Patent Grant
7240797
The present invention relates generally to packaging and dispensing systems for food products, and more particularly relates to a single-step apparatus for storing, handling, and dispensing individual sandwich-sized servings of food products, and a method for the same.
There is currently an increasingly large consumer demand for low-cost sanitary foods which are packaged and ready-to-eat. A variety of techniques and materials have been used for packaging various types of food products in order to provide for their safe storage, shipping, and handling, as well as to provide for their easy consumption.
One common type of ready-to-eat food is the sandwich (or sandwich-type foods such as hamburgers, hotdogs, pita-sandwiches, falafel sandwiches, gyros, subs, heros, tacos, burritos, etc., which will hereinafter be collectively referred to as sandwiches). Sandwiches find widespread use in fast-food-type operations. Additionally, sandwiches are commonly used for school lunches and other packaged meals (e.g., in airline meals, and in vending machines).
The bread in sandwiches usually absorbs moisture from the sandwiches' fillings. This moisture adversely affects the sandwiches' taste and texture. Accordingly, when moist fillings such as egg salad or tuna salad are used, the sandwiches must be consumed within a relatively short period of time, which is inconvenient and uneconomical. Sandwiches which are intended to last for several hours or more are generally made with relatively dry fillings, such as turkey, salami, or ham.
In the airline industry, it is typical that from the time the food is prepared by a caterer until the time the food is served to passengers aboard an aircraft, four or more hours will have passed. Because of this delay, airlines typically serve sandwiches which have substantially dry fillings, and avoid sandwiches which contain moist fillings such as tuna salad or egg salad.
A large number of moist and/or sticky products are commonly used as sandwich fillers. Moist and/or sticky sandwich fillers include egg salad, tuna salad, chicken salad, and peanut butter and/or jelly, as well as various condiments such as mustard, ketchup, and tomatoes. Sandwiches made using many of these products require refrigeration or special handling to insure that they do not spoil. However, refrigeration at times may be inconvenient or unavailable. Moreover, refrigeration adversely affects the taste of the bread and therefore may not be desirable or advantageous.
Although there are a number of prior art methods to deal with the aforementioned problems associated with sandwiches containing moist and/or sticky fillings, none of them provide for an easily-dispensed, sanitary, long-lasting, fresh-tasting sandwich.
One common prior art method requires that the sandwich filler be packed separately from the bread. Although this method does keep the bread from absorbing moisture from the filling, it requires that the user make the sandwich after unpacking the bread and unpacking the filler, which is inconvenient. Additionally, the extra handling involved in making the sandwich increases the likelihood that the sandwich will become contaminated, and requires the use of utensils which may be unavailable.
Another method uses an array of chemicals to seal meat that is used in sandwiches and to inhibit bacterial growth. The completed sandwiches are then vacuum-sealed. However, because chemicals are added to the food product, the flavor and/or consistency of the food is altered. Additionally, this system does not provide for individual selection of various combinations of breads and fillers.
U.S. Pat. No. 4,653,685 to Leary, et al., entitled “Dual compartment sandwich package,” discloses a dual compartment sandwich package fabricated of foamed polystyrene or the like and adapted to retain therein in appealing and acceptable form a sandwich including a hot meal portion, such as a hamburger, and a cool trimmings portion, such as lettuce and tomato. The package comprises two compartments, one for containing the hot meal portion and the other to retain the cool trimmings portion. While this product maintains the sandwich components in an acceptable condition for a longer period of time than a fully assembled sandwich would be, it requires a larger container (which is about twice as large as a single-compartment container) and additional materials, and also requires the user to assemble the sandwich before use, thus adding inconvenience and increasing the likelihood of contamination during assembly.
U.S. Pat. No. 5,312,641 to Castillo, entitled “Non-spread peanut butter slices and method of making,” discloses a non-spread, sliced peanut butter product containing chunky peanut butter, powdered egg white, flour, and an emulsifier. The ingredients are mixed together, and pressed or extruded into sheets which are about the length and width of a bread slice and about 0.2 inches thick. However, this product has a different composition and texture from conventional peanut butter and requires that the user handle the product when applying it to the bread.
U.S. Pat. No. 6,165,521 to Mayfield, entitled “Food products utilizing edible films and method of making and packaging same,” discloses an edible material thin film which is applied to at least one side of a sticky or moist food product. The food product with edible material thereon may be used to make sandwiches, or stored without additional protection. However, because this material is added to the food product, it alters the flavor and/or consistency of the food and is therefore not desirable. Additionally, the invention does not provide for a sanitary holding means before the food product is applied to a desired object, such as a slice of bread. Moreover, the invention does not provide for the inclusion of gravy or other liquids with the food product.
Thus, there is a need for an easy-to-use packaged food dispenser which dispenses sandwiches that are fresh, sanitary and that have bread that is not soggy. Additionally, there is a need for a dispenser that can dispense packaged foods which does not require the use of utensils to remove the food from the package and apply it to the desired object. Furthermore, there is a need for a dispenser which can dispense packaged foods (such as sandwiches) from vending machines (and refrigerators and the like) while extending the life of the food. Moreover, there is a need for a package and dispenser which are ideally suited for fast-food meals, airline meals, and meals for armed-forces personnel.
The present invention provides a packaging and dispensing system that overcomes the disadvantages of the prior art discussed above. The packaging and dispensing system comprises a sealed dispenser which keeps the food (hereinafter filler, sandwich contents or simply contents) contained therein fresh and which provides for easy application of the filler (without utensils) to a desired surface (such as slices of bread or a plate), while minimizing the possibility of contamination. The present invention is ideally suited for the packaging and dispensing of sandwich fillers, sandwiches, and the like. The sealed dispenser can be used alone or can be used with other packaging means (e.g., an outer container, an outer box means, etc.).
