The present invention relates to packaging for snack-sized food pieces, such as cheese.
For example, a snack-sized piece of cheese may be coated with wax and be openable by way of a peel strip. These packages have limitations with the types of food, and even the types of cheese, that can be packaged. And, these packages provide only a single food piece having a single flavor and do not provide variety within the snack-sized package.
In one aspect, the invention provides a pre-packaged cheese snack having a tray including two receptacles with a hinge there between so that the receptacles can be oriented in a stacked orientation and movable to an open orientation. The receptacles have a shape and a volume. The pre-packaged cheese snack also has a snack-sized piece of perishable cheese in each receptacle such that each piece of cheese has generally the same shape and volume as its respective receptacle. The pre-packaged cheese snack also has a sealing member enclosing each piece of cheese in the respective receptacle, the sealing member being removable to allow access to the pieces of cheese. A fastener holds the receptacles in the stacked orientation to form a single pod, the fastener being movable to allow the receptacles to be moved to the open orientation.
In another aspect, the invention provides a pre-packaged cheese snack having a tray including two receptacles with a hinge there between so that the receptacles can be oriented in a stacked orientation and movable to an open orientation. The receptacles have a shape and a volume. The pre-packaged cheese snack also includes a snack-sized piece of cheese in one of the receptacles. A sealing member encloses the piece of cheese in the respective receptacle, the sealing member being removable to allow access to the piece of cheese. A fastener holds the receptacles in the stacked orientation to form a single pod, the fastener being movable to allow the receptacles to be moved to the open orientation.
In yet another aspect, the invention provides a pre-packaged cheese snack having a tray including two receptacles wherein the receptacles are in a stacked orientation. The pre-packaged cheese snack also includes a snack-sized piece of cheese in each receptacle. A sealing member encloses each piece of cheese in the respective receptacle, the sealing member being independently removable to allow access to one piece of cheese. A fastener holds the receptacles in the stacked orientation to form a single pod, the fastener being movable to allow the receptacles to be separated from one another.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other constructions and of being practiced or of being carried out in various ways.
The hinge 20, including a perforated seam or no perforations, may be formed at the same time as the first and second receptacles 16, 18 in the thermoform machine. In other constructions, the perforations may be formed after forming the receptacles 16, 18, e.g., by cutting. The perforations may be cut before or after the receptacles 16, 18 are sealed with the food pieces 10, 12 therein, as will be discussed below. In other constructions, the tray 14 may be formed using other suitable methods and from other suitable materials.
The tray 14 includes a rim or flange 22, which generally includes a main flange area 24 of substantially uniform radius around each of the first and second receptacles 16, 18 and a tab 26, or elongated flange portion, on opposite sides of the tray 14. The tab 26 has a larger radius than the main flange area 24 as it extends farther away from the respective receptacle 16, 18. The flange 26 is generally flat or planar for receiving a sealing member 28 (
Each of the first and second receptacles 16, 18 has a three-dimensional form including a shape and a volume. Each receptacle 16, 18 starts at a respective opening 34, 36 in the flange 22 from which the respective receptacle 16, 18 is recessed and defines a three-dimensional form. The openings 34, 36 define an open end 38 (respectively) of the receptacles 16, 18 and largely define the shape of the receptacles 16, 18. In the illustrated construction, the openings 34, 36 are round which may include circular, oblong, and oval-shaped. In other constructions, the openings 34, 36 may have other shapes, such as a triangle, a rectangle, a square, another polygon, or other geometric shapes, and may have rounded corners. Each receptacle 16, 18 is further defined by sidewalls 40, 42 and a base 44, 46, respectively, which further define the three-dimensional form. The sidewalls 40, 42 may generally follow the shape of the respective opening 34, 36, starting at the opening 34, 36, and then extending away from the opening 34, 36. The sidewalls 40, 42 may gradually taper to a narrower diameter farther from the opening 34, 36 and converge towards the base 44, 46, or may remain substantially straight having the same approximate diameter farther from the opening 34, 36. The base 44, 46 defines a closed end 48 of the receptacle 16, 18 and may be generally flat, or planar. In other constructions, the base 44, 46 may be rounded in three-dimensional form, and may appear as a seamless, gradual convergence of the sidewalls 40, 42 into the closed end 48.
