Blank and methods of constructing a container from the blank

A blank of foldable sheet material for forming a container is provided. The blank includes a top panel, a front tuck flap extending from a front edge of the top panel, and a top side panel extending from a side edge of the top panel. The blank also includes a bottom panel, a front panel extending from a front edge of the bottom panel, and a corner portion. The corner portion includes a minor diagonal panel extending and a major diagonal panel. The corner portion also includes a corner panel hingedly connected to the minor and major diagonal panels. The front panel is configured to engage the front tuck flap to at least partially define a first releasably secure closure of the container, and the top side panel includes a front edge configured to engage the minor diagonal panel to at least partially define a second releasably secure closure of the container.

BACKGROUND

The field of the disclosure relates generally to a container formed from a sheet of material, and more particularly to a container that includes side locking features and a front tuck flap.

It is well known in the food industry, including the pizza industry, to provide a food product to a consumer that is packaged in film, foil, paperwrap, a box, or a container. Such containers provide a convenient package to carry the food product from the producer of the food product to a table or other location for consumption by the consumer of the food product. It is also convenient to place multiple containers in a bag, such as an insulated bag, so a customer and/or delivery person is able to carry those containers from the restaurant for consumption elsewhere. At least some of these containers may be time-consuming to form. Moreover, at least some such known containers do not include easily formed features that facilitate securing a lid to a base of the container when the container is closed.

BRIEF DESCRIPTION

In one aspect, a blank of foldable sheet material for forming a container is provided. The blank includes a top portion including a top panel, a front tuck flap extending from a front edge of the top panel, and a first top side panel extending from a first side edge of the top panel. The blank also includes a bottom portion including a bottom panel, a first bottom side panel extending from a first side edge of the bottom panel, a front panel extending from a front edge of the bottom panel, and a corner portion. The corner portion includes a first minor diagonal panel extending from a front edge of the first bottom side panel and a first major diagonal panel extending from a first side edge of the front panel. The first major diagonal panel has a length greater than a length of the first minor diagonal panel. The corner portion also includes a first corner panel hingedly connected to the first minor and major diagonal panels. The front panel is configured to engage the front tuck flap to at least partially define a first releasably secure closure of the container in a closed position, and the first top side panel includes a front edge configured to engage the first minor diagonal panel to at least partially define a second releasably secure closure of the container in the closed position.

In another aspect, a container formed from a blank of foldable sheet material is provided. The container includes a top portion including a top panel hingedly connected to a front tuck flap along a front edge of the top panel and to a first top side panel along a first side edge of the top panel. The container also includes a bottom portion including a bottom panel, a first bottom side panel hingedly connected to a first side edge of the bottom panel, a front panel hingedly connected to a front edge of the bottom panel, and a corner portion. The corner portion includes a first minor diagonal panel extending from a front edge of the first bottom side panel and a first major diagonal panel extending from a first side edge of the front panel. The first major diagonal panel has a length greater than a length of the first minor diagonal panel. The corner portion also includes a first corner panel hingedly connected to the first minor and major diagonal panels. The first corner panel overlaps and is substantially parallel to the bottom panel. The front panel is engaged by the front tuck flap to at least partially define a first releasably secure closure of the container, and a front edge of the first top side panel is engaged by the first minor diagonal panel to at least partially define a second releasably secure closure of the container.

In another aspect, a method of constructing a container from a blank of sheet material is provided. The method includes rotating a first corner panel of the blank about a respective fold line toward an interior surface of the first blank to form a base. The blank includes a bottom panel, a first bottom side panel hingedly connected to a first side edge of the bottom panel, a front panel hingedly connected to a front edge of the bottom panel, and a corner portion. The corner portion includes a first minor diagonal panel extending from a front edge of the first bottom side panel and a first major diagonal panel extending from a first side edge of the front panel, the first major diagonal panel having a length greater than a length of said first minor diagonal panel. The corner portion also includes a first corner panel hingedly connected to the first minor and major diagonal panels. The rotating causes further rotation of the first major diagonal panel, the first minor diagonal panel, the front panel, and the first bottom side panel about respective fold lines toward the interior of the blank, such that, after the rotating, the corner panel is overlapping and substantially parallel to the bottom panel of the blank, and the first major diagonal panel, the first minor diagonal panel, the front panel, and the first bottom side panel are substantially perpendicular to the bottom panel. The method also includes rotating a first top side panel of the blank about a respective fold line toward the interior surface of the blank to form a lid. The blank further includes a top panel hingedly connected to a front tuck flap along a front edge of the top panel and to the first top side panel along a first side edge of the top panel. The method further includes rotating the lid toward the base such that the front panel is engaged by the front tuck flap to at least partially define a first releasably secure closure of the container, and a front edge of the first top side panel is engaged by the first minor diagonal panel to at least partially define a second releasably secure closure of the container.

