Abstract:
A container for a single serving of ready-to-eat food includes opposing side walls, an open top and a cup integral with at least one of the side walls and protruding into the interior of the container. The cup is used to dispense a condiment to accompany the food. The cup includes at least one first cup wall that is configured to fold against the at least one side wall to dispose the cup in a closed position, and to unfold to open the cup into the interior of the container. The cup is urged towards the open and closed position by an overcenter mode of operation whereby partially opening or closing the cup initially encounters resistance, which causes connected container walls to bow; continued opening or closing past the overcenter point allows container walls to flatten, thereby urging the cup towards the open or shut position.

Description:
This application claims priority based on U.S. Patent Application No. 62/243,884 entitled “CONTAINER WITH INTEGRAL CONDIMENT CUP” filed Oct. 20, 2015, which is herein incorporated by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to collapsible, disposable containers of the type typically used for providing individual ready to eat single serve portions of food. More particularly, invention relates to an open—topped container of the type which is collapsible for transport and storage. 
     BACKGROUND 
     The restaurant and food industry makes widespread use of collapsible, disposable containers for serving ready to eat portions of foods such as French fries. Typically, a serving container is formed from a cardboard blank, which can be at least partially assembled, pre-folded and shipped to the customer in a flattened pre-assembled or partially assembled form. The flattened container may be opened on-site (for example, at a restaurant or the like) to form an open-topped serving container which can be filled with a serving of food or other product. In most cases, further assembly of the container is not required apart from opening the container from a flattened and folded form into a three-dimensional container. Single-serve containers are typically fabricated from a semi-rigid material such as cardboard, which may be coated with a waterproof or water resistant coating on one or both sides. 
     A convenient configuration for a preformed open-topped container of this type is one that is generally rectangular with a tapered configuration to permit stacking of opened containers, both before these are filled with food portion and for disposal after use. The open top permits filling of the container from above and also for food to be easily removed from the container by the consumer. 
     Certain food articles such as French fries are typically served with a condiment such as ketchup. Condiments are often added directly to the foodstuff within the container. However, this can lead to leakage, sogginess and other problems. It is often preferable to provide the condiment separately to allow the consumer to dip pieces one at a time. However, providing a condiment in a separate cup is also problematic. It has been proposed to integrate a small condiment cup or similar holder with a larger food container, such that both the primary food article and the condiment may be served to the consumer in a single container unit. For example, see U.S. Pat. No. 8,505,807 to Herman, U.S. Pat. No. 5,540,333 to Gonzalez et al. and U.S. Pat. No. 6,216,946 to Cai. 
     SUMMARY 
     According to one aspect, the invention relates to a container comprising side walls, an open top and a cup integral with at least one of said side walls. The cup protrudes at least partially into the interior of the container body for holding a relatively small portion, in relation to the volume of the container, of a substance such as a condiment. The cup can be unfolded to protrude into the interior of the container when the container is opened. When unfolded into an open configuration, the cup is at least partially positioned within the inside of the container body for easy access from the main container opening. The cup comprises at least one first cup wall that is configured to fold against a side wall of the container. Folding the cup wall against the container wall folds the cup into a closed position, while unfolding the cup wall away from the container wall opens the cup to protrude into the interior of the container whereby a portion of the wall of the container forms a wall of the cup. 
     The invention further relates to a blank comprising a sheet of semi-rigid material configured to form the container as described herein. 
     It will be seen that although the present example described herein relates to a container for serving food, the present container is not limited to this use but may be used for holding any suitable article or product. 
     Directional references herein such as “up”, “down”, “horizontal” and the like are used purely for convenience of description and do not limit the scope of the invention described herein. Furthermore, any dimensions provided herein are presented merely by way of an example and unless otherwise specified do not limit the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view from the front and above of a food container according to the present invention, with the condiment cup closed. 
         FIG. 2  is a side elevational view of the container. 
         FIG. 3  is a plan view from above of the container, with the condiment cup in the closed position. 