Multiple trays 14 may be formed in the thermoform machine at the same time, from the same or different formable film. When multiple trays 14 are formed from the same formable film, each individual tray 14 is cut out as a single unit upon exiting the thermoform machine. Insertion of the food pieces 10, 12 may occur while the tray 14 is still in the thermoform machine, but in other constructions the food pieces 10, 12 may be inserted after the tray 14 exits the thermoform machine.
Each snack-sized food piece 10, 12 may be formed from soft or hard cheese, or from another food such as meat. Snack sized is defined herein as between about 5 grams and about 20 grams per piece, more specifically between about 10 grams and about 15 grams, and in the illustrated construction the food piece may be about 12.5 grams of food. The typical consumer may bite the snack-sized food piece 10, 12 once or twice before completing consumption; however, it is understood in the art that the exact amount in a single bite differs from consumer to consumer, and that some consumers may require less than, or more than, one or two bites to consume the food piece 10, 12. In other constructions, the food piece 10, 12 may be bite sized, e.g., sized so the average consumer can consume the food piece 10, 12 in a single bite. For example, the bite sized food piece 10, 12 may be between about 1 grams and about 14 grams, more specifically between about 5 grams and about 9 grams, or about 7 grams of food.
The food piece 10, 12 may be pre-formed or pre-cut to the approximate shape and volume of the respective receptacle 16, 18. For example, the snack-sized food piece 10, 12 may be a perishable natural cheese piece, which may be prepared from bulk block form, each cheese piece being cut from the block into generally the same shape and volume as the respective receptacle 16, 18. It should be understood that “generally the same shape and volume as the receptacle” includes slight variations, such as the receptacle 16, 18 being overfilled or underfilled, consistently or inconsistently, or the food piece 10, 12 having defects in shape. For example, when the receptacle 16, 18 is generally circular in cross-section, as illustrated, the food piece 10, 12 is also generally circular in cross-section. Soft cheese in addition to hard cheese may be utilized. In some constructions, the softer cheeses (or other soft foods) may be formed within the tray 14, under vacuum, from a cubed form or other shape or form having the approximate volume of the respective receptacle 16, 18 but not necessarily the same approximate shape as the respective receptacle 16, 18. Under vacuum, the piece of soft cheese deforms to the approximate shape of the receptacle 16, 18. The above provides an opportunity to insert flavored cheeses into the tray 14 in addition to cheese with inclusions, thereby offering greater variety and flavor profiles. Furthermore, the first and second receptacles 16, 18 may contain the same type of cheese, different types of cheese, or different types of foods. For example, cheddar, Swiss, gouda, blue, brie, pepperjack, brick, muenster, mozzarella, Havarti, parmesan, feta, camembert, etc. are all different cheese types. Different cheese types may also include different flavors, colors, and inclusions in the same cheese variety, such as Havarti with dill and Havarti with horseradish, or white cheddar and yellow cheddar. As another example, there may be different types of food such as cheese, or other food, in one receptacle 16, 18 and meat, or other type of food (such as nuts, seeds, dried fruit, granola, crackers, wafers, biscuits, etc.), in the other receptacle 16, 18. In other constructions, more than one food piece 10, 12 may be inserted into a single receptacle 16, 18. For example, multiple smaller pieces of food, such as cheese chunks or slabs or slices, nuts, seeds, small meat chunks, dried fruit pieces, granola, crackers, wafers, biscuits, etc., may also be inserted into the receptacles 16, 18 as desired.
