Molded fiber food container

Abstract

A molded fiber article with a rim construction is provided. The article includes a first wall, at least one sidewall extending from the first wall, and a first peripheral rim connected to a distal end of the at least one sidewall. The article is configured to be selectively coupled with a second article having an identical rim construction. The first rim comprises a first rim section including a first protrusion and a first locking protrusion, and the second rim section includes a first recess and a first locking hole. When the article is coupled to the second article, the first rim section of the first article is coupled to the second rim section of the second article and the first rim section of the second article is coupled to the second rim section of the first article.

Description

[0001] MOLDED FIBER FOOD CONTAINER

[0002] TECHNICAL FIELD

[0003] The present invention is generally directed to a carton or container, and specifically a container that includes a rim construction that enables two such containers to be secured together in an inverted arrangement to provide an enclosed container or clamshell-style container.

[0004] BACKGROUND ART

[0005] Clamshell containers are common and familiar in everyday use, particularly for holding carry-out food, eggs, and other items. Such clamshell containers typically comprise a base and a lid which are connected by a living hinge. For many years, the most popular material used to manufacture such clamshell containers has been expanded polystyrene (“EPS”) foam. Recently, molded fiber has increasingly replaced EPS foam as a result of increased environmental concerns. Furthermore, rigid plastic lidded containers have also gained market share.

[0006] Additionally, half-shell containers having two identical articles invertedly aligned such that the articles are releasably coupled together are also generally known in the art. However, these half-shell containers have failed to gain any significant market share for various reasons. One problem with current half-shell container designs is that the use of features such as steep angles, undercuts, sharp radii, and other features can be manufactured with thermoplastic materials, but not with molded fiber. Another problem with half-shell containers constructed from molded fiber is that the locking and latching features of the articles are often subjected to heat, steam, moisture and humid conditions as a result of food items placed within the article, and such conditions can cause the locking and latching features to soften, deform and weaken or fail. For those considering molded fiber as a material, the locking features are challenging to create, are complex and difficult for food service operators or consumers to use, and / or are subject to weakening or failure during use.

[0007] Accordingly, a need exists for a molded fiber half-shell container having locking features that are adapted for efficient manufacturability using molded fiber equipment and processes. A need further exists for a molded fiber half-shell container having locking features that are adapted for simple, quick, and intuitive usability. DISCLOSURE OF INVENTION

[0008] The present invention is directed generally to a molded fiber article having a rim construction configured to enable the article to be selectively coupled with a second article. The present invention is further directed to two or more half-shell articles that may optionally be released or secured together to form a container assembly, which may be configured as an enclosed container, clamshell-style container, or the like. In some embodiments, the article may be manufactured from molded pulp, molded fiber, or the like, although other materials are possible. The article may incorporate a press-to-close or tap-to-close latch design that permits two articles to be releasably locked or secured together in a manner that does not require elaborate or complex manual operations.

[0009] One embodiment of the present invention is generally directed to a molded fiber article comprising at least one compartment defined by a first wall, at least one sidewall extending from the first wall, and a first peripheral rim provided at a distal end of the at least one sidewall. The first rim comprises a first rim sect on or male section including a first protrusion and at least one locking protrusion. The first rim further comprises a second rim section or female section including a first recess and at least one locking hole. The female section may further include a second protrusion and a third protrusion, wherein the recess is located between and defined by the second protrusion and the third protrusion. In some embodiments, the article may include multiple male sections and female sections.

[0010] The male section and female section may each extend along approximately one half of the rim, although other constructions are possible. The male section and female section of the article are configured to connect, interlock, or mate with the opposite section of a second article having a generally identical rim construction, where the second article is inverted relative to the first article. Depending on the arrangement and orientation of the second article relative to the first article prior to coupling to the two articles together, the second article may also need to be rotated relative to the first article in order to align the corresponding male and female sections of the articles, and the locking protrusions and locking holes of the articles. The locking protrusion(s) may be located on a portion of a distal edge of the rim. The locking hole(s) may be fully enclosed within the female section of the rim. The locking hole(s) and locking protrusion(s) may be configured to be coupled with locking protrusion(s) and locking hole(s) of the second article.

[0011] When two articles are releasably secured together, the second article is inverted relative to the first article, then the second article is pressed into the first article. In some arrangements, the second article is inverted and rotated one hundred eighty (180) degrees prior to being pressed onto the first article (for example, if the two articles have the same orientation and are arranged side- by-side prior to inversion). Other arrangements of the first article and second article are possible such that the second article must be inverted, rotated, or maneuvered for the second article to be positioned to mate with the first article. The male section and female sections of the two articles are pressed into and mated together to form a seal. The shape of the locking hole(s) and locking protrusion(s) may be configured to couple the articles together without any manual manipulation of any of the locking holes or the locking protrusions.

[0012] In one embodiment, the article may include multiple compartments, where such compartments may be used for separating different foods or items in the article. The compartments may be any number of compartments and in any size or shape desired for the separation of food.

[0013] In one embodiment, two articles may be hingedly attached to one another along at least a portion of the distal edges of the rims of each article by a hinge. The hinge allows each article to circumferentially rotate relative to one another about a hinge axis defined by the hinge. The articles may be attached at multiple locations intermittently along the distal edges to define the hinge, or the hinge may extend continuously along the distal edges of the rims.

