U.S. patent application number 14/816921 was filed with the patent office on 2015-11-26 for snap-fold containers.
The applicant listed for this patent is Mandarin Associates Ltd.. Invention is credited to Barro de Gast.
Application Number | 20150336708 14/816921 |
Document ID | / |
Family ID | 51164408 |
Filed Date | 2015-11-26 |
United States Patent
Application |
20150336708 |
Kind Code |
A1 |
de Gast; Barro |
November 26, 2015 |
SNAP-FOLD CONTAINERS
Abstract
The invention disclosed includes various durable containers
constructed from sheet materials including a plurality of living
hinges. The containers are configured to snap into an assembled
position from a relatively flat position by the application of
pressure to one or more sidewalls wherein that pressure deforms the
one or more sidewalls into a concave position, thereby holding the
container into place until the contain is collapsed once again for
storage or cleaning.
Inventors: |
de Gast; Barro; (Purmerend,
NL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Mandarin Associates Ltd. |
Kowloon |
|
HK |
|
|
Family ID: |
51164408 |
Appl. No.: |
14/816921 |
Filed: |
August 3, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14157001 |
Jan 16, 2014 |
9126720 |
|
|
14816921 |
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61753325 |
Jan 16, 2013 |
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Current U.S.
Class: |
220/4.29 |
Current CPC
Class: |
B65D 59/04 20130101;
B65D 5/3685 20130101; B65D 11/18 20130101; B65D 5/0209 20130101;
B65D 5/2023 20130101; B65D 5/2057 20130101; B65D 11/1833
20130101 |
International
Class: |
B65D 6/18 20060101
B65D006/18; B65D 59/04 20060101 B65D059/04 |
Claims
1. A configurable container, comprising: first, second, third, and
fourth sidewalls, wherein the first sidewall is provided opposite
the third sidewall and the second sidewall is provided opposite the
fourth sidewall; a floor connected to the first, second, third, and
fourth sidewalls and forming an interior space defined by the floor
and the sidewalls; the first sidewall having a first lower living
hinge extending along an interface of the floor and the first
sidewall, and a first intermediate living hinge positioned between
the first lower living hinge and an upper end of the first
sidewall; the second sidewall having a second lower living hinge
extending along an interface of the floor and the second sidewall,
and a second intermediate living hinge positioned between the
second lower living hinge and an upper end of the second sidewall;
the third sidewall having a third lower living hinge extending
along an interface of the floor and the third sidewall, and a third
intermediate living hinge positioned between the third lower living
hinge and an upper end of the third sidewall; and the fourth
sidewall having a fourth lower living hinge extending along an
interface of the floor and the fourth sidewall, and a fourth
intermediate living hinge positioned between the fourth lower
living hinge and an upper end of the fourth sidewall; the first
lower living hinge following a curved path and the third lower
living hinge following a curved path, the second lower living hinge
following a straight path and the fourth lower living hinge
following a straight path; whereby when the first, second, third,
and fourth sidewalls are joined together to form an upper rim and
the interior space, the container is selectively configurable
between a first position in which the collapsible container is
substantially flat, and a second position in which the collapsible
container is expanded, the curved path of the first lower living
hinge and the curved path of the third lower living hinge urging
the first sidewall and the third sidewall toward the interior space
when the container is in the second position.
2. The container of claim 1, wherein the container is constructed
from first, second, and third sheets of separate material.
3. The container of claim 2, wherein the three separate sheets of
material are formed from polymer plastic.
4. The container of claim 1, wherein the container is constructed
from a single sheet of polymer plastic sheet material.
5. The collapsible container of claim 1, further comprising a cover
having a top and a bottom, wherein the cover is constructed from a
single sheet of material and contains at least one opening
positioned between the top and the bottom, the cover being sized to
receive the collapsible container within the opening, wherein the
floor of the container is positioned adjacent the bottom of the
cover when the container is within the cover.
6. The collapsible container of claim 5, wherein the single sheet
of material is a polymer plastic material.
7. The collapsible container of claim 1, wherein the curved paths
of the first lower living hinge and the curved path of the third
lower living hinge have substantially opposing radii of
curvature.
8. The collapsible container of claim 7, wherein the first, second,
third, and fourth sidewalls are each connected to the floor in both
the first position and the second position.
