The teachings herein relate to food containers and methods for preparing, storing and/or transporting food items.
U.S. Pat. No. 6,231,906 (Alessi) discloses a packaging system for tart shells that includes transparent lower and upper halves connected together and lockable together by protrusions and recesses in the halves. The upper and lower halves have one or more chambers defined by chamber halves formed in the lower and upper halves that combine together to form each chamber. In the preferred embodiments, anywhere from one to eight chambers may be provided in the packaging system. Concerning each such chamber, the lower half of the packaging system includes a recess sized and configured to receive the undersurface of a tart shell. The upper chamber half includes a generally dome-shaped portion designed to overlie a recess within the tart shell that is normally filled with an edible material and has a lower periphery spaced radially inwardly from the lower periphery of the lower chamber half. Radially outwardly from the lower periphery of the dome-shaped portions, a ledge is formed that overlies the outer periphery of the lower chamber half. This ledge is sized and configured to capture the periphery of a tart shell contained within the chamber and prevents movement of the tart shell out of snug engagement with the lower chamber half.
U.S. Patent Application Publication No. 2009/0242569 (Solmon) discloses a food product package capable of stabilizing a food product being stored therein. The food product package may include a base, a cover and an insert. The cover may be fastened to the base and the insert may be disposed between the base and the cover. A body of the base may include at least one pocket adapted to hold a food product, such as a cupcake. The insert may be positioned onto the base such that an edge portion of the insert may contact the food product. When the cover is fastened to the base, a portion of the cover may press the insert against the base to thereby securely hold the food product in place.
U.S. Pat. No. 6,176,375 (Truscell et al.) discloses a container that has a hollow base and a cap to store a filled food product having an edible shell with a peripheral flange. The base has a top member with an opening, a bottom member and an upstanding wall member that connects the top and bottom members. The opening in the top member and the upstanding wall member are dimensioned such that the shell is capable of being partially contained within and supported by the base while the flange of the shell is vertically spaced above the uppermost part of the base. The cap is connected to the base to enclose the filled food product. The cap is dimensioned and configured such that, when the filled food product is positioned in the base and the cap is connected to the based to enclose the food product, a middle portion of the cap engages the flange and projects downwardly therefrom, and a lower portion of the cap closes the cap to the base such that the cap presses the filled food product to the base. The container thereby prevents movement of the filled food product relative to the base, while the flange is vertically spaced above the uppermost part of the base to enable the filled food product to be gripped by the flange for easy removal from the base.
This summary is intended to introduce the reader to various aspects of the applicant's teaching, but not to define any invention. In general, disclosed herein are one or more containers and methods using the containers to store and transport food items, including decorated food items.
In accordance with at least one broad aspect of the teachings described herein, a combination of a container and a plurality of food items nested within the container includes a base having a base peripheral edge and at least a first cavity and a second cavity in the base to receive respective ones of the food items. The first cavity may include a first inner surface extending along a first cavity axis generally terminating in a first cavity rim and the second cavity may include a second inner surface extending along a second cavity axis and generally terminating in a second cavity rim. A first food item may be item nested in the first cavity. The first food item may include a first outer surface supported by the first inner surface of the first cavity and a first upper surface. The first upper surface may have a first decorated section at least partially bounded by a first food item undecorated peripheral section. A second food item may be nested in the second cavity. The second food item may have a second outer surface supported by the second inner surface of the second cavity and a second upper surface. The second upper surface may have a second decorated section at least partially bounded by a second food item undecorated peripheral section. The combination may include a lid having a lid peripheral edge and an upper lid surface. The lid may be movable between a closed position, in which the lid peripheral edge is engaged with the base peripheral edge and the upper lid surface covers at least a portion of each cavity, and an open position in which the lid peripheral edge and base peripheral edge are disengaged to allow access to the food items. At least a first protrusion may extend downwardly from the upper lid surface when the lid is in the closed position. The first protrusion may have a distal end spaced apart from the upper lid surface. The first protrusion may include a first protrusion first retainer adjacent the distal end of the first protrusion. When the lid is in the closed position the first protrusion first retainer may be proximate the upper surface of the first food item and may overlie a portion of the first food item undecorated peripheral section of the first food item to inhibit relative axial movement between the first food item and the first cavity to retain the first food item within the first cavity without damaging the first decorated section when the container is inverted. The first protrusion may also include a first protrusion second retainer adjacent the distal end of the first protrusion. When the lid is in the closed position the first protrusion second retainer may be proximate the upper surface of the second food item and may overlie a portion of the undecorated peripheral section of the second food item to inhibit relative axial movement between the second food item and the second cavity to retain the second food item within the second cavity without damaging the second decorated section when the container is inverted.
When the lid is in the closed position the first protrusion first retainer may contact the first food item undecorated peripheral section.
When the lid is in the closed position the spacing in a direction parallel to the first cavity axis between the first food item undecorated peripheral section and the first protrusion first retainer may be between about 0 mm and about 10 mm.
When the lid is in the closed position an uppermost portion of the decorated portion of the first food item may be axially spaced apart from the upper lid surface by a decoration spacing distance and the first protrusion first retainer may be axially spaced apart from the first food item undecorated peripheral section by a retainer spacing distance that is less than the decoration spacing distance.
The first cavity may have a first cavity sidewall and a first cavity bottom wall. The first cavity sidewall may extend downwardly from the first cavity rim to the first cavity bottom wall. The first cavity rim and the first cavity sidewall may be coaxial about the first cavity axis. The first protrusion may extend lengthwise along a first protrusion axis, and the first protrusion first retainer may terminate laterally at a first retainer edge. The first retainer edge may be disposed laterally intermediate the first cavity rim and the first cavity axis when the lid is in the closed position.
The first protrusion first retainer further comprises a first abutment surface extending laterally outwardly from the first retainer edge towards the first protrusion axis, and when the lid is in the closed position the first abutment surface generally faces the at least a portion of the first food item undecorated peripheral section of the first food item in the first cavity and is generally parallel to a plane containing the first cavity rim.
The first cavity may have a first cavity depth measured from the plane containing the first cavity rim to the first cavity bottom wall in the direction the first cavity axis. When the lid is in the closed position a longitudinal distance between the first abutment surface and the plane containing the first cavity rim may be less than 15% of the first cavity depth.
The first retainer edge may have a length that is between about 5% and about 50% of the length of the first cavity rim.
