Foldable Packaging Container and Producing Method Thereof

Abstract

A foldable packaging includes a base panel and a folding strap defining a folding line. The folding strap is arranged to fold around the peripheral edge of the base panel along the folding line thereof to form a tridimensional container. The folding strap further includes a reinforcing layer provided at said folding strap at a position above said folding line of said folding strap.

Description

NOTICE OF COPYRIGHT

A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to any reproduction by anyone of the patent disclosure, as it appears in the United States Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.

BACKGROUND OF THE PRESENT INVENTION

Field of Invention

The present invention relates to packaging container, more particularly to a foldable packaging container comprising a folding strap which is pliable enough to fold around the peripheral edge of a base panel and sturdy enough to withstand substantial weight and pressure.

Description of Related Arts

Paper-based packaging is frequently utilized in packaging industry for containing a wide range of consumer goods. For the nature of paper-based material, the packaging product is advantageous in relatively lightweight, inexpensive, and being easily disposed and/or recycled. Many of the packaging products are made in a flat-form for ease of transportation and storage and can be folded to create a tridimensional container defining a housing compartment to hold a specific item therewithin. However, there is a number of disadvantages existing in the conventional paper-based packaging products.

Conventionally, a foldable packaging includes a base panel and a folding strap arranged to encircle around the peripheral edge of the base panel to form a tridimensional container having a housing compartment defined by the confines thereof to receive an item, such as a birthday cake, therewithin. In order to facilitate folding the folding strap at the base panel along the peripheral edge thereof, the folding strap must be pliable enough to be easily bent and deformed with respective to the geometry and size of the peripheral edge of the base panel. Contradictorily, the finished packaging container with pliable folding strap as the surrounding wall thereof is unable to guarantee a sufficient strength to withstand substantial weight and pressure.

More specifically, in order to enhance the pliability of the folding strap, the thickness thereof is generally reduced resulting in a degradation of the rigidness thereof. Therefore, the folded packaging container would be crushed or deformed, even if a small load is applied at the surrounding wall (formed by the folding strap). In addition, the base panel is generally adjoined with the folding strap merely via an adhesive layer provided therebetween. That is to say, the adhesive layer is to the mere element configuring the sole bonding connection between the base panel and the folding strap to weakly prevent the base panel detaching from the folding strap.

Further, the base panel of the conventional packaging container commonly has a regular shape, such as rectangular or round shape. In a specific example as shown in FIG. 1A to FIG. 1C of the drawings, the conventional packing container 10P includes a rectangular-shaped base panel 11P and a folding strap 12P flapping around the peripheral edge of the base panel 11P to create a tridimensional packaging cavity 10P therein for packaging an item in rectangular shape. Such conventional structure of the base panel 11P and the folding strap 12P limits the shape of the conventional packaging container 10P to regular shape such as square, rectangular or round shape. In addition, even though the base panel 11P is in a regular form, an overlap or wrinkle is occurred at some portions of the folding strap 12P, especially at the corner portions thereof, because of an imperfect alignment between the folding strap 12P and the peripheral edge of the base panel 11P, as shown in FIG. 1. The overlaps or the wrinkles at the folding strap not only damage the overall intact appearance of the product but also increase the difficult to apply adhesive layer between the folding strap and the base panel.

Therefore, a packaging container having an irregular shape, such as heart shape having a varying curvature peripheral edge, will definitely maximize the difficult in the alignment between the base panel and the folding strap. However, such need is truly existed and strong in the market. In particular, the heart-shaped packaging container is highly desired in Valentine's Day, Thanksgiving Day and Christmas Day to package merchandise, such as chocolate, flower, jewelry, and etc., which represents love visibly and creates a romantic atmosphere effectively. In such case, the aesthetic feature of the overall appearance of the packaging container is defiantly an issue, that even a small wrinkle or overlap at the folding strap would ruin the whole romantic feeling given by the exclusive appearance.

Further, after the folding strap is folded around the base panel along a folding line defined thereat, the folding strap at the bottom side of the base panel is totally exposed to the exterior, which not only damages the total aesthetic appearance, but also causes the printing or impacting any graphic design to the external surface of the packaging container difficult. It is well known that adding additional decorative elements such as enterprise trademark, or other customized designs is a necessity in packaging industry.

Moreover, as mentioned above, the pliable folding strap is usually made of thin paper-based material, making the folding lines difficult to manufacture, for the reason that if the folding line is scored too shallow, the folding strap may be waved around or even extended beyond the folding line in the folding operation, while if the folding line is scored too deep, the whole strength of the folding strap is further detracted, such that the folding strap can be vulnerable to tear apart in the folding process or potentially rupture in the usage of the packaging container.

In addition, the folding strap and the base panel are independent components in conventional packaging products. In order to ensure a precise assembly of the packaging container, an operator must cautiously affix a portion of the folding strap at the base panel for establishing an initial positioning datum. As such, the rest of the folding strap must be precisely attached to the peripheral edge of the base panel precisely along the folding line thereof. However, it is not easy to achieve a precise positioning datum in a short period time even for a skilled operator, for the reason that only a small offset at the initial positioning datum would result in a big deviation between the ideal folding line and the actual formed folding line. Therefore, after attaching the folding strap at the base panel to form the positioning datum, the operator commonly would slightly adjust the folding strap for achieving a precise initial start by long-years of experience. That is to say, the conventional packaging is not convenient for the operator to assembly in use, which is time-consuming and depends on the skill level of the operator.

SUMMARY OF THE PRESENT INVENTION

The invention is advantageous in that it provides a paper-based foldable packaging container and producing method thereof, wherein the folding strap of the packaging container is pliable enough to fold along the peripheral edge of the base panel and sturdy enough to withstand a substantial weight and pressure at the same time.

Another advantage of the invention is to provide a paper-based foldable packaging container and producing method thereof, wherein a reinforcing layer is attached to the folding strap at a position above the folding line of the folding strap to strengthen the folding strap, while not affecting the foldability thereof.

Another advantage of the invention is to provide a paper-based foldable packaging container and producing method thereof, wherein the lower edge of the reinforcing layer is overlapped with the folding line, such that the reinforcing layer provides another folding limit line to aid the folding line of the folding strap to align with the peripheral edge of the base panel in the assembling process.