9. The collapsible container of claim 8, wherein the first and
third sidewalls are each connected to the second and fourth
sidewalls in both the first position and the second position.
10. The collapsible container of claim 7, wherein the first,
second, third, and fourth sidewalls are each configured to be
connected to the floor in both the first position and the second
position, and further wherein the first and third sidewalls are
each configured to be connected to the second and fourth sidewalls
in both the first position and the second position.
11. The collapsible container of claim 7, further comprising a
cover having a top and a bottom, the cover having at least one
opening positioned between the top and the bottom, the cover being
sized to receive the collapsible container within the opening,
wherein the floor of the container is positioned adjacent the
bottom of the cover when the container is within the cover.
12. The collapsible container of claim 11, wherein the cover
further surrounds the second sidewall and the fourth sidewall when
the container is within the cover.
Description
PRIORITY CLAIM
[0001] This application is a continuation of U.S. application Ser.
No. 14/157,001, filed Jan. 16, 2014, which claims the benefit of
U.S. provisional application Ser. No. 61/753,325 filed Jan. 16,
2013, the contents of each of which are hereby incorporated by
reference.
FIELD OF THE INVENTION
[0002] This invention generally relates to folding containers,
particularly including containers that are formed from flat sheet
material and fold to form a three-dimensional container.
BACKGROUND OF THE INVENTION
[0003] In retail sales, including and especially those pertaining
to gifts, electronics, and food items, there is a need for
packaging design that is inexpensively manufactured and storable in
a flattened condition until ready for use. In such environments,
the flattened packaging design must be easily assembled with
minimal effort and the packaging design must provide an interior
holding compartment for storing an item, protecting the item from
significant damage resulting from an impact of the kind experienced
during shipping or handling.
[0004] In housewares, including and especially those pertaining to
kitchen and bathroom containers, there is a need for durable
container design that serves a practical function in the kitchen or
bathroom, such as the function of collecting garbage, holding
washed dishware for drying, or straining pasta or vegetables.
Containers for these purposes must be easily cleaned and stored and
they often require handles for easy transportation, filling, and
emptying. There is also a need to minimize the amount of space
required for storage of such containers when the container is not
in use given that storage space in most kitchens and bathrooms is
limited.
[0005] Therefore, the invention as disclosed herein pertains
generally to a container design that combines various attributes
desirable for use in retail sales or in kitchens and bathrooms, or
in other fields of use where the claimed containers would provide
value. Particularly, the invention as disclosed herein combines the
attributes of inexpensive manufacture, durability, collapsibility,
and ease of assembly with minimal effort.
SUMMARY OF THE INVENTION
[0006] The invention is generally in the form of a collapsible
container configured with fold lines enabling the container to
expand and hold its position in the expanded configuration.
[0007] One version of the invention is a collapsible container
constructed from a single sheet of material comprising first,
second, third, and fourth sidewalls, wherein the first sidewall is
provided opposite the third sidewall and the second sidewall is
provided opposite the fourth sidewall; wherein the invention
further comprises a substantially planar bottom surface; an
interior compartment surrounded on four sides by said first,
second, third, and fourth sidewalls and on the bottom by said
substantially planar bottom surface; and at least three living
hinges integrally formed in each of said first, second, third, and
fourth sidewalls, wherein the living hinges are positioned in a
manner permitting the container to be easily snapped into an
assembled position.
[0008] Another example of the invention further comprises a
collapsible container constructed from a single sheet of material
comprising first, second, third, and fourth sidewalls, wherein the
first sidewall is provided opposite the third sidewall and the
second sidewall is provided opposite the fourth sidewall; a
substantially planar bottom surface; an interior compartment
defined on four sides by said first, second, third, and fourth
sidewalls and on the bottom by said substantially planar bottom
surface; wherein the single sheet of material forming the cover is
a polymer plastic material; and wherein the single sheet of
material includes at least six living hinges.
