Patent Application
20170190501
The invention relates to a container for transporting food products and more particularly to a container assembly for transporting and thermally insulating soup.
Many commercial prepared food retailers, restaurants, catering services, and the like provide catering, delivery, or to-go services for consumers for multi-person gatherings such as meetings, parties, or other events. Due to factors such as speed, affordability, and health, soup has become an increasingly common and desired food option for consumers. In order to provide for multi-person gatherings, portable bulk soup containers exist in order to transport the soup from the food provider's facility to the designated location of the gathering.
However, many problems exist in transporting soup. Initially, certain soups must maintain a certain range of temperatures for quality assurance and/or regulatory reasons. Current containers are unable to substantially maintain the desired range of temperatures of the soup. Additionally, soup ladles or other similar serving utensils are the simplest and most efficient means for serving soup from the container to an individual. However, some hulk soup containers do not provide an opening that is large enough or an ergonomic shape that is conducive to receive the soup ladle or serving utensils while also providing an efficient means for filling the container with the food product. Furthermore, some bulk soup containers can be unwieldy and unable to withstand the weight of the bulk soup. Certain containers can also be difficult to assemble.
It would therefore be desirable to provide a portable container assembly for transporting soup that is sturdy, ergonomically configured, and substantially maintains a desired temperature of the soup that can also be easily manufactured and assembled.
Compatible and attuned with the present invention, a portable container assembly and method of assembling a portable container assembly for transporting soup that is sturdy, ergonomically configured, and substantially maintains a desired temperature of the soup that can also be easily manufactured and assembled has surprisingly been discovered.
According to an embodiment of the invention a blank for a sleeve is disclosed. The blank includes a plurality of panels each hingedly coupled to an adjacent one of the plurality of panels. A top panel is hingedly coupled to an end of a first one of the plurality of panels. The top panel includes a first section and a second section hingedly coupled to the first section. The first section has an aperture formed therein. The aperture is configured to receive a portion of a container therethrough. The second section has a recess formed in an edge thereof. A first flap is hingedly coupled to an end of a second one of the plurality of panels. A retaining tab is formed in at least one of the first flap and the second one of the plurality of panels. A portion of the retaining tab is detachable from the at least one of the first flap and the second one of the plurality of panels.
According to another embodiment of the invention a container assembly for use in containing a food product is disclosed. The container assembly includes a receptacle having a mouth defining an opening. The receptacle is configured to receive a liquid or semi-liquid food product. The container assembly includes a sleeve. The sleeve has a plurality of sidewalls forming a cavity. The sleeve includes a cover hingedly coupled to a first one of the plurality of sidewalls and moveable from an open position to a closed position. The cover includes a top wall and plurality of partitions extending from the top wall. A first one of the plurality of partitions has a depression formed on an inner surface thereof. A retaining tab is hingedly coupled to a second one of the plurality of sidewalls. The retaining tab cooperates with the depression in the closed position of the cover to maintain the cover in the closed position.
According to another embodiment of the invention, a kit includes at least one blank formable into a sleeve. The sleeve including a plurality of sidewalls and a cover hingedly coupled to a first one of the plurality of sidewalls. The cover includes a plurality of partitions extending therefrom. A first one of the plurality of partitions has a depression formed on an inner surface thereof. A second one of the plurality of sidewalls has a retaining tab hingedly coupled thereto. The retaining tab cooperates with the depression to maintain the cover in a closed position. The kit includes at least one receptacle configured to contain at least one of a liquid and a semi-liquid food product. The receptacle has a mouth defining an opening. The kit further includes at least one insulation layer configured to envelope the receptacle.
The above, as well as other objects and advantages of the invention, will become readily apparent to those skilled in the art from reading the following detailed description of a preferred embodiment of the invention when considered in the light of the accompanying drawings which:
The following detailed description and appended drawings describe and illustrate various embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. The terms “bottom,” “top,” and “side” are for purposes of relative orientation only and not as an absolute position. In respect of the methods disclosed, the steps presented are exemplary in nature, and thus, the order of the steps is not necessary or critical.
The receptacle 12 is configured for receiving the food product and may or may not include a handle. In certain embodiments, the receptacle 12 is formed of plastic such as high density polyethelyne configured to tolerate a food product with a high temperature. Other materials such as polypropylene, polycarbonate, polyethylene pterethalate (PET), polyvinyl chloride (PVC), or other plastics can be employed depending on the desired food product, and the temperature thereof, to be received in the receptacle 12. However, it is understood the receptacle 12 can be formed from any durable material as desired such as metal or foam, for example, without departing from the scope of the instant disclosure. In a non-limiting example, the receptacle 12 is a bulk soup receptacle configured to contain soup in bulk such as a receptacle configured to contain 64 ounces or 128 ounces. The receptacle 12 is configured to contain food products having temperatures of about 180 degrees Fahrenheit or 82.2 degrees Celsius.
The receptacle 12 includes an annular mouth 17 defining an opening 18 configured to receive the food product and a serving utensil 15 therethrough. The mouth 17 can be any diameter as desired. In a non-limiting example, the diameter of the mouth is 89 to 110 millimeters or greater to facilitate receiving the utensil 15. A lid 19 is coupled to the mouth 17 of the receptacle 12 to selectively cover the opening 18 of the receptacle 12. The receptacle 12 is any receptacle such as a bottle or pouch, for example, configured to hold food products according to safety and regulatory requirements.
