WO2004085267A2

WO2004085267A2 - Reclosable food container

Info

Publication number: WO2004085267A2
Application number: PCT/US2004/008394
Authority: WO
Inventors: Steven H. Roseth
Original assignee: Mastercraft Packaging Corporation
Priority date: 2003-03-19
Filing date: 2004-03-18
Publication date: 2004-10-07
Also published as: US20040182916A1; WO2004085267A3

Abstract

A reclosable food container is created from a unitary blank. The container includes a bottom panel, a first lateral side panel extending from the bottom panel; a first opposing side panel extending from the bottom panel on an opposing side to the first lateral side panel; a second lateral side panel extending from the bottom panel; a second opposing side panel extending from the bottom panel on an opposing side to the second lateral side panel; a plurality of foldable gussets, each gusset hingedly connecting two adjacent side panels; a first closure panel extending from the first lateral side panel, the first closure panel comprising a first hook closure device; and a second closure panel extending from the first opposing side panel, the second closure panel comprising a second hook closure device.

Description

RECLOSABLE FOOD CONTAINER

BACKGROUND

Field

A reclosable food container suitable for use in the take-out food industry. More particularly, an easily openable and reclosable food container having a cavity which is erected from a single unitary blank.

Relevant Art

The expansion of the take-out and prepared food industry over the last several years has increased demand for suitable containers. The Chinese food pail is well-known in the take-out food industry. It is preconstructed at the manufacturing plant by folding the pre-cut blank and fastening the gussets with glue or metallic wire. This simplifies use by the food seller who need merely fill the container and close the lid. Another type of food carton is fashioned in a shallower configuration.

Still another type of food container is fashioned in the form of an open food container for storing a predetermined amount of food. It is erected at the point of purchase from a pre-cut, pre-scored carton blank. These blanks are typically erected by manually performing numerous time consuming folding and tucking operations at the point of sale. The resulting container often leaks at the corner formed by interlocking tabs and slots. Some variations employ glue to secure the adjacent panels, but leaking remains a problem. Such containers are unsatisfactory for packaging many prepared or take-out foods.

The invention is illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to "an" or "one" embodiment in this disclosure are not necessarily to the same embodiment, and such references mean at least one. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a food container blank;

FIG. 2 is a perspective view of the food container blank shown disposed in its planar, unfolded configuration;

FIG. 3 is a perspective view of the food container blank shown during a folding operation;

FIG. 4 is a perspective view of the food container blank shown during a folding operation;

FIG. 5 is a perspective view of the food container blank shown during a folding operation;

FIG. 6 is a perspective view of the food container blank after it has been folded to form the food container, being shown in its erected position ready for stacking with other like food containers into a nested bundle;

FIG. 7 is a perspective view of the food container shown in its erected position, with one pair of closure panels being partially folded into the closed position;

FIG. 8 is a perspective view of the food container shown with the second pair of closure panels folded down and interlocked to define the closed food container;

FIG. 9 is an elevated cross-sectional view of the food container taken along line 9-9 of FIG. 8;

FIG. 10 is an elevated cross-sectional view of the food container taken along line 10-10 of FIG. 8;

FIG. 11 is a perspective view of the food container of FIG. 1 with short side closure flaps overlaying the long side closure flaps.

FIG. 12 is a plan view of a modified embodiment of the food container blank shown in FIG. 1; FIG. 13 is a perspective view of the food container assembled from the blank shown in FIG.12;

FIG. 14 is a perspective view of the food container shown with a folded partition installed in the receptacle portion to establish more than one isolated food storage compartment;

FIG. 15 is a view of a score line between panels; and

FIG. 16 is a cross-sectional view of a score line.

DETAILED DESCRIPTION

Referring to FIG. 1, one embodiment of the blank for forming food container 1 (shown in FIG. 6) is described below. Blank 22 is formed from a single sheet of paperboard material suitable for holding, heating (reheating) and cooking food. This material can include any type of paperboard that can withstand the heat generated in a microwave or convection oven. In one embodiment, blank 22 may be formed of such commercially available materials as solid bleached board (SBS) and "ovenboard", having a weight in the range from about 14 point to about 42 point. In one embodiment, paperboard may be coated and/or laminated with a material (for example a polymer) so that the container can hold liquids.