[0009] In another version, the invention comprises a snap-fold
kitchen implement comprising first, second, third, and fourth
sidewalls, wherein the first sidewall is provided opposite the
third sidewall and the second sidewall is provided opposite the
fourth sidewall; wherein the first and third sidewalls snap into a
concave position when the kitchen implement is assembled and
wherein the second and fourth sidewalls are disposed generally
parallel to each other when the kitchen implement is assembled; and
wherein the snap-fold kitchen implement includes a plurality of
holes to facilitate water drainage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Preferred and alternative examples of the present invention
are described in detail below with reference to the following
drawings:
[0011] FIG. 1A is a perspective view of a snap-fold container and
cover made in accordance with principles of the invention.
[0012] FIG. 1B is a perspective view of a snap-fold container made
in accordance with principles of the invention.
[0013] FIG. 1C is a plan view of an unassembled snap-fold container
made in accordance with principles of the invention.
[0014] FIG. 1D is another plan view of an unassembled snap-fold
container made in accordance with principles of the invention.
[0015] FIG. 1E is a plan view of an unassembled snap-fold cover
made in accordance with principles of the invention.
[0016] FIG. 2 is a plan view of an unassembled snap-fold X-box made
in accordance with principles of the invention.
[0017] FIG. 3 is a plan view of an unassembled pen case or
alternatively, sunglass case made in accordance with principles of
the invention.
[0018] FIG. 4A is a plan view of an unassembled alternate pen case
or alternatively, sunglass case made in accordance with principles
of the invention.
[0019] FIG. 4B is a perspective view of an assembled pen case in
accordance with FIG. 4A.
[0020] FIG. 5A is a plan view of an unassembled snap-fold waste bin
made in accordance with principles of the invention.
[0021] FIG. 5B is a perspective view of a snap-fold waste bin made
in accordance with principles of the invention.
[0022] FIG. 6A is a perspective view of a snap-fold colander made
in accordance with principles of the invention.
[0023] FIG. 6B is a perspective view of an unassembled (i.e.,
collapsed) snap-fold colander made in accordance with principles of
the invention.
[0024] FIG. 6C is another perspective view of an unassembled (i.e.,
collapsed) snap-fold colander made in accordance with principles of
the invention.
[0025] FIG. 6D is a detailed view of the tabs used for fastening a
snap-fold colander made in accordance with principles of the
invention.
[0026] FIG. 6E is a side view of a snap-fold colander made in
accordance with principles of the invention.
[0027] FIG. 6F is an end view of a snap-fold colander made in
accordance with principles of the invention.
[0028] FIG. 7A is a perspective view of a snap-fold dish rack made
in accordance with principles of the invention.
[0029] FIG. 7B is a perspective view of an unassembled (i.e.,
collapsed) snap-fold dish rack made in accordance with principles
of the invention.
[0030] FIG. 7C is a plan view of an unassembled snap-fold dish rack
made in accordance with principles of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] In the versions of the invention that follow, three
dimensional containers are formed from flat sheet material that is
folded along living hinges to produce sidewalls and other
structural members as desired. In many cases, living hinges are
incorporated to have curvature or angles that are other than right
angles in order to form convex or concave sidewalls that are prone
to holding their shape. At the same time, application of an
opposing force can pop the walls out of their rigid upright state
and into a flattened, i.e., "collapsed" position. The containers
according to the present invention are sometimes referred to as
"snap-fold" containers because the fold along pre-stressed
locations and can produce a snapping sound as they are forced into
an expanded position.
[0032] As shown in FIG. 1A, a first version of the invention is a
snap-fold slide box, as described further below. The slide box
includes two components, including the box 1 and its cover 5. The
box is formed from flat stock material cut into a shape that allows
the flat stock material to be folded to form the box.
[0033] In the version as shown in FIG. 1B, the box 1 includes a
central opening 10 cut to allow the box to form an upper rim 11 and
opening for receiving items to be stored in the box. In the same
fashion, if the lid is removed, the box portion may serve as a bowl
or similar such open-topped container. Other portions of the stock
material (best seen in FIG. 1C, folded flat) serve as a first
sidewall 12, a second sidewall 13, a third sidewall 14, a fourth
sidewall 15, and a floor 16. As shown, each of the four sidewalls
is integrally formed from the same material and therefore attached
to a respective one of the four sides forming the top of the box.
In the illustrated version the box is substantially square (though
with two of the opposing sides that are bowed inward); in other
versions it may be rectangular or otherwise shaped, including
modified geometric shapes such as a hexagonal shape with inwardly
bowed sides. Likewise, the slide box and other containers as
described below may be used for a wide variety of intended
purposes, such as holding eyewear, food items, clothing, office
materials, electronics items, or others.
