Abstract:
A foldable utensil set including a bowl, dish, cup and spoon each foldable from a prescored plastic sheet which is semitransparent to allow angled folds at the corner to be visible as an aesthetic feature. The rims of the bowl and cup have portions at two different levels to prevent liquid from reaching the level of the mating snaps used to secure the bowl and cup in the folded condition. The spoon is folded from a flat sheet having two contiguous sections scored so as to form a handle and bowl portion when folded. The dish has side edges stiffened with a fold over section which also holds the folds in position. Oval shaped scoring is provided as an aesthetic feature and to aid in forming corners on the utensils when being folded.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention concerns food service utensils such as bowls, cups, and dishes, which are foldable from flat sheets. Such utensils have been developed and provide the advantage of easy storability. See, for example, U.S. Publication No. 2005/10384 A1 which describes a handled cup folded from a plastic sheet cut and scored in a particular pattern. Additional similar vessels are currently sold under the ORIKASO™ trademark. While such foldable vessels have been provided, it is not believed that implements such as serving spoons have heretofore been proposed.  
         [0002]     It is the object of the present invention to provide foldable food service utensils which are of improved utility and appearance, and are easier to fold up, and have other advantages over foldable utensils heretofore provided.  
         [0003]     It is a further object of the present invention to also provide other foldable utensils such as spoons and other implements.  
       SUMMARY OF THE INVENTION  
       [0004]     The above objects and other objects which will be appreciated upon a reading of the following specification and claims are achieved by providing foldable spoons and other such implements formed from a folded sheet cut in a pattern having a generally rectangular handle section made up of several pleat folds flattened together and a contiguously connected bowl section foldable into a spoon bowl.  
         [0005]     Two longitudinal fold lines extend along the handle section and into the bowl section where they blend into curved score lines, with a third intermediate longitudinal score line terminating at the handle section.  
         [0006]     These three folds form accordion or pleated folds which can be flattened together to form an elongated handle comprised of three layers of plastic sheeting. The bowl section is defined by two upturned sides formed by score lines extending from the handle section, the two sides having curved shapes intersecting the handle section. Sets of triangular fold lines create a down sloping surface at the rear of the spoon bowl.  
         [0007]     An auxiliary handle wrap section is folded around the flattened together layers of the handle section and held in place with snaps to hold the layers together, the wrap also acting to stiffen the handle.  
         [0008]     Foldable vessels such as bowls, dishes, cups, or the like are also provided formed from semitransparent tinted sheets of plastic such as polypropylene which are cut and scored in particular patterns. The tinted semitransparent plastic sheets allow folded edges at corners of the vessels to be visible through other folded over portions of the sheeting to create an enhanced aesthetic appearance by creating interesting visual features at the corners of the vessel.  
         [0009]     The bowl and cup vessels incorporate mating snaps to hold the same in their folded state. One or more parts of the rim of the formed vessel are lower than one or more other parts of the vessel rim to prevent the liquid level in the vessel from reaching the level of the mating snaps which are located adjacent rim parts at a higher level.  
         [0010]     Pointed end oval patterns are created at folded corners by score lines which reduce the severity of the bending required to form corners and also provide an attractive visual feature to improve the overall appearance of the vessel. 
     
    
     DESCRIPTION OF THE DRAWING FIGURES  
       [0011]      FIG. 1  is a pictorial view of a foldable serving spoon according to the present invention.  
         [0012]      FIG. 1A  is a pictorial view of a partially folded serving spoon shown in  FIG. 1 .  
         [0013]      FIG. 2  is a bottom view of the serving spoon shown in  FIG. 1 .  
         [0014]      FIG. 3  is top view of the serving spoon shown in  FIGS. 1 and 2 .  
         [0015]      FIG. 4  is a right side view of the serving spoon shown in  FIGS. 1-3 , the left side view being a mirror image.  
         [0016]      FIG. 5  is a rear end view of the serving spoon shown in  FIGS. 1-4 .  
         [0017]      FIG. 6  is a front end view of the serving spoon shown in  FIGS. 1-5 .  
         [0018]      FIG. 7  is a plan view of a flat sheet cut and scored in a pattern to enable it to be folded into the serving spoon shown in  FIGS. 1-6 .  
         [0019]      FIG. 8  is a pictorial view of a foldable bowl according to the present invention.  
         [0020]      FIG. 8A  is a partially inverted and folded view of the foldable bowl shown in  FIG. 8 .  
         [0021]      FIG. 9  is an enlarged top view of the bowl shown in  FIG. 8 .  