[0014] Further advantages, features, and details of the invention are elucidated on the basis of preferred embodiments thereof, wherein reference is made to the accompanying drawings.

[0015] BRIEF DESCRIPTION OF DRAWINGS

[0016] In the accompanying drawings, which form a part of the specification and are to be read in conjunction therewith in which like reference numerals are used to indicate like or similar parts in the various views:

[0017] FIG. 1 is a plan view of an article with a rim construction in accordance with one embodiment of the present invention;

[0018] FIG. 2 is a plan view of the article of FIG. 1 coupled to a rotated and inverted article having an identical rim construction in accordance with one embodiment of the present invention;

[0019] FIG. 3 is a perspective view of the article of FIG. 1;

[0020] FIG. 4 is an enlarged partial cross-sectional view of a rim section of the rim construction of the article of FIG. 1 along section 4-4;

[0021] FIG. 5 is an enlarged partial cross-sectional view of a rim section of the rim construction of the article of FIG. 1 along section 5-5;

[0022] FIG. 6 is an enlarged partial cross-sectional view of a rim section of the rim construction of the article of FIG. 1 along section 6-6; FIG. 7A is a cross-sectional view of the article of FIG. 2. along section 7-7;

[0023] FIG. 7B is an enlarged cross-sectional view of a portion of a rim section of the article in balloon 7B of FIG. 7A;

[0024] FIG. 7C is an enlarged cross-sectional view of a portion of a rim section of the article in balloon 7C of FIG. 7A;

[0025] FIG. 8 is a plan view of an article with a rim construction in accordance with another embodiment of the present invention;

[0026] FIG. 9 is a perspective view of the article of FIG. 8;

[0027] FIG. 10 is a plan view of an article with a rim construction in accordance with another embodiment of the present invention;

[0028] FIG. 11 is a perspective view of the article of FIG. 10 in an open position;

[0029] FIG. 12 is a perspective view of the article of FIG. 10 in a closed position;

[0030] FIG. 13 is a plan view of an article with a rim construction in accordance with another embodiment of the present invention;

[0031] FIG. 14 is a perspective view of the article of FIG. 13; and

[0032] FIG. 15 is a perspective view of the article of FIG. 13 coupled to a rotated and inverted article having an identical rim construction in accordance with another embodiment of the present invention.

[0033] BEST MODE FOR CARRYING OUT THE INVENTION

[0034] The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not necessarily been maintained in the drawing figures. It will be appreciated that any dimensions included in the drawing figures are simply provided as examples and dimensions other than those provided therein are also within the scope of the invention.

[0035] The following detailed description of the invention references specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The present invention is defined by the appended claims and the description is, therefore, not to be taken in a limiting sense and shall not limit the scope of equivalents to which such claims are entitled. The present invention is directed generally to an article 10 for holding components such as food or other items. Two half-shell articles 10a, 10b may optionally be releasably locked or secured together to form a container assembly 1, which may be configured as an enclosed container, clamshell-style container or the like. In other embodiments, a single article 10 may be used independently to operate as a tray, bowl, plate, or other open top container.

[0036] In some embodiments, the article 10 may be manufactured from molded pulp, molded fiber, or the like, and it may be constructed using conventional or otherwise suitable molded fiber forming processes and equipment now known or hereinafter developed. The article 10 may incorporate a press-to-close or tap-to-close latch design that permits two articles 10a, 10b to be releasably locked or otherwise secured together in a manner that does not require elaborate or complex manual operations. The article 10 design may further be optimized for efficient manufacturing using molded fiber equipment and processes.

[0037] Referring generally to FIGS. 1-7, one embodiment of the present invention is directed to an article 10 comprising at least one compartment 11 defined by a first wall 12 and one or more sidewalls 14 extending therefrom. The compartment 11 may be a variety of shapes, including but not limited to. a square, rectangle, quadnlateral, circle, oval, triangle, hexagon, or any other suitable shape. The article 10 may include any number of sidewalls 14 to correspond to the shape of the first wall 12. For example, as shown in FIG. 1, the article 10 includes four sidewalls 14 extending from each side of the first wall 12. Each sidewall 14 may be flat, curved or rounded and may be connected to the first wall 12 or other sidewall(s) 14 through rounded or sharp comers.

[0038] As best shown in FIGS. 1 and 3, the article 10 may include a rim 15 that extends from an edge 14a of the sidewalls 14. The rim 15 may be substantially parallel with the first wall 12. The rim 15 may be divided into two or more sections, including a first or male section 16 and a second or female section 18. As shown in FIGS. 1-7, the male section 16 and female section 18 may each extend along approximately one half of the rim 15, although other constructions are possible. In some embodiments, each of the male section 16 and the female section 18 may extend less than one half of the rim 15. In some embodiments, the rim 15 may include two or more male sections 16 and two or more female sections 18 disposed around the rim 15.

[0039] As best shown in FIGS. 1 and 3. according to one embodiment, the male seed on 16 may extend along a first section of the outer edge 14a located opposite of where sidewalls 14 connect to first wall 12. The female section 18 may extend along a second section (opposite the first section) of the outer edge 14a. FIGS. 1 and 3 illustrate an embodiment where each of the male section 16 and the female section 18 extend continuously, or uninterrupted along the first and second sections of the outer edge 14a, respectively. In other embodiments (not shown), one or both of the male section 16 and the female section 18 may be discontinuous or include one or more interruptions around the edge 14a. The rim 15 may include at least one transition area 17 between the male section 16 and female section 18. The transition area 17 may be configured as a portion of outer edge 14a absent either the male section 16 or female section 18.