In one embodiment, blank 22 has a planar, unitary construction and a substantially rectangular gross geometry as shown in FIG. 1. Blank 22 has an interior side which contacts the contents of an assembled food container, and an exterior side exposed to the ambient environment. Blank 22 also has a plurality of edges which define outer boundaries, and a plurality of fold and/or score lines which hingedly connect adjacent panels. Edge portions and fold and/or score lines are formed in a paperboard sheet using conventional high-speed cutting and embossing technology. As described below, a folding sequence may be used to erect food container 1 from blank 22. Blank 22 includes bottom panel 4 characterized by a rectangular shape and a surface area defined by a first and second pair of opposing bottom edge fold lines 23, 24 and 25, 26, respectively. For reference purposes, center of bottom panel 4 is indicated by numeral 27. The first and second pair of opposing side panels 5, 6 and 7, 8 are hingedly connected to bottom panel 4 along the first and second pair of opposing bottom fold lines 23, 24 and 25, 26, respectively. Each of the first and second pair of opposing side panels are characterized by fold lines which define its area, as well as the adjacent panels that are hingedly connected thereto. The specific character of each panel will now be described.

First side panel 5 is contiguous with and hingedly connected to bottom panel 4 along first bottom fold line 23. Side panel 5 has a surface area defined by first top fold line 27, first left side fold line 28, first right side fold line 29 and first bottom fold line 23. The terms "left," "right," "top," and "bottom" are defined by reference to center point 27 of bottom panel 4 in FIG. 1. As shown, first top and bottom fold lines 27 and 23 are substantially parallel, and first left and right side fold lines 28 and 29 may be substantially parallel or may diverge from first bottom fold line 23 at a predetermined obtuse angle beta, in one embodiment more than about 90 degrees, and in another embodiment, more than about 100 degrees.

Second side panel 6 is disposed opposite first side panel 5 and is contiguous with and hingedly connected to bottom panel 4 along second bottom fold line 24. Second side panel 6 has a surface area defined by second top fold line 30, second left side fold line 31, second right side fold line 32 and second bottom fold line 24. As shown, second top and bottom fold lines 30 and 24 are substantially parallel, and second left and right side fold lines 31 and 32 may be substantially parallel or may diverge from second bottom fold line 24 at predetermined obtuse angle beta, in one embodiment more than about 90 degrees, and in another embodiment, more than about 100 degrees.

Third side panel 7 is contiguous with and hingedly connected to bottom panel 4 along third bottom fold line 25. Third side panel 7 has a surface area defined by third top fold line 33, third left side fold line 34, third right side fold line 35 and third bottom fold line 25. As shown, third top and bottom fold lines 33 and 25 are substantially parallel, and third left and right side fold lines 34 and 35 may be substantially parallel or may diverge from third bottom fold line 25 at predetermined obtuse angle beta, in one embodiment more than about 90 degrees, and in another embodiment, more than about 100 degrees.

Fourth side panel 8 is disposed opposite third side panel 7 and is contiguous with and hingedly connected to bottom panel 4 along fourth bottom fold line 26. Fourth side panel 8 has a surface area defined by fourth top edge fold line 36, fourth left side fold line 37, fourth right side fold line 38 and fourth bottom fold line 26. As shown, fourth top and bottom fold lines 36 and 26 are substantially parallel and fourth left and right side fold lines 37 and 38 may be substantially parallel or may diverge from fourth bottom fold line 26 at predetermined obtuse angle beta, in one embodiment more than about 90 degrees, and in another embodiment, more than about 100 degrees. These opposing side panels 5, 6 and 7, 8 define four pair of adjacent side panels, i.e., i _f O O_{f f} O clΩCL O / _*

As illustrated in FIG. 1, foldable gussets 9, 10, 11, and 12 are formed by hingedly connected adjacent side panels. As shown in FIG. 6, when opposing side panels 5, 6 and 7, 8 are folded substantially upright, food container receptacle 2 with access opening 3 is formed and, as shown in FIG. 5, gussets 9, 12 and 10, 11 and are folded against an exterior portion of adjacent side panels 5 and 6, respectively. At this point side panels 5 through 8 are disposed upright at angles alpha (α) and theta (θ), measured with respect to bottom panel 4. In one embodiment, alpha and theta are substantially the same angle, while in another embodiment, alpha and theta are different angles. In one embodiment, alpha and theta are greater than about 90 degrees, and in another embodiment, greater than about 100 degrees.