         [0022]      FIG. 10  is an enlarged bottom view of the bowl shown in  FIGS. 8 and 9 .  
         [0023]      FIG. 11  is a right side view of the bowl shown in  FIGS. 8-10 , the left side view being identical.  
         [0024]      FIG. 12  is a front view of the bowl shown in  FIGS. 8-11 , the rear view being identical.  
         [0025]      FIG. 13  is a plan view of a flat sheet cut and scored in a pattern enabling it to be foldable into the bowl shown in  FIGS. 8-12 .  
         [0026]      FIG. 14  is a pictorial view of a foldable cup according to the present invention.  
         [0027]      FIG. 14A  is a pictorial view of the foldable cup shown in  FIG. 14 , in a partially folded condition.  
         [0028]      FIG. 15  is a top view of the cup shown in  FIG. 14 .  
         [0029]      FIG. 16  is a bottom view of the cup shown in  FIGS. 14 and 15 .  
         [0030]      FIG. 17  is a right side view of the bowl shown in  FIGS. 14-16 , the left side view being identical.  
         [0031]      FIG. 18  is a front view of the bowl shown in  FIGS. 14-17 , the rear view being identical.  
         [0032]      FIG. 19  is a plan view of a sheet cut and scored in a pattern enabling it to be foldable into the cup shown in  FIGS. 14-18 .  
         [0033]      FIG. 20  is a pictorial view of a foldable dish according to the present invention.  
         [0034]      FIG. 21  is a top view of the dish shown in  FIG. 20 .  
         [0035]      FIG. 22  is a bottom view of the dish shown in  FIGS. 20 and 21 .  
         [0036]      FIG. 23  is a right side view of the dish shown in  FIGS. 20-22 , the left side view being identical.  
         [0037]      FIG. 24  is a front view of the dish shown in  FIGS. 20-23 , the rear view being identical.  
         [0038]      FIG. 25  is a plan view of a sheet cut and scored in a pattern enabling it to be foldable into the dish shown in  FIGS. 20-24 .  
         [0039]      FIG. 26  is a plan view of a sheet cut and scored in a pattern enabling it to be foldable into a fork.  
         [0040]      FIG. 27  is a plan view of a sheet cut and scored in a pattern enabling it to be foldable into a combined spoon and fork.  
         [0041]      FIG. 28  is a plan view of a sheet cut and scored in a pattern enabling it to be foldable into a dipper or Chinese type spoon.  
         [0042]      FIG. 29  is a plan view of a sheet cut and scored in a pattern enabling it to be foldable into a brush.  
         [0043]      FIG. 30  is a plan view of a sheet cut and scored in a pattern enabling it to be foldable into a short handled scoop or beach shovel. 
     
    
     DETAILED DESCRIPTION  
       [0044]     In the following detailed description, certain specific terminology will be employed for the sake of clarity and a particular embodiment described in accordance with the requirements of  35  USC 112, but it is to be understood that the same is not intended to be limiting and should not be so construed inasmuch as the invention is capable of taking many forms and variations within the scope of the appended claims.  
         [0045]     Referring to the drawings, and particularly  FIGS. 1-7 , a foldable serving spoon  10  is shown, including a handle  12  at one end and spoon bowl  14  at the other.  
         [0046]     The spoon  10  is formed from a flat sheet  16  which is cut and scored in the pattern shown in  FIG. 7  enabling it to be folded into the spoon  10 .  
         [0047]     The sheet  16  is of a suitable plastic such as a food contact grade of polypropylene 0.6 mm thick which has been die cut and scored in the pattern shown in  FIG. 7  so as to create a series of fold lines arranged to enable the sheet  16  to be readily foldable into the spoon  10  shown in  FIGS. 1-6 . The scoring is preferably done with a heated die edge at the time that the sheet is being die cut in a manner known in the art.  
         [0048]     The cut pattern produces a generally rectangular section  18  and an integral section  20  having a rounded end projecting from one side of the bottom part A of the section  18 .  
         [0049]     The scoring pattern includes a first series of equally spaced parallel fold lines  22  extending from side-to-side across the lower part of the first section  18 . Rounded corners  24  may be provided at the right side of the rectangles formed by the lines  22 .  
         [0050]     The upper part B of the section  18  is also scored with a series of lengthwise parallel fold lines  26 , two of the lines  26 - 1 ,  26 - 2  relatively closely spaced and two others  26 - 3 ,  26 - 4  even more closely spaced.  
