Patent Publication Number: US-6209781-B1

Title: Disposable, foldable container

Description:
BACKGROUND OF INVENTION 
     1. Field of the Invention 
     The present invention relates to disposable containers. More particularly, the present invention relates to containers for storing and dispensing a liquid. 
     2 Description of Related Art 
     With the increased use of what can be characterized as up-scale coffee at meetings and the like, there is a need to provide an economical service of supplying such coffee from an off site location. Typically, the coffee is ordered from a shop specializing in what can be characterized as “up-scale” coffee. Most usually, the coffee is delivered in relatively large vacuum containers. A problem with such delivery is that the vacuum containers must be retrieved by the coffee shop sometime after the conclusion of the consumption of the coffee contained therein. Typically what this entails is that a person from the coffee shop must coordinate a return trip to retrieve the vacuum containers. This trip is sometimes difficult to coordinate and certainly entails the time of at least one person to make the return trip to retrieve the empty vacuum containers. Alternatively, a fiber beverage container may be used to transport the coffee. Such beverage container is detailed in U.S. Pat. No. 5,715,992. The beverage container disclosed in the &#39;992 patent has a major disadvantage from an ergonomic standpoint. The spout out of which the coffee is poured is located proximate the top side of the beverage container. Accordingly, the beverage container must be tipped through an exaggerated rotation in order for the coffee contained therein to be discharged through the upwardly disposed spout. Such tipping can expose the hand of the user to hot vapors emanating from the heated coffee. Further, in order to fully discharge the coffee contained in the container, the container must be tipped to an orientation in which the side having the spout disposed therein is substantially downward and horizontal. The action of the operator to effect such disposition is a nearly unnatural pouring action. 
     A further disadvantage of the container disclosed in the &#39;992 patent is that a spout  9  must be fixedly internally disposed in the front  13  of the container. In the production process, the spout must be separately formed and then must be fitted to the container. After insertion of the spout, the container is no longer flat when in the folded disposition, making packing and shipping more difficult. 
     There is a need in the industry for a disposable container to transport beverages. Clearly an advantage of such a container is the fact that the container is readily disposable after use, thereby making a return trip by the provider unnecessary. The container should be ergonomically designed in order to readily facilitate the discharge of beverage therefrom. Further, it is desirable that such container substantially shield the hand of the user from any hot vapors emanating from the hot coffee. 
     SUMMARY OF THE INVENTION 
     The present invention substantially meets the aforementioned needs of the industry. Principally, by locating the spout from which the coffee is discharged proximate the bottom side section of the container, substantially all of the coffee contained therein may be discharged with virtually no tilting action on the part of the user of the container. Additionally, a shield is provided to substantially deflect hot vapors away from the hand of the user of the container. 
     The present invention is a disposable container that includes support structure that is shiftable between a disposable disposition and an erect disposition, the support structure defining an interior container space when in the erect disposition. The erect support structure has a bottom side section and a generally opposed and spaced apart top side section. A first end section extends between the bottom side section and the top side section and has an aperture defined therein, the aperture being disposed proximate the bottom side section. A second end section is spaced apart from the first end section and extends between the bottom side section and the top side section. 
     In a further embodiment, the present invention is a disposable container that includes support structure that is shiftable between a disposable disposition and an erect disposition, the support structure defining an interior container space when in the erect disposition. The erect support structure has a first end section, the first end section having an aperture defined therein, the aperture being disposed proximate a bottom side section. A bladder for holding a liquid is disposable in the interior container space. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective front quarter view of the container of the present invention; 
     FIG. 2 is a perspective rear quarter view of the container of FIG. 1; 
     FIG. 3 is a plan form view of the container support structure blank; 
     FIG. 4 is a plan form view of a container support structure blank first side in the glued configuration with the plan form view of FIG. 3 depicted in phantom; 
     FIG. 5 is a plan form view of a container support structure blank second side in the glued configuration; 
     FIG. 6 is a perspective view of the container bladder; and 
     FIG. 6A is a perspective view of a bladder cap having an integral spout. 
