Patent Publication Number: US-2022219866-A1

Title: Container with integral hinged connection

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This Application claims priority to U.S. Provisional Patent Application Ser. No. 63/137,631, filed on Jan. 14, 2021, to Keegan Yang et al., entitled “Container with Integral Hinged Connection,” currently pending, the entire disclosure of which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     Clamshell-style cartons and containers are commonly used for holding and serving food items as well as other types of contents. These cartons are often configured with a base portion and a cover portion connected together by a hinged connection that allows the cover portion to rotate between open and closed configurations relative to the base portion. The hinged connection of these cartons is typically configured as a “living hinge” formed by a thin strip of material connecting the base portion and the cover portion together. This thin strip of material is easily bendable and allows for closure between the base and cover portions. 
     Traditionally, such clamshell-style cartons and containers have been made of a single material consisting of expanded polystyrene or solid plastic. Additionally, such clamshell-style cartons have begun to be constructed from a molded fiber or pulp material, which is more environmentally-friendly than expanded polystyrene and plastic. However, there are operational considerations for molded fiber and pulp that generally limit the features that can be incorporated into the hinged connection as compared to the traditional expanded polystyrene or solid plastic. In particular, because molded fiber requires the use of a wet slurry of fiber material that is pressed into the shape of the carton through the use of material dies, it can be difficult to form curved portions and transition sections between different components of the carton, particularly those curved portions and transition sections having tight radiuses. As a result, cracks, fractures, and weak points can easily form along the perimeter rim and flange of the cover and base portions of the finished carton product, as well as the hinged connection that connects the cover and base portions together. 
     These fracture points and weak points can affect the bending of the hinged connection and prevent proper closing of the carton. When the cover portion is rotated relative to the base portion, bending can occur along the fracture points and weak points existing along the base and cover perimeter flange and cause the carton to bend and deform at regions other than the desired hinge line. As a result, the cover portion does not properly align with the base portion and can make it difficult to properly position the container in a closed configuration. This can be further impacted if the finished carton product undergoes even slight distortion or changes in shape as the molded fiber dries after being formed. 
     Accordingly, a need exists for an improved hinged connection and carton design that can allow the carton to be constructed from a molded fiber or pulp material while still allowing for proper bending along the hinge line of the carton. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention is directed generally to a clamshell-style container or carton and a hinged connection for a clamshell-style carton. The carton may include a base portion and a cover portion connected together by the hinged connection. The base portion may include a bottom wall, a base perimeter sidewall, and a base perimeter rim and a base perimeter flange extending from the base perimeter sidewall. The cover portion may similarly include a cover wall, a cover perimeter sidewall, and a cover perimeter rim and a cover perimeter flange extending from the cover perimeter sidewall. Both the base portion and the cover portion may include a rear perimeter sidewall section and corresponding perimeter rim and perimeter flange where the hinged connection is provided. 
     The hinged connection may be provided along the base perimeter rim and flange and the cover perimeter rim and perimeter flange located along the base and cover rear sidewall sections. The base perimeter flange and the cover perimeter flange may be connected together to form a hinge axis of the hinged connection. The hinged connection may also be configured as a living hinge to allow the cover portion to selectively rotate relative to the base portion about a hinge axis so that the carton and the cover panel may transition between an open configuration and a closed configuration. 
     The hinged connection may include one or more hinge tabs provided along both the base perimeter flange and the cover perimeter flange. Corresponding hinge tabs along each of the base and cover perimeter flanges may connect together at the hinge axis and form openings between the base perimeter flange and the cover perimeter flange. 
     The hinged connection may include a series of interlocking structural elements formed into the base portion and the cover portion along the base perimeter flange and cover perimeter flange. The structural elements may be configured as corresponding projecting elements and recessed elements that join together when the cover portion is rotated relative to the base portion. The structural elements may assist in allowing the cover portion to appropriately fit onto and remain in close engagement with the base portion. The structural elements may also function as stiffening elements to strengthen the rigidity of the hinged connection and limit deformation and fracture along the hinged connection. 
     The structural elements may include one or more first structural elements that are configured as channels, recesses, grooves, depressions, indentions or the like formed into the cover perimeter flange. The structural elements may further include one or more second structural elements that are configured as outward protrusions, projections, ridges or the like extending outward from the base perimeter rim toward the base perimeter flange. The second structural elements may be positionally aligned with the first structural elements so that each of the second structural elements are at least partially received within one of the first structural elements when the cover portion is rotated into the closed position. 
