Patent Grant
6892932
This invention relates to packaging in general and in particular to cartons for food products such as pizza, breadsticks, chicken wings, and the like.
In the pizza and food-to-go industries, millions of orders of side-item type products are sold each year. Examples of such products include breadsticks, chicken wings, and pizza slices. One of the most prevalent types of cartons used for packaging these products is the corrugated paperboard carton. This carton comes in both folder type and clamshell type. The folder type carton is shipped as a flat blank and then erected into a carton at the point of use (i.e., the pizzeria). The clamshell type carton is erected in the factory and then shipped as an open clamshell.
These cartons can be categorized into two groups based on status of wall engagement. The two groups are (1) wall-engaged cartons and (2) non-wall-engaged cartons. A “wall-engaged carton” is one in which at least two wall structures are engaged one to the other, such that when the cover of the carton is in opened disposition those two wall structures remain in an erected position. A “non-wall-engaged carton” is one in which none of the wall structures of the carton are engaged one to another.
Various structural arrangements can be used for engaging adjacent walls of a carton. Some arrangements allow for efficient erection of a blank into a box, others do not. One particular structure that allows for efficient erection of a box is a non-folding wall-engagement tab. This invention is disclosed in Correll U.S. Pat. No. 5,381,949 granted Jan. 17, 1995.
Another structural consideration for side-item cartons is having an article-retaining structure for holding a sauce cup, for example, as well as perhaps some other article. Many pizzerias pack one or more sauce cups with their side-item products. Traditionally these cups have been placed next to the food product. However, there are two problems with this. First, the sauce cup often gets greasy. Second, some health departments consider it to be unsanitary for articles handled by human hands to come into contact with a ready-to-eat food product. As a result, it would be desirable to have a way of packing sauce cups and other articles so that these articles are positioned out of contact with the food product.
One prior art box has been invented to address this problem. Known as the “Kickers Box,” it is used by Domino's Pizza for packaging chicken strips (which the company calls Kickers™). Essentially, the Kickers Box is a small version of the company's hexagonal D-type pizza box except with a special compartment at the front third of the box for holding two sauce cups. The compartment is created by a plurality of three interconnected panels. The first panel is attached to the top edge of the front wall of the box and is disposed parallel to the bottom panel. It has two holes in it for holding two sauce cups. The second panel is attached to the first panel and is disposed perpendicular to the first panel and serves as support for the first panel. The third panel is attached to the second panel and is disposed perpendicular to the second panel and is tucked underneath the connecting panels that connect the two diagonal walls to the front wall structure of the box.
This box is particularly defined in VanEsley et al. U.S. Pat. No. 6,568,586 granted May 27, 2003.
However, the Kickers Box has at least three drawbacks. First, it consumes a relatively large amount of material and, therefore, is relatively expensive. Second, it contains numerous flaps and, therefore, is time-consuming and awkward to erect from a blank into a box. Third, after product has been placed into the box, closing the cover on the box can be time-consuming due to the many cover flaps that need to be manipulated for tuck-in. In view of these three problems, it would be desirable to have a carton for side-item products that is material-saving, cost efficient, and easy-to-handle.
One particular carton that has a small number of flaps and, thereby, is efficient for handling is a carton disclosed in Correll U.S. Pat. No. 5,752,651. However, even though it has only one cover flap, the side walls of the carton each have a flap attached to the front end which requires folding prior to erecting the blank into a box. Therefore, it would be desirable to have a carton with side walls free of flaps altogether. Another potential drawback of this carton is that it has no article-retaining structure for holding a sauce cup separately from the food product carried in the carton. As previously discussed, the Kickers Box has an article-retaining structure for holding a sauce cup. However, it requires substantial additional material in manufacture of the blank. So it would be desirable to have a carton with a material-efficient article-retaining structure.
In short, it would be highly desirable to provide a food carton that overcomes the above-described problems and drawbacks associated with packaging side-item products.
In general terms, my invention is a blank and carton that provides for efficient, cost-effective, and/or sanitary packaging of food products such as breadsticks, chicken wings, pizza slices, and the like.
