Multiple pastry box

Information

  • Patent Grant
  • 6296120
  • Patent Number
    6,296,120
  • Date Filed
    Monday, February 7, 2000
    24 years ago
  • Date Issued
    Tuesday, October 2, 2001
    23 years ago
Abstract
A container assembly for carrying display-packaged delicate baked goods includes a container having opposing side walls interconnected with opposing end walls, a bottom interconnected with each of the side and end walls, a top, and an interior. A retaining tray has at least one aperture therein, and is removably received in the container interior. The retaining tray is dimensioned such that the container side and end walls restrict movement of the retaining tray in a direction perpendicular to the container side and end walls. The retaining tray includes at least one spacing member extending therefrom and spacing the retaining tray from an underlying surface. A display package includes a pan portion and a top removably secured to the pan portion. The pan portion includes a projection extending outwardly therefrom, and is removably received within the aperture until the projection contacts the retaining tray. The projection is disposed on the pan portion such that the display package is suspended from the retaining tray within the aperture above the underlying surface, thereby restricting the display package from movement in a direction perpendicular to the container side and end walls and in a direction toward the bottom of the container.
Description




FIELD OF THE INVENTION




The present invention relates to containers and, more particularly, to containers for the storage and transportation of baked goods.




DESCRIPTION OF THE RELATED ART




Baked goods, such as pastries, cakes, and pies, are delicate items which are easily damaged during the shipping and handling thereof Furthermore, such baked goods are known as “impulse” items because a consumer often purchases baked goods without the prior intention of so doing. In order to increase the likelihood of creating the impulse to buy within the consumer, baked goods are prominently and attractively displayed in a high-traffic area of a retail establishment. The buying impulse is created by appealing to the consumer's senses of sight and smell. Aesthetics are a critical factor in the creation within the consumer of the impulse to purchase a baked good. An aesthetically appealing baked good is much more likely to create the buying impulse within a consumer than an unattractively displayed baked good or one with degraded aesthetics. The aesthetics of baked goods can be negatively impacted due to their delicate nature. Thus, it is desirable to preserve and protect the aesthetic quality of baked goods.




Many bakeries supply baked goods to a number of geographically-dispersed customers such as restaurants and retail outlets. The distribution channel may include, for example, a central bakery which produces large quantities of baked goods. The baked goods are then placed in shipping containers for distribution, and delivered to the customer location by, for example, a delivery truck. Once at the customer location, the shipping containers which contain the baked goods are then carried by hand or upon a wheeled cart from the delivery truck to a location within the retail outlet. During transportation from the bakery to the customer, the shipping containers may be stacked one on top of another, and are likely to encounter relatively rough handling which may result in the baked goods suffering some degradation in aesthetic quality.




Various individual display packages have been developed which enable the aesthetic display of an individual baked good at the point of sale by affording the consumer a relatively unobstructed view of the contents of the package. However, the individual display packages do not effectively protect baked goods during the distribution thereof from the central bakery to the customer location. The protective properties of the typical individual display package are sacrificed in order to achieve the desired aesthetic or display qualities. Such individual display packages may not be stacked one on top of another, nor may they be packed in quantity within a shipping container, without damaging the display package or the baked goods therein which, in turn, degrades the aesthetics of the baked good. Therefore, baked goods are typically packaged in small quantities. Very delicate baked goods, such as pastries, tend to be packaged individually. Even the individually packaged baked goods, however, still require very careful handling if their aesthetic appeal is to be preserved.




Even with careful handling, the individual display packages may shift within the delivery truck or within shipping containers during distribution. Such shifting often results in damage to the baked goods or in damage to the individual display packages. Damage to either the baked good or its display package degrades the overall attractiveness of the display of the baked good, reduces the aesthetic quality thereof, and therefore reduces the likelihood of creating the buying impulse within a consumer.




The above factors result in various inefficiencies within the distribution channel. Valuable delivery truck space is wasted due to an inability to stack boxes. Other examples of such inefficiencies include the additional hours of labor required to accomplish delivery due to the small quantities of baked goods contained in each package, an increased number of trips are required to deliver a given quantity of baked goods, and the special care which must be taken by a delivery person in order to minimize damage to the baked goods. Furthermore, due to damage in transit and delivery, shrinkage occurs from the amount of product which leaves the central bakery to the amount of product which reaches the customer in saleable condition and without loss of aesthetic quality. Such inefficiencies all result in higher operating costs and lower profits.




