U.S. patent application number 10/191671 was filed with the patent office on 2004-01-08 for insulated water-tight container.
Invention is credited to Cardinale, Salvatore J..
Application Number | 20040004111 10/191671 |
Document ID | / |
Family ID | 29999997 |
Filed Date | 2004-01-08 |
United States Patent
Application |
20040004111 |
Kind Code |
A1 |
Cardinale, Salvatore J. |
January 8, 2004 |
Insulated water-tight container
Abstract
An insulated container for shipping, transporting, or storing
warm or cold items is disclosed, useful for maintaining temperature
of items stored or shipped within the container, the container
assembly consisting of at least one layer of rigid or semi-rigid
material, and at least one layer of flexible, thermally insulating,
water-resistant material, in the form of a pouch, which pouch is
secured to the rigid material at areas which allow easy
reconfiguration of the container to form a finished container
having desirable insulating and water-resistant
characteristics.
Inventors: |
Cardinale, Salvatore J.;
(Mill Valley, CA) |
Correspondence
Address: |
Thomas W. Cook
Thomas Cook Intellectual Property Attorneys
3030 Bridgeway, Suite 425
P.O. Box 1989
Sausalito
CA
94965
US
|
Family ID: |
29999997 |
Appl. No.: |
10/191671 |
Filed: |
July 8, 2002 |
Current U.S.
Class: |
229/117.32 ;
206/594; 229/103.11 |
Current CPC
Class: |
B65D 5/10 20130101; B65D
5/0227 20130101; B65D 81/3823 20130101; B65D 5/3628 20130101; B65D
5/606 20130101 |
Class at
Publication: |
229/117.32 ;
206/594; 229/103.11 |
International
Class: |
B65D 005/56 |
Claims
What is claimed is:
1. A water-resistant container, comprising: a container having a
first folding sidewall and a second folding sidewall, the first and
second folding sidewalls being opposing container sidewalls, the
first and second folding sidewalls each having two opposing edges
creating widths, the first and second folding sidewalls having fold
lines approximately midway between their opposing edges, the fold
lines running approximately from the top of each of the first and
second folding sidewalls to the bottom of each of the first and
second folding walls, the container having a first non-folding
sidewall and a second non-folding sidewall, the first and second
non-folding sidewalls being opposing container walls, the first and
second folding sidewalls affixed at two of their edges to two edges
of the first and second non-folding sidewalls to form a tubular
section, the tubular section having a top end and a bottom end, the
first end of the tubular section having a plurality of flaps
attached thereto, the second end of the tubular section having a
plurality of flaps attached thereto, the first and second folding
sidewalls and the first and second non-folding sidewalls having
interior surfaces facing the interior of the tubular section and
exterior surfaces facing the exterior of the tubular section, the
intersection of the edges of the first and second folding sidewalls
with the edges of the first and second non-folding sidewalls
creating corners of the container, the first and second non-folding
sidewalls having areas near the corners of the container, on the
interior surfaces of the non-folding sidewalls, for attachment
means, and a pouch having an interior, a first exterior side, a
second exterior side, a bottom edge, a right edge, a left edge, a
plurality of top edges forming a top opening, the pouch being
formed from a flexible and water-resistant material, the pouch
residing within the tubular section of the container, the right
edge of the pouch residing near the fold line of the first folding
sidewall and the left edge of the pouch residing near the fold line
of the second folding sidewall, the top edges of the pouch
extending from the top end of the tubular section at least a
distance equal to one-half the width of the folding sidewalls, the
bottom edge of the pouch extending from the bottom end of the
tubular section at least a distance equal to one-half the width of
the folding sidewalls.
2. The water-resistant container of claim 1, further comprising
means for attaching the first exterior side of the pouch to the
attachment areas of the first non-folding sidewall, and means for
attaching the second exterior side of the pouch to the attachment
areas of the second non-folding sidewall.
3. The water-resistant container of claim 2, wherein the flexible
and water-resistant material is also thermally insulative.
4. The water-resistant container of claim 3, wherein the flexible,
water-resistant, and thermally insulative material comprises at
least one layer of material having bubbles of gas entrapped
therein.
5. The water-resistant container of claim 4, wherein the flexible,
water-resistant, and thermally insulative material further
comprises at least one layer of reflective material.
6. The water-resistant container of claim 5, wherein the means for
attaching the pouch to the interior surfaces of the walls of the
outer container comprises an adhesive.
7. The water-resistant container of claim 6, wherein the means for
attaching the pouch to the interior surfaces of the walls of the
outer container comprises a releasable adhesive.
8. The water-resistant container of claim 7, further comprising
means for sealing the pouch top opening.
9. The water-resistant container of claim 1, wherein the flexible
and water-resistant material is also thermally insulative.
10. The water-resistant container of claim 9, wherein the flexible,
water-resistant, and thermally insulative material comprises at
least one layer of material having bubbles of gas entrapped
therein.
11. The water-resistant container of claim 10, wherein the
flexible, water-resistant, and thermally insulative material
further comprises at least one layer of reflective material.
12. A thermally insulative container, comprising: a container
having a first folding sidewall and a second folding sidewall, the
first and second folding sidewalls being opposing container
sidewalls, the first and second folding sidewalls each having two
opposing edges creating widths, the first and second folding
sidewalls having fold lines approximately midway between their
opposing edges, the fold lines running approximately from the top
of each of the first and second folding sidewalls to the bottom of
each of the first and second folding walls, the container having a
first non-folding sidewall and a second non-folding sidewall, the
first and second non-folding sidewalls being opposing container
walls, the first and second folding sidewalls affixed at two of
their edges to two edges of the first and second non-folding
sidewalls to form a tubular section, the tubular section having a
top end and a bottom end, the first end of the tubular section
having a plurality of flaps attached thereto, the second end of the
tubular section having a plurality of flaps attached thereto, the
first and second folding sidewalls and the first and second
non-folding sidewalls having interior surfaces facing the interior
of the tubular section and exterior surfaces facing the exterior of
the tubular section, the intersection of the edges of the first and
second folding sidewalls with the edges of the first and second
non-folding sidewalls creating corners of the container, the first
and second non-folding sidewalls having areas near the corners of
the container, on the interior surfaces of the non-folding
sidewalls, for attachment means, and a pouch having an interior, a
first exterior side, a second exterior side, a bottom edge, a right
edge, a left edge, a plurality of top edges forming a top opening,
the pouch being formed from a flexible and thermally insulative
material, the pouch residing within the tubular section of the
container, the right edge of the pouch residing near the fold line
of the first folding sidewall and the left edge of the pouch
residing near the fold line of the second folding sidewall, the top
edges of the pouch extending from the top end of the tubular
section at least a distance equal to one-half the width of the
folding sidewalls, the bottom edge of the pouch extending from the
bottom end of the tubular section at least a distance equal to
one-half the width of the folding sidewalls.
13. The water-resistant container of claim 12, further comprising
means for attaching the first exterior side of the pouch to the
attachment areas of the first non-folding sidewall, and means for
attaching the second exterior side of the pouch to the attachment
areas of the second non-folding sidewall.
14. The thermally insulative container of claim 13, wherein the
flexible and water-resistant material is also water tight.
15. The thermally insulative container of claim 14, wherein the
flexible, water-resistant, and thermally insulative material
comprises at least one layer of material having bubbles of gas
entrapped therein.
16. The thermally insulative container of claim 15, wherein the
flexible, water-resistant, and thermally insulative material
further comprises at least one layer of reflective material.
17. The thermally insulative container of claim 16, wherein the
means for attaching the pouch to the interior surfaces of the walls
of the outer container comprises an adhesive.
18. The thermally insulative container of claim 17, wherein the
means for attaching the pouch to the interior surfaces of the walls
of the outer container comprises a releasable adhesive.
19. The thermally insulative container of claim 18, further
comprising means for sealing the pouch top opening.
20. The thermally insulative container of claim 12, wherein the
flexible and water-resistant material is also thermally
insulative.
21. The thermally insulative container of claim 13, wherein the
flexible, water-resistant, and thermally insulative material
comprises at least one layer of material having bubbles of gas
entrapped therein.
22. The thermally insulative container of claim 14, wherein the
flexible, water-resistant, and thermally insulative material
further comprises at least one layer of reflective material.
23. A method of making a water-tight container comprising the steps
of: taking a flat blank for a tubular assembly, the blank having,
in order, a first side panel, a second side panel, a third side
panel, and a fourth side panel, the blank having a plurality of
fold lines between the first, second, third, and fourth side
panels, the blank having bottom flaps along its bottom edge for
forming a bottom closure, and top flaps along its top edge for
forming a top closure, taking a length of plastic sheet material in
lay flat tubular form, the plastic sheet material having a first
side and a second side, and a first edge and a second edge, the
plastic sheet material being sealed at one end and open at the
other end, the plastic sheet material having a lay flat width
approximately equal to one-half the combined width of the side
panels of the flat blank, securing a first attachment means to the
second side panel of the blank, securing a second attachment means
to the fourth side panel of the blank, laying the plastic sheet
material on the flat blank with the width of the plastic sheet
material extending across the width of the second side panel, the
plastic sheet material also extending across approximately one-half
the width of the first side panel and across approximately one-half
the width of the third side, thereby attaching the plastic sheet
material to the first attachment means of the blank, the sealed end
of the plastic sheet material positioned generally near the ends of
the bottom flaps of the blank, the open end of the plastic sheet
material positioned generally near the ends of the top flaps of the
blank, thereby attaching the first side of the plastic sheet
material to the first attachment means of the blank in such
position, folding approximately one-half the width of the first
side panel across the plastic sheet material, folding approximately
one-half the width of the third side panel, and the fourth panel,
across the plastic sheet material, so that a first free edge of the
folded first side panel approximately meets a second free edge of
the fourth side panel, thereby attaching the second side of the
plastic sheet material to the second attachment means, and securing
the first free edge of the folded first side panel to the second
free edge of the fourth side panel, thereby forming a tubular
folded container assembly with the plastic sheet material adhered
to the inside of the tubular assembly along the first and second
attachment means.
24. method of making a water-tight container of claim 23, further
comprising the steps of expanding the tubular folded container
assembly to create a volume therewithin, and then folding the
bottom flaps to form a bottom for the expanded container
assembly.
25. The method of making a water-tight container of claim 24,
further comprising the step of closing the open end of the plastic
sheet material to form a water-tight pouch.