Each foldable gusset 9 through 12 is characterized by fold lines and edges which define its area, and by adjacent panels that are hingedly connected thereto. The specific character of these corner gussets are now described with continuing reference to FIG. 1. First foldable gusset 9 is contiguous with first and third side panels 5 and 7, and has first corner edge 39 and first corner (i.e., diagonal) fold line 40, which divides the gusset into first left corner panel 41 and first right corner panel 42. First left corner panel 41 has a surface area defined by first right side fold line 29, first corner fold line 40 and a first portion of first corner edge 39. Similarly, the first right corner panel 42 has a surface area defined by third left side fold line 34, first corner fold line 40 and a second portion of first corner edge 39.

Second foldable gusset 10 is contiguous with third and second side panels 7 and 6, and has second corner edge 43 and second corner fold line 44 which divides second gusset 10 into second left corner panel 45 and second right corner panel 46. Second left corner panel 45 has a surface area defined by third right side fold line 35, second corner fold line 44 and a first portion of second corner edge 43. Second right corner panel 46 has a surface area defined by second left side panel fold line 31, second corner fold line 44 and a second portion of second corner edge 43.

Third foldable gusset 11 is contiguous with second and fourth side panels 6 and 8, and has third corner edge 47 and third corner fold line 48 which divides third gusset 11 into third left corner panel 49 and third right corner panel 50. Third left corner panel 49 has a surface area defined by second right side fold line 32, third corner fold line 48 and a first portion of third corner edge 47. Third right corner panel 50 has a surface area defined by fourth left side fold line 37, third corner fold line 48 and a second portion of third corner edge 47.

Fourth foldable gusset 12 is contiguous with fourth and first side panels 8 and 5, and has fourth corner edge 51 and fourth corner fold line 52 which divides fourth gusset 12 into fourth left corner panel 53 and fourth right corner panel 54. Fourth left corner panel 53 has a surface area defined by fourth right side fold line 38, fourth corner fold line 52 and a first portion of fourth corner edge 51. Fourth right corner panel 54 has a surface area defined by first left side fold line 28, fourth corner fold line 52 and a second portion of fourth corner edge 51. As illustrated in FIG. 1, first pair of opposing closure panels 15 and 16 are hingedly connected to first pair of opposing side panels 5 and 6, respectively. Panels 15 and 16 are dimensioned to close off a portion of access opening 3 of erected food container 1 when these panels are folded down, interlocked, and disposed substantially parallel to bottom panel 4, as illustrated in FIG. 7.

First closure panel 15 has a surface area generally defined by first top fold line 27, left closure panel edge 55 and first right closure panel edge 56. First closure panel 15 has first hook closure device 200, including first engaging member 202 and first notch 204 adapted to receive second engaging member 212 on second closure panel 16.

Second closure panel 16 has a surface area generally defined by second top fold line 30, second left closure panel edge 57, and second right closure panel edge 58. Second closure panel 16 has second hook closure device 210, including second engaging member 212 and second notch 214 adapted to receive first engaging member 202 of first closure panel 15.

First and second closure panels 15 and 16 also have edge portions indicated by 55B, 56B; and 57B, 58B, respectively, which may be substantially parallel to each other and/or to bottom fold lines 25 and 26.

Similarly, a second pair of closure panels 17, 18 extend from opposing side panals 7 and 8 respectively and a dimension to close off a portion of the opening of the cavity, as illustrated in FIG. 8.1n one embodiment, both pairs of closure flaps are dimensioned such that relatively little of the opening in the container is left unoccluded when either pair of flaps it folds to the closed configuration. In one embodiment either pair of flaps occlude at least 85% of the area of the opening.