Another advantage of the invention is to provide a paper-based foldable packaging container and producing method thereof, wherein the folding line can be slightly shallow formed along the folding strap to ensure a sufficient strength thereof, while a precise alignment between the folding line and the peripheral edge of the base panel is secured by the reinforcing layer. In other words, the folding line in the present invention is easier to manufacture because of the reinforcing layer.

Another advantage of the invention is to provide a paper-based foldable packaging container and producing method thereof, wherein the folding strap further comprises a self-adjusting arrangement provided at a portion of the folding strap below the folding line to fittedly adjust the bending manner of the folding strap with respect to the curvature of the peripheral edge of the base panel so as to fittedly fold the folding strap at the peripheral edge of the base panel.

Another advantage of the invention is to provide a paper-based foldable packaging container and producing method thereof, wherein the folding strap of the present invention is able to fit with irregular-shaped base panel, such as a heart-shaped base panel having a peripheral edge with varying curvature.

Another advantage of the invention is to provide a paper-based foldable packaging container and producing method thereof, wherein a portion of the folding strap is pre-affixed at a predetermined position of the base panel, so as to provide an initial precise positioning datum for guiding a precise alignment between the folding line of the folding strap and the peripheral edge of the base panel.

Another advantage of the invention is to provide a paper-based foldable packaging container and producing method thereof, wherein the paper-based foldable packaging container of the present invention is convenient and easy to produce in a precise and quick manner.

Another advantage of the invention is to provide a paper-based foldable packaging container and producing method thereof, wherein the paper-based foldable packaging container further comprises a cover panel overlappedly provided at the bottom side of the base panel for concealing the folding portions of the folding strap below the folding line, such that the overall aesthetic appearance of the packaging container is intact and enhanced.

Another advantage of the invention is to provide a paper-based foldable packaging container and producing method thereof, wherein the cover panel is attached to the bottom side of the base panel for enhancing the bonding connection between the folding strap and the base panel to prevent potential rupture or detachment.

Another advantage of the invention is to provide a paper-based foldable packaging container and producing method thereof, wherein an additional decorative element, such as an enterprise logo or other customized designs, can be easily impacted at the reactively intact exterior surface of the packaging container.

Another advantage of the invention is to provide a paper-based foldable packaging container and producing method thereof, wherein two end flaps of the folding strap is overlapped with each other to form an interlocked mechanism for preventing the folding strap to flap away from the peripheral edge due to the rebounding force provided by the bent folding strap in the assembly process.

Another advantage of the invention is to provide a paper-based foldable packaging container and producing method thereof, wherein the paper-based foldable packaging container before folding to form a tridimensional container is in flat layer form with a compact size for convenient shipment and storage, and that it is processed and folded in shape to create a three-dimensional packaging container having a packaging cavity therein for packaging a specific item when in usage.

Another advantage of the invention is to provide a paper-based foldable packaging container and producing method thereof, wherein no expensive or complicate structure is required to employ in the present invention. Therefore, the present invention successfully provides an economic and efficient solution for providing a foldable packaging container with better performance.

Additional advantages and features of the invention will become apparent from the description which follows, and may be realized by means of the instrumentalities and combinations particular point out in the appended claims.

According to the present invention, the foregoing and other objects and advantages are attained by a foldable packaging container which comprises:

a base panel having a peripheral edge and a folding line formed along the peripheral edge; and

a folding strap, having at least a portion adapted to be pre-connected with the peripheral edge of the base panel, being arranged to fold around the peripheral edge of the base panel along the folding line formed at the folding strap to form a tridimensional packaging container at an assembly position, wherein the tridimensional packaging container comprises a base portion formed by the base panel and a surrounding wall extended upwardly from the base portion, wherein the surrounding wall is formed by the folding strap and the folding strap further comprises a reinforcing layer provided at a position above the folding line of the folding strap.

In one embodiment of the present invention, a lower edge of the reinforcing layer is substantially overlapped with the folding line.

In one embodiment of the present invention, the folding strap is integrally coupled at a portion of the base panel for providing an initial positioning datum to guide the folding strap to fittedly fold around the peripheral edge of the base panel along the folding line thereof.

In one embodiment of the present invention, the base panel is in heart shape, wherein a mid-portion of the folding strap is integrally affixed at a lower convex vertex portion of the heart-shaped base panel and the folding strap is sidewardly and integrally extending from the lower convex vertex portion in a substantially symmetrical manner.

In one embodiment of the present invention, two end flaps of the folding strap, defined at the two end portions thereof, is overlappedly with each other to form an interlocked mechanism.

In one embodiment of the present invention, the two end flaps of the folding strap are overlapped with each other at a position at an upper concave vertex portion of the heart-shaped base panel.

In one embodiment of the present invention, the folding strap further comprises a self-adjusting arrangement formed at a portion of the folding strap below the folding line of the folding strap for adjusting the bending manner of the folding strap with respect to a curvature of the peripheral edge of the base panel so as to fittedly fold the folding strap around the peripheral edge along the curvature thereof.

In one embodiment of the present invention, the self-adjusting arrangement comprises a plurality of the v-shaped notches indently formed at a portion below the folding line of the folding strap in a parallel manner.

In one embodiment of the present invention, each of the v-shaped notches has a vertex point and two side edge outwardly and inclinedly extended from the vertex point to define an opening therebetween, wherein a size of the opening is adjustably minimized with respect to the curvature of the peripheral edge of the base panel.

In one embodiment of the present invention, a distribution of the notches is corresponded to the varying curvature of peripheral edge of the base panel.

In one embodiment of the present invention, an angle of the opening of the notch is ranged from 15° to 135°.

In one embodiment of the present invention, the two side edges of each notch are substantially adjacent with each other at the assembly position.

In one embodiment of the present invention, the foldable packaging container further comprises a cover panel overlappedly coupled at a bottom side of the base panel.

In one embodiment of the present invention, a double-sided adhesive layer is formed at a portion below the folding line of the folding strap for bonding the folding strap at base panel and the cover panel at the base panel.

