A foldable article

Abstract

 A foldable article is arranged to form a larger container 92 in a first folded form. The article comprises a panel 12 which is flat in the first form. The panel 12 defines two lines 30, 32 for folding the panel 12. The article can be folded to form a smaller container 94 in a second folded form in which the panel 12 is folded about the or each line 30, 32.

Description

[0001] The present invention relates to a foldable article, and is particularly but not exclusively concerned with a container for foodstuffs, and more particularly a pizza box.

[0002] It is common for pizza, for example when delivered to a home, to be delivered in a pizza box. A known pizza box is a shallow rectangular corrugated cardboard box with a fold open lid. The known box is made large enough to accommodate the size of the pizza which is to be delivered, and the size of the box is not arranged to be changed once it has been manufactured. Therefore, if, for example, some leftover pizza remains and the consumer wishes to preserve this leftover pizza, the box in which the pizza was delivered will be larger than necessary to store the leftover pizza. As a result, it may not be practical for the consumer to use the pizza box to store the pizza, for example, in the refrigerator. This causes the consumer inconvenience when wishing to store leftover pizza.

[0003] The known pizza box is formed with several round holes in two opposite side walls at about half of the height of the walls. These holes are for ventilation to aid in preserving the quality of the pizza stored within as it travels to the consumer by allowing the escape of steam which might otherwise make the pizza base less crisp. The holes of the known prior box are formed by removing material from the pizza box blank during the manufacturing process. This need to remove the cut material from the pizza box blank involves a manufacturing step which costs both money and time in the manufacturing process, and which requires quality control monitoring to ensure the material has been removed.

[0004] According to one aspect of the invention, there is provided a foldable article forming a container in a first folded form, the article comprising a panel which is flat in the first form, wherein the panel defines at least one line for folding the panel, and wherein the panel is folded about the or each line to form a container in a second folded form.

[0005] With such a folded article, a user may form a second smaller container from the first container, and as such, may store in the second container the reduced contents of a product or substance initially stored in the first container, for example, left over pizza which was delivered in the larger form of box can be stored in the second smaller form.

[0006] The panel may be polygonal, and, more preferably, rectangular. In this way the folded article is simple to manufacture and assemble.

[0007] Preferably the panel is a base panel.

[0008] In a preferred embodiment the line for folding the panel is parallel to one edge of the panel. Advantageously, the panel defines at least two lines for folding the panel. The or at least two said lines for folding may be substantially parallel to one another. In this way the container in its second folded form is more symmetrical.

[0009] Preferably at least one line for folding the panel spans substantially one dimension of the panel.

[0010] In a preferred embodiment the folded article comprises at least one second panel associated with the first panel. Preferably, the or at least one second panel defines a line of weakness separating the or at least one second panel into two panel portions. The line of weakness may intersect the end of the panel fold line. Preferably the article further defines a line for folding a portion of the second panel once the line of weakness has been broken. In this way a flap may be formed in the second panel. Preferably the line for folding a portion of the second panel is provided in one second panel portion. Preferably the line for folding a portion of the second panel intersects the end of the or a panel fold line. Preferably a cut line or second line of weakness is provided between the first line of weakness and the line for folding a portion of the second panel to form a flap. More preferably, the cut line or second line of weakness is also along a fold line between the first panel and the second panel. In this way a flap may formed in the second panel hinged at one end thereto, and the flap may be folded inside the container to provide a more secure means for closing the smaller container.

[0011] Preferably the part of the first panel to one side of the or at least one said fold line in the first panel forms a lid for the container in the second form.

[0012] The line of weakness and the line for folding the portion of the second panel maybe substantially parallel to each other to create a substantially rectangular flap. Preferably, however, the or at least one line of weakness extends rearward from the first end in the direction of the lid for the container in the second form. In this way, it is easier, when forming the smaller container, to tuck a rear portion of the second panel over the flap.

[0013] Preferably the container in the first form has a lid connected through a fold line to the remainder of the article. Preferably the lid is arranged to be detached at the fold line by which it is connected to the remainder of the article.

[0014] Preferably the folded article is made of cardboard.