Third closure panel 17 has a surface area generally defined by third top fold line 33, third left closure panel edge 59 and third right closure panel edge 60. Third closure panel 16 has third hook closure device 220, including third engaging member 222 and third notch 224 adapted to receive fourth engaging member 232 on fourth closure panel 18. Fourth closure panel 18 has a surface area generally defined by fourth top fold line 36, fourth left closure panel edge 61 and fourth right closure panel edge 62. Fourth closure panel 16 has fourth hook closure device 230, including fourth engaging member 232 and fourth notch 234 adapted to receive third engaging member 222 on third closure panel 17.

Closure panels 17 and 18 also have edge portions indicated by 59B, 60B; and 61B and 62B, respectively, which may be substantially parallel to each other and/or to bottom fold lines 23 and 24. Notably, in one embodiment, the pairs of closure panels may be folded into the closed configuration in an arbitrarily order. Moreover, in one embodiment, the structural integrity and leak resistance of the container are not jeopardized when the underlying of the pair of closure panels do not interlock.

Referring now to FIGS. 2 through 6, method of erecting food container 1 from blank 22 will be described. As shown in FIG. 2, food container blank 22 is disposed in plane 65 designated as 0 degree reference.

As shown in FIG. 3, pair of opposing side panels 5 and 6 are folded about lines 23 and 24 into a partially upright position at about 20 degrees from reference plane 65. During this first stage of the folding operation, gussets 9, 10, 11 and 12 are lifted away from reference plane 65 as shown.

Opposing side panels 7 and 8 are rotated in the upright direction as shown in FIG. 4. Left and right panels of each gusset are brought into face-to- face contact with each other.

As illustrated in FIG. 5, first and second pair of opposing side panels 5, 6 and 7, 8 are disposed in a substantially upright configuration.

Referring again to FIG. 5, adhesive 13 is applied to the exterior surface of each left and right end portion of side panels 5 and 6. Thereafter, gussets 9 through 12 are folded against the exterior surfaces of panels 5 and 6 where adhesive 13 has been applied. With adhesive 13 between each folded gusset and exterior surface, gussets 9 through 12 are secured after a time period sufficient for curing, thereby providing assembled food container 1, as shown in FIG. 6. The fact that the cavity is formed from a contiguous sheet prevents leaking at the gussets as long as a substantially upright orientation is maintained.

In one embodiment, assembled food container 1 may be inserted within a receptacle portion of a previously constructed food container. In this food container nesting arrangement, suitable pressure can be applied to the folded down gussets while the adhesive sets, ensuring that the gussets are not permitted to unfold during curing.

In another embodiment, the folding sequence can be reversed so that gussets 9 through 12 are secured to respective end portions of side panels 7 and 8.

Referring now to FIGS. 6-10, food container 1 is illustrated. Reclosable food container 1, which is formed from the single unitary blank 22 shown in FIGS. 1 through 5, may include receptacle portion 2 of generally trapezoidal dimensions. Access opening 3 is provided in the receptacle portion 2 to permit introduction of consumable goods.

As illustrated, the trapezoidal-like volume of receptacle portion 2 is defined by rectangular shaped bottom panel 4, and substantially upstanding pair of opposing side panels, i.e., first and second side panels 5, 6 and third and fourth side panels 7, 8, respectively. Each pair of adjacent side panels 5 and 7, 7 and 6, 6 and 8, and 8 and 5 are hingedly connected by folded gussets 9, 10, 11, and 12, respectively. Each folded gusset is unitary with its adjacent side panels, and secured to the exterior surface of one adjacent side panel by adhesive 13 applied between each folded gusset and exterior surface as shown in FIG. 5. Adhesive 13 should resist melting when exposed to microwave and other heat radiation. Other suitable fasteners, for example, staples, clips, etc. may be used instead of adhesive 13.

In one embodiment, each folded gusset has a geometry approximating a triangle, assuring that upper edge 14 of each folded gusset extends substantially along respective top fold lines 27 and 30 between closure flaps and side panels, as illustrated in FIG. 6. This feature ensures maximum support to side panels 5 and 6 and improves the overall structural integrity of food container 1.

In another embodiment, as illustrated in FIGS. 9 and 10, first and second side panels 5 and 6, respectively, are disposed at an obtuse angle alpha (α) (as measured from the rectangular bottom panel 4) to form trapezoidal-like receptacle portion 2. Similarly, third and fourth side panels 7 and 8, respectively, are disposed at an obtuse angle theta (θ) (as measured from the rectangular bottom panel 4) to form trapezoidal-like receptacle portion 2. This volumetric geometry facilitates stacking or nesting of successive receptacle portions for storage or shipping purposes.