According to another aspect of the present invention, the present invention provides a foldable packaging container comprising:

a base panel; and

a folding strap integrally and sidewardly extended from a portion of the base panel for providing an initial positioning datum to guide an alignment between the folding strap and the base panel, wherein at an assembly position, the folding strap is capable of fittedly folding around a peripheral edge of the base panel along a folding line defined along the folding strap to form a tridimensional packaging container having a base portion formed by the base panel and a surrounding wall formed by the folding strap and extended upwardly from the base portion.

According to another aspect of the present invention, the present invention provides a foldable packaging container comprising:

a base panel; and

a folding strap integrally and sidewardly extended from a portion of the base panel for providing an initial positioning datum to guide an alignment between the folding strap and the base panel, wherein the folding strap further comprises a self-adjusting arrangement formed at a portion of the folding strap below the folding line of the folding strap for adjusting a bending manner of the folding strap with respect to a curvature of a peripheral edge of the base panel, wherein at an assembly position, the folding strap is capable of fittedly folding around the peripheral edge of the base panel along the folding line to form a tridimensional packaging container having a base portion formed by the base panel and a surrounding wall formed by the folding strap and extended upwardly from the base portion.

According another aspect of the present invention, the present invention further provides a producing method of a foldable packaging container, comprising the steps of:

configuring a base panel in an irregular shape, such as heart shape;

configuring a folding strap; and

integrally affixing a portion of the folding strap at a peripheral edge of the base panel.

According another aspect of the present invention, the producing method of the present invention further comprises the steps of:

establishing an initial positioning datum by integrally affixing a portion of said folding strap at the base panel;

fittedly folding the folding strap around the base panel at the peripheral edge thereof; and

retaining the folding strap at the base panel in position.

Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.

These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic view of a conventional foldable packaging container.

FIG. 1B is a perspective view of the above conventional foldable packaging container after it is folded and assembled to form a conventional tridimensional packaging container with regular shape.

FIG. 1C is another perspective view of the conventional foldable packaging container after it is folded and assembled.

FIG. 2 is a perspective view of a foldable packaging container according to a preferred embodiment of the present invention.

FIG. 3 is a front perspective view of the foldable packaging container after it is folded and assembled according to the above preferred embodiment of the present invention.

FIG. 4 is a rear perspective view of the foldable packaging container after it is folded and assembled according to the above preferred embodiment of the present invention.

FIG. 5 is an exploded view of the foldable packaging container according to the above preferred embodiment of the present invention.

FIG. 6 is a schematic view illustrating the adjusting notches of the self-adjusting arrangement according to the above preferred embodiment of the present invention.

FIG. 7 is a schematic view illustrating the distribution of the adjusting notches at the folding strap with respect to the varying curvature of the peripheral edge of the base panel according to the above preferred embodiment of the present invention.

FIG. 8 is a perspective view with a partial magnification view of the interlocked mechanism formed by the two end flaps of the folding strap according to the above preferred embodiment of the present invention.

FIG. 9 is a perspective view of the foldable packaging container with a cover panel according to the above preferred embodiment of the present invention.

FIG. 10 is a perspective view of the foldable packaging container, illustrating impacting a decorative element at the foldable packaging container, according to the above preferred embodiment of the present invention.

FIG. 11 is an exploded view of the cover and the container of the foldable packaging container according to the above preferred embodiment of the present invention.

FIG. 12 is a perspective view of the foldable packaging container, illustrating the container being covered by the cover, according to the above preferred embodiment of the present invention.

FIGS. 13 to 16 are schematic views illustrating producing steps of forming the folding strap according to the above preferred embodiment of the present invention.

FIG. 17 is a perspective view illustrating the base panel and the folding strap of the foldable packaging container before folding according to the above preferred embodiment of the present invention.

FIG. 18 is a rear schematic view illustrating an assembling step of attaching the folding strap around the peripheral edge of the base panel of the foldable packaging container according to the above preferred embodiment of the present invention.

FIG. 19 is a perspective view illustrating the interior of the container of the foldable packaging container according to the above preferred embodiment of the present invention.

FIG. 20 is an exploded perspective view illustrating the bottom structure of the container of the foldable packaging container according to the above preferred embodiment of the present invention.

FIG. 21 is an exploded perspective view illustrating the cover, the container and the item being received in the packaging cavity of the container of the foldable packaging container according to the above preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following description is disclosed to enable any person skilled in the art to make and use the present invention. Preferred embodiments are provided in the following description only as examples and modifications will be apparent to those skilled in the art. The general principles defined in the following description would be applied to other embodiments, alternatives, modifications, equivalents, and applications without departing from the spirit and scope of the present invention.

Referring to FIG. 2 to FIG. 4 of the drawings, a foldable packaging container 10 according to a preferred embodiment is illustrated, wherein the foldable packaging container 10 is produced in a flat layer form before folding for the ease of shipment and storage, and is constructed to be folded to form a tridimensional container 10A having a packaging cavity 13A therein to contain a specific item for packaging purpose.

As shown in the FIG. 2 and FIG. 3 of drawings, the foldable packaging container 10 comprises a base panel 11 and a folding strap 12, wherein at an assembly position, the folding strap 12 is arranged to be fittedly folded around a peripheral edge 110 of the base panel 11 to form the tridimensional container 10A.

Further, as shown in FIG. 3, the tridimensional container 10A folded from the foldable packaging container 10 comprises a base portion 11A formed by the base panel 11, a surrounding wall 12A formed from the folding strap 12 and upwardly extended from the base portion 11A at the peripheral edge 110 of the base panel 11 to define the packaging cavity 13A therewithin, wherein a specific item can be received in the packaging cavity 13A for fulfilling the packaging purpose. Accordingly, the folding strap 12 is folded along the peripheral edge 110 of the base panel 11 in such a manner that a portion of the folding strap 12 is flapped to attach to a bottom side of the base panel 11 for retaining the folding strap 12 at the base panel 11, while the left portion of the folding strap 12 is perpendicularly and upwardly extended from the base panel 11 to form the surrounding wall 12A of the container 10A thereby.

