Foldable structure   

This patent claims priority of U.S. Provisional Patent Application Ser. Nos. 61/130,606 filed on Jun. 2, 2008 and 61/214,132 filed on Apr. 20, 2009, and incorporates the same herein by reference.

FIELD OF THE INVENTION

The present invention relates to a foldable structure that may be cut from a single blank of sheet material and folded and assembled without the use of glue, and more particularly, to an assembled structure having triangular opening at an end portion.

BACKGROUND OF THE INVENTION

Foldable structures are well known in the packaging art. Cartons are typically constructed from flat blanks that are pre-cut from sheets of paperboard and pre-scored to create fold lines. The carton blank includes a number of panels to form the sides of the carton. A blank for a rectangular carton or carton, for example, will have four main panels, which form the four sides of the carton. A closure flap is generally attached to each of the top and bottom end of the blank to allow the carton to be opened and closed when constructed. Additionally, minor flaps, or dust flaps, may be present at each of the top and bottom end of the blank. The minor flaps aid in keeping dust and debris out of the carton.

Many different shapes and sizes of foldable structures are known in the prior art. In many prior art foldable structures, their assembly from a blank sheet of material to a form from which they can be easily folded to or assembled to a desired configuration (e.g., a carton) often involves a gluing step. In the gluing step, one or more seams or sides of the prior art structures are glued together in order to enable the blank sheet of material to be folded from a flat storage configuration to a desired configuration (e.g., a carton). In many prior art methods of manufacturing foldable structures, the gluing step is necessary in order for the structure to be folded or assembled to and maintain its desired configuration (e.g., a carton).

A disadvantage associated with the gluing step involved in manufacturing prior art foldable structures is that it necessitates at least one extra step in the manufacturing process of forming a blank of sheet material into a desired configuration (e.g., a carton). This additional step often accounts for a significant percentage of the total time required in manufacturing a blank of sheet material into a desired configuration (e.g., a carton).

The gluing step also often adds significantly to the manufacturing costs. This is especially so when only a limited number of products embodying the invention are being produced and the cost involved in applying glue to the blank of sheet material and incorporating a gluing step in the overall assembly of the product cannot be spread over a large number of products.

Additionally, the gluing is further disadvantageous for non-commercial assembly of a products such as foldable cartons by, for example a home user, since such a non-commercial user may not have the glue or the specific type/grade of glue needed to complete assembly of the structure in situations which assembly is required.

What is needed to reduce the time and cost involved in the manufacture of foldable structures such as cartons is a product that can be assembled from a single blank of sheet material into a three-dimensional configuration such as a box, scoop or other configuration that does not require glue or glue-like substances, or a gluing step in its manufacture.

SUMMARY

The foldable structure of the present invention includes a structure formed from a single blank of sheet material and is assembled without the use of glue or other adhesive materials. The structure may be configured as a carton and may include a bottom wall defining opposing first and second side ends and opposing top and bottom ends. A first sidewall may be foldably connected to the first side end of the bottom wall and a second sidewall may be foldably connected to the second side end of the bottom wall.

A bottom end wall assembly may be foldably connected to the bottom end of the bottom wall. The bottom end wall assembly may include a first bottom end panel bordered by a first fold line and opposing second and third fold lines. A second bottom end panel may be foldably connected to the first bottom end panel along the first fold line with the second bottom end panel also being bordered by a fourth fold line opposite the first fold line. A third bottom end panel may be foldably connected to the second bottom end panel along the fourth fold line.

A first triangular bottom panel may be foldably connected to the first bottom end panel along the second fold line and a second triangular bottom panel may be foldably connected to the first bottom end panel along the third fold line.

