Patent Grant
8393529
N/A
N/A
Pizza delivery is a multi-billion dollar industry. The growth of the business has kept pace with the development of suitable containers for carrying the pizza. The modern pizza delivery box such as that used by the large retail chain stores is, in many ways, the ideal delivery system. In order to be an ideal delivery system, the boxes must possess a combination of traits. The boxes must keep the pizza warm, be sturdy enough to withstand the delivery process, and be inexpensive to manufacture. Boxes known in the art achieve each of these characteristics. One example is that disclosed in U.S. Pat. No. 5,702,054.
Although boxes found in the art are nearly ideal delivery vehicles for getting the product to the customer, none successfully address post-delivery customer needs. More specifically, most boxes found in art present a disposal problem. Pizza boxes are typically larger than indoor household trash receptacles. In order to dispose of the box, customers must crush or tear the box in order to reduce its size so that it may easily fit into a household trash receptacle. Additionally, the box is typically too large to easily fit into the household refrigerator for storing leftover pizza.
The subject of several patents is the improvement of the typical pizza box to help alleviate these shortcomings. For example, U.S. Pat. Nos. 5,273,206 and 5,197,659 disclose pizza box designs incorporating score-lines designed to facilitate rolling the pizza box into a cylindrical shape when empty for ease of disposal. U.S. Pat. No. 5,305,949 discloses a pizza box incorporating removable punch-out sections and weakening lines, which facilitate folding the box in half for ease of disposal. U.S. Pat. No. 5,209,392 discloses a box incorporating a transverse perforation, which facilitates breaking the box in two for ease of disposal. Each of the foregoing patents address the need for making the box more easily disposable but do not address leftover storage needs. In addition, each of these designs incorporate extensive score-lines or perforations that are needed to make the box more easily disposable but also significantly weaken the structural integrity of the box during the delivery process. None of these designs incorporate means for selectively weakening the structural integrity of the box by the consumer post-delivery. Additionally, these designs are complex, and may prove difficult to use by many consumers.
Other patents address both ease of disposal and the need to have a box that can accommodate multiple volumes. U.S. Pat. No. 5,071,062 discloses a box incorporating perforated score lines so that the top portion may be ripped off while the bottom portion of the box is retained and folded into a second enclosed box structure for the storage of left over pizza. U.S. Pat. No. 6,375,066 discloses a box design incorporating transverse perforation lines through the lid and bottom portions of the box and an additional fold line which together facilitate breaking the box in two and folding the open end shut for use as a secondary storage container. U.S. Pat. No. 7,051,919 discloses a box incorporating perforations and score lines, which facilitate the removal of multiple pieces of the original box and the folding of the remainder of the box into a tapered box structure for the storage of leftover pizza. However, each of these designs utilize extensive perforations and score lines that significantly weaken the box structure while none incorporate means for selectively weakening the structural integrity of the box by the consumer post-delivery. Further, these designs are also complex, and may prove difficult to use by many consumers. Additionally, none disclose means for easily storing an entire half pizza as leftovers.
The present invention overcomes the shortcomings of the prior art and provides an easily disposable pizza box that may also be used as a storage container for holding leftover pizza. The present invention incorporates means for reducing the size of the box structure by first splitting the box into two overall pieces (the splitting means). This facilitates disposal of the box in household trash receptacles. Optionally, a portion of the split box may be folded shut generating a second closed box structure that may be used to store leftovers. The present invention most preferably utilizes a pull-tab cord design as the primary means of weakening the box structure to facilitate separating the overall box into two portions. However, perforations may be used as a substitute for the pull-tab cord. Further, perforations may be used in addition and in conjunction with the pull-tab cord in order to facilitate cleaner edges when the box is torn apart and or to reduce the effort required to tear the box in two. Depending upon the exact placement of the splitting means, the halves may or may not be equal in size. Further, the resulting open ends of one or both of the resulting halves may incorporate preformed score lines and or perforations that facilitate folding the open end shut, thereby forming a second closed box structure. In a preferred embodiment of the present invention, one portion of the split box is sized so that when the open end is folded shut, the second closed box is essentially half the volume of the first original box. By most preferably incorporating a destructive pull-tab cord design instead of extensive preformed perforations as the primary means of weakening the box structure, the structural integrity of the box is not significantly weakened as compared to the typical pizza box until the customer chooses to pull the tab in order to split the first box for disposal or store leftover pizza by folding one of the split portions of the first box closed generating a second box. Further, the present invention incorporates a simplified design that is easy for a consumer to use. The present invention incorporates means whereby the consumer, after splitting the first box, may optionally generate the second closed box without first opening the lid.