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     The disposable container of the present invention is shown generally at  10  in the drawings. The disposable container  10  includes a support structure  12  and, in a preferred embodiment, a bladder  14 . The support structure  12  is formed from a blank  16  as depicted in FIGS. 3-5. The blank  16  is erectable from the folded dispositions of FIGS. 3-5 to the erect dispositions of FIGS. 1 and 2. 
     The blank  16  of the support structure  12  is foldable to define components comprising a center support section  18 , a first end support section  20 , a second end support section  22 , and a handle  24 . The center support section  18  includes a bottom side section  26 , first side sections  28   a ,  28   b , second side sections  30   a ,  30   b , and overlapping top side sections  32   a ,  32   b.    
     The first component of the support section  12  is the bottom side section  26 . The bottom side section  26  is preferably formed in a parallelogram shape defined by parallel, spaced apart fold lines  34   a ,  34   b  and parallel, spaced apart fold lines  36   a ,  36   b . It should be noted that the fold lines  34   a ,  34   b  and  36   a ,  36   b , as well as all the succeeding fold lines to be described, may be scored in the material forming the blank  16  in order to facilitate readily folding along such fold lines. 
     The first side sections  28   a ,  28   b , are defined by the previously described fold lines  34   a ,  34   b  and the fold lines  38   a ,  38   b , respectively. The fold lines  38   a ,  38   b  are preferably disposed in a parallel relationship with fold lines  34   a ,  34   b . First side sections  28   a ,  28   b  are further defined by fold lines  40   a ,  40   b . The fold lines  40   a ,  42   a , and  40   b ,  42   b  are preferably not parallel, thereby defining first side sections  28   a ,  28   b  in generally trapezoidal shapes. 
     Outboard of first side sections  28   a ,  28   b  of the center support section  18  on the blank  16  depicted in FIG. 3, are second side sections  30   a ,  30   b . The second side sections  30   a ,  30   b  are defined in part by fold lines  38   a ,  38   b  and  44   a ,  44   b , respectively. Preferably, the fold lines  38   a  and  44   a  are disposed in a parallel relationship and the fold lines  38   b  and  44   b  are also disposed in a parallel relationship. The second side sections  30   a ,  30   b  are further defined by end margins  46   a ,  46   b , respectively, and fold lines  48   a ,  48   b , respectively. As with first side sections  28   a ,  28   b , the second side sections  30   a ,  30   b  are trapezoidal in shape, the end margins  46   a ,  46   b  not being in a parallel relationship with respect to the fold lines  48   a ,  48   b , respectively. 
     As depicted in FIG. 3, the overlapping top side sections  32   a ,  32   b  are disposed outboard from the blank  16  of the second side sections  30   a ,  30   b . The overlapping top side sections  32   a ,  32   b  are defined by an edge margin  50   a ,  50   b  disposed in a parallel relationship to the fold lines  44   a ,  44   b , respectively. The overlapping top side section  32   b  is additionally defined by the fold line  51 . The fold line  51  is collinear with the edge margin  50   b . As will be described below, handle  24  is formed integral with the overlapping top side section  32   b  along the fold line  51 . 
     The ends of the overlapping top side sections  32   a ,  32   b  are defined by parallel and spaced apart fold lines  52   a ,  52   b  and fold lines  54   a ,  54   b , respectively. 
     The second support section  12  component is the first end support section  20 . The first end support section  20  of the blank  16  is formed of front outer panel  60 , front inner panels  62   a ,  62   b , and tabs  64   a ,  64   b.    
     The front outer panel  60  includes a hexagonal panel  66 . The hexagonal panel  66  is defined by fold line  36   a  and parallel, spaced apart fold line  71 . Hexagonal panel  66  is further defined by side margins  68   a ,  68   b  adjoining fold lines  70   a ,  70   b . Outer panel tabs  72   a ,  72   b  are formed integral with hexagonal panel  66  along fold lines  70   a ,  70   b , respectively. The tabs  72   a ,  72   b  are defined by an outer margin  74 . 
     A spout aperture  76  is defined in the hexagonal panel  66 . The spout aperture  76  is disposed proximate the bottom side section  26  adjacent to the fold line  36   a.    
     A tongue  78  is formed integral with the hexagonal panel  66  along fold line  71 . The tongue  78  has an upper portion  80  separated from a lower portion  82  by the fold line  83 . A slit  84  is defined in the lower portion  82  extending substantially between the fold line  71  and a semi-circular cutout  86 . The semi-circular cutout  86  has its base resting along the fold line  83 . 