While the present invention can be used with many products (e.g., deli meats, hotdogs, hamburgers, corn-on-the-cob, etc.), it is particularly suited for packaging of single-serve portions of moist and/or sticky foods (such as tuna salad or egg salad) within sandwiches. Additionally, the present invention, or individual units of it, may be used alone or in combination with each other to dispense combinations of individual single-service portions. Additionally, the present invention, when constructed utilizing suitable materials, can be used to store foods when cooling and/or warming them, during other phases of preparing and handling them, and while serving them. For example, a hotdog vendor can use the present invention to cook and dispense hotdogs (with or without the buns) without coming into contact with, and possibly contaminating, the hotdog filler and/or bun.
The current invention comprises an inner container and an optional outer container. The inner container contains the filler and comprises a center member, a holding means, an outer cover, and one or more draw members. The outer cover has an inner periphery and an outer periphery as well as one or more ends (e.g., a first end and a second end). The outer periphery of the outer cover is releasably attached to the center member so that the combination formed by the outer cover and the center member forms a cavity for holding the filler. The draw member(s) is/are attached to the end(s) of the outer cover. One or more optional tab members, suitable for grasping, are attached to the draw member. The draw member transfers a force from the tab member to the outer cover or from the user to the outer cover, which force peels the outer cover from the center section, thus folding the outer cover over itself as it is removed from the center section.
In alternative embodiments, the outer cover comprises at least two sheets. For example, the outer cover can be comprised of a first sheet and a second sheet. The first sheet and the second sheet are releasably attached to each other, as described infra, so as to form a continuous sheet which is shaped and sized similarly to the single outer cover as discussed supra. The first sheet and the second sheet have an inner and an outer periphery. An attachment means sealably secures parts of the outer peripheries of both the first sheet and the second sheet to the center member so that the combination formed by the first sheet, the second sheet, and the center member forms a cavity for holding the filler. A first draw member is attached to the first end of the first sheet and a second draw member is attached to the second end of the second sheet (wherein the first end of the first sheet and the second end of the second sheet when attached to each other correspond to the corresponding parts of the outer cover). The first draw member operates to transfer a force from the user to the first sheet, which force peels the first sheet from the center member (and optionally separates the first sheet from the second sheet). Likewise, a second draw member is attached to the second sheet and acts to transfer a force from the user to the second sheet, which force peels the second sheet from the center member.
In yet other alternative embodiments, the center member (or parts thereof) is formed integrally with the outer cover from the same sheet of material. The center member is attached to the outer cover via one or more weakened lines. A holding means is attached to the center member. The outer cover is folded over itself so as to form a cavity for holding the filler. The center member is then attached to itself and/or to the outer cover so as to seal the cavity. In use, the outer cover is removed from the center member (at the weakened lines). Alternatively, the outer cover can comprise two or more portions. The first sheet and the second sheet are releasably attached to each other as described infra, so as to form a continuous portion which is shaped and sized similarly to the single outer cover as discussed supra. The first sheet and the second sheet have an inner and an outer periphery. The center member is releasably attached to either or both the first sheet and the second sheet so that the combination formed by the first sheet, the second sheet, and the center member forms a cavity for holding the filler. A first draw member is attached to the first sheet and a second draw member is attached to the second sheet. The first draw member operates to transfer a force from the user to the first sheet, which force peels the first sheet from the center member. Likewise, the second draw member is attached to the second sheet and acts to transfer a force from the user to the second sheet, which force peels the second sheet from the center member, thus exposing the filler.
The optional outer container is suitable for holding the combination that is formed by the slices of bread or other sandwich portions (hereinafter, the sandwich halves), and the inner container, which is located between the sandwich halves. Without limitation, the outer container may be constructed from a flexible material (e.g., paper, foil, plastic, laminates, suitable polymers, or the like), a rigid or substantially rigid material (e.g., plastic, cardboard, foam, rigid polymers, etc.), or a combination of these or similar materials.
Either or both the outer container and the inner container can be held within an outer box means. The outer box means can also hold additional items such as a drink container, a snack container (e.g., one containing crackers or the like), and other desired items as are common in prepackaged meals such as Lunchables™ by Oscar Meyer Foods, Madison, Wis., Giggles to Go™ Sandwich Lunch Kit by Venetian Bakery™, Northlake, Ill., or airline meals as are commonly served aboard commercial flights. Without limitation, the box means may be constructed from a non-rigid material (e.g., paper, foil-backed paper, plastic, solid polymers, or the like), a rigid or substantially rigid material (e.g., plastic, cardboard, foam, solid polymers etc.), or a combination of these or similar materials.
In use, one or more inner containers are placed between the sandwich portions (e.g., slices of bread, the sandwich halves, etc.). The inner containers are then opened by removing the outer cover from the center member as discussed supra, thereby opening the cavity. The complete sandwich is then removed from the center member.
Alternatively, one or more inner containers are placed in proximity to a desired object (e.g., a plate or a single slice of bread). The inner container(s) is (are) then opened by peeling the outer cover from the center member thereby releasing the filler(s) onto the desired object.
It is further contemplated that the outer cover may be partially peeled away from the center member, thus partially exposing the filler contained within the cavity. The filler is then removed or eaten directly from the partially-opened cavity.
One method of this invention comprises the packaging of a sandwich filler within the inner container and sealing the outer cover of the inner container. The inner container is then optionally placed between two sandwich portions for final assembly of both the sandwich portions and the filler portion into a single sandwich by the consumer, and for consumption by the consumer.
Another method of this invention comprises the packaging of a sandwich filler within the inner container and securing the inner container within the outer container for final assembly for use by the consumer.
The inner container can be placed within the optional outer container so that the combination formed by the sandwich slices and the inner container is held in a desired position for storage, shipping and/or dispensing.
The inner container is ideally suited for dispensing the filling without the need for utensils, while minimizing the possibility of contaminating the sandwich.
It is an object of the current invention to provide for a sealed package which can be dispensed from vending machines and the like.
It is a further object of the current invention to provide for a sealed package which will keep a sandwich and its filling fresh for a longer period of time than if the sandwich and its filling were packaged with conventional methods.
It is a further object of the current invention to provide for a sealed package for a filling or other food product without the need for refrigeration.