As illustrated in FIG. 6, food container 1 also includes a first pair of opposing closure panels 15 and 16, and a second pair of opposing closure panels 17 and 18. These flaps typically extend vertically upright when the food containers are nested and when food is introduced to receptacle portion 2, either pair of closure flaps 15, 16, or 17, 18 may be folded downwardly into a position substantially parallel with bottom panel 4 and first hook closure device 200 and second hook closure device 210 being interlocked to close off a portion of access opening 3, (as illustrated in FIG. 7 for flaps 15, 16).

In another embodiment, closure flaps 17 and 18 can be folded down prior to flaps 15 and 16, so that hook closure devices 220 and 230 can be interlocked to close off a portion of access opening 3 (illustrated in FIG. 11). Alternatively, the first fold closure flaps may not be interlocked without jeopardizing the leak resistance and integrity of the structure. (The arbitrary nature of which pair to fold first and the fact that interlock the first folded pair is optional makes the container of one embodiment faster and easier to use).

Referring now to FIG. 8, closure flaps 17 and 18, which extend from opposing side panels 7 and 8, are capable of being folded downwardly into a position substantially parallel with bottom panel 4 and third hook closure device 220 and fourth hook closure device 230 being interlocked to close off a portion of access opening 3. When closure flaps 17 and 18 are folded downwardly into a position substantially parallel with bottom panel 4 and over closure flaps 15 and 16, as shown in FIG. 8, the remaining portion of access opening 3 is effectively closed off.

When at least the top most pairs of hook closure devices 200, 210 or 220, 230 are interlocked food container 1 is closed. First through fourth hook closure devices 200, 210, 220, and 230 permit opening and closing food container 1 by disengaging and interlocking, respectively, hook closure devices 200, 210, 220, and 230. In one embodiment, both opposing pairs hook closure devices are interlocked when the container is closed.

In another embodiment, third hook closure device 220 and fourth hook closure device 230 are interlocked first, and then closure flaps 15 and 16 are folded and first hook closure device 200 and second hook closure device 210 are interlocked. In another embodiment, closure flaps 15 and 16 are closed, but first hook closure device 200 and second hook closure device 210 are not interlocked, and then closure flaps 17 and 18 are folded down, and third hook closure device 220 and fourth hook closure device 230 are interlocked to close off access opening 3. In another embodiment, closure flaps 17 and 18 are folded down, but third hook closure device 220 and fourth hook closure device 230 are not interlocked, then closure flaps 15 and 16 are folded over closure flaps 17 and 18, and first hook closure device 200 and second hook closure device 210 are interlocked to close off access opening 3.

As illustrated in FIG. 8, third closure device 220 is shown sitting on top of closure flap 18, and fourth hook closure device 230 is shown resting on top of closure flap 17. In another embodiment, third hook closure device 220 may be interlocked with fourth hook closure device 230 such that third hook closure device is under closure flap 18, and fourth hook closure device 230 is under closure flap 17 (as shown in FIG. 13). This provides a sleeker appearance to the closed container as the hook closure devices are hidden from view. In another embodiment, first hook closure device 200 and second hook closure device 210 may be interlocked so that first hook closure device 200 is under closure flap 16 and second hook closure device 210 is under closure flap 15 (not shown). As illustrated in FIG. 14, folded partition 21 may be inserted into the bottom portion of a food container prior to packaging food. Partition 21 divides food receptacle portion into more than multiple storage compartments 2 A and 2B. In another embodiment, partition 21 includes four hingedly connected panels 21A, 21B, 21C and 21D. Panels 21B and 21C are folded back upon each other in a face-to-face relationship, with panels 21A and 21D disposed against bottom panel 4 to provide base panels for the storage compartments. With the installation of partition 21, multiple consumables may be physically isolated for separate storage or presentation.

Blank 322 is shown in FIG. 12. Each corner edge 39, 43, 47 and 51 of blank 322 is rectilinear over its entire length, rather than piece-wise linear, as in food container blank 22.