For example, the sealing member 28 includes a flexible film, or thin film, that is heat sealed to the flange 22 of the tray 14. The sealing member 28 is appreciably more flexible than the semi-rigid or rigid material used for the tray 14 so the sealing member 28 can be peeled away from the relatively more rigid structure of the tray 14 while the tray 14 generally maintains integrity of shape as the sealing member 28 is bent and peeled. In some constructions, the seal includes an adhesive. The sealing member 28 may be sealed to the first and second portions 30, 32 as a single piece of material, though in other constructions it may be sealed on the flange 22 as two separate pieces, which may be separated before or after the sealing on the flange 22. The term “a sealing member enclosing each food piece in the respective receptacle” should be understood herein to mean either a single piece of material enclosing each food piece 10, 12 or more than one piece of material cooperating to collectively enclose each food piece 10, 12 in the respective receptacle 16, 18. Perforations may be formed through the sealing member 28 material proximate the hinge 20, or at another location, to allow the sealing member 28 to be independently removable from the first and second portions 30, 32. A vacuum may be applied to remove air from the receptacles 16, 18, for preserving freshness of the food pieces 10, 12, during sealing of the sealing member 28. The sealing member 28 may be formed from a thin sheet of polymeric material, such as PET/EVOH/PE with a peelable seal. The sealing member 28 may be transparent or translucent so the food pieces 10, 12 are visible to the consumer. In other constructions, the sealing member 28 may be opaque. The sealing member 28 may also include printed indicia A1 thereon. At this stage, the tray 14 is sealed and in an open position (
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The sleeve 52 has a generally tubular form, which is hollow on the inside and has two open ends 54a, 54b to receive the closed tray 14 therein. The closed tray 14 may be received in a direction perpendicular to the axis Y, as shown, or in any other suitable direction such as parallel or transverse to the axis Y. In the illustrated construction, the sleeve 52 includes four rectangular sides, each side being substantially planar. In other constructions, the sleeve 52 may include other tubular or generally tubular forms having substantially planar sides, curved sides, or a combination of both. In some constructions, the sleeve 52 may generally follow the contours of the closed tray 14. Other shapes and forms are also possible.
The sleeve 52 is formed from a thin, semi-rigid or rigid sheet of polymeric or paper-based material, such as wood pulp. The material may be formed as a generally planar sheet and then 1) cut, 2) folded or bent, and 3) glued or locked (e.g., by a locking tab) into the tubular form. In other constructions, the material may be formed as one continuous tubular piece and may further be shrunk (e.g., by way of heat or a chemical process) to engage the tray 14 in the closed position. The sleeve 52 holds the tray 14 in the closed position by direct engagement with both the first portion 30 and the second portion 32. More specifically, the sleeve 52 may engage the closed tray 14 on generally opposite sides of the sealing member 28, e.g., on the base 44 of the first receptacle 30 and the base 46 of the second receptacle 32. In other constructions, the sleeve 52 may have a non-tubular form, such as a generally C-shaped or U-shaped form, which may be formed of a more rigid material, which also engages the first and second portions 30, 32 of the closed tray 14. Thus, the sleeve 52 inhibits the closed tray 14 from moving towards the open position. While the sleeve 52 holds the sealed tray 14 in the closed position, the sleeve 52 is also movable by application of sufficient force by a consumer such that the holding force is overcome and the closed tray 14 can be opened, e.g., moved towards the open position (
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In other constructions, other fasteners may be employed to hold the tray 14 in the closed position, such as a carton or other structure, or other form of adhesion.
In any of the constructions herein, the fastener (e.g., the sleeve 52, the adhesive label 56, etc.) may include an insulative material, such as cellulose fibers or clay nanocomposite foams, to prolong the refrigerated temperature of the food pieces 10, 12 after removal from the refrigerator. For example, the sleeve 52 and the adhesive label 56 are particularly well suited for being formed from materials having insulative properties. This may be in addition, or in place of, the insulative properties of the tray 14 discussed above.
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Terms such as “generally”, “substantially”, “approximate” and “about”, are defined herein to mean “exactly or deviating slightly from, e.g., deviating within manufacturing tolerances or deviating within an amount confusingly similar to the exact amount or characteristic” as understood in conjunction with any other definitions provided herein.
Thus, the disclosure provides a pre-packaged food snack 100 giving consumers the opportunity to open half of the package to access one of the food pieces 10, 12 while maintaining freshness of the latter half for later, if one were to choose to do so. The disclosure also provides an opportunity to provide variety within the single pod as each half of the tray 14 may include different cheese types, including different varieties, flavors, colors, and inclusions. The pre-packaged food snack provides an opportunity for messaging on the sealing member 28 from each half of the package, as well as on the sleeve 52 and the adhesive label 56, when employed. The pre-packaged food snack also provides for ease of opening. Furthermore, the disclosure provides a pre-packaged cheese snack that insulates the perishable food pieces 10, 12 to prolong freshness in ambient temperatures while the consumer is on the go. Various features and advantages of the invention are set forth in the following claims.