It is a further object of the current invention to provide for a sealed package for a filling which can be easily opened and consumed.
It is a further object of the current invention to provide for a sealed individual serving of a filling. The individual serving which is contained within the inner container is then easily combined with two slices of bread to form a sandwich. The sandwich may be contained within an optional outer container.
It is a further object of the current invention to provide for the ability to keep the filler separate from the bread, thus preserving both the bread and the filler.
It is a further object of the current invention to provide for a modular sealed dispenser system wherein a plurality of inner containers can be stacked upon, and used with, other like inner containers which hold various fillers.
It is a further object of the current invention to provide for a sealed inner container with an outer cover which substantially cleans itself upon removal of the outer cover from the center member.
It is a further object of the current invention to provide for a package means for sandwich fillers in which the package is constructed from inexpensive materials and may be manufactured in large quantities at low cost, is easy to open and use, and permits the efficient utilization of the food product contained within the package.
Additional objects and advantages of the current invention will be set forth in the description which follows.
There is thus provided in accordance with the present invention an apparatus for packaging a sandwich filler comprising a center member adapted to provide space for the sandwich filler, an outer cover having a first end and a second end, the outer cover releasably attached to the center member so as to form a cavity for the sandwich filler, and a removal means attached to the first end and the second end of the outer cover such that pulling the removal means away from the center member causes the separation and removal of the outer cover from the center member, thereby exposing the sandwich filler contained therein.
There is also provided in accordance with the present invention an apparatus for packaging a sandwich filler comprising an outer cover having a first end and a second end, the outer cover folded over the sandwich filler forming a first portion and a second portion, the first portion peripherally sealed to the second portion so as to form a cavity for the sandwich filler and removal means attached to the first end and the second end of the outer cover such that pulling the removal means causes tearing of the first portion from the second portion, thereby causing the removal of a portion of the outer cover, thereby exposing the sandwich filler contained therein.
There is further provided in accordance with the present invention an apparatus for packaging a sandwich filler comprising a first center member and a second center member arranged so as to provide space for the sandwich filler, a first outer cover and a second outer cover, the outer periphery of the first outer cover releasably attached to a first side of the first center member and the second center member, the outer periphery of the second outer cover releasably attached to a second side of the first center member and the second center member so as to form a cavity for the sandwich filler, a removal means attached to the first outer cover and the second outer cover such that pulling the removal means causes the separation and removal of the first outer cover and the second outer cover from the first center member and the second center member, thereby exposing the sandwich filler contained therein, a first holding means attached to the first center member, and a second holding means attached to the second center member, wherein once the first outer cover and the second outer cover are removed, pulling the first holding means and the second holding means in opposite directions causes the first center member to separate from the second center member.
There is also provided in accordance with the present invention an apparatus for packaging a filler comprising a center member adapted to provide space for the filler, an outer cover having a first end and a second end, the outer cover releasably attached to the center member so as to form a cavity for the filler, and a removal means attached to the first end and the second end of the outer cover such that pulling the removal means away from the center member causes the separation and removal of the outer cover from the center member, thereby exposing the filler contained therein.
The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
The following terms and definitions apply throughout this document.
The term “adhesive” is used to denote all suitable types of adhesives, including but not limited to pressure-sensitive adhesives, transfer adhesives, adhesive coatings, thermal adhesives, cohesives, epoxies, and glues, as well as thermal bonding, pressure bonding and other suitable methods of bonding the desired materials together.
The term “weakened line” is used to denote perforated, scored or other types of lines which are sufficiently weakened so that a desired force will cause separation of the weakened line. Additionally, tear strips, reinforcing cords or other suitable objects can be placed in close proximity to the weakened line so as to enhance the separation of the weakened line.
The terms “sandwich halves” and “sandwich portions” are used to denote bread slices, pita slices, cut rolls, or other objects which are placed on either side of the inner container and onto which the filler is deposited. Moreover, when using pita slices, the inner container may be placed within the pita slices or between them.
The terms “draw means” and “removal means” refer to draw members and/or other force-transmitting members for the removal of the outer cover. For instance, a draw member may be replaced by a rigid element which extends in any way, as desired, and which transmits a force from a desired object to the outer cover. The terms “filler,” “sandwich contents” or “contents” refer to a sandwich filler (e.g., a hamburger, hotdog, deli slices, peanut butter, tuna, etc. as has been described elsewhere in this document) or other desired object which is placed within the dispenser's cavity and dispensed by the inner container.
The term “holding means” refers to holding members or other means which are attached to either or both the center member and the outer cover. The primary function of the holding means is to keep the outer cover and the inner container in position during removal of the outer cover from the inner container. Throughout this document, in embodiments where the holding member(s) or holding means is attached only to the center member, it will be assumed that the holding members or holding means is attached to the outer cover.
The term “tab member” refers to a tab or handle designed to facilitate grasping and pulling the draw member (or other draw means). The tab member can be made integrally with the draw member from the same material as the draw member, or can be made of another type of material, such as a rigid plastic or cardboard. The tab member may be embossed, shaped, colored, or otherwise formed so as to indicate its proper use and so as to enable the user easily to grasp and pull it. Tab members include the first and second tab as well as the jointly formed common tab, as will be discussed infra.
In a majority of the embodiments, the adjacent interior portions of the outer cover are either fixably or releasably attached to each other except at those points where the center member intervenes between them, at which points the outer cover is either fixably or releasably attached to the center member. Throughout this document, in embodiments that employ a center member which is placed between and is releasably attached to the first portion and the second portions of the outer cover, it will be assumed that the first portion is attached to the second portion of the outer cover. The one or more center members are placed at selected locations or continuously along the outer perimeter of the outer cover. Moreover, in some embodiments the center member can, at select locations, be attached to the exterior surface of the outer cover.
Note that throughout the present invention, interchangeability of components is contemplated and the corresponding terms throughout this specification including the claims may therefore be substituted for one another as desired as would be reasonable to one skilled in the art. For example, a first sheet and a second sheet may be substituted for the outer cover, in which case an attachment means must be included.
