Folded wooden container

Abstract

A container (10) may have a wooden panel (20) having a film (30) adhered to a surface of the wooden panel. The wooden panel is formed into a receptacle having a bottom wall (11) and side walls (12). Retaining tabs (13) are connected to a first set of the side walls and overlappingly adhered to a second set of the side walls to hold a shape of the receptacle. Hinges are between the bottom wall and the side walls, and between the retaining tabs and the first set of the side walls, the hinges defined by the film. The container is characterized in that the wooden panel has partial cuts (24) and webs at a location of the hinges prior to forming, and the webs (24a) are fractured at the joints in the container.

Description

TECHNICAL FIELD

[0001] The application relates to wooden containers used in the packaging industry for products such as foodstuff or objects or materials of various types.BACKGROUND

[0002] Containers are traditionally used when packaging foodstuff in liquid or loose form, objects, material. While plastics have been commonly used due to their properties, there remains a demand for the use of natural fibers for containers. There are various reasons for the popularity of natural fibers for containers, notably the compostable nature of some of these natural fibers, the possibility of using recycled fibers, the low carbon footprint and the sustainability, to name a few advantages. In particular, wood panels may provide structural strength for heavier and / or more voluminous packaged goods. However, there are issues related to permeability of wood and to its absorbing capacity. Moreover, cost effectiveness may also favor plastics over wood containers.

[0003] It would therefore be desirable to improve manufacturing techniques and wooden containers based on the above.SUMMARY

[0004] In one aspect, there is provided a container comprising: a wooden panel having a film adhered to a surface of the wooden panel, the wooden panel formed into a receptacle having a bottom wall and side walls, retaining tabs connected to a first set of the side walls and overlappingly adhered to a second set of the side walls to hold a shape of the receptacle, and hinges between the bottom wall and the side walls, and between the retaining tabs and the first set of the side walls, the hinges defined by the film; characterized in that the wooden panel has partial cuts and webs at a location of the hinges prior to forming, and the webs are fractured at the joints in the container.

[0005] Further in accordance with the aspect, for instance, the wooden panel is a panel of plywood.

[0006] Still further in accordance with the aspect, for instance, fibers of a first ply of the plywood are oriented transversely to fibers of an adjacent second ply of the plywood.

[0007] Still further in accordance with the aspect, for instance, the partial cut is a kiss cut.

[0008] Still further in accordance with the aspect, for instance, the partial cut penetrates at least 50% of a thickness of the wooden panel.

[0009] Still further in accordance with the aspect, for instance, the film covers an entire surface of the wooden panel.

[0010] Still further in accordance with the aspect, for instance, the film is in an interior of a cavity of the receptacle.

[0011] Still further in accordance with the aspect, for instance, the film is a sheet of polymer.

[0012] Still further in accordance with the aspect, for instance, the film is a sheet of paper.

[0013] Still further in accordance with the aspect, for instance, the film is a waterproof film.

[0014] Still further in accordance with the aspect, for instance, the film is a grease-barrier film.

[0015] Still further in accordance with the aspect, for instance, an exterior surface of the container is natural wood.

[0016] Still further in accordance with the aspect, for instance, a geometry of container flares toward a top open end thereof.

[0017] Still further in accordance with the aspect, for instance, adjacent ones of the side walls are abutted against one another without adhesive.

[0018] Still further in accordance with the aspect, for instance, the wooden panel is a single wooden panel used for an entirety of the container.DESCRIPTION OF THE DRAWINGS

[0019] Reference is now made to the accompanying figures in which: Fig. 1 is a perspective view of a folded wooden container in accordance with the present disclosure; Fig. 2 is a plan view of the folded wooden container of Fig. 1; Fig. 3 is a sectional view taken along lines 3-3 of Fig. 2; Fig. 4 is a sectional view taken along lines 4-4 of Fig. 2; Fig. 5 is a wooden panel used to form the folded wooden container of Figs. 1 and 2; and Figs. 6A and 6B are schematic views showing a folding of the wooden container into its three-dimensional shape from a panel configuration. DETAILED DESCRIPTION

