WO2024243544A1

WO2024243544A1 - Foldable container

Info

Publication number: WO2024243544A1
Application number: PCT/US2024/031068
Authority: WO
Inventors: Andreas Veltjens; Marco REMUS; Matthias Köhler; Heidi KERSTING; Armine BARTELMANN; Brenda NILSSON; Raik FRITZSCHE; Patrick PFRIEM; Sascha Di NARDI
Original assignee: Sonoco Development Inc
Current assignee: Sonoco Development Inc
Priority date: 2023-05-25
Filing date: 2024-05-24
Publication date: 2024-11-28
Anticipated expiration: 2025-11-25
Also published as: US20240391644A1

Abstract

The invention comprises a container (10) comprising a base (22) and at least four sidewalls (12, 14) extending upwardly from the base. A first sidewall (14) and a second sidewall (14) which is opposite the first sidewall each comprise at least a first panel (16) and a second panel (16). The first panel and the second panel are connected to each other by a first seam (18). The base comprises an interior surface and an exterior surface. The base is thinner in the location of a pattern disposed on the interior surface of the base and the interior pattern comprises an "X" shaped configuration. The base is thinner in the location of a pattern disposed on the exterior surface of the base and the exterior pattern comprises a first line extending from the first seam of the first sidewall to the first seam of the second sidewall.

Description

Foldable Container

CROSS-REFERENCE TO RELATED APPLICATIONS

[01] This application claims priority to European Patent Application 23305834.6, filed on May 25, 2023, the contents of which is incorporated by reference herein in its entirety.

BACKGROUND

[02] There is a general desire to not only provide containers and packages that are sustainable and recyclable, but also to reduce the size and/or volume of such used containers and packages. Through ingenuity and hard work, the inventors have developed a container which is sustainable, recyclable, and the size/volume of the container can be reduced after consumption of the product contained therein. Said alternatively, the container of the invention can be folded to a smaller size/volume after consumption of the product contained therein and prior to recycling.

SUMMARY

[03] In an embodiment, the invention comprises a container comprising a base and at least four sidewalls extending upwardly from the base. In an embodiment, a first sidewall and a second sidewall which is opposite the first sidewall each comprise at least a first panel and a second panel, the first panel and the second panel being connected to each other by a first seam. In an embodiment, the base comprises an interior surface and an exterior surface, wherein the base is thinner in the location of a pattern disposed on the interior surface of the base and wherein the interior pattern comprises an “X” shaped configuration. In an embodiment, the base is thinner in the location of a pattern disposed on the exterior surface of the base and wherein the exterior pattern comprises a first line extending from the first seam of the first sidewall to the first seam of the second sidewall. [04] In an embodiment, the at least four sidewalls terminate in a flange.

In an embodiment, a belt portion is affixed to the flange and the belt portion is configured to retain the container in a closed configuration. In an embodiment, the belt portion is configured to attach to a latch. In an embodiment, the latch is disposed adjacent the base and a central portion of a third sidewall. In an embodiment, the at least four sidewalls terminate in a flange and wherein the belt portion comprises a cover portion that is commensurate in size and shape with the flange.

[05] In an embodiment, a belt portion is affixed to a third sidewall, wherein the belt portion is configured to retain the container in a closed configuration. In an embodiment, the belt portion wraps about the first sidewall and second sidewall when the container is in a closed configuration. In an embodiment, the first seam comprises a thinned area of the first sidewall and the second sidewall. In an embodiment, the thinned area is disposed on an interior surface of the first sidewall and the second sidewall.

[06] In an embodiment, the at least four sidewalls include a third sidewall and a fourth sidewall which do not comprise seams. In an embodiment, the first sidewall and the second sidewall additionally comprise a second seam and a third seam, the second seam disposed between the first panel and a first comer of the sidewall opposite the first seam and the third seam disposed between the second panel and a second comer of the sidewall opposite the first seam. In an embodiment, the “X” shaped configuration comprises: a line extending from the second seam of the first sidewall to the third seam of the second sidewall; and a line extending from the third seam of the first sidewall to the second seam of the second sidewall. In an embodiment, the base is thinner in the location of an additional pattern disposed on the exterior surface of the base, wherein the exterior additional pattern comprises: a second line extending from the second seam of the first sidewall to the second seam of the second sidewall; and a third line extending from the third seam of the first sidewall to the third seam of the second sidewall.