26. A method of making a water-tight container comprising the steps
of: taking a flat blank for a tubular assembly, the blank having,
in order, a first side panel, a second side panel, a third side
panel, and a fourth side panel, the blank having a plurality of
fold lines between the first, second, third, and fourth side
panels, the blank having bottom flaps along its bottom edge for
forming a bottom closure, and top flaps along its top edge for
forming a top closure, taking a length of plastic sheet material in
lay flat tubular form, the plastic sheet material having a first
side and a second side, and a first edge and a second edge, the
plastic sheet material being sealed at one end and open at the
other end, the plastic sheet material having a lay flat width
approximately equal to one-half the combined width of the side
panels of the flat blank, laying the plastic sheet material on the
flat blank with the width of the plastic sheet material extending
across the width of the second side panel, the plastic sheet
material also extending across approximately one-half the width of
the first side panel and across approximately one-half the width of
the third side, the sealed end of the plastic sheet material
positioned generally near the ends of the bottom flaps of the
blank, the open end of the plastic sheet material positioned
generally near the ends of the top flaps of the blank, folding
approximately one-half the width of the first side panel across the
plastic sheet material, folding approximately one-half the width of
the third side panel, and the fourth panel, across the plastic
sheet material, so that a first free edge of the folded first side
panel approximately meets a second free edge of the fourth side
panel, and securing the first free edge of the folded first side
panel to the second free edge of the fourth side panel, thereby
forming a tubular folded container assembly with the plastic sheet
material residing within the tubular assembly.
27. method of making a water-tight container of claim 26, further
comprising the steps of expanding the tubular folded container
assembly to create a volume therewithin, and then folding the
bottom flaps to form a bottom for the expanded container
assembly.
28. The method of making a water-tight container of claim 27,
further comprising the step of closing the open end of the plastic
sheet material to form a water-tight pouch.
Description
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to an insulated container for
shipping, transporting, or storing warm or cold items. More
particularly, the present invention relates to a new thermally
insulated container assembly, which assembly is water-tight and
thermally protective of its contents, as well as insulated, so that
container contents may be maintained at constant temperature, while
fluids or solids associated with the contents, if any, may be
retained within the container during storage or shipment. The
container assembly utilizes a layer of rigid or semi-rigid
material, and at least one layer of flexible, thermally insulating,
reflective, water-tight material, in the form of a pouch or pocket,
fastened to the rigid material in such fashion as to allow easy and
inexpensive manufacture, and compact storage in a "knock down,"
substantially flat, configuration. When desired, a user may quickly
and conveniently manipulate the knock down assembly to create a
volume within the container, thereby forming a finished container
having desirable insulating and water-resistant characteristics in
which the user may keep or store warm or cold items with their
associated fluids.
BACKGROUND ART OF THE INVENTION
[0002] In many insulated containers, rigid materials are combined
with insulating materials to form containers having insulating
properties. By use of such containers, product suppliers may ship
perishable products refrigerated or at room temperature, live or
frozen, to customers while controlling the environment in which the
perishable products are placed, or while simply extending the
useful life of such products before they spoil. Examples of such
uses for containers used in shipping include the shipment of fresh
fish, in which a customer has requested that the product not be
frozen, fresh flowers, around which a cool and moist environment
should be maintained, and frozen tissues for research. With all
such products, maintenance of constant or low temperature will help
preserve freshness and quality of the products. Maintenance of
constant or low temperature will also extend the useful life of the
products, and often thereby increase the distance over which such
products may be shipped, as extending the time during which a
product is preserved extends the time for shipment during which
such product may reach its destination. In other insulated
containers of this same general description, the usefulness of the
container is in preserving the temperature of foods or beverages
used in picnics, family outings, ball games, and other recreational
activities.
[0003] Containers of these types which have been successfully
employed for these purposes include insulated containers made from
cardboard and individual pieces of insulating material, such as
Styrofoam or other lightweight foam type insulation. These types of
containers are often constructed by gluing individual pieces of
insulating foam material to the interior surfaces of a cardboard
container, which is formed as a box, or by inserting separate foam
pieces to insulate each container surface. While these containers
offer advantageous high thermal resistance, cutting and gluing
pieces of foam to construct the finished container requires
substantial assembly time, with the result that containers formed
in this way are expensive to assemble, and are not water tight.
[0004] Similar containers include insulated containers made of
plastic foam, typically expanded polystyrene, formed in a mold to
the desired shape. In some cases, additional corrugated pieces may
be used to provide additional structural support. While this type
of container also offers high thermal resistance and, in addition,
ease of assembly, the resulting container is rigidly set in its
final form at the time of manufacture. As a result, this type of
container requires substantial floor space and volume to store and
transport prior to, during, and after use. Moreover, expanded
polystyrene is generally considered to have a high impact on the
environment as undesirable byproducts are released upon its
manufacture and disposal. In addition, polystyrene decomposes
slowly, and, due to its airy and bulky nature, it occupies a large
volume in land-fill disposal sites.
[0005] Another type of container generally suited for shipment of
perishable products consists of generally rigid walls made of
corrugated cardboard or other suitable material, to which is bonded
a flexible, sealable, insulative material having bubbles of gas
entrapped therein to provide thermal insulation. One form of such
material is commonly referred to as "bubble wrap," however rubber
or plastic foam or other material having the characteristics
described herein may be employed in the present invention. The
flexible material may have a reflective surface, or an additional
layer of flexible reflective material, attached to the rigid walls
or flexible, sealable, insulative material, to increase thermally
resistant efficiency. While this type of container is well suited
to some applications, and has distinct advantages over other types
of insulated containers, the containers of this type appearing in
prior art, with the exception of one disclosed in a prior patent to
this inventor, do not allow for easy assembly by a user, with
resulting savings in time and costs. Nor, generally, are such
containers in the prior art water-tight for retention of fluids,
such as runoff from melting ice, associated with the products
shipped.
[0006] Finally, various apparatus and methods have been used in
container construction to preserve the contents within the
container from breakage or degradation due to mechanical shock
experienced while moving the container. Such apparatus and methods
include utilization of elastomeric sheets secured to the interior
of a hard-case carton, combinations of foam bodies and air sacs
placed within the container, and various inflatable mats, tubes,
envelopes, and flaps. However, such apparatus and methods do not
exhibit a knock-down, hard-shell, exterior, and a pre-located and
secured, interior pouch, thereby simultaneously also exhibiting
water-tight, thermally-insulative, and shock-absorbing
properties.
[0007] It may be appreciated, in light of the foregoing discussion,
that there is a need for an environmentally friendly, affordable,
insulated container, suitable for shipping perishable products, and
suitable for providing convenient temperature control, where the
container is easy to manufacture, thermally resistant, watertight,
resistant to mechanical shock, lightweight, compact prior to
assembly, and easy to assemble by a user. The present invention is
directed precisely to such useful characteristics.
[0008] A number of schemes have been devised to accomplish one or
more of the goals set forth above. These schemes include
single-piece and multi-part containers of cardboard, foam, and
plastic flexible, sealable, insulative material materials. Various
designs and configurations for such apparatus include:
[0009] U.S. Pat. No. 3,772,712 to Renn et al., which discloses a
bag, the lower portion of which is secured within the lower portion
of a container.
[0010] U.S. Pat. No. 3,952,940 to Malcolm, which discloses a
container for liquids formed of a paperboard carton and an inner
tubular liner of flexible plastic film adhered to portions of the
walls of the carton.
[0011] U.S. Pat. No. 3,957,195 to Lin, which discloses a container
assembly composed of a plastic bag and a hollow paper body.
[0012] U.S. Pat. No. 4,030,603 to Angell, which discloses a method
for packaging fragile articles in which such articles are held by
heat treat-shrink wrap within a frame and hard container.
[0013] U.S. Pat. No. 4,194,439 to Zimmermann, which discloses a
method for making a folded lined paperboard container and liquid
proof liner having an automatic bottom which locks in a set-up
position when the container is manipulated from a flat knock-down
condition to a set-up position.
[0014] U.S. Pat. No. 4,235,065 to Freeman, which discloses a method
for packaging fragile-articles in which an expandible tube is
layered between such articles, and then filled with gas and closed
with a valve, thereby occupying space withing a container.
[0015] U.S. Pat. No. 4,262,801 to Avery, which discloses an
apparatus having flexible and outer container bodies having
inflatable chambers which hold articles placed there between.
[0016] U.S. Pat. No. 4,284,205 to Hirata, which discloses a pouch
inserted in a cylindrical-shell to create a foldable cup.
[0017] U.S. Pat. No. 4,573,202 to Lee, which discloses an apparatus
having an outer shell and an inner inflatable envelope.
[0018] U.S. Pat. No. 4,660,737 to Green et al., which discloses a
packaging container formed of a flexible pouch inserted in a
closely form-fitting relationship with an outer rigid carton.
[0019] U.S. Pat. No. 4,854,474 to Murray et al., which discloses a
collapsible, self-standing, liquid-tight drinking cup formed of a
plastic film liner secured to the inner surfaces of foldably
interconnected paper-board panels.
[0020] U.S. Pat. No. 4,889,252 to Rockom et al., which discloses an
insulated container formed of corrugated paperboard and a layer of
flexible material having air bubbles and foil.
[0021] U.S. Pat. No. 5,009,326 to Reaves et al., which discloses an
insulated multi-part container of corrugated cardboard, folded and
stapled to form an enclosure, with one-piece insulated liner.
[0022] U.S. Pat. No. 5,638,978 to Cadiente, which discloses an
insulated waterproof container for the shipment of produce.
[0023] U.S. Pat. No. 6,296,134 to Cardinale, which discloses an
insulated water-tight container consisting of at least one layer of
rigid or semi-rigid material, and at least one layer of flexible,
thermally insulating, water-resistant material, in the form of a
pouch secured to the rigid material.
[0024] In the above-noted inventions, and in other prior art,
cardboard, when formed into a box, is a popular material in the
shipping industry because it is inexpensive and relatively light
weight when compared to its strength. As a result, insulated
containers composed in part of cardboard or paperboard help
minimize shipping costs. However, cardboard alone is not suitable
in those applications in which temperature should be maintained
within the container, and it is not suitable in those applications
where the contents of the container is a fluid, such as water, or
where fluid is important to preserving the contents. Prior efforts
at achieving a suitable container for such purposes have therefore
focused on configurations and materials which have desirable
characteristics when used in combination with cardboard, or which
have both rigidity and such characteristics when used without
cardboard.