         [0051]     Two male snaps  28  are affixed at either end of the lower part A and two female snaps  30  are mounted at either end of the upper part B for a purpose described below.  
         [0052]     The projecting section  20  has opposite straight sides  32  at a part contiguous to the first section  18  which extend to curved sides  34  converging together at a rounded tip  36 .  
         [0053]     The rounded end section  20  has a pattern of score lines including a pair of straight lines  38  extending in alignment from two outboard score lines  22 - 1  and  22 - 3  of the section  18  for a portion of the length of section  20 .  
         [0054]     A pair of second fold lines  40  diverge from a point X at the left end of the centered fold line  22 - 2  of the section  18  to a point Y intersecting one of the straight lines  38 . A slight curved line  42  connects the points Y forming a centered triangle  44  with a curved base.  
         [0055]     A pair of straight lines  46  angle out from each point Y to intersect straight side  32  at a backward slanting angle.  
         [0056]     Also emanating towards the rounded point  36  from each point Y are respective curved pairs of fold lines  48  forming narrow pointed end ovals  50 .  
         [0057]     To form the spoon  10 , the sheet  16  is first inverted from the position shown in  FIG. 7 .  
         [0058]     The lines  21 - 1 ,  2 - 3  are pleated accordion style to raise the center fold line  22 - 2  and fold down the adjacent areas W, bringing up the two side areas V as seen in  FIG. 7A . This creates a central ridge with the point X elevated. A cross score line  39  extending across all of the areas W and V allows the areas U and T to be angled out from the areas V and W when those areas are flattened together to form the handle  12 . This creates the outwardly flaring rear part of the bowl section  14 , the triangle  44  sloping down the middle of the bowl section. The folding of these areas causes the triangle  44  to slope down and the side areas U brought up to be alongside the areas T adjacent the triangle  44 .  
         [0059]     The areas V and W are flattened together to create a bar like handle  12  capable of resisting bending if spoon bowl  14  is loaded to as to be capable of effectively functioning as a handle.  
         [0060]     In order to keep the layers of the handle  12  flattened together, the upper Section B is wrapped around these flattened layers, area “Q” folded over the sides and areas “P” over the thickness of the handle. Snaps  30  and  28  are mated together to maintain the handle layers flattened together.  
         [0061]     The side areas S are also brought up to form spoon bowl sides, together with side areas U, sloping down to the rounded tip  36 . The two oval areas  50  form an angled transition of these sides adjacent to a bottom area R of the spoon bowl  14 .  
         [0062]      FIGS. 8-13  show a foldable vessel comprised of a bowl  52 . This general type of fold up vessel is known in the carryout Chinese restaurant trade, with flat sheets of treated paperboard pre-creased to facilitate fold-up.  
         [0063]     The foldable bowl  50  is formed from a flat sheet  54  of plastic preferably polypropylene of slightly greater thickness than the spoon, i.e. 0.8 mm.  
         [0064]     The sheet  34  has a perimeter edge  56  defining a multisided shape, such as the square shown. A series of scored fold lines  58  form a closed shape (i.e., a square, although a triangle and other shapes are also possible) here having sides corresponding to those of the perimeter edge  56 , and associated in the same way so that the sides of the square extend in the same general direction as a corresponding side of the perimeter edge  56 .  
         [0065]     Pairs of diverging fold lines  60 ,  62  emanate from each corner of the closed shape and extend to the perimeter edge, forming triangular areas B. Two pairs of opposite side areas C and D are thus left between triangular areas B.  
         [0066]     A male snap  64  is fixed at each corner of each side area C and D. A hole  68  is punched into the sheet  54  at the top of each triangular area B located so that when the area B is folded along side D onto the outside of the side by folding along lines  60 ,  62 , the male snap can engage a mating female snap through the aligned hole  64 .  
         [0067]     According to one feature of the present invention the perimeter edge  56 C of the sides C forming a part of the bowl rim are curved outwardly while the edges  56 D of sides D forming the remainder of the bowl rim are straight across. The snaps  66 ,  68  are located adjacent the outwardly curved edge.  
         [0068]     The edge at the upper corners of the sides D is also slightly curved to be a match to the curve of the edge of the area B.  
         [0069]     When the sides C and D are folded up, a triangular pleat is formed by areas B and the overlying area of the sides D, the pleat  70  overlying the sides C, allowing the snaps  66 ,  68  to be mated.  