The present invention is applicable to food-storage dispensers and the like, and is characterized by an inner container which is comprised of a center member, one or more outer covers, at least one draw member, and a holding means. It will be appreciated that the filler is completely contained within the inner container without the need for additional packaging.
It will be further appreciated by one skilled in the art that the various embodiments of the present invention may be constructed using different materials, such as paper, cardboard, plastic, foam, aluminum foil, paperboards, laminates, other types of solid polymers, and other materials of suitable construction.
A top-view illustration of a single-piece outer cover and attached draw members according to a first embodiment of the present invention is shown in
A top-view illustration of an alternative single-piece outer cover and attached draw members according to a first embodiment of the present invention is shown in
When an inner container is placed between the sandwich halves, full-width draw members prevent the lateral edges of either or both the outer cover and the draw members from dragging on the adjacent sandwich half during removal of the outer cover from the center member. This is the preferred embodiment when using soft breads for the sandwich halves and should be used when the lateral edges of the outer cover stick to the sandwich halves.
A side-view illustration of a first embodiment of the inner container of the present invention having a single outer cover is shown in
The inner container comprises the outer cover 76, a center member 78, the first draw member 80, the second draw member 82, and a holding member 84. The outer cover is folded back over itself in the area that is adjacent to, and located along, the mid fold 86, so that the interior side 88 of the outer cover faces itself and so that the outer periphery of the outer cover is substantially aligned with and superposes itself. Alternatively, the outer periphery of the outer cover can be offset such that it does not have to be substantially aligned with itself (this will be desirable if using asymmetrically shaped center members). The outer periphery of the outer cover is releasably attached to the center member using a suitable sealing process (described infra) so as to form a cavity for holding the filler. Suitable sealing methods include thermal, pressure, adhesive, pressure-sensitive-adhesive, and other suitable methods as are known in the art, or combinations thereof, as will be discussed infra.
The outer cover is shaped and sized such that the outer periphery of the outer cover covers that area of the center member to which the outer cover is to be attached. In alternative embodiments, the outer cover is shaped and sized such that its outer periphery extends beyond the outer periphery of the center member.
The center member has a height HHH which is preferably sufficient so that the outer cover preferably does not bulge substantially due to the thickness of the filler contained within the inner container.
The first draw member and the second draw member are used as a means for removing the outer cover from the center member. The first end 90 of the first draw member extends far enough beyond the edge of the combination formed by the center member and the outer cover so that the first end is easily accessible to a user, and is provided with an optional first tab 92. The first tab should be shaped and sized such that a user may easily grasp the tab when using the invention. The second end 98 of the first draw member is attached to the first end 106 of the outer cover adjacent to fold 112.
The first end 94 of the second draw member extends beyond the perimeter of the outer cover so that it is easily accessible to a user, and is provided with an optional second tab 96. The second tab should be shaped and sized similarly to the first tab such that a user may easily grasp the tab when using the invention. The second end 108 of the second draw member is attached to the second end 110 of the outer cover adjacent to fold 114.
If desired, the lengths of the first draw member and the second draw member can differ so that the first end of the first draw member and the first end of the second draw member are offset (as shown).
In alternative embodiments, the first draw member and the second draw member are formed from a single sheet of material which is folded at a location that is adjacent to the first end of the first draw member so as to form a first draw member and a second draw member.
In yet other alternative embodiments, the first draw member and the second draw member are joined together in the area adjacent to the first end of the first draw member and the first end of the second draw member. Furthermore, if desired, the first tab and the second tab may be attached to each other or combined so as to form a single pull tab which is suitable for grasping. Such a pull tab provides an easy way for a user to grab and remove the outer cover thus exposing the sandwich contents to the bread.
A means for holding the inner container is provided. The means for holding the inner container should be attached to the center member (or, in alternative embodiments, can be releasably attached to the outer cover itself) and should be capable of maintaining a force which approximately is equal to the force exerted by the draw members when the inner container is being opened. In alternative embodiments, suitable holding means include straps, tabs, or other protrusions which are attached to, or formed integrally with, the center member, and which maintain the desired position of the center member during use of the invention (e.g., during filling and/or dispensing). Other suitable holding means include indentations (e.g., perforations, knurling, etc.) in (or attached to) the center member which would enable the user to grasp the center member. In yet other alternative embodiments, the holding means can comprise an adhesive which is attached to the inner container.
The holding means holds the inner container in a desired position when the outer cover is removed from the center member of the inner container (thus opening the inner container). Additionally, the holding means can be used for storing (e.g., hanging on a refrigerator shelf), holding (e.g., when taking the inner container out of a refrigerator etc.), and transporting the inner container. Furthermore, the means for holding can be used to hold those parts of the inner container which are still contained within the two sandwich halves after the outer cover is removed from the inner container.
A suitable holding means comprises a holding member 84. The holding member is shaped and sized such that it can slide into an optional opening or retention slot (as will be described infra) and includes a locking means such as notches 116 which are shaped and sized so as to lock the holding means into place for use, as will be described infra. Moreover, if required, the holding member should flex sufficiently to allow the notches to lock into place. Additionally, in alternative embodiments, the holding member is shaped and sized such that the user may grasp it for handling. In alternative embodiments, the locking means is an adhesive or other bond. In yet other alternative embodiments, the locking means may be attached directly to the center member, in which case the holding member is unnecessary.
The holding member is constructed from a flexible material and is attached to the base member 104 of the center member using pressure bonding, thermal bonding, adhesive, pressure-sensitive adhesive, or other suitable bonding methods as are known in the arts and which are compatible with the materials used. In alternative embodiments, the holding member may be formed integrally with the center member from the same sheet of material. Alternatively, the holding member may be constructed from a rigid material.
In other alternative embodiments, the holding means can be located on the same side as either or both the first tab and the second tab. In alternative embodiments, the first and second ends of the outer cover can extend so that they touch each other and, if desired, can also be releasably attached to each other, preferably using a pressure-sensitive adhesive or other suitable bond as is known in the art. In yet other alternative embodiments, one or more center members may be combined and used jointly when forming the inner container.