[0034] The flat or "sheet" stock material used to form the box is
preferably a plastic material of a type and thickness that will
retain substantial rigidity even when formed from relatively thin
panels. Suitable sheet materials include polymer plastic materials
including polypropylene. Plastic material injection molding
processes may also be used to form the initially flat template
prior to folding into a three dimensional shape. In other versions,
the stock material may be cardstock, cardboard, or other
paper-based materials.
[0035] The upper rim 11 forming the box adjoins the four sidewalls,
in which two of the top corners adjoining the sidewalls at the rim
11 are comprised of living hinges 21 and 23 and are substantially
straight at the intersection of the sidewalls 12 and 14 with rim
11, while the other two opposing corners comprised of living hinges
22 and 24 follow a path of curvature that is bowed inwardly and
generally toward the center of the box, substantially at the middle
of each of the sidewalls 13 and 15. In each case, the flat stock
material is formed with living hinges in each of the locations
where top corners formed by living hinges 21, 22, 23, and 24 are to
be formed, thereby facilitating the transformation of the flat
stock material into a three dimensional box. As noted above, a pair
of opposing living hinges 21, 23 are substantially straight while a
second pair of opposing living hinges 22, 24 are bowed inward.
[0036] Living hinges suitable for use in accordance with principles
of the invention include those that are flexible or flexure bearing
made from the same material as the two rigid pieces of material on
either side of the hinge. Living hinges are typically formed by
cutting, stamping, or otherwise weakening the material along the
flexure point to enable bending at that point. Preferably the
living hinge will be formed from material and in a manner that
permits multiple uses over time in such a manner as to preserve the
structural integrity of the container by protecting against
substantial wear on the living hinge at the flexure point.
[0037] At about the midpoint of each sidewall, central living
hinges 31, 32, 33, and 34 are formed such that they extend
horizontally along the sidewall when the box is formed into its
three dimensional shape. Thus, the stock material has four sidewall
living hinges 31, 32, 33 and 34 positioned to be about half way
between the top and the bottom of the sidewalls.
[0038] At the bottom of the sidewalls a bottom living hinge is
provided. In the case of the opposing pair of straight sidewalls 12
and 14, the bottom living hinges 41, 43 are also straight and
parallel to the top living hinges 21, 23 and middle living hinges
31, 33. In the case of the opposing pair of bowed sidewalls, the
bottom living hinges 42, 44, the living hinge is bowed outward to
follow a line of curvature that is substantially a mirror image of
the top living hinges adjacent them.
[0039] In order to assemble the box, the flat stock material is
folded at each of the living hinges to create a box with a top,
four sidewalls, and a bottom. The distal portion of each sidewall,
distant from the bottom living hinges, forms a plurality of flaps
that are used for securing the sidewalls to the bottom of the box.
In one version, such as that of FIG. 1C, the flaps may be sonic
welded, glued, or otherwise permanently adhered to the bottom
portion 16 of the box to permanently create an assembled box shape.
In other versions, such as in FIG. 1D one or more tabs (e.g., 51,
52, 53) may be formed about the perimeter of one or more of the
sidewalls and/or the bottom section, with complementary slots
(e.g., 61, 62, 63) positioned to receive the tabs.
[0040] Once the ends are joined by inserting the tabs into the
slots or gluing, welding or otherwise adhering them, it will
generally form the shape of a box. Even in this form, however, the
box may be flattened by folding the sidewalls along the middle
sidewall living hinges 31, 32, 33, 34. To configure the box as an
upright, rigid structure, the living hinges are pressed inward,
generally toward the center of the box. More particularly, the pair
of living hinges 32, 34 on the bowed sidewalls are pressed inward.
This causes the bowed sidewalls to snap as they bow inward, forming
a bowed shape along the upper living hinges 22, 24.
[0041] An optional slide box cover 5 is constructed so that it can
be assembled to provide a sliding cover for the box 1 described
above. As with the box 1, the cover is preferably formed from a
flat sheet stock material such as a substantially rigid or
semi-rigid plastic material. Thus, as shown in FIG. 1E, the flat
sheet stock material is formed or cut into a shape having separate
portions that define a box top 70, first sidewall 71, second
sidewall 72, third sidewall 73, and bottom 74. The cover described
above and as illustrated has only three sidewalls, leaving one side
open to receive the box in a sliding fashion.