     The structural elements may additionally include one or more third structural elements that are configured as outward protrusions, projections, ridges or the like extending outward from the cover perimeter flange near the cover perimeter rim, and one or more fourth structural elements that are configured as channels, recesses, grooves, depressions, indentions or the like formed into the base perimeter rim near the base perimeter flange. Similar to the first and second structural elements, the third and fourth structural elements may be positionally aligned and configured so that each of the third structural elements are at least partially received within one of the fourth structural elements when the cover portion is rotated into the closed position. 
     Other aspects and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments of the accompanying drawing figures 
    
    
     
       DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       In the accompanying drawings, which form a part of the specification and are to be read in conjunction therewith in which like reference numerals are used to indicate like or similar parts in the various views: 
         FIG. 1  is a top plan view of a container in accordance with one embodiment of the present invention; 
         FIG. 2  is a top perspective view of the container of  FIG. 1 ; 
         FIG. 3  is a bottom perspective view of the container of  FIG. 1 ; 
         FIG. 4  is a side elevation view of the container of  FIG. 1 ; 
         FIG. 5  is a perspective view of a hinged connection for a container in accordance with one embodiment of the present invention; 
         FIG. 6  is a top plan view of the hinged connection for a container of  FIG. 5 ; 
         FIG. 7  is a partial top perspective view of the hinged connection for a container of  FIG. 5 ; 
         FIG. 8  is a schematic side elevation view of a hinged connection for a container in accordance with one embodiment of the present invention, illustrating the container in an open configuration; 
         FIG. 9  is a schematic side elevation view of the hinged connection for a container of  FIG. 8 , illustrating the container in a closed configuration; and 
         FIG. 10  is a schematic perspective view of the hinged connection for a container of  FIG. 8  in accordance with one embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not necessarily been maintained in the drawing figures. 
     The following detailed description of the invention references specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. It will be appreciated that some or all of the various features and structures described and shown with respect to each of the specific embodiments referenced herein may be combined to form additional or alternative embodiments having such combinations and that such combinations are within the scope of the present invention. 
     Referring to the figures, the present invention is directed to a clamshell-style container or carton  10  and a hinged connection  100  for a carton  10 . As described in greater detail herein, hinged connection  100  may be configured as an integral hinge within a carton  10  and may include one or more interlocking structural elements defined into carton  10  to facilitate the bending of carton  10  about hinged connection  100 . Carton  10  may be constructed from a molded fiber or pulp material, which may comprise fibers derived from at least or more of wood, sugarcane, bagasse, wheat, other plants, recycled paper or paperboard, or other suitable cellulosic or non-cellulosic materials. However, it will also be recognized that the carton  10  may suitably be constructed from other materials, including without limitation, paperboard, plastic or polymer-based materials, polystyrene, and the like. Carton  10  may further be designed and configured for holding various types of food items for use in the food service industry; however, carton  10  may suitably be used and configured for holding any number of different types of items or contents. 
     Turning to  FIGS. 1-4 , carton  10  may include a base portion  12  and a cover portion  14  connected together by hinged connection  100 . Base portion  12  may include a bottom wall  16  and a perimeter sidewall  18  extending from the perimeter of bottom wall  16 . Perimeter sidewall  18  may include a rear sidewall section  20  adjacent hinged connection  100  as best shown in  FIG. 1 . Base portion  12  may further include a base perimeter rim  22  formed around the upper region of perimeter sidewall  18  and a base perimeter flange  24  extending from base perimeter rim  22  and providing an outer terminal edge around the perimeter of base portion  12 . 
     Similarly, cover portion  14  may include a top wall  26  and a perimeter sidewall  28  extending from the perimeter of top wall  26 . Perimeter sidewall  28  of cover portion  14  may include a rear sidewall section  30  adjacent hinged connection  100  and opposite rear sidewall section  20  of base portion  12  as best shown in  FIG. 1 . Cover portion  14  may further include a cover perimeter rim  32  formed around the upper region of perimeter sidewall  28  and a cover perimeter flange  34  extending from cover perimeter rim  32  and forming an outer terminal edge around the perimeter of cover portion  14 . 
     As illustrated in  FIGS. 1-4 , according to certain embodiments of the present invention, carton  10  may optionally include one or more internal dividing walls or partitions provided within base portion  12  that separates the interior space of base portion  12  into one or more compartments. Additionally, according to certain embodiments, one or both of base portion  12  and cover portion  14  may include ribs, stiffening elements, tabs or locking components, and/or other structural elements formed into carton  10 , such as those commonly utilized in known clamshell-style carton and container designs. It is recognized that such structural elements may not necessarily comprise novel features of carton  10  and may be included or omitted depending on the particular embodiment of carton  10 . 