In other alternative embodiments, the center member is a flat sheet of material and has no substantial height. For example, parts of the center member (e.g., the side members) may be partially made integrally with the outer cover from the same sheet of material. The outer cover is separated from the center member by a weakened line (e.g., a score, tear-strip or other suitable method as is known in the art). The base member is then attached to the outer cover, and during separation of the outer cover from the base member, the side members are formed.
In use, the inner container is filled by attaching the lower portion of the outer cover to the center member so as to form a cavity for containing the filler. The filler is then placed on the lower portion of the outer cover, and the outer cover is then releasably attached to the center member. The optional upper and lower sandwich halves are then placed adjacent to the upper and lower sides of the inner container and, optionally, held in position using an optional outer container or box means etc. as will be described infra. Alternatively, the filler is placed on a portion of the outer cover, and the outer cover is then releasably attached to the center member. The optional sandwich halves are then applied as described supra.
A top planar-view-illustration of the first embodiment of the inner container of the present invention, as shown in
The draw members which are used are depicted as shown in
In alternative embodiments, the side members may extend outward from the base member parallel to each other. In yet other alternative embodiments, the side members join each other at both ends so as to form a ring-like structure. In other embodiments, either or both side members are eliminated. In yet other alternative embodiments, one or more side members, or parts thereof, may be removable from the center member. In other alternative embodiments, a cross member is attached to the outer cover adjacent to the outer cover fold 86, and extends between the side members so as to provide additional rigidity to the outer cover (especially in those embodiments which use a multipart outer cover). The cross member can be optionally attached to either or both the outer cover and the center member.
In alternative embodiments, the base member or the bond between the base member and the outer cover, can be curved, “V” shaped, or shaped in some other way that will reduce the force required to break the bond between the outer cover and the base member. For example, the side members may form a “V” shape meeting at the center of the “V,” in which case the base member is eliminated.
A side-view illustration of a second embodiment of the inner container of the present invention, having a two-piece (multipart) outer cover, is shown in
A side-view illustration of a third embodiment of the inner container of the present invention having a single outer cover is shown in
A top-planar-view illustration of a third embodiment of the inner container of the present invention, as shown in
A perspective-view illustration of a fourth embodiment of the inner container of the present invention with a partial cutaway of the outer cover is shown in
A perspective-view illustration of a fifth embodiment of the inner container of the present invention having a two-part center member and using a two-part outer cover, is shown in
The first center section has distal ends 198. The second center section has distal ends 199. The distal ends of the first center section are located adjacent to the distal ends of the second center section so that the first and second center sections encircle the desired filler.
The first outer cover (seen with partial sections cut away) has an interior side, an exterior side 200, an inner periphery 197, an outer periphery 201, and a first end 202 which projects from the outer perimeter of the outer periphery of the first outer cover. The second outer cover (seen peeled away from the second center section) is shaped and sized similarly to the first outer cover and has an interior side, an exterior side, an inner periphery, an outer periphery, and a second end which projects from the outer perimeter of the outer periphery of the second outer cover.
The first draw member extends from the first end of the first outer cover, and comprises a first end and an opposed second end 151, and an optional first tab 203. The second end of the first draw member is attached to a first end of the first outer cover. Likewise, the second draw member 194 extends from the second end of the second outer cover and comprises a first end 153, an opposed second end, and a second tab 155. The second end of the second draw member is attached to the second end of the second outer cover.
The outer periphery of both the first outer cover and the second outer cover are releasably attached (e.g., using adhesive, etc.) to both the first center section and the second center section so that the interior sides of both the first outer cover and the second outer cover face each other, and such that a cavity suitable for holding a filling is formed. The first tab and the second tab superpose each other and are attached to each other so as to form a common tab.
The means for holding the first and the second center sections comprises a first holding member and a second holding member. The first holding member 204 is attached to the first center section and provides a means for handling the inner container both before and after use. A second holding member 206 is provided for separating and removing the second center section from the first center section after the first and second outer covers are removed. After the first and second outer covers are removed from the center member, the center sections are removed from each other by pulling the holding members in opposite directions. If desired, the center member is then slid away from the filler 157. Narrow draw members are shown for clarity, and, in actual embodiments, full-width draw members are preferred.
A locating means (e.g., a weakened line, a tab, a hinge, a notch, a friction fitting, or other suitable locating method) is used to positively locate the center sections relative to each other so that after the outer covers are removed from the first and second center sections, the center sections are held adjacent to each other until they are separated from each other by the user. For example, adhesive tape having a desired strength can be attached to both the first center section and the second center section adjacent to, and across, the distal ends of both center sections. The tape should be sufficiently strong such that the center sections remain attached to each other during removal of the outer covers. After the outer covers have been removed, pulling the first and second holding members in opposite directions will break the tape and allow the center sections to be pulled apart from each other.
In alternative embodiments, one side of the adjacent distal ends of the first and second center sections are hingedly connected, while the other side is releasably attached so that after the first and second outer covers are removed from the first and second center sections, the first and second center sections can be pivoted (rather than separated) and then removed from the filler.
In alternative embodiments, only a single outer cover is used. This outer cover is wrapped around the second holding member such that the mid fold of the outer cover is adjacent to the second holding member.
In yet other alternative embodiments, the adjacent distal ends of the first and second center sections are hingedly connected to each other while the other pair of adjacent distal ends are releasably attached to each other so that after the outer covers are removed from the first and second center members, the first and second center members can be pivoted and removed from the filler. In yet other alternative embodiments, the first center member is attached to the second center sections at a weakened line (e.g., a score, perforation, etc.) and, if desired, they are separated from each other by pulling their holding members in opposite directions. In further alternative embodiments, the first and second center members are releasably attached to each other using a friction fit (e.g., a tab and a notch or other engaging means).