Therefore, what is needed in the art is a shipping container which enables the shipment of a relatively large quantity of delicate baked goods and which protects the baked good from damage. Furthermore, what is needed in the art is a shipping container which enables the shipment of a relatively large quantity of individually display-packaged delicate baked goods and which preserves the aesthetic appearance of the baked good and its individual display package.




SUMMARY OF THE INVENTION




The present invention provides a multiple pastry box which permits the packing and shipping of a quantity of individually display-packaged pastries within a single carton, and which protects the pastries and the individual display packages from damage, thereby preserving their aesthetic quality.




The invention comprises, in one form thereof, a container assembly, including a container having opposing side walls interconnected and spaced apart by opposing end walls, a bottom interconnected with the side and end walls, a top, and an interior. A retaining tray defines at least one aperture and is removably received in the container interior. The retaining tray is dimensioned such that the container side and end walls restrict movement of the retaining tray in a direction perpendicular to the container side and end walls. The retaining tray includes at least one spacing member extending therefrom and spacing the retaining tray a predetermined distance from an underlying surface. A display package includes a pan portion and a top removably secured to the pan portion. The pan portion includes at least one projection extending outwardly therefrom, and is removably received within the aperture until the projection contacts the retaining tray. The projection is disposed on the pan portion such that the display package is suspended from the retaining tray within the aperture and above the underlying surface, thereby restricting the display package from movement in a direction perpendicular to the container side and end walls and in a direction toward the bottom of the container.




An advantage of the present invention is that the display-packages are restricted from horizontal displacement during packaging, handling and transport.




Another advantage of the present invention is that the display packages are restricted from vertical movement during packaging, handling and transport.




Yet another advantage of the present invention is that the aesthetic quality of the display packages is preserved during packaging, handling and transport.




A still further advantage of the present invention is that a large quantity of display packages containing delicate baked goods may be shipped within one container without degraded aesthetics.











BRIEF DESCRIPTION OF THE DRAWINGS




The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become apparent and be better understood by reference to the following description of one embodiment of the invention in conjunction with the accompanying drawings, wherein:





FIG. 1

is an exploded perspective view of one embodiment of a multiple pastry box of the present invention;





FIG. 2

is a side, partially sectioned view of the retainer trays and display packages of

FIG. 1

; and





FIG. 3

is a perspective view of a display package of FIG.


1


.











Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.




DETAILED DESCRIPTION OF THE DRAWINGS




Referring now to the drawings and particularly to

FIG. 1

, there is shown a multiple pastry box


10


including container


12


, retainer trays


14




a


and


14




b


, and display packages


16


.




Container


12


includes opposing side walls


20


,


22


, end walls


24


,


26


, bottom


28


and a top portion having two side flaps


30


,


32


and two end flaps


34


,


36


, all of which conjunctively define box interior


38


. Container


12


is closed by folding end flaps


34


,


36


inward toward the interior


38


until the flaps are substantially parallel with bottom


28


. Then, side flaps


30


,


32


are likewise folded inward toward box interior


38


until they are substantially parallel with bottom


28


. The side flaps


30


,


32


will thus overlie end flaps


34


,


36


. The side flaps


30


,


32


form a junction therebetween which extends the entire length of the top of container


12


. The container


12


can then be securely closed by, for example, applying tape over side flaps


30


,


32


. The tape preferably is applied such that it covers the junction or intersection of flaps


30


,


32


, thereby joining the flaps together along a substantial length of the junction formed therebetween, and then extends onto end walls


24


,


26


. Container


12


is opened by cutting or removing the tape and reversing the process described above, i.e., the side flaps


30


,


32


are folded out relative to interior


38


and, thereafter, the end flaps


34


,


36


are also folded out relative to interior


38


, thereby rendering accessible any contents previously placed in interior


38


. The bottom


28


of container


12


can, for example, be formed of flaps similarly to the top or, alternatively, formed of a solid one-piece construction. Container


12


is formed of, for example, corrugated cardboard or other suitable material, and is dimensioned to contain a predetermined number of baked goods.




