Paperboard container with sidewall features and method of manufacturing thereof
A disposable paperboard container, and method for manufacturing the same, formed into a geometric shape having a bottom wall with a bottom transition segment about the periphery of the bottom wall leading to an upstanding sidewall extending to an upper rim, wherein an undulation of paperboard resides along the peripheral area of the lower portion of the sidewall to form a stepped lower sidewall, the stepped lower sidewall being joined to a smooth upper sidewall that extends upward tapered outward; wherein the stepped lower sidewall includes a first bend and a second bend of paperboard about the periphery of the lower sidewall and a transition segment between the first and second bend extends radially outward to form a rim about the peripheral area of the lower portion of the sidewall.
1 . A disposable container constructed of paperboard formed into a geometric shape, the container comprising a bottom wall joined to an upwardly extending sidewall leading to an outwardly extending upper rim, said bottom wall having a central portion and an outer peripheral area bordered by a bottom radius formed as a curved bottom transition segment joining the bottom wall to the sidewall, wherein said sidewall has a sidewall height between said curved bottom radius and said outwardly directed upper rim the container; wherein
an upper portion of the sidewall has a generally smooth tapered configuration that extends upward and outwardly, and a lower portion of the sidewall has a stepped configuration immediately adjacent and extending from said curved bottom transition segment, said stepped configuration comprising a lower bend directing the paperboard to join the curved bottom transition segment to an outwardly extending rim segment, and said rim segment is joined with an upper bend directing the paperboard generally upward from said outwardly extending rim segment to said upper portion of the sidewall, wherein said lower bend has an inner convex surface and said upper bend has an inner concave surface and said outwardly extending rim segment has a flat upper surface.
2 . The disposable paperboard container of claim 1 , wherein the entirety of said stepped configuration resides within a lower half of said sidewall height.
3 . The disposable paperboard container of claim 1 , wherein said outwardly extending rim segment resides within a lower quarter of said sidewall height.
4 . The disposable paperboard container of claim 1 , wherein said stepped configuration is positioned immediately adjacent said bottom radius to form an expanded bottom area located radially outward from the bottom wall.
5 . The disposable paperboard container of claim 1 , wherein the bottom wall has a central portion having a generally domed shape such that a central portion of the bottom wall resides at a height above the outer peripheral area of the bottom wall.
6 . The disposable paperboard container of claim 1 , wherein said outwardly extending rim segment of the stepped configuration has a radial span that is approximately 0.04 inches.
7 . The disposable paperboard container of claim 1 , wherein said geometric shape of the container comprises a paper plate with a substantially round outer periphery.
8 . The disposable paperboard container of claim 1 , wherein said geometric shape of the container comprises a paperboard platter with an elongated outer peripheral shape.
9 . The disposable paperboard container of claim 1 , wherein said geometric shape of the container comprises a outer peripheral shape having elongated sides.
10 . A disposable container constructed of paperboard that is formed into a geometric shape having a bottom wall having a central portion and an outer peripheral area bordered by a bottom radius joining the bottom wall to an upstanding sidewall that extends radially outward and upward to an upper rim portion extending radially outwardly from the top of the sidewall, wherein said sidewall has a sidewall height comprised of a lower sidewall portion adjacent the bottom wall and an upper sidewall portion adjacent said upper rim portion, comprising;
an undulation of paperboard formed about a circumference of the sidewall immediately adjacent said bottom radius and said undulation resides within the lower portion of the sidewall, said undulation having a first curved segment extending from the bottom radius to an outwardly extending transition segment and a second curved segment extending upwardly to join the transition segment to said upper portion of the sidewall, wherein said outwardly extending transition segment has a flat upper surface.
11 . The disposable container of claim 10 , wherein said outwardly extending transition segment has a radial span of about 0.04 inch.
12 . The disposable container of claim 10 , wherein said first curved portion is an outwardly directed bend of the paperboard extending from said bottom radius, wherein said undulation is positioned immediately adjacent the bottom radius to form an expanded bottom area positioned radially outward of the bottom wall.
13 . The disposable container of claim 10 , wherein the entirety of the sidewall undulation resides in the lower half of the height of the sidewall.
14 . The disposable container of claim 10 , wherein the outwardly extending transition segment resides in the bottom quarter of the height of the sidewall.
15 . The disposable container of claim 10 wherein said geometric shape of the container comprises a paper plate with a substantially round outer periphery.
16 . The disposable container of claim 10 wherein said geometric shape of the container comprises a paperboard platter with an elongated outer peripheral shape.
17 . The disposable container of claim 10 wherein said geometric shape of the container comprises a peripheral shape having elongated sides.
18 . The disposable container of claim 10 , wherein said outwardly extending transition segment comprises a rim with an upper surface having a radial span of about 0.04 inches.
19 . A method of manufacturing a disposable paperboard container comprising the steps of:
providing a paperboard blank with an outer peripheral dimension;
applying pressure to said blank between forming dies having mating projections and recesses to form a geometric shape of a container having a bottom wall and a peripheral bottom radius, wherein said peripheral bottom radius joins the bottom wall to a sidewall portion that extends upwardly to an outwardly extending rim;
wherein said method of forming a geometric shape of the container comprises the step of applying pressure to the paperboard between forming dies having a mating projection and recess to form a stepped configuration of the paperboard within the sidewall, said stepped configuration of paperboard comprising a first bend of paperboard joining said peripheral bottom radius to an outwardly extending transition segment which leads to a second bend of paperboard joining the stepped configuration to a smooth portion of the sidewall, and wherein said outwardly extending transition segment comprises a substantially flat upper surface.
20 . The method of claim 19 wherein forming a stepped configuration of paperboard in the sidewall comprises applying pressure to said paperboard between forming dies to form an undulation of the paperboard within a lower half of an overall height of the sidewall.
21 . The method of claim 19 wherein forming the stepped configuration of paperboard in the sidewall comprises forming said outwardly extending transition segment with a substantially flat upper surface having a radial span of about 0.04 inch.
22 . The method of claim 19 wherein said stepped configuration of paperboard is formed in the sidewall about the entire circumference of the sidewall.
23 . The method of claim 19 wherein said stepped configuration of paperboard is formed within a lower half of the sidewall immediately adjacent the bottom radius to form an expanded bottom area positioned radially outward of the bottom wall.