[0025] As a result, various inventions of the prior art, such as
those of the above-noted patents, employ combinations of various
insulating materials, whether rigid or flexible, and water-tight or
water-resistant layers or barriers. A variety of insulating and
water-resistant effects may be achieved where these materials are
combined and formed as directed by prior art. Thus, good insulative
properties are achieved by containers utilizing preformed foam,
however preformed foam does not allow compact storage, while foam
sheets require expensive assembly and cannot achieve
water-tightness. In the alternative, cardboard with flexible
plastic bubble sheets may be easy to manufacture, however most such
arrangements are not water-tight, or are time consuming for a user
to assemble if stored and shipped in compact, "knock down" form. In
addition, the construction of such arrangements are somewhat
expensive because multiple sheets are required.
[0026] The present invention is directed to combining these
desirable features to achieve an insulated container suitable for
shipment or storage of a wide variety of products in the same
container, notably perishable products. Accordingly, a single,
low-cost container, may be utilized for wide variety of purposes,
and at the same time have those characteristics which make the
container widely available, quickly assembled, and easily employed.
While the devices disclosed in prior patents fulfill their
respective objectives, prior patents and inventions do not describe
or suggest an insulated, water-tight shipping container, easy and
inexpensive to manufacture, compact in storage and shipment, and
quickly reformed by a user to produce the final container having
the desirable characteristics mentioned herein.
DISCLOSURE OF INVENTION
SUMMARY OF THE INVENTION
[0027] An insulated container utilizing corrugated cardboard or
paperboard to achieve structural rigidity consists in its simplest
form of the cardboard, an insulating material, and perhaps a means
for resisting the transmission of fluids or vapors through the
cardboard. The insulating material is typically fastened to the
cardboard, or simply placed within the cardboard carton after the
cardboard is formed into an open box. The means for containing
fluids or vapors, if present, may be placed inside the insulating
material, or between the insulating material and the cardboard.
Padding or Styrofoam "peanuts" are often also used to cushion the
contents of the container against mechanical shock, and such
protective systems may be employed with insulating and
water-resistant materials in appropriate applications.
[0028] The present invention provides a new assembly, easy and
inexpensive to manufacture, and compact in its folded "knock down"
configuration, in which configuration the assembly may be stored or
shipped while occupying a minimum of space. The present invention
is an assembly easy for a user to quickly reconfigure into a
insulated and water-tight container, which container is suitable
for storing or shipping products requiring a controlled
temperature, and which container may also hold fluids and vapor
found with the other contents of the container.
[0029] In one preferred embodiment of the present invention, an
insulated container assembly is comprised of a rigid or semi-rigid
outer container or box, and a one-piece insulated liner in the form
of a bag or pouch. The outer container may be composed of
corrugated cardboard, paperboard, plastic, or other material having
sufficient structural rigidity and strength to satisfy the
application at hand. Accordingly, corrugated cardboard is the
likely material of choice for an insulated container designed to
ship cut flowers, and for many other applications, while colored
plastic might be more suitable to, and therefore chosen for, a
picnic basket or sporting event beverage cooler application.
[0030] The outer container generally will include four sidewalls, a
top and a bottom, or flaps which form a top and a bottom when
folded over the opening at the end of the container formed by the
four sidewalls. The top or flaps are generally appended to the
rigid or semi-rigid sidewalls of the container or, preferably,
formed integrally with such side walls in a single die-cut "blank."
If the container is formed in such a single blank, the blank is
then folded along preset fold lines to form the sidewalls, and at
least two opposing edges of the blank are secured to one another
with adhesive to form a tubular section of sidewalls, with closure
flaps extending from each end of the tubular section. The top and
bottom flaps may consist of a single flap at each side of the
blank, or more than one flap at each side of the blank, so that one
or more flaps are available for closure at the end of the tubular
section when the sidewalls and tubular section are formed from the
blank upon its folding. In the alternative, the blank may be cut
without end flaps at one end, and separate top lid closure
separately cut and supplied to the user along with the side wall
tubular section. The bottom flap or flaps (depending on the number
of flaps utilized to close the bottom end of the tubular section)
are affixed so as to form part of the bottom closure. Thus, for
instance, where a single flap is used to bridge the bottom opening
of the tubular section, an area along its edge is attached to the
opposing side of the tubular section. Where two flaps are used to
bridge the bottom opening, the flaps are attached to each other. In
each case, at least two additional flaps affixed to adjacent sides
of the tubular section are desirable to complete the closure at the
bottom of the tubular section.
[0031] The general nature of the invention being thus explained, it
may be appreciated that confusion may arise in terminology as the
details of the blank are described, along with the method of
construction resulting in a finished container ready for use. To
avoid such confusion, the following terminology will be used:
[0032] The four portions of the die-cut blank which may be bounded
on their sides by fold or score lines (or an edge of the blank)
when the blank is in lay flat form, which portions bear flaps and
may be folded to create a tubular form, will be referred to as
"side panels." The same four portions of the blank when folded,
whether before or after expansion of the container, will be
referred to as "sidewalls." The exception to this terminology is
with reference to two of the opposing side panels among these four
side panels, which opposing side panels are intended to bend to
allow the container to expand and collapse when in use, and so
have, as set forth more fully below, additional fold or score
lines. These opposing side panels may also be referred to as
"folding side panels" and the corresponding sidewalls in the
expanded container may also be referred to as "folding sidewalls."
The remaining two side panels, also opposing one another, but
intended to move toward and away from one another during the
process of expanding or collapsing the container, may also be
referred to as "non-folding side panels," and the corresponding
sidewalls in the expanded container may also be referred to as
"non-folding sidewalls."
[0033] The edges of the side panels having appended top flaps,
which edges form a single line when the blank is in lay flat form,
will be referred to as the "top" edges of the side panels, and the
single line of such side panel top edges the "top" of the blank.
Such top edges will also define the "top" of the container when the
blank is folded and the container expanded and ready for use; the
top flaps comprise additional material appended to the top edges of
the side panels. The edges of the side panels having appended
bottom flaps, which edges form a single line when the blank is in
lay flat form, will be referred to as the "bottom" edges of the
side panels, and the single line of such side panel bottom edges
the "bottom" of the blank. Such bottom edges will also define the
"bottom" of the container when the blank is folded and the
container expanded and ready for use; the bottom flaps comprise
additional material appended to bottom edges of the side
panels.
[0034] When the blank is in lay flat form, each side panel will
have a "width" measured parallel to the top of the blank, such
widths being equal to the distance between the fold or score lines
between panels (or between a fold or score line and an end of the
blank). The width of each top or bottom flap appended to each side
panel will be measured consistently, i.e., parallel to the top of
the blank. When the blank is in lay flat form, each side panel will
have a "height" measured perpendicular to the top of the blank,
such heights being equal to the distance between the fold or score
lines drawn between each side panel and its appended top and bottom
flaps. The distance each flap extends from the side panel or
sidewall to which it is appended will be the "length" of such
flaps, and the distal edge of each flap shall be its "end."
[0035] As a result of the above terminology, when the side panels
are folded and the container constructed according to the present
invention, the widths of two side panels of the blank will equal
the length of the sidewalls of the finished container, while the
widths of the remaining (alternate) two side panels of the blank
will equal the width of the sidewalls of the finished container. It
may be appreciated, however, that if all such sidewall widths are
not equal, the width of two opposing sidewalls may correspond to
the overall length of the expanded container. As a further result
of this terminology, when the side panels are folded and the
container constructed according to the present invention, the
height of all side panels of the blank will equal the height of the
sidewalls of the finished container.
[0036] Continuing, the blank which will form the outer container of
the present invention, prior to folding, may be cut so that all
side panels are of equal width, thereby creating a square when the
expanded container is viewed from above (i.e., a square "footprint"
for the expanded container). However, a more usual configuration
for the sidewalls of the expanded container results when the blank
is cut so as to form two wider side panels and two narrower side
panels (all side panels remaining equal in height), thereby
creating a rectangle when the expanded container is viewed from
above (i.e., a rectangular "footprint" for the expanded container).
As noted above, two of the side panels, those corresponding to the
folding sidewalls, will generally have scores, or fold lines,
extending the height of such side panels. The folding side panels
will comprise at least alternate panels in the die-cut blank.
Accordingly, such folding side panels will also be opposing
sidewalls of the container in its expanded configuration. The
scores or fold lines of the folding sidewalls generally extend from
approximately the midpoint of the top of each folding side panel,
to approximately the midpoint of the bottom of the corresponding
folding side panel. While these folding side panels may be folded
by a user without fold or score lines, the score or fold lines of
the folding side panels allows the folding side panels to be easily
folded top to bottom, approximately in half, during manufacture,
and the corresponding folding sidewalls to be easily folded in the
same way again after manufacture to expand or collapse the
container during use. Such folding results in movement of the
non-folding sidewalls toward each other, thereby collapsing the
container to its knock-down configuration. In containers having
wider and narrower sidewalls, in a preferred embodiment, the scores
and fold lines of the folding side panels are preferably formed in
the narrower side panels. However, the present invention also works
well when the wider side panels bear scores or fold lines, and the
present invention specifically includes such a configuration.
[0037] The bottom of the outer container of the present invention
(in its expanded configuration) will, as noted above, usually
comprise bottom flaps. The bottom flaps appended to the side panels
are generally cut to correspond approximately in width to the width
of such side panels. However, at least one such flap is also
generally cut sufficiently long to meet or overlap the end of the
corresponding flap appended to the opposing sidewall. That is, when
the tubular section of side panels is manipulated into its open,
volume creating configuration, the flaps appended to two of the
opposing sidewalls meet or overlap one another at their distal ends
when such flaps are folded toward one another. An area of overlap
for two such bottom flaps is important to the operation of some
embodiments of the present invention, as such overlap provides an
area to apply adhesive or other fastening means so that the bottom
flaps may be affixed to one another (along their area of overlap).
This area of overlap is generally provided by forming the bottom
flaps of approximately equal length, with the exception of one such
bottom flap which is formed longer, its distal edge thereby
extending further from the sidewall to which it is appended.