DETAILED DESCRIPTION

The following detailed description illustrates the disclosure by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the disclosure, describes several embodiments, adaptations, variations, alternatives, and use of the disclosure, including what is presently believed to be the best mode of carrying out the disclosure.

The present disclosure provides a stackable, collapsible container. In some embodiments, the container includes a first releasably secure closure of a lid and a base, defined by engagement of a front tuck flap on the lid and a front panel of the base, and the container also includes a second releasably secure closure of the lid and the base, defined by engagement of front edges of the side panels of the lid and minor diagonal panels of the base. The container is constructed from a blank of sheet material. The blank is formed by a machine that imparts fold lines, cut lines, and other lines of weakness to the blank. In one embodiment, the container is fabricated from a paperboard material. The container, however, may be fabricated using any suitable material, and therefore is not limited to a specific type of material. In alternative embodiments, the container is fabricated using cardboard, plastic, fiberboard, paperboard, foamboard, corrugated paper, and/or any suitable material known to those skilled in the art and guided by the teachings herein provided.

Unless otherwise indicated, the terms “first,” “second,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, for example, a “second” item does not require or preclude the existence of, for example, a “first” or lower-numbered item or a “third” or higher-numbered item.

In an example embodiment, the container includes at least one marking thereon including, without limitation, indicia that communicates the product, a manufacturer of the product, and/or a seller of the product. For example, the marking may include printed text that indicates a product's name and briefly describes the product, logos and/or trademarks that indicate a manufacturer and/or seller of the product, and/or designs and/or ornamentation that attract attention. “Printing,” “printed,” and/or any other form of “print” as used herein may include, but is not limited to including, ink jet printing, laser printing, screen printing, giclee, pen and ink, painting, offset lithography, flexography, relief print, rotogravure, dye transfer, and/or any suitable printing technique known to those skilled in the art and guided by the teachings herein provided. In another embodiment, the container is void of markings, such as, without limitation, indicia that communicates the product, a manufacturer of the product, and/or a seller of the product. Furthermore, the container may have any suitable size, shape and/or configuration, i.e., any suitable number of sides having any suitable size, shape and/or configuration as described and/or illustrated herein. In one embodiment, the container includes a shape that provides functionality, such as a shape that facilitates packaging a food item, a shape that facilitates transporting the container, and/or a shape that facilitates stacking and/or arrangement of a plurality of containers.

Referring now to the drawings, and more specifically toFIGS. 1 and 2, although as described above a container may have any suitable size, shape, and/or configuration,FIGS. 1 and 2illustrate the construction or formation of a first embodiment of a container. Specifically,FIG. 1is a top plan view of a first example embodiment of a blank100of sheet material.FIG. 2is a perspective view of a first example embodiment of a container200formed from blank100shown inFIG. 1.

Referring toFIG. 1, blank100has a first or interior surface112and an opposing second or exterior surface114. Further, blank100defines a leading edge116and a trailing edge118. Blank100includes, from leading edge116to trailing edge118, a front tuck flap134, a top panel120, a back panel122, a bottom panel124, and a front panel142, coupled together along preformed, generally parallel, fold lines126,128,130, and132, respectively. Fold lines and/or hinge lines as described herein may include any suitable line of weakening and/or line of separation known to those skilled in the art and guided by the teachings herein provided.

More specifically, top panel120extends from front tuck flap134along fold line126, back panel122extends from top panel120along fold line128, bottom panel124extends from back panel122along fold line130, and front panel142extends from bottom panel124along fold line132. In the example embodiment, front tuck flap134includes a pair of offset edges131disposed at opposite ends of front tuck flap134. More specifically, offset edges131are offset from leading edge116of blank100. In alternative embodiments, front tuck flap134does not include offset edges131.

