,
or embossed or thinned lines of material. The extended end portions 154, 156
may further be
folded around the end edges 20, 22 and under the bottom wall 14 to facilitate,
for example,
compact packaging of the container 10 or a plurality of the containers 10
contained in a package.
The container 10 may be transformed from the collapsed configuration to the
erected
configuration by application of a force or forces to the container 10. A force
or forces may be
applied to the end wall hinges 44, 66, either internally or externally of the
container 10, to bias or
move the end wall hinges 44, 66 outwardly from each other. For example, a
force may be applied
to cause generally oppositely directed resultant forces to act on the end
walls 24, 26.
Alternatively, a force or forces may be applied to cause relative pivoting
movement between the
first and second sections 40, 42 of the first end wall 24 and/or to cause
relative pivoting
movement between the first and second sections 62, 64 of the second end wall
26. Additionally
and/or alternatively, a force or forces may be applied to cause relative
pivoting movement
between the first section 40 of the first end wall 24 and the bottom wall 14
and/or to cause
pivoting movement between the first section 62 of the second end wall 26
and/or the bottom wall
14. As a further alternative, a force a may be applied to cause a generally
oppositely directed
resultant forces to be applied to the container 10 in a direction extending
between the support
structure 12 and the upper portion 116, to cause expansion of the container
10.
Application of a force or forces to move the container 10 between collapsed
and erected
configurations may be facilitated by additional structure associated with one
or more of the end
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13
walls 24, 26, side walls 32, 34, bottom wall 14 and/or side panels 112, 114 of
the container 10,
such as structure which may facilitate forming a gripping surface and/or
applying a leveraged
force thereto. Such additional structure may include, without limitation,
tabs, wall edge or facial
finger indentations, or increased friction surfaces and the like, loops or
levers for directly or
indirectly transmitting a force from a user to a portion of the container 10
for causing the
container 10 to either move from the collapsed configuration toward the
erected configuration or
to move from the erected configuration toward the collapsed configuration, or
for applying a
restraining anchor force such as to control the bottom wall position while
erecting one or more
end walls 24, 26.
In the erected configuration, as seen in Figs. 1 and 2, the upper portion 116
comprises a
flexible openable and closable portion of the container 10, where contents may
be placed in or
taken out of the container 10 through the open mouth 122 of the upper portion
116. The side
panels 112, 114 may be biased away from each other to facilitate access
through the opening 122.
For example, additional structure may be provided to the side panels 112, 114
to facilitate
maintaining the side panels 112, 114 in a more open state. Such additional
structure may include,
without limitation, a stay or stays 170, 172 located at a mid-span location of
the top of one or both
of the side panels 112, 114 or positioned along other locations of the side
panels 112, 114. The
stay or stays may comprise flexible or rigid members, generally exhibiting
some dead-fold or
position lockable functionality for maintaining at least a portion of the side
panels 112, 114 in a
desired position. A stay exhibiting such functionality may comprise metal wire
or thin sheet
material, including fibrous papers and boardstocks, dead-foldable polymer
sheet, and molded,
formed, stamped or cut rigid parts with a lockable hinge-like mechanism. Other
stay materials
exhibiting similar functionality may also be used.
Alternatively, or additionally, the structure for biasing or maintaining the
flexible panels
112, 114 in a more open position may comprise structure for facilitating
maintaining the side
panels 112, 114 more aligned with the adjacent end walls 24, 26 and/or side
walls 32, 34. For
example, means altering the material properties of the side panels 112, 114,
including but not
limited to force transmission elements or stiffening elements for transmitting
forces between the
side panels 112, 114 and the end walls 24, 26 and/or the side walls 32, 34 may
be provided.
Referring to Figs. 7-12, the container 10 may further include means
facilitating access to
contents located in the container by manipulation of the side panels 112, 114.
In particular, in the
illustrated embodiment of the container 10, areas for separating the side
panels 112, 114 from
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14
each other and/or from the end walls 24, 26 and side wall 32, 34 may be
provided including, for
example, a frangible area or areas 174 (see also Figs. I and 2) extending
along at least one of the
edge seams 118, 120, and may also include a further frangible area 176
extending adjacent an
upper edge of the end walls 24, 26 and side walls 32, 34. In accordance with
one method of
providing access to the container 10, the side panels 112, 114 may be
separated fully or partially
along the at least one frangible area 174, and the side panels 112, 114 may be
folded and/or rolled
toward the bottom wall 14 along the end walls 24, 26 and side walls 32, 34, as
illustrated in Fig.
7. In addition, the edge portion of the side panels 112, 114 including the
reusable closure 124
may be folded back toward the open end of the container 10 and retained in
position by a
fastening structure, such that an outwardly facing surface 178 of the upper
portion 116, defined by
inner surfaces of the side panels 112, 114, are overlapped or covered by the
folded portion or
portions of the side panels 112, 114. Optionally, a further frangible area may
be provided, such
as at the other one of the edge seams 118, 120 or another location, to allow
multiple sections of
the side panels 112, 114 to be folded and/or rolled over to facilitate
separation of the side panels
112, 114. Preferably, the separated material is separated in one piece; or
alternatively in two or
more pieces. The separated material may be fully removable from the container
10 or may still be
attached at one or more points about which the material can be pivoted.