BRIEF DESCRIPTION OF THE DRAWINGS

The objects and features of the invention may be understood with reference to the following detailed description of an illustrative embodiment of the invention taken together with the accompanying drawing in which:

FIG. 1 is a plain view of a single sheet of material of a first illustrated embodiment of the foldable structure of the present invention;

FIGS. 2-4 are perspective views depicting the folding of the single sheet of material of FIG. 1;

FIG. 5 is a perspective view of a folded structure in the form of a carton formed from the single sheet of material of FIG. 1 in accordance with a first illustrated embodiment;

FIG. 6 is a plain view of a single sheet of material of a second illustrated embodiment of the foldable structure of the present invention;

FIGS. 7 and 8 are perspective views depicting the folding of the single sheet of material of FIG. 6; and

FIG. 9 is a perspective view of a folded scoop formed from the single sheet of material of FIG. 6 in accordance with a second illustrated embodiment.

DETAILED DESCRIPTION

Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, FIG. 5 shows a first illustrated embodiment of the formed carton 150 of an embodiment of the present invention. The blank 10 of this first illustrated embodiment of the carton 150 is shown in FIG. 1.

With reference to FIG. 1, the blank 10 of the first illustrated embodiment of the foldable structure of the present invention is cut from a single sheet of material such as paper board or cardboard. The blank includes a substantially square bottom panel 12 at its center that is bordered by four fold lines 14, 16, 18, 20.

First right and left side panels 22, 24 are formed unitarily with the bottom panel 12 and are separated from the bottom panel 12 by fold lines 14, 18. Both the first right and left side panels 22, 24 are each bordered by three additional fold lines 26, 28, 30, 32, 34, 36. It is noted first right and left side panels 22, 24 are preferably identically dimensioned relative to one another and are each preferably configured as an isosceles trapezoid.

Second right and left side panels 38, 40 are formed unitarily with the first right and left side panels 22, 24, respectively, on opposite sides of the first right and left side panels 22, 24 from the bottom panel 12. Second right and left side panels 38, 40 are respectively separated from the first right and left side panels 22, 24 by fold lines 28, 34.

It is to be appreciated that second right and left side panels 38, 40 are preferably identically dimensioned relative to one another and are each also preferably configured as an isosceles trapezoid. It is to be further appreciated that the aforesaid isosceles trapezoid configuration of second right and left side panels 38, 40 are preferably respectively identical to that of the aforesaid isosceles trapezoid configuration of first right and left side panels 22, 24 wherein the first right side panel 22 is a mirror image of the second right side panel 38 (via fold line 28) and the first left side panel 24 is a mirror image of the second left side panel 40 (via fold line 34).

A first bottom end panel 42 is formed unitarily with bottom end panel 12 and is separated therefrom by fold line 16 and is additionally bordered by fold lines 44, 46, 48. Second bottom end panel 50 is formed unitarily with first bottom end panel 42 and is separated therefrom by fold line 46 and is additionally bordered by fold line 52. And a third bottom end panel 54 is formed unitarily with second bottom end panel 50 and is separated therefrom by fold line 52.

It is to be appreciated that each first, second and third bottom end panels 42, 50, 54 are preferably configured in a rectangular configuration having equal dimensions relative to one another.

On a opposing side of bottom panel 12 relative to first bottom end panel 42, first top end panel 56 is formed unitarily with bottom end panel 12 and is separated therefrom by fold line 20 and is additionally bordered by fold lines 58, 60, 62. Second top end panel 64 is formed unitarily with first top end panel 56 and is separated therefrom by fold line 60 and is additionally bordered by fold line 66. And a third top end panel 68 is formed unitarily with second top end panel 64 and is separated therefrom by fold line 66.

It is to be appreciated that each first, second and third top end panels 56, 64, 68 are preferably configured in a rectangular configuration having equal dimensions relative to one another. It is further to be appreciated that each first, second and third top end panels 56, 64, 68 have respectively equal dimensions to first, second and third bottom end panels 42, 50, 54.