[0042] The flat sheet stock for the box cover further includes a
series of living hinges, positioned substantially in the same
locations as for the box. Likewise, the living hinges for the cover
may be formed in the same manner, such as by stamping, heating,
scoring, molding, or other processes to create weakened zones that
serve as living hinges.
[0043] In order to serve as an open-sided cover, the cover includes
opposing sides that are formed with straight living hinges at the
juncture between the sidewalls and the top of the cover, and a
curved living hinge at the top of the third sidewall. The curvature
of the living hinge at the top of the third sidewall 73 follows a
path of curvature that is the same as that incorporated into the
opposing curved sidewall 13 for the box 1, as described above.
Thus, when the box 1 is inserted into the cover 5, it is able to
slide along the substantially straight sidewall sections 12 and 14
rather than along curved walls.
[0044] As with the box 1, the box cover 5 may be assembled from its
flat stock material into a three dimensional cover by gluing, sonic
welding, or otherwise adjoining lower flaps formed on the sidewalls
to portions of the bottom section 74. In other versions, tabs and
slots or other mechanical features and fasteners may be used.
[0045] Because the box cover has intermediate or central living
hinges (as with the box), it can be flattened (i.e., collapsed)
even in the assembled position. Thus, a downward force against the
top of the box causes the intermediate sidewall living hinges to
bow outwardly, allowing the cover to become flattened. Because the
third sidewall is curved inward along the lines of curvature
forming the living hinges at the top and bottom of the third
sidewall, the sidewall will remain rigid and upright despite the
application of a downward force against the top of the box cover.
At some point, an increased force overcomes the natural support
created by the curvature, causing the material to snap or pop as it
flexes outward and folds at the intermediate living hinges. At that
point, the cover can become substantially flattened for storage.
The box cover and box may be flattened in an easier manner with
less force by applying a central outward force on the curved
sidewalls from within. This will cause the curved sidewalls to
deform outwardly until the intermediate sidewall living hinges bow
outwardly enough to fold (with a snap), allowing the cover or box
to be flattened (i.e., collapsed).
[0046] In an alternate version of the slide box, the container may
comprise two sliding covers constructed substantially as shown in
FIG. 1E but without the box. In this version, a first open-sided
cover is constructed as described above and a second open-sided
cover is configured in the same way but sized to allow the second
cover to be slideably received within the first cover. Thus, when
the second cover is received within the first cover, the resulting
container will be double-walled on four sides of the cubic
rectangle and single-walled on two sides. Complementary concave and
convex notches or other locking mechanisms may optionally be
included to secure the covers to one another in the closed
position.
[0047] Additional versions of snap-fold containers are further
illustrated below. In one version shown in FIG. 2, the container 2
is in the form of what is referred to as an "X-Box." This label is
used principally because the box is somewhat formed as an X when
viewed from the top. More specifically, all four of the sidewalls
45, 46, 47, and 48 are bowed inwardly from what otherwise would be
a standard rectangular or square shape. As compared with the slide
box, as described above with reference to FIGS. 1A through 1E, the
principal difference with container 2 is that the upper and lower
living hinges of the X-Box (respectively, 45a, 45b, 46a, 46b, 47a,
47b, 48a, and 48b) are all formed along lines of curvature, whereas
with the slide box as described above with reference to FIGS. 1A
through 1E, only one pair of opposing sidewalls had curved living
hinges and the other pair of sidewalls has straight living
hinges.
[0048] A further version of the invention is depicted in FIG. 3 and
it is in the form of a case 3, labeled as a pen case but equally
suitable for other purposes such as holding sunglasses or other
eyewear. Two versions of such pen or eyewear cases are described
below. In a first version, the case is formed initially from flat
stock material as with the examples above. In this case, a case top
81 is formed adjacent a case bottom 82, with a straight living
hinge 87 between them. In each case, the case top and bottom are
formed with a generally rectangular shape, having straight-sided
ends and long sides that are curved inward at the middle.
