Abstract:
A lower receptacle section with a flat base and upwardly sloping side walls mates with an upper cover section a flat top and downwardly sloping side walls. A hinge connects portion of the lower section lip to a portion of the upper cover section lip. Integrally formed v-shaped ribs in the flat base and the flat top provide structural strength, and pre-formed creases (or fold lines) facilitate folding of the food box for disposal.

Description:
BACKGROUND 
   This invention relates to foldable boxes and, more particularly, to insulated boxes which allow for the enclosure and transportation of food, which may be easily disposed of by destructive folding, and which are environmentally safe (biodegradable). The food box may also be referred to herein as a container. 
   DISCUSSION 
   Humans played a major role in environmental pollution for many years, and now that the damage is clear we have started the cleanup process. People became accustomed to throwing things “away” and never realized where “away” was. Solid waste was thrown away into trash containers, dumped into landfills, compacted and covered with dirt. It was assumed that the garbage would break down and mix with the soil. However, over the years the garbage became a major problem. It wasn&#39;t breaking down and landfills were beginning to overflow. This overflow of garbage in the landfills can lead to the release of hazardous gases and can contribute to water pollution. The realization that our planet was fragile and our environment was in danger became apparent. Attempts to preserve the environment became a priority. 
   Reducing, re-using and recycling, are the three principal methods of attacking the problem of overflowing landfills. 
   Reducing, in the context of waste, means using less. A good example of reducing is to use cloth towels instead of paper ones. Re-using helps us find ways to use materials we would normally throw away such as cardboard, grocery and plastic bags. Recycling is a processing technique used so items can also be used again-crushing glass bottles to make new glass, turning paper back into pulp to make new paper, shredding plastics to make fillings for jackets, and mixing grass cuttings with food scraps for fertilizer are all good examples of this process. 
   Although many communities have instituted recycling, this approach requires a commitment to the four steps of a successful program: collecting, sorting, reclaiming and reusing. Paper, glass and aluminum top the list of commonly recycled materials. Paper is recycled by using water and chemicals to remove the ink to create pulp. Pulp is cleaned, processed into tiny fibers and made into paper again. Aluminum is ground into small chips, melted down and made into solid bars. As a result, new cans can be made. Glass is broken up into a form of broken glass called cullet. Cullet is then melted down and reused again and again. 
   Another approach, termed “Zero Waste,” requires that products be made from renewable and recoverable materials, and emphasizes that throughout their life-cycles these products must not pose a threat to the workers who make them, to the consumers who buy and utilize them, and to future generations who will deal with the environmental impacts of their disposal, reuse, recycling, or composting. Zero Waste products and processes are not an idealistic dream; even today Zero Waste principles are being practiced. Examples include algae-based packaging foam and biodegradable single-use cutlery. These two everyday products could easily replace some of the plastic, single-use, and non-biodegradable items that fill our landfills and create unnecessary waste and pollution in their production. 
   Potato starch and limestone are being combined to produce a biodegradable quick-serve food containers such as bowls and plates. Cornstarch-based forks and spoons will easily break down in a compost pile into earth-friendly byproducts. The cutlery is made from a readily available renewable resource: corn. 
   Recent growth in food take-out and delivery has resulted in more portable food boxes and, simultaneously, created more garbage for landfills. Traditional food boxes, due to their large dimensions and high rigidity, present considerable difficulty with regard to disposal. The assembled box is relatively large when compared with an opening in a trash receptacle. Once deposited in the trash receptacle, the assembled food box occupies an inordinate amount of space, seriously reducing the remaining space in the trash receptacle for other garbage. In addition, the structural integrity of a traditional food box and the presence of food product make folding, cutting, or separating a traditional food box difficult. 
   Take-out food containers made of cardboard allow more rapid heat loss than insulated containers such as expanded polystyrene foam hinged containers. Moisture causes cardboard to weaken thereby making the cardboard food box unsuitable for use in microwave ovens. Cardboard boxes can harbor bacteria, paper dust, and cardboard shavings which pose possible health problems and affect the smell and taste of the food. Migration of odors through the cardboard also affect the taste of the food. 