As illustrated in FIG. 13, the effect of this modification is that upper edge 314 of each folded gusset extends downwardly at a predetermined angle below respective top fold lines 27 and 30. Third closure device 220 is shown in phantom since it is folded under closure flap 18, and fourth closure flap 230 is shown in phantom since it is folded under closure flap 17.

In one embodiment, hook closure device 200 and hook closure device 210; and/or hook closure device 220 and hook closure device 230; can be engaged with each other with one hand when closing the food container. In another embodiment, hook closure device 200 and hook closure device 210; and/or hook closure device 220 and hook closure device 230 can be disengaged from each other with one hand when opening the food container.

FIG. 15 illustrates a section of score line 27 between side panel 5 and closure flap 15. Score line 27 includes a configuration having scored portions 90 and unscored portions 92. Scored portions 90 have length LI 94. Unscored portions 92 have a length L296.

In one embodiment, length LI 94 is between about 0.1 and about 2.0 inches. In another embodiment, length LI 94 is between about 0.2 and about 1.5 inches. In another embodiment, length LI 94 is between about 0.5 and about 1.25 inches. In another embodiment, length LI 94 is about 1.0 inches. In one embodiment, length L296 is between about 0.01 and about 0.5 inches. In another embodiment, length L2 96 is between about 0.05 and about 0.3 inches. In another embodiment, length L296 is between about 0.1 and about 0.25 inches. In another embodiment, length L296 is about 0.2 inches.

FIG. 9 shows a sectional view along the line 9-9 of FIG. 8. FIG. 9 shows a portion of score line 27 with scored portions 90 and unscored portions 92. Scored portions 90 have length LI 94. Unscored portions 92 have length L296. Scored portions 90 have depth of scoring Dl 98. The paperboard has thickness D2 99. The ratio of penetration is defined as the ratio of depth of scoring Dl 98 divided by thickness of the paperboard D2 99.

In one embodiment, the ratio of penetration of score line 27 is between about 0.1 and about 0.9. In another embodiment, the ratio of penetration of score line 27 is between about 0.2 and about 0.8. In another embodiment, the ratio of penetration of score line 27 is between about 0.3 and about 0.7. In another embodiment, the ratio of penetration of score line 27 is between about 0.45 and about 0.55. In another embodiment, the ratio of penetration of score line 27 is about 0.5.

While FIGS. 8 and 9 illustrate score line 27 between side panel 5 and closure flap 15, the discussion of FIGS. 8 and 9 is also applicable to score lines O_f όό_f euro. Ό.

In one embodiment, score lines 30, 33, and/or 36 have a ratio of penetration the same as or similar to score line 27. In another embodiment, score lines 30, 33, and/or 36 meet one or more of the parameters discussed above for score line 27.

In one embodiment, fold lines 23, 24, 25, 26, 28, 29, 31, 32, 34, 35, 37, 38, 40, 44, 48, and/or 52 have a ratio of penetration less than score lines 27, 30, 33, and/or 36.

In one embodiment, fold lines 23, 24, 25, 26, 28, 29, 31, 32, 34, 35, 37, 38, 40, 44, 48, and/or 52 have a ratio of penetration between about 0.0 and about 0.4. In another embodiment, fold lines 23, 24, 25, 26, 28, 29, 31, 32, 34, 35, 37, 38, 40, 44, 48, and/or 52 have a ratio of penetration between about 0.01 and about 0.2. In another embodiment, fold lines 23, 24, 25, 26, 28, 29, 31, 32, 34, 35, 37, 38, 40, 44, 48, and/or 52 have a ratio of penetration of about 0.05.

In one embodiment, fold lines 23, 24, 25, 26, 28, 29, 31, 32, 34, 35, 37, 38, 40, 44, 48, and/or 52 may have a lower ratio of penetration since the fold lines define the container, and are not used to open or close the lid of the container. In one embodiment, score lines 27, 30, 33, and/or 36 may have a higher ratio of penetration than fold lines 23, 24, 25, 26, 28, 29, 31, 32, 34, 35, 37, 38, 40, 44, 48, and/or 52, since score lines 27, 30, 33, and/or 36 are used in the operation of opening and closing the lid of the container.