[0015] According to a second aspect of the invention, there is provided a blank including two panels connected through a discontinuous fold line, one panel defining a tab at the or at least one discontinuity, the tab extending past the fold line into the other panel, the boundary of the tab with respect to the other panel being defined by a cut line or line of weakness, such that when the panels are folded about the fold line, the tab moves out of the plane of the said other panel leaving an aperture.

[0016] In this way, it is not necessary to form holes in the box blank by removing material during the manufacturing process in order to create ventilation holes in the assembled box. Instead, a hole is formed when the blank is folded along the discontinuous fold line and the tab moves out of the plane of the panel in which it is defined. Therefore, a manufacturing step is eliminated without sacrificing an important feature of the assembled box.

[0017] In a preferred embodiment the boundary line and the notional continuation of the fold line define a polygon, and more preferably define a quadrilateral, and more preferably still define a trapezium. In this way the tab moves easily out of the plane of the said panel when leaving an aperture.

[0018] Preferably the blank is for erection into a carton.

[0019] Preferably one of the said panels is arranged to form a lid on the erected carton and preferably the said other panel is arranged to form a tuck-in flap.

[0020] In a preferred embodiment the lid panel is rectangular, and more preferably the lid panel is square.

[0021] Preferably the discontinuous fold line comprises two discontinuous portions. In this way two apertures are formed between the first and second panel respectively.

[0022] In a preferred embodiment the blank comprises a third panel connected through a discontinuous fold line, one panel defining a tab at the or at least one discontinuity, the tab extending past the fold line into the other panel, the boundary of the tab with respect to the other panel being defined by a cut line or a line of weakness, such that when the panels are folded about the fold line, the tab moves out of the plane to said other panel leaving an aperture.

[0023] Preferably the blank is made of cardboard.

[0024] According to a third aspect of the invention, there is provided a carton erected from a blank as described in the second aspect of the invention, the carton comprising a base panel and at least one associated wall panel, the or at least one wall panel having a first end attached to the base panel and having a second opposite free end, the wall panel defining at least one indentation at a location along the edge of the second free end of the wall panel corresponding to the equivalent location of the said aperture on the lid portion, the indentation having a shape complementary to the aperture on the lid portion.

[0025] In this way the indentation and the aperture line up to form a hole for ventilation in the erected blank.

[0026] Two embodiments of the invention will now be described by way of example and with reference to the accompanying drawings, in which:

Figure 1 is a plan view of the blank of the first embodiment of the invention;

Figure 2 is a perspective view of the blank of Figure 1 in the first folded form;

Figure 3 is a side elevation in the direction of the arrow A of the box of Figure 2;

Figure 4 is a perspective view of the box of Figure 2 with the lid portion removed, showing flaps formed in the wall panels; and

Figure 5 is a perspective view of the box of Figure 4 in a second folded form.

Figure 6 is a plan view of the blank of the second embodiment of the invention;

Figure 7 is a perspective view of the blank of Figure 6 in the first folded form;

Figure 8 is a side elevation in the direction of the arrow A of the box of Figure 7;

Figure 9 is a perspective view of the box of Figure 7 with the lid portion removed, showing flaps formed in the wall panels; and

Figure 10 is a perspective view of the box of Figure 9 in a second folded form.

[0027] Referring to Figures 1 to 3, the planar blank 10 of the embodiment of the invention is made of a sandwiched corrugated cardboard construction and comprises a square base panel 12 which is connected at a front end through a fold line 14 to a rectangular front wall panel 16. The base panel 12 is connected at a rear end through a fold line 18 to a rectangular rear wall panel 20. At its sides, the base panel 12 is connected through respective fold lines 22 to respective rectangular side wall panels 28. Front wall panel 16, rear wall panel 20 and side wall panels 28 are substantially of equal height.

[0028] The base panel 12 has an additional two fold lines 30, 32 which span the width of the base panel 12 between the side wall panels 28. Fold lines 30, 32 are spaced apart equally either side of a line of symmetry extending across the base panel 12 midway between the front end and the rear end of the base panel, and are spaced from each other the width of the side wall panel 28.