     Turning to  FIGS. 5-10 , hinged connection  100  may be incorporated into carton  10  along the upper ends of base rear sidewall section  20  and cover rear sidewall section  30  and connect base portion  12  and cover portion  14  together. In particular, as best shown in  FIG. 5 , hinged connection  100  may be incorporated into carton  10  along base perimeter rim  22  and flange  24  and cover perimeter rim  32  and flange  34  formed along rear sidewall sections  20  and  30  of base portion  12  and cover portion  14 , respectively. Hinged connection  100  may be configured as a “living” hinge structure that connects base portion  12  and cover portion  14  together. Hinged connection  100  may further allow cover portion  14  to selectively rotate relative to base portion  12  along rear sidewall sections  20  and  30  so that carton  10  may be transitioned between an open configuration (where cover portion  14  is rotated away from base portion  12 ) and a closed configuration (where cover portion  14  is positioned over or on top of base portion  12 ). According to certain embodiments, the resiliency of hinged connection  100  may be configured to maintain carton  10  in the open configuration unless cover portion  14  is closed and latched to base portion  12 . 
     As shown schematically in  FIGS. 8-10  (and illustrated in  FIG. 5 ), hinged connection  100  may be configured within the rim and flange portions  22 ,  24  and  32 ,  34 , respectively, of base portion  12  and cover portion  14 . In particular, hinged connection  100  may include the regions of base perimeter rim  22  and flange  24  and cover perimeter rim  32  and flange  34  positioned adjacent to base rear sidewall section  20  and cover rear sidewall section  30 . 
     As best shown in  FIGS. 5-7 , adjacent rear sidewall section  20 , base perimeter rim  22  may be configured as a raised rim formed along the upper edge of rear sidewall section  20  and base perimeter flange  24  may extend generally horizontally outward from the lower, outer end of perimeter rim  22 . As further shown in  FIGS. 5-7 , adjacent cover rear sidewall section  30 , cover perimeter rim  32  may be configured as a raised rim formed along the upper edge of sidewall  28  and cover perimeter flange  34  may extend generally away from the lower outer end of perimeter rim  32 . As further shown in  FIGS. 8-10 , cover perimeter flange  34  may include a downwardly extending depressed region  36  extending from perimeter rim  32  and an outer, generally horizontally-extending end region  38  extending from depressed region  36 . As best shown in  FIG. 9 , the depressed region  36  can be configured to generally conform to the shape and curvature of base perimeter rim  22  to allow cover perimeter flange  34  to engage base perimeter rim  22  when carton  10  is placed in the closed configuration. As further shown in  FIG. 9 , when carton  10  is placed in the closed configuration, base perimeter rim  22  may be at least partially received within depressed region  36  of cover perimeter flange  34 . 
     As shown in  FIGS. 5-7 , the outer edges of base perimeter flange  24  and cover perimeter flange  34  may be connected together to form a hinge line or hinge axis  102  of hinged connection  100 . Hinge line  102  may be configured as a line of weakness extending longitudinally along the length of hinged connection  100  and provide the axis of rotation between cover portion  14  and base portion  12 . 
     As shown in  FIGS. 5-7 , hinged connection  100  may include one or more hinge projections or tabs  104  and  106  provided along base perimeter flange  24  and cover perimeter flange  34 , respectively. As shown in  FIGS. 5-7 , hinge tabs  104  may be connected to and/or extend outward from the edge of base perimeter flange  24 , and hinge tabs  106  may be connected to and/or extend outward from the edge of cover perimeter flange  34 . Hinge tabs  104  and  106  may also be configured as the outermost extended portions of base perimeter flange  24  and cover perimeter flange  34 , respectively, and not necessarily be a separate, distinguishable component therefrom in certain embodiments of the invention. As shown in  FIGS. 5-7 , each hinge tab  104  of base portion  12  may be connected to a corresponding hinge tab  106  of cover portion  14  along the defined hinge line or axis  102 . Collectively, hinge tabs  104  and  106  may form hinge line or axis  102  as a weakened line or folding line between base perimeter flange  24  and cover perimeter flange  34  adjacent rear sidewall sections  20  and  30 . Hinge axis  102  may provide the axis of rotation about which cover portion  14  rotates relative to base portion  12  when carton  10  is transitioned between the open and closed configurations. 