The container may be of one-piece, integrally formed unitary construction comprising the base, lid, the first protrusion extending downwardly from the lid, the first protrusion first retainer and the first protrusion second retainer, and a hinge that pivotably connects the lid and the base for moving the lid between the open and closed positions.
A first protrusion engagement member may be provided on the distal end of the first protrusion and a mating first base engagement member may be on the base. When the lid is in the closed position the first protrusion engagement member may engage the first base engagement member to laterally align the first protrusion relative to the base.
The lid may include a lid sidewall extending between the lid peripheral edge and the upper lid surface. A sidewall first retainer may extend laterally inward from the lid sidewall. When the lid is in the closed position the sidewall first retainer may extend laterally inwardly from the lid sidewall and may overlie a portion of the first food item undecorated peripheral section to inhibit relative axial movement between the first food item and the first cavity to retain the first food item within the first cavity without damaging the first decorated section when the container is inverted.
When the lid is in the closed position the sidewall first retainer may extend laterally inward of the first cavity rim.
The first food item may include an edible body portion and a disposable wrapper at least partially surrounding the edible body portion and disposed between the body portion and the first inner surface. The wrapper may include an exposed upper wrapper edge and may be removable from the edible body portion prior to consumption of the first food item. The first food item undecorated peripheral section may include the upper wrapper edge.
The edible body portion may include a body portion upper surface comprising the decorated section and an undecorated body surface portion surrounding the decorated section and the first food item undecorated peripheral section may include the undecorated surface portion of the edible body portion.
The first protrusion may include a hollow interior and the lid upper surface may include a lid aperture in communication with the hollow interior. The lid aperture and hollow interior may be sized to accommodate insertion of a thumb or a finger of a user grasping the container.
The base peripheral edge may include a base sealing member having at least first, second and third base sealing surfaces, and the lid peripheral edge may include a lid sealing member having at least corresponding first, second and third lid sealing surfaces. When the lid is in the closed position, each base sealing surface may engage one corresponding lid sealing surface to seal the container.
One of the base sealing member and the lid sealing member may include a tongue member and the other of the base sealing member and the lid sealing member comprises a groove sized to snugly and releasably receive the tab member when the lid is in the closed position.
The tongue member may include at least one first securing member and the groove may include at least one complimentary second securing member. When the lid is in the closed position the first securing member may engage the second securing member to releasably secure the lid in the closed position.
The tongue member may include an inner seal edge and an outer seal edge that is laterally spaced outwardly from the inner seal edge by a seal offset distance. The first, second and third base sealing surfaces may define respective surface widths, and the sum of the widths of the first, second and third base sealing surfaces may be greater than the seal offset distance.
According to another broad aspect of the teachings described herein a combination of a container and a plurality of food items nested within the container may include base having a base peripheral edge and a first cavity in the base. The first cavity may include a first inner surface extending along a first cavity axis and generally terminating in a first cavity rim. A first food item may be nested in the first cavity. The first food item may include a body portion having an upper body surface. The body upper surface may have a decorated section. The first food item may include a disposable wrapper provided on the body portion and disposed between the body portion and the first inner surface. The wrapper may include an exposed upper wrapper edge at least partially surrounding the decorated section of the upper body surface. The wrapper may be removable from the body portion prior to consumption of the first food item. The container may include a lid having a lid peripheral edge and an upper lid surface. The lid may be movable between a closed position, in which the lid peripheral edge is engaged with the base peripheral edge and the upper lid surface covers at least a portion of each cavity, and an open position in which the lid peripheral edge and base peripheral edge are disengaged to allow access to the food items. A first retainer may be on the lid. When the lid is in the closed position the first retainer may extend generally inwardly toward the first cavity axis proximate the first food item and may overlie a first portion of the upper wrapper edge. When the container is inverted with the lid in the closed position relative axial movement between the first food item and the first cavity may be limited by contact between the first retainer and the upper wrapper edge to inhibit damaging the decorated section.
When the lid is in the closed position the sidewall first retainer may the first portion of the upper wrapper edge.
When the lid is in the closed position the sidewall first retainer may be axially spaced apart from the first portion of the upper wrapper edge by between about 0 mm and about 10 mm.
When the lid is in the closed position an uppermost portion of the decorated portion of the first food item may be axially spaced apart from the upper lid surface by a decoration spacing distance and the first protrusion first retainer may be axially spaced apart from a plane containing the wrapper upper edge by a retainer spacing distance that is less than the decoration spacing distance.
The first cavity may have a first cavity sidewall and a first cavity bottom wall. The first cavity sidewall may extend downwardly from the first cavity rim to the first cavity bottom wall. The first cavity rim and the first cavity sidewall may be coaxial about the first cavity axis. The first retainer may terminate laterally at a first retainer edge that is laterally intermediate the first cavity rim and the first cavity axis when the lid is in the closed position.
A second retainer may be disposed on the lid and when the lid is closed the second retainer may be proximate the first food item and may overlie a second portion of the upper wrapper edge whereby when the container is inverted with the lid in the closed position relative axial movement between the first food item and the first cavity may be limited by contact between the second retainer and the upper wrapper edge.
A first protrusion may extend downwardly from the upper lid surface when the lid is in the closed position. The first protrusion may have a distal end spaced apart from the upper lid surface. When the lid is in the closed position the distal end of the first protrusion may be proximate the upper surface of the first food item and the distal end of the first protrusion may provide the second retainer.
The first protrusion may include a hollow interior and the lid upper surface may include a lid aperture in communication with the hollow interior. The lid aperture and hollow interior may be sized to accommodate insertion of a thumb or a finger of a user grasping the container.
According to another broad aspect of the teachings described herein, a container for holding a plurality of food items may include a base having a base peripheral edge and plurality of cavities in the base. Each cavity may have an inner surface generally terminating in a cavity rim. The plurality of cavities may include at least a first cavity having a first cavity rim and a second cavity having a second cavity rim. The container may include a lid having a lid peripheral edge and an upper lid surface. The lid may be moveable between a closed position, in which the lid peripheral edge engages the base peripheral edge and the upper lid surface covers at least a portion of each cavity, and an open position to allow access to the plurality of cavities. At least one protrusion may extend downwardly from the upper lid surface when the lid is in the closed position. The protrusion may have a distal end that is spaced apart from the upper lid surface. A first retainer may be adjacent the distal end of the at least one protrusion. When the lid is in the closed position the first retainer may be positioned proximate the first cavity to engage a first food item nested within the first cavity so that when the lid is in the closed position and the container is inverted relative movement between the first food item and the first cavity is limited by contact between the first food item and the first retainer. A second retainer may be adjacent the distal end of the at least one protrusion, and when the lid is in the closed position the second retainer may be positioned proximate the second cavity to engage a second food item nested within the second cavity so that when the lid is in the closed position and the container is inverted relative movement between the second food item and the second cavity is limited by contact between the second food item and the second retainer.