     The first end support section  20  includes generally opposed inner panel halves  62   a ,  62   b . The inner panel halves  62   a ,  62   b  are formed integral with the overlapping top side sections  32   a ,  32   b , respectively, along the fold lines  52   a ,  52   b , respectively. Each of the inner panel halves  62   a ,  62   b  has a cooperative cutout  90   a ,  90   b  respectively defined therein. As will be seen, the cutouts  90   a ,  90   b  cooperate to define an aperture that is generally the same size as the spout aperture  76  and is brought into registry with the spout aperture  76  when the support structure  12  is in its erect disposition. The periphery of the inner panel halves  62   a ,  62   b  is generally defined by an extension of the edge margin  50   a ,  50   b , respectively, side margins  92   a ,  92   b , side margins  94   a ,  94   b , and end margins  96   a ,  96   b , respectively. The two tabs  64   a  and  64   b  of the first end support section  20  are positioned generally between the front outer panel  60  and the two front inner panels  62   a ,  62   b . The tabs  64   a ,  64   b  are generally trapezoidal in shape being defined by four sides. The four sides of the tabs  64   a ,  64   b  are defined by fold lines  40   a ,  40   b , side margins  98   a ,  98   b , side margins l 00   a ,  100   b , and end margin  102   a ,  102   b , respectively. It should be noted that side margins  100   a  and l 00   b  lie substantially coincident with side margins  68   a ,  68   b  of the front outer panel  60  and are preferably formed by making a single cut separating tabs  64   a ,  64   b  from hexagonal panel  66 . 
     The third component of the support section  12  is the second end support section  22 . Second end support section  22  of the support structure  12  is preferably formed of seven individual subcomponents. The seven individual subcomponents are bottom flap  104 , ears  106   a ,  106   b , locking tabs  108   a ,  108   b , and top flaps ll 0   a ,  110   b.    
     The bottom flap  104  is formed integral with the bottom side section  26  along fold line  36   b . The bottom flap  104  has two projections  112   a ,  112   b . The projections  112   a ,  112   b  generally flank a locking cutout  114 . The locking cutout  114  is defined in part by lower margin  116 . 
     The ears  106   a ,  106   b  are generally triangular in shape and are formed integral with the first side sections  28   a ,  28   b , respectively, along the fold lines  42   a ,  42   b , respectively. 
     The locking tabs  108   a ,  108   b  are disposed generally outboard of the locking ears  106   a ,  106   b . The locking tabs  108   a ,  108   b  are formed integral with second side sections  30   a ,  30   b , respectively, along the fold lines  48   a ,  48   b , respectively. Each of the locking tabs  108   a ,  108   b  has a tab projection  118   a ,  118   b , respectively. As will be seen, the tab projections  118   a ,  118   b  play a key role in locking the second end support section  22  in the erect configuration. 
     The top flaps ll 0   a ,  110   b  are formed integral with the overlapping top side sections  32   a ,  32   b , respectively, along fold lines  54   a ,  54   b , respectively. 
     The final major component of the blank  16  of the support structure  12  is the handle  24 . The handle  24  is formed integral with the overlapping top side section  32   b  along the fold line  51 . 
     The handle  24  has two handle halves  120   a ,  120   b  that are generally mirror images of each other. The handle  24  functions as a support device when grasped by a human hand, as depicted in FIG.  1 . The handle halves  120   a ,  120   b  are joined along the fold line  121 . Each of the handle halves  120   a ,  120   b  has a finger cutout  122   a ,  122   b , respectively. Additionally, handle half  120   a  includes a cutout insert  124  disposed within the finger cutout  122   a . The cutout insert  124  is formed integral with the handle half  120   a  along fold line  126 . Cutout insert  124  is additionally defined by marginal cut  128  extending from the ends of the fold line  126  around the periphery of the finger cutout  122   a  and the cutout insert  124 . 