In the example embodiment, front tuck flap134has a width W1that is less than a width W2of top panel120, such that a pair of free edges160of top panel120are defined on opposing sides of, and substantially co-linear with, fold line126. Free edges160and fold line126cooperate to form a front edge of top panel120, and fold line128defines a back edge of top panel120. In alternative embodiments, width W1is equal to or greater than width W2, such that top panel120does not include free edges160.

Top panel120includes a first top side panel162and a second top side panel164extending therefrom along respective opposing fold lines166and168. More specifically, first top side panel162extends from top panel120along fold line166, and second top side panel164extends from top panel120along fold line168. Fold lines166and168define side edges of top panel120. Each of first top side panel162and second top side panel164includes a front edge174that is configured to engage one of minor diagonal panels136to at least partially define the second releasably secure closure of container200in a closed position260. For example, in the illustrated embodiment, each of first top side panel162and second top side panel164includes a front portion171proximate front edge174, and a locking tab172that extends from front edge174. More specifically, in the example embodiment, each locking tab172is configured to be received in a locking aperture250defined in a minor diagonal wall210of container200to at least partially define the second releasably secure closure of container200in closed position260, as shown inFIG. 2.

In the example embodiment, top panel120includes a pair of rounded front corner edges170. Each rounded front corner edge170extends between a free edge160and a respective side edge of top panel120. Alternatively, top panel120does not include rounded front corner edges170.

Bottom panel124has a first bottom side panel176and a second bottom side panel178extending therefrom along respective opposing fold lines180and182. More specifically, first bottom side panel176extends from bottom panel124along fold line180, and second bottom side panel178extends from bottom panel124along fold line182. Fold lines180and182define side edges of bottom panel124. Furthermore, each bottom side panel176and178includes a back tab184extending from a respective back edge186of the bottom side panel176or178. Each back edge186is defined by a fold line. Each back tab184is separated from back panel122by a cut line190, and further separated from an adjacent one of top side panels162and164by a cut line192. In an alternative embodiment (not shown), each back tab184extends from one of top side panels162and164such that a fold line couples back tab184to top side panel162or164, and a cut line separates each back tab184from bottom side panel176or178.

In the example embodiment, each bottom side panel176and178also has a minor diagonal panel136extending from a respective front edge188of the bottom side panel. Each bottom side panel front edge188is partially defined by a cut line187that defines a slot-forming tab144on bottom side panel front edge188, and further at least partially defined by at least one fold line189extending from an end of cut line187. In the example embodiment, the at least one fold line189is a pair of fold lines189that extend from opposing edges of cut line187. Each slot forming tab144is configured to form one of locking apertures250of container200, as shown inFIG. 2, when minor diagonal panel136is rotated about fold line189.

Front panel142includes a pair of oppositely disposed side edges143. Each side edge143is defined by a fold line. A major diagonal panel145extends from each side edge143. Each major diagonal panel145has a length greater than a length of each minor diagonal panel136, wherein the length of major diagonal panel145is measured between a respective fold line143and a respective side edge147of major diagonal panel145, and the length of minor diagonal panel136is measured between a respective fold line188and a front edge148of minor diagonal panel136.

Fold line132defines a front edge of bottom panel124, and fold line130defines a back edge of bottom panel124. In addition, bottom panel124includes a pair of oppositely disposed angled edges146that extend from opposing ends of fold line132to bottom panel side edges180and182, respectively. Each angled edge146is defined by a respective fold line. A corner panel138extends from each angled edge146. Moreover, each corner panel138is separated from an adjacent minor diagonal panel136by a fold line149, and is separated from an adjacent major diagonal panel145by a respective fold line150. In addition, each minor diagonal panel136is separated from an adjacent major diagonal panel145by a respective cut line151.

Front panel142is configured to engage front tuck flap134to at least partially define a first releasably secure closure of container200in closed position260. For example, in the illustrated embodiment, a notch140is defined in trailing edge118along each side edge143of front panel142. Each notch140is configured to receive at least a portion of front tuck flap134to at least partially define the first releasably secure closure of container200in closed position260, as shown inFIG. 2. In alternative embodiments, any suitable number of notches140disposed at any suitable location are configured to receive any suitable portion of front tuck flap134. In the example embodiment, front panel142has a width W3that is less than or equal to width W1of front tuck flap134. In alternative embodiments, width W3is greater than width W1.