When the lid is in the closed position the first retainer may extend laterally inwardly of the first cavity rim and may overlie a portion of the first cavity.
The first cavity may have a first cavity sidewall and a first cavity bottom wall. The first cavity sidewall may extend downwardly from the first cavity rim to the first cavity bottom wall. The first cavity rim and the first cavity sidewall may be coaxial about a first cavity axis. The first protrusion may extend longitudinally along a first protrusion axis. The first retainer may terminate laterally at a first retainer edge that is laterally intermediate the first cavity rim and the first cavity axis when the lid is in the closed position.
The first retainer may also include a first abutment surface extending laterally outwardly from the first inner edge. When the lid is in the closed position the first abutment surface may be generally downward facing and may be generally parallel to a plane containing the first cavity rim.
The first cavity may have a first cavity depth measured in the direction the cavity axis. When the lid is in the closed position a longitudinal distance between the first abutment surface and the first cavity rim may be less than about 15% of the first cavity depth.
A length of the first retainer edge comprises between 5%-35% of the length of the first cavity rim.
When the lid is in the closed position the second retainer may extend laterally inwardly of the second cavity rim and may overlie a portion of the second cavity.
The container may be of one-piece, integrally formed unitary construction comprising the base, lid, the first protrusion extending from the lid, the first retainer and the second retainer and a hinge that pivotably connects the lid and the base for moving the lid between the open and closed positions.
A protrusion engagement member may be provided on the distal end of the at least one protrusion and a mating base engagement member may be on the base. When the lid is in the closed position the protrusion engagement member may engage the base engagement member.
The lid may include a lid sidewall extending between the lid peripheral edge and the upper lid surface. A sidewall retainer may extend laterally inward from the lid sidewall. When the lid is in the closed position the sidewall retainer may extend laterally inwardly of the cavity rim of the first cavity.
According to yet another broad aspect of the teachings described herein, a unitary one-piece container for holding a plurality of food items may include a base having a base peripheral edge and at least four cavities arranged in a two-by-two pattern in the base. Each cavity may be configured to receive a respective one of the plurality of food items and may have a cavity inner surface generally terminating at a cavity rim and extending along a cavity axis. The at least four cavities may include a first cavity, a second cavity, a third cavity and a fourth cavity. The container may include a lid having a lid peripheral edge and an upper lid surface. A portion of the lid peripheral edge may be hingedly connected to the base peripheral edge so that the lid is moveable between a closed position, in which the lid peripheral edge engages the base peripheral edge to seal the container and the upper lid surface covers at least a portion the first, second, third and fourth cavities, and an open position to allow access to the first, second, third and fourth cavities. A retaining protrusion may extend longitudinally from the upper lid surface. The retaining protrusion may have a distal end that is spaced apart from the upper lid surface. When the lid is in the closed position the retaining protrusion may extend from the upper lid surface proximate the base and may be disposed between the first, second, third and fourth cavities in a lateral direction. A protrusion first retainer may be adjacent the distal end of the retaining protrusion, and when the lid is in the closed position the protrusion first retainer may be disposed proximate the first cavity to overlie an undecorated portion of a first food item nested within the first cavity to inhibit relative axial movement between the first food item and the first cavity. A protrusion second retainer may be adjacent the distal end of the retaining protrusion, and when the lid is in the closed position the protrusion second retainer may be disposed proximate the second cavity to overlie an undecorated portion of a second food item nested within the second cavity to inhibit relative axial movement between the second food item and the second cavity. A protrusion third retainer may be adjacent the distal end of the retaining protrusion, and when the lid is in the closed position the protrusion third retainer may be disposed proximate the third cavity to overlie an undecorated portion of a third food item nested within the third cavity to inhibit relative axial movement between the third food item and the third cavity. A protrusion fourth retainer may be adjacent the distal end of the retaining protrusion, and when the lid is in the closed position the protrusion fourth retainer may be disposed proximate the fourth cavity to overlie an undecorated portion of a fourth food item nested within the fourth cavity to inhibit relative axial movement between the fourth food item and the fourth cavity.
When the lid is in the closed position, the protrusion first retainer may extend laterally inwardly of the cavity rim of the first cavity, the protrusion second retainer may extend laterally inwardly of the cavity rim of the second cavity, the protrusion third retainer may extend laterally inwardly of the cavity rim of the third cavity and the protrusion fourth retainer may extend laterally inwardly of the cavity rim of the fourth cavity.
The first cavity may have a first cavity sidewall and a first cavity bottom wall. The first cavity sidewall may extend downwardly from the first cavity rim to the first cavity bottom wall. The first cavity rim and the first cavity sidewall may be coaxial about a first cavity axis. The first protrusion may extend longitudinally along a first protrusion axis, and the first retainer may terminate laterally at a first retainer edge. The first retainer edge may be disposed laterally intermediate the first cavity rim and the first cavity axis when the lid is in the closed position.
The first retainer further may include a first abutment surface extending laterally outwardly from the first inner edge. When the lid is in the closed position the first abutment surface may be generally downward facing and is generally parallel to a plane containing the first cavity rim.
The first cavity may have a first cavity depth measured in the direction the cavity axis, and when the lid is in the closed position a longitudinal distance between the first abutment surface and the first cavity rim may be less than about 15% of the first cavity depth.
A length of the first retainer edge may be between 5%-35% of the length of the first cavity rim.
The first protrusion may include a hollow interior and the lid upper surface comprises a lid aperture in communication with the hollow interior, the lid aperture and hollow interior sized to accommodate insertion of a thumb or a finger of a user grasping the container.