In specific terms, my invention is a blank and carton that provides one or more of the following structural arrangements:
1. A configuration of two mated blanks each having a flap-free side wall with a non-folding front-wall-engagement tab projecting from a front end;
2. A configuration of two mated blanks each having a side wall with a free rear end disposed at an acute angle to a bottom edge of the side wall;
3. A blank having a side wall with a non-folding front-wall-engagement tab projecting from a front end and that's erectable (a) into a partially-erected carton having a front wall disposed in a particular first position and (b) into a fully-erected carton having the front wall disposed in a particular second position;
4. A carton having a side-wall-locking ancillary panel attached to a top edge of a front wall and capable of retaining a side wall of the carton in an upright position;
5. A carton having a first wall with a tab-receiving opening having an outside edge obliquely disposed to a bottom panel and, thereby, capable of causing an adjacent wall to be disposed at an oblique angle to the bottom panel;
6. Two mated blanks each having an article-retaining structure attached to a side wall, with the blanks being matable in a first mated relationship and also in a second mated relationship;
7. Three mated blanks each having an article-retaining structure attached to a side wall, with the blanks being matable in two mating relationships and alignable at the ends;
8. A blank for a carton having an article-retaining structure comprising a first panel attached to a top edge of a side wall.
9. A closed carton having an article-retaining structure that's exposed to view;
10. A carton having an article-retaining structure comprising a first panel attached to a top edge of a side wall and a second panel attached to the first panel.
11. A carton having an article-retaining structure comprising a cup-holding panel attached to a top edge of a wall and having a hole-opening flap disposed in a downward-extending position and with an edge of the flap disposed in close proximity to the bottom panel, thereby providing support for the cup-holding panel; and
12. A partially-erected open carton having an outward-extending non-deployed article-retaining structure attached to an upright wall, whereby the article-retaining structure is disposed outside of the holding cavity of the partially-erected carton.
My invention typically would be used for packaging food products such as breadsticks, chicken wings, pizza slices, and the like. However, it could take other forms for other purposes, as well.
A complete understanding of the invention can be obtained from the detailed description that follows.
The main object of my invention is a blank and carton that provides for efficient packaging of food products.
The advantages of my invention are (1) material savings, (2) cost savings, and (3) efficient carton handling operations.
Further objects and advantages of the invention will become apparent from consideration of the following detailed description, related drawings, and appended claims.
Between drawings, like reference numerals designate corresponding parts.
Referring now to the drawings, there is illustrated a preferred embodiment of the invention in the format of a one-piece paperboard blank and, correspondingly, in the format of a box created from the blank. The intended use for the embodiment is as a food carton or, specifically, as a carton for packaging side-items such as breadsticks, chicken wings, pizza slices, and the like. However, it will be appreciated, as the description proceeds, that my invention may be realized in different embodiments and may be used in other applications.
Referring particularly to blank 10 of
Bottom panel 20 has a left-to-right width 22.
Rear end wall 30 has first and second free ends 32 and 32′ and a left-to-right width 48 (indicated at the top of the drawing). It is noted that rear end wall width 48 is less than bottom panel width 22.
Cover 40 comprises a cover panel 42 attached to rear end wall 30 at a fold line and a cover front flap 44 attached to a front edge of cover panel 42 at a fold line. Cover panel 42 has opposing first and second free side edges 46 and 46′. Cover panel 42 has a left-to-right width 48. It is noted that cover panel width 48 is less than bottom panel width 22. It is also noted that cover panel 42 is a full-length cover panel, meaning that it spans the entire distance from rear end wall to front end wall in the carton format.
Side walls 50, 50′ are attached to bottom panel 20 at respective bottom edges 51 and 51′. The side walls also have top edges 52, 52′ and free rear ends 54, 54′, respectively. Free rear ends 54, 54′ are disposed at an acute angle 55 to the bottom edge 51, 51′. In the case of side wall 50, it is noted that top edge 52 is a free top edge (meaning, free of attachment to another panel). The side walls also have non-folding front-wall-engagement tabs 56, 56′ respectively projecting from a free front end of the side walls. As illustrated in
Front wall structure 60 comprises a front end wall 62 attached to bottom panel 20 at a bottom edge 63. Structure 60 further comprises an ancillary panel 64 attached to a top edge of front end wall 62 at a fold line. Front end wall 62 has a height 66. It is noted that height 66 is less than height 59 of side walls 50, 50′.
Positioned along the fold line joining ancillary panel 64 to front end wall 62 is a slot-forming slit 68 which opens into a slot for receiving cover front flap 44 when the blank is erected into a carton.