[0029] The base panel 12 further comprises two elongate apertures 34 spaced apart at the front end of the base panel with a long front edge of each aperture 34 adjacent the fold line 14. The centre of each aperture 34 is located approximately one quarter the width of the base panel 12 from respective fold lines 22.

[0030] The front wall panel 16 is slightly wider than the base panel 12 and extends therebeyond at respective ends by approximately the thickness of the material of the blank 10. The front wall panel 16 is further connected at an opposite side to that connected to the base panel 12 to a first side of a hinge portion 38 through a fold line 40. The hinge portion 38 tapers inwardly at an angle of approximately 45° from the first side to a second opposite side, such that the second side is narrower than the first side at respective ends by approximately the thickness of the material of the blank 10.

[0031] The hinge portion 38 is further connected through a fold line 41 to a first edge of a generally rectangular tuck-in flap 44. A second opposite edge of the tuck-in flap 44 is provided with two spaced apart, outwardly-extending tabs 42. The size and position of the tabs correspond to the size and position of the two elongate apertures 34 on the base panel 12. The outward edges of the tabs 42 are parallel to the second edge of the tuck-in-flap 44, and the side edges of the tabs taper outwardly from the second edge of the tuck-in-flap to the outward edge of the flap.

[0032] A circular aperture 46 is formed centrally on the panels 16 and 44, spanning the hinge portion 38.

[0033] Each side wall panel 28 has a free edge 48 opposite to the respective fold line 22. Each free edge 48 is provided with two spaced-apart indentations 52 located symmetrically along the length of each side panel wall 28. Each indentation 52 has an inner edge parallel to the free edge 48 of the respective side wall panel 28 and has two walls which taper inwardly to the inner edge.

[0034] Each side wall panel 28 is connected at its rear edge to a rear side wall flap 58 through a fold line 60. Each flap 58 is generally rectangular and tapers slightly along an inside edge from the respective fold line 60 to an edge opposite the fold line. Each flap 58 extends rearwardly away from the side panel walls 28 for a distance equal to the width of the rear intermediate wall panel 20.

[0035] Similarly, each side wall panel 28 is connected at its front edge to a front side wall flap 64 through a fold line 70. Each flap 64 is generally rectangular and tapers slightly along an inside edge from the fold line 40 to an edge opposite the respective fold line 70. Each flap 64 extends forwards to line up generally with the free edge of the tuck-in flap 44.

[0036] A fold line 72 extends across each side wall panel 28 parallel to and adjacent the fold line 32 of the base panel 12. Perforations 76 extend across each side wall panel 28 parallel to and adjacent the fold line 30.

[0037] A cut 74 is formed along each fold line 22, the cut spans between the intersections of fold lines 30 and 32 with the respective fold line 22.

[0038] A lid panel 80 has the same width as the base panel 12 and approximately the same length less the thickness of the material of the blank 10. The panel 80 is connected at a front end to the rear wall panel 20 through a perforated fold line 82. The lid panel 80 is connected at a rear edge to a generally rectangular rear flap 84, which has rounded corners, through a fold line 86.

[0039] The lid panel 80 is connected at each side to two generally rectangular side flaps 81 through respective discontinuous fold lines 83. The flaps 81 have the same width as the side wall panels 28. The discontinuity of the fold lines 83 is provided by trapezoidal tabs 88 that are defined by a three-sided cut extending away from the lines 83 into the flaps 81. A pair of the tabs 88 is provided for each fold line 83 and the tabs are positioned so as to co-operate with the indentations 52 as described below. The tabs 88 are substantially the same shape as the indentations 52 but are slightly smaller.

[0040] The flaps 81 each define two arcuate indentations 86 on the free edges opposite the discontinuous fold lines 83.

[0041] In use, when the blank 10 is to be erected, the side wall panels 26, the rear intermediate wall panel 20 and the front wall panel 16 are folded about the fold lines 22, 18, 14. The flaps 58, 64 are folded inwardly inside the box by folding along the fold lines 60, 70. Tuck-in flap 44 is folded inwardly by means of the hinge portion 38 about the fold lines 40, 41 to trap the flaps 64 between the front wall panel 16 and the tuck-in flap 44. The tuck-in flap 44 is secured in position by tucking the tabs 42 into respective apertures 34. This action locks the front wall panel 16 and side wall panels 28 in planes perpendicular to the plane of the base panel 12.