However, other means for providing an area of overlap for two
bottom flaps are easily envisioned, and within the scope of the
present invention, as are other attachment means for bottom flaps
when such flaps do not overlap.
[0038] When the bottom flaps are affixed to one another, one of the
flaps may then be folded against or along the edge of the other
flap, thereby allowing the opposing, non-folding sidewalls to which
the flaps are affixed to approach each other. In this way the outer
container may be collapsed to a knock-down configuration or, by
reversing the movement of the opposing sidewalls, expanded to its
open configuration, ready to receive articles within the volume
created thereby. While the same flexibility between configurations
may be achieved with a single flap appended to a bottom edge of one
sidewall and extending to the bottom edge of the opposing sidewall
(and affixed to an area adjacent to such edge, the flap being
folded approximately in half during collapse), the preferred
embodiments utilize two flaps as set forth herein.
[0039] The remaining flaps of the closure at the bottom of the
container, that is, the bottom flaps appended to the remaining
folding sidewalls, may be cut long or short. However, whether long
or short, such flaps also bear scores or fold lines extending
substantially their length, from approximately the midpoint of
their line of intersection with a sidewalls to approximately the
midpoint of their distal edge. Such fold or score lines extend the
fold or score lines impressed into the opposing folding sidewalls,
thereby allowing these bottom flaps to bend, easily following the
movement of the corresponding folding sidewalls as these sidewalls
are bent or straightened during manufacture or use.
[0040] It may be appreciated that, once the ends of the blank are
affixed to one another to form the tubular section, the above
system of (i) folding along the length of the two opposing folding
sidewalls and (ii) folding at least one bottom flap appended to the
non-folding sidewalls, allows the container of the present
invention to be collapsed around its "perimeter" (i.e. from folding
sidewall to folded bottom flap to opposing sidewall) to its
knock-down configuration. By simply reversing such folding, thereby
straightening both the folding sidewalls and the bottom flaps, a
user may expand the container to its full volume.
[0041] The top of the container may then be closed by the top
flaps, or by separate closure ususal in the industry, and sealed.
In one such closure and sealing arrangement, the top may consist of
four top flaps, two of which bear cutouts for insertion of the ends
or corners of the other two top flaps, which top flaps may be
scored for easy bending or folding. The top of the outer container,
or the top flaps, may, in addition, feature a handle, or be capable
of being formed into a handle, for ease of carrying the finished
insulated container, or the outer container may carry, separately
from the top or flaps, a handle attached to its exterior. It may
also be noted that the folding sidewalls may be folded "outwardly,"
so that the fold extends from the body of the (knocked down)
container, or the narrow sidewalls may be folded "inwardly," so
that the fold extends within the body of the container in its knock
down configuration.
[0042] The one-piece insulated liner of the present invention may
be formed from one or more sheets of flexible, thermally
insulative, waterproof and air tight material (the "pouch
material"), or the liner may be formed from separate sheets having
only one of these properties each. In its simplest form, the
material utilized to form the liner need only be air tight, so that
the liner, once formed from such material into a pouch as set forth
below, may be water-tight when sealed at its top. Generally,
however, both thermal insulation and waterproofing may be most
simply accomplished in a single sheet utilizing recently available
and inexpensive materials. One material of choice using currently
available materials is a flexible plastic layer having at least one
layer of air bubbles entrapped therein (sometimes commonly known as
"bubble wrap") laminated to a layer of metalized polyester or
foil.
[0043] This pouch material may be formed in a variety of ways, but
is commonly formed by bonding a first layer of smooth plastic to a
second layer of plastic having a surface with regularly spaced
depressions pushed into it. Upon bonding, the first and second
layer adhere in areas in which depressions are not formed, while
remaining separated layers at the areas of the depressions. The
result of such bonding is entrapment of air in the areas of the
second layer in which the depressions were formed. Alternate means
for constructing pouch material incorporate baffles between
successive layers, which baffles comprise plastic "walls" between
layers. The result of such construction is a material having at
least two layers, where the layers do not themselves contact one
another, but only contact the walls extending between the layers.
The insulative characteristics of such a layered construction are
enhanced.
[0044] A pouch material having further enhanced thermal resistance
characteristics may be obtained by constructing these materials in
the presence of an inert gas, or other gas having a lower heat
transmission rate than air. In such case, the bonded layers of the
pouch material thereafter holds the gas selected within the walls
of the liner. Regardless of the gas or gas mixture utilized, a
third layer of plastic is often bonded to the second layer of
plastic in a fashion similar to that set forth above, thereby
further entrapping gas or gases between the second and third
plastic sheets. Further plastic sheets, creating more gas bubbles,
may be added in this way to increase thermal resistivity. The
multiple sheets after such fabrication together create a single,
multi-layer sheet of pouch material. One or more of the individual
sheets of plastic comprising the pouch material may be composed of
a plastic having reflective properties, to thereby reduce heat
transfer by radiation. In the alternative, another layer of
reflective plastic or other material may be attached to the pouch
material, or separately used with the pouch material to reduce heat
loss by radiation.
[0045] Other configurations are possible based on similar
water-tight and thermally insulative materials, such as those
developed by Berkeley Labs. Using such alternative materials, a gas
may be injected into the walls of the pouch through an open valve,
and held within the liner by the airtight material and the valve
upon its closing. Alternatively, a portion of the pouch material
may be composed of permeable elastomeric material, and the space
within the walls of the liner injected with a small amount of gas
other than air, oxygen or nitrogen. Such other gas may be selected
from among a wide variety of gasses which have lower diffusion rate
across the permeable material than air, gasses such as carbon
dioxide. Finally, its is also possible to construct the present
invention utilizing multilayer plastic material wherein the layers,
while holding a gas as in the preferred embodiment, are connected
only at their edges. In such way, an inflatable pouch may be
created which expands to surround and protects fragile materials
after the pouch has been inflated.
[0046] In one preferred embodiment of the present invention, a
single sheet of pouch material is simply cut into a rectangular
shape, folded over once, and the cut edges matched. Some edges of
the pouch material are then sealed, leaving unsealed those edges
most distant from the fold line, thereby forming a pouch, with top
opening away from the fold line, and base of the pocket at the fold
line. Alternatively, a single sheet may be folded over after being
cut, and sealed along a side adjacent to, and along a side opposite
to, the fold line.
[0047] A variety of means may be utilized to seal the pouch
material, however the sealing of edges to create a pouch may be
quite easily accomplished in one preferred embodiment by the
application of heat to the areas to be sealed as such areas are
pressed together. The combination of heat and pressure causes the
flexible plastic material to melt slightly, deflating bubbles
incorporated into the material, and bonding together successive
layers of plastic. Alternate means for sealing the edges to form a
pouch include gluing, folding and sewing, or other means calculated
to form a water-tight seal. The cutting and sealing as described
results in water-tight and insulative pocket, which may remain flat
as originally folded and sealed or expanded to allow the insertion
of cargo.
[0048] The plastic pouch material is cut to a width which, when so
folded and sealed, will fit conveniently within the sidewalls of
the outer container when the outer container is flattened into its
knock down configuration. As so sized, the pouch material will also
fit conveniently within the sidewalls of the outer container when
it is expanded to its final three dimensional shape, and may follow
the side walls in such expansion if attached to them. The pouch
material is also cut to a length which, when so folded, sealed, and
placed within the outer container, will extend through the outer
container when it is flattened, and out the top and bottom of the
flattened container (excluding flaps). When so placed within the
outer container, the base of the pocket of insulating material, at
the fold line, extends below the bottom edges of the sidewalls of
the outer container, while the opening of the pocket, away from the
fold line, may extend past the top edges of the sidewalls of the
outer container to allow ample material to overlap or join the top
edges of the pouch material to seal the pouch after expanding and
filling the container.
[0049] One variation on the construction of the pouch within the
scope of the present invention includes the forming of cuts in the
pouch material extending from the top edge of the pouch a distance
approximately equal to the length the pouch extends above the top
of the sidewalls when the pouch is properly placed on the blank.
Such cuts may be utilized to allow fastening of the material on
either side of the cuts to the top end flaps, and so easy closure
of the pouch when the top flaps are folded to closure. Another
variation on the construction of the pouch within the scope of the
present invention includes using pouch material which is inflatable
after manufacture of the pouch. Such pouch material may be formed
into a pouch and placed uninflated on the blank, and fastened to
it, prior to constructing the tubular arrangement of the present
invention. Once the tubular arrangement is formed and the bottom
flaps fastened to each other or to the opposing wall as set forth
below, the completed container may be shipped in its lay flat
configuration, and the user may inflate the insulative pouch after
the container is expanded to its usable configuration. The
inflatable pouch meeting these characteristics must be specially
designed with areas at each corner where the pouch cannot be
inflated, such areas then remaining uninflated during later
expansion. Such corner areas are necessary to effective operation
of a pouch which may be later inflated by a user, as only by not
inflating corners can a pouch of this type fit and expand correctly
into a hard container. It may be noted that pouch material having
this description is available, as is at least one finished pouch
having the desired characteristics.
[0050] In one preferred embodiment of the present invention, the
distance the base of the pocket of insulating material extends from
the sidewalls of the container is approximately equal to or greater
than one half the width of the narrowest sidewall. As a result, the
pocket may be drawn open to form a square or rectangle when viewed
from either top or bottom, and the dimension of the resultant
square or rectangle allows the pocket of insulating materials to
approximately cover the area occupied by the outer container in its
expanded configuration when viewed from the top or the bottom. The
distance the opening of the pocket of insulating material extends
from the top flap fold line of the container is also generally
equal to or greater than one half the width of the narrowest side
wall. As a result, the top of the pocket has sufficient material to
cover the area occupied by the bottom of the outer container, when
viewed from the top or the bottom, in its expanded configuration.
The top of the pocket also generally has sufficient material to
allow sealing of the top of the pocket, even in its expanded
configuration, when the opening of the pocket of insulating
material extends from the top of the container a distance greater
than one half the width of the narrowest side wall.
[0051] A means for attaching the pouch to the blank, or to the
interior of the tubular section of the outer container, is
generally utilized in the present invention, generally in the form
of an adhesive. The attachment means, when used, is located on both
sides of the pouch in one preferred embodiment, along lines at a
distance from the edges of the pouch of just over one-half the
width of the folding sidewalls of the container. When the pouch is
properly placed on the blank during construction, the adhesive may
be applied to the pouch along such lines on the pouch, or along the
areas of the non-folding side panels near their edges (i.e., near
the "corners" of the outer container once the side panels are
folded and the container expanded), or along each of these areas.