As mentioned above, good pliability and sufficient rigidity of the folding strap 12 (surrounding wall 12A of the container 10A) are contradictory technical features that are hard to meet at the same time. Commonly, in order to enhance the pliability of the folding strap 12, its thickness must be reduced, resulting in a degradation of the rigidity thereof, such that the conventional packaging container 10P is unable to withstand a substantial weight and pressure. On the contrary, a folding strap 12P with sufficient thickness could guarantee a rigidity to withstand the applied load at the conventional packaging container 10P, but the foldability of the folding strap 12P is significantly minimized because of the decreased pliability thereof.

In order to overcome such contradictory technique features in the prior art, the foldable packaging container 10 of the present invention provides a reinforcing layer 123 attached to the folding strap 12 to enhance the rigidity of the folding strap 12 thereby while not affecting the foldability thereof simultaneously. In particular, as shown in FIG. 2 to FIG. 4 of the drawings, a folding line 120 is formed along the folding strap 12 for guiding the folding operation of the folding strap 12 around the base panel 11, wherein at the assembly position, a portion of the folding strap below the folding line 121 is folded to attach to the bottom side of the base panel 11 so as to retain the left portion of the folding strap above the folding line 122 in position, as the surrounding wall 12A of the container 10A. In other words, the portion of the folding strap 12 below folding line 121 of the folding strap 12 substantially determines the foldability of the folding strap 12, such that it would be practical to keep the folding strap 12 flexible at the portion of the folding strap below the folding line 121 for maintaining a good foldability while increasing the thickness of the portion of the folding strap 12 above the folding line 122 to acquire a sufficient strength of the surrounding wall 12A of the container 10A at the same time.

As shown in the FIG. 5 of the drawings, the reinforcing layer 123 is overlappedly provided at the folding strap 12 at a position that a lower edge 1231 of the reinforcing layer 123 substantially overlaps with the folding line 120 and an upper edge thereof 1232 is extended upwardly from the lower edge 1231, such that the thickness of the portion of the folding strap 12 above the folding line 122 is increased while the thickness of the portion of the folding strap 12 below the folding line 121 is remained the same. Therefore, the portion of the folding strap 12 above the folding line 122 is strengthened to prevent the container 10A from being crushed or ruptured easily. At the same time, the pliability of the portion of the folding strap 12 below the folding line 121 is not affected, such that the portion of the folding strap 12 below the folding line 121 can be easily bent with respect to the folding line 120 to encircle and surround the peripheral edge 110 of the base panel 11 at the assembly position.

It is worth mentioning that the lower edge 1231 of the reinforcing layer 123 is substantially overlapped with the folding line 120 in such a manner that the reinforcing layer 123 provides another folding limit line to limit the folding strap 12 to fold in line with the folding line 120.

It is well known that the folding line 120 is always an issue in the production of the packaging materials, for the reason that if the folding line 120 is formed too shallow, the actual folding line 120 may be waved around or even extended beyond the designed folding line 120 in the folding practice, and that if the folding line 120 is formed too deep, the whole structure of the folding strap 12 is further detracted, such that the folding strap 12 may be vulnerable to tear apart in the folding process or potentially rupture in the usage of the container 10A. In the present invention, since the reinforcing layer 123 functions another folding limit line for the folding strap 12 to comply with in the folding process, the folding line 120 formed at the folding strap 12 can be slightly shallowed to maintain a relatively strong structure so as to prevent potential rupture or tearing apart. Those who skilled in the art would easily understand that, an addition functional layer might be added into the folding strap 12, i.e. a liquid-resistant layer. In such cases, the worry of breaking the structure of the addition function layer during forming the folding line 120 at the folding strap 12 is substantially minimized because of the shallowed folding line 120.

Further, as shown in the FIG. 2, the base panel 11 of the present invention can be made in irregular shape other than in a regular shape form, such as rectangular or round shape as in the prior art. In particular, the base panel 11 in this preferred embodiment is formed, such as by a die cut technique, in a substantially heart shape, wherein the heart-shaped base panel 11 has a lower convex vertex 111, an upper concave vertex 112 and two side edges 113, 114 extended between the lower convex vertex 111 and upper concave vertex 112 to define a heat-shape area. Accordingly, the geometry feature of the peripheral edge 110 of base panel 11 (formed by the two side edges 113, 114) in this preferred embodiment is complicated with varying curvature at different portions of the peripheral edge 110, and the difficult of aligning and folding of the folding strap along the such peripheral edge is overcome by the innovative configuration and structure of the folding strap 12 with respect to the base panel 11 of the present invention. According to the preferred embodiment of the present invention, the folding strap 12 is able to be alignedly folded along the peripheral edge 110 of the base panel 11 in a rapid and easy manner.

In particular, in order to fittedly fold the folding strap 12 to align with the peripheral edge 110 of the base panel 11 to prevent any overlaps or wrinkles, a self-adjusting arrangement 124 is employed in the present invention, wherein the self-adjusting arrangement 124 is provided at the portion of the folding strap below the folding line 121 to fittedly adjust the bending manner of the folding strap 12 with respective to the geometry feature of the peripheral edge 110 of the base panel 11 so as to fittedly fold the folding strap 12 at the base panel 11 along the peripheral edge 110 thereof.

More specifically, as shown in the FIG. 6, the self-adjusting arrangement 124 further comprises a plurality of adjusting notches 1240 indently formed at the portion of the folding strap 12 below the folding line 121 in a substantially parallel manner. When the folding strap 12 is aligned folded around the peripheral of the base panel 11 in the folding process, the shapes of the adjusting notches 1240 are changed with respective to the curvature of the peripheral edge 110 of the base panel 11, so as to fittedly adjust the bending manner of the folding strap 12 to align with the curvature of the peripheral edge 110 of the base panel 11.

In particular, the adjusting notches 1240, according to the preferred embodiment, is formed in a V shape, wherein each of the V-shaped adjusting notches 1240 has a vertex point 1241 and two side edges 1242, 1243 outwardly extended from the vertex point 1241 to define an opening 1244 therebetween, wherein the angles and sizes of the openings 1244 are adjustably minimized with respective to the curvature of the peripheral edge 110 of the base panel 11, as the folding strap 12 is circling around the base panel 11, as shown in FIG. 6. In other words, the complicated varying curvature of the peripheral edge 110 of the base panel 11 is fittedly matched by the varying self-changes of the openings 1244 of the adjusting notches 1240 in this preferred embodiment of the present invention.