Ancillary panel 64 has opposing first and second end edges 70 and 70′. It is noted that ancillary panel 64 is a side-wall-locking ancillary panel. This is achieved by the special configuration of end edges 70, 70′. As illustrated in
Front end wall 62 comprises opposing first and second tab-receiving openings 80 and 80′. As illustrated in
Front end wall 62 further comprises a tab-receiving slot 65 which serves to engage with article-retaining structure 90 in the erected carton.
Article-retaining structure 90 comprises a first panel 92 attached to top edge 52′ of side wall 50′ and a second panel 94 attached to panel 92. This two-panel arrangement constitutes a plurality of interconnected panels. It is noted that in the preferred embodiment this plurality of interconnected panels consists of two panels only. Panel 92 contains a cup-holder opening 96 and a hole-opening flap 97. Accordingly, this panel could be referred to as a “cup-holder panel.” Flap 97 is hingedly attached to the edge of cup-holder opening 96 by a narrow bridge of material 98. When a sauce cup is inserted into opening 96, hole-opening flap 97 bends downward and assumes a vertical disposition with bridge of material 98 holding it in place. Second panel 94 has a tab 99 which inserts into tab-receiving slot 65 in front end wall 62 when blank 10 is erected into carton 12. This engages article-retaining structure 90 with front wall structure 60 and, thereby, serves to hold panel 94 in a vertical disposition in the erected carton. Article-retaining structure 90 has an outermost edge 95.
As the term is used herein, an “article-retaining structure” is any structural component of a blank or carton that is configured to hold a particular article, such as a sauce cup, in a substantially fixed position or within a particular confined area within the carton. An article-retaining structure typically comprises multiple interconnected panels, but it is possible for the structure to comprise only a single panel.
In the preferred embodiment the outward-extending non-deployed article-retaining structure (i.e., panels 92, 94) is disposed coplanar to the wall panel (50′), to which it is attached. However, it's possible for the structure to assume other positions, such as extending outwardly at an angle to the wall panel. It is noted that such an outward-extending position would be considered to be an outward-extending non-deployed disposition and, thereby, within the scope of the definition. By comparison,
Each of the blanks has opposite front and rear end edges 106 and 108, respectively, formed by furthermost extremities of the blank. It is noted that the end edges of one blank are substantially aligned with the opposite end edges of an adjacent blank. (In the drawing the end edges are not exactly aligned due to the gap between the blanks. Without the gap, however, the end edges should closely align.)
It is noted that between adjacent mated units of blank 10 two mating relationships are possible. The first relationship is depicted by blanks 101 and 102. The second relationship is depicted by blanks 102 and 103.
In the first mating relationship (between blanks 101 and 102), side wall 50 of each blank is disposed in a recess created by the other blank. The particular recess is created by free rear end 54 of side wall 50, free end 32 of rear end wall 30, and free side edge 46 of cover panel 42. It also is noted that there's an alternate way of describing this mating relationship, which is: At least a portion of top edge 52 of side wall 50 of each blank faces side edge 46 of cover panel 42 of the adjacent blank. Finally, it is noted that in each blank rear end 54 of side wall 50 is disposed at an acute angle to the bottom edge of the side wall (this acute angle is labeled as angle 55 in FIG. 1).
In the second mating relationship (between blanks 102 and 103), article-retaining structure 90 of the adjacent blanks are disposed adjacent one another. In this relationship at least a portion of outermost edge 95 of article-retaining structure 90 of each blank faces side edge 46′ of cover panel 42 of the adjacent blank. It is also noted that there's an alternate way of describing this mating relationship, which is: Panel 94 of each blank is disposed in a recess created by rear end 54′ of side wall 50′, end 32′ of rear end wall 30, and side edge 46′ of cover panel 42 of the adjacent blank.
The foregoing describes the preferred embodiment of the invention. However, alternative configurations are possible, as follows.
A first alternative configuration would be to convert rear end wall 30 to a “full-length” rear wall that spans the entire distance between side walls 50, 50′. This might be done for the purpose of completely closing off the rear side of the carton.
Another alternative configuration would be to replace the single hole-opening flap 97 with a multiple flap arrangement. An example is illustrated in
Another alternative configuration would be to construct panel 94 of the article-retaining structure so that it engages with rear end wall 30 instead of, or in addition to, engaging with front wall structure 60.