These are the primary areas for attachment between the pocket and
the outer container. In one embodiment of the present the invention
the pocket must be attached in this fashion, at or near both side
edges, to all four corners of the outer container (when expanded),
near the fold lines at the intersection of the sidewalls. The
attachment between the pocket and sidewalls is accomplished
preferably by adhesive placed between the material of the pocket
and the area adjacent the edges of the wider sidewalls, however the
means for attachment of the insulating material to the corners of
the outer container may be glue, tape, a combination of glue and
separable tape of the "velcro" type, or by any other means which
does not pierce the pouch material, or cause unequal strain at any
point in the material. Methods of attachment which allow for
removal of the insulated pocket from the outer container have the
additional advantage of allowing cleaning of the pocket after
separation from the cardboard, thereby preserving the structural
integrity of the cardboard against weakening by contact with water,
and recycling the outer container and insulative pocket
separately.
[0052] It should be specifically noted here that, while the
adhesive or other attachment means set forth above assists in
maintaining the pouch in its proper position within the outer
container, and assists expansion of the pouch when the outer
container is expanded, attachment means is not necessary to all
embodiments of the present invention. In some embodiments the pouch
may simply reside within the tubular section of the outer container
during shipment, and the pouch will expand within the outer
container during use, both by action of the sidewalls against the
pouch, and by action of the contents of the pouch as such contents
require volume within the pouch when placed within it.
[0053] Once the tubular assembly with folded bottom and attached
pouch are constructed according to the apparatus set forth herein,
a user wishing to employ the present invention may, as noted more
fully below in relation to the method of the present invention,
simply grasp the tubular assembly, manipulate it to expand the
assembly by moving the non-folding side panels apart, and lock the
assembly in its expanded configuration by locking the folding side
panel bottom flaps into the non-folding side panel flaps, by taping
or gluing the bottom flaps to each other or to the side walls of
the now expanded container, or by other appropriate means. In its
expanded configuration, the assembly of the present invention is
open to accept articles for shipment or carrying, closed at the
bottom, capable of closure at the top by means of top flaps and
excess material at the top of the pocket, and, once so closed, a
container having an exterior hard shell, and a water-tight interior
pouch resistant to transfer of heat into or out of the
container.
[0054] The manufacture of the present invention involves a series
of steps, beginning with the cutting of a blank for the tubular
assembly from a rigid or semi-rigid material. In such manufacture,
a measure of such material sufficient to create the finished
product is cut to create a flat blank having the requisite side
panels and flaps. The blank may be scored or pressed along
appropriate lines during cutting to create the scores or fold lines
of the blank of the present invention, or such scoring or pressing
may take place before or after such cutting of the blank. A measure
of insulative and water-tight material sufficient in size to create
a pocket or pouch of appropriate size is also cut, folded, and
sealed along at least two sides (leaving open at least one side).
The pocket is, once formed, placed at the correct position on the
blank, or upon adhesive residing on the blank, or adhesive is
applied to the pocket and then the pocket is placed at the correct
position upon the blank. The blank is then folded over the pocket
and the edges at the ends of the blank affixed to one another by
additional adhesive or other suitable means. Finally, the distal
edge of at least one flap of the non-folding side panels is folded
over the edge of the opposing non-folding side panel, or over the
distal edge of the opposing flap of the opposing non-folding side
panel, and fastened in such position to create a folded bottom for
the container. In the alternative, adhesive may be applied to the
correct positions on the pocket, or the interior of the tubular
section once formed, and the pocket then placed in the correct
position within the tubular section, and the tubular section then
collapsed to its knock-down configuration. While these methods of
construction are stated somewhat generally to provide guidance on
the overall process, the preferred method proceeds more
specifically as follows:
[0055] Starting with a measure of rigid or semi-rigid material, a
blank is cut in a shape which, in one embodiment of the present
invention, has material sufficient to form four side panels for
creating the sidewalls of the present container once constructed,
at least one bottom flap at one side of the blank for forming a
closure at the bottom of the container once constructed, and at
least one top flap at the other side of the blank for forming a
closure at the tope of the container once constructed. The bottom
flaps are formed of unequal length in one preferred embodiment, the
longer bottom flap appended to a non-folding side panel residing
between two folding side panels. The blank is also cut to form an
end tab at one end of the blank in one preferred embodiment, the
end tab usable for affixing one end of the blank to the other end
of the blank using adhesive or other suitable means, thereby
creating the tubular construction of the container. Before the
blank is cut, or in the blank itself as or after it is formed, a
number of fold lines or score lines are impressed in the material
of the blank, which fold lines define the four side panels, the top
flap or flaps, the bottom flaps or flaps, and the end tab. These
fold or score lines allow the blank to bend easily between the side
panels to create the four sidewalls, to create the top and bottom
flaps for closure, and to create the end tab for forming the
tubular assembly when the end tab is affixed to the area near the
edge of the opposing end of the blank. Two additional fold or score
lines are impressed the length of each folding side panel, along
the mid line of each such panel. An additional fold or score line
is, in one embodiment of the present invention, impressed along a
line near the distal edge of the longer bottom flap, for easy
bending of that bottom flap once the tubular assembly is formed,
and the bottom flaps affixed to one another using attachment means
as set forth below.
[0056] Starting again with a measure of flexible, thermally
insulative, waterproof and air tight "pouch material," in one
preferred embodiment a sheet of such material is cut in the proper
shape and size to "fit" the blank. More specifically, the sheet is
generally cut in a rectangular shape with a width such that, if the
sheet is centered on a non-folding side panel of the rigid blank,
the sheet will extend beyond the side edges of that side panel
(i.e., beyond the fold or score lines between side panels) a
distance of about one-half the width of the folding side panels.
The sheet of pouch material is also cut with a length such that, if
the sheet is centered on a non-folding side panel of the blank, the
sheet, if folded in half, will also extend beyond the bottom edge
of that side panel (i.e., beyond the fold or score line between
that side panel and the bottom flaps) a distance of about one-half
the width of the folding side panels, and beyond the top edge of
that panel (i.e., beyond the fold or score line between that
non-folding side panel and the top flap or flaps) a distance of at
least one-half the width of the folding side panels.
[0057] Once cut, the measure of pouch material is generally folded
in half upon itself, the edges and ends matched, and the material
sealed along its two side edges. Such sealing creates a pouch or
pocket in lay flat form comprised of two sides of flexible pouch
material, a fold line between the sides of the pouch at its bottom,
two sealed side edges, the side edges often showing seal or melt
lines where the material is sealed to itself along the edges, and
one open end at the unsealed edges across from the fold line. While
somewhat less convenient and more bulky, the pouch may also be
formed from two separate pieces which together have dimensions
approximately equal to the single measure noted above. Such
separate pieces may be joined along three edges to create the lay
flat pouch with one open end required by the present invention.
[0058] Whether formed of a single piece in the preferred embodiment
or from two separate pieces, the corners of the pocket adjacent the
fold line of the pocket, once formed, may be cut to reduce bulk,
and then resealed to regain water-tight and thermal properties. The
angle and amount of such cut corner cutting may vary, however the
preferred angle of cut is about 45 degrees, and the preferred
distance of such cut from the corner of the pouch prior to cutting
should be a distance of about one-half the width of the folding
side panels of the rigid cut blank. While the corners of the pouch
may be cut to reduce bulk in some applications, the preferred
embodiment is to leave the corners, which may be easily folded into
the container or under the flaps at the bottom of the container
during expansion. The material of the corners may also be simply
kept together by melting it near the line where the corners might
be cut in some embodiments, or melting all the material of the
corners of the pouch.
[0059] Returning to the flat blank cut from rigid or semi-rigid
material, a means for attaching the end of the blank or, in the
preferred embodiment, end tab (or tabs) of the blank, is secured to
the end of the blank or end tab. As a result, the end tab may be
affixed by such attachment means to the area near the edge of the
opposing end of the blank, to thereby create a tubular shape from
the blank. In a similar way, means for attaching the bottom flaps
to one another is secured to at least one bottom flap, near its
distal edge. As a result, one bottom flap may be affixed by such
attachment means to the opposing, non-folding side panel or, in a
preferred embodiment, to the opposing bottom flap. Other attachment
means may be secured to both non-folding side panels at least along
the areas close to the edges of such side panels. While the areas
to which attachment means, when used, are secured may be fairly
narrow, a wider placement of such attachment means results in a
fuller connection between the pocket and the blank, and ultimately
a smoother interior compartment within the pocket once the
container is opened to its expanded configuration. In addition, the
adhesive or other means of attachment of the pouch to the blank,
when used, may be such as to allow removal of the pouch from the
container for separate disposal or recycling of the pouch and outer
container, or the means for attachment in some applications may be
durable to keep the pouch securely within the outer container.
[0060] Of course, the steps in the process of the present invention
may be reversed in that the attachment means secured to the end
tab, bottom flaps, and side panels may be secured to the flat blank
prior to formation of the pouch as set forth above, or these steps
may be taken in any order (as noted below, attachment means may
also be applied to the end tab, bottom flaps, and side panels
either before placing the pouch onto the rigid blank or
afterwards).
[0061] After the rigid or semi-rigid blank is properly cut, and
attachment means secured to at least one end tab and bottom flap as
set forth above, and after the pouch or pocket of the present
invention has been formed from the pouch material has been formed
by cutting, folding, and sealing as set forth above, the pocket may
then be joined with the blank, and attached to it using the
attachment means secured to the blank. This is accomplished in one
preferred embodiment by placing the pocket on the blank, and on the
attachment means on the non-folding side panels of the blank, so
that the pocket is approximately centered over such side panel
between two folding side panels, such that the sealed side edges of
the pocket extend across the fold or score lines between the
non-folding side panel and each folding side panel, and further
across about one-half the width of each such folding side panel. In
such position, the edges of the pocket extend approximately up to
the fold or score line running the length of each folding side
panel. In its positioning, the pocket is also placed on the blank
as set forth above in a position such that the bottom of the
pocket, at the pocket fold line, extends from the bottom edge of
the non-folding side panel and across most of the length of the
longer bottom flap appended to that side wall (i.e., almost to its
distal edge). In such position, the bottom edge of the pocket then
extends approximately up to the fold or score line near the distal
edge of the longer bottom flap, a distance of approximately
one-half the width of the folding side panels. In such position,
finally, the top edges of the pocket forming its open end also
extend beyond the top edge of the non-folding side panel, and
across the top flap attached to that panel, a distance of at least
one half the width of the folding side panels.
