WO2020231248A1

WO2020231248A1 - A collapsible and stackable wooden food container

Info

Publication number: WO2020231248A1
Application number: PCT/MY2020/050028
Authority: WO
Inventors: Yong Khang ONG; Ah Tee ONG; Wah Yak LIM
Original assignee: Pt. Bima Nugraha
Priority date: 2019-05-13
Filing date: 2020-05-08
Publication date: 2020-11-19
Also published as: JP2022534679A

Abstract

The present invention discloses a collapsible and stackable wooden container (101, 102, 201, 202) suitable for use as a food container, the container (101, 102, 201, 202) comprising a base (111, 121, 211, 221) having first and second opposing surfaces, the first surface is hinged with side end walls (112, 212) foldable relative to the base (111, 211) from a collapsed stowed condition in which the side end walls (112, 212) overlap the base (111, 211) to a deployed condition in which the side end walls (112, 212) are substantially upright relative to the base (111, 211) to form an open top box, characterised in that the second surface comprises tab walls (122, 222, 322) being such that when at least two such containers (101, 102, 201, 202, 301, 302) are stacked on top of another, the tab walls (122, 222, 322) are configured to prevent the stacked containers (101, 102, 201, 202, 301, 302) from lateral detachment.

Description

A COLLAPSIBLE AND STACKABLE WOODEN FOOD CONTAINER

FIELD OF INVENTION

The invention relates to a storage container. More particularly, the invention relates to a wooden food container which is collapsible and stackable.

BACKGROUND OF THE INVENTION

Jubako are generally referred to as stacked containers with a lid. Jubako containers are also notably used during New Year’s in Japan for Osechi dishes. In some common occasions, Jubako containers may be utilised to carry food for outing or even lunch. However, such stackable containers are not foldable. The main drawback of unfoldable containers is that more space is needed for storing the container after the production and during the delivery of the container. Furthermore, when the empty containers are stacked together during the transportation, they can be easily damaged or deformed. In addition to that, many of the containers are made of non- biodegradable materials such as plastic which pollutes our living environment and even causes harm to the ecosystems on earth. Wooden food container is an alternative type of container that can be folded into a flat piece. Nevertheless, the common form of wooden food container is prone to leakage when the container is packed with food and sauce or gravy.

Therefore, there is a need for such stackable containers to be foldable, non-leakable and biodegradable. The invention provides such a collapsible and stackable wooden food container that solves the above mentioned problems. SUMMARY OF INVENTION

The invention provides a collapsible and stackable wooden container suitable for use as a food container, the container comprising a base having first and second opposing surfaces, the first surface is hinged with side end walls foldable relative to the base from a collapsed stowed condition in which the side end walls overlap the base to a deployed condition in which the side end walls are substantially upright relative to the base to form an open top box, characterised in that the second surface comprises tab walls being such that when at least two such containers are stacked on top of another, the tab walls are configured to prevent the stacked containers from lateral detachment. A lid can be provided for closing the open top box.

In one embodiment of the invention, the container can be formed by the attachment of first and second portions. The first portion may comprise a base hinged with the foldable side end walls, the second portion may comprise a base with the tab walls and the bases of the first and second portion can be attached together to form the container. The base of the first portion or the second portion can also have at least one cut-away section to provide thermal expansion or contraction tolerance for preventing deformation of the container.

In another embodiment of the invention, the second surface may further comprise at least one stopper for securing the container in the deployed condition when at least two such containers in their deployed condition are stacked on top of another.

Preferably, the hinged connections between at least the side end walls and the base have a coating of a leakproof substance to seal wood pores within the connections to avoid those pores from absorbing liquid which causes the container to deform.

Preferably, the tab walls can be sized so that the side end walls in the stowed condition can be received substantially flush within the depth of tab walls for packaging purposes.

Preferably, the container may further comprise one or more flexible sheets disposed at an outer surface of one or more opposing side end walls when the side end walls are in the deployed condition and connected to edges of adjacent side end walls, whereby the sheets are foldable between the collapsed stowed condition and the deployed condition and their folding movements are synchronised with the movements of its adjacent side walls.

Preferably, at least one side end wall has one or more undercut portions and its adjacent side end walls each has a tab to engage with the undercut portions when the side end walls are in the deployed condition so as to secure the side end walls in the deployed condition to prevent the side end walls from bending inwardly.

One skilled in the art will readily appreciate that the invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments described herein are not intended as limitations on the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawing the preferred embodiments from an inspection of which when considered in connection with the following description, the invention, its construction and operation and many of its advantages would be readily understood and appreciated.