         FIG. 4  is a perspective view from above, showing the condiment cup in the open position for receiving a condiment. 
         FIG. 5  is a side elevational view of the condiment holder in the open position. 
         FIG. 6  is a perspective view from above, in the open position. 
         FIG. 7  is a plan view showing the container in a folded position. 
         FIGS. 8A through 8C  provide plan views from above, showing an opening sequence of the cup in which  FIG. 8A  shows the cup in a closed (inwardly folded) position,  FIG. 8B  shows the cup in a partially open position and  FIG. 8C  shows the cup in a fully open position. The outward bowing of the container walls has been exaggerated in  FIG. 8B . 
         FIG. 9  is a plan view showing a cardboard blank for forming the container, in a substantially flattened and fully open position. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention is described in the context of a preferred use as a food container. However, it will be seen that the invention may be used for holding other products. 
     Turning to  FIGS. 1-3 , a food container  10  is shown, comprising a container body  2  and integral condiment cup  4 . The cup  4  is shown in these views in the closed position, prior to receiving a condiment therein. Container  10  may be fabricated from a semi rigid, resilient material such as paperboard or cardboard, which is optionally coated on the outside and/or inside to be water and/or grease resistant. 
     Container  10  comprises an open topped, tapering rectangular configuration defined by walls  12 ,  14 ,  16  and  18  respectively, an open top  28  and a floor  30 , which is seen in  FIG. 3 . Walls  14  and  16  form the forward portion of container  10  and walls  12  and  18  define the rearward portion thereof. The various walls meet at folds  20 ,  22 ,  24  and  26  respectively. The container tapers slightly outwardly and upwardly, whereby the opened containers may be stacked when condiment cup  4  is closed. 
     Floor  30  is formed by four overlapping flaps  124 ,  126 ,  128  and  130 , as discussed below. In  FIG. 3 , these flaps are shown in a partially closed position to more clearly delineate the individual flaps. In use, floor  30  would normally be substantially or fully closed to prevent leakage. 
     The open top  28  of container  10  is defined by a continuous upper rim  29  that surrounds open top  28  when container  10  is assembled. Rim  29 , which consists of the upper edges of walls  12 - 18 , slopes downwardly and forwardly towards the front of container  10  whereby the container opening  28  angles downwardly to thereby increase the size of opening  28  and improve user access. A forward portion of opening  28  of container  10  may be level or have a slight downward slope. Rim  29  at the rear portion of container  10  slopes steeply upwardly to define an upwardly-projecting, peak-like rear projection  32  formed by rear walls  12  and  18 , where these project upwardly in two triangular regions. Projection  32  comprises a V-shaped cross section defined by the respective walls  12  and  18  that form a valley meeting at fold  26 . Projection  32  defines the rear wall of condiment cup  4  as described below. 
     The entirety of rear wall  18  and a portion of rear wall  12  are formed from double layers of cardboard, comprising inner layers  12   a  and  18   a  respectively, and outer layers  12   b  and  18   b  respectively. Projection  32  is thus defined by double wall layers of cardboard. At the region of projection  32 , the respective inner and outer layers  12   a  and  12   b  and  18   a  and  18   b  are not adhered together and may be separated from each other. As described below, the respective inner layers at this location can be folded away from the respective outer layers to form a condiment cup  4  that projects into the interior of container  10 . Condiment cup  4  is thus defined by inner walls  12   a  and  18   a  and outer walls  12   b  and  18   b , when these are separated from each other. 
     Turning to  FIGS. 4-6 , container  10  is shown with the condiment cup  4  in the open position. In this position, condiment cup  4  opens upwardly to hold a condiment therein (not shown). 