[0062] Once in position on the blank, the pocket may be simply
pressed into contact with the attachment means residing along the
edges of the non-folding side panel of the blank, to thereby attach
the pocket to the blank near such edges, or attach the pocket to a
larger area of the wider side panel of the blank wherever the
attachment means has been applied to the side panel (as set forth
above). In the alternative, the pocket may simply reside in the
proper position without attachment means, and the process of
construction may continue (as set forth below).
[0063] After the pocket is positioned correctly on the blank and
attached to the blank using the procedure set forth above, a user
may then easily fold one-half of one folding side panel, at the
fold line of that panel, over a side edge of the pocket and across
the body of the pocket, the user thereby folding the end of the
blank over the pocket near its edge a distance equal to about
one-half the width of the folding side panel. At the other side of
the pocket, a user may also easily fold one-half of the other
folding side panel, along with the remainder of the blank, at the
fold line of the folding side panel, across the other side edge of
the pocket and across the body of the pocket. The user thereby
folds the other end of the blank over the pocket near its second
edge a distance equal to about the width of the wider side panel
plus about one-half the width of the narrower side panel. Of
course, the order of folding of the folding side panels over the
pocket as set forth above may be reversed with the same overall
result.
[0064] When each end of the blank has been folded as set forth
above, the ends of the blank, or the end tab at one end of the
blank and the other end of the blank in the preferred embodiment,
or end tabs at each end of the blank, may overlap. Since the ends
of the blank, or the end tab at the end of the blank, bear
attachment means applied previously as set forth above,
construction continues when the ends of the blank, or one or more
end tabs at the ends of the blank, overlap, by pressing the ends of
the blank, or such end tab and other end of the blank, together.
This brings one end of the blank into contact with the attachment
means residing along the edge of the other end of the blank, or the
end tab, into contact with the attachment means residing along the
other end of the blank, thereby securely fastening the ends of the
blank together to create a (flattened) tubular arrangement of both
wide and narrow side panels (with flaps). Since the pocket of the
present invention was appropriately placed on the blank, and
fastened to it via appropriately placed attachment means prior to
folding the blank in at least one preferred embodiment, the tubular
arrangement of side panels, once folded as set forth above, has
within it the previously positioned pocket. Since the pocket of the
present invention was placed on one non-folding side panel of the
blank prior to folding the blank, and since attachment means was
appropriately placed on the other non-folding side panel of the
blank prior to folding the blank in at least one preferred
embodiment, both non-folding side panels of the tubular arrangement
of side panels, once folded as set forth above, may be securely
attached to the pocket by the attachment means. As a result, the
tubular arrangement of side panels after folding has within it, and
securely attached to it in some preferred embodiments, the
previously placed pocket. If attachment means is used, the areas of
attachment of the pocket to the side panels correspond to the area
on the non-folding side panels to which attachment means was
previously applied. It should be noted that the order of steps in
applying the attachment means to the appropriate places to secure
the pouch to the blank during construction, of attachment means is
used, may be reversed. That is, the attachment means may be applied
to the end tab, bottom flaps, and side panels either before placing
the pouch onto the rigid blank or afterwards, or in any order, and
the attachment means may be applied to either such areas on the
blank, or on corresponding areas of the pouch, or both prior, to
bringing the pouch and blank together.
[0065] After the pocket is positioned correctly on the blank and
attached to the blank (in one embodiment) using the procedure set
forth above, and the ends of the blank attached to one another as
set forth above, a user may then easily fold the edge of the longer
bottom flap (appended to one of the non-folding side panels), at
the fold line at the distal end of that flap, over the edge of the
opposing bottom flap. When the longer bottom flap has been folded
as set forth above, the distal edges of the flaps of the
non-folding side panels may overlap. Since the area near one or
both distal edges of such bottom flaps bear attachment means
applied as set forth above, construction continues when such bottom
flaps overlap by pressing the areas having such attachment means
together. This brings one area of one bottom flap into contact with
the attachment means residing along the area of the opposing bottom
flap, thereby securely fasten the distal ends of the bottom flaps
together to create a folded bottom end for the tubular assembly. Of
course, the order of folding of the bottom flaps to create the
folded bottom end for the tubular assembly may be reversed without
changing the end product, i.e. a tubular assembly, with folded
bottom end, and attached pocket within.
[0066] As an alternative to the above procedure, for constructing
the container of the present invention, the pocket of insulating
material may be inserted into the outer container once it has been
folded to a tubular assembly, with end tab, opposing blank edge,
and bottom flaps secured as above. While not as desirable for a
number of reasons, such a procedure may be utilized when a slow set
adhesive or other means is used to fasten the pouch to the interior
of the tubular section, or when the pocket and outer container are
to be constructed without attachment means between them. In such
procedure, the pouch is again positioned so that opposite edges at
the sides of the pouch extend into the folds of the folding
sidewalls of the container, with such edges adjacent the fold lines
of such sidewalls. Further, the base of the pouch is positioned so
that the fold line at its base extends into the folded bottom
created by the bottom flaps when the container is in its knock down
position. Once the pocket is in position within the sidewalls of
the container, the pocket is attached to the sidewalls near the
edges of the corresponding non-folding sidewalls of the outer
container as before in those embodiments utilizing attachment means
between pouch and outer container.
[0067] As a result of manufacture in the method described herein,
the present invention, as noted above, may be incorporated into an
insulated container assembly which is capable of being folded flat,
with side walls of the outside container in the knock down
configuration, and with the flattened flexible, sealable,
insulative material of the pocket residing within the side walls.
To utilize the present invention, a user may select a flattened
container of appropriate size, and manipulate the outer container
to expand it in the manner set forth herein. Upon such expansion,
the flexible, sealable, insulating pocket of one version of the
present invention is pulled along with the (non-folding) side walls
of the outer container, thereby filling the volume created upon its
expansion. At the top of the box, the opening of the pocket opens
naturally when the outer container is expanded, thereby allowing
placement of articles within the pocket and the outer container. At
the bottom of the outer container, the bottom of the pocket is
reformed as the corners of the outer container, at the fold lines
between side walls, pull the opposing sides of the pocket away from
each other. At the same time, and in response to such pulling, the
sealed edges of the pocket are pulled inward, in one preferred
embodiment, toward the main body of the pocket.
[0068] The user continues to expand the outer container until it
reaches a point at which the sidewalls are perpendicularly oriented
to their adjoining sidewalls, and the bottom or bottom flaps may be
manipulated into position to close the outer container at its
bottom. At the point of maximum expansion of the outer container,
the insulated pocket is reformed so that the pouch material runs
substantially all around the inside of the sidewalls, and extends
from the top of the container. Meanwhile, as the outer container is
opened, the sealed side edges of the pouch near the midline of the
folding sidewalls of the outside container are drawn toward the
center of the container, as is the fold line of the pouch at the
bottom of the container.
[0069] At full expansion of the outer container, the bottom of the
outer container formed by the joined flaps of the non-folding
sidewalls forms a substantially flat surface. The remaining flaps
(i.e., the flaps of the folding sidewalls) may then be easily
folded over the bottom of the outer container, and secured in place
by appropriate means. Such folding over the bottom of the container
will also generally result in folding the flaps of the folding
sidewalls over the exposed bottom corners of the inner pouch, which
normally project from the interior of the contain out between the
folding sidewalls and the now straightened flaps of the non-folding
sidewalls. In a rectangular "J lock" bottom box design, the bottom
closure is normally accomplished when the flaps of the folding
sidewalls are folded around the bottom of the container after
expansion, and folded into and locked into place in slots formed in
the flaps of the non-folding sidewalls. Closure of the pocket at
its top then may proceed by folding the pocket material, and
securing it in place, or otherwise securing the ends of the pocket
material to form a closure. Such closure may be accomplished in a
variety of ways currently in use, including use of a "lip &
tape" (or lip with adhesive, or pressure sensitive tape) design,
with or without folding the edges of the opening to achieve tighter
closure. In most cases the pouch material, secured near the edges
of the pocket opening, are used to close the pocket upon folding.
However, a preferred method of closure in the commercial shipping
market is through use of a continuous rotary sealer or heat sealer
in which a user may apply, generally by hand, both pressure and
heat to melt the edges of the pocket opening together. By such
means, a user may create a pocket having water-tight
characteristics even if the container as a whole is upended during
shipment. Upon completing the closure of the pocket, the user may
close the outer container in the way dictated by the design of the
outer container.
[0070] By the above process, the user may store the insulated and
watertight container assembly in its knock down configuration
pending use, select and quickly manipulate assembly to reconfigure
the assembly to its final expanded shape, and secure the assembly
in such final shape, ready to receive articles. The reconfiguration
process is both quick and convenient for the user, and the
resultant container inexpensive and readily available. Further, by
means of the present invention, a manufacturer may quickly and
inexpensively provide a light weight, durable, insulated, and
water-tight container which may be manipulated into its final shape
by the user, and store and ship such assembly using a minimum of
space and cost.
[0071] The more important features of the invention have thus been
outlined, rather broadly, so that the detailed description thereof
that follows may be better understood, and in order that the
present contribution to the art may be better appreciated.
Additional features of specific embodiments of the invention will
be described below. However, before explaining preferred
embodiments of the invention in detail, it may be noted briefly
that the present invention substantially departs from pre-existing
designs of the prior art, and in so doing provides the manufacturer
and distributer with the highly desirable ability to easily and
inexpensively manufacture the new assembly in a compact, folded
"knock down" configuration, and store or ship the assembly in such
configuration while occupying a minimum of space. The design of the
present invention has distinct advantages over prior art. Thus, the
assembly of the present invention provides an assembly easy for a
user to quickly reconfigure into a insulated and water-tight
container, which container is suitable for storing or shipping
products such as flowers, fruits, beverages, or other products
requiring a controlled temperature. It also allows the insulated
container incorporating the design to hold fluids and vapor within
the container thereby increasing insulative properties of the
container, while preventing fluids from leaking through the
container with resultant mess and loss of structural integrity. It
also provides a water-tight or water-resistant liner in a
collapsible, structurally rigid exterior, for space saving storage
of thermally sensitive contents and any associated fluids.