[07] In an embodiment, the second line is offset from a third sidewall and the third line is offset from a fourth sidewall. In an embodiment, the first comer and second corner are curved. In an embodiment, the base exterior line pattern is disposed in the center of the base.

[08] In an embodiment, the invention comprises a method of folding the container comprising: applying pressure to the first seam of the first sidewall and the first seam of the second sidewall; and compressing a third sidewall and a fourth sidewall toward one another. In an embodiment, the invention comprises a method of folding the container comprising: applying pressure to the first seam of the first sidewall and the first seam of the second sidewall; compressing a third sidewall and a fourth sidewall toward one another; and wrapping the belt portion about the closed container and affixing the belt portion to a latch.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

[09] Having thus described the present disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

[010] FIG. 1 is an embodiment of a perspective view of the container of the present invention, illustrating the open configuration (1), a bent configuration (2), a folded configuration (3), and a collapsed, closed configuration (4);

[Oil] FIG. 2 is an embodiment of a perspective view of the container of the present invention, illustrating the collapsed, closed configuration;

[012] FIG. 3 is an embodiment of a perspective view of the container of the present invention, illustrating the folded configuration;

[013] FIG. 4 is an embodiment of a top view of the container of the present invention, illustrating the open configuration;

[014] FIG. 5 is an embodiment of a bottom view of the container of the present invention, illustrating the open configuration;

[015] FIG. 6 is an embodiment of a bottom view of the container of the present invention, illustrating the closed configuration;

[016] FIG. 7A is an embodiment of a top view of the container of the present invention, illustrating the transition from the open to the closed configuration;

[017] FIG. 7B is an embodiment of a bottom view of the container of the present invention, illustrating the transition from the open to the closed configuration;

[018] FIG. 8 illustrates a snap mechanism in an embodiment of the present invention; [019] FIG. 9 illustrates an embodiment of a side view of the container of the present invention, illustrating the closed configuration;

[020] FIG. 10 illustrates an example of a filled container of the present invention, sealed closed with a sealing film; and

[021] FIGs. 11A-11G illustrate an embodiment of the container of the present invention, in the open configuration.

DETAILED DESCRIPTION

[022] In an embodiment, the invention comprises a sustainable, recyclable container having a foldable design, which in addition to being sustainable and recyclable, reduces the volume of overall waste from the container. In an embodiment, the container is produced and delivered to the downstream customer in its unfolded, fully expanded configuration. In an embodiment, the container is biased to remain in this open, expanded configuration. The container may then be filled with a product (e.g. yogurt, snacks, cheese, pudding, etc.) and may be sealed closed. After purchase by the end consumer and consumption of the product contained therein, the container can be folded and disposed of in a space-saving manner. The foldable shape of the present invention makes a significant contribution to reducing the volume of waste material. In an embodiment, the waste volume of the container may be reduced by approximately 60% in the folded configuration of the container.

[023] In one embodiment, the container comprises a thermoplastic polymeric material. The thermoplastic polymeric material may comprise any polyolefin known in the art. In a particular embodiment, the container material comprises polypropylene. In an embodiment, the polypropylene may be a homopolymer, random copolymer, or block copolymer.

[024] In other embodiments, any polyester known in the art may be utilized as the material for the invention. In a particular embodiment, the container material comprises polyethylene terephthalate. In other embodiments, any polyethylene known in the art may be utilized as the material for the invention. The polyethylene may be low density or high density. [025] In an embodiment, the container comprises a single polymer or is a mono-material, for recyclability purposes. In an embodiment, the container comprises at least 50% recycled polymer, the remaining percentage comprising virgin material. In an embodiment, the sealing film which closes the container may comprise polypropylene or polyethylene terephthalate and is, in an embodiment, the same material as that which comprises the container body. In this embodiment, the sealing film does not need to be removed from the container body prior to recycling and can be recycled in a mono-material recycling stream. [026] The container may comprise any suitable material, and therefore is not limited to a specific type of material. In alternative embodiments, the container is fabricated using cardboard, paperboard, corrugated board, other paper-based materials, composite materials, and/or any suitable material or combination of materials known to those skilled in the art. The container may have any suitable size, shape, and/or configuration (i.e., number of sides), whether such sizes, shapes, and/or configurations are described and/or illustrated herein. For example, in one embodiment, the container includes a shape that provides functionality, such as a shape that facilitates transporting the container and/or a shape that facilitates stacking and/or arranging a plurality of containers.