     A front (inner) wall of condiment cup  4  is defined by opposing triangular flaps  40  and  42  (see  FIG. 1 ), which form the uppermost regions of inner walls  12   a  and  18   a  respectively. Flaps  40  and  42  form an upwardly projecting tongue when cup  4  is unfolded into the interior of container  10 , to receive a product therein, Flaps  40  and  42  are defined by fold lines  44  and  46  respectively, which delineate flaps  40  and  42  from the respective inner walls  12   a  and  18   a  respectively. Flaps  40  and  42  meet at central fold  26  (see  FIG. 1 ). 
     The rear wall of condiment cup  4  is defined by truncated triangular regions  48  and  50  of walls  18  and  12 . Regions  48  and  50  form the uppermost portions of outer walls  18   b  and  12   b  respectively. Regions  48  and  50  are continuous with the respective outer walls and are not delineated by a fold line or other specifically defined boundary. The uppermost edge of regions  48  and  50  are scalloped downwardly to improve user access to cup  4  to facilitate opening of cup  4  from the closed position. 
     In use, container  10  is normally supplied to a user in an assembled and flattened configuration as shown  FIG. 7 . In this configuration, walls  16  and  18  are continuous and planar with each other and likewise walls  12  and  14  are continuous and planar with each other. Container  10  may be opened to form the open position of  FIGS. 1-6 , wherein the respective walls  12 - 18  are at right angles relative to the adjacent walls. 
     When container  10  is unfolded into the open position, condiment cup  4  is initially disposed in the closed position shown in  FIGS. 1-3 . Typically, container  10  will then be filled with an individual serving of food such as French fries. The condiment cup  4  may then be opened into the position shown in  FIGS. 4-6  to receive a condiment therein. For this purpose, the user urges flaps  40  and  42  forwardly, by contacting the uppermost portions thereof where these are exposed by the downwardly scalloped edges of regions  48  and  50 . This action opens up cup  4  to receive a condiment or other foodstuff. 
     As seen in detail in  FIGS. 8A through 8C , cup  4  is urged towards either of the closed or open positions by an overcenter mode of action. According to this mode of action, flaps  40  and  42  become biased towards the fully open position, once these have been urged past the overcenter position. Likewise, flaps  40  and  42  become biased towards the closed position, once these are urged past the overcenter position towards the closed position. The over center operation is achieved by the resiliency of walls  12  and  18 . Walls  12  and  18  comprise two layers of cardboard which increases their rigidity and enhances the over center biasing effect exerted when these walls flex as cup  4  is urged towards the open or closed positions. The extent of overlapping material need not cover the entirety of walls  12  and  18 , but in the present case it these walls comprise a double layer adjacent to all or substantial upper portions thereof adjacent to upper rim  29  when cup  4  is closed. The double wall region thus provides a stiffening effect along substantially the full extent of rim  29  where this traverses walls  12  and  18 . 
       FIG. 8A  depicts container  10  with integral cup  4  in the closed position. In this configuration, cup walls  12   a  and  18   a  are flush with container walls  12  and  18  respectively. Container walls  12  and  18  are planar in this configuration.  FIG. 8B  depicts container  10  with integral cup  4  in a partially open position, approximately midway between open and closed. In this configuration, cup walls  12   a  and  18   a  are spaced apart from container walls  12  and  18 . 
     Furthermore, as cup walls  12   a  and  18   a  are brought into planar alignment with each other as cup  4  is opened, the respective cup walls exert an outward force on container walls  12  and  18 ; this causes container walls  12  and  18  to bow outwardly, which is shown in an exaggerated form in  FIG. 8B . The maximum outward bowing is achieved when cup walls  12   a  and  18   a  are in planar alignment. The outward bowing of container walls  12  and  18  causes them to exert a countervailing inward force against cup walls  12   a  and  18  which urges them towards a folded position. As the cup is opened, container walls  12  and  18  become progressively more outwardly bowed until they reach their maximum outward bowing, at the point where cup walls  12   a  and  18   a  are in planar alignment. This is the “overcenter” position. Continued opening of the cup walls then allows container walls  12  and  18  to start to straighten, which urges cup  4  towards the fully open position ,which is reached when container walls  12  and  18  are once again planar. As a result, once urged past the overcenter position, cup  4  effectively “snaps” into the fully open position. Cup  4  is securely retained in the fully open position by the container walls  12  and  18  resisting any bowing in either direction. 