[0020] Referring to the drawings and more particularly to Fig. 1 and 2, a folded wooden container in accordance with the present disclosure is generally shown at 10. The folded wooden container 10 may also be known as a cellulose container, due to the use of wood as its main constituent. The container 10 may be referred to as a receptacle, a cup, a pot, a package, a tray, among other possible names. Moreover, while a container is shown, other objects may be made of wood in accordance with the present disclosure, such as cups, trays, bowls, among examples. The container 10 may or may not be used with a lid that may be releasably secured to a top of the container 10 to close a top open end of the container 10. The lid may or may not be made of transparent plastic, of cellulose, of wood, etc. The container 10 may be used for packaging various items, whether in liquid, solid, gel, viscous forms, or as loose material or matter, granules, etc. The container 10 may be impermeable to water and liquids, and / or to grease and oils. In a variant, the folded wooden container 10 has the capacity to maintain its structural integrity in freezer temperatures, in refrigerator temperatures. The folded wooden container 10 may be used in warming process of its contents, and in the heating process of its contents, as it may be used in an oven, without affecting substantially its properties. The expression « folded » is used herein to describe part of the manufacturing of the wooden container 10, starting from a panel, with folding-like actions to give the wooden container 10 its three-dimensional shape. The use of "folded" does not necessarily imply that there are folds in the wood panel, as the present disclosure describes a fracture or rupture of the wooden panel. Other monikers may be used to describe the wooden container 10.

[0021] The container 10 has wood as a main material, and more particularly wood in the form of a panel 20 (Fig. 5). The wood is said to be the main material in that it makes up the greatest proportion by weight and / or by volume of the empty container 10. In a variant, the wood panel used is a plywood panel. The plywood panel may have two or more plies (i.e., veneers, layers, subpanels) that are glued together (e.g., laminated, adhered, etc). The number of plies may depend on the thickness of the plies and on the desired panel thickness for the container 10. In a variant, the fibers of interconnected plies are oriented so as to be transverse to one another, from one ply to another. In an embodiment, the transverse relation is perpendicularity. Such transverse orientation is optional, but may strengthen the panel. The various plies may be in the form of unrolled wooden sheets, as a possibility. This being said, while a plywood panel(s) may be used, other wood panel configurations can be used, including planks, boards. The wood of the container 10 may be a panel of solid wood, instead of being a composite like a plywood.

[0022] Additives can be added to the wood to give selected characteristics to the cellulose. The selected characteristics may include colour, moisture resistance, enhanced shock resistance. Moreover, the wooden panel making up the container 10 may be printed and / or pyrographed. For this reason, the wooden panel may also be known as a coated wooden panel (a.k.a., coated wooden), and may have one or both of its surfaces coated, for receiving and containing ink. The coating may be of different types, but a mineral-based coating is particularly well suited to be used due to its eco-friendliness, and its capacity to act as an ink-receiving coating. For example, the coating may be a clay or limestone based coating. Other coatings may be used, including polymeric coatings. Also, adjuvants or solutes may be part of the coatings. In an embodiment, the coating may be said to be an integral part of the wooden panel, in that the coating is impregnated into the surface of the wood and cannot be detached from it, unlike a film laminated to a surface of the wood. The coating may be said to be a non-film coating, the coating may be applied in a liquid state onto the wooden panel, such that the coating may penetrate the surface(s) of the wooden panel. The coating may include a varnish.

[0023] The container 10 shown in Fig. 1 defines an inner cavity or receptacle (i.e., the container 10 is concave), by a bottom wall 11 and side walls 12. As observed, the bottom wall 11 is shown defining a generally rectangular shape (four sides), when seen from a top view, but any other appropriate polygonal shape may be used with other possible geometries. The shapes may include, square, hexagonal, octagonal, among possible straight-edge peripheral shapes. Geometries may include prisms and boxes, among possible geometries. In a variant, the container 10 may be constituted of flat surfaces and straight edges between surfaces, as observed.

