Water-tight and temperature-insulating expandable-collapsible container

Abstract

The invention relates to a two-layer substrate structure in 2D form configured for expansion to a 3D double-wall container, comprising : an inner portion comprising an inner base, and inner front, rear, and two side walls; an outer portion comprising an outer base, and outer front, rear, and two side walls; wherein the inner and outer portions are configured to be folded and bonded in a loop-like structure in cros s-section, before expanding the loop-like structure to the 3D double wall container form.

Description

[0001] WATER-TIGHT AND TEMPERATURE-INSULATING EXPANDABLE- COLLAPSIBLE CONTAINER

[0002] FIELD OF THE INVENTION

[0003] The field of the invention generally relates to cardboard containers .

[0004] BACKGROUND OF THE INVENTION

[0005] Various food products (such as ice cream and the like) sold in liquid or frozen form require containers with temperature isolation and liquid-tight characteristic.

[0006] In a non-limiting example, various ice cream parlors sell ice cream in large capacity (500 grams or more) for home consumption. Given the time passed until arriving home, the ice cream container needs temperature isolation and liquid tight.

[0007] One common container for ice cream delivery is solid plastic-made. Typically, this container suffers from poor temperature isolation. The provision of temperature isolation to this type of container (typically requiring a double wall with air occluded in between) significantly adds to the amount of plastic used, the complexity of container production, and the overhead costs. This plastic- made container (even in its single-wall form) suffers from two additional drawbacks: (a) Plastic is not an environmentfriendly material, as it doesn't biodegrade or recycle well; and (b) The container distribution to the ice cream parlor (or to the manufacturer's plant) before the packaging of the product and its disposal after the product's consumption is very space-wasting, given the large 3D rigidity of the container and the amount of air occluded in it. Another type of temperature-isolating container commonly used is made of foam polystyrene. Unfortunately, this type of container suffers from the same deficiencies as the plastic-made container mentioned above. Concerning recycling, foam polystyrene (Styrofoam) recycles even worse than plastic and is banned for use in many countries.

[0008] A more environment-friendly thermal container, for example, for use by ice cream parlors, is described in EP 3,765,381. The container generally includes two or more parts: (a) a first double-wall cardboard-made bathtub-like tray; (b) a cardboard double-wall lid; and (c) optionally, a second double-wall (or single-wall) bathtub-like tray configured for insertion into the first tray. EP 3,765,381 never indicates whether its container is liquid-impermeable, but it seems that an additional enveloping layer of polyethylene or the second double wall tray is mandatory for impermeability. While being more environmentally friendly compared to the entirely plastic-made container commonly used, this latter container still suffers from two main drawbacks: (a) It is still distributed from the container's manufacturer to the ice cream parlors (or any other user) in a rigid 3D form (given the rigidity of all its parts) - therefore consuming a significant shipment volume given the air occluded, for example within the interspaces between the container and the lid's double-walls; and (b) Following the content's consumption, the disposal of the container still consumes a large volume.

[0009] The invention aims to provide an improved liquid-tight and temperature-isolation container entirely made of environmentally friendly material. Another object of the invention is to provide a liquid- tight and temperature-isolating container distributed to the product's packaging user in a minimal volume form, significantly saving transportation costs and storage space.

[0010] Another object of the invention is to enable easy and fast reduction of the container to its minimal volume after consumption of its content.

[0011] It is still another object of the invention to provide a process for producing the above container at a simple and low cost.

[0012] Other objects and advantages of the invention become apparent as the description proceeds.

[0013] SUMMARY OF THE INVENTION

[0014] The invention relates to a two-layer substrate structure in 2D form configured for expansion to a 3D double-wall container, comprising: an inner portion comprising an inner base, and inner front, rear, and two side walls; an outer portion comprising an outer base, and outer front, rear, and two side walls;wherein the inner and outer portions are configured to be folded and bonded in a loop-like structure in cross-section, before expanding the loop-like structure to the 3D double-wall container form.