With reference toFIGS. 1 and 2, to construct container200from blank100, a base202of container200and a lid206of container200are formed. To form base202, corner panels138are rotated about respective fold lines146toward interior surface112to overlap at least a portion of bottom panel124. After rotation, corner panels138are substantially parallel to bottom panel124such that interior surface112of each corner panel138is adjacent to interior surface112of bottom panel124. Bottom panel124and corner panels138form a bottom wall203of container200.

When corner panels138are rotated toward interior surface112, major diagonal panels145, minor diagonal panels136, and front panel142are also rotated about respective fold lines146,143,150,149, and132toward interior surface112because of the interconnectivity of each of major diagonal panels145, minor diagonal panels136, and front panel142with corner panels138. In addition, bottom side panels176and178are also rotated about respective fold lines180and182toward interior surface112because of the interconnectivity of bottom side panels176and178with respective minor diagonal panels136. As such, major diagonal panels145, minor diagonal panels136, bottom side panels176and178, and front panel142are rotated into position concurrently with corner panels138in one motion. Major diagonal panels145form respective major diagonal walls208, and minor diagonal panels136form respective minor diagonal walls210. Bottom side panels176and178are configured to form a portion of respective first and second side walls216and218, and front panel142is configured to form a portion of a front wall220. After rotation, bottom side panels176and178, front panel142, major diagonal walls208, and minor diagonal walls210are substantially perpendicular to bottom wall203.

In the example embodiment, when minor diagonal panels136are rotated, slot-forming tabs144separate from minor diagonal panels136, forming locking apertures250in each minor diagonal wall210adjacent first and second side walls216and218. Further, when corner panels138are rotated into position, front edges148of each minor diagonal panel136contact an adjacent major diagonal panel145, and side edges147of each major diagonal panel145are adjacent to, but spaced from, a respective adjacent bottom side panel176and178. Each minor diagonal wall210extends from front edge188of the respective bottom side panel176and178at an acute angle relative to the bottom side panel, and each major diagonal wall208extends from one of side edges143of front panel142at an obtuse angle relative to front panel142. A recess226is defined by each major diagonal wall208, minor diagonal wall210, and corner panel138. Further, each of bottom side panels176and178cooperates with an adjacent minor diagonal wall210and an adjacent major diagonal wall208to define a respective chamber230within a cavity232of base202. Each chamber230is separated from one of recesses226by a corresponding minor diagonal wall210.

Back tabs184are rotated about respective fold lines186toward interior surface112to form a portion of a back wall236that at least partially defines cavity232. It should be understood that back tabs184may be rotated into position before or after corner panels138are rotated toward interior surface112.

To construct lid206of container200, top side panels162and164are rotated about respective fold lines166and168toward interior surface112, and front tuck flap134is rotated about fold line126toward interior surface112, such that top side panels162and164and front tuck flap134are perpendicular to top panel120. It should be understood that lid206may be formed before base202is formed.

To close container200, lid206is rotated toward base202along fold lines128and130. As lid206is rotated toward base202, back panel122is rotated about fold line130to form back wall236. More specifically, back wall236is formed when back panel122is adjacent to back tabs184. Additionally, when container200is closed, top panel120forms a top wall204of container200, and front tuck flap134engages front panel142to form front wall220of container200and at least partially define the first releasably secure closure of lid206and base202. In the example embodiment, each notch140receives at least a portion of front tuck flap134to at least partially define the first releasably secure closure of lid206and base202. More specifically, each notch140receives one of pair of offset edges131of front tuck flap134to at least partially define the first releasably secure closure of lid206and base202. In alternative embodiment, each notch140receives any suitable portion of front tuck flap134.