[0040] As shown in FIGS. 2 and 7, the male section 16 and female section 18 of an article 10a are configured to connect, interlock, or mate with the opposite section of a second, generally identical article 10b, where the article 10b is inverted relative to article 10a. In some arrangements, the article 10b is inverted and rotated one hundred eighty (180) degrees prior to being pressed onto the article 10a. Other arrangements of the article 10a and article 10b are possible such that the second article 10b must be inverted, rotated, or maneuvered for the second article 10b to be positioned to mate with the first article 10a. In such a configuration, the male section 16 of article 10a is connected to the female section 18 of article 10b and the male section 16 of article 10b is connected to the female section 18 of article 10a, as described in greater detail below. The second article 10b may be defined as being generally identical to the first article 10a by having a generally identical shape and construction of the nm 15 with the male section 16 and female section 18; however, the specific configuration an arrangement of the one or more compartments 11 formed within the second article 10b may be different from the specific construction and arrangement of the one or more compartments 11 of the first article 10a.

[0041] FIG. 4 illustrates an enlarged cross-sectional view of the rim 15 in the male section 16 of the article 10. In the male section 16, the rim 15 may include a first protrusion 20, an inner rim surface 21, and an outer rim surface 25. The distal edges of the inner and outer rim surfaces 21, 25 may be formed at substantially the same elevation as the edge 14a of the sidewalls 14. The first protrusion 20 may extend outwardly from the rim 15 and may be in the form of a protuberance, deformation, distortion, bend, bulge, bump, lump, hump, knob, swelling, rib, or the like. The protrusion 20 may include an inner si de wall 22, an outer sidewall 24, and an upper wall 23 connecting the sidewalls 22, 24. The sidewalls 22, 24 may be substantially vertical or may be angled such that the width of the upper wall 23 is less than (or greater than) the distance between the inner rim surface 21 and outer rim surface 25. According to one embodiment, as illustrated in FIG. 4, the sidewalls 22 and 24 extend from the distal edges of the outer and inner rim surfaces 21 and 25, respectively, at an inward angle toward upper wall 23 so that the width of the first protrusion 20 is greater at the base of the sidewalls 22 and 24 adjacent to rim surfaces 21 and 25 relative to the upper wall 23. However, it is recognized that any number of different configurations of the first protrusion 20 may be utilized in alternative embodiments. The sidewalls 22, 24 and upper wall 23 may be flat or rounded and may be connected to one another through rounded or sharp comers. The distal edge of the outer rim surface 25 may terminate at an elevation approximately equal to the edge 14a of the sidewalls 14.

[0042] As shown in FIG. 1, the male section 16 may also include at least one locking protrusion 30 located on a portion of a distal edge of the outer rim surface 25. The locking protrusion 30 may extend outwardly from the outer rim surface 25 and may be shaped as a rounded or rectangular protrusion in the form of a tab, protuberance, deformation, bend, bulge, bump, lump, hump, knob, swelling, or the like. As best illustrated in FIG. 1, locking protrusion 30 may be configured as a tab that extends outwardly from outer rim surface 25 and includes a curved or arcuate perimeter edge 31 with a convex profile. In other embodiments, the perimeter edge 31 may have a concave shape, linear, straight, or other desired profile. When not in use, the outer edge 31 of the locking protrusion 30 may be positioned at a different elevation than the edge 14a of the sidewalls 14.

[0043] FIG. 5 illustrates an enlarged cross-sectional view of the rim 15 in the female section 18 of the article 10. In the female section 18, the rim 15 may include a recess 40. The recess 40 may be in the form of a depression, recession, indention, valley, or the like and may have a first sidewall 42, a bottom wall 43, and a second sidewall 44. The first sidewall 42 and the second sidewall 43 may extend generally upward or away from remainder of the rim 15 in the direction opposite the first wall 12. The female section 18 may also include a second protrusion 46 and third protrusion 48 on either side of the recess 40 to define the recess 40, where the protrusions 46, 48 may be in the form of a protuberance, deformation, distortion, bend, bulge, bump, lump, hump, knob, swelling, rib, or the like.

[0044] As shown in FIG. 5, the second protrusion 46 may be formed on an inner region of the rim 15 adjacent edge 14a. The second protrusion 46 may be defined by an inner sidewall 45 that extends away from and is coextensive with edge 14a of the sidewall 14, the first sidewall 42 of the recess 40, and a peak 47 extending between and connecting the sidewalls 45 and 42 and positioned at an elevation greater than the height of the sidewalls 14. The third protrusion 48 may be formed on an outer region of the rim 15 with the recess 40 located between the third protrusion 48 and the second protrusion 46. The third protrusion 48 may be defined by the second sidewall 44 (of recess 40), an outer rim surface 50, and a peak 49 extending between and connecting the second sidewall 44 and outer rim surface 50. The peak 49 may be positioned at an elevation greater than the height of the sidewalls 14 and edge 14a of the sidewalls 14. A distal edge of the outer rim surface 50 may terminate at approximately the same elevation as the edge 14a of the sidewalls 14. In some embodiments, the peaks 47, 49 of the protrusions 46, 48 are the same elevation as the upper wall 23 of the first protrusion 20. In some embodiments, the elevation of the peak 47 of the second protrusion 46 may be less than the peak 49 of the third protrusion 48. In other embodiments, the elevation of the peak 47 of the second protrusion 46 may be equal to or greater than the peak 49 of the third protrusion 48. In one embodiment, the elevation of the bottom wall 43 of the recess 40 is approximately the same elevation as the edge 14a of the sidewalls 14.