Retainer trays


14




a


and


14




b


are of substantially identical construction and, therefore, only retainer tray


14




a


will be described in detail, such description being equally applicable to retainer tray


14




b


. Referring now to

FIG. 2

, retainer tray


14




a


includes planar top member


40


, side walls


42


,


44


, and end walls


46


,


48


. Retainer tray


14




a


is designed to fit snugly within container


12


and is therefore dimensioned such that there is only a slight clearance between retainer side walls


42


,


44


and container side walls


20


,


22


, and between retainer end walls


46


,


48


and container end walls


24


,


26


. The minimal clearance between the side and end walls of retainer tray


14




a


and the container side and end walls


42


,


44


and


46


,


48


, respectively, ensures retainer tray


14




a


will not be displaced in the horizontal plane when disposed in interior


38


of container


12


. Retainer tray


14




a


is constructed of, for example, corrugated cardboard, paperboard, or, alternatively, injection molded plastic. Retainer tray


14




a


may be constructed by the folding or forming of one piece of, for example, cardboard or paperboard, or may be constructed of separate pieces of material attached or connected together.




Side walls


42


,


44


of retainer tray


14




a


are substantially perpendicular to top planar member


40


. Likewise, end walls


46


,


48


, are substantially perpendicular to planar member


40


. Side walls


42


,


44


and end walls


46


,


48


enable stacking of one retainer tray on top of another. When the retainer trays are stacked one on top of another, side walls


42


,


44


and end walls


46


,


48


create a vertical separation


49


between the respective planar members


40


of each retainer tray. The height of side walls


42


,


44


and end walls


46


,


48


determines the vertical separation or space


49


created between the respective planar top members of the stacked retainer trays.




Planar member


40


defines, for example, six apertures


50




a


,


50




b


,


50




c


,


50




d


,


50




e


and


50




f


therein. Apertures


50




a


-


50




f


are, for example, substantially cylindrical in shape, each being dimensioned to receive and support one of display packages


16


. In general, the shape of the aperture corresponds to the shape of the package


16


.




Display packages


16


include a pan portion


70


, cover


72


and flange


74


. Pan


70


includes a closed bottom portion


76


and an open top portion


78


. Flange


74


is integral with pan


70


and extends radially-outward therefrom. Flange


74


is disposed, for example, near the open top portion


78


of pan


70


. Cover


72


is removably secured to the open top portion


78


of pan


70


by use of, for example, projections (not shown) which snap through complementary features (not shown) in pan


70


. Alternatively, cover


72


can be constructed in a way, or from a material, which renders it elastically deformable. Cover


72


can then be removably secured to pan


70


by elastic deformation over a complementary feature such as, for example, a ridge or ring (not shown) formed around the open top


78


of pan


70


. Display packages


16


are, for example, cylindrical in shape, having a slightly outward flare, and are constructed of, for example, a transparent plastic in order to aesthetically display a baked good contained therein.




Flange


74


is disposed, for example, around the entire perimeter of pan


70


proximate to the open top


78


thereof. Apertures


50




a


-


50




f


are dimensioned to receive pan


70


of display package


16


. However, flange


74


extends radially outward from pan


70


such that flange


74


does not pass through apertures


50




a


-


50




f


. Rather, flange


74


interferes with the outer perimeter of apertures


50




a


-


50




f


and rests on flat planar member


40


of retainer tray


14


. Thus, pans


70


are suspended from planar member


40


within apertures


50




a


-


50




f


by their respective flanges


74


. When the retainer trays are stacked, the portion of the pan


70


below flange


74


is disposed between the stacked retainer trays


14




a


and


14




b


, within the space


49


created by side walls


42


,


44


and end walls


46


,


48


. The vertical separation or space


49


between the stacked retainer trays


14




a


,


14




b


can be adjusted by changing the height of side walls


42


,


44


and/or end walls


46


,


48


during manufacture thereof. Thus, various depths of pans


70


and various heights of covers


72


can be accommodated. Furthermore, virtually any size or shape of pan


70


can be accommodated by changing the shape and dimensions of apertures


50




a


-


50




f.






In use, container


12


is supplied to an end user in, for example, a ready-to-use form, or in a flat or condensed form requiring some assembly. When supplied in a flat or condensed form efficiencies of shipping are realized. When containers


12


are supplied in the flat or condensed form, the top end and side flaps, and a bottom are pre-cut and creased to simplify assembly of container


12


. Assembly is accomplished by closing the bottom


28


of container


12


. Bottom


28


is closed, for example, by a procedure similar to that described above for the closing of top flaps


30


-


36


. Bottom end flaps (not shown) are folded inward until the end flaps are substantially perpendicular to end and side walls


24


,


26


and


20


,


22


, respectively. Bottom side flaps (not shown) are then folded inward, over the bottom end flaps, until the bottom side flaps are substantially perpendicular to the end and side walls


24


,


26


and


20


,


22


, respectively. The bottom of container


12


is then closed by, for example, applying tape to the junction formed between the bottom side flaps and then onto end walls


20


,


22


. Container


12


is thus ready to receive display-packaged backed goods for delivery.