A right bottom triangular panel 70 is unitarily formed with first right side panel 22 and first bottom end panel 42. Right bottom triangular panel 70 is separated from first right side panel 22 by fold line 26 and from first bottom end panel 42 by fold line 48 and is additional bordered by fold line 72. Right bottom flap panel 74 is unitarily formed with right bottom triangular panel 70 and is separated therefrom by fold line 72.

A right top triangular panel 76 is unitarily formed with first right side panel 22 and first top end panel 56. Right top triangular panel 76 is separated from first right side panel 22 by fold line 30 and from first top end panel 56 by fold line 62 and is additional bordered by fold line 78. Right top flap panel 80 is unitarily formed with right top triangular panel 76 and is separated therefrom by fold line 78.

A left top triangular panel 82 is unitarily formed with first left side panel 24 and first top end panel 56. Left top triangular panel 82 is separated from first left side panel 24 by fold line 36 and from first top end panel 56 by fold line 58 and is additional bordered by fold line 84. Left top flap panel 86 is unitarily formed with left top triangular panel 82 and is separated therefrom by fold line 84.

A left bottom triangular panel 88 is unitarily formed with first left side panel 24 and first bottom end panel 42. Left bottom triangular panel 88 is separated from first left side panel 24 by fold line 32 and from first bottom end panel 42 by fold line 44 and is additional bordered by fold line 90. Left bottom flap panel 92 is unitarily formed with left bottom triangular panel 88 and is separated therefrom by fold line 90.

It is to be appreciated that each aforesaid triangular panel 70, 76, 82, 88 are each identically dimensioned and configured as an equilateral triangle. Likewise, each aforesaid flap panel 74, 80, 86, 92 are each identically dimensioned and configured as a rectangle.

The above described single blank of sheet material 10 is preferably folded and assembled into the first illustrated embodiment of the carton 150 of the present invention without the use of glue or adhesives or other means of adhering one carton component to another.

In folding and assembling the above described blank 10 into the first illustrated carton embodiment 150 of the present invention (FIG. 5), and with reference now to FIGS. 2 and 3 (with continuing reference to FIG. 1), the first bottom end panel 42 and right and left bottom triangular panels 70, 88 are folded along fold lines 16, 26, 32 in an upward direction relative to bottom panel 12. The first left side panel 24 and left top triangular panel 82 are then folded along fold lines 18 and 58, and similarly the first right side panel 22 and right top triangular panel 76 are folded along fold lines 14 and 62, in an upward direction relative to bottom panel 12.

It is to be appreciated that the triangular geometry of right and left bottom triangular panels 70 and 88 cause the first bottom end panel 42 to reside at an acute inclined angle relative to bottom panel 12.

The right and left bottom flap panels 74 and 92 are then folded along respective fold lines 72 and 90 in a downward direction until the respective end portions of each right and left bottom flap panel 74 and 92 abut, or are in close proximity, to one another such that due to the triangular fold lines 72, 90 of the right and left bottom triangular panels 70, 88, the right and left bottom flap panels 74, 92 reside in a plane parallel to that of the bottom panel 12. As is partially shown in FIG. 3, first right and left side panels 22, 24 now form the respective opposing side walls of the formed carton 150.

With reference now to FIGS. 3 and 4 (with continuing reference to FIG. 1), the second bottom panel 50 is folded along fold line 46 in a downward direction relative to bottom panel 12 such that the bottom surface 51 of second bottom panel 50 is coplanar with the respective top surfaces of right and left bottom flap panels 74, 92. Next, the third bottom panel 54 is folded about fold line 52 whereby the third bottom panel 54 is friction fitted into the triangular open end portion 100 formed by first bottom end panel 42, right and left bottom triangular panels 70, 88 and right and left bottom flap panels 74, 92 such that the bottom surface 55 of the third bottom panel 54 is coplanar with the respective bottom surfaces of right and left bottom flap panels 74, 92.