[0024] Reference will now be made to the container 10 when laid on a horizontal surface as in Fig. 1 and thus with its open top end. In such an orientation, the container 10 may be said to have the side walls 12 projecting generally upwardly from the bottom wall (e.g., perpendicular to the bottom wall 11, or at other angles). As described herein, the side walls 12 may be hinged to the bottom wall 11. It can be observed that the side walls are at an angle of more than 90 degrees from the bottom wall 11, such that an inner cavity of the container 10 flares upwardly. Stated differently, a geometry of container 10 may be said to flare toward a top open end thereof. This may give a stacking capability to the container 10, as piled up empty containers 10 mate due to the flaring shape. There are four different side walls 12 shown based in the exemplary geometry, with two larger side walls, shown as 12A, and two smaller side walls, shown as 12B. The smaller side walls may be said to be end walls. The side walls 12 may also be all of the same size and / or same width. Moreover, the side walls 12A and 12B may be said to be lateral walls, in contrast to the bottom wall 11. In the figures, reference numerals are shown as 12A and 12B, and concurrent reference to the side walls is made as side walls 12 in the present text. A rim (i.e., ridge, sealing flange, flange, sealing rim, etc) may optionally be present to define the top open end of the container 10, but is not shown in the embodiment of Fig. 1, in which top open end of the container 10 is defined by the edges of the side walls 12.

[0025] Retaining tabs 13 may be connected to the side walls 12A in the manner shown in Figs. 1 and 3. Other expressions could be used to describe the "retaining tabs", such as connection tab, connection bracket, connection wall, retaining wall, connection panel, etc. As described herein, the retaining tabs 13 are hinged to the side walls 12A. Alternatively, the retaining tabs 13 may be connected to the side walls 12B, or to a combination of the side walls 12A and 12B. Stated differently, the retaining tabs 13 are connected to a first set of side walls 12, such as by a hinge of film as described later, and are overlappingly adhered to a second set of the side walls 12. The retaining tabs 13 may have different shapes. However, in order to maximize the use of a wooden panel, the retaining tabs may be triangular as shown, with or without rounded corners.

[0026] Fold lines 14, also known as sharp edges, are shown between the bottom wall 11 and the side walls 12. Other fold lines 14 may be between the side walls 12 and retaining tabs 13. The fold lines 14 result from the folding of the panel 20 (Fig. 5) from which the container 10 is made. The use of "fold" does not necessarily imply that there are folds in the wood panel, as the present disclosure describes a fracture or rupture of the wooden panel between walls, with the folds being in a film hinging the walls together. Other monikers may be used to describe the wooden container 10. Adjacent side walls, namely pairs of side walls 12A and 12B in Figs. 1 and 4, meet at joint lines 15. In the illustrated embodiment, the joint lines 15 are not folds. The joints lines 15 are the edge of one of the side walls 12 - in the illustrated embodiment, side walls 12B-, abutted against a plane of the adjacent side wall 12 - in the illustrated embodiment, side walls 12A. The reverse arrangement is possible, with retaining tabs 13 being connected to the side walls 12B instead of being connected to the side walls 12A as shown. An adhesive, waterproof coating and / or other substance may be on the edges of a joint line. However in an embodiment adjacent side walls 12A and 12B abut each other without adhesive.

[0027] The bottom wall 11 and the side walls 12, and retaining tabs 13 may be made of a single panel of wood, shown in Fig. 5, as detailed below, though this is an option. The outer exposed surface of the container 10 may be defined by the bottom wall 11, the side walls 12 and the retaining tabs 13, as the retaining tabs 13 cover part of the exterior surface of the side walls 12B as shown. As detailed below, the outer exposed surface may have the wood exposed, though it may optionally be considered to provide some additional surface coatings to provide given characteristics to the container 10, such as waterproofness or airtightness. The coatings may be applied before of after the forming of the container 10.