   Applicant&#39;s foldable insulated food box invention addresses the problems related to both the quantity of garbage and also the character of the garbage. A heat-retaining food container includes creases in top and bottom sections which promote easy folding into quarters for compact disposal, thereby reducing the volume of the garbage. Compared to other food containers, expanded polystyrene containers and other expanded foam containers retain heat better and are more environmentally friendly both in manufacture and disposal. Expanded foam containers facilitate embossed graphics and unique design elements such as eye-catching colored foam—elements which increase marketplace identification and add a contemporary look. Integral v-shaped ribs (sometimes also referred to herein as grooves) and corner gussets add structural strength to the container by reducing flexing and warping. Yet, these same v-shaped ribs and corner gussets cooperate with pre-formed creases to enable easy folding of the container for disposal. A fastener retains the folded container in a compact packet for disposal. 
   Applicant&#39;s invention, when made from biodegradable materials such as potato starch and limestone laminates, also improves the character of the garbage being sent to the landfill. Whereas cardboard containers, corrugated containers, and containers made from expanded polystyrene may require decades to decompose, applicant&#39;s biodegradable food box decompose much more rapidly. 
   SUMMARY OF THE INVENTION 
   Applicant&#39;s foldable insulated food box invention provides a lower receptacle section with a flat base and side walls sloping outwardly and upwardly from the flat base to a lower section lip. An upper cover section includes a flat top and side walls sloping outwardly and downwardly from the perimeter of the flat top to an upper section lip which mates with the lower section lip. A hinge connects a portion of the lower section lip to a portion of the upper cover section lip. Integrally formed v-shaped ribs in the flat base and the flat top provide structural strength, and pre-formed creases (or fold lines) facilitate folding of the food box for disposal. 
   Other objects, features, and advantages of the present invention will become clear from the following description of the preferred embodiment when read in conjunction with the accompanying drawings and appended claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  shows the foldable insulated food box of the present invention. 
       FIG. 2  shows a corner of the foldable insulated food box of  FIG. 1  as a human hand flattens the box. 
       FIG. 3  is a view of the interior of the foldable insulated food box shown in  FIGS. 1 and 2  as the foldable insulated food box might arrive from a mold. 
       FIG. 4  is a view of the exterior of the foldable insulated food box shown in  FIGS. 1 and 2  as the foldable insulated food box might arrive from a mold. 
       FIG. 5  is another view of the foldable insulated food box of  FIGS. 1–4 . 
       FIG. 6  is a detailed view of the foldable insulated food box of  FIGS. 1–5  showing the intersection of diagonal v-shaped ribs (see  FIGS. 1–4 ). 
       FIG. 7  is a partially cut away detailed view of a hinged corner of the foldable insulated food box of  FIGS. 1–6 . 
       FIG. 8  is a detailed view, partially cut away, of a tab and a receiver (also shown in  FIG. 5 ). 
       FIG. 9  is a cross-section along  9 — 9  in  FIG. 5 . 
       FIG. 10  is a cross-section along  10 — 10  in  FIG. 6 . 
       FIG. 11  is a cross-section along  11 — 11  in  FIG. 7 . 
       FIG. 12  is a cross-section along  12 — 12  in  FIG. 7 . 
       FIG. 13  is a pictorial view of the lower receptacle section of the foldable insulated box of applicant&#39;s invention wherein the upper cover section beyond the hinge has been cut away. 
       FIG. 14  is a detailed view of a gusseted corner of the lower receptacle section of the foldable insulated food box shown in  FIG. 13 . 
       FIG. 15  is a view of the insulated food box of  FIGS. 1–14  wherein one half of the collapsed insulated food box, already folded across one of the diagonal v-shaped ribs, is further folded across the second v-shaped rib. 
       FIG. 16  is a view of the collapsed food box, now folded into roughly one-fourth of its original size, with an elastic band attached to hold the food box in a collapsed and folded state for disposal. 
       FIG. 17  is a view of another foldable insulated food box according to the present invention. 
       FIG. 18  is a partially cut away detailed view of another foldable insulated food box according to applicant&#39;s invention. 
       FIG. 19  shows the foldable insulated food box separated at a corner while the box is being flattened by a pair of human hands. 
       FIG. 20  is a pictorial view of the lower receptacle section of the foldable insulated food box according to applicant&#39;s invention. 
       FIG. 21  is a detailed view of a corner of the foldable insulated food box shown in  FIG. 20 . 