[0042] The lid panel 80 is brought to a position overlying the base panel 12 by folding about fold line 18 and perforated fold line 82. Side flaps 81 are folded inwardly about fold line 83 leaving tabs 88 protruding from the lid portion 80 and exposing apertures 90 in the flaps 81, as shown in Figure 3. Rear flap 84 is folded about fold line 86. The flaps 81, 84 are tucked inside the front and side panel walls 16, 28 as shown in Figures 2 and 3 to form the closed box 92. In this configuration, the apertures 90 and the indentations 52 line up to form ventilation holes for the contents of the erected blank 10.

[0043] In this way it is not necessary to form holes in the box blank by removing material during the manufacturing process in order to create ventilation apertures in the assembled box. Instead, the apertures 90 are formed when the blank 10 is folded along the discontinuous fold line 83 and the tab 88 moves out of the plane of the panel 81 in which it is defined. Therefore, a manufacturing step is eliminated without sacrificing an important feature of the assembled box.

[0044] Referring now to Figures 4 and 5, a smaller box 94 may be formed from the large box formed from the blank 10. The lid portion 81 is removed from the rear wall panel 20 by tearing along the perforated fold line 82 of the erected box 92. Intermediate side wall flaps 96 are formed in the side wall panels 28 by breaking the line of perforations 76 and folding inwardly the portion of sidewall panel between the perforations 76 and fold line 72.

[0045] Fold lines 30, 32 in the base panel 12 are folded inwardly to cause the rear half 98 of the base panel to rise up and overlie substantially the front half 100 of the base panel 12. The intermediate side wall flaps 96 are tucked inside. The rear portions 102 of the side wall panels 28 are tucked over flaps 96 and inside front portions 104 of the side wall panels. The rear wall panel 20 is tucked inside of the tuck-in-flap 44. It will be appreciated that, as seen in Figure 5, there are no apertures in the wall panels 28 of the smaller box 94.

[0046] Thus, a user may form the second smaller box 94 from the first box 92 to store in the second box the reduced contents of a product or substance initially stored in the first box. For example, leftover pizza or other foodstuff which was delivered in the larger form of box can now be stored more conveniently in the second, smaller form of box.

[0047] Figures 6 to 10 show the second embodiment. The second embodiment is similar to the first and only the differences from the first embodiment will be described. The same reference numerals will be used for equivalent features.

[0048] Two trapezoidal tabs 188 are provided in the base panel 12 and side wall panels 28 in the same way as tabs 88 are provided in the lid panel 80 and flaps 81. Apertures 190 are exposed when side wall panels 28 are folded inwardly about fold line 22. The tabs 188 and apertures 190 are positioned in the rear half 98 of base panel 12 in a position to co-operate with the frontmost indentations 52 of sidewalls 28 as described below.

[0049] In use, when the smaller box 94 is formed, the apertures 190 and the indentations 52 line up to form two ventilation holes in the smaller box as shown in Figures 7 to 10.

[0050] In the second embodiment, the line of perforations 76 is replaced by the line of perforaions 176 extending across each side wall 28. The inner end of the line of perforations 176 is adjacent the fold line 30 of the base panel 12 and the line of perforations 176 instead of being parallel to the fold line 20 extend in a straight line rearward. In this way it is easier, when forming the smaller box 94, to tuck the rear portions 102 of the side wall panels 28 over flaps 96.

[0051] The erected box or folded article in accordance with the invention can be made of any suitable material and can have one, two, three or more ventilation holes. It will be obvious to the person skilled in the art that various proportions and shapes of box may be used based on the invention as described herein.

Claims

1. A foldable article forming a container in a first folded form, the article comprising a panel which is flat in the first form, wherein the panel defines at least one line for folding the panel, and wherein the panel is folded about the or each line to form a container in a second folded form.