[0028] The combination of the bottom wall 11 and the side walls 12 define a concavity that may be referred to as the inner cavity of the container 10. It is the inner cavity that acts as a receptacle for receiving goods in the container 10. The volume of the inner cavity may depend on the contemplated use. The inner cavity is shown as defined by the continuous, smooth surfaces of the bottom wall 11 and side walls 12, with the fold lines 14 separating the bottom wall 11 and side walls 12, and the joint lines 15 separating the side walls 12A and 12B.

[0029] Referring now to Fig. 5, a panel 20 is shown, with the panel 20 optionally being the main constituent of the container 10 of Fig. 1, and with the panel 20 and film 30 forming an assembly that may be, with adhesive, the sole constituents of the container 10. In a variant, a single panel of wood (e.g., plywood) is cut into the panel 20 of Figs. 5, 6A and 6B. In a variant, at least one of the two main surfaces of the panel 20 has a film 30 covering a substantial portion thereof. The film 30 may cover the entire main surface of the panel 20. In a variant, the film 30 covers the surface of the panel 20 that will define the inner cavity of the container 10.

[0030] The film 30 may be a polymer sheet, a paper sheet, a combination thereof, with or without coatings. For example, the film 30 may be wax paper. The film 30 is adhered to the panel 20 in any appropriate way, e.g., with adhesives, via fusion, lamination, etc. The nature of the film 30 may be selected as a function of the desired characteristics, such as waterproofness, grease barrier, etc.

[0031] The panel 20 may be cut so as to have a peripheral contour P, the peripheral contour P having a container specific outline. For example, a substantial portion of the peripheral contour P may define an outer edge of the container 10 of Fig. 1, with the potential exception of the retaining tabs 13. In an embodiment, the panel 20 is cut into the shape of Fig. 5 by a die cutter, through other options are contemplated (e.g., laser cutting). In a manufacturing process, the panel 20 is cut into the shape of Fig. 5 after the film 30 has been adhered to the wooden panel, though it could be applied after the cutting.

[0032] In the panel 20, bottom wall portion 21 would correspond to the bottom wall 11 of the formed container 10. Likewise, side wall portions 22 would correspond to the side walls 12 of the formed container 10. For example, side wall portions 22A correspond to side walls 12A, while side wall portions 22B correspond to side walls 12B. Retaining tab portions 23 would correspond to the retaining tabs 13 of the formed container 10. In the panel 20 of Fig. 5, the lines 25 between the side walls portions 22B and the retaining tab portions 23 are cuts made through the entire thickness of the panel 20.

[0033] In contrast, lines 24 (or like weakening lines) may be defined in a surface of the panel 20, at locations of the fold lines 14 in the formed container 10. As observed in Figs. 6A and 6B, the lines 24 penetrate a surface of the panel 20 but do not perforate through the whole thickness of the panel 20. In a variant, the lines 24 are partial cuts into the thickness of the panel 20, such as penetrating at least 50% of the thickness. They may be said to be partial, in that a web 24A of wood remains present after the cutting. Figs. 6A and 6B show that the panel 20 may be plywood having three plies 20A, 20B, 20C, with the ply 20C defining the surface of the panel 20 facing the inner cavity of the formed container 10, and thus having the film 30 secured thereon in a coplanar manner. In the illustrated variant, the line 24 is cut through the plies 20A and 20B, but does not penetrate ply 20C, or leaves the web 24A. As alternative embodiments, other ones of the plies may not be fully cut by the line 24, or may not be cut at all. Moreover, while plywood is shown, it is possible to use other wood panel configurations, such as a panel of solid wood. The line 24 may also be referred to as a kiss-cut line 24, due to the presence of the web 24A.

[0034] Different types of tools may be used to form the lines 24 or like weakening lines, such as wheel cutters, laser cutters, knives, heated edges, etc. There results in the panel 20 localized linear weaknesses facilitating a forming of the panel 20 into the container 10, to form the fold lines 14.