Accordingly, this water-tight container design satisfies airline
cargo regulations relating to shipping with water and ice, and
melted ice runoff containment. The rigid exterior of the present
invention may itself be manufactured with water resistant adhesives
for durability and reusability. Finally, the assembly of the
present invention is designed and composed of such materials that
it utilizes less material overall in construction and, eventually,
disposal, without the use of cloroflorohydrocarbons (CFCs), while
the construction of the assembly allows reuse. Accordingly, the
assembly is less environmentally burdensome.
[0072] These consequences arising by use of the present invention
result in substantial savings in user time, and substantial savings
in expense in manufacture and distribution, and reduction in
storage area until the user determines that a container having the
characteristics noted herein are required, at which point the
insulated container system of the present invention is simply
applied to the task at hand.
OBJECTS OF THE INVENTION
[0073] The principal object of the present invention is to provide
a new insulated container assembly for use in transporting
temperature sensitive goods, with the additional characteristic of
providing a means for retaining fluids and vapors within the
container.
[0074] A further object of the present invention is to provide an
insulated container assembly which may be inexpensively and easily
manufactured utilizing standard, readily available materials.
[0075] A further object of the present invention is to provide an
insulated container assembly which may be transported and stored
when not in use in a flattened configuration, thereby preserving
space and reducing transportation and storage costs.
[0076] A further object of the present invention is to provide an
insulated container assembly which is quickly and easily expanded
by a user from its folded configuration to its configuration when
in use.
[0077] A further object of the present invention is to eliminate
the need for voluminous, rigid, three dimensional insulating liners
which must be carried separately, and placed in position within a
container after it has been expanded.
[0078] A further object of the present invention is to provide
consumers with a convenient, more environmentally sound option to
the disposable coolers currently constructed of expanded
polystyrene foam.
[0079] A further object of the present invention is to provide an
insulated, water-tight container utilizing an interior pouch of
standard size which may be fitted to a rigid outer container of
varying dimensions.
BRIEF DESCRIPTION OF DRAWINGS
[0080] The invention will be better understood and objects other
than those set forth above will become apparent when consideration
is given to the following detailed description thereof. Such
description makes reference to the annexed drawings wherein:
[0081] FIG. 1 is a top-side perspective view of a flexible plastic
layer having at least one layer of air bubbles entrapped therein
laminated to a layer of metalized polyester or foil.
[0082] FIG. 2 is a top-side perspective view of the flexible
plastic layer of FIG. 1, in which the layer has been folded once,
and the edges matched and sealed after folding to create a pouch.
In FIG. 2 the corners of the pouch near the fold line have been cut
and resealed to reduce bulk.
[0083] FIG. 3 is a plan view of a rigid or semi-rigid outer
container cut blank prior to assembly, and showing preferred areas
for application of adhesive or other attachment means, apparent
fold lines, and insertion points for joining bottom flaps after
expansion.
[0084] FIG. 4 is a top-side perspective view of the rigid outer
container of FIG. 3, upon which the pouch or pocket of the present
invention has been place, and affixed in its preferred position by
contact of the pouch with the attachment means appearing in the
preferred areas of FIG. 3.
[0085] FIG. 5 is a top-side perspective view of the rigid outer
container of FIG. 4, in which the side panels of the blank have
been folded toward each other over the pouch, and the end tab at
one end of the blank, with its attachment means, placed in contact
with the other end of the blank and affixed thereto using the
attachment means, thereby creating the tubular arrangement of
sidewalls. Prior to completion of construction, FIG. 5 shows the
bottom flaps appended to the wider sidewalls in unequal width,
prior to folding of one bottom flap over the other to create the
bottom, and FIG. 5 also shows each narrower sidewall in folded
configuration prior to expansion of the container.
[0086] FIG. 6 shows the same top-side perspective view of FIG. 5,
still in knock down configuration, but with one bottom flap of one
of the wider sidewalls now affixed to the other bottom flap of the
other wider sidewall along the area near their distal edges,
thereby creating a bottom for the container.
[0087] FIG. 7 is a perspective view of the bottom of the rigid
outer container of FIGS. 5 and 6, in which the outer container and
the flexible plastic pouch of the preceding figures have been
expanded to create a volume into which objects may be placed. When
so viewed from the bottom, the bottom flaps, which have been
affixed to each other near their distal edges, have unfolded to
create a bottom for the container while the container expands. At
the same time the pouch affixed to the interior of the container
sidewalls has also expanded.
[0088] FIG. 8 is a top-side perspective view of a the rigid outer
container of FIG. 7, wherein the flexible plastic pouch has
followed the side walls of the outer container in its expansion,
thereby opening the interior of the pouch to receive objects, with
the free top edges of the pouch extending beyond the body of the
container to allow closure of the pouch with the material so
extending.
[0089] FIG. 9 is a flow chart diagram of the process of
manufacturing the present invention from rigid or semi-rigid
material (to form the blank), and flexible, waterproof, air-tight,
and insulated material (to form the pouch or pocket).
DESCRIPTION OF A FIRST PREFERRED EMBODIMENT
[0090] Referring initially to FIG. 1, a flexible plastic layer 5
having at least one layer of air bubbles entrapped therein
laminated to a layer of metalized polyester or foil (sometimes
commonly known as "bubble wrap") is shown. The layer 5 has edges 11
at each end, edges 12 along each side of the layer.
[0091] In FIG. 2, the flexible plastic layer 5 of FIG. 1 is shown
folded midway along fold line 13, end edges 11 have been matched
with each other, and side edges 12 have been matched with
themselves. In such position, side edges 12 are sealed along their
length, generally creating a seal line 14. Upon sealing, the layer
5 forms a pouch or pocket 10 with an opening 15, two sealed side
edges 12, and a fold of continuous material at the central fold
line 13. In FIG. 2, the pouch of flexible plastic is may also be
cut at its corners 16 near the central fold line 13 to reduce bulk
of the pouch 10 once it is positioned within the rigid container
sidewalls of the container after expansion. However, in most cases
such cuts at corners 16 is not necessary, the excess material being
easily folded later between bottom flaps of the container. The
angle of cut for the corners 16 appearing in FIG. 2, if such cuts
are made, is the preferred angle of about 45 degrees. The amount of
material cut from corners 16, if such cuts are made, is the amount
removed when cutting at a 45 degree angle at a distance from the
corner 16 of the pouch 10 of about one-half the width of the
narrower side panels of the outer container. FIG. 2 two shows the
cut edges 17 where the corners 16 of pouch 10 have been removed,
and corner seal lines 18 as cut edges 17 have been resealed to
retain the water-tight and thermal properties of the pouch 10 prior
to cutting corners 16. However, as noted above, the pouch corners
may remain uncut in many applications with good effect.
[0092] Referring now to FIG. 3, a single piece of rigid or
semi-rigid outer container material is shown cut into a blank 20
laying flat prior to its assembly. Top flaps 21, bottom flaps 22,
non-folding side panels 23, folding side panels 24, and a single
end tab 25 are formed from the rigid container material by cutting
away excess material. At the end of blank 20 opposite end tab 25,
blank mating edge 31 is shown.
[0093] After cutting the container blank, or at the same time as
the blank is cut, fold lines 9 are pressed into blank 20 between
non-folding side panels 23 and folding side panels 24, to provide a
means for easy folding of all side panels against one another. As a
result of pressing such fold or score lines into blank 20, top
flaps 21 and bottom flaps 22 may be easily folded at top flap fold
lines 28 and bottom flap fold lines 29, and all side panels may be
easily folded against one another. Additionally, fold or score
lines 30 are pressed or scored into folding side panels 24 of blank
20 midway between non-folding side panels 23, to allow easy folding
of narrow side panels in half lengthwise (i.e., top to bottom in
the expanded container). Additionally, end tab fold line 6 is
pressed or scored at the end of blank 20 to allow easy bending of
end tab against the body of blank 20. Finally, bottom flap fold
line 7 is pressed or scored into bottom flap 22 to allow easy
bending along the edge of bottom flap 22, thereby allowing flap
area 19 of bottom flap 22 to bend for attachment to opposing bottom
flap 22, and so allow flexure of bottom flaps one against the other
after such attachment so that the container of the present
invention may be collapsed or expanded as needed. Fold line 7 in
this preferred embodiment is formed as two fold lines pressed into
the blank close together, allowing the volume within this fold in
the knockdown configuration to vary, thereby allowing the container
to easily fit around pouch material of different thickness.
[0094] FIG. 3 also shows first preferred areas 26 as preferred
areas for application of fastening means, generally adhesive, which
will eventually be used to attach the pouch of FIG. 2 to the
container blank 20. Preferred areas 26 are the most important areas
to establish such attachment, as these preferred areas correspond
approximately to a distance from the edges 12 of the pouch 10 of
about one-half the width of the folding side panels 24 of the blank
20. In such position, attachment between non-folding side panels 23
and the pouch will allow non-folding side panels 23 to open the
pouch 10 upon expansion of the container prior to use. However,
additional adhesive may be applied to other, secondary attachment
areas 27, or even over the area of the entire area of the
non-folding side panels 23 in some applications if additional
strength is desired. Adhesive is also applied to attachment area 19
for attaching bottom flap 22 to opposing bottom flap 22.
[0095] When constructed as set forth in FIG. 3, a convenient method
of manufacture of the outer blank 20 is disclosed, so as to make
assembly with pouch 10 possible with minimal expense and effort. In
such assembly, outer blank 20 is first cut as shown in FIG. 3, and
adhesive (not shown), or an adhesive strip (not shown), is applied
or secured to the preferred areas 26, after which pouch 10 is set
on blank 20 so that the pouch rests between folding side panel fold
lines 30. In such position a mid-line of pouch 10, running from the
mid point of opening 15 to the mid point of fold line 13, is
equidistant from such fold lines 30. Pouch 10 is also positioned so
that pouch fold line 13 rests at or near bottom flap fold line 7.
In such position the top edges 11 of pouch 10 rest near the distal
edge of top flap 21. By such placement, pouch 10 is placed in
contact with the adhesive or adhesive strip of the preferred areas
26 near the edges of wider panels 23, and is thereby secured to
such areas 26. In such position, pouch end edges 11 may extend
beyond top flaps 21, however pouch bottom at fold line 13 should
not extend beyond bottom fold line 7 of bottom flap 22.