[0045] The sidewalls 42. 44 of the recess 40 may be substantially vertical or may be angled such that the width of the bottom wall 43 is less than (or greater than) the distance between the peaks 47, 49 of the second and third protrusions 46, 48. The sidewalls 42, 44 and bottom wall 43 may be flat or rounded and may be connected to one another through rounded or sharp comers. The inner sidewall 45 and outer rim surface 50 may be flat or rounded and may be connected to the peaks 47, 49 through rounded or sharp comers.

[0046] As shown in FIG. 1, the female section 18 may include a locking hole or aperture 60 configured to be coupled with a locking protrusion 30 in the male section 16. The locking hole 60 and locking protrusion 30 are positioned such that they are aligned when a second inverted article 10b is placed on a first article 10a, as shown in FIGS. 2 and 7. The locking hole 60 may be formed within the female section 18 such that a portion of the recess 40 is removed, although other formations are possible. The locking hole 60 may include an inner wall 62 and an outer wall 64 that may extend lengthwise along the length of rim 15 and female section 18. The inner wall 62 and the outer wall 64 are connected together by side edges to define the perimeter boundary edge of the locking hole 60. As shown in FIG. 1, in one embodiment, the locking hole 60 may have a generally oval, capsule, stadium, or discorectangle shape; however, locking hole 60 may have any other suitable shape (e.g., circular, rectangular, etc.).

[0047] Each of the inner wall 62 and the outer wall 64 may be configured in a variety of ways to improve coupling with the locking protrusion 30. The walls 62, 64 may be curved, straight, or extend into the locking hole 60. As shown in FIG. 1, according to one embodiment, the outer wall 64 may be curved with an inward curve or angled profile (e.g., a concave profile) so that the locking hole 60 includes a perimeter boundary edge that is concavely shaped. The locking hole 60 may be configured to be any number of shapes, including but not limited to. a rectangle, oval, semi-circle, circle, square, hexagon, or any other suitable shape. In certain embodiments, a central portion of the outer wall 64 extends inwardly toward the interior of the locking hole 60 so that the width of the locking hole 62 (as defined by its perimeter boundary edges, including inner and outer walls 62 and 64) near the central portion is less than its width near its outer ends. As shown in FIG. 1, in one embodiment, the locking hole 60 is entirely enclosed within the female section 18 of the rim 15. As shown in FIG. 1, the locking hole 60 is defined by the inner and outer walls 62 and 64 that are located interiorly within the rim 15 and that converge together at their sides to form a perimeter boundary edge of the locking hole 60 that is fully enclosed and located entirely w ithin the interior of the female section 18 of the rim 15.

[0048] FIG. 6 illustrates an enlarged cross-sectional view of the rim 15 in the female section 18 of the article 10 and further illustrates the profile of the locking hole 60 according to one embodiment. As shown, the locking hole 60 may be located within the recess 40 and extend within the sidewalls 42 and 44 thereof. As further shown in FIG. 6, the outer wall 64 of the locking hole 60 may be located within the sidewall 44 and the inner wall 62 of the locking hole 60 may be located within the sidewall 42. The outer wall 64 may be positioned at an elevation greater than that of the inner wall 62 so that the outer wall 64 is positioned at a greater distance from the base of the rim 15 relative to the inner wall 62.

[0049] FIG. 7 show s an enlarged cross-sectional view' of a first article 10a removably coupled to a second article 10b to form a container assembly 1. For clarity, the components of article 10a include “a” after the numbered component, while corresponding components on article 10b include after the numbered component. As illustrated in FIGS. 7B and 7C, the locking protrusion 30a is engaged with the locking hole 60b, while the locking hole 60a is engaged with the locking protrusion 30b on the opposite side of the container assembly 1. When the second article 10b is pressed onto the first article 10a with a downward force, the locking protrusions 30a, 30b are elastically deformed by at least one edge of the locking holes 60a, 60b. In one embodiment, the perimeter edge 31a and 3 lb of each locking protrusion 30a and 30b deflect as a result of contact with the perimeter boundary edge defined by the outer wall 64a and 64b, respectively of the locking protrusions 60a and 60b. The locking protrusions 30a, 30b return to the original shape once they are positioned on the opposite side of the locking holes 60a, 60b as show n in FIGS. 7B and 7C, respectively. During such pressing operation, an edge (such as the edge defined by the outer walls 64a and 64b) of the locking holes 60a, 60b may also be deformed before returning to its original shape. This engagement may create a tactile or audible snap, thereby ensuring to a user that the two articles 10a, 10b are locked together.