Fig. 1 shows a perspective view of stacked containers (first embodiment) (deployed condition).

Fig. 2 shows a cross-section view of the stacked containers (first embodiment) (deployed condition).

Fig. 3 shows an exploded view of the stacked containers (first embodiment)

(deployed condition).

Fig. 4 shows a perspective view of the stacked containers (first embodiment)

(collapsed stowed condition).

Fig. 5 shows a cross-section view of the stacked containers (first embodiment) (collapsed stowed condition).

Fig. 6 shows an exploded view of the stacked container (first embodiment)

(collapsed stowed condition).

Fig. 7 shows a perspective view of a first portion of the container (first embodiment) (deployed condition).

Fig. 8 shows a perspective view of the first portion of the container (first embodiment) (collapsed stowed condition).

Fig. 9 shows a process of forming the first portion (first embodiment).

Fig. 10 shows a perspective view of a second portion of the container (first embodiment).

Fig. 11 shows an inner top view of the second portion (first embodiment) (unassembled).

Fig. 12 shows an inner top view of the second portion (first embodiment)

(assembled).

Fig. 13 shows a perspective view of a lid of the stacked containers (first embodiment).

Fig. 14 shows a process of forming the lid (first embodiment).

Fig. 15 shows an attachment of the first portion to the second portion so as to form the container (first embodiment) which embodies therein the principle features of the invention. Fig. 16 shows a perspective view of the stacked containers (second embodiment) (deployed condition).

Fig. 17 shows a cross-section view of the stacked containers (second embodiment) (deployed condition).

Fig. 18 shows an exploded view of the stacked containers (second embodiment) (deployed condition).

Fig. 19 shows a perspective view of the stacked containers (second embodiment) (collapsed stowed condition).

Fig. 20 shows a cross-section view of the stacked containers (second embodiment) (collapsed stowed condition). Fig. 21 shows an exploded view of the stacked container (second embodiment)

(collapsed stowed condition).

Fig. 22 shows a perspective view of the first portion of the container (second embodiment) (deployed condition).

Fig. 23 shows a perspective view of the first portion of the container (second embodiment) (collapsed stowed condition).

Fig. 24 shows a process of forming the first portion (second embodiment).

Fig. 25 shows a process of forming the second portion (second embodiment).

Fig. 26 shows an exploded perspective view of the second portion (second embodiment) (unassembled).

Fig. 27 shows a perspective view of a second portion of the container (second embodiment) (assembled).

Fig. 27 A shows a cross-section view of the second portion of the container taken from A- A of Fig. 27 (second embodiment) (assembled).

Fig. 28 shows the attachment of the first portion to the second portion so as to form the container (second embodiment).

Fig. 29 shows a perspective view of the stacked containers (third embodiment).

Fig. 30 shows a cross-section view of the stacked containers (third embodiment). Fig. 31 shows an exploded view of the stacked containers (third embodiment).

Fig. 32 shows a perspective view of the first portion of the container (third embodiment) (unassembled).

Fig. 33 shows a perspective view of the first portion of the container (third embodiment) (assembled).

Fig. 34 shows an exploded perspective view of the second portion (third embodiment) (unassembled).

Fig. 35 shows a perspective view of a second portion of the container (third embodiment) (assembled).

Fig. 36 shows a cross-section view of a second portion of the container taken from B-B of Fig. 35 (third embodiment) (assembled).

Fig. 37 shows the attachment of the first portion to the second portion so as to form the container (third embodiment).

DETAILED DESCRIPTION OF THE INVENTION

The invention will now be described in greater detail, by way of example, with reference to the drawings.

Referring to Figs 1 to 3, the first embodiment of the stacked assembly as illustrated therein comprises at least two containers 101, 102 one stacked on top of another, each of the container 101, 102 comprises a base 111, 121 having first and second opposing surfaces. Preferably, the first surface is hinged with side end walls 112 foldable relative to the base 111 from a collapsed stowed condition in which the side end walls 112 overlap the base 111 to a deployed condition in which the side end walls 112 are substantially upright relative to the base 111 to form an open top box. A wooden lid 130 can be provided to close the open top box of the uppermost container 101. The second surface comprises tab walls 122 being configured to receive the top portion of the side end walls 112. As such, when the containers 101, 102 in the deployed condition are stacked on top of another, the tab walls 122 can prevent the stacked containers 101, 102 from lateral detachment.

As Shown in Figs. 4 to 6, the containers 101, 102 are also stackable when they are in the collapsed stowed condition. Preferably, the tab walls 122 or the lid 130 are sized so that the side end walls 112 in the stowed condition can be received substantially flush within the depth of tab walls 122 or the lid 130. The stacked containers 101, 102 in the collapsed stowed condition can save significant amount of space and also prevent the stacked assembly from deformation during the packaging and transportation.