[0035] Figs. 6A and 6B show the folding of the panel 20 at the lines 24. Because of the presence of the web 24A, there is a solid bond shown in Fig. 6A between interconnected panel portions, such as 21 and 22A (shown), but also between 21 and 22B, and between 22A and 23. The web 24A has the film 30 thereon. As the panel portions are folded relative to one another at the lines 24, the web 24A factures (i.e., breaks, ruptures). However, because of the elasticity and / or flexibility of the film 30, the film 30 remains present between the panel portions, and becomes a hinge (e.g., Fig. 6B) at the fold lines 14. As the film 30 is present at the fold lines 14, the fold lines 14 have the properties of the film 30, such as waterproofness, etc. It may be said that the film 30 at the fold lines 14 remains whole, remains complete.

[0036] The use of the weakening lines 24 (e.g., kiss-cut), along with the film 30 being applied before the folding from Fig. 6A to 6B, ensures that the various panel portions 21, 22, 23 are natively aligned, in comparison to a manufacturing technique in which the panel portions 21, 22 and / or 23 would be individually cut and then positioned relative to one another in the manner shown in Fig. 5. The fold lines 14 may therefore be referred to as kiss-cut fold lines 14. The edges of the walls 11, 12 and 13 separated by the fold lines 14 may be said to be fractured edges, or may be said to have fractured edge portions. The fold lines 14 may each be said to include a fractured web portion, or fractured wooden web portion. The fractured edge portions may be said to have negative complementary geometries, i.e., one surface geometry is the negative of the surface geometry of the other. This can be seen in Fig. 6B, in which the opposite outlines of the fractured web 24A are negatives of one another. The fracture of the web 24A, as some fibers of wood from the web may remain present and may extend from one wall to another. Thus the expression « fracture » includes the fracture being partial. This approach of fracturing a kiss-cut line 24 may be said to preserve the integrity and properties of the film 30 at the fold lines 14. The approach of fracturing may also limit the gap between adjacent walls 11 and 12, and may result in a precise and accurate positioning of the walls 11 and 12 relative to one another.

[0037] In some instances, such as when the container 10 is used for fruits or like solids, it may be desired to have holes in the container 10, and thus holes may be present, for instance in the main surfaces of the side walls 12 (e.g., for air flow). However, unless desired, there are no holes in the corners or fold lines 14 between the bottom wall 11 and the side walls 12 in the formed container 10.

[0038] In order to fold the panel 20 into the container 10, prior to subject same to a heating process, one possible sequence is given, with reference to Fig. 5. Other folding sequences could be used. The panel 20 must be cut into the shape and configuration of Fig. 5, using any appropriate cutting technique. This includes the joint lines 24 and cut lines 25. The film 30 may have been adhered before the cutting, or after the cutting, but before the folding. The panel 20 is oriented to have its surface covered by the film 30 facing in a direction of folding so as to form the inner cavity of the container 10. According to the sequence, in a first step, the webs 24A of the lines 24 are fractured by folding movement. As an option, the wall portions 22B are first folded relative to the panel portion 21. Then, the wall portions 22A are folded relative to the panel portion 11, until they come into abutment with the wall portions 22B that have already been folded. Finally, the tab portions 23 may be folded relative to the wall portions 22A into contact with the exterior surface of the side wall portions 22B. These maneuvers may be done manually, or using robotic equipment. There may be an adhesive between the tab portions 23 and the exterior surface of the side wall portions 22B, whether it is added during the folding, or pre-applied. In a variant, the film 30 may act as adhesive. The adhesive may include a tape, such as a double-sided tape.