     As best shown in  FIG. 6 , hinge tabs  104  and  106  may be spaced apart along the length of perimeter flanges  24  and  34  and define openings or gaps  108  along a length of the hinge axis  102  of hinged connection  100  and between adjacent hinge tabs  104 / 106 . According to an alternative embodiment (not shown), each of base perimeter flange  24  and cover perimeter flange  34  may include a continuous hinge tab  104  and  106 , respectively, that extends along all or a portion of the hinge axis  102  of hinged connection  100  without any openings or gaps  108 . Additionally, carton  10  and hinged connection  100  may be configured without any hinge tabs  104  and  106 , and the outer edges or base perimeter flange  24  and cover perimeter flange  34  are directly connected together to form hinge axis  102 . 
     As shown in  FIGS. 5-7 , hinged connection  100  may include a series of interlocking structural elements  110 - 116  that are formed into base portion  12  and cover portion  14  and are configured to conform and fit together when carton  10  is placed into the closed configuration and cover portion  14  is rotated about hinged connection  100  and onto base portion  12 . The one or more structural elements  110 - 116  may be configured as corresponding projecting elements and recessed elements that join together when cover portion  14  is rotated onto base portion  12  via hinged connection  100  and assist in allowing cover portion  14  to appropriately fit onto and remain in close engagement with base portion  12 . Structural elements  110 - 116  may also operate as stiffening elements for hinged connection  100  in order to increase the strength, resiliency, and/or rigidity of hinged connection  100  and reduce the potential for deformation and fracture of hinged connection  100  during use with carton  10 . 
     As shown in  FIGS. 5-7 , hinged connection  100  may include one or more first structural elements  110  provided on cover perimeter flange  34 . As best shown in  FIGS. 6 and 7 , each first structural element  110  may be configured as a channel, recess, groove, depression, indention or the like formed into cover perimeter flange  34  along depressed region  36  and outer end region  38 . As further shown, each first structural element  110  may extend into flange  34  so that the directly adjacent portions of flange  34  on each end of first structural element  110  extend upward and/or outward beyond first structural element  110  and first structural element  110  is depressed, recessed, or indented between such adjacent portions of flange  34 . As best shown in  FIG. 6 , hinged connection  100  may include a plurality of first structural elements  110  provided along the length of hinged connection  100  in a spaced arrangement. As further shown in  FIG. 6 , in certain embodiments, each first structural element  110  may be positionally aligned with an opening  108  along hinge axis  102  so that each first structural element  110  is located between adjacent hinge tabs  106  along the length of cover perimeter flange  34 . 
     As further shown in  FIGS. 5-7 , hinged connection  100  may include one or more second structural elements  112  provided on base perimeter rim  22  and base perimeter flange  24 . Second structural elements  112  may also be configured to generally correspond to first structural elements  110 . As best shown in  FIGS. 6 and 7 , each second structural element  112  may be configured as an outward protrusion, projection, ridge or the like that extends outward from the outer portion of base perimeter rim  22 . As further shown, each second structural element  112  may be formed in base perimeter rim  22  so that each second structural element extends upward and/or outward and beyond the directly adjacent portions of rim  22  on each end of second structural element  112 . As best shown in  FIG. 6 , hinged connection  100  may include a plurality of second structural elements  112  provided along the length of hinged connection  100  in a spaced arrangement. 
     As best shown in  FIG. 6 , second structural elements  112  may be generally aligned with the arrangement and positioning of first structural elements  110 . As shown, each second structural element  112  may generally conform to a corresponding first structural element  110  that is positioned on the opposite side of hinge axis  102  so that the inward-oriented first structural element  110  may receive the outward-oriented second structural element  112  when cover portion  14  is rotated about hinge axis  102  into an overlaid arrangement with base portion  14  and carton  10  is placed into the closed configuration. As also shown in  FIG. 6 , in certain embodiments, each second structural element  112  may be positionally aligned with a corresponding first structural element  110  as well as an opening  108  along hinge axis  102  so that each second structural element  112  is located between adjacent hinge tabs  104  along the length of base perimeter flange  24 . 
     As further shown in  FIGS. 5-7 , hinged connection  100  may include one or more third structural elements  114  provided on cover perimeter flange  34  and adjacent cover perimeter rim  32 . As best shown in  FIGS. 6 and 7 , each third structural element  114  may be configured as a raised projection, protrusion, ridge or the like extending upward from the depressed region  36  of cover perimeter flange  34  adjacent cover perimeter rim  32 . As further shown, each third structural element  114  may be formed onto cover perimeter rim  32  and flange  34  so that the third structural element  114  extends outward and/or upward from rim  32  and flange  34  and beyond the directly adjacent portions of rim  32  and flange  34  on each end of third structural element  114 . As best shown in  FIG. 6 , hinged connection  100  may include a plurality of third structural elements  114  provided along the length of hinged connection  100  in a spaced arrangement. According to certain embodiments, third structural elements  114  may be positioned along the length of hinged connection  100  to generally align with and correspond to first structural elements  110 . As best shown in  FIGS. 5 and 6 , each third structural element  114  may be provided adjacent a corresponding first structural element  110  so that a respective third structural element  114  is positioned on the opposite end of cover perimeter flange  34  relative to a respective first structural element  110 . 