Those who skilled in the art would easily understand that in order to avoid any overlap or wrinkles occurring at the folding strap 12, the two side edges 1242, 1243 of each of the adjusting notches 1240 cannot be overlapped with each other in the folding process.

Accordingly, since the curvature of the peripheral edge 110 of base panel 11 is varied at different portions, it is important to well-design the distribution of the adjusting notches 1240 at the folding strap 12 with respective to the curvature distribution of the peripheral edge 110 of the base panel 11, as well as the angles of the openings 1244 of the adjusting notches 1240 at different portions of the folding strap 12, in order to prevent the two side edges 1242, 1243 overlapped with one another in the folding process.

According to the preferred embodiment of the present invention, the base panel 11 is embodied in a substantial heart shape, wherein the curvature of peripheral edge 110 at the side edge 113, 114 thereof is gradually increased from the lower convex vertex 111 to the upper concave vertex 112. Therefore, in this preferred embodiment, it is practical to define the peripheral edge 110 of the base panel 11 into four regions, including a small-curvatured region 115 defined from the lower convex vertex 111 to a mid-portion of the left side edge 113 of the base panel 11, a large-curvatured region 116 extended from the mid-portion of the left side edge 113 to the upper concave vertex 112 and another small-curvatured region 115 and large-curvatured region 116 defined on the opposite right side 114, as shown in FIG. 7 of the drawings.

Accordingly, the adjusting notches 1240 corresponding to the large-curvatured regions 116 of the peripheral edge 110 of the base panel 11, when folding the folding strap 12 around the base panel 11, is preferably arranged in a high-density distribution. In other words, more adjusting notches 1240 should be parallelly formed at the corresponding portion of the folding strap 12 to further soften the structure of the folding strap 12 thereby, as to well-fit with the large-curvatured regions 116 of the base panel 11.

On the contrary, the adjusting notches 1240 corresponding to the small-curvatured regions 115 of the peripheral edge 110 of the base panel 11, when folding the folding strap 12 around the base panel 11, is preferably arranged in a low-density distribution. In other words, fewer adjusting notches 1240 should be parallelly formed at the corresponding portions of the folding strap 12 with larger intervals between each two adjacent adjusting notches 1240 to well-adapt to the small-curvatured regions 115 of the base panel 11.

It is important to mention that since the adjusting notches 1240 corresponding to the large-curvatured regions 116 of the base panel 11 would be deformed more intensively than the notches 1240 corresponding to the small-curvatured regions 115 of the base panel 11, such that the angels of the openings 1244 of the adjusting notches 1240 corresponding to the large-curvatured regions 116 would be decreased more than those of the adjusting notches 1240 corresponding to the small-curvatured regions 115. Therefore, to the angels of the adjusting notches 1240 corresponding to the small-curvatured regions 115 are preferably smaller than those of the adjusting notches 1240 corresponding to the large-curvatured regions 116, such that the two side edges 1242, 1243 of each of the adjusting notches 1240, both corresponding to the large-curvatured regions 116 and corresponding to the small-curvatured regions 115, would be located adjacently with each other, while on overlaps occurs at the same time.

It is important to mention that the angels of the adjusting notches 1240 are varied at different regions of the folding strap 12 for fittedly align with the varying curvatures of the peripheral edge 110 of the base panel 11, wherein the angels of the adjusting notches 1240 in this preferred embodiment are ranged from 15° to 135°.

Those who skilled in the art would easily understand that the base panel 11 may be further defined into more regions, such as six regions or eight regions, according to the curvature distribution of the peripheral edge 110 of the base panel 11, which is not a limit in the present invention. Moreover, the base panel 11 may be embodied in any other shapes, such as peach shape, or crescent shape, in other embodiments of the present invention. Accordingly, the distribution of the adjusting notches 1240 at the folding strap 12 is different and should be re-designed to fit with the curvature variation of the peripheral edge 110 of the differently shaped base panel 11.

Further, an adhesive layer 125 is provided between the folding strap 12 and the base panel 11 for retaining the folding strap 12 at the base panel 11 around the peripheral edge 110 thereof in position, so as to form the surrounding wall 12A of the container 10A thereby. In particular, the adhesive layer 125 is provided at the portion of the folding strap 12 below the folding line 121, wherein when the folding strap 12 is folded around the base panel 11 along the folding line 120, the portion of the folding strap 12 below the folding line 121 is flapped inwardly and extended to contact with a bottom face of the base panel 11, such that the portion of the folding strap 12 below the folding line 121 is stuck to the base panel 11 at the bottom side thereof.

According to the preferred embodiment, the adhesive layer 125 is embodied as a double-sided adhesive element provided at the portion of the folding strap 12 below the folding line 121. Prior to the assembly process, one face of the double-sided adhesive layer 125 is covered by a cover layer, and the cover layer is ripped off to expose the adhesive layer 125 so as to adhere the folding strap 12 to the bottom side of the base panel 11 thereby in the assembly process. It worth mentioning that the adjusting notches 1240 of the self-adjusting arrangement 124 are formed prior to attaching the adhesive layer 125 at the portion of the folding strap 12 below the folding line 121 for keeping the intact structure of the adhesive layer 125.

Those who skilled in the art would easily understand that the adhesive layer 125 can be applied and formed at any time point during the assembly process. For example, in other alternative modes of the preferred embodiment of the present invention, the adhesive layer 125 can be formed by applying a gluing material between the folding strap 12 and the base panel 11, wherein such operation of applying the gluing material can be performed at any time during the assembly process, i.e. prior to the folding operation of the folding strap 12 or after the folding operation of the folding strap 12, which should not be considered as a limitation in the present invention.

As shown in the FIG. 2 and FIG. 3 of the drawings, in order to further facilitate the folding operation of the folding strap 12 around the base panel 11, a portion of the folding strap 12 is integrally affixed at a predetermined position of the base panel 11 for creating an initial precise positioning datum to guide a precise alignment between the folding line 120 of the folding strap 12 and the peripheral edge 110 of the base panel 11.