[027] In an embodiment, the container is not cylindrical or ovular. In an embodiment, the container is generally or relatively square or rectangular in cross-section. Other shapes may be contemplated, such as triangular, pentagonal, hexagonal, or the like. In a triangular container, for example, the flexible sidewalls may comprise one or two of the triangular sidewalls. In the hexagonal container, for example, the flexible sidewalls may comprise two or four sidewalls. One of skill in the art would understand how to apply the concepts disclosed herein to containers of different configurations. In an embodiment, the container has rounded edges or corners between its sidewalls, but has flat sidewalls.

[028] FIG. 1 illustrates an embodiment of the container 10 in an open configuration. In this configuration, the container may comprise a base 22 and at least one sidewall 12, 14 extending upwardly from the base. In an embodiment, the container may comprise three, four, five, or more sidewalls. In an embodiment, the at least one sidewall may terminate in a flange or rim 24 which forms an opening into the container interior 32. A sealing film, membrane, or lid may be removably affixed to the flange or rim 24. [029] In a particular embodiment, the container comprises four sidewalls. In an embodiment, in the expanded, open configuration, the sidewalls of the container, between the corners thereof, are flat (not curved). In an embodiment, two of the sidewalls opposite one another 12 may be more rigid than the adjacent sidewalls 14. In an embodiment, two of the sidewalls opposite one another 12 may not comprise multiple panels. In an embodiment, the flexible sidewalls 14 may comprise a plurality of sections or panels 16. The sidewall sections 16 may be adjacent each other and together may form the flexible sidewall 14. The sidewall panels 16 may comprise the same material as the rigid sidewalls 12, and may, in and of themselves, each be rigid, but may be joined by flexible seams 18, 38. In an embodiment, the seams 18, 38, 48, 58 comprise the same material as the sidewalls 12, 14, but the material in the location of the seams 18, 38, 48, 58 is thinner than the material throughout the remainder of the sidewall 14 (the panels 16). The material may be thinned using any method known in the art. In an embodiment, the container is injection molded and the seams 18, 38, 48, 58 are formed during the injection molding process. For example, the molding tool may be configured to provide a thinner available area for the injected material at the location of the seams 18, 38, 48, 58. In another example, the material may be stretched under heat and/or pressure in the location of the seams 18, 38, 48, 58. In another example, less material may be extruded in the location of the seams 18, 38, 48, 58. In still another example, the material may be thinned using a laser, chemical treatment, perforations, and/or score lines that do not extend the depth of the sidewall, each in the location of the seams 18, 38, 48, 58.

[030] While applicant refers to the seams 18, 38, 48, 58 as comprising thinned areas, it should be understood, with reference to FIGs. 11A-1 IF, that the seams 18, 38, 48, 58 may comprise hinges, indentions, channels, concavities, or the like, into the sidewall or base of the container. In an embodiment, the hinges, indentions, channels, concavities, or the like may be formed in one surface of the sidewall or base (inner or outer surface) and may not be present on the opposite surface. For example, FIG. HE illustrates seam 18, visible on the interior surface of a sidewall 14, but not visible on the exterior surface of the opposite sidewall 14. Thus, the hinges, indentions, channels, concavities, or the like may be formed such that they extend only partially into the sidewall or base. In an embodiment, the base has hinges, indentions, channels, concavities, or the like on each surface (inner and outer) and, thus, the hinges, indentions, channels, concavities, or the like extend less than halfway into the depth of the base. In an embodiment, the hinges, indentions, channels, concavities, or the like of the sidewall also extend less than halfway into the depth of the sidewall. In an embodiment, the seams 18, 38, 48, 58 comprise one-way hinges, such that they are predisposed to hinge in one direction and resist hinging in the opposite direction. In an embodiment, the seams 18, 38, 48, 58 comprise living hinges, flat hinges, double hinges, butterfly hinges, or bi-stable hinges.