According to yet another broad aspect of the teachings described herein, a container may include a base having a base peripheral edge and a plurality of cavities in the base. Each cavity may be for holding a respective food item and may have an open upper end bounded by a cavity rim. The container may include a lid having a lid peripheral edge and a covering surface laterally internal of the lid peripheral edge. The lid may be movable relative to the base between an open position in which the base is generally uncovered by the lid, and a closed position in which the lid generally covers the base and the lid peripheral edge is engaged with the base peripheral edge. At least one retaining protrusion may depend downwardly from the covering surface of the lid. The retaining protrusion may extend along a protrusion axis that is oriented generally vertically when the lid is in the closed position. The protrusion axis may be laterally spaced between two or more of the plurality of cavities. A plurality of retainers may be associated with each cavity and affixed to the lid. Each retainer may extend laterally inwardly of the cavity rim of the respective cavity when the lid is in the closed position. At least one of the retainers associated with each cavity may be disposed on a respective one of the at least one retaining protrusions.
The container may be of one-piece, integrally formed, unitary construction, the container further comprising a hinge member connecting together the lid and the base, the hinge member defining a hinge axis about which the lid is pivotable relative to the base when moving the lid between the open and closed positions.
The at least one retaining protrusion may include a first protrusion having a distal end spaced apart from the cover surface of the lid and a plurality of retainers adjacent the distal end.
Each cavity may have a respective cavity axis extending generally parallel to the protrusion axis when the lid is in the closed position. When the lid is in the closed position each retainer may be disposed laterally intermediate the cavity rim and cavity axis of the respective cavity.
The plurality of cavities may include a first cavity having a first cavity axis, a second cavity having a second cavity axis, a third cavity having a third cavity axis and a fourth cavity having a fourth cavity axis. When the lid is in the closed position, the at least one retaining protrusion may be disposed laterally between the first, second, third and fourth cavities and the protrusion axis may be generally equidistant from the first, second, third and fourth cavity axes.
When the lid is in the closed position, the protrusion axis may be located at the intersection of a first plane extending between the first and third cavity axes, and a second plane extending between the second and fourth cavity axes.
According to yet another broad aspect of the teachings described herein, a method of providing packaged food items on display in a retail store may include the steps of:
a) preparing a plurality of food body portions of respective food items in a preparation facility;
b) decorating each of the food body portions of the food items with a decoration portion on an upper surface of the food base portion;
c) after steps a) and b), loading each of the decorated food items into respective cavities of a container, the container may have a lid with at least one protrusion, the protrusion may have at least a first retainer and a second retainer extending laterally outwardly from a distal end of the protrusion;
d) after step (c), closing the lid, wherein closing the lid moves the first retainer to engage a first marginal portion of a first upper surface of a first food item in the container and moves the second retainer to engage a second marginal portion of a second upper surface of a second food item in the container; and
e) after step (d), transporting the container away from the preparation facility for indirect or direct delivery to the retail store.
After steps (a) and (b), and before step (e), the method may include freezing the decorated food items.
After step (e), the method may include placing the container for display on a sales shelf in the retail store.
Before said placing step, the method may include thawing the decorated food items.
According to yet another broad aspect of the teachings described herein, a method of packaging decorated food items for transport may include the step of preparing a first food item in a preparation facility. The first food item may include an edible body portion. The edible body portion may include an upper body surface and a side surface. The side surface may be at least partially covered by a removable wrapper. The removable wrapper may terminate in an upper wrapper edge at least partially surrounding the upper body surface.
The method may also include decorating at least a portion of the upper body surface with an edible decoration portion to provide a decorated section and loading the first food item into a respective first cavity in a base of a container. The cavity may extend along a cavity axis and the container having a closable lid with at least first and second retainers.
The method may include closing the lid, wherein closing the lid moves the first and second retains to overlie respective first and second portions of the upper wrapper edge whereby when the container is inverted with the lid closed relative axial movement between the first food item and the first cavity is limited by contact between the upper wrapper edge and at least one of the first and second retainers.
The method may also include transporting the container away from the preparation facility for indirect or direct delivery to the retail store.
The method may also include freezing the decorated food items.
The method may also include placing the container for display on a sales shelf in the retail store.
The method may also include thawing the decorated food items.
The drawings included herewith are for illustrating various examples of containers that include one or more aspects of the teaching of the present specification and are not intended to limit the scope of what is taught in any way. In the drawings:
Various apparatuses, and/or methods will be described below to provide an example of an embodiment of the invention. No embodiment described below limits any claimed invention and any claimed invention may cover apparatuses or methods that differ from those described below. The claimed inventions are not limited to apparatuses or methods having all of the features of any one apparatus or method described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or method described below is not an embodiment of any claimed invention. Any invention disclosed in an apparatus or method described below that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors or owners do not intend to abandon, disclaim or dedicate to the public any such invention by its disclosure in this document.
Containers for storing or transporting food items can include a base and an openable lid. The lid and base can be sealingly connectable to each other when the lid is in the closed position to help maintain the freshness of the food items in the container. The lid can be removable from the base (to an open position) to allow a user to open the container and access the food items.
The base of the container can include a plurality of cavities for holding the food items. For example, if the food items are cupcakes, the base of a container can include a plurality of cavities that are configured to snugly receive at least a portion of the cupcakes, for example the baked, body portion of the cupcake.
After each cupcake is prepared and decorated it can be placed within a respective cavity in a container. Nesting each cupcake (or other food item) within a respective cavity can help retain the cupcake in two, lateral directions, for example the “x” and “y” directions or the left-right and forward-backward directions. Nesting the cupcakes in this manner may help prevent the cupcakes from shifting laterally relative to the container base when the container is transported, for example when carried in a delivery truck. Preventing lateral movement of the cupcakes may help prevent neighbouring cupcakes from sliding and contacting each other or the sides of the container. Contact between adjacent cupcakes or between the cupcakes and the container may damage the cupcakes. Such contact may also disturb or damage any frosting or other decorations provided on top of the cup cake.