Similarly, first top panel 56 is folded along fold line 20 in an upward direction relative to bottom panel 12 whereby right and left flap panels 80, 86 are then folded along respective fold lines 78 and 84 in a downward direction until the respective end portions of each right and left top flap panel 80, 86 abut, or are in close proximity, to one another such that due to the triangular fold lines 78 and 84 of the right and left top triangular panels 76, 82 the right and left top flap panels 80, 86 reside in a plane parallel to that of the bottom panel 12.

Like the second bottom panel 50, the second top panel 64 is folded along fold line 60 in a downward direction relative to bottom panel 12 such that the bottom surface of second top panel 64 is coplanar with the respective top surfaces of right and left top flap panels 80, 86. And like the third bottom panel 54, the third top panel 68 is folded about fold line 66 whereby the third top panel 68 is friction fitted into the triangular open end portion formed by first top end panel 56, right and left top triangular panels 76, 82 and right and left top flap panels 80, 86 such that the bottom surface of the third top bottom panel 68 is coplanar with the respective bottom surfaces of right and left top flap panels 80, 86.

The second right and left side panels 38, 40 may then be folded downward along respective fold lines 28, 34 relative to the bottom panel 12 to provide additional structural integrity to respective first right and left side panels 22, 24 forming the respective opposing sidewalls for carton 150. Alternatively, the second right and left side panels 38, 40 may be folded in a first upward and then downward movement along respective fold lines 28, 34 relative to the bottom panel 12 to provide at least a partial enclosure for the carton cavity 130 formed by carton 150. Alternatively, it is to be appreciated the second right and left side panels 38, 40 may be omitted from blank 10 or may be bound by perforated scored fold lines 28, 34 so as to be removed at the user\'s discretion.

It is to be appreciated that the cross-sectional area of each opposing triangular open end portion 100 of carton 150 forms a prism like configuration having an equilateral triangle cross section.

The above description with reference to FIGS. 1-5 completes the assembly of the blank 10 of FIG. 1 into its carton configuration 150 shown in FIG. 5.

The blank 200 of the foldable structure of a second illustrated embodiment of the second invention is similar to that of the first illustrated embodiment with regards to having a open triangular end portion forming a prism like configuration having an equilateral triangular cross section. The blank 200 of the second illustrated embodiment of the present invention is also cut from a single sheet of carton material such as paper board or card board. The blank is shown in FIG. 6 and includes a generally rectangular bottom panel 210 bounded by three fold lines 212, 214, 216. Right and left side panels 218, 220 are formed unitarily with the bottom panel 210. The right and left side panels 218, 220 are provided on opposite sides of the bottom panel 210 and are separated from the bottom panel by fold lines 212, 216 respectively. The right and left side panels 218, 220 are preferably of identical dimensions with each configured as a triangle having a curved wall 222, 224. Each right and left side panel 218, 220 is additionally bounded by another fold line 226, 228.

A right triangular panel 230 is unitarily formed with right side panel 218, and on an opposite side of the bottom panel 210, a left triangular panel 230 is unitarily formed with left side panel 220. Each right and left triangular panel 230, 232 is each additionally bound by two fold lines 234, 236, 238, 240.

A right flap panel 242 is unitarily formed with right triangular panel 230 and is separated therefrom by fold line 234. Likewise left flap panel 244 is unitarily formed with left triangular panel 232 and is separated therefrom by fold line 238.

It is to be appreciated that each right and left triangular panel 230, 232 is identically dimensioned and configured as an equilateral triangle. Likewise, each aforesaid right and left flap panel 242, 244 is identically dimensioned and configured as a rectangle.

A first end panel 246 is positioned intermediate the right and left triangle panels 230, 232 and is unitarily formed with the bottom panel 210 and each right and left triangular panel 230, 232 being separated therefrom by respective fold lines 214, 236, 240. The first end panel 246 having a generally rectangular configuration.

A second end panel 250 is unitarily formed with the first end panel 246 and is separated therefrom by fold line 248. And a third end panel 254 is unitarily formed with the second end panel 250 and is separated therefrom by fold line 252. Preferably the second and third end panels 250, 252 are identically dimensioned relative to one another and are each configured as an isosceles trapezoid, wherein the second end panel 250 is a mirror image of the third end panel 254, via fold line 252.