More specifically, as mentioned above, in case that the folding strap 12 and the base panel 11 are independent components, an operator must cautiously affix a portion of the folding strap 12 at the base panel 11 to establish an initial positioning datum for guiding the further folding operation of the folding strap 12 around the base panel 11, which is of great importance for acquiring a precise actual folding line 120 in line with the designed folding line 120. However, it is not easy to achieve a precise positioning datum in a short period time even for a skilled operator, since even a small offset at the initial positioning datum would result in a big deviation between the ideal folding line 120 and the actual formed folding line.

Accordingly, in the present invention, the initial precise positioning datum is pre-provided prior to the folding operation of the folding strap 12 by integrally coupling the folding strap 12 at the base panel 11. In particular, a mid-portion of the folding strap 126 is integrally coupled at the lower convex vertex portion 111 of the heart-shaped base panel 11, such that the folding strap 12 is integrally and sidewardly extended from the lower convex vertex portion 111 of the base panel 11 in a substantially symmetrical manner. Therefore, the operator could complete the folding operation of the folding strap 12 in a short period of time while enabling the folding strap 12 to have a precise alignment.

It worth mentioning that the length of the folding strap 12 is slightly greater than that of the peripheral edge 110 of the base panel 11, such that when the folding strap 12 encircles around the base panel 11, two end flaps 1271, 1272 of the folding strap 12, defining at the two end portions thereof, are partially overlapped with each other to form an interlocked mechanism 127 for enhancing the bonding connection between the folding strap 12 and the base panel 11, as shown in FIG. 8 of the drawings.

More specifically, as the operator guide the two end flaps 1271, 1272 to encircle the folding strap 12 around the peripheral edge 110 of the base panel 11, the folding strap 12 is potentially to flap away from the peripheral edge 110 due to the rebounding force provided by the bent folding strap 12, prior to bonding the folding strap 12 at the bottom side of the base panel 11 via the adhesive layer 125. In this preferred embodiment, the interlocked mechanism 127 formed by the two end flaps 1271, 1272 of the folding strap 12 remains the folding strap 12 in position for preventing any flapping backward movement thereof prior to the bonding operation of the adhesive layer 125.

Preferably, in this preferred embodiment, the two end flaps 1271, 1272 of the folding strap 12 are overlapped at a position adjacent to upper concave vertex portion 112 of the heart-shaped base panel 11 for the reason that the upper concave vertex portion 112 of the heart-shaped naturally provides a location for the folding strap 12 to ride on and form the interlocking structure 127 thereat conveniently. Moreover, as mentioned above, the folding strap 12 is integrally and sidewardly extended from the lower convex vertex portion 111 of the base panel 11 in a substantially symmetrical manner, such that the main load of the folding strap 12 is centralizedly distributed at the lower convex vertex portion 111 and upper concave vertex portion 112, while the connections between the folding strap 12 and the base panel 11 at the at the lower convex vertex portion 111 and upper concave vertex portion 112 are substantially strengthened by the interlocked mechanism 127 at upper concave vertex portion 112 and the integrally affixing arrangement at the lower convex vertex portion 111 in the present invention. Therefore, the container 10A formed from the foldable packaging container 10 is able to withstand a substantial weight and pressure.

Moreover, in the present invention, an addition adhesion medium 1273 is provided between the two end flaps 1271, 1272 of the folding strap 12 to form the interlocked mechanism 127 thereby. In particular, the additional adhesion medium 1273 might as well embody as a double-sided adhesive element provided at an inner side of one of the two end flaps 1271, 1272 of the folding strap 12, wherein prior to the folding operation, one face of the double-sided adhesive layer 125 is covered by a cover layer, and the cover layer is ripped off to expose the adhesive layer 125 for bonding the two end flaps 1271, 1272 together so as to form the interlocked mechanism 127 thereby. Those who skilled in the art would easily understand that the interlocked mechanism 127 can be embodied in any other form such as hook-and-loop fasteners or the like as long as the interlocked mechanism 127 is able to bond the two end flaps 1271, 1272 of the folding strap 12 together.

Further, as shown in the FIG. 9, the foldable packaging container 10 of the present invention further comprises a cover panel 13, wherein the cover panel 13 is arranged to overlap at the bottom side of the base panel 11 for covering and concealing the folding portions of the folding strap 12 at the bottom side of the base panel 11, so as to enhance the overall aesthetic appearance of the packaging container 10A thereby.

More specifically, the cover panel 13 overlappedly provided at the bottom side of the base panel 11 has a substantially same shape and size with the base panel 11, such that the folding portions of the folding strap 12 exposed to the exterior are substantially covered by the cover panel 13. As such, the overall exterior surface of the container 10A is intact and free from any exterior structural features, facilitating impacting additional decorative elements 130, such as an enterprise logo or other customized designs, thereat conveniently, which is shown in FIG. 10.

It is worth mentioning that the cover panel 13 attached to the bottom side of the base panel 11 further enhances the bonding connection between the folding strap 12 and the base panel 11 to allow the container 10A to withstand a relatively larger load without rupture or detachment.

Further, as shown in FIG. 11 and FIG. 12 of the drawings, the foldable packaging container 10 of the present invention may further comprise a cover 14 such as a covering lid, wherein the cover 14 is supported at an upper portion of the surrounding wall 12A of the container 10A to enclose the item received within the storage cavity. Likewise, the foldable packaging container 10 may further comprises an inner member 15, as shown in FIG. 21, such as a platform or holding device for containing or holding the item to be received in the packaging cavity 13A of the container 10A.

Referring to FIG. 13 to FIG. 17 of the drawings, a producing method of the foldable packaging container 10 is illustrated, wherein the producing method comprises the steps of:

(a) configuring a base panel 11 embodied in a heart shape;

(b) configuring a folding strap 12; and

(c) integrally affixing at least a portion of the folding strap 12 at a predetermined position of the base panel 11;

The configuring step (b) of the folding strap 12 further comprises the steps of:

(b1) forming a folding line 120 along the folding strap 12;

(b2) overlappedly attaching a reinforcing layer 123 to the folding strap 12 at a position that a lower edge of the reinforcing layer 123 substantially overlaps with the folding line 120 and an upper edge of the reinforcing layer 123 is extended upwardly from the lower edge along the folding strap 12; and

(b3) configuring a self-adjusting arrangement 124 at a portion of the folding strap below the folding line 121.