         [0070]     In this position, the curved edges  56 C form a higher rim part than the lowest point X of straight edges  56 D which form a lower dipping curved rim part. This configuration prevents over filling of the bowl  52  to the point where the liquid level would reach that of the mating snaps  66 , as well as enhancing the appearance of the bowl  52 .  
         [0071]     The plastic sheet  54  is semitransparent which adds a distinct aesthetic effect since the inner edge of the pleats  70  defined by the fold line  62  becomes visible through overlying portions of the sheet, combining with the outer edge defined by the fold line  60 , which becomes visible from the inside. Thus, an attractive design feature is created to make the appearance of the folded vessel significantly more pleasing.  
         [0072]     Referring to  FIGS. 14-19 , a foldable cup  74  is shown which has some similarities to the bowl  52  described above. That is, a flat sheet of a plastic  76  has a central closed shape (here, a square) formed by a series of fold lines  78 . In order to create walls steeper than the bowl  52  so as to be suitable for a cup, two triangular areas B- 1 , B- 2  are formed at each of the corners with narrower sides C, D than the bowl. A pair of fold lines  80  combine with elongated ovals  84  to form triangular areas B- 1  which create a rounded corner  86  at the intersection of flaps  80  with sides C and D. The ovals  84  reduce the bending stress at the corners as well as presenting a pleasing visual feature.  
         [0073]     The flaps  88  are large enough to overlap as seen in  FIGS. 14, 17  so that a single set of snaps  90 ,  92  can hold both flaps  88  on each side, passing through two holes  94  in one corner of the flaps  88  and a hole  96  on one side of the other flaps  88 .  
         [0074]     The top edge  98  of each side C are curved down while the top edges  100  of the sides D and  102  of flaps  88  are curved up to keep the maximum level of liquid below the snaps  90 ,  92  in similar fashion to the bowl  52 .  
         [0075]     Referring to  FIGS. 20-25 , a foldable dish  104  is shown of a rectangular configuration with a pair of low, substantially vertical side walls  106  and end walls  108 . The foldable dish  104  is formed by folding a flat plastic sheet  110  of a general rectangular shape, preferably food contact grade polypropylene, 0.8 mm thick as in the bowl and cup described above.  
         [0076]     A generally rectangular bottom area “A” is formed by a pair of scored fold lines  112  defining the long side of the dish  104 , and two pairs of shallowly curved fold lines  114  forming pointed end oval areas “B”. The sides  106  are formed by rectangular areas C outside the fold lines  112  while ends  103  are formed by rectangular areas D outside fold line pairs  114 .  
         [0077]     A pair of triangular areas E, F are formed by extensions of fold lines  112  and angled fold lines  116  extending out from the corners where the sides  106  and ends  108  abut.  
         [0078]     Flap strips  120  are formed by closely spaced double fold lines  118  defining the upper edge of the sides.  
         [0079]     Holes  122  are formed in each of the triangular areas E, F which become aligned when the sides  112  and ends  108  are folded up and triangular areas are folded together to project outwardly forming a triangular flap  124 . The triangular flaps  124  are wrapped over the outside of the sidewalls  106  ( FIGS. 28, 29 ).  
         [0080]     The rectangular flaps  120  are then folded out and over the triangular flaps  124  and the sides  106  ( FIGS. 20, 23 ). Male snaps  126  and now aligned female snaps  128  are snapped together through more aligned holes  122  in the triangular flaps  124  to secure the folded condition of the dish  104 .  
         [0081]     The rectangular flaps  120  serve to stiffen the longer sides  108 .  
         [0082]     The semitransparent plastic allows viewing of the triangular flaps  124  through the rectangular flaps  120  and sides  106  as seen in  FIG. 20 , adding a pleasing visual effect as described above.  
         [0083]     It will be appreciated that the various foldable utensils in the set can be varied in size and proportions.  
         [0084]      FIGS. 26-30  are variations of the foldable handled utensil described in  FIGS. 1-7A .  
         [0085]     In  FIG. 26 , lines  128  are formed on the leading edge of the bowl  130  to provide a foldable fork from a flat sheet.  
         [0086]     In  FIG. 27 , shorter serrations  132  provide a “spork” or combined spoon and fork  134 .  
         [0087]     In  FIG. 28 a  Chinese spoon or dipper  136  is provided by eliminating some of the fold lines to create a deeper bowl  138 .  
         [0088]      FIG. 29  shows a foldable brush  140  formed by providing a series of bristles  142  projecting from a handle section.  
         [0089]      FIG. 30  shows a large scoop or beach shovel  144  having a large bowl  146  and a proportionately shorter handle  148 .