A perspective-view illustration of the fifth embodiment of the inner container of the present invention, as shown in
A perspective-view illustration of the fifth embodiment of the inner container of the present invention, as shown in
A top-view illustration of the single-piece outer cover and attached draw members according to the sixth embodiment of the present invention is shown in
In alternative embodiments, the holding means is formed by extending the side extensions at longitudinal edges 231 and 233 (which extend along the longitudinal length of the side extensions between the first and second ends of the outer cover) by any desired length.
A top-planar-view illustration of a sixth embodiment of the inner container of the present invention having a composite center member and a single-piece outer cover is shown in
Alternatively, the outer cover, holding member, retained portion and first and second draw members are all formed integrally from the same sheet of material. The different portions of the single sheet of material are assigned different names to illustrate the different functions performed by each portion. Further, the weakened lines may be eliminated and optional ‘V’ notches used to direct the tearing forces along the length of the outer cover (dashed lines 226). The forces are applied when the draw members are pulled so as to remove most of the outer cover to expose the sandwich filler therein while a small retained portion remains behind.
The outer cover is folded over itself (at the mid fold) and is releasably attached to the base member (which is formed integrally with the holding member from the same sheet of material—and is actually a part of the holding member) using any suitable bond (e.g., adhesive, thermal bonding, pressure, pressure-sensitive adhesive bonding, etc.). The adjacent opposed surfaces of the side extensions are attached to each other using a suitable bonding method (e.g., adhesives, thermal bonding, pressure, pressure-sensitive adhesive bonding, etc.) so as to form the completed side members. Optional separation notches 232 are located adjacent to the ends of the outer cover and intersect the weakened lines. The separation notches act to concentrate forces transferred from the draw members to the weakened lines so as to cause the weakened lines to tear. The separation notches are shown as large V-shaped cutouts but, in actuality, can be any type of weakened line. The holding member is attached to the center member. The first and second draw members are formed integrally with the outer cover from the same sheet of material. Optional tab means suitable for grasping are attached to the first and second draw members. Filler 236 is located within the inner container.
A sectional-view illustration of the sixth embodiment of the present invention taken along line 11A—11A of
A sectional-view illustration of the sixth embodiment of the present invention taken along line 11B—11B of
A sectional-view illustration of the inner container of the present invention, as shown in
A perspective-view illustration of a seventh embodiment of the inner container of the present invention having a composite center member and a single-piece outer cover is shown in
The outer cover 212 is folded over itself (at the mid fold) and is releasably attached (in the area that lies between the weakened lines 226 and is adjacent to the first and second ends 228 and 229 respectively) to the base member 634 using a suitable bond (e.g., adhesive, thermal bonding, pressure, pressure-sensitive adhesive bonding, etc.). The side extensions of the outer cover are attached to the adjacent side member of the center member using a suitable bond (e.g., adhesive, thermal bonding, pressure, pressure-sensitive adhesive bonding, etc.) thus forming the completed side members. In use, the outer cover separates from the side members at the weakened lines.
A perspective-view illustration of the inner container of the present invention, as shown in
A perspective-view illustration of the inner container of the present invention, as shown in
A perspective-view illustration of the inner container of the present invention, as shown in
A perspective-view illustration of an eighth embodiment of the inner container of the present invention using a composite center member is shown in
A sectional-view illustration of the eighth embodiment of the inner container taken along line 16—16 of
A perspective-view illustration of a ninth embodiment of the inner container of the present invention with a partial cutaway of the outer cover and the first draw member is shown in
The outer cover is shaped and sized such that its outer periphery can be releasably attached to the center member (e.g., as shown the outer cover has a slight V-bend which is centered on the mid fold). A first draw member 612 and a second draw member 614 are attached to the outer cover. The first tab of the first draw member and the second tab of the second draw member are attached to each other so as to form an optional common tab 616. A filler (e.g., a hotdog as shown) 618 is contained within the inner container. A holding means comprising a holding member 620 is attached to the base member. The inner container is optionally heat stable and can be placed in an oven or other suitable device to cook or warm the filler if so desired. Additionally, the side members and/or the outer cover can be made from an optional transparent material so that the user can view the filler if so desired. In alternative embodiments, the inner container includes an optional weakened area or line which opens to release excess pressure when heating the inner container.
A cross-sectional-view illustration of the ninth embodiment of the inner container of the present invention, taken along line 18—18 of
A side-view illustration of the ninth embodiment of the inner container inserted within a hotdog bun, with the outer cover opened and removed, is shown in
A side-view illustration of the ninth embodiment of the inner container as shown in
An exploded top-planar-view illustration of a first embodiment of an outer container, with the inner container as shown in
The side panels of the outer container include side folds 286. The side panels are folded about their side folds and terminate on one side at the first fold 288 which is adjacent to the first side panel, and on the other side, at the second fold 290, which is adjacent to the second side panel. The side panels further include a side portion bottom 292 which is optionally cut so that the outer container remains upright if placed in an upright position and a side panel top 300, both of which extend from the first fold to the second fold and are folded about the side fold 286. The first side panel has a free edge 294 which extends between the first folds 288, and has an indentation which extends toward the first fold. Likewise, the second side panel has a free edge 296 which extends between the first folds, and has an indentation which extends toward the bottom panel. Alternatively, either or both of the free edges can be shaped as desired. The outer container has an opening which is located opposite the bottom panel, and which is defined by the free edges 294 and 296 of the first side panel and the second side panel respectively, and the side panel top 300 of the side panels 278. The outer container should be sized such that it holds the sandwich halves tightly and prevents the sandwich halves from moving when the outer cover is removed from the center member. Each second fold 290 extends from the adjacent side panel top to the side panel bottom, running substantially parallel to the adjacent first fold.
The inner container 74 is similar to the inner container which is shown in
In one method of use, the inner container is filled and then inserted into the opening of the outer container so that the holding member slides into and engages the retention slot so that the inner container is firmly attached to the outer container. The outer container is then unfolded and the bottom panel is firmly positioned to hold the outer container in the opened position. Sandwich halves are then placed on either or both sides of the inner container and are held in position by the outer container.