In one aspect of the invention, each of the container 101, 102 can be formed by the attachment of first and second portions 110, 120 (Fig. 15). The first and second portions 110, 120 can be attached together via glue adhesive or any suitable type of fastening means.

Referring to Figs. 7 to 9, the first portion 110 as illustrated therein can be formed by at least five separate wooden sheets, the wooden sheets include a substantially rectangular base 111 and four piece of side end walls 112. The base 111 and the side end walls 112 are jointed/assembled together using leakproof tapes before the wooden sheets are laminated on both sides with polyethylene coating glassine paper. As such, the side end walls 112 are independently foldable between the collapsed stowed condition as shown in Fig. 8 and the deployed condition as shown in Fig. 7. The side end walls 112 overlap the base 111 when the first portion 110 is in the collapsed stowed condition and the side end walls 112 are substantially upright relative to the base 111 to form an open top box which can be closed by the lid 130 when the first portion 110 is in the deployed condition.

The first portion 110 may further comprise a pair of flexible sheets 113, one disposed at an outer surface of an opposing pair of side end wall 112 when the side end walls 112 are the deployed condition, and connected to adjacent edges of the other pair opposing of side end walls 112. The flexible sheets 113 are also foldable between the collapsed stowed condition and the deployed condition and their folding movements are synchronised with the movements of the side end walls 112.

The introduction of the flexible sheets 113 has limited the movements of the side end walls 112 not to outwardly bend further from their upright position. The flexible sheets 113 are made of glassine paper with leakproof coating. Such leakproof coating is preferably made of Polyethylene coating material but it should be noted that the material can be easily replaced with other adhesives with leakproof property. The leakproof coating is important because a glassine paper without the coating will be wet & tear by sauce or gravy when they are in contact with each other. Hence, not only the leakproof coating can provide oil or water resistant to the flexible sheets 113, it also strengthen the overall integrity of the flexible sheets 113.

Wood pores will exposed at score lines of the first portion 110 and these pores are capable of absorbing the liquid from the food and further causes leakage or deformation of the side end walls & the base. As a result, the first portion 110 can be further applied with the leakproof substance, preferably made of food grade glue adhesive, along the score lines to prevent such leakage and to seal off exposed wood pores within the score lines before the lamination of the polyethylene coating glassine paper on the first portion 110 to avoid wood pores from absorbing liquid which can cause the first portion 110 to deform.

Alternatively, at least one side end wall 112 has one or more undercut portions and its adjacent side end walls 112 each has a tab 114 to engage with the undercut portions 115 when the side end walls 112 are in the deployed condition so as to secure the side end walls 112 in the deployed condition to prevent the side end walls 112 from bending inwardly.

Referring to Fig 10, the second portion 120 as illustrated therein can be formed by a one-piece laminated/without lamination wooden sheet, the wooden sheet comprises a base 121 with the tab walls 122. One or more stopper 125 can be provided for preventing the side end walls 112 from movements so that the stacked containers 101, 102 can be secured in its deployed condition. Preferably, the base 121 of the second portion 120 can have at least one cut-away portion 126 to provide thermal expansion or contraction tolerance so that the deformation of the container 101, 102 can be minimised. The cut-away portion can be in any shape such as circular, rectangular and etc. As shown in Figs. 11 & 12, each tab wall 122 has a two-layered wall formed by an inner and outer elongated member 123, 124. The elongated members 123, 124 are a one-piece extended portion from the base 121 of the second portion 120. Preferably, member 124 is shorter in length than member 123 so that the bend stacking of the members 123, 124 provides sufficient space for the joining of two adjacent tab walls 122 in their upright configuration.

Preferably, the lid 130 has a configuration similar to the second portion 120 as shown in Figs 13 & 14. The lid 130 comprises a first base 133 stacked with a second base 134 with at least one cut-away portion which functions the same as the cut-away portion 126 of the second portion 120. The lid 130 also includes tab walls 131 which are connected to the edges of the stacked bases 133, 134 in an upright configuration, and a plurality of stoppers 132 for preventing the side end walls 112 from movements so that the stacked containers 101, 102 can be secured in its deployed condition.