     The blank  16  of the support structure  12  may be cut, stacked, and shipped substantially as depicted in FIG.  3 . Preferably, the blank  16  is prefolded as depicted in FIGS. 4 and 5. The preferred folding action is depicted as arrows  1  and  2  in FIG.  4 . The overlapping top side section  32   b  disposed on the overlapping top side section  32   a  and adhered thereto by glue or other means of bonding along glue line  130 . The glue line  130  is brought into registry with strip  131  on the underside of top side section  32   a , front inner panel  62   a  and top flap  110   a . Strip  131  is depicted in phantom in FIG.  3 . 
     To erect the support structure  12  of the disposable container  10  as depicted in FIGS. 4 and 5, pressure may be applied inwardly on the fold lines  38   a  and  38   b . It should be noted that in the folded configuration of FIGS. 4 and 5, the fold lines  38   a ,  38   b  form the side margin of the folded blank  16 . Such pressure causes the center support section  18  to form a generally hexagonal shape in cross section as depicted in FIGS. 1 and 2. The first end support section  20  and the second end support section  22  may then be put in place to afford an element of rigidity to the now hexagonal center support section  18 . 
     Commencing with the second end support section  22  (as depicted in FIG.  2 ), in a preferred order, the top flap  110   a ,  110   b  is folded downward through an arc of approximately 90 degrees. It should be noted that due to the gluing along glue line  130 , the top flaps  110   a ,  110   b  are held together as a unitary structure. 
     The next step is to fold the two ears  106   a ,  106   b  inward along fold lines  42   a ,  42   b . The ears  106   a ,  106   b  are rotated through an arc of approximately 90 degrees to lie in substantially the same plane as the top flap  110   a ,  110   b.    
     The next step is to fold the bottom flap  104  upward through an arc of approximately 90 degrees such that it partially overlies the top flaps  110   a ,  110   b  in a parallel relationship thereto. 
     Finally, the locking tabs  108   a ,  108   b  are rotated inward along fold lines  48   a ,  48   b , respectively. Such rotation through an arc of approximately 90 degrees provides that a portion of the respective locking tabs  108   a ,  108   b  overlies the projections  112   a ,  112   b  of the bottom flap  104 . The tab projections  118   a ,  118   b  are then tucked in behind the lower margin  116  of the locking cutout  114  of the bottom flap  104  to create an interlocking relationship between the locking tabs  108   a ,  108   b  and the bottom flap  104 . This interlocking relationship locks the second end support section  22  in place providing a measure of rigidity to both the second end support section  22  and the center support section  18  of the blank  16 . 
     Turning to the first end support section  20  (as depicted in FIG.  1 ), erection of the first end support section  20  is accomplished first by rotating the inner panel halves  62   a ,  62   b  downward through an arc of substantially 90 degrees along the fold line  52   a ,  52   b . It should be noted that inner panel half  62   b  overlies a portion of inner panel  62   a  and is affixed thereto along the previously noted glue line  130 . In such disposition, the cutouts  90   a ,  90   b  act cooperatively to define an aperture having substantially the same shape as the spout aperture  76 . In such disposition, the end margins  96   a ,  96   b  are substantially parallel to and proximate the fold line  36   a . The tabs  64   a ,  64   b  may then be folded inward by rotating the tab  64   a ,  64   b  through a substantially 90 degree arc about the respective fold lines  40   a ,  40   b.    
     The front outer panel  60  is then rotated into place by folding the front outer panel  60  upward through an arc of substantially 90 degrees about the fold line  36   a . Prior to reaching the full upward travel of the front outer panel  60 , the tabs  72   a ,  76   b  are folded inward along fold lines  70   a ,  70   b  such that the tabs  72   a ,  72   b  frictionally engage the inner surface of the second side sections  30   a ,  30   b . The fold lines  70   a ,  70   b  are then parallel to and proximate the end margins  46   a ,  46   b  of the second side sections  30   a ,  30   b , respectively. The disposition of the front outer panel  60  with respect to the front inner panel  62   a ,  62   b  is such that the spout aperture  76  is in registry with the aperture defined by cutouts  90   a ,  90   b . It should be noted that preferably the length dimension of the top side sections  32   a ,  32   b  (taken along fold lines  44   a ,  44   b ) is greater than the length dimension of bottom side section  26  (taken along fold lines  34   a ,  34   b ). The first end support section  20  then slants rearward from the fold line  71  to the fold line  36   a  and is therefore not parallel with second end support section  22 . 