     Closing of cup  4  follows the reverse sequence as its opening. As cup  4  is urged towards the closed configuration, container walls  12  and  18  are caused to bow outwardly until they reach their maximum outward bowing at the overcenter position. Continued urging of cup  4  towards the closed position then causes container walls  12  and  18  to flex back towards the planar position, thereby “snapping” cup  4  shut and retaining it in the closed position until opened. In this manner, cup  4  is securely held in either of the fully closed or fully open position. 
     As flaps  40  and  42  are urged towards the open or open position, this action opens flaps  40  and  42  away from each other, thereby bowing walls  12  and  18  outwardly. The double wall structure of walls  12  and  18  increases their rigidity. This has the effect of allowing these walls to apply a relatively large force tending to resist arcuate bending. These walls are bowed outwardly in response to the outward urging applied when cup  4  is opened or closed. Walls  12  and  18  are biased against a bending force applied to them and apply a countervailing force as these are urged into an arcuate configuration. The resulting forces tend to urge flaps  40  and  42  into the fully open or fully closed positions, since when in these positions, the respective walls  12  and  18  are planar. The result is that as cup  4  is opened from a closed position, it encounters increasing resistance as walls  12  and  18  are bowed, until approximately the midway point when continued opening starts to draw flaps  40  and  42  together. At this point, which is effectively the overcenter “tipping point”, continued opening of cup  4  is urged by the force of walls  12  and  18  reverting towards their planar positions. Accordingly, cup  4  is biased towards the fully closed or fully open position depending on which side of the overcenter tipping point flaps  40  and  42  are positioned. 
     Turning to  FIG. 9 , a blank  100  is shown in a flattened position for forming into a container  10  as described herein. Blank  100  comprises, viewed from left to right in  FIG. 8 , triangular flap  102  that forms outer wall  12   b  when folded; trapezoidal panel  104  that forms inner wall  12   a  when folded; trapezoidal panel  106  that forms wall  14  when folded; trapezoidal wall  108  that forms wall  16  when folded; trapezoidal wall  110  that forms inner wall  12   a  when folded; and trapezoidal panel  112  that forms inner wall  18   a  when folded. 
     The respective panels are joined by folds  114 ,  116 ,  118 ,  120 , and  122  along their side edges. 
     Floor  30  of a container  10  is formed by four bottom flaps  124 ,  126 ,  128  and  130  that extend from panels  106 ,  108 ,  110  and  112  respectively. The respective bottom flaps are joined by folds to the respective panels. Flaps  124  and  128  in turn comprise protruding sub-flaps  132  and  14 , which are configured to allow folding of the assembled container. 
     Container  10  is assembled by folding blank  100  together whereby panel  102  is folded onto outside surface of panel  110  and secured thereto by an adhesive. Flap  102  is folded to form outer wall  12   b , panel  110  forms inner wall  12   a.  It will be seen that flap  102  covers only an upper portion of panel  110  whereby outer wall  12   a  forms a portion of wall  12 . 
     The resulting partially assembled blank may be shipped and stored in a folded, flattened configuration as seen in  FIG. 7 . When ready for use, the container may be unfolded into an open container  10 . 
     In order to seal container  10  against leakage of liquids, a strip of adhesive may be applied along a side edge of panel  112 , for contacting panel  104  to thereby form a watertight seal where the blank  100  contacts itself upon assembly into container  10 . As well, adhesive may be applied between flaps  128  and  130  and also flaps  124  and  126  to thereby partially assemble floor  30 . 
     The scope of the invention should not be limited by the preferred embodiments set forth in the examples but should be given the broadest interpretation consistent with the description as a whole. The claims are not to be limited to the preferred or exemplified embodiments of the invention.