[031] In an embodiment, a first seam 18 is disposed in the center or approximate center of a flexible sidewall 14. In this embodiment, the first seam 18 may be configured to bend or hinge inwardly, moving toward the central axis of the container, upon application of external pressure to the sidewall 14. In an embodiment, two central first seams 18 are disposed opposite one another on opposite flexible sidewalls 14 and each are configured to each bend or hinge inwardly, each moving toward the central axis of the container. In an embodiment, the flexible sidewalls 14 flex such that the container folds in an accordion fashion.

[032] In an embodiment, a second seam 38 is disposed between a flexible sidewall 14 and a comer 20 of the container. In an embodiment, a second seam 38 is disposed between each flexible sidewall 14 and each corner 20 of the container. In an embodiment, the second seams 38 may be configured to allow panels 16 to bend or hinge inwardly, toward from the central axis of the container, upon application of external pressure to the first seam 18.

[033] In an embodiment, the rigid sidewalls 12 and the flexible sidewalls 14 are joined by curved comers 20. In other embodiments, a panel having a more sharp angle or a right angle comer may join the rigid sidewalls 12 and the flexible sidewalls 14. In an embodiment, each comer 20 comprises a curved panel which does not bend or flex upon application of external pressure to the first seam 18.

[034] In an embodiment, the thinning treatment discussed herein may be applied selectively to the various seams of the container. For example, the thinning treatment discussed herein may be applied to the internal surface (with respect to the internal cavity of the container) of the sidewall 14 in the location of the first seams 18 and to the external surface of the sidewall 14 in the location of the second seams 38. This selective application of the thinning treatment may predispose the container to fold in the designated manner. Likewise, the disposition of a hinge, indention, channel, etc. on the internal surface (with respect to the internal cavity of the container) of the sidewall 14 in the location of the first seams 18 and to the external surface of the sidewall 14 in the location of the second seams 38 allows the designated folding mechanism.

[035] In an embodiment, the base of the container, illustrated in FIG. 5, may have a smaller circumference and/or diameter than the circumference and/or diameter of the upper portion of the at least one sidewall 12, adjacent the rim or flange. In an embodiment, the base 22 of the container may also have seams 18. The base 22 may, in an embodiment, have internal surface seams 48 (with respect to the internal cavity of the container) and external surface seams 58. In an embodiment, the internal surface seams 48 and external surface seams 58 are formed in the same manner as the sidewall seams 18, 38. In an embodiment, the internal surface seams 48 are formed in an “X” configuration, each end of the “X” initiating at a sidewall second seam 38, extending across the base 22, and terminating at an opposite sidewall second seam 38.

[036] In an embodiment, the external surface seams 58 are formed in the base 22, perpendicular to sidewall seams 18, 38. In an embodiment, each external surface seam 58 initiates at a sidewall seam 18 or 38, extends across the base 22, and terminates at an opposite sidewall second seam 18 or 38, respectively.

[037] In an embodiment, the thinning treatment discussed herein to form seams 38 and 48 may be applied to the internal surface (with respect to the internal cavity of the container) of the base 22 in the location of the internal surface seams 48 and to the external surface of the base 22 in the location of the external surface seams 58. Likewise, the disposition of a hinge, indention, channel, etc. on the internal surface (with respect to the internal cavity of the container) of the base 22 in the location of the internal surface seams 48 and to the external surface of the base 22 in the location of the external surface seams 58 allows the designated folding mechanism.

[038] In an embodiment, portions of the base 22 of the container fold inwardly as the container is moved from the open, expanded configuration to the closed configuration. In an embodiment, the “X” shaped internal surface seams 48 bend inwardly, with respect to the internal cavity of the container (see FIGs. 7A-7B). This internal flexion allows portions of the base 22 of the container to fold into the internal cavity of the container, conserving space.

[039] FIG. 11C illustrates the interior of the base 22 as panels 60, 62. Panels 60 are disposed adjacent a rigid sidewall 12. Panels 62 are disposed adjacent a flexible sidewall 14.