An exploded bottom-planar-view illustration of the outer container with the inner container as shown in
A perspective-view illustration of an opened outer container with the attached inner container of
A perspective-view illustration of an opened outer container with the attached inner container of
A perspective-view illustration of a second alternative embodiment of an outer container incorporating a box-type container is shown
A perspective-view illustration of the outer container of
A perspective-view illustration of the outer container of
A perspective-view illustration of the outer container of
The third flap is sized similarly to the second flap, but may be larger or smaller than the second flap if desired. The first and second flaps are sized such that they retain the sandwich halves in position when the outer cover is removed from the inner container. Additionally, the first and second flaps (as well as the optional side flaps) should not interfere with the movement of the outer cover as it is being removed from the inner container.
A side-view illustration of the outer container of
A front-view illustration of the outer container of
A top-view illustration of the outer container of
A side-view illustration of a third alternative embodiment of an outer container incorporating a clamshell-type container is shown
Clamshell-type containers are well-known in the art. See, for example, U.S. Pat. No. 5,131,551, to Wells, entitled “One-piece merchandising container,” U.S. Pat. No. 4,653,685, to Leary, et al., entitled “Dual compartment sandwich package,” and U.S. Pat. No. 4,132,344, to Jewell, entitled “Foam sandwich package,” all of which are incorporated herein by reference in their entirety.
A side-view illustration of the outer container of
A side-view illustration of the outer container of
A front-view illustration of the outer container of
A side-view illustration of an alternative embodiment of the outer container of
An exploded side-view illustration of an alternative embodiment of the outer container of
In alternative embodiments, a heat pad like that disclosed in U.S. Pat. No. 4,522,190, to Kuhn, et al., entitled “Flexible electrochemical heater,” can be placed proximate to, or incorporated into, the inner container and can be activated before use of the current invention, thus providing a portable heated meal.
The inner container 776 (seen behind the partial cutaway view of the side panel 770) should fit flush (below the rim) of the second cavity in which it is placed, so that the second cavity seal fits flush over the opening of the cavity. The cavity seals are peeled off the tray portion and the cover portion before consumption. Alternatively, a single cavity seal may be used to seal both the first cavity and the second cavity. Suitable methods of releasably attaching the cavity seal to the container include thermal bonding, pressure bonding, adhesive bonding, or other suitable methods of bonding. Alternatively, the cavity seal comprises a semi-flexible sheet of material (e.g., polypropylene, paper, foam, or other types of polymers, etc.) which is slidably engaged with a flange around the entire outer container or with the flange around each rim. See, for example, U.S. Pat. No. 5,213,256, to Cyr, entitled “Container Assembly Having a Removable Insert/Divider,” incorporated herein by reference in its entirety. In yet other alternative embodiments, the cavity seal comprises a semi-flexible sheet of material (e.g., polypropylene) which is molded and friction fit to a flange (or other suitable member) of the cover portion and tray portion. If using a molded cavity seal, then the inner container does not have to fit flush within the cavity in which it is placed.
The cavity seal and outer cover are made from a clear or translucent material so that the customer can view the sandwich halves and filler before purchase, if desired. Alternatively, the opacity of the cavity seal and/or the outer cover can vary (e.g., the cavity seal can be reflective or opaque). For example, the first cavity seal can be made from a reflective material to reflect heat while the second cavity seal and the outer cover of the inner container can be made of a clear material to transmit heat and allow the user to view the filler contained within the inner container. In order to provide for a hermetic seal of the second cavity, the holding member 773 is optionally attached to the rear panel so that it is contained entirely within the interior of the second cavity.
In use, the cover portion is partially closed, the cavity seals are removed to expose the common tab (or other tab means), and the outer cover is removed from the inner container as described elsewhere in this document. In alternative embodiments, the cavity seals can be removed either when the clamshell is closed or opened.
In alternative embodiments, the common tab extends through a slot provided in the front panel. The slot should be shaped and sized such that the outer cover can be pulled through the slot when opening the inner container. The common tab is optionally releasably attached to the front panel so as to seal the slot in the second cavity. In use, the cover portion is folded upon the tray portion before the cover portions and the outer cover are removed from the inner container.
A top-view illustration of the outer container of
A side-view illustration of the outer container of
A side-view illustration of a fourth alternative embodiment of an outer container incorporating a clamshell-type box in the closed position is shown
The clamshell-type container and its structure are well known in the art. See, for example, U.S. Pat. No. 5,205,476, to Sorenson, entitled “Clamshell carton having an improved latching mechanism,” and U.S. Pat. No. 4,877,178, to Eisman, entitled “Paperboard foldable carton,” both of which are incorporated herein by reference in their entirety.
A side-view illustration of the outer container of
A front-view illustration of the outer container of
A side-view illustration of the outer container of
A partial cutaway side-view illustration of the inner container and outer container of the present invention, with sandwich halves inserted, is shown in
A partial cutaway side-view illustration of an inner container and outer container of
A partial cutaway side-view illustration of the inner container and attached outer container of
A partial cutaway side-view illustration of the inner container and attached outer container of
A perspective-view illustration of a fifth alternative embodiment of an outer container incorporating a tubular body is shown in
In alternative embodiments, the outer container further includes a minor opening located adjacent to the major opening. The minor opening is shaped and sized such that the outer cover and the attached draw members can pass through it when the package is opened, but small enough so that the sandwich halves cannot pass though it. The minor opening is removed or opened so that the completed sandwich can pass through the major opening when the sandwich halves are removed from the outer container. In yet other alternative embodiments, the outer container is constructed from a rigid or semi-rigid material.
A perspective-view illustration of the outer container with a removable cover portion as shown in
A cutaway side-view illustration of the tubular outer container shown in
A perspective-view illustration of the inner container of
In alternative embodiments the outer container forms a hermetic seal around the sandwich halves and optionally the inner container, and has a removable cover section. In yet other alternative embodiments, the outer container includes a cover portion so as to fully conceal the sandwich halves contained within. The cover portion is attached to the outer container via a weakened line (e.g., scoring, perforating, adhesives, etc.). Before the inner container is opened, the outer cover portion of the outer container is removed. The outer cover should be shaped and sized such that the sandwich can be readily removed from within.