     At this point, the handle  24  is placed into its erect disposition. This is accomplished by rotating the handle  24  through an arc of approximately 90 degrees along the fold line  51 . The handle half  120   b  is then rotated downward along fold line  121  through an arc of substantially 180 degrees to lie parallel with handle  120 . At this point the finger cutouts  122   a ,  122   b  are in registry. The cutout insert  124  is then rotated through an arc of substantially 180 degrees such that the cutout insert  124  passes through the finger cutout  122   b  and lies along side the surface of the handle half  120   b . In this way, the cutout insert  124  tends to lock the handle halves  120   a ,  120   b  together. 
     Finally, the tongue  78  is folded rearward along fold line  71  to a point where the slit  84  engages the handle  24 , thereby assisting in locking the handle halves  120   a ,  120   b  together. The upper portion  80  of the tongue  78  is then bent rearward about the fold line  83  to a position substantially overlying the front portion of the handle  24 . In this disposition, the upper  80  and the lower portion  82  of the tongue  78  substantially shield the hand of a user that is grasping the handle  24  from hot liquid vapors. 
     In a preferred embodiment, the container  10  includes a liquid bladder  14 . The liquid bladder  14  of the present invention is depicted in FIGS. 6 and 6 a . Bladder  14  includes a liquid receptacle  142 . In a preferred embodiment, the liquid receptacle  142  is formed of a clear plastic material that is designed to retain and hold liquids having a temperature of up to 250 degrees F. The liquid receptacle  142  is bonded to a semi-rigid neck  144 . The neck  144  preferably has a circular cross section having a diameter that is slightly less than the diameter of the spout aperture  76 . The neck  144  terminates in a threaded mouth  146 . The threaded mouth  146  has a diameter that is greater than the diameter of the spout aperture  76 . A threaded cap  148  is provided to sealingly engage the threads of the threaded mouth  146 . 
     In an alternative embodiment of the bladder  14 , depicted in FIG. 6 a , the threaded cap  148  has a preferably integrally formed spigot  150 . The spigot is provided with a valve handle  152  for selectively opening and closing a valve (not shown) disposed within the spigot  150 . 
     In operation, after erection of the support structure  12  of the disposable container  10 , the liquid receptacle  142  of the bladder  14  is inserted through the spout aperture  76 . The neck  44  is engaged within the spout  76 . When the support structure  12  is supported on its second end support section  22 , the liquid receptacle  142  depends from the neck  144  and is supported by the periphery of the threaded mouth  146  (the mouth  146  opening generally upward). In this disposition, the threaded cap  148  may be removed from the threaded mouth  146  and liquid may be poured into the liquid receptacle  142  through the neck  144 . 
     After the liquid receptacle  142  has been substantially filled with liquid, the threaded cap  148  can be sealingly engaged with the threaded mouth  146 . The support structure  12  of the disposable container  10  may be then turned to any other disposition without fear of discharge of liquid from the bladder  14 . 
     In the alternate embodiment in which the threaded cap contains a threaded spigot  150 , the disposable container  10  may be supported on its bottom side section  26  proximate the edge of a supporting structure such that the spigot  150  projects over the edge of the supporting structure. A cup or other liquid receptacle may be then placed beneath the threaded spigot  150 . Actuation of the valve handle  152  to open the valve (not shown) will then result in the discharge of liquid from the liquid receptacle  142 . 
     It should be noted that the support structure  12  of the disposable container  10  has a plurality of uses. One such use is as a biodegradable semi-permanent birdhouse. For such use, the support structure  12  is preferably formed of a weather resistant fiberboard or plastic material. In use, the disposable container  10  is placed in a location to attract nesting birds. At the end of the nesting season, when an ordinary birdhouse must be cleaned out, the disposable container  10  is simply removed and disposed of with the accumulated nesting material inside. For such use, the cutouts  122   a ,  122   b  in the handle  24  are preferably a circular aperture through which a cord may be passed to suspend the container  10  from a tree branch or the like. 
     Those skilled in the art will recognize that there are numerous variations and modifications of this invention which are encompassed by its scope. Accordingly, the foregoing description should be considered illustrative of the invention and not deemed to limit its scope.