[0015] In an embodiment of the invention, the two-layer substrate is characterized by: a first of the two layers is the inner portion, which comprises: the inner base having 4-sides; the inner front, rear, and two side walls, each said inner wall foldably borders one side of the inner base, respectively; and, four pairs of triangular wings, each pair of wings is located at one corner of the inner base, the two triangular wings in the pair are separated by a common folding line, and each wing also borders one inner wall, respectively; and a second of said two layers is said outer portion, which comprises: the outer base having 4-sides; the outer front, rear, and two side walls, each said outer wall foldably borders one side of the outer base, respectively; and wherein the substrate further comprises four spacers, each spacer borders one of said inner walls; wherein to expand said substrate to a 3D double-wall container, the side walls and the front and rear walls of both the inner and the outer portion are raised, thereby forming the 3D double-wall container, and wherein at the 3D double-wall container each said pairs of triangular wings is folded and positioned in between one of said inner walls and one of said outer walls, respectively, to form a liquid-tight structure at said 3D double-wall container.

[0016] In an embodiment of the invention, the outer portion is divided into first and second outer sub-portions that are adhesively attachable to one another via a tab at an edge of one of said outer sub-portions.

[0017] In an embodiment of the invention, the two-layer substrate further comprising cover tabs for covering at least several of said pairs of wings at their location in between an outer and an inner wall, respectively.

[0018] In an embodiment of the invention, the two-layer substrate further comprising four top spacers, two of said spacers bridging, respectively, an inner wall and an outer wall, and each of the other two of said spacers bridging, respectively, another outer wall and an extension. In an embodiment of the invention, each said extension is connected at one side to one of said top spacers, and at an opposing side to an engagement tab, which in turn is engageable with one of said outer walls.

[0019] In an embodiment of the invention, each said engagement between an engagement tab and an outer wall, respectively, utilizes a cut in the outer wall.

[0020] In an embodiment of the invention, the two-layer substrate further is further provided with a separate lid, covering the 3D double-wall container.

[0021] In an embodiment of the invention, the lid has either a double-wall or a single-wall structure.

[0022] In an embodiment of the invention, the dimensions of each inner portion's wall are smaller than of respective dimensions of an adjacent outer portion's wall, respectively, and the dimensions of the inner portion's base are smaller than the dimensions of the outer portion's base.

[0023] In an embodiment of the invention, the inner and outer bases are squared.

[0024] In an embodiment of the invention, the two-layer substrate is configured for distribution from a manufacturing facility to a consumer in its 2D structure, ready for onsite expansion to said 3D double-wall container.

[0025] In an embodiment of the invention, each inner and outer wall is slanted relative to vertical. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In the drawings:

[0027] - Figs, la and lb show the container's substrate in its initial form, according to a first embodiment of the invention;

[0028] - Figs. 1c and Id show how the substrate of Fig. la is folded to a loop-like 2D structure in cross-section, ready for distribution to a 1stconsumer, according to a first embodiment of the invention;

[0029] - Figs, le-lh show the various stages of expanding the looplike structure of Fig. ID to a 3D container, according to a first embodiment of the invention;

[0030] - Fig. li shows the container in its final 3D form, ready for handing with content to a 2ndconsumer, according to a first embodiment of the invention;

[0031] - Fig. 2a shows the container's substrate in its initial form, according to a second embodiment of the invention;

[0032] - Figs. 2b and 2c show how the substrate of Fig. 2a is folded to a loop-like 2D structure in cross-section, ready for distribution to a 1stconsumer, according to a second embodiment of the invention;

[0033] - Figs. 2d-2f show the various stages of expanding the looplike structure of Fig. ID to a 3D container, according to a second embodiment of the invention;

[0034] - Fig. 2g shows the container in its final 3D form, ready for handing with content to a 2ndconsumer, according to a second embodiment of the invention;

[0035] - Fig. 3a shows the container's substrate in its initial form, according to a third embodiment of the invention;

[0036] - Fig. 3b shows how the substrate of Fig. 3a is folded to a loop-like 2D structure in cross-section, ready for distribution to a 1stconsumer, according to a third embodiment of the invention;