[0049] Each of the top and the bottom includes a first sidewall 83,
84 having opposing curved sides meeting at the same point to
generally form a marquise or "football" shape. An opposing second
sidewall is formed by a pair of similarly shaped panels 85, 86. In
the case of the opposing sidewalls, a first panel may optionally
include a scalloped, recessed portion 88 while the second panel
includes an extending tab 89 to better allow a user to grasp the
second panel and fold it downward.
[0050] The pen case is constructed into a three dimensional form
from its initial flat configuration by first folding the living
hinge 87 separating the top and bottom panels. The first sidewall
is then formed by folding each of the curved panels along the
curved living hinges separating the sidewalls from the top and
bottom panels. The curvature of the living hinges will typically
cause the plastic sheet material to snap or pop as it flexes into
position. The opposite sidewalls will likewise be formed by folding
them and snapping them into position. In one version of the case,
an additional flap may be formed along either the top or the bottom
(or both) and then joined to the opposite section by gluing,
welding, inserting tabs, or other means.
[0051] In an alternate version shown in FIG. 4, another pen or
sunglass case 75 is formed substantially as with the sliding box as
described above. Thus, it includes a top, a bottom, and four
sidewalls. Likewise, most preferably, a first pair of opposing
sidewalls has straight sides (owing to a straight living hinge) and
a second pair of opposing sidewalls has bowed sides (which is the
result of curved living hinges).
[0052] One difference between this alternate pen case 75 and the
sliding box 1 as described above with reference to FIGS. 1A to 1D
(i.e., not including the cover 5) is that the pen case 75 does not
include an open top, but rather forms a fully enclosed case. A
further difference is that the pen case is intended to be opened
along one sidewall. The sidewall that can open may be formed with
tab and scallop features as described above with reference to FIG.
4 (elements 88 and 89), or may have different closure features. As
illustrated, a first panel 91 forming the opening sidewall includes
a peripheral inward scallop 92 having a pair of prongs, and a
central slot 96. A second panel 93 forming the opening sidewall
includes an outward tab 95 and a curved slit 94. A pair of openings
96, 97 are positioned along the living hinge separating the bottom
panel from the second sidewall panel 93. When closing the sidewall,
the first panel 91 is folded into position and then the second
sidewall panel 93 is folded into position. The pair of prongs are
received within the pair of openings 96, 97, while the outward tab
95 is received within the slot 96. This combination of features
will securely hold the case 75 in the closed position. To open the
case, the user grasps a portion of the tab 95 along the slit to
remove it and pry open the sidewall.
[0053] An additional version of the invention is illustrated in
FIGS. 5A and 5B, in the form of a bin such as a wastebasket. As
illustrated, in the plan view of a flattened bin in FIG. 5A and the
perspective view of an expanded bin of FIG. 5B, the bin includes a
pair of opposing sides formed with corners along a bowed path of
curvature. The bottom also has straight edges on two opposing
sides, and bowed edges along the other opposing sides.
[0054] A further version of the invention is illustrated in
connection with FIGS. 6A to 6F below as a colander 100. As
illustrated, the colander includes a plurality of through-holes 101
to allow for liquid to drain through the colander 100. The holes
may be arranged differently to form a ventilated crate, or the same
article may be formed without holes to create a box or crate for
carrying or storing items.
[0055] As shown best in FIG. 6C, the colander is preferably formed
in three separate panels 110, 111, 112. The first panel 110
comprises separate sections that make up a floor 121 and a pair of
opposing sidewalls 120, 122 of the crate. As shown, each of the
floor and opposing sidewalls includes several through-holes for
drainage. A second panel 111 attaches to the first panel, generally
along an edge in the floor of the first panel. Similarly, a third
panel 112 attaches to the first panel, generally along an opposite
edge in the floor of the first panel. In this fashion the second
and third panels (111 and 112) form a pair of opposing sidewalls
which, together with the first pair of opposing sidewalls 120, 122,
combine to form the four sidewalls of the generally rectangular
cubic colander. As shown best in FIG. 6D (illustrating a close-up
view of a cutaway of the flattened container of FIG. 6C), the
second and third panels 111 and 112 may be attached to the first
panel 110 using a series of rivets or by gluing, press-fitting, or
other means. Preferably, plastic or stainless steel fastening
components are used to avoid rusting.