Following is a procedure for erecting blank 10 into carton 12.
First, using both hands grasp the blank at the front ends of side walls 50, 50′. Hold the blank vertically with the outside facing you and the cover end down.
Second, simultaneously fold side walls 50, 50′ inward to an acute angle (approximately 70 degrees) to bottom panel 20.
Third, while holding the side walls at the acute angle, fold front end wall 62 inward with your thumbs. End-wall-engagement tabs 56, 56′ will push open swing flaps 84 and project through tab-receiving openings 80, 80′.
Fourth, while holding front end wall 62 down, simultaneously pull side walls 50, 50′ outward until they abut side-wall-retaining outside edges 82, thereby causing the side walls to be held in an upright position. This also will cause tabs 56, 56′ to hold front end wall 62 in an upright position, resulting in the partially-erected carton 12 depicted in
Fifth, fold article-retaining structure 90 inward and down until panel 92 is parallel to bottom panel 20 and panel 94 is perpendicular to panel 92 and tab 99 is engaged in tab-receiving slot 65.
Sixth, fold ancillary panel 64 downward and fold cover panel 42 forward and over the cavity of the carton and, finally, slide cover front flap 44 into slot 68 in front wall structure 60.
I have disclosed a blank and carton that provides for efficient, cost-effective, sanitary packaging of food products such as breadsticks, chicken wings, pizza slices, and the like.
Within the drawing of the blank, a fold line between component parts of the invention is depicted with a dashed line. Within the context of this invention, a fold line can be created by a number of means such as, for example, by a crease or score in the board, by a series of aligned spaced short slits in the board, and by a combination of aligned spaced short and long slits. In conclusion, as referred to herein, a fold line is any line between two points on the blank or box along which the board is intended to be folded when the blank is being erected into a box or when the box is being manipulated as described herein. The type of fold lines shown in the drawings are presently preferred but it will be appreciated that other methods known to those skilled in the art may be used. As used herein, the term “hingedly attached” refers to two panels (or a panel and a flap) joined together at a fold line, and does not imply any degree of movability of the panels in the erected box format.
Within the foregoing discussion of the invention, the labeling of components as “first” and “second” is for reference purposes only and does not indicate any particular location of the components within the blank or carton.
The illustrated number, size, shape, type, and placement of components represent the preferred embodiment; however, many other combinations and configurations are possible within the scope of the invention. For example, the preferred embodiment of the invention is depicted as a folder-style carton. However, the particular aspect of the invention involving the article-retaining structure is applicable to clamshell-style cartons, as well, and if so applied would be considered to be within the scope of the invention. This also applies to blanks for clamshell-style cartons that have the particularly-defined article-retaining structure. Within the foregoing description of the invention and the subsequent claims, the term “cover” is used. Within the context of this description, the term “cover” refers to a cover panel and all flaps or panels attached to the cover panel (excluding, of course, a wall panel that would be attached to the bottom panel).
The foregoing discussion has pertained mainly to packaging for side-item food products. However, it should be realized that my invention could be used for other purposes, as well. In conclusion, it is understood that the invention is not to be limited to the disclosed embodiment but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which-scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.
| Number | Name | Date | Kind |
|---|---|---|---|
| 2375843 | Gottlieb | May 1945 | A |
| 2924372 | Kirkeby | Feb 1960 | A |
| 3005584 | Coe | Oct 1961 | A |
| 3899119 | Roccaforte | Aug 1975 | A |
| 4265393 | Orchard | May 1981 | A |
| 4431128 | Dirico | Feb 1984 | A |
| 5381949 | Correll | Jan 1995 | A |
| 5549241 | Correll | Aug 1996 | A |
| 5553771 | Correll | Sep 1996 | A |
| 5657925 | Norris | Aug 1997 | A |
| 5752651 | Correll | May 1998 | A |
| 5788081 | Bates | Aug 1998 | A |
| 5890648 | Cai | Apr 1999 | A |
| 6213389 | Cai | Apr 2001 | B1 |
| 6568586 | VanEsley et al. | May 2003 | B1 |
| Number | Date | Country | |
|---|---|---|---|
| 20040099720 A1 | May 2004 | US |