[0037] - Fig. 3c shows the container in its final 3D form, ready for handing with content to a 2ndconsumer, according to a third embodiment of the invention; - Fig. 4a shows the container's substrate in its initial form, according to a fourth embodiment of the invention;

[0038] - Fig. 4b shows how the substrate of Fig. 4a is folded to a loop-like 2D structure in cross-section, ready for distribution to a 1stconsumer, according to a fourth embodiment of the invention;

[0039] - Fig. 4c shows the container in its final 3D form, ready for handing with content to a 2ndconsumer, according to a fourth embodiment of the invention; and

[0040] - Fig. 5 shows the container of the invention, covered with a lid.

[0041] DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0042] The invention provides a liquid-tight, temperatureisolating container made of environmentally friendly materials. As is elaborated hereinafter, the container of the invention can be shipped to the packaging entity (i.e., the entity that inserts the final product into the container) in a 2D saving space form. The container can be easily expanded to its 3D form just before use and may be collapsed back to its 2D form after usage for disposal.

[0043] Figs, la to li show the first embodiment of the invention's container 100. Figs, la and lb show a 2D foldable sheet of cardboard (for example) used to create the double-wall, expanded-collapsible container of the invention. Figs, lc- lh illustrate the stages for expanding the 2D sheet, forming the 3D final container shown in Fig. li.

[0044] Sheet 100, shown in Fig. la, can be made of, for example, cut corrugated cardboard, or cut thin cardboard preferably coated with a liquid impermeable layer (a process widely known in the art). Fig. lb indicates only the facets (walls) of layer 100. The meaning of each sheet's components' is detailed in a table form at the end of this description.

[0045] Sheet 100 is typically divided into an inner portion 102, forming the container's interior, and an outer portion 101, which may be divided into two outer sub-portions 101a and 101b forming the container's exterior. In general, inner portion 102 includes the internal base 102, interior two side walls 105a and 105b, and interior front and rear walls 107a and 107b, respectively. The outer sub-portions 101a and 101b include the external base 103, the external side walls 106a and 106b, respectively, and the external front and rear walls 108a and 108b, respectively. In addition, sheet 100 includes top longitudinal spacers 110a and 110b and top transverse spacers Illa and 111b. Sheet 100 also includes (a) two extensions, 118a and 118b, each ending with respective engagement tabs 120a and 120b, respectively, and (b) two insertion cuts 112a and 112b, for engagement with engagement tabs 120a and 120b, respectively. In addition, and as also elaborated below, sheet 100 also includes several hidden assisting elements, such as (a) eight triangular wings 104a, 104b, 104c, 104d, 104e, 104f, 104g, and 104h, divided into four pairs of such bordering elements, (b) four optional hidden cover tabs 122a, 122b, 122c, and 122d, and (c) an attachment tab 116.

[0046] The terms "inner" and "internal" are used interchangeably throughout this description. Likewise, "outer" and "external" are used interchangeably.

[0047] Sheet 100 also includes various top and bottom folding lines whose locations are marked in the drawings and detailed at the "list of parts" table (at the end of the description). The functions of the folding lines become apparent given this description and the drawings.

[0048] Given sheet 100, and as an initial step shown in Fig. lc, the outer sub-portions 101a and 101b are downfolded (relative to the situation shown in Fig. la) while the bottom edge 133 of outer sub-portion 101a is adhesively attached to the top of attachment tab 116 of outer subportion 101b, forming a "loop-like" part in cross-section. More specifically, in the structure best shown in Fig. Id, the external layer 101, made of the two sub-portions 101a and 101b (now attached to one another), is shown on top of the inner layer 102. This structure is a substantially two- dimensional (2D) form, enabling packing hundreds of units 100 one on top of the other and compactly delivering them to 1stconsumers, such as ice cream manufacturers, fish distributors, ice cream parlors, or similar consumer who wishes to pack frozen or liquid content within the container, etc.