     As further shown in  FIGS. 5-7 , hinged connection  100  may include one or more fourth structural elements  116  provided on base perimeter rim  22 . As shown, fourth structural elements  116  may be formed into base perimeter rim  22  and be configured as indentions, channels, grooves, depressions, recesses or the like defined into base perimeter rim  22 . As further shown, each fourth structural element  116  may extend into rim  22  so that the directly adjacent portions of rim  22  on each end of fourth structural element  116  extend upward and/or outward beyond fourth structural element  116  and fourth structural element  116  is depressed, recessed, or indented between such adjacent portions of rim  22 . As best shown in  FIGS. 6 and 7 , hinged connection  100  may include a plurality of fourth structural elements  116  provided along the length of hinged connection  100  in a spaced arrangement. As also shown in  FIG. 6 , each fourth structural element  116  may be provided immediately adjacent to a second structural element  112 . 
     As best shown in  FIG. 6 , fourth structural elements  116  may be generally aligned with the arrangement and positioning of third structural elements  114  so that a four structural element  116  positionally corresponds to a respective third structural element  114  relative to the hinge axis  102 . As shown, each fourth structural element  116  may generally conform to a corresponding third structural element  114  that is positioned on the opposite side of hinge axis  102  so that when the inward-oriented fourth structural element  116  may receive the outward-oriented third structural element  114  when cover portion  14  is rotated about hinge axis  102  into an overlaid arrangement with base portion  14 . 
     Structural elements  110 - 116  may be configured to collectively form a series of interlocking components along the length of hinged connection  100 . As best shown in  FIGS. 6 and 7 , each second structural element  112  may be shaped and configured to generally conform to the shape of a corresponding first structural element  110  so that the second structural element  112  may be received within the first structural element  110  when carton  10  is placed into a closed configuration. Additionally, corresponding first and second structural elements  110  and  112 , respectively, may be positionally aligned with respect to one another relative to hinge axis  102  and located at approximately equal distances from hinge axis  102  so that second structural element  112  may be at least partially received into first structural element  112  when carton  10  is placed into the closed configuration. Each third structural element  114  may be shaped and configured to generally conform to the shape of a corresponding fourth structural element  116  so that the third structural element may be received within the fourth structural element  116  when carton  10  is placed into the closed configuration. Similarly, corresponding third and fourth structural elements  114  and  116 , respectively, may be positionally aligned with one another relative to hinge axis  102  and approximately equidistant from hinge axis  102  so that third structural element  114  may be at least partially received within fourth structural element  116  when carton  10  is placed in the closed configuration. 
     Collectively, structural elements  110 - 116  may facilitate proper rotation of cover portion  14  relative to base portion  12  and allow carton  10  to properly transition between the open configuration and the closed configuration. Structural elements  110 - 116  may be positioned along the length of hinged connection  100  and provide structural rigidity to base perimeter rim  22  and flange  24  and cover perimeter rim  32  and flange  34  to urge rotation of cover portion  14  about hinge axis  102  and limit deformation and deflection of base perimeter flange  24  and cover perimeter flange  34  when carton  10  transitions between the open configuration and closed configuration. Further, structural elements  110 - 116  may be selectively arranged along the length of hinged connection  100  to provide increased structural rigidity of carton  10  while still enabling carton  10  to be constructed from a molded fiber or pulp material. As a result, the configuration of hinged connection  100  with first and second structural elements  110  and  112 , and optionally third and fourth structural elements  114  and  116 , positioned along the length of hinge axis  102  increases the strength and integrity of the hinged connection  100  to reduce or limit undesired bending or buckling of the hinged connection  100  when carton  10  is transitioned between the open and closed configurations. Further, the configuration of hinged connection  100  can reduce or limit weak points or fracture points within hinged connection  100  that can affect the desired closing of carton  10 . 
     From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure. It will be understood that certain features and sub combinations are of utility and may be employed without reference to other features and sub combinations. Since many possible embodiments of the invention may be made without departing from the scope thereof, it is also to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative and not limiting. 
     The constructions described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present invention. Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required”. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention.