US20120152963A1

US20120152963A1 - Thermally insulated container

Info

Publication number: US20120152963A1
Application number: US13/135,681
Authority: US
Inventors: Emmon Scott; Julie Anne Becker; Sharon Ann Hoffman; Michael Ray Hofstetter
Original assignee: Shen Manufacturing Co Inc
Current assignee: Shen Manufacturing Co Inc
Priority date: 2010-07-13
Filing date: 2011-07-12
Publication date: 2012-06-21

Abstract

A thermally insulated container is disclosed. The thermally insulated container comprises a body, wherein said body includes portions that are demarked by non-seamed folds and portions that are demarked by seams, wherein the body includes a top, and at least one side, wherein said top and at least one side are demarked by a non-seamed fold.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. provisional application Ser. No. 61/363,935 filed on Jul. 13, 2010 and U.S. provisional application Ser. No. 61/441,205 filed on Feb. 9, 2011, the complete disclosures of which are herein incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention
The disclosure relates to a thermally insulated container and method for manufacturing the same.
2. Brief Description of the Related Art
Containers are known in the art. Although known containers perform adequately for their intended use, improvements are nevertheless continuously being sought in order to advance the art. In food handling and delivery, it is important that the food be delivered at a desired temperature, but, in addition, the food should remain appealing, so it not only remains at a desired temperature (e.g., hot for hot foods), but also at a desired texture and not soggy.
A need exists for an apparatus and method to maintain foods at a desired temperature, including hot foods, while preventing the foods from becoming soggy or taking on an undesirable texture or property that may otherwise alter the desirability of the food item including its taste.

SUMMARY OF THE INVENTION

A thermally insulated container is disclosed. According to preferred embodiments, the thermally insulated container comprises a body that includes portions that are demarked by non-seamed folds and portions that are demarked by seams.
According to some preferred embodiments, a thermally insulated container is provided that has a body with a top, and at least one side, wherein said top and at least one side are demarked by a non-seamed fold.
It is an object of the present invention to provide thermally insulated container for holding and transporting foods.
It is another object of the present invention to provide a thermally insulated container that is configured to facilitate opening and closing the access panel so the contents of the container may be accessed while a user is holding the container.
It is another object of the invention to accomplish the above objects by providing an insulated container that is configured to minimize or prevent the loss of heat through the container.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will now be described, by way of example, with reference to the accompanying drawings, in which:

FIGS. 1A-1B are perspective views of an exemplary thermally insulated container.

FIG. 2 is a partial side view of an exemplary thermally insulated container of FIG. 1A according to arrow 2.

FIG. 3 is a top view of an exemplary unit of material in an unfurled orientation that is subsequently furled to form the thermally insulated container of FIGS. 1A-2.

FIG. 4A is a side view of the unit of material of FIG. 3 according to arrow 4A.

FIGS. 4B-4C are side views of the unit of material of FIG. 4A in folded orientations for partially forming the thermally insulated container of FIGS. 1A-1B.

FIG. 4D is a side view of the unit of material in a folded orientation for forming the thermally insulated container of FIGS. 1A-1B.

FIGS. 4E-4F are side views of the unit of material in a folded orientation for forming the thermally insulated container of FIGS. 1A-1B.

FIG. 5A is a cross-sectional view of the unit of material of FIG. 3 according to line 5A-5A.

FIG. 5B is a cross-sectional view of the unit of material of FIG. 1A according to line 5B-5B.

FIGS. 6A-6B are perspective views of an exemplary thermally insulated container.

FIG. 7 is a top view of an exemplary unit of material in an unfurled orientation that is subsequently furled to form the thermally insulated container of FIGS. 6A-6B.

FIG. 8A is a side view of the unit of material of FIG. 7 according to arrow 8A.

FIGS. 8B-8C are side views of the unit of material of FIG. 8A in folded orientations for partially forming the thermally insulated container of FIGS. 6A-6B.

FIG. 8D is a side view of the unit of material in a folded orientation for forming the thermally insulated container of FIGS. 6A-6B.

FIGS. 8E-8F are side views of the unit of material in a folded orientation for forming the thermally insulated container of FIGS. 6A-6B.

FIG. 9A is a side view of an exemplary thermally insulated container of FIG. 6A according to arrow 9A.

FIG. 9B is a cross-sectional view of the thermally insulated container of FIG. 6A according to line 9B-9B.

FIG. 10A is a cross-sectional view of an embodiment of the unit of material of FIG. 7 according to line 10-10.

FIG. 10B is a cross-sectional view of an embodiment of the unit of material of FIG. 7 according to line 10-10.

FIG. 11 is a perspective, exploded view of the unit of material of FIG. 10A or FIG. 10B.

FIGS. 12A and 13A are perspective views of an exemplary sheet of material placed upon a cutting platen.

FIGS. 12B and 13B are perspective views of a plurality of components of material utilized for forming the unit of material of FIG. 11 that have been cut from the sheet material of FIGS. 12A and 13A.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The figures illustrate exemplary implementations of a thermally insulated container. Based on the foregoing, it is to be generally understood that the nomenclature used herein is simply for convenience and the terms used to describe the invention should be given the broadest meaning by one of ordinary skill in the art.
Referring initially to FIGS. 1A-1B, an exemplary implementation of a container is shown at 10. An embodiment of the container 10 may be sold under the trademark HEATZA that is commercially available from Arden Corporation of Southfield, Mich.
Referring to FIG. 3, the container 10 is formed from a single unit of material 12. The unit of material 12 includes a geometry that is formed from a plurality of panels 14 that are integrally connected to one another. The plurality of panels 14 are demarcated from one another by a plurality of fold lines, hinges, or the like, which are shown generally at 16. In an embodiment, the plurality of hinges 16 may be formed in any desirable manner such as, for example, by removing material proximate an area or zone where the hinges 16 are to be formed, or, alternatively, forming/molding an area or zone where the hinges 16 are to be formed with a notch, channel, or the like (e.g., a “V shaped” channel). Alternatively, the plurality of hinges 16 may not be treated in a particular manner (e.g., by material removal, forming, molding or the like), and, the plurality of hinges 16 may occur naturally as a result of a user/manufacturer folding the single unit of material 12.
The plurality of panels 14 may be identified as follows. Although the following description sets forth a particular “name” for each panel, the name given to each panel is based upon an illustrated orientation of the panel in FIGS. 1A-4F and should not be utilized to limit the scope of the claimed invention. In an implementation, the plurality of panels 14 may include a rear panel 14 a that connects an upper panel 14 b and a lower panel 14 c. The upper panel 14 b and rear panel 14 a form a first hinge 16 a of the plurality of hinges 16. The lower panel 14 c and the rear panel 14 a form a second hinge 16 b of the plurality of hinges 16.
The plurality of panels 14 may further include a first front panel 14 d, a first side panel 14 e and a second side panel 14 f. The first front panel 14 d, first side panel 14 e and second side panel 14 f each extend from and are integrally connected to the upper panel 14 b. The upper panel 14 b and the first front panel 14 d form a third hinge 16 c of the plurality of hinges 16. The upper panel 14 b and the first side panel 14 e form a fourth hinge 16 d of the plurality of hinges 16. The upper panel 14 b and the second side panel 14 f form a fifth hinge 16 e of the plurality of hinges 16.
The plurality of panels 14 may further include a second front panel 14 g. The second front panel 14 g extends from and is integrally connected to the lower panel 14 c. The lower panel 14 c and the second front panel 14 g form a sixth hinge 16 f of the plurality of hinges 16.
The plurality of panels 16 may further include a central flap panel 14 h, a first side flap panel 14 i and a second side flap panel 14 j. The central flap panel 14 h, first side flap panel 14 i, and second side flap panel 14 j each extend from and are integrally connected to the second front panel 14 g. The second front panel 14 g and the central flap panel 14 h form a seventh hinge 16 g of the plurality of hinges 16. The second front panel 14 g and the first side flap panel 14 i form an eighth hinge 16 h of the plurality of hinges 16. The second front panel 14 g and the second side flap panel 14 j form a ninth hinge 16 i of the plurality of hinges 16.
In an implementation, each panel 14 a-14 j of the plurality of panels 14 includes a substantially square/rectangular shape geometry. Although the illustrated embodiment sets forth each panel 14 a-14 j of the plurality of panels 14 including a substantially square/rectangular shape geometry, each panel 14 a-14 j of the plurality of panels 14 may be formed to include any geometry, such as, for example, circular, triangular or the like.
When the unit of material 12 is folded about the plurality of hinges 16, the unit of material 12 may be arranged in a configuration that forms the container 10 that is shown in FIGS. 1A-1B. Although the term “folded” is used in describing the arrangement for forming the container 10, one or more additional manufacturing steps may be included in addition to the “folding” step described above. In an implementation, the one or more additional manufacturing steps may include the step of “seaming” (e.g., sewing, stitching, adhering or the like) together one or more edges of the plurality of panels 14. Accordingly, in an implementation, manufacturing steps for forming the container 10 may include at least the steps of “folding” and “seaming” the unit of material 12.
In an implementation, the container 10 may be formed from the unit of material 12 as follows at FIGS. 4A-4F. Referring to FIGS. 4A-4B, the rear panel 14 a, first side panel 14 e and second side panel 14 f may be folded downwardly (see, e.g., arrow D1 in FIG. 4A and arrow D2 in FIG. 4B) about the hinges 16 a, 16 d-16 e relative to the upper panel 14 b. Then, a first side edge 14 a′ (see FIG. 3) of the rear panel 14 a may be seamed with a rear edge 14 e′ (see FIG. 3) of the first side panel 14 e, and, a second side edge 14 a″ (see FIG. 3) of the rear panel 14 a may be seamed with a rear edge 14 f (see FIG. 3) of the second side panel 14 f.
Referring to FIG. 4C, the lower panel 140 may be folded upwardly (see, e.g., arrow D3 in FIG. 4C) about the second hinge 16 b relative to the rear panel 14 a. Then, a first side edge 14 c′ (see FIG. 3) of the lower panel 14 c may be seamed with a side edge 14 e″ (see FIG. 3) of the first side panel 14 e, and, a second side edge 14 c″ (see FIG. 3) of the lower panel 14 c may be seamed with a side edge 14 f′ (see FIG. 3) of the second side panel 14 f.
Referring to FIGS. 1B and 4D, as a result of folding and seaming the unit of material 12 as described above, the panels 14 a-14 c and 14 e-14 f form a pocket or receiving-cavity, which is shown generally at 18 (see FIG. 1B), and an access opening 20 (see FIG. 1B). Accordingly, as seen in FIG. 1B, one or more objects, F, B, may be inserted through the opening 20 and deposited into the receiving-cavity 18.
Referring to FIGS. 4D-4E, the access opening 20 may be selectively closed-out by one or more of the first front panel 14 d and the second front panel 14 g. In order to close-out the access opening 20, the first front panel 14 d is permitted to be selectively folded downwardly (see, e.g., arrow D4 in FIG. 4D) about the third hinge 16 c relative to the upper panel 14 b, and, the second front panel 14 g is permitted to be selectively folded upwardly (see, e.g., arrow D5 in FIG. 4D) about the sixth hinge 16 f relative to the lower panel 14 c. By arranging the first front panel 14 d and the second front panel 14 g as described above, the first front panel 14 d and second front panel 14 g may be said to “overlap” one another (see also, e.g., FIG. 2); the overlapping arrangement may not only function in closing out the access opening 20, but, also, inhibits the movement of heat, H (see FIG. 5B), through the overlapping arrangement of the panels 14 d, 14 g and out of the receiving-cavity 18.
Further, the central flap panel 14 h is permitted to be disposed over the upper panel 14 b as a result of permitting the central flap panel 14 h to be selectively folded (see, e.g., arrow D6 in FIG. 4E) about the seventh hinge 16 g relative to the second front panel 14 g. Further, the first side flap panel 14 i is permitted to be disposed over the first side panel 14 e as a result of permitting the first side flap panel 14 i to be selectively folded (see, e.g., arrow D7 in FIG. 4E) about the eighth hinge 16 h relative to the second front panel 14 g. Further, the second side flap panel 14 j is permitted to be disposed over the second side panel 14 f as a result of permitting the second side flap 14 j to be selectively folded (see, e.g., arrow D7 in FIG. 4E) about the ninth hinge 16 i relative to the second front panel 14 g.
Referring to FIG. 1B, prior to closing-out the access-opening 20 as described above, a user may deposit the one or more objects, F, B into the receiving-cavity 18. In an implementation, the one or more objects, F, B, may include one or more foodstuff units, F, and/or one or more boxes or sub-containers that contain the one or more foodstuff units, F. The one or more foodstuff units, F, may include, but is not limited to, pizza. The one or more boxes, 1B, may include, but is not limited to, a folded, paperboard box.
Although an embodiment of the foodstuff unit, F, may include pizza, the foodstuff unit, F, is not limited to pizza, and may include, for example, baked items, fried items, cooked items, liquids, or any other type of food or beverage. Further, although an embodiment of the foodstuff unit, F, is described to include what may be a hot/heated item (e.g., pizza, a baked item, a fried item, a cooked item or the like), the foodstuff unit, F, may include a foodstuff unit, F, having a temperature approximately equal to or less than room temperature, such that, for example, the foodstuff unit, F, may be said to be cooled, cold or frozen.
According to an embodiment, the container 10 may be utilized as a pizza delivery container, and, as such, may include thermal insulating properties; accordingly, in an embodiment, the container 10 may be referred to as a “thermally insulated container.” The thermal insulating properties of the container 10 may function in a manner that promotes maintaining temperature of the pizza, F, or mitigating heat loss of the pizza, F, from the time the pizza, F, is removed from an oven at, for example, a pizzeria to the time when the pizza, F, is presented to, for example, a customer at a delivery location. Thus, as is described in an embodiment in the following disclosure, the container 10 may be formed to include one or more layers, one or more materials and/or one or more structural configurations that may lend to the maintaining of temperature or mitigating of heat loss of the pizza, F, during transport of the pizza, F, from, for example, the pizzeria to, for example, the customer.
First, as described above, the structural configuration of the container 10 in of itself may maintain temperature or mitigate heat loss of the pizza, F. When looking to the unfurled orientation of the container 10 in FIG. 3, the panels 14 a and 14 d-14 f are one with and connected to the upper panel 14 b such that the panels 14 a and 14 d-14 f may “drop down” from the upper panel 14 b and form a “dome structure.” Referring to FIG. 5B, because heat, H, rises, any heat, H, emanating from the pizza, F, may be trapped by the dome structure such that the trapped heat, H, within the receiving-cavity 18 may functionally maintain the temperature of or mitigate heat loss of the pizza, F. Further, because the panels 14 a and 14 d-14 f are permitted to fold about the hinges 16 a, 16 c-16 e relative to the upper panel 14 b and are not separate elements that are otherwise sewn or stitched to the upper panel 14 b proximate the location of the hinges 16 a, 16 c-16 e, the lack of sewn/stitched structure at the hinges 16 a, 16 c-16 e prevents punctures or openings from being formed in the dome structure formed by the panels 14 a-14 b and 14 d-14 f, which would otherwise provide locations (e.g., openings/holes/passages) for the heat, H, to escape from within the receiving-cavity 18.
Second, as described above, one or more layers and/or one or more materials of the container 10 in of itself may maintain temperature of or mitigate heat loss of the pizza, F. Referring to FIG. 5A, the unit of material 12 may include a multi-layer structure 22 with each layer 22 a-22 c formed from a different material. In an embodiment, the multi-layer structure 22 may include three layers 22 a, 22 b and 22 c. The layer 22 a may be an outer layer that is exposed to atmosphere, A. The layer 22 c may be an inner layer that forms the receiving-cavity 18. The layer 22 b may be an intermediate layer disposed between the outer layer 22 a and the inner layer 22 c.
The inner layer 22 c may include an olefin fabric. The intermediate layer 22 b may include a closed-cell foam (i.e., not an open-cell foam). The outer layer 22 a may include a marine vinyl.
The olefin fabric 22 c of the inner layer may include a water-wicking characteristic for drawing moisture away the folded, paperboard box, B, such that “sogginess” of the folded paperboard box, B, is mitigated. The closed-cell foam of the intermediate layer 22 b may include polyethylene or the like in order to provide the multi-layer structure 22 with a highly insulative-characteristic that assists in the maintaining the temperature of or mitigating heat loss of the pizza, F. The marine vinyl outer layer 22 a may include a hydrophobic property that prevents water (e.g., rain) from being absorbed into any layers 22 a-22 c of the multi-layer structure 22 while also promoting insulative qualities of the container 10 for maintaining the temperature of or mitigating heat loss of the pizza, F.
Referring to FIGS. 1A-1B and 2-3, an embodiment of the container 10 may include a carrier assembly 24 that is connected to one or more panel 14 a-14 j of the plurality of panels 14. The carrier 24 may include an upper carrier portion 26 and a lower carrier portion 28 (see FIGS. 2-3). The upper carrier portion 26 includes one or more straps 30 connected to an upper handle 32. The lower carrier portion 28 includes a lower handle 34 (see FIGS. 2-3).
Each of the upper carrier portion 26 and the lower carrier portion 28 may be attached to the marine vinyl outer layer 22 a by any desirable attachment configuration. In an embodiment, each of the upper carrier portion 26 and the lower carrier portion 28 may be attached to the marine vinyl outer layer 22 a with an adhesive. Alternatively, each of the upper carrier portion 26 and the lower carrier portion 28 may be attached to the marine vinyl outer layer 22 a by way of a stitched configuration; however, as described above, a stitching may result in one or more of the plurality of panels 14 being punctured, which may undesirably permit heat to escape from within the receiving-cavity 18. Accordingly, if the upper carrier portion 26 and the lower carrier portion 28 are attached to the marine vinyl outer layer 22 a by way of a stitched configuration, any perforations to one or more of the plurality of panels 14 may be limited or strategically-located at particular panels 14 a-14 j of the plurality of panels 14 that are less prone to permitting rising heat, H, to escape from within the receiving-cavity 18.
In an embodiment, the one or more straps 30 may be connected to one or more of the upper panel 14 b and first and second side panels 14 e, 14 f In an embodiment, the one or more straps 30 may originate from corners 36 of the first and second side panels 14 e, 14 f that are closest to the lower panel 14 c; by locating the one or more straps 30 in a manner such that they originate from corners 36 of the first and second side panels 14 e, 14 f closest to the lower panel 14 c, the container 10 may be less prone to sagging or tipping back/forth or side-to-side once the one or more straps 30 are tensioned in response to a user gripping and supporting the handle 32 as gravity pulls the container 10 in the opposite direction.
In an embodiment, the lower handle 34 may be connected to and centrally located upon the lower panel 140. Once attached to the lower panel 14 c, a user may slide/locate one or more fingers between the lower handle 34 and the lower panel 14 c such that the user's hand may be located in a “palm up” orientation (i.e., the user's palm opposingly-faces the lower panel 14 c) for supporting the container 10 in a substantially similar manner as a server or waiter would support a serving tray. Because the user may support the container 10 with one hand in a “palm up” orientation, the user's free hand (i.e., the hand that is not utilized for supporting the container 10) is permitted to unfurl the overlapping arrangement of the panels 14 d, 14 g according to directions opposite that of the arrows, D4-D7, in a one-handed manner.
Referring to FIG. 1B, an embodiment of the container 10 may further include a plurality of fasteners 38, such as, for example, hook-and-loop fasteners (e.g., VELCRO®), for connecting one or more panels 14 a-14 j to one or more other panels 14 a-14 j of the plurality of panels. Although the fasteners 38 may include VELCRO®, the fasteners are not limited to including VELCRO® and may alternatively include any desirable fastener, such as, for example, magnets, clasps, snaps, clips of the like.
In an embodiment, the hook-and-loop fasteners 38 may be located upon on one or more of the outer layer 22 a, the inner layer 22 c, the one or more straps 30 or the like. According to an embodiment, the fasteners 38 may be utilized for connecting the inner layer 22 c of one or more of the central/side flap panels 14 h-14 j to the outer layer 22 a of one or more of the one or more straps 30 and upper handle 32 that is/are arranged upon the first side panel 14 e, the second side panel 14 f and the upper panel 14 a.
Referring to FIGS. 1A-1B, an embodiment of the container 10 may further include one or more exterior pockets 40 formed by a layer of material 42 secured to the outer layer 22 a of at least one panel 14 a-14 j of the plurality of panels 14. The layer of material 42 may include a sheet of substantially transparent plastic for permitting a user to see the contents (e.g., money, receipts, driving directions or the like) contained within the pocket 40. At least three (of four) sides of the layer of material 42 of material may be secured to the outer layer 22 a of at least one panel 14 a-14 j of the plurality of panels 14 for forming the pocket 40; accordingly, a user may access the contents of the pocket 40 proximate the fourth side of the layer of material 42 that is not secured to the outer layer 22 a of at least one panel 14 a-14 j of the plurality of panels 14.
Referring to FIGS. 6A-6B, an exemplary implementation of a container is shown at 100. An embodiment of the container 100 may be sold under the trade-name HEATZA that is commercially available from Arden Corporation of Southfield, Mich.
Referring to FIG. 7, the container 100 is formed from a single unit of material 102. The unit of material 102 includes a geometry that is formed from a plurality of panels 104 that are integrally connected to one another. The plurality of panels 104 are demarcated from one another by a plurality of fold lines, hinges, or the like, which are shown generally at 106. In an embodiment, the plurality of hinges 106 may be formed/molded in any desirable manner such as, for example, by removing material proximate an area or zone where the hinges 106 are to be formed, or, alternatively, forming/molding an area or zone where the hinges 106 are to be formed/molded with a notch, channel, or the like (e.g., a “V shaped” channel). Alternatively, the plurality of hinges 106 may not be treated (e.g., by material removal, forming, molding or the like) in a particular manner, and, the plurality of hinges 106 may occur naturally as a result of a user/manufacturer folding the single unit of material 102.
The plurality of panels 104 may be identified as follows. Although the following description sets forth a particular “name” for each panel, the name given to each panel is based upon an illustrated orientation of the panel in FIGS. 6A-9B and should not be utilized to limit the scope of the claimed invention. In an implementation, the plurality of panels 104 may include a rear panel 104 a that connects an upper panel 104 b and a lower panel 104 c. The upper panel 104 b and rear panel 104 a form a first hinge 106 a of the plurality of hinges 106. The lower panel 104 c and the rear panel 104 a form a second hinge 106 b of the plurality of hinges 106.
The plurality of panels 14 may further include a first front panel 104 d, a first side panel 104 e and a second side panel 104 f. The first front panel 104 d, first side panel 104 e and second side panel 104 f each extend from and are integrally connected to the upper panel 104 b. The upper panel 104 b and the first front panel 104 d form a third hinge 106 c of the plurality of hinges 106. The upper panel 104 b and the first side panel 104 e form a fourth hinge 106 d of the plurality of hinges 106. The upper panel 104 b and the second side panel 104 f form a fifth hinge 106 e of the plurality of hinges 106.
The plurality of panels 104 may further include a second front panel 104 g. The second front panel 104 g extends from and is integrally connected to the lower panel 104 c. The lower panel 104 c and the second front panel 104 g form a sixth hinge 106 f of the plurality of hinges 106.
Unlike the second front panel 14 g of the plurality of panels 14, the plurality of panels 104 do not include a central flap panel 14 h, a first side flap panel 14 i and a second side flap panel 14 j extending from the second front panel 104 g; however, the plurality of panels 104 include a first tuck flap panel 104 h, a second tuck flap panel 104 i and a central flap panel 104 j. The first tuck flap 104 h connects a first end 104 d′ of the first front panel 104 d to a first end 104 e′ of the first side panel 104 e. The second tuck flap 104 i connects a second end 104 d″ of the first front panel 104 d to a first end 104 f′ of the second front panel 104 f. The central flap panel 104 j extends from and is integrally connected to the second front panel 104 g.
Each of the first tuck flap panel 104 h and the second tuck flap panel 104 i includes a first tuck portion 104 h′, 104 i′ connected to a second tuck portion 104 h″, 104 i″. The first tuck portion 104 h′ extends from first end 104 d′ of the first front panel 104 d, and, the first tuck portion 104 i′ extends from the second end 104 d″ of the first front panel 104 d. The second tuck portion 104 h″ extends from the first end 104 e′ of the first side panel 104 e, and, the second tuck portion 104 i″ extends from the first end 104 f of the second front panel 104 f.
The first tuck portion 104 h′ connects to the second tuck portion 104 h″ to form a seventh hinge 106 g of the plurality of hinges 106. The first tuck portion 104 i′ connects to the second tuck portion 104 i″ of the second tuck flap panel 104 i to form an eighth hinge 106 h of the plurality of hinges 106. The central flap panel 104 j and the second front panel 104 g form a ninth hinge 106 i of the plurality of hinges 106.
In an implementation, each panel 104 a-104 j of the plurality of panels 104 includes a substantially square/rectangular shape geometry. Although the illustrated embodiment sets, forth each panel 104 a-104 j of the plurality of panels 104 including a substantially square/rectangular shape geometry, each panel 104 a-104 j of the plurality of panels 104 may be formed to include any geometry, such as, for example, circular, triangular or the like.
When the unit of material 102 is folded about the plurality of hinges 106, the unit of material 102 may be arranged in a configuration that forms the container 100 that is shown in FIGS. 6A-6B. Although the term “folded” is used in describing the arrangement for forming the container 100, one or more additional manufacturing steps may be included in addition to the “folding” step described above. In an implementation, the one or more additional manufacturing steps may include the step of “seaming” (e.g., sewing, stitching, adhering or the like) together one or more edges of the plurality of panels 104. Accordingly, in an implementation, manufacturing steps for forming the container 100 may include at least the steps of “folding” and “seaming” the unit of material 102.
In an implementation, the container 100 may be formed from the unit of material 102 as follows at FIGS. 8A-8F. Referring to FIGS. 8A-8B, the rear panel 104 a, first side panel 104 e, second side panel 104 f first tuck flap panel 104 h and second tuck flap panel 104 i may be folded downwardly (see, e.g., arrow D1 in FIG. 8A and arrow D2 in FIG. 8B) about the hinges 106 a, 106 d-106 e (noting that the hinges 106 d, 106 e extend along the ends 104 d′, 104 d″ of the first front panel 104 due to the first and second tuck flap panels 104 h, 104 i being shared with the first and second side panels 104 e, 104 f), relative to the upper panel 104 b. Then, a first side edge 104 a′ (see FIG. 7) of the rear panel 104 a may be seamed with a rear edge 104 e″ (see FIG. 7) of the first side panel 104 e, and, a second side edge 104 a″ (see FIG. 7) of the rear panel 104 a may be seamed with a rear edge 104 f″ (see FIG. 7) of the second side panel 104 f.
Referring to FIG. 8C, the lower panel 104 c may be folded upwardly (see, e.g., arrow D3 in FIG. 8C) about the second hinge 106 b relative to the rear panel 104 a. Then, a first side edge 104 c′ (see FIG. 7) of the lower panel 104 c may be seamed with a side edge 104 e′″ (see FIG. 7) of the first side panel 104 e, and, a second side edge 104 c″ (see FIG. 7) of the lower panel 104 c may be seamed with a side edge 104 f′″ (see FIG. 7) of the second side panel 104 f.
Referring to FIG. 6B, as a result of folding and seaming the unit of material 102 as described above, the panels 104 a-104 c and 104 e-104 f form a pocket or receiving-cavity, which is shown generally at 108, and an access opening 110. Accordingly, one or more objects, F, B, may be inserted through the opening 110 and deposited into the receiving-cavity 108.
Referring to FIGS. 8D-8E, the access opening 110 may be selectively closed-out by one or more of the first front panel 104 d and the second front panel 104 g. In order to close-out the access opening 110, the first front panel 104 d is permitted to be selectively folded, downwardly (see, e.g., arrow D4 in FIG. 8D) about the third hinge 106 c (noting that the third hinge 106 c extends along the ends 104 e′, 104 f′ of the first and second side panels 104 e, 104 f due to the first and second tuck flap panels 104 h, 104 i being shared with the first front panel 104 d) relative to the upper panel 104 b, and, the second front panel 104 g is permitted to be selectively folded upwardly (see, e.g., arrow D5 in FIG. 8D) about the sixth hinge 106 f relative to the lower panel 104 c.
As a result of the first front panel 104 d being folded in the direction of the arrow, D4, a compound motion of the first front panel 104 d and first and second tuck flap panels 104 h, 104 i is permitted to occur; in other words, the responsive to the movement of the first front panel 104 d in the direction of the arrow, D4, the first ands second tuck flap panels 104 h, 104 i are each permitted to collapse about the seventh and eighth hinges 106 g, 106 h for automatically moving in a “self tucking” arrangement such that the first and second tuck flap panels 104 h, 104 i close out the sides of the access opening 110. Further, by arranging the first front panel 104 d and second front panel 104 g as described above, the first front panel 104 d and second front panel 104 g may be said to “overlap” one another; the overlapping arrangement may not only function in closing out the upper and lower sides of the access opening 110, but, also inhibits the movement of heat, H (see FIG. 9B), through the overlapping arrangement of the panels 104 d, 104 g and out of the receiving-cavity 108. Further, after the tucking and overlapping arrangement of the panels 104 d, 104 g-104 i is provided, the central flap panel 104 j is permitted to be disposed over the upper panel 104 b as a result of permitting the central flap panel 104 j to be selectively folded (see, e.g., arrow D6 in FIG. 8E) about the ninth hinge 106 i relative to the second front panel 104 g.
Referring to FIG. 6B, prior to closing-out the access-opening 110 as described above, a user may deposit the one or more objects, F, B into the receiving-cavity 108. In an implementation, the one or more objects, F, B, may include one or more a foodstuff units, F, and/or one or more boxes or sub-containers that contain the one or more foodstuff units, F. The one or more foodstuff units, F, may include, but is not limited to, a pizza. The one or more boxes, B, may include, but is not limited to, a folded, paperboard box.
Although an embodiment of the foodstuff unit, F, may include pizza, the foodstuff unit, F, is not limited to pizza, and may include, for example, baked items, fried items, cooked items, liquids, or any other type of food or beverage. Further, although an embodiment of the foodstuff unit, F, is described to include what may be a hot/heated item (e.g., pizza, a baked item, a fried item, a cooked item or the like), the foodstuff unit, F, may include a foodstuff unit, F, having a temperature approximately equal to or less than room temperature, such that, for example, the foodstuff unit, F, may be said to be cooled, cold or frozen.
According to an embodiment, the container 100 may be utilized as a pizza delivery container, and, as such, may include thermal insulating properties; accordingly, in an embodiment, the container 100 may be referred to as a “thermally insulated container.” The thermal insulating properties of the container 100 may function in a manner that promotes maintaining temperature of the pizza, F, or mitigating heat loss of the pizza, F, from the time the pizza, F, is removed from an oven at, for example, a pizzeria to the time when the pizza, F, is presented to, for example, a customer at a delivery location. Thus, as will described in an embodiment in the following disclosure, the container 100 may be formed to include one or more layers, one or more materials and/or one or more structural configurations that may lend to the maintaining of temperature or mitigating of heat loss of the pizza, F, during, for example, transport of the pizza, F, from the pizzeria to the customer.
First, as described above, the structural configuration of the container 10 in of itself may maintain temperature or mitigate heat loss of the pizza, F. When looking to the unfurled orientation of the unit of material 102 that forms the container 100 in FIG. 7, the panels 104 a and 104 d-104 f are one with and connected to the upper panel 104 b such that the panels 104 a and 104 d-104 f may “drop down” from the upper panel 104 b and form a “dome structure.” Referring to FIG. 9B, because heat, H, rises, any heat, H, emanating from the pizza, F, may be trapped by the dome structure such that the trapped heat, H, within the receiving-cavity 108 may functionally maintain the temperature of or mitigate heat loss of the pizza, F. Further, because the panels 104 a and 104 d-104 f are permitted to fold about the hinges 106 a, 106 c-106 e relative to the upper panel 104 b and are not separate elements that are otherwise sewn or stitched to the upper panel 104 b proximate the location of the hinges 106 a, 106 c-106 e, the lack of sewn/stitched structure at the hinges 106 a, 106 c-106 e prevents punctures or openings from being formed in the dome structure formed by the panels 104 a-104 b and 104 d-104 f which would otherwise provide locations (e.g., openings/holes/passages) for the heat, H, to escape from within the receiving-cavity 108.
Second, as described above, one or more layers and/or one or more materials of the container 100 in of itself may maintain temperature of or mitigate heat loss of the pizza, F. Referring to FIGS. 10A, 10B, the unit of material 102, 102′ may include a multi-layer structure 112 (see FIG. 10A), 112′ (see FIG. 10B) with each layer 112 a-112 d formed from a different material.
Referring to FIG. 10A, the multi-layer structure 112 may include layers 112 a, 112 b, 112 c and 112 d. The layer 112 a may be an outer layer that is exposed to atmosphere, A. The layer 112 d may be an inner layer that forms the receiving-cavity 108. The layers 112 b, 112 c may be intermediate layers disposed between the outer layer 112 a and the inner layer 112 d. The layer 112 b may be disposed adjacent the outer layer 112 a, and the layer 112 c may be disposed adjacent the inner layer 112 d.
The outer layer 112 a may include a general purpose, flame retardant, laminated polyester. The general purpose, flame retardant, laminated polyester outer layer 112 a may be commercially available and sold under the trade-name “Black Value.”
The first intermediate layer 112 b adjacent the outer layer 112 a may include a first, upper side 112 b ₁and a second, lower side 112 b ₂. The first, upper side 112 b ₁may include a reflective, “shiny” side, whereas the second, lower side 112 b ₂may include a non-reflective, “non-shiny” side. In an embodiment, the first intermediate layer 112 b may include aluminum foil. Alternatively, in an embodiment, the first intermediate layer 112 b may include Mylar. The first intermediate layer 112 b may include a thickness that is approximately equal to 0.0007 inches.
The second intermediate layer 112 c adjacent the first intermediate layer 112 b may include a closed-cell foam (i.e., not an open-cell foam) polyester batting. The inner layer 112 d adjacent the second intermediate layer 112 c may include an olefin woven fabric.
The olefin woven fabric 112 d of the inner layer may include a water-wicking characteristic for drawing moisture away the folded, paperboard box, B, such that the folded paperboard box, B, is mitigated from becoming soggy. The closed-cell foam polyester batting of the second intermediate layer 112 c includes a highly insulative characteristic. The first intermediate layer 112 b reflects or re-directs heat, H, back toward the receiving-cavity 108. The outer layer 112 a may include a hydrophobic property that prevents water (e.g., rain) from being absorbed into any layers 112 b-112 d of the multi-layer structure 112.
Referring to FIG. 10B, the multi-layer structure 112′ may include layers 112 a, 112 b, 112 c and 112 d. The multi-layer structure 112′ is substantially similar to the multi-layer structure 112 of FIG. 10A, however, unlike the first intermediate layer 112 b of the multi-layer structure 112, the first intermediate layer 112 of the multi-layer structure 112′ includes two layers 112 b′ and 112 b″; in an embodiment, the first intermediate layer 112 b of the multi-layer structure 112′ may be commercially available and sold under the trade-name “Silver Energy Shield.”
The first layer 112 b′ of the first intermediate layer 112 includes a polyester film, and, the second layer 112 b″ of the first intermediate layer 112 includes a first; upper side 112 b ₂″ having and a reflective, “shiny” characteristic second, lower side 112 b ₂″ having a non-reflective, “non-shiny” characteristic, In an embodiment, the second layer 112 b″ of first intermediate layer 112 b may include aluminum foil; the polyester film first layer 112 b′ may be laminated to the aluminum foil second layer 112 b″. Alternatively, in an embodiment, second layer 112 b″ of the first intermediate layer 112 b may include Mylar. The first layer 112 b′ of the first intermediate layer 112 b may include a thickness that is approximately equal to 0.00043 inches. The second layer 112 b″ of the first intermediate layer 112 b may include a thickness that is approximately equal to 0.0007″.
Referring to FIG. 11, an implementation of the multi-layer structure 112, 112′ of the unit of material 102, 102′ is shown. The outer layer 112 a may be formed from three separate components, 112 a′, 112 a″ and 112 a′″ that are connected (e.g., seamed) together prior to assembly/joining with the remaining layers 112 b-112 d of the multi-layer structure 112, 112′. The first component 112 a′ is generally characterized by the geometry of the panels 104 b, 104 d-104 f and 104 h-104 i. The second component 112 a″ is generally characterized by the geometry of the panels 104 a, 104 c. The third component 112 a′″ is generally characterized by the geometry of the panels 104 g, 104 j. Each of the first intermediate layer 112 b, the second intermediate layer 112 c and the inner layer 112 d may be formed from as a single component.
Through experimentation, it was discovered that the when the panels 104 a-104 j formed by the unit of material 102, 102′ was folded and seamed (see FIGS. 8A-8F), the relative stiffness of the outer layer 112 a formed by one component (i.e. not three components) of material resulted in a high degree of difficulty in manufacturing the container 100. As a result, the outer layer 112 was separated into the three components, 112 a′, 112 a″ and 112 a′″ in order to relieve difficulty associated with the folding and seaming of an outer layer formed by one, component of material. Referring to FIGS. 12A-13B, in addition to the increased manufacturability of the component 100 as described above, by separating the outer layer 112 a into three components, 112 a′, 112 a″ and 112 a′″, a reduced amount of waste material, W (see FIGS. 12B, 13B), was realized due to the ability for a manufacturer to maximize utilization of, for example, a fifty-four inch roll of material, M (see FIGS. 12A, 13A), positioned upon a cutting platen, P.
Referring to FIGS. 6A-6B, an embodiment of the container 100 may include a carrier assembly 114 that is connected to one or more panel 104 a-104 j of the plurality of panels 104. The carrier 114 may include an upper carrier portion 116 and a lower carrier portion 118 (see FIG. 7). The upper carrier portion 116 includes one or more straps 120 connected to an upper handle 122. The lower carrier portion 118 includes a lower handle 124 (see FIG. 7).
Each of the upper carrier portion 116 and the lower carrier portion 118 may be attached to the outer layer 112 a by any desirable attachment configuration. In an embodiment, each of the upper carrier portion 116 and the lower carrier portion 118 may be attached to the outer layer 112 a with an adhesive. Alternatively, each of the upper carrier portion 116 and the lower carrier portion 118 may be attached to the outer layer 112 a by way of a stitched configuration; however, as described above, a stitching may result in one or more of the plurality of panels 104 being punctured, which may undesirably permit heat to escape from within the receiving-cavity 108. Accordingly, if the upper carrier portion 116 and the lower carrier portion 118 are attached to the outer layer 112 a by way of a stitched configuration, any perforations to one or more of the plurality of panels 104 may be limited or selectively-located to particular panels 104 a-104 j of the plurality of panels 104 that are less prone to heat leakage from within the receiving-cavity 108.
In an embodiment, the one or more straps 120 may be connected to one or more of the upper panel 104 b and first and second side panels 104 e, 104 f In an embodiment, the one or more straps 120 may originate from corners 126 of the first and second side panels 104 e, 104 f that are closest to the lower panel 104 c; by locating the one or more straps 120 in a manner such that they originate from corners 126 of the first and second side panels 104 e, 104 f closest to the lower panel 104 c, the container 100 may be less prone to sagging or tipping back/forth or side-to-side once the one or more straps 120 are tensioned in response to a user gripping and supporting the handle 122 as gravity pulls the container 100 in the opposite direction.
In an embodiment, the lower handle 124 may be connected to and centrally located upon the lower panel 104 c. Once attached to the lower panel 104 c, a user may slide/locate one or more fingers between the lower handle 124 and the lower panel 104 c such that the user's hand may be located in a “palm up” orientation (i.e., the user's palm opposingly-faces the lower panel 104 c) for supporting the container 100 in a substantially similar manner as a server or waiter would support a serving tray. Because the user may support the container 100 with one hand in a “palm up” orientation, the user's free hand (i.e., the hand that is not utilized for supporting the container 100) is permitted to unfurl the overlapping arrangement of the panels 14 d, 14 g according to directions opposite that of the arrows, D4-D6, in a one-handed manner.
Referring to FIGS. 6A-6B, an embodiment of the container 100 may further include a plurality of fasteners 128, such as, for example, hook-and-loop fasteners (e.g., VELCRO®), for connecting one or more panels 104 a-104 j to one or more other panels 104 a-104 j of the plurality of panels. Although the fasteners 128 may include VELCRO®, the fasteners 128 are not limited to includes VELCRO® and may alternatively include any desirable fastener, such as, for example, magnets, clasps, snaps, clips of the like.
The fasteners 128 may be located on one or more of the outer layer 112 a and the inner layer 112 d. According to an embodiment, the fasteners 128 may be utilized for connecting the inner layer 112 d of the central flap panel 104 j to the outer layer 112 a of the upper panel 104 b.
Refining to FIGS. 7 and 9A, an embodiment of the container 100 may further include one or more exterior pockets 130 formed by a layer of material 132 secured to the outer layer 112 a of at least one panel 104 a-104 j of the plurality of panels 104. The layer of material 132 may include a sheet of transparent plastic such that a user may see the contents (e.g., money, receipts, driving directions or the like) of the pocket 130. At least three (of four) sides of the layer of material 132 may be secured to the outer layer 112 a of at least one panel 104 a-104 j of the plurality of panels 104 such that a user may access the contents of the pocket proximate the fourth side of the layer of material 132 that is not secured to the outer layer 112 a of at least one panel 104 a-104 j of the plurality of panels 104.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims. For example, the actions recited in the claims can be performed in a different order and still achieve desirable results.