[0050] As illustrated in FIGS. 2 and 7A-C, when two articles 10a, 1 b are releasably secured together, the article 10b is inverted relative to article 10a and positioned above the article 10a. Next, article 10b may be pressed into article 10a. During such pressure, the first protrusion 20a of article 10a is pressed into and mates with the recess 40b. and the first protrusion 20b is pressed into and mates with the recess 40a. Preferably, the angle and curvature of the first protrusion 20, recess 40, second protrusion 46. and third protrusion 48 are configured such that the mating of opposite sections forms a seal. In one embodiment, the shape, taper angle and profile of the first protrusion 20, defined by the walls 22, 23 and 24, generally conforms to the shape, taper angle and profile of the recess 40, defined by the walls 42, 43 and 44, so that the first protrusion may be received within the recess 40. The angle of orientation of the walls 22 and 24 of the first protrusion 20 may be approximately equal to the angle of orientation of the walls 42 and 44 of the recess 40. The seal formed by the mating connection between the first protrusion 20 and the recess 40 may prevent food from escaping from the sides of the container assembly 1 and does not require the manual manipulation of either rim 15a, 15b. Such seal also promotes stability and decreases any movement of either article 10a, 10b while the articles are releasably secured together.

[0051] The shape of the locking hole 60 and locking protrusion 30 may be configured to allow a user to press on the first wall 12b of a second article 10b to easily couple the locking holes 60a, 60b with the locking protrusions 30a, 30b without any manual manipulation of the components of the locking holes 60a, 60b or the components of the locking protrusions 30a, 30b. In one embodiment, the perimeter edge 31 of the locking protrusion 30 has a convex shape and the perimeter boundary edge of the locking hole 60 defined by the outer wall 64 thereof has a concave shape. This reduces the total deflection required of the locking protrusion 30 (particularly the perimeter edge 31) and the outer wall 64 of the locking hole 60 when locking protrusion 30 is mated with the locking hole 60. The reduction of total required deflection of each component assists in allowing the perimeter edge 31 of the locking protrusion 30 and the outer wall 64 of the locking hole 60 to maintain shape after the locking protrusion 30 is connected to the locking hole 60, particularly when each article 10a and 10b are constructed from molded fiber. Further, since the user does not have to manually manipulate the locking hole 60 or locking protrusion 30, the time spent by a user coupling two articles 10a, 10b together is reduced. Incorporating the locking hole 60 within the recess 40 between the second protrusion 46 and third protrusion 48 allows for the effect of an undercut without the difficulty' of shaping molded fiber into an undercut. The configuration described may also help to prevent food from escaping from the locking hole 60 during use.

[0052] As further shown in FIGS. 1 and 2, the article 10 may' include a tab 32 that may be configured to facilitate the selective coupling and de-coupling of the article 10 with a second similar article. The tab 32 extending may form part of or extend from the outer rim surface 25 of the rim 15 any may have any suitable shape, including without limitation, a generally rectangular, trapezoidal, semicircle, triangular, or discorectangle shape. As shown in FIGS. 1 and 2, according to one embodiment, the tab 32 may be formed as part of the outer rim surface 25 with recesses formed into the outer rim surface 25 on each side of the tab 32. The tab 32 may be formed on the male section 16 of the rim 15 and may be positioned adjacent the one or more locking protrusions 30. The tab 32 may assist with the coupling and de-coupling of two articles 10a and 10b by providing a surface area for a user to grip one article 10a relative to the other article 10b.

[0053] Another embodiment of the present invention is illustrated in FIGS. 8 and 9 as article 110. Features that are similar to the article 10 shown in FIG. 1 are identified with similar reference numbers, plus 100 (e.g., rim 15 and rim 115). The article 110 comprises multiple compartments 111 defined by a first wall 112 and one or more sidewalls 114 extending therefrom, where such compartments may be used for separating different foods in the article 110. The compartments 111 may be any number of compartments 111 and in any size or shape desired for the separation of food. A rim 115 extends from an edge 114a of the sidewalls 114, where the rim 115 may be divided into two or more sections, including a first or male section 116 and a second or female section 118.

[0054] As illustrated in FIGS. 8 and 9, the rim 115 of the configured in the same manner as rim 15 of article 10 described above. In the male section 116. the rim 115 may include a first protrusion 120, an inner rim surface 121, and an outer rim surface 125. The male section 116 may further include a tab 132 positioned adjacent the protrusion 120. The protrusion 120 may include an inner sidewall 122, an outer sidewall 124, and an upper wall 123 connecting the sidewalls 122, 124. The male section 116 may also include at least one locking protrusion 130 located on a portion of a distal edge ofthe outer rim surface 125. The locking protrusion 130 may include an outer perimeter edge 131 similar to edge 31 described in the embodiment above. In the female section 118, the rim 115 may include a recess 140 extending outwardly toward the first w all 112. The female section 118 may also include a second protrusion 146 and third protrusion 148 on either side of the recess 140 extending outw ardly away from the first wall 112. Further, the female section 118 may include a locking hole 160 configured to be coupled with a locking protrusion 130, where the locking hole 160 may include an inner wall 162 and an outer wall 164 that may extend lengthwise along the length of rim 115 and female section 118.

[0055] Because the rim 115 of article 110 is configured in the same manner as the rim 15 of article 10, the article 10 may be inverted and secured to the article 1 10 to form a container assembly 1. The first protrusion 120 of the male section 116 of article 110 may be pressed into the recess 40 of the female section 18 of the article 10 and the first protrusion 20 of the male section 16 of article 10 may be pressed into the recess 140 of the female section 118 of article 110 in the same manner as described above with reference to articles 10a and 10b. Similarly, the at least one locking protrusion 130 of article 110 may be inserted and received into the corresponding locking hole 60 of article 10 and the at least one locking protrusion 30 of article 10 may be inserted and received into the corresponding locking hole 160 of article 110 in the same manner as described above.

[0056] In some embodiments, the article 110 may include multiple male sections 116 and multiple female sections 118. Each male section 116 may include one or more locking protrusions 130, and each female section may include one or more locking holes 160 located opposite of and aligned with the locking protrusions 130. The locking protrusions 130 and locking holes 160 are configured such that the locking protrusions 130b and locking holes 160b of a second inverted article 110b are aligned with the locking protrusions 130a and locking holes 160a of a first article 110a.

[0057] Another embodiment of the present invention is illustrated in FIGS. 10-12 as article assembly 201 comprising two articles 210 (also referred to herein as 210a and 210b) that are hingedly attached to one another. Features that are similar to the article 10 shown in FIG. 1 are identified with similar reference numbers, plus 200 (e.g.. rim 15 and rim 215). Each article 210 may comprise one compartment or multiple compartments 211 defined by a first wall 212 and one or more sidewalls 214 extending therefrom, where such compartments may be used for separating different foods or items in the article 210. The compartments 211 may be any number of compartments 211 and in any size or shape desired for the separation of food. A rim 215 extends from an edge 214a of the sidewalls 214, where the rim 215 may be divided into two or more sections, including a first or male section 216 and a second or female section 218.

[0058] In the male section 216, the rim 215 may include a first protrusion 220, an inner rim surface 221, and an outer rim surface 225. The male section 216 may further include a tab 232 positioned adjacent the protrusion 220. The protrusion 220 may include an inner sidewall 222, an outer sidewall 224, and an upper wall 223 connecting the sidewalls 222, 224. The male section 216 may also include at least one locking protrusion 230 located on a portion of a distal edge of the outer rim surface 225. The locking protrusion 230 may include a perimeter edge 231 that may be configured similarly to perimeter edges 31 and 131 described in the embodiments above. In the female section 218, the rim 215 may include a recess 240 extending outwardly toward the first wall 212. The female section 218 may also include a second protrusion 246 and third protrusion 248 on either side of the recess 240 extending outwardly aw ay from the first w all 212. Further, the female section 218 may include a locking hole 260 configured to be coupled with a locking protrusion 230 in the same manner as locking protrusion 30 and locking hole 60 described with above with respect to article 10, where the locking hole 260 may include an inner wall 262 and an outer wall 264 that may extend lengthwise along the length of rim 215 and female section 218.

[0059] The articles 210a, 210b are hingedly attached along at least a portion of the distal edges of the rims 215a, 215b by ahinge 280 so that each article 210a and 210b may circumferentially rotate relative to one another about a hinge axis defined by the hinge 280. The articles 210a, 210b may be attached at multiple locations intermittently along the distal edges of the rims 215a, 215b to define the hinge 280. or the hinge 280 may extend continuously along the distal edges of the rims 215a and 215b. In some embodiments, each article 210 may have multiple male sections 216 and female sections 218. In other embodiments, as shown in FIGS. 10-12, the article 210a may include a rim 215a having a male section 216a only, and the article 210b may include a rim 215b having a female section 218b only. As shown in FIG. 12, the male section 216a and female section 218b of an article assembly 201 are configured to mate and be releasably secured together, where the articles 210a, 210b are configured to circumferentially rotate around hinge 280 until pressed together. In some embodiments, the articles 210a, 210b include at least one locking protrusion 230 and at least one locking hole 260. In other embodiments, as shown in FIGS. 10-12, only the first article 21 a may include at least one locking protrusion 230. and only the second article 210b may include at least one locking hole 260. The locking protrusions 230 and locking holes 260 are configured such that the locking protrusions 230b and locking holes 260b of a second inverted article 210b are aligned with the locking holes 160a and locking protrusions 230a of a first article 110a. respectively.

[0060] Another embodiment of the present invention is illustrated in FIGS. 13-15 as article 410 of assembly 401. Features that are similar to the article 10 show n in FIG. 1 are identified with similar reference numbers, plus 400 (e.g., rim 15 and rim 415). The article 410 may include a tab 432 that may be configured to facilitate the selective coupling and de-coupling of the article 410 with a second similar article. The tab 432 of the article 410 may have an alternative configuration than the tab 32 of article 10 shown in FIG. 1. The article 410 may otherwise be configured in an identical manner to the article 10 shown in FIG. 1. Further, the article 410 in FIGS. 13-15 is illustrated with multiple compartments 411 defined by a first wall 412 and one or more sidewalls 414 extending therefrom, where such compartments may be used for separating different foods or other items in the article 410; however, the compartments 41 1 may be any number of compartments 411 or a single compartment 411, and in any size or shape desired for the separation of food or other items desired to be contained therein. The tab 432 of article 410 may be used to assist in the mating and separation of two articles 410a. 410b. FIGS. 13-15 illustrate the tab 432 extending outwardly from the outer rim surface 425. The tab 432 may have a generally rectangular, semicircle, triangular, or discorectangle shape; however, the tab 432 may have any other suitable shape. In some embodiments, the elevation of the tab 432 is equal to that of the outer rim surface 425. In other embodiments, the elevation of the tab 432 may extend above or below the elevation of the outer rim surface 425. In other embodiments, the elevation profile of the tab 432 may vary across the length of the tab 432, or the elevation profile may be identical to the profile of the outer rim surface 425. As shown in FIGS. 13-15, according to one embodiment, the tab 432 may be positioned on the outer rim surface 425 between two spaced apart locking protrusions 430; however, it is recognized that the tab 432 may be positioned in other locations along the rim outer surface 435 and relative to the one or more locking protrusions 430 provided on the rim 415 in alternative embodiments.

[0061] As shown in FIG. 13, the tab 432 may extend past the outermost edge of the outer rim surface 425; however, in other embodiments, the outermost edge 432 may be coterminous with the outermost edge of the outer rim surface 425. Such extension of the tab 432 past the outermost edge of the outer nm surface 425 may offer a larger surface area for a user to manipulate the tab(s) 432 while releasably coupling two articles 410a, 410b together. In some embodiments, the tab 432 may be embossed or otherwise marked with instructions (e.g., “PUSH” or “PRESS HERE”) to inform a user how to use the tab 432 when securing together or separating two articles 410a, 410b.

[0062] FIG. 15 shows articles 410a. 410b releasably coupled together to form the assembly 401. For clarity, the components of article 410a include “a” after the numbered component, while corresponding components on article 410b include “6” after the numbered component. To couple the articles 410a, 410b together, a user may manipulate the tab 432b of article 410b to press article 410b onto article 410a. A user may also pinch the tab 432b of article 410b against the recess 440a of the article 410a in order to engage the locking protrusion(s) 430 and locking hole(s) 460 of the articles 410a, 410b and secure the articles 410a, 410b together. In other embodiments, a user may manipulate the tab 432a of article 410a to press article 410a onto article 410b and pinch the tab 432a of article 410a into the recess 440b of article 410b in order to engage the locking protrusion(s) 430 and locking hole(s) 460 of the articles 410a. 410b and secure the articles 410a, 410b together. In some embodiments, a user may use only one tab 432 of either article 410a, 410b to press the articles 410a, 410b together, while in other embodiments, both tabs 432 may be used to press the articles 410a, 410b together. To separate articles 410a, 410b that are releasably coupled together, a user may manipulate the tab 432b of article 410b by pulling it away from article 410a to detach the articles 410a. 410b; alternatively, a user may manipulate the tab 432a of article 410a away from article 410b. In some embodiments, a user may use only one tab 432 of either article 410a, 410b to separate the articles 410a, 410b, while in other embodiments, both tabs 432 may be used to separate the articles 410a, 410b.

[0063] Because the rim 415 of article 410 is configured in the same manner as the rim 15 of article 10 (and the rim 115 of article 110), the article 410 may be inverted and secured to an article 10 or an article 110 form a container assembly 1. The articles 410, 110. 10 may be connected and separated in the same manners described above with reference to articles 10a and 10b. Additionally, the tab 432 of the article 410 may be used to assist in the connecting and separating of article 410 with an article 10 or 110 in the same manner as described above.

[0064] In some embodiments, the article 10. 110, 210. 410 may be constructed from molded pulp, molded fiber, or the like. In other embodiments, the article 10, 110, 210, 410 may alternatively be constructed from other suitable materials, including but not limited to paper, paperboard, polyethylene, polypropylene, polyethylene terephthalate (PET), or other materials suitable for use as an article 10, 110, 210, 410. In some embodiments, the container assembly 1, 101, 201. 401 may include two articles 10. 1 10, 210, 410 manufactured from molded pulp or molded fiber. In other embodiments, the container assembly 1, 101, 201, 401 may include an article 10, 110, 210, 410 constructed from molded pulp or molded fiber and an article 10, 110, 210, 410 constructed from a different material. The article 10, 110, 210, 410 may also be manufactured from molded pulp or molded fiber and configured for mating with a container composed of a different material but having the same rim structure.

[0065] Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any of the individual embodiments described above. The embodiments described herein are not meant to be an exhaustive presentation of how the various features of the subject matter herein may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.

[0066] The numerical ranges in this disclosure are approximate, and thus may include values outside of the range unless otherwise indicated. Numerical ranges include all values from and including the lower and the upper values, in increments of one unit, provided that there is a separation of at least two units between any lower value and any higher value. These are only examples of what is specifically intended, and all possible combinations of numerical values between the lowest value and the highest value enumerated, are to be considered to be expressly stated in this disclosure.

[0067] As used herein, “a,” “an,” or “the” can mean one or more than one. For example, “an” image can mean a single image or a plurality of images.

[0068] The term “and / or” as used in a phrase such as “A and / or B” herein can include both A and B; A or B; A (alone); and B (alone). Likewise, the term “and / or” as used in a phrase such as “A, B, and / or C” can include at least the following embodiments: A, B, and C; A, B, or C; A or C; A or B; B or C; A and C; A and B; B and C; A (alone); B (alone); and C (alone).

[0069] As used herein, the term “about” when referring to a measurable value such as an amount, a temporal duration, and the like, can include variations of + / - 20%, more preferably + / - 10%, even more preferably + / -5% from the specified value, as such variations are appropriate to reproduce the disclosed methods and systems.