   

   DETAILED DESCRIPTION 
   In the following detailed description, like numerals and characters designate like elements throughout the figures of the drawings. 
   Referring generally to the drawings and more particularly to  FIG. 1 , a foldable insulated food box  50  has a lower receptacle section  52  and a similarly-shaped upper cover section  54 . The sections  52 ,  54  are joined by a hinge  56  along rear edges  57 ,  59 , respectively, of the sections  52  and  54 . The hinge  56  permits the upper section  54  to close over the lower section  52 . 
   Still referring to  FIG. 1 , the lower receptacle section  52  has a flat base  58  and upwardly extending walls  60   a ,  60   b ,  60   c , and  60   d . The side walls  60   a ,  60   b ,  60   c , and  60   d  slope outwardly from the perimeter of the base  58  to a lip  70 . The upper cover section  54  similarly has a flat top  62  of about the same size as the base  58  and side walls  64   a ,  64   b ,  64   c , and  64   d  that slope outwardly from the perimeter of the flat top  62  to a lip  72 . The lip  70  of the base  58  mates with the lip  72  of the top  62  when the food box  50  is closed. The sloped side walls  60   a ,  60   b ,  60   c ,  60   d ,  64   a ,  64   b ,  64   c  and  64   d  allow for space-saving stacking before use. A fastener  74  attached to the side wall  60   a  prevents the food box  50  from unfolding once it is collapsed (See  FIG. 16 ). 
   Still referring to  FIG. 1 , tabs  66   a  and  66   b  formed on the lip  72  of the upper cover section  54  are located at a position opposite the hinge  56  along the lip  72  of the side wall  64   d . A pair of receivers  68   a  and  68   b  for tabs  66   a  and  66   b , respectively, are located in the lip  70  of the lower receptacle section  52  so that the tabs  66   a  and  66   b  tuck into the receivers  68   a  and  68   b  to hold keep the food box  50  closed. 
   Still referring to  FIG. 1 , a diagonal v-shaped rib  76   a  crosses the food box  50  from corner  78   a  to corner  78   c . Another diagonal v-shaped rib  76   b  crosses the food box  50  from corner  78   b  to corner  78   d.    
   While the food box  50  illustrates a rectangular shape, the food box  50  may assume other shapes such as a square, a circle or an octagon. In addition, the food box  50  is generally constructed from a single sheet of expandable polystyrene foam although other materials could be used instead (See  FIG. 17 ). 
   Referring now to  FIG. 2 , a human hand pressing down on the v-shaped rib  76   a  at the corner  78   a  of the upper cover section  54  of the foldable insulated food box  50  is shown. 
   Referring now to  FIG. 3 , a food box  50  in the open position prior to being flattened is shown. A diagonal v-shaped rib  76   c  crosses the lower receptacle section  52  from corner  78   e  to corner  78   g  while another diagonal v-shaped rib  76   d  crosses the lower receptacle section  52  from corner  78   f  to corner  78   h . Yet another diagonal v-shaped rib  76   a  crosses the upper cover section  54  of the food box  50  from corner  78   a  to corner  78   c . The diagonal v-shaped rib  76   b  crosses the food box  50  from corner  78   b  to corner  78   d . In each of the corners  78   a ,  78   b ,  78   c ,  78   d ,  78   e ,  78   f ,  78   g , and  78   h , a corresponding gusset (a reinforcing triangular insert)  80   a ,  80   b ,  80   c ,  80   d ,  80   e ,  80   f ,  80   g , and  80   h  is located. 
   Referring now to  FIG. 4 , an open food box  50  which has been flattened is shown. The gussets  80   a ,  80   b ,  80   c ,  80   d ,  80   e ,  80   f ,  80   g , and  80   h  illustrated in  FIG. 3  have been flattened into creases (the gusset&#39;s former fold lines)  84   a ,  84   b ,  84   c ,  84   d ,  84   e ,  84   f ,  84   g , and  84   h  at the ends of the diagonal groove creases  76   a ,  76   b ,  76   c , and  76   d . Lip creases  90  and  92  are also formed on the lower receptacle section  52  and on the upper cover section  54 , respectively, as a result of flattening the food box  50 . In addition, a fold line  94  is formed on the side walls  60   a ,  60   b ,  60   c , and  60   d  of the lower receptacle section  52  when the food box  50  is flattened. Another fold line  96  appears on the side walls  64   a ,  64   b ,  64   c , and  64   d  of the upper cover section  54  when the food box  50  is flattened. 