Claims

1. A thermally insulating container, comprising:

a body, wherein said body includes portions that are demarked by non-seamed folds and portions that are demarked by seams, wherein the body includes

a top, and

at least one side, wherein said top and at least one side are demarked by a non-seamed fold.

2. The thermally insulating container of claim 1, wherein said body further includes an end, wherein said top and said end are demarked by a non-seamed fold.

3. The thermally insulating container of claim 1, wherein said body further includes an opening flap, wherein said top and said opening flap are demarked by a non-seamed fold.

4. The thermally insulating container of claim 1, wherein said body is comprised of:

at least in part, closed cell foam.

5. The thermally insulating container of claim 1, wherein said body includes an outer portion comprised of: at least in part, vinyl.

6. The thermally insulating container of claim 5, wherein said vinyl is marine vinyl.

7. The thermally insulating container of claim 1, wherein said body is comprised of:

at least in part; olefin fabric.

8. The thermally insulating container of claim 1, wherein said body includes a cover, wherein said cover and said opening flap at least partially overlap each other.

9. A thermally insulating container, comprising:

a body defining a cavity therein;

an access-opening opening to said cavity;

cover means for covering the access opening.

10. The container of claim 9, wherein said body comprises an insulating layer.

11. The container of claim 10, wherein said insulating layer comprises closed cell foam.

12. The container of claim 11, wherein said closed cell foam comprises polyethylene foam.

13. The container of claim 10, wherein said body defines a compartment therein, and wherein said body comprises an inner layer that defines said compartment.

14. The container of claim 13, wherein said inner layer comprises at least in part olefin fabric.

15. The container of claim 9, wherein said cover means is formed from a plurality of panels.

16. The container of claim 15, wherein said plurality of panels are structurally arranged to form a structure to mitigate heat loss.

17. The container of claim 16, wherein said plurality of panels includes a first panel that comprises an upper panel of said container, and wherein at least one first cover panel is continuous with said upper panel.

18. The container of claim 17, wherein said access opening comprises a first side edge and a second side edge, and wherein said cover means includes at least one second cover panel that is swingably hinged with said body portion and movable for positioning over said access opening, said cover means including at least one first side cover panel that is foldable beyond said first side edge when said at least one second cover panel is positioned over said access opening, and at least second side cover panel that is foldable over said second side edge when said at least one cover panel covers said access opening.

19. The container of claim 9, wherein said body comprises a multi-layer structure including an outer layer that is exposed to the atmosphere, and inner layer that forms said cavity, and an intermediate layer disposed between the outer layer and the inner layer.

20. The container of claim 19, wherein the inner layer comprises an olefin fabric, the intermediate layer comprises a closed-cell foam, and wherein the outer layer comprises a marine vinyl.