In addition, when container200is closed, top side panel162cooperates with bottom side panel176to form first side wall216of container200, and top side panel164cooperates with bottom side panel178to form second side wall218of container200. More specifically, exterior surface114of each top side panel162and164contacts interior surface112of respective bottom side panel176and178, and front portion171of each top side panel162and164is at least partially disposed within one of chambers230. Moreover, each front edge174of top side panels162and164engages one of minor diagonal panels136to at least partially define the second releasably secure closure of container200in closed position260. For example, in the illustrated embodiment, locking tab172of each front edge174is received in a respective locking aperture250of minor diagonal walls210, at least partially defining the second releasably secure closure of lid206and base202.

Additionally, front portion171of top side panel162is received between bottom side panel176and side edge147of adjacent major diagonal panel145, and front portion171of top side panel164is received between bottom side panel178and side edge147of adjacent major diagonal panel145. In certain embodiments, each front portion171is so received in a friction fit, defining a third releasably secure closure of lid206and base202. In alternative embodiments, each front portion171is so received in a clearance fit and/or a non-contact fit.

Prior to closing container200, a product, such as a food product, may be placed within base202. As such, when lid206engages base202, the product is secured within cavity232by lid206and base202.

As such, the following steps are performed to form container200from blank100: (1) rotate corner panels136toward bottom panel124to form base202; (2) rotate back tabs184toward interior surface112to form a portion of back wall236; (3) rotate front tuck flap134and top side panels162and164toward interior surface12to form lid206; and (4) rotate lid206toward base202to form side walls216and218and front wall220. In an alternative embodiment, steps (1) and (2) are interchanged. In another alternative embodiment, step (3) is performed before steps (1) and (2).

FIG. 3is a top plan view of a second example embodiment of a blank300of sheet material. Similar to blank100, blank300includes, from a leading edge316to a trailing edge318, a front tuck flap334, a top panel320, a back panel322, a bottom panel214, and a front panel342. Blank300also includes corner panels338and major diagonal panels345.FIG. 4is a perspective view of a second example embodiment of a container400formed from blank300shown inFIG. 3. Blank300and container400are substantially similar to blank100and container200shown inFIGS. 1 and 2, except as otherwise noted. In particular, front tuck flap334does not include offset edges such as offset edges131of blank100, and no notches such as notches140of blank100are defined along side edges343of front panel342. Instead, the first releasably secure closure of lid406and base402is at least partially defined by a friction fit between exterior surface314of front tuck flap334and interior surface312of front panel342.

Similar to blank100, each of a first top side panel362and a second top side panel364of blank300includes a front portion371proximate a front edge374, and a locking tab372that extends from front edge374. A front edge388of each bottom side panel376and378includes a slot-forming tab344configured to form a locking aperture450in one of minor walls410of container400when a minor diagonal panel336is rotated to form container400. Each locking tab372is received in one of locking apertures450to at least partially define the second releasably secure closure of container400in closed position460.

FIG. 5is a top plan view of a third example embodiment of a blank500of sheet material. Similar to blank100, blank500includes an interior surface512and an interior surface514, a top panel520, a bottom panel524, minor diagonal panels536, corner panels538, and major diagonal panels545.FIG. 6is a perspective view of a third example embodiment of a container600formed from blank500shown inFIG. 5. Similar to container200, container600includes side walls616and618. Blank500and container600are substantially similar to blank100and container200shown inFIGS. 1 and 2, except as otherwise noted. In particular, similar to blank100, a front tuck flap534includes a pair of offset edges531disposed at opposite ends of front tuck flap534. More specifically, offset edges531are offset from a leading edge516of blank500. In alternative embodiments, front tuck flap534does not include offset edges531. Also similarly, a notch540is defined in a trailing edge518of blank500along each side edge543of a front panel542. Each notch540is configured to receive at least a portion of front tuck flap534to at least partially define the first releasably secure closure of container600in a closed position660. For example, in the illustrated embodiment, each notch540receives one of pair of offset edges531of front tuck flap534to at least partially define the first releasably secure closure of lid606and base602. In alternative embodiments, each notch540receives any suitable portion of front tuck flap534.

Each of a first top side panel562and a second top side panel564of blank500includes a front portion571proximate a front edge574. However, unlike blank100, front edge574does not include a locking tab such as locking tab172(shown inFIG. 1), and a front edge588of bottom side panels576and578does not include a slot-forming tab such as slot-forming tab144(shown inFIG. 1). Instead, each front edge574is configured to engage interior surface512of one of minor diagonal walls610in a friction fit when container600is in a closed position660, to at least partially define the second releasably secure closure of lid606and a base602.