2. An article as claimed in claim 1, wherein the panel is polygonal.

3. An article as claimed in claim 1, wherein the panel is rectangular.

4. An article as claimed in claim 1, 2 or 3, wherein the panel is a base panel.

5. An article as claimed in any preceding claim, wherein the or at least one line for folding the panel is parallel to one edge of the panel.

6. An article as claimed in any preceding claim, wherein the or at least one line for folding the panel spans substantially one dimension of the panel.

7. An article as claimed in any preceding claim, wherein the folded article comprises at least one second panel associated with the first panel.

8. An article as claimed in any preceding claim, wherein the or at least one second panel defines a line of weakness separating the second panel into two panel portions.

9. An article as claimed in claim 8, wherein the line of weakness intersects the end of the or at least one panel fold line.

10. An article as claimed in claim 8 or claim 9, wherein the article further defines a line for folding a portion of the second panel once the line of weakness has been broken.

11. An article as claimed in claim 10, wherein the line for folding a portion of the second panel is provided in the second panel.

12. An article as claimed in claim 10 or claim 11, wherein the line for folding a portion of the second panel intersects the end of the or a panel fold line.

13. An article as claimed in claim 10, 11 or 12, wherein a cut line or second line of weakness is provided between the first line of weakness and the line for folding a portion of the second panel to form a flap.

14. An article as claimed in claim 13, wherein the cut line or second line of weakness is along a fold line between the first panel and the second panel.

15. An article as claimed in any preceding claim, wherein the part of the first panel to one side of the or at least one said fold line in the first panel forms a lid for the container in the second form.

16. An article as claimed in claim 15 when dependent on any of claims 8 to 14, wherein the or at least one line of weakness extends rearward from the first end in the direction of the lid for the container in the second form.

17. An article as claimed in any preceding claim, wherein the panel defines at least two lines for folding the panel.

18. An article as claimed in claim 17, wherein the said lines for folding are substantially parallel to one another.

19. An article as claimed in any preceding claim, wherein the container in the first form has a lid connected through a fold line to the remainder of the article.

20. An article as claimed in claim 19, wherein the lid is arranged to be detached at the fold line by which it is connected to the remainder of the article.

21. An article as claimed in any preceding claim, wherein the folded article is made of cardboard.

22. A blank including two panels connected through a discontinuous fold line, one panel defining a tab at the or at least one discontinuity, the or each tab extending past the fold line into the other panel, the boundary of the or each tab with respect to the other panel being defined by a cut line or line of weakness, such that when the panels are folded about the fold line, the or each tab moves relative to the said other panel to come out of the plane of the said other panel leaving an aperture.

23. A blank as claimed in claim 22, wherein the line defining the boundary of the or each tab and a line forming a notional continuation of the fold line across the tab define a polygon.

24. A blank as claimed in claim 23, wherein the line defining the boundary of the or each tab and a line forming a notional continuation of the fold line define a trapezium.

25. A blank as claimed in claim 22, 23 or 24, wherein the blank is for erection into a carton.

26. A blank as claimed in claim 25, wherein one of the said panels is arranged to form a lid on the erected carton.

27. A blank as claimed in any of claims 22 to 26, wherein the said other panel is arranged to form a tuck-in flap.

28. A blank as claimed in any of claims 22 to 27, wherein the discontinuous fold line comprises two discontinuities.

29. A blank as claimed in any of claims 22 to 28, wherein the blank comprises a third panel connected through a discontinuous fold line, one panel defining a tab at the or at least one discontinuity, the or each tab extending past the fold line into the other panel, the boundary of the or each tab with respect to the other panel being defined by a cut line or a line of weakness, such that when the panels are folded about the fold line, the or each tab moves relative to the said other panel to come out of the plane of the said other panel leaving an aperture.

30. A blank as claimed in any of claims 22 to 29, wherein the blank is made of cardboard.

31. A carton erected from a blank according to any of claims 22 to 30, the carton comprising a base panel and at least one associated wall panel, the or at least one wall panel having a first end attached to the base panel and having a second opposite free end, the wall panel defining at least one indentation at a location along the edge of the second free end of the wall panel corresponding to the equivalent location of the said aperture on the lid portion, the indentation having a shape complementary to the aperture on the lid portion.

Drawing