[0056] Each of the panels described above includes integrally
formed living hinges to allow the assembled colander to be expanded
or collapsed, as desired. FIG. 6B shows the colander 100 in a
collapsed position. As shown in FIG. 6C, the second and third
panels each include a first living hinge 111a, 112a positioned
along the location where the second and third panels are joined to
the first panel. The second and third panels (elements 111 and 112,
respectively) further include an intermediate living hinge 111b,
112b and an upper living hinge 111c, 112c. Preferably, a handle 115
is formed as a cutout region and positioned in the space between
the intermediate and upper living hinges.
[0057] The first panel similarly includes several living hinges.
The floor 121 of the first panel is defined by a pair of opposing
edges (located where the second and third panels are attached) on
two sides and by a pair of living hinges 120a, 122a defining the
separation between the floor and the opposing sidewalls 120, 122
formed in the first panel. Each of the sidewalls 120, 122 includes
an intermediate living hinge 120b, 122b. When the panels are
attached and the colander or container is in the expanded position,
the four intermediate living hinges, 120b, 122b, 111b, 112b are
each positioned at the same height above the floor of the
colander.
[0058] The side panels are configured to attach to one another at
an upper location on the sidewalls. In one version, the first panel
includes four tabs 130, 131, 132, 133, with a pair of the tabs
located on each side of the first panel, each of the pairs
extending generally outward and generally away from one another.
The second and third panels each comprise a pair of complementary
fastening locations for securing one of the four tabs to one of the
four fastening locations. In one version, the tabs are secured to
the second or third panels using rivets, snap-fit features, or the
like. Most preferably, one or more mating ribs, notches, or other
features is also provided to ensure that the tab cannot rotate at
its point of attachment, and therefore the panels are attached to
one another in a fixed fashion whereby they cannot rotate at the
attachment point.
[0059] For example, as shown in FIG. 6D (providing a partial
cutaway view of portions of panels 110 and 111), in one version
there is provided a snap fit fixture 140 sized to snap into and be
received by a grommet or similar receptacle 130. Preferably, on
either side of the snap fit fixture, two anti-rotational elements
140a, 140b are provided whereby the tabs 130, 131, 132, 133 are
locked into place and prevented from moving rotationally relative
to the radius of a corresponding snap fit fixture 140.
[0060] Each of the second and third panels 110 and 111 is formed
with a pair of feet formed at the base, with the panel having a
narrow base extending generally outward at an angle from each side
as it extends upward such that the width at the intermediate living
hinges 120b and 122b is greater than the width at the base. In the
illustrated version shown best in FIG. 6C, the portion of the
second and third sidewalls between the intermediate living hinges
120b and 122b and the upper living hinges 111c and 112c is of a
substantially uniform width, such that the panel is formed with
generally parallel sidewalls in that section. The upper living
hinges 111c and 112c are formed along an arc following a radius of
curvature. Thus, as seen best in FIG. 6F, the distance H1, H3
between the intermediate living hinge 112b and the upper living
hinge 112c is smaller at each the outer edges of the side panels
112 (and 111) than the distance H2 is at a central location along
the side panel 112 (and 111). Similarly, the lower living hinges
111a, 112a are formed along a curvature in which the curvature is
oriented opposite that of the upper living hinges; in other words,
while the upper living hinge 112c has an upward arc, the lower
living hinge 112a has a downward arc. This combined shape of the
panels and the orientation of the living hinges causes the side
panels 111 and 112 to bow inward (along the path defined by the
upper living hinges) when the colander is pressed into the
assembled position. Conversely, the intermediate living hinges
112b, 111b are each formed along a straight line in a common plane,
thereby allowing the colander to fold into a flat configuration
when collapsed.
[0061] One or more ribs 160 may further be provided at desired
locations on the panels to serve as stops to retain the edges of
the panels adjacent one another in the expanded position. In one
version, the first panel may include several ribs positioned to
face into an interior of the colander in the expanded position and
formed along edges of the sidewall portion of the first panel. When
the colander is expanded and the edges of the sidewalls are urged
toward one another, edges of the second and third panels abut the
ribs to prevent the edges from being urged to an interior portion
of the colander. Thus, the ribs can serve to align the colander and
ensure the edges are retained closely adjacent one another.