Retainer trays


14




a


and


14




b


may also be supplied in a pre-formed or in a flat or condensed form. If supplied in the flat or condensed form, side walls


42


,


44


and end walls


46


,


48


are pre-cut and creased to simplify assembly. Furthermore, interlocking features (not shown) are also pre-formed in the flat for retainer trays


14




a


and


14




b


, further simplifying assembly thereof. Assembly of retainer tray


14




a


is accomplished by folding side walls


42


,


44


until they are substantially perpendicular to planar member


40


. End walls


44


,


46


are likewise folded, in the same direction as side walls


42


,


44


, until they are substantially perpendicular to planar member


40


. The end walls


44


,


46


and side walls


42


,


44


are interconnected by, for example, tape or an interlocking feature integral therewith.




Once assembled, retainer tray


14




a


is placed within interior


38


of container


12


. Then, pans


70


of display packages


16


, which contain finished or partially finished baked goods, are then placed into a respective one of apertures


50




a


-


50




f


. The covers


72


may have already been attached to pans


70


, or may be attached at this point. Display packages


16


are received within a respective one of apertures


50




a


-


50




f


until flange


74


contacts the outside perimeter of that respective aperture and/or planar member


40


, thereby preventing any further downward displacement of display package


16


. Thus, display package


16


is suspended by flange


74


within a respective aperture from planar member


40


. The portion of pan


70


below flange


74


is disposed in the space


49


formed by the separation created between planar member


40


and the bottom of container


12


by side walls


42


,


44


and/or end walls


46


,


48


of retainer tray


14




a


. The minimal clearance between retainer side walls


42


,


44


and container side walls


20


,


22


, and between retainer end walls


46


,


48


, and container end walls


24


,


26


, respectively, ensures retainer tray


14




a


will not be displaced in a direction perpendicular to side and end walls


20


,


22


, and


24


,


26


, respectively, when disposed in interior


38


of container


12


. The placement of display package


16


within a respective one of apertures


50




a


-


50




f


ensures display package


16


will not be displaced in a direction perpendicular to side and end walls


20


,


22


, and


24


,


26


, respectively. Furthermore, the suspension of display package


16


by flange


74


from retaining tray


14




a


prevents the downward displacement of display package


16


.




A second retainer tray


14




b


is then assembled and placed into container


12


. Side walls


42


,


44


and/or end walls


46


,


48


of retainer tray


14




b


act to vertically space apart the respective planar members


40


of retainer tray


14




a


and retainer tray


14




b


. Pans


70


and/or display packages


16


, containing finished or partially finished baked goods, are then placed within a respective one of apertures


50




a


-


50




f


of retainer tray


14




b


. The spacing between retainer tray


14




a


and


14




b


is chosen such that display packages


16


within retainer tray


14




a


, prevented from downward displacement by flanges


74


, are further prevented from upward movement by the overlying retainer tray


14




b


and/or the display packages


16


contained therein.




This process of placing retainer trays into container


12


and placing pans


70


and/or display packages


16


into the apertures of the retainer tray is repeated until container


12


has reached its capacity. Container


12


is then closed as described above.




In the embodiment shown, the top of container


12


is shown as being integral with container


12


and including flaps


30


-


36


. However, it is to be understood that the top of container


12


may be alternatively formed as one piece of material integral with, or separate from, container


12


.




Apertures


50




a


-


50




f


, in the embodiment shown, are shown and described as being cylindrical in shape. However, it is to be understood that the apertures may be of virtually any shape which corresponds to the particular display package being placed therein.




In the embodiment shown, container


12


and retainer trays


14




a


,


14




b


, are shown and described as being constructed of cardboard and/or paperboard. However, it is to be understood that container


12


and retainer trays


14




a


,


14




b


can be alternatively constructed out of, for example, injection molded plastic, sheet metal, or virtually any other suitable material.