A right triangular tab panel 256 is unitarily formed with a side portion of third end panel 254 and is separated therefrom by fold line 258. And an opposite side portion of third end panel 254 is unitarily formed with a left triangular tab panel 260 and is separated therefrom by fold line 262. Each right and left triangular tab panel 256, 262 is preferably identically dimensioned relative to one another.

The above described blank 200 of the second illustrated embodiment of the foldable structure of the present invention shown in FIG. 6 is quickly and easily folded into and assembled into its foldable structure scoop configuration 300 preferably without the use of glues or adhesives or any other equivalent means of adhering one structural component to another.

The illustrated embodiment of the scoop 300 of the present invention is assembled from the single blank 200 of sheet material shown in FIG. 6 in substantially the same manner as the aforesaid first illustrated embodiment of the foldable structure of the present invention.

In folding and assembling the above described blank 200 into the scoop 300 embodiment of the present invention (FIG. 8), and with reference now to FIGS. 7 and 8 (with continuing reference to FIG. 6), the first end panel 246 and right and left triangular panels 230, 232 are folded along fold lines 214, 226, 228 in an upward direction relative to bottom panel 210. The left side panel 220 and left triangular panel 232 are then folded along fold lines 216, 240, and similarly the right side panel 218 and right triangular panel 230 are folded along fold lines 212, 236 in an upward direction relative to bottom panel 210.

It is to be appreciated that the triangular geometry of right and left triangular panels 230, 232 cause the first end panel 246 to reside at an acute inclined angle relative to bottom panel 210.

With primary reference now to FIG. 8, the right and left flap panels 242, 244 are then folded along respective fold lines 234, 238 in a downward direction until the respective end portions of each right and left flap panel 242, 244 abut, or are in close proximity, to one another such that due to the triangular fold lines 234, 238 of the right and left triangular panels 230, 232, the right and left flap panels 242, 244 reside in a plane parallel to that of the bottom panel 210. As is partially shown in FIG. 8, right and left side panels 218, 220 now form the opposing side walls of the formed scoop 300.

The second end panel 250 is then folded along fold line 248 in a downward direction relative to bottom panel 210 such that the bottom surface 251 of second end panel 250 is coplanar with the respective top surfaces of right and left flap panels 242, 244. Next, the third end panel 254 is folded about fold line 252 whereby the third end panel 254 is friction fitted into the triangular open end portion 270 formed by first end panel 246, right and left triangular panels 230, 232 and right and left bottom flap panels 242, 244 such that the bottom surface 255 of the third end panel 254 is coplanar with the respective bottom surfaces of right and left flap panels 242, 244. Similarly, the right triangular tab panel 256 abuts adjacent the right triangular panel 230 (as shown in FIG. 8) and the left triangular tab panel 260 abuts adjacent the left triangular panel 232.

It is to be appreciated that right and left triangular tab panels 256, 262 may be omitted from blank 200 or may be bound by perforated scored fold lines 258, 262 so as to be removed at the user\'s discretion.

The above description with reference to FIGS. 6-9 completes the assembly of the blank 200 of FIG. 6 into its scoop 300 configuration shown in FIG. 9. Specifically, scoop 300 is formed as a scoop-like structure having a scoop-like open end 310 portion for scooping and retaining objects in a carton region 330 formed by the aforesaid panels of blank 200.

And like carton 150 of the first illustrated embodiment (FIG. 5), it is to be appreciated that the cross-sectional area of the formed triangular open end portion 270 of scoop 300 forms a prism like configuration having an equilateral triangle cross section.

While the illustrated embodiments of the present invention has been described by reference to specific embodiments, it should be understood that modifications and variations of the invention may be constructed without departing from the scope of the invention defined herein and by the following claims.