As illustrated in Figs. 7 and 8, the fastening structure for retaining the
folded edge portion
of the side panels 112, 114 may comprise a section or sections of an
interlocking closure element
180 located on the surface 178 of the upper portion 116 for cooperating and
mating with at least
one of the elements 126, 128 of the reusable closure 124. For example, after
the upper portion
116 is folded toward the bottom wall 14 along the outside of the support
structure 12, the edge
portion of the side panels 112, 114 including the reusable closure 124 may be
folded back toward
the open end of the container 10 to position the reusable closure 124 in
interlocking engagement
with the interlocking closure element 180 located on the surface 178.
Figs. 9 and 10 illustrate an alternative fastening structure fastening
structure for retaining
the folded edge portion of the side panels 112, 114 in the folded position.
The fastening structure
may comprise a pocket structure 182 defining a pocket or pockets located on
the support structure
12. The pocket structure 182 is illustrated as a triangular structure and may
be located, for
example, on one or more of the end walls 24, 26 and defines a slit or slits
184, or similar structure,
for receiving a corner 186 formed by folding the edge portion of the side
panels 112, 114 after the
upper portion 116 is folded along the outside of the support structure 12.
Retention of the upper
portion 116 in the described folded configuration is not limited to the
mechanisms described
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above and may comprise other mechanisms including, without limitation,
material retaining
dimple(s) or aperature(s), hook and loop fasteners, adhesives including
pressure sensitive
adhesives, snap fit connections, clips, rubber bands, mechanical fasteners,
grips and/or clamps.
5 In providing the container access illustrated in Figs. 7-10, it is not
necessary for the entire
upper portion 116 formed by both side panels 112, 114 to be folded toward the
bottom wal114.
For example, half of the upper portion 116, as defined by one of the side
panels 112, 114 may be
folded to provide access through one side of the upper portion 116.
Alternatively, the side panels
112, 114 may be slit or torn along additional locations to provide access
through an area less than
10 or greater than the area defined by one of the side panels 112, 114.
In accordance with an alternative method of providing access to the container
10, the side
panels 112, 114 may be separated along one or more of the frangible portions
or areas 174, as
seen in Fig. 11, and the side panels 112, 114 may be further separated from
the end walls 24, 26
15 and side walls 32, 34 along frangible portion or area 176 to permit
substantially complete removal
of the side panels 112, 114 from the end walls 24, 26 and side walls 32, 34
(Fig. 12).
The frangible portions or areas 174, 176 may be formed by predefined areas or
lines of
weakness and/or tear-oriented material properties. Examples of predefined
areas or lines of
weakness include, without limitation, perforations, mechanical or laser
scores, material thinning
and/or tear tapes positioned at or adjacent to desired separation locations.
Alternatively,
separation can occur along lines, portions or areas of releasable attachment
such as lap, fin, butt
seams or seals whether joined by adhesive, cohesive, heat seal, welding or
other means. As a
further alternative, a spanning material, e.g., pressure sensitive adhesive
tape, may be torn or
removed to cause separation of the panel(s). Additionally, means may be
provided for facilitating
the tear or separation process including without limitation anchor/pull tags,
loops or other tactile
means facilitating a user's identification of the frangible area and/or to
facilitate grip and/or force
application to the container 10. Identification of the frangible area or areas
may further be
facilitated by a visual indicator or indicators including without limitation
color portions, such as
applied or printed color strip(s) and/or a visually distinguishable material
characteristic which
may be located at or adjacent to the frangible area and may include a visual
indicator extending
along either side of the frangible area, such as may be provided by a visually
identifiable laser
score or area(s) exhibiting a difference in opacity or translucency relative
to adjacent area(s).
Further, tear prevention structure may be provided adjacent to the frangible
areas to prevent the
tear from propagating beyond the frangible area.
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16
Structure for facilitating access to the container 10 is not limited to
manipulation of the
side panels 112, 114. Additional, structure may be provided to the area of the
support structure 12
and may include removable or displaceable structure associated with one or
more of the end walls
24, 26 and side walls 32, 34 permitting a portion or portions of the container
10 to be removed,
reformed or otherwise manipulated to improve access to the interior of the
container 10.
In one use of the container 10, the container 10 may be sealed and used for
storage of any
contents contained in the container 10. In such a use, the top portions of the
side panels 112, 114
may be joined together, such as by means of the above-described reusable
closure 124. Joining or
engagement of the side panels 112, 114 together may be accompanied by a
certain amount of
movement of the side panels 112, 114 as the side panels pivot about the hinges
140, 142 and fold
at the angled hinges 162, 164, 166, 168 forming the outwardly extending end
portions 154, 156
(Fig. 13). The folded state of the side panels 112, 114 defines a generally
flat top surface for the
container 10 along a plane substantially coincident with the location of the
hinges 136, 138, 140,
142. Accordingly, other containers may be stacked on the container 10 in a
manner similar to the
stackability provided by known rigid or semi-rigid storage containers.