According to the preferred embodiment, the self-adjusting arrangement 124 further has a plurality of adjusting notches 1240 indently formed at the portion of the folding strap 12 below the folding line 121 in a substantially parallel manner, wherein the shapes of the adjusting notches 1240 are preferred to be formed with respect to the curvature of the peripheral edge 110 of the base panel 11, so as to fittedly adjust the bending manner of the folding strap 12 to align with the curvature of the peripheral edge 110 of the base panel 11.

Moreover, the distribution of the adjusting notches 1240 at the folding strap 12 and the angles of the openings 1244 of the adjusting notches 1240 at different portions of the folding strap 12 are corresponding to the curvature distribution of the peripheral edge 110 of the base panel 11, as to prevent the two side edges 113, 114 overlapped with one another in the folding process.

Accordingly, the step (b3) of configuring the self-adjusting arrangement 124 further comprises the steps of:

(b31) indently forming a plurality of adjusting notches 1240 at the portion of the folding strap below the folding line 121 in a substantially parallel manner; and

(b32) distributing the adjusting notches 1240 at the folding strap 12 corresponding to the curvature of the peripheral edge 110 of the base panel 11.

Further, in the step (c) of integrally affixing a portion of the folding strap 12 at a predetermined position of the base panel 11, a mid-portion of the folding strap 126 is integrally coupled at the lower convex vertex portion 111 of the heart-shaped base panel 11, such that the folding strap 12 is integrally and sidewardly extended from the lower convex vertex portion 111 of the base panel 11 in a substantially symmetrical manner.

Accordingly, the step (c) of integrally affixing a portion of the folding strap 12 at a predetermined position of the base panel 11, further comprises the steps of:

(c1) integrally affixing a mid-portion of the folding strap 126 at a lower convex vertex portion 111 of the heart-shaped base panel 11; and

(c2) extending the folding strap 12 sidewardly from the lower convex vertex portion 111 of the base panel 11 in a substantially symmetrical manner.

Further, according to the preferred embodiment of the present invention, an adhesive layer 125 is provided between the folding strap 12 and the base panel 11 for retaining the folding strap 12 at the base panel 11 around the peripheral edge 110 thereof in position, so as to form the surrounding wall 12A of the container 10A.

Accordingly, the adhesive layer 125 can be embodied as a double-sided adhesive element provided at the portion of the folding strap 12 below the folding line 121, wherein prior to the assembly process, one face of the double-sided adhesive layer 125 is covered by a cover layer, and the cover layer is ripped off to expose the adhesive layer 125 for adhering the folding strap 12 to the bottom side of the base panel 11 thereby at the assembly process. It is worth mentioning that the adjusting notches 1240 of the self-adjusting arrangement 124 are formed prior to attaching the adhesive layer 125 at the portion of the folding strap below the folding line 121 for keeping the intact structure of the adhesive layer 125.

Accordingly, the producing method further comprises a step of:

forming a double-sided adhesive layer 125 between the folding strap 12 and the base panel 11 after the step (b2) of configuring the self-adjusting arrangement 124.

It is important to mention that the foldable packaging container 10 can be produced in a single location or different locations. For example, the base panel 11 may be made at a first location (e.g. cutting facility) and then transported to a second location, where the folding strap 12 is made and prepared for being adjoined with the base panel 11.

Referring to FIG. 18 to FIG. 21 of the drawing, the producing method of the present invention further comprises an assembly process to fold and assemble the foldable packaging container 10 to form the container 10A, wherein the assembly process comprises the steps of:

(i) establishing an initial positioning datum by integrally affixing a portion of the folding strap 12 at the base panel 11

(ii) fittedly folding the folding strap 12 around the base panel 11 at the peripheral edge 110 thereof; and

(iii) retaining the folding strap 12 at the base panel 11 in position.

Accordingly, in the step (i) of establishing an initial positioning datum, a mid-portion of the folding strap 126 is integrally coupled at the lower convex vertex portion 111 of the heart-shaped base panel 11, such that the folding strap 12 is integrally and sidewardly extended from the lower convex vertex portion 111 of the base panel 11 in a substantially symmetrical manner.

Further, the step (ii) of fittedly folding the folding strap 12 around the base panel 11 further comprises the steps of:

(ii-1) extending the folding strap 12 along the peripheral edge 110 of the base panel 11, wherein a portion of the folding strap below the folding line 121 is folded inwardly to the bottom side of the panel and the left portion of the folding strap 12 above the folding line 122 is perpendicularly and upwardly extended from the base panel 11;

(ii-2) self-adjusting the shape of the adjusting notch of the adjusting arrangement; and

(ii-3) fitting the bending manner of the folding strap 12 with respect to the curvature of the peripheral edge 110 of the base panel 11.

Accordingly, the step (iii) of retaining the folding strap 12 at the base panel 11 in position, further comprises the steps of:

(iii-1) interlocking two end flaps 1271, 1272 of the folding strap 12 at a convex vertex portion of the base panel 11; and

(iii-2) configuring an adhesive layer 125 between the folding strap 12 and the base panel 11 for retaining the folding strap 12 at the base panel 11 around the peripheral edge 110 thereof in position.

It is important to mention that, in the preferred embodiment, the adhesive layer 125 can be embodied as a double-sided adhesive element provided at the portion of the folding strap below the folding line 121, wherein prior to the assembly process, one face of the double-sided adhesive layer 125 is covered by a cover layer, and the cover layer is ripped off to expose the adhesive layer 125 for adhering the folding strap 12 to the bottom side of the base panel 11 thereby at the assembly process.

Accordingly, the step (iii-2) of configuring the adhesive layer 125 between the folding strap 12 and the base panel 11, further comprises the step of:

(iii-21) exposing the adhesive layer 125 of the double-sided adhesive layer 125; and

(iii-22) bonding the folding strap 12 at the base panel 11 around the peripheral edge 110 thereof in position.