[0062] Each of the first, second, and third panels includes an
upper portion, above the upper living hinge. The upper portion
includes a central region that terminates along a curved edge that
follows a path of curvature parallel to that of the upper living
hinge. Outer ends of the upper portion of the panels, however,
flare outward to provide a wider engagement surface and a larger
area of contact between adjacent panels, thereby providing greater
structural rigidity in the expanded position.
[0063] In the illustrated version, one or both of the upper ends of
the sidewalls 120, 122, includes a spout 123, 124 to facilitate
pouring items (such as pasta, after having been drained) from the
colander. As shown in FIGS. 6E and 6F, the spout may be formed to
bow outward along substantially the entire length of the sidewall
of the colander.
[0064] The feet 149 formed in the second and third panels
preferably extend below the lower living hinges 111a, 112a, thereby
forming a foundation that will support the floor 121 of the
colander above a horizontal surface such as a sink when the
colander is expanded and in use. Most preferably, the feet include
ribbing around the perimeter for greater strength.
[0065] In a preferred version, the products described above are
formed from any suitable plastic material, with the separate panels
being integrally molded with living hinges created as areas with
thinned material making the living hinges more flexible.
[0066] Yet other versions of snap-fold containers made in
accordance with principles of the invention are further illustrated
in the FIGS. 7A through 7C. One version of the invention folds into
a dish rack 150. As shown in FIG. 7C, the dish rack 150 is formed
with three panels, 151, 152, 153, the panels being structurally
similar to the colander as described above. Thus, a first panel 151
forms a floor and pair of opposing sidewalls 154 and 155 of the
dish rack, while second and third panels 152, 153 are joined to the
first panel to form a second pair of opposing sidewalls 156,
157.
[0067] As with the colander, the second and third panels each
include three living hinges in which the intermediate living hinge,
152b, 153b, extends along a straight line while the upper and lower
living hinges 152a, 153a, 152c, 153c, are bowed, with the lower
living hinge being curved downward and the upper living hinge being
bowed upward. The second and third panels are further formed with
feet as described above.
[0068] In order to form the container into a dish rack, additional
ribs, for example 168, 170 and extensions, for example 165, 167 are
formed in the panels. Thus, the front panel is formed with several
elongate cutouts 165, 167 that straddle the upper living hinge.
When folded along the upper living hinge, these elongate cutouts
extend vertically and provide locations for supporting cups or
glasses. In addition, the space vacate by the cutouts 165, 167 to
form posts for holding glasses also creates an opening 190 suitable
for accepting cutlery. The cutlery can be inserted through the
openings where it stands in an upright position, resting on the
floor and leaning against the rim of the opening.
[0069] Similarly, the edges of the first panel are formed with a
series of outwardly extending fingers 168, 170. When the dish rack
150 is assembled and in the expanded position, these fingers face
toward one another; that is, they are formed on opposite sides of
the container and project inwardly toward one another and toward
the center of the container. Because the fingers are sized and
configured to receive a plate between them, in the expanded
position they can each provide support for a plate in a vertical
position.
[0070] The floor of the first panel 151 is further formed with a
series of upwardly extending ribs 180 with the ribs 180 being
spaced apart to receive a rim of a plate and thereby provide
support for plates placed between the ribs in a vertical position.
The floor panel 151 may further include additional upward ribs or
flanges 192, 193, formed to be positioned under the cutlery
openings when the container is expanded. While the vertical portion
of the elongate cutouts are useful for supporting cups and glasses,
the openings in the cutouts are functional for receiving cutlery.
This second ribbing is positioned along the floor of the first
panel cooperate with the openings to prevent the cutlery from
sliding downward and along the floor.
[0071] As shown in FIG. 7C, the dish rack begins in an entirely
flat configuration. By attaching sides to one another, it
progresses to the shape of FIG. 7B, in which it remains flattened
but is assembled. Urging the opposing sides inward produces the
expanded position of FIG. 7A.
[0072] While the preferred embodiment of the invention has been
illustrated and described, as noted above, many changes can be made
without departing from the spirit and scope of the invention.
Accordingly, the scope of the invention is not limited by the
disclosure of the preferred embodiment. Instead, the invention
should be determined entirely by reference to the claims that
follow.
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