[0039] Once folded in accordance with the sequence set out in Fig. 5, or any other sequence, there results a container shaped as in Fig. 1. The container 10 may then be subject to a conditioning process. For example, pressure and / or heat may be applied on the overlaid assembly of the walls 12B and retaining tabs 13 to ensure adherence therebetween. This may be done for example using a press, a mold, an oven, etc. Other steps may be present in the conditioning process. This may also include printing, pyrographing, etc. Thus, the container 10 may be inserted into a mold cavity or other heat forming apparatus to be subjected to pressure and / or heat that will secured overlaid panels / walls / tabs. In an embodiment, a pressure on the container 10 is increased to reach a predetermined value of a given amount of time at a desired temperature, for the securing of the overlaid panels / walls / tabs, 12B and 13 in Fig. 1. The pressure, temperature and duration of the process may be varied to achieve the afore-mentioned securing, preferably in cycles in an order of magnitude of seconds.

[0040] In addition to the film 30 that is on the wooden panel 20 prior to folding, an additional coating may be applied after the forming of the container 10. The coating may be any appropriate type of coating to provide some characteristics to the container 10. For example, the coating may be a wax, a polymer, a metal (e.g., aluminum foil), and as a result properties such as airtightness, waterproofness, may be enhanced in the container 10. Additional coating layers may be provided, for instance on top of the coating, on the film 30 or on the outer exposed surface of the container 10. The film 30 is inside the inner cavity of the container 10, and therefore shields the goods in the container 10 from the wood, i.e., there is no direct contact. However, it is also possible to have the film 30 on the exterior surface. Chamfered edges could be present in such a scenario.

[0041] The container 10 may generally be described as having a wooden panel having a film adhered to a surface of the wooden panel. The wooden panel may be a single, unseparated wooden panel, i.e., all portions thereof are interconnected by a continuous layer portion of wood, prior to forming. The wooden panel is formed into a receptacle having a bottom wall and side walls. Retaining tabs are connected to a first set of the side walls and overlappingly adhered to a second set of the side walls to hold a shape of the receptacle. Hinges are between the bottom wall and the side walls, and between the retaining tabs and the first set of the side walls, the hinges defined by the film. The container is characterized in that the wooden panel has partial cuts and webs at a location of the hinges prior to forming, and the webs are fractured at the joints in the container.

[0042] The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without departing from the scope of the invention disclosed. For example, lids may also be made according to the technique described for the container 10. Still other modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the appended claims.

Claims

1. A container comprising: a wooden panel having a film adhered to a surface of the wooden panel, the wooden panel formed into a receptacle having a bottom wall and side walls, retaining tabs connected to a first set of the side walls and overlappingly adhered to a second set of the side walls to hold a shape of the receptacle, and hinges between the bottom wall and the side walls, and between the retaining tabs and the first set of the side walls, the hinges defined by the film; characterized in that the wooden panel has partial cuts and webs at a location of the hinges prior to forming, and the webs are fractured at the joints in the container.

2. The container according to claim 1, characterized in that the wooden panel is a panel of plywood.

3. The container according to claim 2, characterized in that fibers of a first ply of the plywood are oriented transversely to fibers of an adjacent second ply of the plywood.

4. The container according to any one of claims 1 to 3, characterized in that the partial cut is a kiss cut.

5. The container according to any one of claims 1 to 3, characterized in that the partial cut penetrates at least 50% of a thickness of the wooden panel.

6. The container according to any one of claims 1 to 5, characterized in that the film covers an entire surface of the wooden panel.

7. The container according to any one of claims 1 to 6, characterized in that the film is in an interior of a cavity of the receptacle.

8. The container according to any one of claims 1 to 7, characterized in that the film is a sheet of polymer.

9. The container according to any one of claims 1 to 7, characterized in that the film is a sheet of paper.

10. The container according to any one of claims 1 to 9, characterized in that the film is a waterproof film.

11. The container according to any one of claims 1 to 10, characterized in that the film is a grease-barrier film.

12. The container according to any one of claims 1 to 11, characterized in that an exterior surface of the container is natural wood.

13. The container according to any one of claims 1 to 12, characterized in that a geometry of container flares toward a top open end thereof.

14. The container according to any one of claims 1 to 13, characterized in that adjacent ones of the side walls are abutted against one another without adhesive.

15. The container according to any one of claims 1 to 14, characterized in that the wooden panel is a single wooden panel used for an entirety of the container.

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