It is worth mentioning that the producing method of the foldable packaging container 10 of the present invention may further comprise a step (d) of providing a cover panel 13 and the assembly process further comprises a step (iv) of overlapping the cover panel 13 at the bottom side of the base panel 11 for concealing the folding portions of the folding strap 12 at the bottom side of the base panel 11.

It worth mentioning that the assembly operation can be easily and precisely performed by an operator even without sufficient experience. Therefore, the present invention successfully provides an economic and efficient solution for providing the container 10A from the foldable packaging container 10 with better performance.

One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.

It will thus be seen that the objects of the present invention have been fully and effectively accomplished. The embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.

Claims

1. A foldable packaging container, comprising:

a base panel having a peripheral edge; and

a folding strap having a folding line defined thereat, wherein said folding strap is arranged to be able to fold around said peripheral edge of said base panel along said folding line thereof to form a tridimensional container which comprises a base portion formed by said base panel and a surrounding wall, formed from said folding strap, extended upwardly from said base portion, wherein said folding strap further comprises a reinforcing layer provided at said folding strap at a position above said folding line of said folding strap.

2. The foldable packaging container as recited in claim 1, wherein a lower edge of said reinforcing layer is substantially overlapped with said folding line to provide an addition folding limit line thereby.

3. The foldable packaging container as recited in claim 2, wherein said base panel is formed in an irregular shape.

4. The foldable packaging container as recited in claim 2, wherein a portion of said folding strap is integrally affixed at said base panel to provide an initial positioning datum.

5. The foldable packaging container as recited in claim 3, wherein a portion of said folding strap is integrally affixed at said base panel to provide an initial positioning datum.

6. The foldable packaging container as recited in claim 5, wherein a mid-portion of said folding strap is integrally affixed at a lower convex vertex portion of said cover panel and said folding strap is sidewardly and integrally extended from said lower convex vertex portion in a substantially symmetrical manner.

7. The foldable packaging container as recited in claim 6, wherein two end flaps of said folding strap, defined at said two end portions thereof, is overlapped with each other to form an interlocked mechanism.

8. The foldable packaging container as recited in claim 7, wherein said two end flaps of said folding strap are overlapped with each other to form said interlocked mechanism at a position at an upper concave vertex portion of said heart-shaped base panel.

9. The foldable packaging container as recited in claim 1, wherein said folding strap further comprises a self-adjusting arrangement formed at a portion of said folding strap below said folding line of said folding strap for adjusting said bending manner of said folding strap with respect to said curvature of said peripheral edge of said base panel.

10. The foldable packaging container as recited in claim 9, wherein said self-adjusting arrangement comprises a plurality of said v-shaped notches indently formed at a portion of said folding strap below said folding line.

11. The foldable packaging container as recited in claim 10, wherein each of said v-shaped notches has a vertex point and two side edges outwardly and inclinedly extended from said vertex point to define an opening therebetween, wherein a size of said opening of each of said adjusting notches is adjustably minimized with respect to said curvature of said peripheral edge of said base panel.

12. The foldable packaging container as recited in claim 11, wherein said notches is distributed corresponding to a varying of said curvature of said peripheral edge of said base panel.

13. The foldable packaging container as recited in claim 12, wherein said adjusting notches, corresponding to said relative large-curvatured portions of said peripheral edge of said base panel, are arranged in a relatively high-density distribution, while said adjusting notches, corresponding to said relatively small-curvatured portions of said peripheral edge of said base panel, are arranged in a low-density distribution.

14. The foldable packaging container as recited in claim 13, wherein angels of openings of said adjusting notches corresponding to said relatively small-curvatured portions are smaller than angles of openings of said adjusting notches corresponding to said relatively large-curvatured portions.

15. The foldable packaging container as recited in claim 14, wherein said angles of said openings of said adjusting notches are ranged from 15° to 135°.

16. The foldable packaging container as recited in claim 8, wherein said folding strap further comprises a self-adjusting arrangement formed at a portion of said folding strap below said folding line of said folding strap for adjusting said bending manner of said folding strap with respect to said curvature of said peripheral edge of said base panel.

17. The foldable packaging container as recited in claim 16, wherein said self-adjusting arrangement comprises a plurality of said v-shaped notches indently formed at a portion of said folding strap below said folding line.

18. The foldable packaging container as recited in claim 17, wherein each of said v-shaped notches has a vertex point and two side edges outwardly and inclinedly extended from said vertex point to define an opening therebetween, wherein a size of said opening of each of said adjusting notches is adjustably minimized with respectively to said curvature of said peripheral edge of said base panel.

19. The foldable packaging container as recited in claim 18, wherein said notches are distributed corresponding to a varying of said curvature of said peripheral edge of said base panel.

20. The foldable packaging container as recited in claim 1, further comprising an adhesive layer provided between said folding strap and said base panel, wherein said adhesive layer is constructed after said self-adjusting arrangement is formed.

21. The foldable packaging container as recited in claim 20, wherein said adhesive layer is a double-sided adhesive element provided at said portion of said folding strap below said folding line.

22. The foldable packaging container as recited in claim 1, further comprising a cover panel arranged to overlap at a bottom side of said base panel to cover and conceal said folding portions of said folding strap at said bottom side of said base panel.

23. The foldable packaging container as recited in claim 22, wherein said cover panel overlappedly provided at said bottom side of said base panel has a substantially same shape and size with said base panel.

24. The foldable packaging container as recited in claim 1, further comprising a cover supported at an upper portion of said surrounding wall of said packaging container for enclosing an item received therein.

25. A producing method of a foldable packaging container comprising the steps of:

configuring a base panel having a peripheral edge; and

integrally affixing at least a portion of a folding strap at said base panel, wherein said folding strap comprises a folding line along said folding strap, wherein said folding strap is arranged to be able to fold around said peripheral edge of said base panel along said folding line thereof to form a tridimensional container which comprises a base portion formed by said base panel and a surrounding wall, formed from said folding strap, extended upwardly from said base portion, wherein said folding strap further comprises a reinforcing layer provided at said folding strap at a position above said folding line of said folding strap.