[040] In an embodiment shown in FIG. 1 ID, the exterior surface of the base 22 is shown as panels 64 and 66. The peripheral panels 64 are adjacent a rigid sidewall 12. The central panels 64 are disposed between the peripheral panels 64. The peripheral panels provide a separation between a first base seam 58 and the sidewall 12. The central panels are separated by a central base seam 58.

[041] As the flexible sidewalls 14 flex inwardly, panels 60 also flex inwardly and panels 62 flex outwardly. See FIG. 7B. Due to the base seam 58 located in the center of the base 22, the panels 62 fold outwardly at the location of base seam 58. See FIG. 7B. Thus, in a fully folded configuration (FIG. 6), a portion of panels 62 will extend outwardly, beyond the folded base 22. In this fully folded configuration, the peripheral panels 64 of the base 22 may remain perpendicular (or substantially perpendicular) to the rigid sidewalls 12.

[042] In an embodiment, the container is biased toward an open configuration and pressure must be applied to the sidewalls of the container in order to transition the container to the closed configuration. For example, as shown in FIG. 7, an individual consumer, after consumption of the container contents, may use their finger to compress the center seam of the flexible sidewalls inwardly, toward a central axis of the container.

[043] In an embodiment, the container comprises a belt portion 26 that is configured to attach to a latch 28. In an embodiment, the belt portion 26 is integral with or permanently affixed to the container at or near the rim or flange 24. In some embodiments, the belt portion 26 may have a cover portion 30 that is commensurate with the opening of the container, as defined by the rim or flange 24. In some embodiments, the cover portion 30 may cover the opening into the container when the container is in an open configuration. In an embodiment, the cover portion 30 may be releasably sealed to the rim or flange 24. In an embodiment, a latch 28 may be disposed at or near the base 22 of the container. The latch 28 may comprise a bulbous element, a hook, a rod, a notch, or any other element known in the art which can be useful for latching. The belt portion 26 may comprise a through hole 32 which is configured to fit over the latch 28 and secure the belt in place. In an embodiment, the belt portion 26 is disposed on the rim/flange 24 along a first rigid sidewall 12 and the latch 28 is disposed on the perimeter of the base 22, adjacent an opposite second rigid sidewall 12. In this configuration, the container can be folded and the belt portion 26 can be positioned down the first rigid sidewall 12, across the folded base 22, and the through hole can be paired with the latch 28. This mechanism secures the container in its folded configuration and prevents the container from returning to its open configuration as it is biased to do. See FIG. 2.

[044] In another embodiment, shown in FIG. 8, the belt portion 26 may pair with a snap fastener mechanism 34, such that the through hole 32 is fitted over a socket and/or cap 36 of the snap fastener and a separate, affixed eyelet and/or stud 38 are then snapped into the socket/cap 36 with the through hole 32 of the belt portion 26 affixed between the socket/cap and the eyelet/stud. In another embodiment, the belt portion 26 comprises an eyelet and/or a stud and the latch 28 comprises a socket and/or a cap which can be affixed thereto. Any affixation means known in the art may be utilized in the invention, such as hook and loop, buttons, snap fasteners, snap buttons, press studs, press fasteners, dome fasteners, poppers, snaps, and tich buttons. In some embodiments, the belt portion 26 may extend fully about the circumference of the folded container. In other embodiments, the belt portion 26 may extend partially about the circumference of the folded container. In some embodiments, such as shown in FIG. 9, the belt portion 26 may extend about the sidewalls of the container. In this embodiment, the belt portion 26 may be integral with or permanently affixed to a first rigid sidewall, may extend circumferentially about the sidewalls of the folded container, and may affix to the same first rigid sidewall using one or more of the affixation methods discussed herein or known in the art.