[0096] After placement of pouch 10 as described above, the ends of
blank 20 may be folded across pouch 10 in such a way as to position
end tab 25 over the outside of mating edge 31, and fastening flap
25 may then be secured to mating edge 31 utilizing the same
adhesive used to secure pouch 10 to preferred areas 26 of blank 20.
After placement of pouch 10 as described above and folding of ends
of blank 20 as described above, the distal edge of flap 22 and the
fastening area 19 proximal to that edge, may be folded across the
bottom edge 13 of pouch 10 in such a way as to position fastening
area 19 over the outside of the mating edge 8 of opposing bottom
flap 22 and fastening area 19 may then be secured to mating edge 8
utilizing the same adhesive used to secure pouch 10 to preferred
areas 26 of blank 20. In this way, a single application of adhesive
may be used to secure the pouch 10 to blank 20 at preferred areas
26, to close blank 20 over pouch 10 during assembly to create a
tubular form, and to seal opposing bottom flaps 22 one to the other
along bottom flap attachment area 19 to create a flexible bottom
for the container of the present invention.
[0097] In FIG. 4, the rigid or semi-rigid blank 20 is shown in
perspective view, with pouch 10 placed in position as set forth
above. In FIG. 4, pouch 10 rests between folding side panel fold
lines 30, with pouch edges 12 on each side of pouch 10 resting near
such fold lines 30. In such position a mid-line of pouch 10,
running from the mid point of opening 15 to the mid point of fold
line 13, is equidistant from such fold lines 30. Pouch 10 is also
positioned so that pouch fold line 13 rests at or near bottom flap
fold line 7. In such position the top edges 11 of pouch 10 rest
near the distal edge of one of top flaps 21. By such placement,
pouch 10 is placed in contact with the adhesive or adhesive strip
of the preferred areas 26 under pouch 10 (not shown) near the edges
of wider panels 23 under pouch 10 (not shown) and is thereby
secured to such areas 26. In such position, pouch end edges 11 may
extend beyond top flaps 21, or not, however pouch bottom at fold
line 13 should not extend beyond bottom fold line 7 of bottom flap
22. End tab 25 is shown with its area for adhesive distal to end
flap fold line 6, and preferred areas for adhesive 26 on
non-folding side panels 23, however in FIG. 4 blank 20 has not yet
been folded along fold lines 30, but rather remains in open
position.
[0098] In FIG. 5, the rigid or semi-rigid blank 20 is shown in the
same perspective view of FIG. 4, with pouch 10 placed in position
as before. However, in FIG. 4, blank 20 has been folded along
narrower panel 24 fold lines 30, and the ends of blank 20 have been
fastened together utilizing end tab 25 affixed over and to the area
adjacent blank mating edge 31 (not shown) of non-folding side panel
23. By such affixation, an angular tube of rigid or semi-rigid
material capable of lying flat (as shown) is created, which tube
may also be expanded into a rectangular tube shape (as shown in
FIG. 7). Such expansion is accomplished by a user when a container
is needed, by bending at fold lines 9 between non-folding side
panels 23 and folding side panels 24. In FIG. 5, the tubular
construction of the now folded blank 20 surrounds pouch 10, with
pouch bottom fold 13 appearing between bottom flaps 22, and
extending approximately up to bottom flap fold line 7. Top flaps 21
are attached to the main body of the blank at fold lines 28, while
bottom flaps 22 are attached to the main body of the outer
container at fold lines 29. The blank has been folded at fold lines
30, while additional fold lines 9 (top fold line only is shown)
allow expansion of the blank 20 into the tubular configuration.
[0099] In FIG. 6, the blank 20 is again shown, and again folded
along fold lines 30, with additional fold lines 9, and end tab 25
secured to non-folding side panel 23 near blank mating edge 31 (not
shown) as in FIG. 5. In FIG. 6, however, bottom flap 22 underneath
pouch 10 has been folded at bottom flap fold line 7 over the bottom
fold 13 of pouch 10, and secured to opposing bottom flap 22 on the
upper side of the container. By such folding and securing, a
flexible bottom for the container is created which allows expansion
and contraction of the container as desired.
[0100] In FIG. 7, the rigid blank 20 is again shown viewed from its
bottom, but in its expanded configuration, with bottom flaps 22 and
bottom flap fold lines 29 nearest the viewer, and top flaps 21 and
top flap fold lines 28 away from the viewer. One fold line 30 is
again apparent, however fold lines 9 are, in the expanded
configuration apparent as the lines of intersection between
non-folding side panels 23 and folding side panels 24. Pouch end
edges 11 may are apparent extending beyond top flaps 21. However,
pouch 10 is no longer apparent through the bottom of the container,
as interior bottom flaps 22 have been manipulated from their fold
down configuration to their expanded configuration. As interior
bottom flaps 22 have been fastened together along bottom flap
attachment area 19 to create a flexible bottom, the bottom of the
container is now closed, with pouch 10 on the interior, and
exterior bottom flaps 22 remaining to be folded into position and
locked in place. In such position, and because of the previous
attachment of pouch 10 to blank 20 along attachment areas 26 (now
shown), the pouch has followed the sidewalls 23 and 24 of the blank
20 in its expansion, thereby also expanding pouch 10. The cut
corners of pouch 10 have largely withdrawn into the container in
FIG. 7, thereby saving volume within the container and bulk when
folding the remaining bottom flaps 22 into position over the bottom
of the container formed by the interior bottom flaps 22. However,
as noted above, pouch 10 may also be formed without cutting corners
16, in which case the material forming such corners may be simply
folded across the bottom formed by interior bottom flaps 22. Such
folding over the bottom of the container will also generally result
in folding the flaps of the folding sidewalls over the exposed
bottom corners of the inner pouch, which normally project from the
interior of the contain out between the folding sidewalls and the
now straightened flaps of the non-folding sidewalls. A user may
continue expansion by folding exterior bottom flaps 22 over the
bottom of the container, and locking the exterior bottom flaps 22
into slots formed in interior bottom flaps 22, or by sealing the
exterior bottom flaps in position or together with tape or by other
conventional means, a solidly constructed bottom for the container
is formed which holds the container open, and ready to receive
articles for transport or storage.
[0101] Referring to FIG. 8, the rigid container of the present
invention is again shown in perspective, from the top, the blank 20
again fully folded at fold lines 9 and expanded to straighten fold
line 30 of folding side panels 24. Pouch 10 again appears in
expanded configuration as it has expanded with the expansion of the
container wider sidewalls 23, and top flaps 21 and pouch opening 15
appear open for receiving objects. In its expanded configuration,
the blank 20 has been opened up by bending at its fold lines 7, and
straightening sidewalls 24 at fold lines 30. The pouch 10 appearing
in FIG. 2 has followed the side walls of the outer container 20 in
FIG. 7, both at the top and the bottom of the pouch 10.
Accordingly, pouch top edges 11 are pulled open by the adhesive at
the interior corners of the outer container applied at the
preferred areas 26, shown in FIG. 3, creating opening 15 in the
pouch 10 through which objects may be passed for placement within
the pouch 10.
[0102] Referring now to FIG. 9, the process of manufacturing the
present invention is shown in flow chart form. In FIG. 9, rigid or
semi-rigid material is selected to form a blank 100 of suitable
characteristics, and a blank is prepared. In such material, fold
lines or score lines are pressed or scored 101, and a blank of the
desired size and shape is then cut 102 as set forth above to
produce a blank with fold lines or score lines in the correct
positions. The blank may be cut 103 and then pressed or scored 104
as set forth above to produce fold lines or score lines at the
correct positions in the material of the blank. However, the most
usual method with operations of this kind, and the preferred method
within the scope of the present invention, is to accomplish the
cutting of the blank 102/103 simultaneously with the scoring or
pressing of the blank 101/104, "cookie cutter" fashion, utilizing a
single cutting and stamping die in a single step. Whether the blank
is cut before, after, or with the placement of fold lines or score
lines, attachment means, generally an adhesive, may then be applied
105 to preferred attachment means areas 26, or additionally to
preferred attachment means 27, or additionally to one entire
surface of each of the non-folding side panels 23.
[0103] Before or after the above series of steps taken to prepare a
blank, or before or after any such steps, a flexible, waterproof,
air-tight, and insulated material is selected to form a pouch 120
of suitable characteristics, and a pouch is prepared. From such
material, a rectangle may be cut 121, and the rectangle folded 122.
In the alternative, two squares or rectangles may be cut 123 having
the same area as the folded rectangle to produce a pouch having the
same volume. Whether a single rectangle is cut 121 and folded 122
or two rectangles are cut 123, the loose edges of the material so
cut are matched 124, at least approximately, for later sealing, or
cutting and sealing. Once the edges of the material are matched
124, the manufacturer may elect to simply seal the side edges 125
(or side and bottom edges in the case of a pouch formed from two
pieces of material), thereby creating a pouch 10 with opening 15,
and corners 16. In the alternative, the manufacturer may elect to
cut the corners 126 of the pouch 10 after sealing, and seal the cut
edges where the corners were cut away 127, thereby creating the
same pouch but with shortened (or not) corners. The manufacturer
may in the alternative cut the edges and corners 128 of the
material simultaneously 128 after matching edges 124, and seal the
side edges and cut edges where the corners were cut away 129 if a
pouch without corners is desired.
[0104] Once a blank is prepared and a pouch is prepared using the
above method, the pouch is placed on the blank 150 in the correct
position as set forth above, between fold lines 30, and the pouch
is pressed into the attachment means 151 of areas 26 (or so much
attachment means as is present in areas 26, 27, and the remainder
of non-folding side panel 23). Once the pouch is securely affixed
to the blank, the blank may then be folded 152 at side panel fold
lines 30, so that end tab and matching edge of the blank overlap,
and end tab and the area at the end of the blank, near its matching
edge may be fastened together 153, thereby creating an angular
tubular arrangement of sidewalls. Once the tubular arrangement of
sidewalls has been created, that longest bottom flap having an area
for fastening 19, may then be folded 154 over the pouch 10, and
over the edge of opposing bottom flap 22, and the attachment means
of that area for fastening 19 used to fasten the first bottom flap
to the opposing bottom flap 155.
* * * * *