FIG. 7is a top plan view of a fourth example embodiment of a blank700of sheet material. Similar to blank100, blank700includes, from a leading edge716to a trailing edge718, a front closure flap734, a bottom panel720, a back panel722, a bottom panel724, and a front panel742. Blank700also includes an interior surface712and an exterior surface714, as well as minor diagonal panels736, corner panel738, major diagonal panels745, and at least one notch740configured to receive at least a portion of front tuck flap734.FIG. 8is a perspective view of a fourth example embodiment of a container800formed from blank700shown inFIG. 7. Blank700and container800are substantially similar to blank100and container200shown inFIGS. 1 and 2, except as otherwise noted. Unlike blank100, a front edge788of bottom side panels776and778does not include a slot-forming tab such as slot-forming tab144(shown inFIG. 1). However, a front edge774of top side panels762and764includes a locking tab772configured to engage interior surface712of one of minor diagonal walls810in a friction fit when container800is in a closed position860, to at least partially define the second releasably secure closure of a lid806and a base802.

In addition, in the illustrated embodiment, a gap785is defined in blank700between at least one of top side panels762and764and an adjacent back tab784. In addition, a slot787is defined in a corresponding at least one of bottom side panels776and778and extends from a back edge786of the bottom side panel. Each gap785cooperates with the corresponding slot787to form a vent870in container800. In alternative embodiments, blank700and container800do not include gap785, slot787, and vent870.

Further in the illustrated embodiment, a top panel720includes a pair of diagonal front corner edges773, rather than rounded front corner edges170(shown inFIG. 1). In alternative embodiments, top panel720includes any suitable front corner edge shape.

Also in the illustrated embodiment, top panel720includes extensions791defined by cut lines. Extensions791are configured to form lifting tabs891of lid806when container800is formed. In alternative embodiments, blank700and container800do not include extensions791and lifting tabs891.

FIG. 9is a top plan view of a fifth example embodiment of a blank900of sheet material. Similar to blank100, blank900includes a leading edge918and a trailing edge918, as well as major diagonal panels945. Blank900is substantially similar to blank100shown inFIG. 1, and is configured to form a container substantially similar to container200shown inFIG. 2, except as otherwise noted. In particular, similar to blank100, a notch940is defined in a trailing edge918of blank900along each side edge943of a front panel942. However, a front tuck flap934does not include offset edges such as offset edges131of blank100. Instead, front tuck flap934has a substantially constant depth D1along substantially an entire length of front tuck flap934that is sized to be received within notches940. More specifically, each notch940has a depth D2that is substantially equal to or greater than depth D1, such that each notch940is configured to receive at least a portion of front tuck flap934to at least partially define the first releasably secure closure of the container in a closed position.

FIG. 10is a top plan view of a sixth example embodiment of a blank1000of sheet material. Blank1000is substantially similar to blank100shown inFIG. 1, and is configured to form a container substantially similar to container200shown inFIG. 2, except as otherwise noted. In particular, blank1000includes a pair of front corner edge projections1070that are configured to form lifting tabs for a lid of the container. In the illustrated embodiment, each projection1070is generally rectangular-shaped. In an alternative embodiment, each projection1070is generally semi-circular-shaped. In other alternative embodiments, each projection1070has any suitable shape that facilitates lifting the lid of the container formed from blank1000.

Embodiments of the above-described container are easily constructed from a flexible unitary blank of paperboard. Further, embodiments of the above-described container include an easily formed first releasably secure closure of a lid and a base, at least partially defined by engagement of a front tuck flap on the lid and a front panel of the base, and an easily formed second releasably secure closure of the lid and the base, at least partially defined by engagement of front edges of the side panels of the lid and minor diagonal panels of the base.

Exemplary embodiments of a container have been described above in detail. The container is not limited to the specific embodiments described herein, but rather, components of the container and/or steps of the method may be utilized independently and separately from other components and/or steps described herein. Further, the described components and/or method steps can also be defined in, or used in combination with, other apparatus and/or methods, and are not limited to practice with only the apparatus and method as described herein.