In one embodiment, score lines 27, 30, 33, and/or 36 have a ratio of penetration less than about 1.0, so that there is a lessened likelihood of leakage through score lines 27, 30, 33, and/or 36. In one embodiment, score lines 27, 30, 33, and/or 36 have a ratio of penetration that makes closing and opening closure flaps 15-18 easier. In another embodiment, score lines 27, 30, 33, and/or 36 have a ratio of penetration so that closure flaps 15-18 fold flatter when in a closed orientation. In another embodiment, score lines 27, 30, 33, and/or 36 have a ratio of penetration so that closure flaps 15-18 have a flat shape rather than a bowed shape.

In another embodiment, fold lines 23, 24, 25, 26, 28, 29, 31, 32, 34, 35, 37, 38, 40, 44, 48, and/or 52 and score lines 27, 30, 33, and/or 36 have a ratio of penetration so that the reclosable food container has a cleaner look. In another embodiment, fold lines 23, 24, 25, 26, 28, 29, 31, 32, 34, 35, 37, 38, 40, 44, 48, and/or 52 and score lines 27, 30, 33, and/or 36 have a ratio of penetration so that the food container is more aesthetically pleasing. In another embodiment, fold lines 23, 24, 25, 26, 28, 29, 31, 32, 34, 35, 37, 38, 40, 44, 48, and/or 52 and score lines 27, 30, 33, and/or 36 have a ratio of penetration so that the food container has a stronger structure.

In the foregoing specification, the container has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes can be made thereto without departing from the broader spirit and scope as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.

Claims

CLAIMSWhat is claimed is:

1. A reclosable food container assembled from a unitary blank, the container comprising: a bottom panel; a first pair of opposing side panels extending from the bottom panel; a second pair of opposing side panels extending from the bottom panel; a plurality of foldable gussets; each gusset connecting two adjacent side panels; and a first pair of opposing closure panels extending from the first pair of opposing side panels and each closure panel having an opposing hook closure device.

2. The reclosable food container of claim 1 further comprising: a second pair of opposing closure panels extending from the second pair of opposing side panels.

3. The reclosable food container of claim 2 wherein a hook closure device extends from each of the second pair of opposing closure panels.

4. The reclosable food container of claim 2 wherein the pairs of closure panels may be closed in an arbitrary order.

5. The reclosable food container of claim 3 wherein all hook closure devices may be hidden when the container is closed.

6. The reclosable food container of claim 3 wherein the pairs closure panels may be closed in an arbitrary order.

7. The reclosable food container of claim 6 wherein the first pair of opposing side panels extend from a shorter side of the bottom panel than the second pair of opposing side panels.

8. The reclosable food container of claim 6 wherein structural integrity of the container is maintained when only a top most pair of opposing hook closure devices are interlocked.

9. The reclosable food container of claim 2 wherein an area of either pair of opposing closure panels exceed 85% of an area of an opening defined by edges of the pairs of opposing side panels distal to the bottom panel.

10. A method of making a reclosable food container from a unitary blank comprising: scoring the unitary blank with at least one of a plurality of score lines and a plurality of fold lines; folding along two pairs of substantially parallel fold lines that define a bottom panel, to form four side panels; folding along four sets of fold lines, each set defining a gusset extending between pairs of side panels of a cavity; folding along at least two fold lines that define a fold between a side panel and a closure panel; adhering each gusset to an outer surface of one of the adjacent side panels; wherein the food container comprises a first closure panel extending from a first side panel, the first closure panel comprising a first hook closure device; and a second closure panel extending from a first opposing side panel, the second closure panel comprising a second hook closure device.

11. An article comprising: a unitary paperboard blank defining a bottom panel; a first pair of opposing side panels extending from the bottom panel; a second pair of opposing side panels extending from the bottom panel; a plurality of foldable gussets, each gusset connecting two adjacent side panels; and a first pair of opposing closure panels extending from the first pair of opposing side panels and each closure panel having an opposing hook closure device.

12. The reclosable food container of claim 11 further comprising: a second pair of opposing closure panels extending from the second pair of opposing side panels.

13. The article of claim 11 wherein the panels are defined by score lines.

14. The article of claim 11 wherein the panels are defined by fold lines.