[0049] It should be noted that the location of tab 116 (and its attachment to the internal portion 102) may vary, such that in some embodiments, the two outer sub-potions 101a and 101b are combined into a united single outer portion 101.

[0050] When necessary to pack a product within the container (e.g., packing of ice cream, fish, etc.) before handing it to a 2nd consumer (such as the one who consumes the ice cream), the unit 100 is expandable within seconds to its final form, in a procedure generally shown in Figs, le to lh. The procedure may involve, for example, the following steps:

[0051] (a) The user raises the two side walls (practically, for each side wall, the internal 105 and external 106 side walls are simultaneously raised, as they are attached to one another) and holds them in the erected position (Figs, le and If);

[0052] (b) The user raises the front internal wall 107b;

[0053] (c) At the two sides of the (already raised) front internal wall 107b, the user folds each pair of side wings 104 about the respective diagonal fold line 142, further folding them about the respective line 133, and maintains each pair of wings behind the respective side of internal wall 107b (see Fig. If);

[0054] (d) At each side of the front internal wall 107b, the user further folds the cover tab 122 to cover the pair of wings 104;

[0055] (e) The user then raises the external (front) wall 108b, such that tabs 122 and wings 104 are maintained in between the internal wall 107b and external wall 108b (Fig. lg);

[0056] (f) The user then folds extension 118b and inserts extension 120b to within cut 112b, as seen in Figs, lh and li. This procedure locks the two side walls (each side wall in its double structure) to the double structure front wall 108b (external) and 107b (internal).

[0057] (g) Steps (b) to (f) above are repeated at the rear side for rear walls 107a and 107b, completing the final container as shown in Fig. li.

[0058] It should be noted that using engagement tabs 120 together with insertion cuts 112 is only one attachment option. Other similar types of attachments may be used, for example, adhesive tape, direct adhesive attachment, Velcro, etc.

[0059] In its final form (shown in Fig. li), each of the container's walls (front, rear, and side walls) has a spaced-apart double structure created by spacers 110 and 111. Moreover, the internal base 102 is spaced apart from the external base 103, given that the internal base and internal walls are somewhat smaller than the dimensions of the external base and external walls, respectively. Therefore, the container provides excellent temperature isolation.

[0060] The container's structure is also liquid-tight. Each folding line 133a-b and 135a-b at the internal's bottom of the container provides a rigid connection impermeable to liquid. Moreover, each possible leakage through the four corners at the internal of the container is rigidly occluded by the four pairs of triangular wings 104. Therefore, there is no possibility of any leakage through the container.

[0061] Moreover, following the product's (e.g., the ice cream) consumption, the user can easily collapse the container back to its 2D form, as shown in Fig. Id. Therefore, the product which is made of, for example, corrugated cardboard, thin cardboard, cut thin cardboard, is environmentally friendly, which is easily and fast disposable.

[0062] Figs. 2a-2g show a second embodiment of the container of the invention. Container 200 is substantially the same as container 100 of Figs, la-li, however, with the engagement tabs positioned at the side walls rather than at the front and rear walls. Similar numeral indications relate to similar functionalities as previously discussed.

[0063] Figs. 3a-3c show a third embodiment of the container of the invention. Container 300 is substantially the same as the container 100 of Figs, la-li, however, has slanted (rather than vertical) front, rear, and side walls. This structure enables the packing of a plurality of containers (in their expanded form), one within the other. In this embodiment, the engagement tabs are locked at the front and rear walls. Again, similar numeral indications relate to similar functionalities as previously discussed.

[0064] Figs. 4a-4c show a fourth embodiment of the container of the invention. Container 400 is substantially the same as the container 300 of Figs. 3a-3c, however, in this embodiment, the engagement tabs are locked at the side walls of the container. Again, similar numeral indications relate to similar functionalities as previously discussed.

[0065] Fig. 5 shows a container 500 closed by a lid 570. The lid may include a spaced-apart double-layer structure (similar to container 100) or a conventional single-layer structure.