An exploded perspective-view illustration of the inner container and flexible outer container of
The side walls 534 have optional concavities 544 which protrude within the cavity so as to hold the sandwich firmly in place within the cavity during shipping. The concavities allow the user to readily grasp the sandwich by the sides for consumption. In alternative embodiments, any suitable protrusion is used so as to prevent the sandwich from moving substantially within the cavity during shipping. Likewise, the bottom wall has one or more optional concave regions which protrude within the cavity to hold the sandwich in place during shipping but allow the user to readily grasp the sandwich for consumption.
The inner container 520 is attached to the bottom wall 536 of the box means via the holding member 528 using an adhesive or other suitable bonding method (e.g., pressure bonding, thermal bonding, locking mechanisms, latches, notches, friction fit, etc.). The holding member should allow the inner container and the optionally attached outer container to move sufficiently so that the outer cover can be removed from the inner container and so that the sandwich can be removed for consumption. Alternatively, the inner container can be (hingedly) attached to the box means using hinges, tabs or other suitable friction-fit methods, or can be formed integrally with the box means. The draw members are placed within the cavity but, in alternative embodiments, the draw members may extend through a slot in one of the adjacent side walls of the cavity such that the draw members and the attached outer cover can be removed from the inner container before the box means is opened. Alternatively, a take-up-spool mechanism can be employed to accept the draw members and the outer cover.
The box cover (only a partial section is shown) is releasably attached to, or formed integrally with, the box portion 548 and hermetically seals the interior (e.g., the primary and the secondary cavities) of the container. To open the outer box means, the box cover is peeled away (e.g., as indicated by arrow T) from the box portion to expose the outer container (and inner container and sandwich halves) contained therein. The box cover is constructed from a flexible material (e.g., Mylar, plastic, cellophane, paper, foil, laminates, etc.) and is attached to the outer box means using pressure bonding or other suitable methods (e.g., thermal bonding, pressure bonding, adhesive bonding, etc.). In alternative embodiments, the box cover can be constructed from a semi-rigid or rigid material. In alternative embodiments, the draw members are releasably attached to a take-up spool so that the draw members and the attached outer cover can be taken up on the spool.
A side-view illustration of the outer box means and inner container and flexible outer container of
A side-view illustration of the box means of
The primary cavity is large enough so that the inner container, the outer container 570, and the sandwich halves 572 can be positioned properly to remove the outer cover. After the outer cover and the attached draw members are removed from the center member, they are discarded.
A side-view illustration of the box means of
The sandwich halves and filler 576 (i.e., the completed sandwich) are pulled (in a direction indicated by arrow Z) from the outer container and the opened inner container 566 contained therein. The inner container 566 and the outer container 570 are then left alone or folded into the cavity so that the user may place the completed sandwich back into the primary cavity for temporary storage. The optional condiments have been removed.
A perspective-view illustration of a sixth alternative embodiment of an outer container incorporating a box-type container is shown
A rear perspective-view illustration of the outer container of
In alternative embodiments, the outer cover includes one or more pockets which are formed integrally with it or are attached thereto. The pockets are opened either before or during removal of the outer cover from the center member such that the contents of the pockets (e.g., salt, ketchup, etc.) are dispensed upon the filler or other desired object. The pockets include weakened lines which tear the pockets, thus opening them due to pressure within the pockets as the outer cover is peeled back over itself.
There are numerous cohesive coatings which may be employed in the practice of this invention to releasably cohere the numerous elements of this invention to each other and especially the outer cover to the center member and the box cover to the box portion. The bond between the outer cover and the center member may be continuous or interrupted.
In embodiments where it is desired to reduce friction between the outer cover and/or the draw members and the sandwich halves, a sheet of material which superposes the outer cover may be placed between the outer cover, the draw member and the adjacent sandwich half.
In all embodiments, the outer cover can be constructed from a transparent material to allow the handler and/or consumer easily to view and select the desired item. Similarly, the outer container and/or the outer box can also be constructed from transparent material. Moreover, the inner container can be provided with a venting means so that the inner container can be vented if desired during heating.
The packaging and dispensing system of the present invention may be provided with any number of configurations and sizes. The size and configuration will typically be determined by the particular food product(s) contained within the inner container, the optional sandwich halves, the outer container, and the box means.
The materials used for the invention include, but are not limited to, papers, foils, cellophane, Mylar, polyethylene, polypropylene, polyester, foams, other types of polymers, or composites of these or other suitable materials. The primary requirements for the packaging materials are the ability to provide a sealable package and compatibility with food products. If desired, the materials should be compatible with optional sterilization techniques and methods employed. Additionally, the materials used for the package must, if required, be easily ripped or torn, and the line of tearing must propagate in a desired direction. In some instances, it might be desirable to add tear strips or other guiding devices/coatings on or in the packaging material to assist in a clean, linear tearing of the package material. It will also be desirable to use materials such as oriented fiber papers to assist in providing clean, linear edges in the packaging material to be torn.
If desired, the cavity can be flushed using any known means (as is known in the art) so as to reduce the oxygen content contained within the cavity and thus extend the life of the filler.
In various embodiments of the present invention, without limitation, to enable the user more easily to use the present invention, the first tab and the second tab (as well as the draw members and other elements) may be colored to contrast with the rest of the package, may be embossed to enhance user touch, feel, and sight, may be cut in a way to indicate direction, and may be numbered, embellished with arrows, or printed with directions to indicate proper use.
It is intended that the appended claims cover all such features and advantages of the invention that fall within the spirit and scope of the present invention. As numerous modifications and changes will readily occur to those skilled in the art, it is intended that the invention not be limited to the limited number of embodiments described herein. Accordingly, it will be appreciated that all suitable variations, modifications and equivalents may be resorted to, falling within the spirit and scope of the present invention.
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