Referring to Figs 16 to 18, a second embodiment of the stacked assembly as illustrated therein comprises at least two containers 201, 202 one stacked on top of another, each of the container 201, 202 comprises a base 211, 221 having first and second opposing surfaces. Preferably, the first surface is hinged with side end walls 212 foldable relative to the base 211 from a collapsed stowed condition in which the side end walls 212 overlap the base 211 to a deployed condition in which the side end walls 212 are substantially upright relative to the base 211 to form an open top box. A wooden lid 230 can be provided to close the open top box of the uppermost container 201. The second surface comprises tab walls 222 being configured to receive the top portion of the side end walls 212. As such, when the containers 201, 202 in the deployed condition are stacked on top of another, the tab walls 222 can prevent the stacked containers 201, 202 from lateral detachment.

As Shown in Figs. 19 to 21, the containers 201, 202 are also stackable when they are in the collapsed stowed condition. Preferably, the tab walls 222 or the lid 230 are sized so that the side end walls 212 in the stowed condition can be received substantially flush within the depth of tab walls 222 or the lid 230. The stacked containers 201, 202 in the collapsed stowed condition can save significant amount of space and also prevent the stacked assembly from deformation during the packaging and transportation.

Preferably, each of the container 201, 202 can be formed by the attachment of first and second portions 210, 220 (Fig. 28). The first and second portions 210, 220 can be attached together via glue adhesive or any suitable type of fastening means.

Referring to Figs. 22 to 24, the first portion 210 as illustrated therein can be formed by at least five separate wooden sheets, the wooden sheets include a substantially rectangular base 211 and four piece of side end walls 212. The base 211 and the side end walls 212 are jointed/assembled together using leakproof tapes before the wooden sheets are laminated on both sides with polyethylene coating glassine paper. As such, the side end walls 212 are independently foldable between the collapsed stowed condition as shown in Fig. 23 and the deployed condition as shown in Fig. 22. The side end walls 212 overlap the base 211 when the first portion 210 is in the collapsed stowed condition and the side end walls 212 are substantially upright relative to the base 211 to form an open top box which can be closed by the lid 230 when the first portion 210 is in the deployed condition.

The first portion 210 may further comprise a pair of flexible sheets 213, one disposed at an outer surface of an opposing pair of side end wall 212 when the side end walls 212 are the deployed condition, and connected to adjacent edges of the other pair opposing of side end walls 212. The flexible sheets 213 are also foldable between the collapsed stowed condition and the deployed condition and their folding movements are synchronised with the movements of the side end walls 212.

Referring to Figs 25 to 27, the second portion 220 as illustrated therein can be formed by at least five separate laminated wooden sheets. The laminated wooden sheets include a base 221 and four piece of elongate side walls 222, each elongate side wall 222 comprises a centre portion 223 and two side portions 224 of a longitudinal length shorter than the centre portion. Score lines by half-cut are provided between the side portion and the centre portion so that the side portions 224 can be folded inwardly toward the centre portion 223 to form the elongate side walls 222, each with a groove 225 extending in a longitudinal direction. The second portion 220 is formed by inserting each edge of the base 221 into a respective groove of the elongate side walls 222, forming the tab walls 222 on both sides of the second portion 220. As shown in Fig. 27A, the second portion 220 has a generally H-shape cross-section taken from A- A of Fig. 27. The first portion 210 is preferably attached to one side of the second portion 220, the tab walls 222 will position the first portion in a space within the tab walls without the need of alignment. Furthermore, the tab walls 222 are able to conceal the lower part of the side end walls 212 of the first portion 210, thereby strengthening the structure integrity of the container 201, 202. The second portion 220 can also act as a natural leakproof barrier to prevent food liquid from leakage. As a result, it does not require the first portion 210 to be applied with leakproof adhesive and hence reducing the manufacturing process and costing.

Figs 29 to 31 shows a third embodiment of the stacked assembly. Preferably, the stacked assembly comprises at least two open top containers 301, 302 one stacked on top of another, and a wooden lid 330 to close the uppermost container 301. Each container 301, 302 is formed by a first portion 310 and a second portion 320. The first portion as shown in Fig. 32 includes four side end walls 311. Each side end wall 311 has two longitudinal edges 312 which are tapered about 45 degree so that two adjacent side end walls 311 can be joined in a substantially perpendicular manner. When all four side end walls 311 are joined together, they form a generally rectangular wall as shown in Fig. 33.

Similar to the second embodiment, the second portion 320 includes a base 321 and four piece of elongate side walls 322 as shown in Fig. 34. Each side wall 322 comprises a centre groove 323 extending longitudinally throughout the length of the side wall 322, and a pair of longitudinal edge 324 which are also tapered about 45 degree so that two adjacent side walls 322 can be joined in a substantially perpendicular manner. As shown in Fig. 35, the second portion 320 is formed by inserting each edge of the base 321 to the centre groove 323 of each side wall 322. Referring to Fig. 36, tab walls 322 are formed on both sides of the second portion 320, creating a generally H-shape cross-section taken from B-B of Fig. 35. Preferably, the first portion 310 is attached to one side of the second portion 320 as shown in Fig. 37, having the same advantages as per the second embodiment.