[045] In an embodiment, the container is injection molded, 3D printed, or formed using any other method known in the art. In an embodiment, the container comprises two intersecting hinges configured in an “X” shape on the interior of the base, three hinges configured in parallel lines on the exterior of the base (one of which is centrally located within the base), a hinge configured on the interior of two opposite sidewalls (centrally located) and two hinges located on the exterior of the two opposite sidewalls. In this embodiment, the “X” shaped hinges initiate and terminate at each of the two hinges located on the exterior of the two opposite sidewalls. Similarly, as to the hinges configured in three parallel lines on the exterior of the base (one of which is centrally located within the base), the two parallel lines which are not centrally located initiate and terminate at each of the two hinges located on the exterior of the two opposite sidewalls. In this embodiment, the two centrally located hinges (one in the exterior surface of the base and one in the interior surface of the sidewall) are approximately perpendicular to one another (but for any angle of the container from base to flange. FIG. 11G illustrates an embodiment of the interior of the container, the dashed lines indicating the hinges which are not visible from the interior of the container.

[046] Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

What is claimed:

1. A container comprising: a base; and at least four sidewalls extending upwardly from the base, wherein a first sidewall and a second sidewall which is opposite the first sidewall each comprise at least a first panel and a second panel, the first panel and the second panel being connected to each other by a first seam; and wherein the base comprises an interior surface and an exterior surface, wherein the base is thinner in the location of a pattern disposed on the interior surface of the base and wherein the interior pattern comprises an “X” shaped configuration, and wherein the base is thinner in the location of a pattern disposed on the exterior surface of the base and wherein the exterior pattern comprises a first line extending from the first seam of the first sidewall to the first seam of the second sidewall.

2. The container of claim 1, wherein the at least four sidewalls terminate in a flange.

3. The container of claim 1 additionally comprising a belt portion that is affixed to the flange, wherein the belt portion is configured to retain the container in a closed configuration.

4. The container of claim 3, wherein the belt portion is configured to attach to a latch.

5. The container of claim 4, wherein the latch is disposed adjacent the base and a central portion of a third sidewall.

6. The container of claim 3, wherein the at least four sidewalls terminate in a flange and wherein the belt portion comprises a cover portion that is commensurate in size and shape with the flange.

7. The container of claim 1 additionally comprising a belt portion that is affixed to a third sidewall, wherein the belt portion is configured to retain the container in a closed configuration.

8. The container of claim 7 wherein the belt portion wraps about the first sidewall and second sidewall when the container is in a closed configuration.

9. The container of claim 1 , wherein the first seam comprises a thinned area of the first sidewall and the second sidewall.

10. The container of claim 9, wherein the thinned area is disposed on an interior surface of the first sidewall and the second sidewall.

11. The container of claim 1, wherein the at least four sidewalls include a third sidewall and a fourth sidewall which do not comprise seams.

12. The container of claim 1, wherein the first sidewall and the second sidewall additionally comprise a second seam and a third seam, the second seam disposed between the first panel and a first comer of the sidewall opposite the first seam and the third seam disposed between the second panel and a second comer of the sidewall opposite the first seam.

13. The container of claim 12, wherein the “X” shaped configuration comprises: a line extending from the second seam of the first sidewall to the third seam of the second sidewall; and a line extending from the third seam of the first sidewall to the second seam of the second sidewall.

14. The container of claim 12, wherein the base is thinner in the location of an additional pattern disposed on the exterior surface of the base, wherein the exterior additional pattern comprises: a second line extending from the second seam of the first sidewall to the second seam of the second sidewall; and a third line extending from the third seam of the first sidewall to the third seam of the second sidewall.

15. The container of claim 14, wherein the second line is offset from a third sidewall and the third line is offset from a fourth sidewall.

16. The container of claim 12, wherein the first comer and second comer are curved.

17. The container of claim 1, wherein the base exterior line pattern is disposed in the center of the base.

18. A method of folding the container of claim 1 comprising: applying pressure to the first seam of the first side wall and the first seam of the second sidewall; and compressing a third sidewall and a fourth sidewall toward one another.

19. A method of folding the container of claim 3 comprising: applying pressure to the first seam of the first sidewall and the first seam of the second sidewall; compressing a third sidewall and a fourth sidewall toward one another; and wrapping the belt portion about the closed container and affixing the belt portion to a latch.

20. A method of folding the container of claim 7 comprising: applying pressure to the first seam of the first side wall and the first seam of the second sidewall; compressing a third sidewall and a fourth sidewall toward one another; and wrapping the belt portion about the closed container and affixing the belt portion to a latch.