[0066] In some embodiments (not shown), the dimensions of the front and side walls (internal and external, respectively) are made the same, therefore providing a square cross-section container (rather than a rectangular cross-section as described so far).

[0067] As noted, the single-layer substrate of Fig. la (including its folding lines) is initially prepared, for example, using a die-cut machine. Then, the layer is folded and adhesively attached, bringing it to the "loop-like" structure (in cross-section) shown in Fig. lc. This simple procedure may also be made manually or by machinery. The expansion of the "loop-like" structure from it 2D to 3D is performed when suitable, for example, at a 1st type of consumer (e.g., the ice-cream factory) or at a second type of consumer (e.g., an ice cream parlor).

[0068] Experiment :

[0069] A container similar to container 300 was prepared from a corrugated cardboard E-Flute (1.5mm) laminated with a thin layer of polyethylene on one side. The container's layer in this specific experiment was cut using a Sample maker process. Then, water was poured into the container and left for 7 days. During this entire period, no leakage whatsoever was detected.

[0070] List of Parts

Claims

CLAIMS1. A two-layer substrate structure in 2D form configured for expansion to a 3D double-wall container, comprising: an inner portion comprising an inner base, and inner front, rear, and two side walls; an outer portion comprising an outer base, and outer front, rear, and two side walls; wherein said inner and outer portions are configured to be folded and bonded in a loop-like structure in crosssection, before expanding the loop-like structure to the 3D double-wall container form.

2. The two-layer substrate structure of claim 1, wherein: a first of said two layers is said inner portion, which comprises:- said inner base having 4-sides;- said inner front, rear, and two side walls, each said inner wall foldably borders one side of the inner base, respectively; and- four pairs of triangular wings, each pair of wings is located at one corner of the inner base, the two triangular wings in the pair are separated by a common folding line, and each wing also borders one inner wall, respectively; and a second of said two layers is said outer portion, which comprises:- said outer base having 4-sides;- said outer front, rear, and two side walls, each said outer wall foldably borders one side of the outer base, respectively; andwherein the substrate further comprises four spacers, each spacer borders one of said inner walls; wherein to expand said substrate to a 3D double-wall container, the side walls and the front and rear walls of both the inner and the outer portion are raised, thereby forming the 3D double-wall container, and wherein at the 3D double-wall container each said pairs of triangular wings is folded and positioned in between one of said inner walls and one of said outer walls, respectively, to form a liquid-tight structure at said 3D double-wall container.

3. The two-layer substrate of claim 1, wherein said outer portion is divided into first and second outer subportions that are adhesively attachable to one another via a tab at an edge of one of said outer sub-portions.

4. The two-layer substrate of claim 2, further comprising cover tabs for covering at least several of said pairs of wings at their location in between an outer and an inner wall, respectively.

5. The two-layer substrate of claim 1, further comprising four top spacers, two of said spacers bridging, respectively, an inner wall and an outer wall, and each of the other two of said spacers bridging, respectively, another outer wall and an extension.

6. The two-layer substrate of claim 5, wherein each said extension is connected at one side to one of said top spacers, and at an opposing side to an engagement tab,which in turn is engageable with one of said outer walls.

7. The two-layer substrate of claim 6, wherein each said engagement between an engagement tab and an outer wall, respectively, utilizes a cut in the outer wall.

8. The two-layer substrate of claim 1, further provided with a separate lid, covering the 3D double-wall container.

9. The two-layer substrate of claim 8, wherein said lid has either a double-wall or a single-wall structure.

10. The two-layer substrate of claim 1, wherein the dimensions of each inner portion's wall are smaller than of respective dimensions of an adjacent outer portion's wall, respectively, and the dimensions of the inner portion's base are smaller than the dimensions of the outer portion's base.

11. The two-layer substrate of claim 1, wherein the inner and outer bases are squared.

12. The two-layer substrate of claim 1, distributed from a manufacturing facility to a consumer in its 2D structure ready for on-site expansion to said 3D double-wall container.

13. The two-layer substrate of claim 1, wherein each inner and outer wall is slanted relative to vertical.

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