[0070] From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are inherent to the structure and method. It will be understood that certain features and sub combinations are of utility and may be employed without reference to other features and sub combinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments of the invention may be made without departing from the scope thereof, it is also to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative and not limiting.

[0071] The constructions described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present invention. Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required”. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.

Claims

CLAIMSWhat is claimed is:

1. A molded fiber article comprising: a first wall; at least one sidewall extending from the first wall; a first peripheral rim extending from a distal end of the at least one sidewall, the first peripheral rim comprising: a first rim section including a first protrusion and a first locking protrusion; and a second rim section including a first recess and a first locking hole; wherein the article is configured to be selectively coupled with a second identical or similarly configured article.

2. The article of claim 1, wherein the first locking hole includes a perimeter wall that fully encloses the first locking hole within the first recess.

3. The article of claim 1, wherein the second rim section further comprises a second protrusion and a third protrusion, wherein the first recess is located between and defined by the second protrusion and the third protrusion.

4. The article of claim 1, wherein the first rim section comprises a plurality of locking protrusions, wherein the plurality of locking protrusions includes the first locking protrusion, and the second rim section comprises a plurality of locking holes, wherein the plurality of locking holes includes the first locking hole.

5. The article of claim 1, wherein a bottom elevation of the first recess is approximately equal to the elevation of the distal end of the at least one sidewall.

6. The article of claim 1, wherein the first locking protrusion further comprises a convex peripheral edge, and wherein the first locking hole further comprises a concave peripheral edge.

7. The article of claim 1, wherein the first locking hole is configured to be selectively coupled with a second locking protrusion of the second article, and the first locking protrusion is configured to be selectively coupled with a second locking hole of the second article.

8. The article of claim 1, wherein the shape of the first protrusion corresponds to the shape of the first recess.

9. The article of claim 1 , wherein the second identical article is manufactured from a nonmolded fiber material.

10. The article of claim 1, wherein the first section of the first peripheral rim includes a tab positioned adjacent to the first locking protrusion.

11. An article comprising: a first wall; at least one sidewall extending from the first walk a first peripheral rim extending from a distal edge of the at least one sidewall, the first peripheral rim comprising: a first rim section including a first protrusion and a first locking protrusion; and a second rim section including a second protrusion and a third protrusion, a recess located between and defined by the second protrusion and the third protrusion, and a first locking hole positioned within the first recess; wherein the first locking hole includes a perimeter wall that fully encloses the first locking hole within the first recess; and wherein the article is configured to be selectively coupled with a second identical or similarly configured article.

12. The article of claim 11, wherein the first rim section comprises a plurality’ of locking protrusions, wherein the plurality of locking protrusions includes the first locking protrusion, and the second rim section comprises a plurality of locking holes, wherein the plurality of locking holes includes the first locking hole.

13. The article of claim 11, wherein the first protrusion of the first rim section extends around approximately one-half of the first peripheral rim, and wherein the first recess of the second rim section extends around approximately one-half of the first peripheral rim opposite the first rim section.

14. The article of claim 11, wherein a bottom elevation of the first recess is approximately equal to the elevation of the distal edge of the at least one sidewall.

15. The article of claim 11 , wherein the first locking protrusion further comprises an outer edge having a convex profile, and wherein the first locking hole further comprises a peripheral edge having a concave profile.

16. The article of claim 11, wherein the first locking hole is configured to be selectively coupled with a second locking protrusion of the second article, and the first locking protrusion is configured to be selectively coupled with a second locking hole of the second article.

17. The article of claim 11 , wherein the first protrusion comprises a first angled protrusion wall and a second angled protrusion wall, and the first recess comprises a first angled recess wall and a second angled recess wall, wherein the first angled protrusion wall is inverse to the first angled recess wall and the second angled protrusion wall is inverse to the second angled recess wall.

18. The article of claim 11 , wherein the article is constructed of molded fiber.

19. A container comprising: a first article comprising: a first wall; at least one sidewall extending from the first wall; a first peripheral rim extending from a distal end of the at least one sidewall, the first peripheral rim comprising: a first rim section including a first protrusion and a first locking protrusion; and a second rim section including a first recess and a first locking hole; a second article comprising:a second wall; at least one sidewall extending from the second wall; a second peripheral rim extending from a distal end of the at least one sidewall, the second peripheral rim comprising: a third rim section including a second protrusion and a second locking protrusion; and a fourth rim section including a second recess and a second locking hole; and wherein the first article may be selectively coupled with the second article in an inverted and overlapped arrangement.

20. The container of claim 19, wherein the first article and the second article are hingedly attached along at least a portion of a first distal edge of the first peripheral rim and a second distal edge of the second peripheral rim by a hinge.

21. The container of claim 19, wherein the first locking protrusion of the first article is received within the second locking hole of the second article and the second locking protrusion of the second article is received within the first locking hole of the first article when the first article is coupled to the second article.

22. The container of claim 21 , wherein the first protrusion of the first article is received within the second recess of the second article and the second protrusion of the second article is received within the first recess of the first article when the first article is coupled to the second article.

23. The container of claim 19, wherein second article comprises two or more compartments defined by the at least one sidewall of the second article.

24. The container of claim 19, wherein at least the first article is constructed of molded fiber.

25. The container of claim 19, wherein the first article comprises a tab provided on the first peripheral rim and extending outwardly from the first rim section and configured to assist with selectively coupling the first article to the second article.

Images