While nesting the cupcakes in individual cavities may help reduce lateral movement, in some instances it may not be sufficient to inhibit vertical movement of the cupcakes relative to the container. For example, with some containers known in the prior art, jostling or shaking of the container (for example, when loaded on a delivery truck traveling along a bumpy road), cupcakes (or other food items) loaded in the container may shift vertically, i.e. in the “z” direction, relative to the container. Containers may also be inverted in the retail store by a customer inspecting the container, during the purchasing and/or checkout process, and/or at other times. Such vertical shifts may cause portions of the cupcakes, particularly the upper, decorated or frosted portions, to contact an upper portion of the container (for example the inner surface of the lid). Such contact may be generally undesirable for several reasons, including because it can ruin the aesthetic appeal of the decoration, can cause unsightly sticking of the decoration material to the inner surface of the lid, and can leave a consumer of the cupcake without the enjoyment of eating the icing or other decoration portion of the cupcake. The Applicant has discovered that providing retainers in the container may help inhibit vertical movement of a cupcake relative to its cavity. That is, when the container is tilted and/or inverted, axial or vertical movement of the cupcakes relative to their respective cavities may be limited by contact between the container's retainers and some portion of the food item. Optionally, the retainers and cupcake can be configured so that the retainers will contact undecorated portions of the cupcake, for example the undecorated peripheral section of the cupcake that surrounds the central decorated section, without contacting the decorated section or otherwise contacting the frosting.
Inhibiting the vertical or axial movement of the cupcakes relative to their respective cavities may help secure the cupcakes within their cavities and may help prevent unwanted contact between the cupcakes, particularly the decorated portions of the cupcakes, and the container lid (or other portions of the container, or other food items).
When using known food containers, one method of preventing damage to the frosting or other decorative portions of a food item, such as a cupcake, is to provide the cupcakes in an undecorated state (i.e. having no frosting or decoration that can be damaged during shipping) at a desired retail store. The undecorated food items (also called ‘blanks’) can be produced (e.g. baked) on-site at the store, or they can be produced off-site and shipped in an undecorated state to the store. However, if decorated cupcakes are desired, an in-store decorator employee is generally required. In some circumstances it may not be feasible or desirable to provide an in-store decorator in each retail store. The Applicant has discovered that it may be advantageous to decorate the cupcakes at a preparation facility before they are delivered to a retail grocery store, and then ship the cupcakes in a decorated state. For example, the cupcakes can be decorated at their manufacturing location (where the blanks are produced), or optionally at another intermediate location, such as a decorating facility. Decorating the blanks in a higher volume, mass-production facility may justify the investment of using automated equipment to apply the decorating. Utilizing automated decorating equipment may increase consistency of the decoration, allow for greater flexibility and complexity of the decoration being applied, and may reduce labour costs, particularly at the retail store level.
One method of providing packaged decorated food articles, for example cupcakes, for display and sale in a retail store can include the step of preparing a plurality of blanks (e.g. cupcake body portions) in a preparation facility. The cupcake bodies can then be decorated with a decoration portion (e.g. frosting, etc.) on an upper surface of the blank. After the cupcakes are decorated they can be loaded into respective cavities of a container. Optionally, the container can be a container having a lid with at least one protrusion that has at least a first retainer and a second retainer extending laterally outwardly from a distal end of the protrusion, as described in more detail below. The container lid can then be closed. If the container contains at least two cupcakes, closing the lid can move the first retainer to engage a first marginal portion of a first upper surface of a first cupcake in the container. Closing the lid can also move the second retainer to engage a second marginal portion of a second upper surface of a second cupcake in the container. A user can then transport the container away from the preparation facility for indirect or direct delivery to the retail store.
Optionally, the decorated food articles can be frozen prior to being shipped (i.e. at the preparation facility). Containers containing a plurality of frozen decorated cupcakes can then be displayed in-store in their frozen state (e.g. in a grocer's freezer section). Alternatively, the decorated cupcakes can be thawed prior to being displayed in-store.
Referring to
The container 100 also includes a lid 108 having a lid peripheral edge 110, an upper lid surface 112 (see also
Optionally, when the lid 108 is in the closed position the engagement of the peripheral edges of the base and lid 102, 108, can provide a generally air-tight seal. Providing a seal around the periphery of the container 100 may help keep the cupcakes or other food items fresh while they are stored in the container. Referring to
The lid 108 includes a corresponding lid sealing member, which may be any element that is configured to sealingly engage with the base sealing member. Referring to
Referring to
When the lid 108 is closed, an air flow passage is defined between the opposed pairs of sealing surfaces 119a-c and 124a-c. In the illustrated example, the length of the air flow passage is defined by the sum of the widths 120a-c of the base sealing surfaces 119a-c. Preferably, the engagement between the tongue 118 and groove 122 (i.e. contact between opposed sealing surfaces 119a-c and 124a-c) is sufficient to substantially inhibit air flow in and out of the container through the air flow passage to help preserve the freshness of the cupcakes, but is not so tight as to significantly impede opening the container 100. Configuring the tongue 118 and groove 122 to be generally easy to separate from each other may help reduce the amount of force a user must apply to open the container 100, and/or may help lessen the jolt or shock to the container 100 when the lid 108 is opened. This may help reduce the likelihood that cupcakes in the base 102 will be jostled or shaken, potentially damaging their frosting, when the lid 108 is opened.
Optionally, the tongue 118 and groove 122 can be sized so that engagement between the base sealing surfaces 119a-c and lid sealing surfaces 124a-c provides very little resistance to opening and/or closing the lid 108. In this configuration, the container 100 may include one or more engagement or securement members that may be used to hold the lid in the closed position, without relying on the frictional engagement between the base and lid sealing surfaces 119a-c and 124a-c. Referring to
Referring to
Preferably, the lid 108 is at least partially transparent. Providing a transparent lid may allow a user to see into the interior of the container while the lid is closed. In the example illustrated, the lid and base are transparent and are integrally formed as a single, one-piece container.
Referring to
Referring to
In the illustrate example, the body portion 142 of a cupcake 140 has a lower or bottom surface 144, an upper surface 146 and an outer or side surface 148 extending from the lower body surface 144 to the upper body surface 146. The body portion 142 may include a baked cake, or cake-like food product. Alternatively, the body portion 142 may be formed by another type of edible food product.
Optionally, some or all of the upper body surface 146 of the cupcake body 142 portion can be decorated, for example using another edible food product, such as icing or frosting 150. In some configurations, substantially the entire upper body surface 146 of the body portion 142 may be covered in frosting 150. Alternatively, the frosting 150 may be limited to only a portion of the upper body surface 146, providing a decorated section 152 and a corresponding undecorated section 154 of the upper body surface 146. If the frosting 150 is generally centered relative to the body portion 142, the undecorated portions 154 of the upper body surface 146 may form part of (or optionally all of) an undecorated peripheral section 156 of the cupcake 140 that generally surrounds the central, decorated section 152 of the upper body surface 146.
In some instances, the frosting 150 will be relatively soft and fragile, and may be prone to deformation or other damage if it comes into contact with another object or surface. Such damage to the frosting 150 may make the decorated cupcake 140 less visually appealing or otherwise interfere with the aesthetic presentation of the cupcake, or other such decorated food item. When transporting such decorated food items (for example from a production facility to a retail store), it may be desirable to reduce the likelihood that the decorated section of the food item, e.g. the frosted section, will be damaged during transport.
Optionally, the body portion of a food item can be wrapped or otherwise covered by a non-edible (i.e. a non-food product) wrapper or sleeve. The wrapper can be removable from the body portion of the food item so that a user may separate the wrapper from the food item prior to consuming the food item.
The wrapper may cover the bottom surface and some or all of the side surfaces of the body portion, but may leave substantially the entire upper body surface exposed for decorating. In this configuration, the wrapper may terminate in an upper wrapper edge that generally surrounds the upper surface of the food item body portion. If the food item is decorated, the decoration (e.g. frosting) may be limited to the upper body surface of the body portion, and may not be applied to cover the upper wrapper edge. In this configuration, the upper wrapper edge may form at least part of the undecorated peripheral section of the food item. If the frosting does not cover the entire upper body surface, the undecorated portions of the upper body surface (for example portions 154 of cupcake 140) may also form part of the undecorated peripheral section (for example section 156 in
One example of a suitable wrapper is a paper “cup”-type wrapper commonly used in the preparation and baking of cupcakes. Such paper wrappers can be placed in a cupcake baking pan and then filled with cupcake batter. The wrappers can be corrugated, smooth or have any other suitable configuration. When the cupcake bodies are baked, the batter is transformed into a cake product and bonds to the paper wrapper. Alternatively, the wrapper need not be paper, and may be formed from any suitable material, including, for example, metal, plastic, silicone and other materials. Preferably, the material of the wrapper is selected to be generally food safe, such that it will not contaminate the food product contained therein. The wrapper may be bonded to the food item during the cooking or preparation process, as described above, or may be attached to an already-prepared food item body portion. The wrapper may be a single-use wrapper that is intended to be disposed after it is separated from the body portion (e.g. a paper wrapper) or may be a re-useable wrapper that is intended to be re-filled with edible food products.
Referring to
In the illustrated example, the wrapper 158 is located between the side surface 148 of the cupcake body 142 and an inner surface 162 of its respective cavity 106. In the illustrated example, the upper wrapper edge 160 and upper body surface 146 each form part of an upper surface of the cupcake 140. Alternatively, the upper wrapper edge 160 may be positioned only part way up the side surface 146 of the body portion 142.
Referring again to
Each cupcake 140 has an outer surface, which contacts and is supported by an inner surface 162 of its respective cavity. In the illustrated example the outer surface of the cupcake 140 that is supported by the inner surface 162 of the cavity 106 is the outer surface the wrapper 158. Alternatively, it can be the side surface 148 and bottom surface 144 of the body portion 142 of the cupcake 140 (or the surfaces of any other type of food item that is not contained in a removable, inedible wrapper).
Referring to
Referring to
To help limit axial or vertical movement between the cupcakes 140 within their respective cavities 106a-d the container 100 includes one or more retainers for engaging the cupcakes when the lid 108 is closed. Optionally, the container 100 can be configured to include at least one retainer, and preferably two or more retainers, to engage each cupcake 140 in the container 100. The retainers can be provided on the lid 108 so that closing the lid moves the retainers into a desired retaining position. The retainers can be provided at any suitable location(s) on the lid 108, including for example extending inwardly from the lid sidewall 114 and/or being provided on one or more internal protrusions or other such features provided on the lid 108, as described below. Optionally, the retainers may be integrally formed with the lid 108, or alternatively, may be separate members connected to the lid 108 in desired locations.
Referring to
In the illustrated example the protrusion 172 is integral with the upper lid surface 112. In other examples, the protrusion 172 may be a separate member that is affixed to the upper lid surface 112.
Referring to
Referring to
In the illustrated example, the protrusion includes a protrusion first retainer 190a that is adjacent the distal end 174 of the protrusion 172. When the lid 108 is in the closed position the protrusion first retainer 190a is positioned proximate the first cavity 106a to engage the cupcake 140 nested therein. Referring to
Configuring the protrusion first retainer 190a to contact substantially only the upper wrapper edge 160, instead of contacting portions of the edible body portion 142, may help prevent the edible body portion 142 from being squeezed or otherwise damaged by contacting the protrusion first retainer 190a. This may help preserve the quality and aesthetic appearance of the cupcakes 140.
For some food products, the preparation of the edible body portion may result in body portions of slightly different sizes and shapes. For example, baking a plurality of cupcake bodies may produce body portions having upper body surfaces that are slightly different from each other. Such variations may affect the height or position of the upper body surface relative to the cavity when the body portions are placed in the container. For some food items, the inedible wrappers may have generally more consistent dimension and/or physical properties than the edible body portions contained therein.
In the illustrated example, the paper wrappers 158 used to surround the cupcakes may be substantially identical. Due to the consistency between multiple wrappers 158, when a wrapped cupcake is placed in its cavity, the position of the upper wrapper edge 160 relative to the protrusion first retainer 190a may be more uniform or consistent, from cupcake to cupcake, than the position of the upper body surface 146 relative to the protrusion first retainer 190a. Configuring the protrusion first retainer 190a to engage the upper wrapper edge 160, instead of the edible upper body surface 146, may allow for tighter tolerances on the design of the protrusion first retainer 190a and the positioning of the protrusion first retainer 190a relative to the expected position of the upper wrapper edge 160.
In some configurations the wrappers 158 may tend to be more rigid and/or durable than the edible body portions. Positioning the retainers to engage the generally more rigid upper wrapper edge 160, instead of or in addition to engaging a portion of the upper body surface 146, may help reduce uncertainty regarding the potential deflection or deformation of the food item when it contacts the retainers. Sufficiently high deflection or deformation of the food item may reduce the effectiveness of the retainers at retaining the food items within their cavities 160a-d, and/or may result in the food item pivoting about the cavity relative to the cavity axis. Pivoting of the food items may allow the decorated portions (i.e. the frosting 150) to contact the lid sidewall 114 or other portions of the container 100 which may damage the decorated section of the food item even if the decorated section does not contact the upper lid surface 112.
In the illustrated example, the container 100 is configured so that the first protrusion retainer 190a extends laterally inwardly of the first cavity rim 168a and overlies a portion of the interior of the first cavity 106a. Alternatively, for example if the undecorated peripheral section 156 of the cupcake extends sufficiently laterally beyond of the cavity rim 168, the protrusion first retainer 190a (and any other retainers provided in proximity to the first cavity 106a) need not extend laterally inboard of the cavity rim 168a in order to overlie the undecorated peripheral section 156 and retain the cupcake 140 within the first cavity 106a.
Referring to
Referring also to
The protrusion retainers 190a-d may help retain the cupcakes 140 within their corresponding cavities 106a-d when the container 100 is inverted, tilted, shaken or jostled in a vertical direction, for example when the container 100 is being transported.
Referring to
In the illustrated example, when the lid 108 is in the closed position, the protrusion 172 is generally centered laterally between the first, second, third and fourth cavities 106a-d and the protrusion axis 192 is generally equidistant from the first, second, third and fourth cavity axes 170a-d. In the example illustrated, the four cavities 106a-d are arranged in a 2×2 matrix with the axes 170a-d of the cavities positioned relative to each other to form the corners of a generally square shape when viewed in plan view (
In the illustrated example, the retainers have generally the same configuration, and analogous features can be provided on each retainer. Therefore, the detailed description of the protrusion third retainer, included below, is understood to apply to each of the retainers and the relationship between the retainers and their corresponding food items and cavities.
Referring again to
Optionally, the shape of the retaining edge 202c can be selected to generally match the shape of the cavity rim 168c. Referring to
The arc length 204c of the retaining edge 202c can be selected so that the retaining edge 202c, and associated abutment surface 200c, can overlie a desired segment of the cavity rim 168c and/or a desired length the undecorated peripheral section 156 of the cupcake 140 in the third cavity 106c (e.g. the upper wrapper edge 160 in the illustrated example). For example, the arc length 204c of the retaining edge 202c can be between about 1% and about 50% of the circumference (or length) of the cavity rim 168c and/or of perimeter length of the upper wrapper edge 160, and optionally can be between about 5% and about 35%, or greater than 50%, of the cavity rim 168c length or upper wrapper edge 160 length. The arc length of the sidewall retainers 188a-d, for example arc length 206c of sidewall retainer 188c, may be the same as the length of the protrusion retainers 190a-d, or, as illustrated may be greater than the lengths of the protrusion retainers 190a-d. In the illustrated example, arc length 206c is greater than arc length 204c, and may be between about 1% and about 65% of the length of the cavity rim 168c and/or of the upper wrapper edge 160.
Referring to
In the illustrated example, the container is configured so that the abutment surface 200c bears against the undecorated peripheral portion 156 of the cupcake 140 (in this example the upper wrapper edge 160) in the third cavity 106c.
Alternatively, the retainers, including the protrusion third retainer 190c, can be positioned so that when the container 100 is upright and the lid is closed the retainers are adjacent to, but not in contact with, the undecorated peripheral section 156 of the cupcake 140, and will only come into contact with the upper wrapper edge 160 when the container 100 is tilted or inverted. In this configuration, when the lid 108 is closed the abutment surface, for example surface 200c, would remain spaced apart from the upper wrapper edge 160 by a generally vertical retainer spacing distance (see for example distance 3207 in
Preferably, the retainer spacing distance (not shown) is less than the axial spacing 208 between a plane 206 (
Referring to
The protrusion 172 has a protrusion height 218 measured axially from the upper lid surface 112 to plane 216. The protrusion height 218 can be selected based on the size of the food item that is to be held in the container. Preferably, the protrusion height 218 is at least equal to the height of the frosting 150 on the cupcake 140. This may help prevent the upper lid surface 112 from contacting the frosting 150 when the lid is closed. Optionally, the protrusion height 218 can be greater than the height of the frosting by an amount selected to provide a desired decoration spacing distance 208.
Referring to
The sidewall retainers 188a-d are configured to operate in a manner analogous to the protrusion retainers 190a-d described above, and include analogous features. In the illustrated example, when the lid 108 is in the closed position each sidewall retainer 188a-d is positioned proximate a respective cavity 106a-d and overlies a portion of the undecorated peripheral sections 156 of the cupcakes 140 contained therein. Optionally, the sidewall retainers 188a-d can extend laterally inwardly of their corresponding cavity rims 168a-d.
In the illustrated example, the sidewall retainer and the protrusion retainer for a given cavity, for example the protrusion third retainer 190c and the sidewall third retainer 188c, can co-operate to help retain the cupcake within the cavity 106c. The sidewall and protrusion retainers can be structurally the same or similar, or can be structurally different. In the illustrated example, each sidewall retainer comprises a sidewall retainer abutment surface 226 and a sidewall retainer retaining edge 228, which are analogous to the abutment surface 200c and retaining edge 202c described above.
Optionally, the container 100 can be of one-piece, integrally formed unitary construction including the base 102, lid 108, the protrusion 172 extending downwardly from the upper lid surface 112, the protrusion retainers 190a-d, the sidewall retainers 188a-d and the hinge 116 that pivotably connects the lid 108 and the base 102. Alternatively, the lid 108 and base 102 can be separately formed members and can be connected together using a hinge or another suitable, openable or releasable connection mechanism.
Referring to
The base 1102 of the six-pack container includes a first cavity 1106a having a first cavity rim 1168a, a second cavity 1106b having a second cavity rim 1168b, a third cavity 1106c having a third cavity rim 1168c, a fourth cavity 1106d having a fourth cavity rim 1168d, a fifth cavity 1106e having a fifth cavity rim 1168e and a sixth cavity 1106f having a sixth cavity rim 1186f. The six cavities 1106a-f are arranged in a 2×3 matrix configuration.
The container 1100 includes a lid 1108 hingedly connected to the base 1102, and the lid 1108 is moveable between a closed position (
Like the container 100 described above, the six-pack container 1100 includes a plurality of retainers to help vertically secure food items, such as cupcakes, within their respective cavities. The plurality of retainers can include a plurality of protrusion retainers and a plurality of sidewall retainers.
Referring to
In this configuration, some of the cavities, for example the second and fourth cavities 1106a and 1106d are invaded by retainers on more than one protrusion. When the lid 1108 is closed, both the first protrusion second retainer 1190b and the second protrusion second retainer 1190bb can engage a cupcake within the second cavity 1106b to help inhibit vertical movement of the cupcake 1140. Like cupcakes 140, the cupcakes 1140 each include a body 1142 and are topped with frosting 1150. Similarly, both the first protrusion fourth retainer 1190d and the second protrusion fourth retainer 1190dd can cooperate to help retain a cupcake in the fourth cavity 1106d.
Referring to
Optionally the lid 1108 can be configured to include a sidewall first retainer 1188a, a sidewall second retainer 1188b, a sidewall third retainer 1188c, a sidewall fourth retainer 1188d, a sidewall fifth retainer 1188e and a sidewall sixth retainer 1188f. In this example, the lid comprises one sidewall retainer for each of the six cavities 1106a-f. In the illustrated example, the sidewall retainers positioned toward the middle of the container, 1188b and 1188d, are smaller than sidewall retainers provided toward the corners of the container 188a, 1188c, 1188e, and 1188f. However, in the illustrated example the protrusion retainers positioned toward the middle of the container, 1190b and 1190bb, and 1190d and 1190dd are longer (when taken together) than the protrusion retainers 1190a, 1190c, 1190e and 1190f. Optionally, the retainers can be sized so that the total length of the retainers associated with each cavity may be approximately equal, or within about 25% of each other. For example the retainer length of the combination of 1190a and 1188a acting on the first cavity 1106a may be approximately the same as the length of the combination of 1188b, 1190b and 1190bb acting on the second cavity 1106b.
Optionally, the number of cavities can be different than the number of sidewall retainers.
Referring to
The nine-pack container 2100 includes nine cavities 2106a-i arranged in a 3×3 configuration. Each cavity has a corresponding cavity rim and cavity sidewall, as described above.
The 9-pack 2100 container also includes a first protrusion 2172a, a second protrusion 2172b, a third protrusion 2172c and a fourth protrusion 2172d extending from the lid upper surface 2112.
The 9-pack 2100 container includes a plurality of retainers 2188 and 2190 to secure cupcakes within the nine cavities 2106a-i. The plurality of retainers includes a plurality of protrusion retainers 2190.
The distal ends of the four protrusions 2172a-d each comprise four protrusion retainers. Each protrusion retainer 2190 is configured to retain a respective cupcake in its cavity. For example, the first protrusion includes a first protrusion first retainer 2190a, a first protrusion second retainer 2190b, a first protrusion third retainer 2190c and a first protrusion fourth retainer 2190d, for retaining cupcakes in the first, second, third and fourth cavities 2106a-d, respectively. As explained above, some or all of the four protrusions 2172a-d can optionally be connected to each other, as illustrated.
Similarly, the fourth protrusion 2172d comprises a fourth protrusion fourth retainer 2190dddd, a fourth protrusion sixth retainer 2190ff, a fourth protrusion eighth retainer 2190h and a fourth protrusion ninth retainer 2190i for engaging cupcakes in the fourth, sixth, eighth and ninth cavities 2106d, 2106f, 2106h and 2106i, respectively.
In the illustrated example, the fourth cavity 2106d is an inboard cavity, which is not adjacent to any portion of the lid sidewall. In this configuration, the fourth cavity 2190 is engaged by four protrusion retainers (the first protrusion fourth retainer 2190d, the second retainer fourth protrusion 2190dd, the third retainer fourth protrusion 2190ddd and the fourth retainer fourth protrusion 2190dddd) and is not engaged by any sidewall retainers. Optionally, the first, second, third and fourth protrusion fourth retainers 2190d-dddd can be interconnected to each other to provide a generally continuous, circular retaining edge that overlaps substantially the entire upper wrapper edge 2160 of the cupcake contained in the fourth cavity 2106d.
Referring to
Container 3100 includes a base 3102, containing a single cavity 3106 and a lid 3108 hingedly connected to the base 3102. In this configuration, the lid includes a first sidewall retainer 3188a, a second sidewall retainer 3188a, a third sidewall retainer 3188aaa and a fourth sidewall retainer 3188aaaa. Each retainer 3188a-aaaa extends laterally inwardly from the lid sidewall 3114, and when the lid 3108 is closed, is positioned to overlie a respective portion of the undecorated peripheral section of the cupcake 3140 in the cavity 3106. In this example, the lid 3108 does not include a protrusion extending inwardly from the upper lid surface 3112. Instead, all of the retainers 3188 for engaging the cupcake 3140 are provided on the lid sidewall 3114.
Referring to
In the illustrated example, a label 3240 is affixed to the outside of the container 3100 and is connected to both the base 3102 and the lid 3108. The label 3240 can be adhered such that it is difficult to remove without tearing so that a user will tear the label 3240 when opening the lid 3108. This may serve as a tamper-evident feature, alerting a subsequent user to the fact that the container 3100 has been previously opened.
Referring to
After steps 1502 and 1504, at step 1506 the decorated food items are loaded into respective cavities of a container. The container has a plurality of retainers for securing the food items, and may have any of the features described herein. Optionally the container may include a lid with at least one protrusion having at least a first retainer and a second retainer extending laterally outwardly from a distal end of the protrusion.
After step 1506, at step 1508 the lid is closed to move the retainers into position in which they overlie respective portions of the undecorated peripheral sections of their respective food items. first retainer to engage a first marginal portion of a first upper surface of a first food item in the container and moves the second retainer to engage a second marginal portion of a second upper surface of a second food item in the container.
After step the lid is closed, step 1510 includes transporting the container away from the preparation facility for indirect or direct delivery to the retail store.
Optionally, at step 1512, the decorated food items can be frozen prior to delivery to the retail store.
At step 1514, the container can be placed for display on a sales shelf in the retail store.
Optionally, before step 1514 the food items can be thawed at step 1516.
What has been described above has been intended to be illustrative of the invention and non-limiting. Modifications may be made without departing from the scope of the invention as defined in the claims appended hereto.
This application is a continuation of U.S. patent application Ser. No. 13/464,469, filed May 4, 2012, which claims the benefit of U.S. Provisional Application Ser. No. 61/482,376, filed May 4, 2011, each of which is hereby incorporated herein by reference.
Number | Date | Country | |
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61482376 | May 2011 | US |
Number | Date | Country | |
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Parent | 13464469 | May 2012 | US |
Child | 15454728 | US |