The present disclosure includes as contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangements of parts may be resorted to without departing from the scope of the invention.

Claims

1. A collapsible and stackable wooden container (101, 102, 201, 202) suitable for use as a food container, the container (101, 102, 201, 202) comprising a base (111, 121, 211, 221) having first and second opposing surfaces, the first surface is hinged with side end walls (112, 212) foldable relative to the base (111, 121, 211, 221) from a collapsed stowed condition in which the side end walls (112, 212) overlap the base (111, 121, 211, 221) to a deployed condition in which the side end walls (112, 212) are substantially upright relative to the base (111, 121, 211, 221) to form an open top box;

characterised in that the second surface comprises tab walls (122, 222) being such that when at least two such containers (101, 102, 201, 202) are stacked on top of another, the tab walls (122, 222) are configured to prevent the stacked containers (101, 102, 201, 202) from lateral detachment.

2. The container (101, 102, 201, 202) according to claim 1 is formed by the attachment of first and second portions (110, 120, 210, 220).

3. The container (101, 102, 201, 202) according to claim 2, wherein the first portion (110, 210) is formed by five pieces of laminated wooden sheets including a base (111, 211) hinged with four pieces of the foldable side end walls (112, 212), the second portion (120, 220) is formed by a one-piece or five pieces of laminated wooden sheet including a base (121, 221) with the tab walls (122, 222) and the bases (111, 211) of the first and second portion (120, 220) are attached together to form the container (101, 102, 201, 202).

4. The container (101, 102) according to claim 3, wherein the base (111, 121) of the first portion (110) or the second portion (120) has at least one cut-away section (126) to provide thermal expansion or contraction tolerance for preventing deformation of the container (101, 102).

5. The container (101, 102) according to any one of claims 1 to 4, wherein the second surface further comprises at least one stopper (125) for securing the container (101, 102) in the deployed condition when at least two such containers (101, 102) in their deployed condition are stacked on top of another.

6. The container (101, 102) according to any one of claims 1 to 5, further comprising a lid (130) for closing the open top box, the lid (130) comprises a first base (133) stacked with a second base (134) with at least one cut-away portion to provide thermal expansion or contraction tolerance so that the deformation of the lid (130) can be prevented.

7. The container (101, 102) according to any one of claims 1 to 6, wherein the hinged connections between at least the side end walls (112) and the base (111) have a coating of a leakproof substance to seal wood pores within the connections to avoid those pores from absorbing liquid which causes the container (101, 102) to deform.

8. The container (101, 102, 201, 202) according to any one of claims 1 to 7, wherein the tab walls (122, 222) are two-layered walls (123, 124, 223, 224) and being sized so that the side end walls (112, 212) in the stowed condition can be received substantially flush within the depth of tab walls (122, 222) for packaging purposes.

9. The container (101, 102, 201, 202) according to any one of claims 1 to 8, further comprising one or more flexible sheets (113, 213) disposed at an outer surface of one or more opposing side end walls (112, 212) when the side end walls (112, 212) are in the deployed condition and connected to edges of adjacent side end walls (112, 212), whereby the sheets (113, 213) are foldable between the collapsed stowed condition and the deployed condition and their folding movements are synchronised with the movements of its adjacent side walls (112, 212), wherein the flexible sheets (113, 213) are made of glassine paper with leakproof coating.

10. The container (101, 102) according to any one of claims 1 to 9, wherein at least one side end wall (112) has one or more undercut portions and its adjacent side end walls (112) each has a tab (114) to engage with the undercut portions (115) when the side end walls (112) are in the deployed condition so as to secure the side end walls (112) in the deployed condition to prevent the side end walls (112) from bending inwardly.

11. The container (201, 202, 301, 302) according to any one of claims 1 to 10, wherein the tab walls (222, 322) each comprises an elongate groove (225, 323) for receiving each edge of the base (211, 321) and thereby forming a generally H-shape cross-section (220, 320).

12. The container (301, 302) according to any one of claims 1 to 11, wherein each side end wall (311) has a pair of longitudinal edges which are tapered about 45 degree in a way such that two adjacent side end walls (311) are joined in a perpendicular manner.

13. The container (301, 302) according to any one of claims 1 to 12, wherein each tab wall (322) has a pair of longitudinal edges which are tapered about 45 degree in a way such that two adjacent side end walls (322) are joined in a perpendicular manner.