In summary, the present invention provides for a sturdy delivery vehicle that incorporates means for splitting the first box into two portions to facilitate disposal and or storage of leftovers. Further, in a preferable embodiment, the split box is designed so the opened end of one portion may be folded closed, generating a sturdy storage container that may be used to store leftovers. Further, in the most preferable embodiment, the split box is designed so the end of the larger portion may be folded closed, generating a sturdy storage container that may be used to store a full half pizza of leftovers. Food containers incorporating the present invention are easy to use and economical to manufacture.
The most preferable embodiment of the present invention utilizes a Pull-Tab 40, 94, connected to a Cord, 50, running against or within the box so that when the consumer pulls it, the Cord, 50, cuts or tears the box material similar to that found in the art and used to open some mailing containers. This weakens the structure of the box so that the box may easily be separated into two pieces. The Pull-Tab, 40, 94, allows the consumer to get a secure grip on the Cord, 50, in order to pull it. In the preferred embodiment the Pull-Tab, 40, 94, is defined by perforations of the box adjacent to the sides of the Cord, 50, and or at one end of the Cord, 50, but in other embodiments may include an additional piece of material attached to the Cord, 50, for the consumer to grip. The Cord, 50, may be made using any material of sufficient strength to tear the box material when pulled. Typically, the Cord, 50, is made of a plastic polymer material. In one preferred embodiment of the present invention, the Cord, 50, is made of polyethylene. In another preferred embodiment of the present invention, the Cord, 50, is made of a woven fibrous material. Several tear tape products are available on the market and some of these are suitable for use in this box structure. The box may be constructed of any material of sufficient strength for use as a pizza delivery container that may be cut or torn by the Cord, 50, material. In the preferred embodiment, the box is made of a corrugated paper cardboard material. In yet another embodiment, the corrugated paper material is coated with a water repellant substance such as wax or a plastic coating found in the art in order to maintain the freshness of the pizza leftovers. Further, in yet another embodiment, a microwave heating surface as found in the art may be attached to or built into the box material.
In order to function properly, the Cord, 50, must be securely attached to the box material. In one embodiment, polymer glue is used to attach the Cord, 50, to the box, but any means of sufficient strength known in the art may be used to attach the cord to the box, for example, pressure sensitive adhesive. In one particular embodiment, the Cord, 50, is attached to the inner surface of the box. In another particular embodiment, the Cord, 50, is attached to the outside surface of the box. In another particular embodiment, the Cord, 50, is inserted within the box material. In embodiments wherein the box is constructed of corrugated material, the Cord, 50, may run either parallel or perpendicular to the direction of corrugations. However, in the most preferable embodiment, the Cord, 50, runs perpendicular to the direction of the corrugations. In yet another embodiment, the Cord, 50, may comprise multiple layers, and be attached to both the inner and outer surface of the box. In yet another embodiment, the Cord, 50, may comprise multiple layers, and be attached to both the inner surface of the box and be inserted within the box material. In yet another embodiment, the Cord, 50, may comprise multiple layers, and be attached to both the outer surface of the box and be inserted within the box material.
Further, perforations may be added along either or both sides of the Cord, 50, in order to reduce the effort required to rip the box or to help generate smoother edges along the rip. These are illustrated in
The present invention may best be described by example. Eight preferred embodiments of the present invention are illustrated. In all illustrations, a solid line represents a cut. A line with large dashes represents folds in the box structure that are most preferably but not necessarily scored using perforations or cuts. Lines denoted by small dashes represent lines that are perforated or otherwise weakened so that the consumer may tear the box material along the line. Lines denoted by small dots represent latent fold lines along which the box is folded to close the open end of the split box. These lines may be denoted by perforations, indentations, or nothing, but perforations may not be necessary, particularly if the fold is parallel to the grain of the cardboard. Lines denoted by dashes perpendicular to the length of the box represent the location of the Cord, 50.
