Disposable foil container

Details Disposable foil container Disposable foil container

1999-02-03

2001-03-13

Shoap, Allan N. (Department: 3727)

Receptacles

End wall structure

One-piece side and end wall

C206S564000, C220S573100, C229S005820, C426S113000

Reexamination Certificate

active

06199715

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates generally to disposable foil containers and, more particularly, relates to a disposable foil container designed to provide superior structural strength.
BACKGROUND OF THE INVENTION
Various disposable and inexpensive cooking utensils, such as containers for use in heating and/or cooking food products, such as hams, roasts, turkeys, etc., have become popular because they are relatively inexpensive and eliminate the need for container cleaning after the heating and/or cooking of the food product has occurred. Such containers are normally formed of a light or thin gauge material such as aluminum foil. Foil containers made from aluminum foil have the heat transference qualities associated with the metal aluminum and because of the minimal amount of metal utilized in the structure, are inexpensive and, consequently, can be disposed of after a single use.
The convenience of having an inexpensive disposable container by utilizing thin gauge metal is achieved with the attendant factor that the container has diminished structural strength. One measure of the structural strength of the container is known as the “bend strength.” The “bend strength” may be defined as the maximum weight which can be lifted by the container prior to the formation of one or more deflection points in the container. A deflection point refers to the formation of a buckle along one of the sides of the container. Thin gauge foil containers are inherently weak and are incapable of carrying heavy loads without bending. Obviously, if the gauge of the metal is increased to increase the “bend strength” of the container, the container cost will also increase.
To achieve added structural strength without increasing the metal gauge and, at the same time, enhance the aesthetic appeal of the container, it is customary to form ribs of varying sizes and designs in the bottom panel and sides of a container. However, the number, shape, and size of the ribs are limited by the elongation capacity of the type of metal and gauge selected. A gauge that is too thin may result in the tearing of the foil as it is formed while a gauge that is too thick may be too difficult to form around complex shapes and sharp angles. Also, the number and depth of the ribs is limited by the elongation capacity, and a tradeoff between the number, shape, and size of the ribs is usually required.
Also, controlled wrinkles or folds are often incorporated in the sides, and the rim of the container is curled or beaded in a variety of ways to increase the overall structural strength of the container. Heretofore, these strength-enhancing features have been generally successful in producing inexpensive and aesthetically-acceptable disposable foil containers suitable for steaming, heating, and/or cooking food products. However, additional strengthening means are still desirable, especially in the bottom panel of larger containers such as those used for cooking heavy loads such as roasts, hams, and turkeys.
SUMMARY OF THE INVENTION
The present invention is a disposable container formed from a single sheet of metal. In accordance with one embodiment, the container includes a bottom panel having a peripheral rib enclosing an interior panel having a central portion, first and second curved traversing ribs, and first and second curved returning ribs. The peripheral rib has first and second side curved sections and first and second end curved sections. Each of the traversing ribs extends toward the central portion and includes a first end and a second end. Both first and second ends of each traversing rib intersect the peripheral rib at a first set of intersections. Each of the returning ribs extends toward the central portion and includes a first and a second end. Both first and second ends of each returning rib intersect the peripheral rib at a second set of intersections.
The container further includes a continuous wall panel encompassing the bottom panel and extending upwardly and outwardly from the bottom panel. The continuous wall panel, which has a continuous curvilinear upper edge, forms a pair of opposing side walls and a pair of opposing end walls.
Also, the container is defined about major and minor axes. The major axis passes through the center of the bottom panel and is located approximately halfway between the opposing side walls of the continuous wall panel and approximately halfway between the side curved sections of the peripheral rib. The minor axis passes through the center of the bottom panel and is located approximately halfway between the opposing end walls of the continuous wall panel and approximately halfway between the end curved sections of the peripheral rib. The major axis substantially bisects the end curved sections, and the minor axis substantially bisects the side curved sections.
In accordance with another embodiment, the container formed from a single sheet of metal includes a bottom panel having first, second, and third ribs. Each of the ribs have a first lower edge, a first upper edge, a second lower edge, a second upper edge, a first surface between the first lower edge and the first upper edge, and a second surface between the second lower edge and the second upper edge. The first, second, and third ribs form a 3-way rib intersection having a flat top surface. At a first smooth transition, the first surface of the first rib interconnects with the first surface of the second rib, the first lower edge of the first rib interconnects with the first lower edge of the second rib, and the first upper edge of the first rib interconnects with the first upper edge of the second rib. At a second smooth transition, the second surface of the second rib interconnects with the second surface of the third rib, the second lower edge of the second rib interconnects with the second lower edge of the third rib, and the second upper edge of the second rib interconnects with the second upper edge of the third rib. At a third smooth transition, the first surface of the third rib interconnects with the second surface of the first rib, the first lower edge of the third rib interconnects with the second lower edge of the first rib, and the first upper edge of the third rib interconnects with the second upper edge of the first rib. The flat top surface is encompassed by the second upper edge of the second rib intersecting with the second upper edge of the third rib at the second smooth transition, the first upper edge of the third rib intersecting with the second upper edge of the first rib at the third smooth transition, and the first upper edge of the first rib intersecting with the first upper edge of the second rib at the first smooth transition.
In accordance with yet another embodiment, the container includes a bottom panel, a continuous wall panel encompassing the bottom panel and extending upwardly and outwardly from the bottom panel. The continuous wall panel forms a pair of opposing side walls, and a pair of opposing end walls. Four corners bridge the side walls and end walls. The pair of side walls includes curvilinear upper side edges having respective radii of curvature. The pair of end walls includes curvilinear upper end edges having respective radii of curvature. Each of the four corners include curvilinear upper corner edges having respective radii of curvature. A continuous rim encompasses an upper edge of the continuous wall panel and projects laterally outwardly therefrom. The continuous rim forms a pair of side rim portions connected to the upper side edges of respective ones of the pair of side walls. The pair of side rim portions have respective inner edges curved on the curvilinear upper side edges of respective ones of the side walls. The side rim portions have respective side outer edges that include three straight segments interconnected at side corners. The continuous rim forms a pair of end rim portions connected to the upper end edges of respective ones of the pair of end walls. The pair of end rim portions have respective inner edges curved on the curvilinear upper end ed

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