In the embodiment shown, Flange


74


is shown and described as disposed proximate to the open top


78


of pan


70


of display package


16


. However, it is to be understood that flange


74


may be disposed at other points along the outside of pan


70


. Furthermore, flange


74


is disclosed as being disposed around the entire perimeter of pan


70


. It is to be understood that flange


74


can be disposed around only a portion of the perimeter of pan


70


and still perform its intended function. Moreover, flange


74


may alternatively be formed as simple projections or stubs extending radially outward from pan


70


.




Cover


72


of pan


70


is, in the embodiment shown, disclosed as including projections (not shown) which snap into corresponding features (not shown) on pan


70


, or as elastically snapping over a ridge disposed proximate to open top


78


of pan


70


. However, it is to be understood that cover


72


may also be configured to elastically deform or snap over flange


74


. Furthermore, cover


72


may include a portion of or form a portion of flange


74


.




While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the present invention using the general principles disclosed herein. Further, this application is intended to cover such departures from the present disclosure as come within the known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.



Claims
  • 1. A container assembly, comprising:a container having opposing side walls interconnected with and spaced apart by opposing end walls, a bottom interconnected with each of said side walls and said end walls, a top, and an interior defined by said side walls, said end walls and said bottom; at least one retaining tray defining at least one aperture therein, said at least one retaining tray being removably received in said interior of said container and being dimensioned such that said side walls and said end walls restrict movement of said retaining tray in a direction perpendicular to said side walls and said end walls, said retaining tray including at least one spacing member extending therefrom and spacing said retaining tray a predetermined distance from an underlying surface; and at least one display package having a pan portion and a top removably secured to said pan portion, said pan portion including at least one projection extending outwardly therefrom, said at least one display package being removably received within said aperture until said projection contacts said retaining tray, said projection being disposed on said pan portion such that said display package is suspended from said retaining tray within said aperture above said underlying surface, said display package thereby being restricted by said aperture from movement in a direction perpendicular to said side walls and said end walls and restricted from movement by said projection in a direction toward said bottom of said container.
  • 2. The container assembly of claim 1, wherein said opposing side walls and said opposing end walls of said container comprise one continuous side wall, said bottom being interconnected with said side wall.
  • 3. The container assembly of claim 1, wherein each of said at least one aperture has a shape corresponding to a shape of said pan suspended therein.
  • 4. The container assembly of claim 1, wherein said pan includes a bottom interconnected with a substantially cylindrical side wall thereby defining an open end opposite said bottom, said projection comprising a flange disposed proximate to and around at least a portion of said open end.
  • 5. The container assembly of claim 4, wherein said side wall of said pan includes a first diameter proximate to said bottom of said pan and a second diameter proximate to said open end of said pan, said second diameter being greater than said first diameter.
  • 6. The container assembly of claim 1, wherein said pan includes opposing side walls interconnected and spaced apart by opposing end walls, and a bottom interconnected with each of said side walls and said end walls thereby defining an open end opposite said bottom, said projection comprising a flange disposed proximate to and around at least a portion of said open end.
  • 7. The container assembly of claim 1, wherein said at least one aperture comprises a plurality of apertures.
  • 8. The container assembly of claim 1, wherein said at least one retaining tray comprises a flat planar member.
  • 9. The container assembly of claim 8, wherein said flat planar member includes two opposing end rails which interconnect and space apart two opposing side rails, said flat planar member interconnected with each of said two end rails and said two side rails, said flat planar member defining said at least one aperture therein.
  • 10. The container assembly of claim 8, wherein said side rails and said end rails cooperate with said side walls and said end walls of said container to restrict displacement of said retaining tray in a direction perpendicular to said side walls and said end walls.
  • 11. The container assembly of claim 8, wherein said at least one spacing member comprises at least one of said two opposing side rails and said two opposing end rails.
  • 12. The container assembly of claim 1, wherein said at least one retaining tray comprises a plurality of retaining trays, each of said retaining trays being received within said container such that said retaining trays are disposed one on top of another, each of said retaining trays being spaced a predetermined distance apart by said at least one spacing member, each of said retaining trays having at least one display package suspended therefrom within a respective aperture, each of said at least one spacing members being dimensioned such that said predetermined distance is greater than a height of said display packages.
  • 13. The container assembly of claim 1, wherein said container top is integral with said container.
  • 14. The container assembly of claim 1, wherein said container is formed from a flat blank of material, said blank being appropriately cut and scored so as to enable folding and assembly of the blank into a finished container.
  • 15. The container assembly of claim 1, wherein said display package is transparent.
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