After assembly, and in order to easily dispose of the box or prepare the box for storing leftovers, the consumer grasps the Pull-Tab, 40, and pulls the Cord, 50, following the Cord, 50, around the box as it is torn through, thereby ripping or cutting the box along the Cord, 50, line. The first box may then be separated into two portions. This particular embodiment includes Lines of Perforation, 26, along both sides of the Cord, 50. In the most preferable embodiment illustrated in
Once the box is separated into two pieces, both pieces may be disposed of directly, or alternatively, the open end of the large piece may be folded closed, forming a second sturdy container structure (a second box). The open end is folded shut as follows. Removable Section A, 36, Removable Section B, 66, and Removable Section C, 60, are torn out of the box along the perforations. The open edge of the Top, 16, is folded in towards the Bottom, 22, of the box along Latent Fold Line B, 64. The Front Closing Tab, 46, and the Rear Closing Tab, 58, are folded inwards towards the Bottom, 22, after separating them from the Lower Front Wall, 34, and Back Wall, 20, along the perforations.
From this point there are a few distinct ways of completing the closed box structure according to the preferences of the consumer. As one option the open edge of the Bottom, 22, with the Front Closing Tab, 46, and the Rear Closing Tab, 58, are folded in along Latent Fold Line A, 54. After folding them up to an angle of approximately ninety degrees relative to the Bottom, 22, the Front Closing Tab, 46, and Rear Closing Tab, 58, are released and allowed to pass through the openings in the folded edge of the Top, 16, created by Removable Section B, 66, and Removable Section C, 60. Once released and opened up into the inside of the second box structure, Closing Tab A and Closing Tab B securely lock the second box closed by preventing the folded open edge of the Bottom, 22, from unfolding. This optional folding method may be performed without the necessity of first opening the second box.
As a second option, the Front Closing Tab, 46, is inserted between the folded leaves of the Lower Front Wall, 34, as the open edge of the Bottom, 22, is folded up towards the Top, 16. The Back Closing Tab, 58, may then be opened into the second box as in the first option to complete the closing operation. In this example of a preferred embodiment of the present invention, one edge of the Front Closing Tab, 46, is angled by its proximity to the Pull-Tab, 40, which facilitates insertion between the leaves of the Lower Front Wall, 34. Other embodiments of the present invention may feature a Front Closing Tab, 46, without such an angle. This optional folding method may also be performed without the necessity of first opening the second box.
As a third option, the second box is first opened, then the open edge of the Bottom, 22, is folded up towards the Top, 16, and the Front Closing Tab, 46, and Rear Closing Tab, 58, are placed against the Front Wall and Rear Wall respectively. Folding the lid shut as in the completion of the first box finishes the closing operation. The consumer may devise other variations in the folding operation.
The reduced size container may now be opened and closed as needed in a manner similar to the original full size container. When closed, the reduced size container is very sturdy and can be used to store leftovers conveniently.
In addition to the features described in Example 1, this particular embodiment includes additional foldable perforation means along the Front Closing Tab, 46, and Rear Closing Tab, 58. This further facilitates folding of the Front Closing Tab, 46, and Rear Closing Tab, 58, inwards toward the open edge of the Bottom, 22, while closing the second box.
In addition to the features described in Example 1, this particular embodiment eliminates perforation means along one edge of the Front Closing Tab, 46, and Rear Closing Tab, 58, within Removable Section B, 66, and the perforation means along Latent Fold Line A, 54, ant Latent Fold Line B, 64. This further facilitates a stronger first box structure.
However, in this particular embodiment, Lines of Perforation are not used along the sides of the Cord, 50.
In order to split the first box into two portions, the box is manually torn along the Line of Perforation, 26. Once torn in this manner, the second box may be folded shut in a manner similar to that described in Example 1.