   Referring now to  FIG. 5 , another view of the food box  50  is shown. The lip  70  on lower receptacle section  52  and the lip  72  on the upper cover section  54  have been brought together to close the food box  50  by placing the tab  66   a  through the receiver  68   a . Diametrically opposite the tab  66   a  and the receiver  68   a  is the hinge  56 . 
   Referring now to  FIG. 6 , a detailed view of the intersection of the diagonal v-shaped ribs  76   a  and  76   b  illustrated in  FIG. 1  is shown. 
   Referring now to  FIG. 7 , the hinge  56  that connects the upper cover section  54  to the lower receptacle section  52  along the periphery of the sections  52  and  54  as illustrated in  FIG. 1  is shown. When the food box  50  is closed, the lip  70  on lower receptacle section  52  aligns with the lip  72  on the upper cover section  54 . 
   Referring now to  FIG. 8 , a detailed view of the box closure formed by inserting tab  66   a  through the receiver  68   a  as illustrated in  FIG. 5  is shown. 
   Referring now to  FIG. 9 , a joint  98  created where the top  62  of the upper cover section  54  meets the side wall  64   a  of the upper cover section  54  as illustrated in FIG.  5  is shown. 
   Referring now to  FIG. 10 , a cross-section of the v-shaped rib  76   b  as illustrated in  FIG. 6  is shown. 
   Referring now to  FIGS. 11 and 12 , a cross-section of the corner gusset  80   b  as illustrated in  FIGS. 3 and 7  is shown. The v-shape  82  of the gusset  80   b  is shallower approaching the top  62  of the upper cover section  54  and deeper approaching the lip  72  of the upper cover section  54  as a result of the sloping side wall  64   a  (See  FIGS. 3 and 7 ). 
   Referring now to  FIG. 13 , four corner gussets  80   e ,  80   f ,  80   g , and  80   h  extending inwardly from the side walls  60   a ,  60   b ,  60   c , and  60   d  of the lower receptacle section  52  of the foldable insulated box  50  are shown. 
   Referring now to  FIG. 14 , a detailed view of the corner gusset  80   e  illustrated in  FIG. 13  is shown. The corner gusset  80   e  is adjacent to the diagonal v-shaped rib  76   c.    
   Referring now to  FIG. 15 , wherein one half of the collapsed insulated food box  50 , already folded across the diagonal v-shaped ribs  76   b  and  76   d , is further folded into quarters across the v-shaped ribs  76   a  and  76   c.    
   Referring now to  FIG. 16 , the collapsed food box  50 , now folding into roughly one-fourth of its original size, with a fastener (elastic band)  74  attached to hold the food box  50  in a collapsed and folded state for disposal is shown. 
   Referring now to  FIG. 17 , a circular foldable insulated food box  100  in accordance with the applicant&#39;s invention is shown. The circular food box  100  has similar characteristics to the food box  50  illustrated in  FIG. 1 . 
   Referring now to  FIG. 18 , another foldable insulated food box  250  includes a lower receptacle section  252  having a lip  270  and an upper cover section  254  having a lip  272 . A fastener  274  attaches to the upper lip  272  and the lower lip  270  to create a hinge so that the upper cover section  254  can be opened for access to the lower receptacle section  252 . The fastener  274  shown in  FIG. 18  is a strip of adhesive material extending along the lips  270 ,  272  of the sections  252 ,  254 , respectively. 
   Referring now to  FIG. 19 , the foldable insulated food box  50  being flattened by a pair of human hands. As force exerted along A, the food box  50  breaks apart at the corners as illustrated by the separation of creases  84   a  and  84   f  as the box  50  is flattened. 
   Referring now to  FIGS. 20 and 21 , another foldable insulated food box  150  is shown. A lower receptacle section  152  of the food box  150  contains v-shaped ribs  176   a  and  176   b  but omits the corner gussets  80   a ,  80   b ,  80   c ,  80   d ,  80   e ,  80   f ,  80   g , and  80   h  shown in  FIG. 3 . 
   The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.