The stackability of the container 10 may be enhanced by providing additional
structure
including, without limitation, additional structure adjacent the top or bottom
of the end panels 24,
26 and or side panels 32, 34, such as a top rim providing a support upon which
the bottom of a
supported container may rest, flared structure comprising some or all of the
end walls 24, 26
and/or 32, 34 being outwardly angled at the upper or lower edges thereof to
provide a positive
engagement with engaged lower or upper edges of a supported or supporting
container, or a rim
extending transversely from an outwardly extending flange adjacent the upper
or lower edges of
some or all of the end walls 24, 26 and/or side walls 32, 34 providing a ledge
for engaging the
lower or upper edges of a supported or supporting container. The structure
facilitating stacking of
containers 10 may be positioned exteriorly or interiorly of the flexible
material 130 to function in
direct contact with a stacked container or indirectly, through the flexible
film, to facilitate
stacking engagement. Other structures for facilitating alignment and/or
engagement of stacked
containers may also be provided.
In general, the end and/or bottom walls may be positioned exteriorly or
interiorly to the
flexible material 130, either completely or in a combination of interior and
exterior positions.
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17
The container 10 may be provided with additional structure to facilitate
handling of the
container 10 including, without limitation, a tab or tabs, handle or strap
formed as part of or
attached to the end walls 24, 26, the side walls 32, 34 and/or the bottom wall
14. For example, a
hand strap may be included to facilitate single handed lifting andlor carrying
of the container 10,
such as a strap provided to the bottom wall 14 to receive one or more fingers
of a user and
facilitating carrying of the container through support of the bottom wall 14.
Handling the container 10 may also be facilitated by structure provided on the
side panels
112, 114. The container 10 may be lifted and/or carried by gripping the
combined side panels
112, 114 between the user's fingers, as may be facilitated by a slip-resistant
or other grip
enhancing surface. Additional structure for enabling a user to grip the side
panels 112, 114 may
include, without limitation, attached or integral tab(s), loop(s), handle
hole(s) and/or strap(s).
In a use of the described container 10, the container may be provided in the
collapsed
configuration during storage or prior to use. Two or more containers 10 in the
collapsed
configuration may be provided with an outer package for convenient storage,
distribution, sale
and transport of multiple containers 10. The package may partially or fully
enclose or envelope
the containers 10. The package can be any known package including but not
limited to bags,
paper or plastic bands, shrink packages, shrink sleeves, stretch sleeves or
bands, cartonboard
packages, flow wrap packages, thermoformed packages, etc. Preferably, the
package encloses or
itself displays, illustrates or contains instructions for use of the
containers 10, including erecting
method(s). In a preferred retail store package, the package is itself either a
consumer usable semi-
rigid or rigid container or even an expanded erectable container 10.
During use, the container 10 may be transformed from the collapsed to erected
configuration, as described above, where the support structure 12 defines a
rigid or semi-rigid
structure and the upper portion 116 defines a flexible bag-like structure that
is openable for
passage of contents. Contents may be placed in the container 10 through the
opening 122, and the
opening 122 sealed using the reusable closure 124. The container 10 and
contents may be placed
in a refrigerator or freezer, if appropriate, for storage and may be stacked
with other containers 10
of similar construction if desired. Further, where the container 10 is formed
of a microwavable
material, the container 10 and enclosed contents may be placed directly in a
microwave oven to
reheat the contents directly in the container 10. Subsequently, a portion or
all of the upper portion
116 may be removed, or separated and positioned away to create a more
accessible opening, to
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18
facilitate access to the contents, where the support structure 12 may be
utilized as a bowl or plate-
like structure for serving the contents, or even directly eating therefrom.
Alternative constructions are useful for certain situations, such as a
container with plural
compartments. For example, a divider, itself optionally erectable, may rise up
from the bottom
wall to section the container into two or more compartments. Another example
is a container
with plural openings.
Not to be limiting, the present invention may contain liquids, solids,
particles and
combinations of contents thereof. Said contents may be an unlimited pallet of
materials and
articles to be used, for example for personal, household, industrial,
automotive, hygienic, farming
or pet maintenance purposes. Food stuff storage such as for human or animal
purposes is a
specific example. Further, the container may be partially or wholly collapsed
prior to use, but
pre-packed with contents such as the non limiting examples of oil and popcorn
kernels prior to
popping; dried instant noodles and vegetables prior to addition of hot water
for creating soup;
dried pet food prior to addition of water, and seasonings prior to addition of
other food
ingredient(s).
All documents cited in the Detailed Description of the Invention are
not to be construed as an admission that it is prior art
with respect to the present invention.
While particular embodiments of the present invention have been illustrated
and
described, it would be obvious to those skilled in the art that various other
changes and
modifications can be made without departing from the spirit and scope of the
invention. It is
therefore intended to cover in the appended claims all such changes and
modifications that are
within the scope of this invention.