In this particular embodiment a Line of Perforation, 26, is used along only one side of the Cord, 50. By utilizing the Line of Perforation, 26, alongside the Cord, 50, on the side corresponding to the larger portion of the split box, the Line of Perforation, 26, facilitates a cleaner torn edge on this side which facilitates a more finished appearance of the second box.
This particular embodiment utilizes Removable Section D which is reduced in size. Therefore, the first folding option described in Example 1 will not work, but this box is most preferably folded according to the second option described in Example 1.
In order to easily dispose of the box or prepare the box for storing leftovers, the consumer grasps the Pull-Tab B, 94, and pulls the Cord, 50, following the Cord, 50, around the box as it is torn through, thereby ripping or cutting the box along the Cord, 50, line. The box is then easily separated into two pieces.
Once the box is separated into two pieces, both pieces may be disposed of directly, or alternatively, the open end of the large piece may be folded closed, forming a second sturdy container structure (the second box). The open end is folded shut as follows. Removable Section A1, 92, Removable Section A2, 102, and Removable Section E, 78, are torn along the perforations and removed. The Front Closing Tab B, 116, and the Rear Closing Tab, 110, are folded inwards towards the Top B, 70, after separating them from the Upper Front Wall B, 68, and Back Wall B, 74, along the perforations. The open edge of the Bottom B, 82, is folded in along the Lower Latent Fold Line, 104, towards the Bottom B, 82, into an angle of essentially ninety degrees. The open edge of the Top B, 70, is then folded in along Upper Latent Fold Line, 114, along with the Front Closing Tab B, 116, and the Rear Closing Tab, 110, to an angle of approximately ninety degrees relative to the Top B, 70. The Front Closing Tab B, 116, and the Rear Closing Tab, 110, are opened so that they are approximately parallel to the Lower Front Wall B, 90, and Back Wall B, 74, respectively. This completes the closing of the second box. This folding method may be performed without the necessity of first opening the second box. The consumer may devise other variations in the folding operation.
The reduced size container may now be opened and closed as needed in a manner similar to the original full size container. When closed, the reduced size container is very sturdy and can be used to store leftovers conveniently.
The Lines of Perforation may be comprised of any perforation found in the art. In one particular embodiment, the Lines of Perforation are comprised of elongated perforations situated at an angle between zero and ninety-degrees in relation to the Cord 50. In yet another particular embodiment, the Lines of Perforation are comprised of perforations that include two elongated cuts situated at essentially ninety-degrees to one another, one cut parallel to the Cord, 50, and joined to one another in order to essentially generate a single perforation. In the most preferable embodiment the elongated cut perpendicular to the Cord, 50, is shorter than the elongated cut parallel to the Cord, 50. The use of this type of perforation beside and parallel to the Cord, 50, results in an extraordinarily clean edge after splitting the box in two.
Each of the boxes depicted in the illustrations are simply examples of preferred embodiments of the present invention. Many other specific designs are possible without departing from the spirit and scope of the present invention. The location of the Cord, 50, May be moved in order to change the size or volume of the pieces of the split box. Means for closing the open end similar to that disclosed in the illustrations may be added to both pieces of the split box instead of only one piece. Additionally, many minor changes may be made and details added to the box structure by those skilled in the art without departing from the spirit and scope of the present invention. Examples include but are not limited to: cuts or perforations along fold lines, small tabs designed to lock folded pieces in position, changes to the angle of certain edges to facilitate folding or closing, and changes to the relative scale of the parts of the structure. Each of these changes and details are commonly added to box structures by those skilled in the art.
The present invention has several key advantages when compared to the prior art. First, the utility of the box as a delivery vehicle is not compromised because the structural integrity of the box is not significantly weakened until the consumer chooses. Once the consumer chooses, the box is easily broken into two conveniently disposable pieces. Second, the open end of one or both portions of the split box may be folded shut forming a sturdy storage container (the second box). Third, the present invention achieves its utility while retaining a simple design that is easy to use and economical to manufacture.
Only those limitations disclosed herein should be used to limit the spirit and scope of the present invention.
This application claims priority from application No. 60/902,486 filed on Feb. 20, 2007.
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