The receptacle 12 is at least partially received by the insulation layer 14. The insulation layer 14 is configured to insulate the receptacle 12 containing the food product and substantially maintain a temperature thereof. In certain embodiments, the insulation layer 14 is configured to substantially maintain the temperature of a cold food product or substantially maintain the temperature of a hot food product. In certain embodiments, the insulation layer 14 is a preformed, metallized, single-bubble, Y-Fold wrap formed by a heat seal process that envelopes a portion of the receptacle 12. However, the insulation layer 14 can be any material configured to insulate the receptacle 12 such as a foam, an expanded polystyrene (EPS), a wood based material, a foil, or any other material or combination of materials configured to insulate the food product, for example. Additionally, it is understood the insulation layer 14 can envelope an entirety of the receptacle 12, if desired.
The receptacle 12 and the insulation layer 14 are received within the sleeve 16, wherein the insulation layer 14 is interposed between the receptacle 12 and the sleeve 16. The sleeve 16 is collapsible and includes a bottom 25 having an automatic bottom set-up, constructed by means of hinged-together bottom flaps (further described hereinbelow), that securely closes the bottom 25 of the sleeve 16. However, it is understood the sleeve 16 can include other types of bottoms now known or later discovered without departing from the scope of the disclosure. The sleeve 16 is formed from a material such as solid bleached sulphate (SBS) paperboard, E-flute natural kraft corrugated, or any other style fiberboard. The sleeve 16 includes a first sidewall 26a, a second sidewall 26b, a third sidewall 26c, and a fourth sidewall 26d cooperating with each other to define a cavity 28 for receiving the receptacle 12 and the insulation layer 14. It is understood, the sleeve 16 can include any number of sidewalls such as more than four sidewalls or fewer than four sidewalls, as desired.
The sleeve 16 includes a cover 20. The cover 20 has a top wall 21, a first partition 30a, a second partition 30b, and a third partition 30c. The top wall 21 is hingedly coupled to the fourth sidewall 26d for movement between a closed position, as shown in
In the embodiment illustrated, the cover 20 further includes a pair of tabs 32 cooperating with a pair of slits 34 configured to facilitate forming and reinforcing the cover 20. The pair of slits 34 are formed adjacent an edge of the top wall 21 and the pair of tabs 32 extend from the first partition 30a to engage with the pair of slits 34.
The cover 20 includes a rim 23 defining an aperture 24 formed in the top wall 21 thereof. The aperture 24 is configured to receive a portion of the receptacle 12. The aperture 24 substantially corresponds to a shape of the mouth 17 of the receptacle 12. In the embodiment illustrated, the rim 23 includes a substantially curvilinear portion 23a and a substantially linear portion 23b to define a segmented circular shape of the aperture 24. The linear portion 23b is configured to engage with a portion of the receptacle 12 to secure the cover 20 in the closed position. However, it is understood the rim 23 can include any number of curvilinear or linear portions to define any shape of the aperture 24, as desired, such as circular, ovular, polygonal, or any other shape for example.
The sleeve 16 further includes a handle 36 coupled thereto and configured to facilitate transporting the container assembly 10. The handle 36 shown is an elongate plastic rope handle having substantially T-shaped ends. Each of the ends of the handle 36 is inserted through a respective slot 38 formed in the second sidewall 26b and the third sidewall 26c of the sleeve 16. The ends of the handle 36 engage with an interior surface of the sidewalls 26b, 26c so that the handle 36 can support the container assembly 10 during transportation thereof It is understood other handle types and configurations can be used, as desired.
The sleeve 16 further includes a first flap 40a, a second flap 40b, and a third flap 40c hingedly coupled to and extending from the first sidewall 26a, the second sidewall 26b, and the third sidewall 26c, respectively. The flaps 40a, 40b, 40c are configured to converge inwardly towards the mouth 17 of the receptacle 12 retained in the sleeve 16. In the closed position, the flaps 40a, 40b, 40c are disposed beneath the top wall 21 of the cover 20, wherein the cover 20 cooperates with the flaps 40a, 40b, 40c to maintain an inwardly converging position of the flaps 40a, 40b, 40c with respect to the sleeve 16. When the cover 20 is in the closed position, the flaps 40a, 40b, 40c disposed beneath the top wall 21 are substantially concealed by the top wall 21. In the embodiment shown, the sleeve 16 includes three flaps 401, 40b, 40c and the edges 42 of the flaps 40a, 40b, 40c have an arcuate shape to correspond to a substantially circular shaped mouth 17. It is understood, the sleeve 16 can include any number of flaps 40a, 40b, 40c such as one flap, two flaps, four flaps, five flaps, six flaps, eight flaps, etc. The flaps 40a, 40b, 40c cooperate with the cover 20 to facilitate improved insulation and durability of the container assembly 10.
As more clearly illustrated in
In the open position of the cover 20, the retaining tab 48 extends outwardly from the first sidewall 26a. In the closed position of the cover 20, the retaining tab 48 folds against an outer surface of the first sidewall 26a. Advantageously, in the closed position, the retaining tab 48 cooperates with the depression 44 to maintain the cover 20 in the closed position. An edge 49 of the retaining tab 48 engages a perimeter surface 43 defining the depression 44 to prevent the cover 20 from pivotally moving from the closed position. It is understood the retaining tab 48 can be coupled to the second sidewall 26b or the third sidewall 26c, if desired. Additionally, the depression 44 can be formed on the second partition 30b or the third partition 30c to correspond to the position of the retaining tab 48, if desired.
The depression 44 has a shape substantially corresponding to a shape of the retaining tab 48. As shown, the depression 44 and the retaining tab 48 have a substantially rectangular shape with a pair of bevelled corners. However, the depression 44 and the retaining tab 48 can have other shapes, if desired. The depression 44 has a depth substantially equal to a thickness of the retaining tab 48 to militate against a movement of the first partition 30a outwardly from the sleeve 16.
As shown in
The blank 50 further includes a first bottom flap 62 hingedly coupled to a first end of the first panel 52, a second bottom flap 64 hingedly coupled to a first end of the second panel 54, a third bottom flap 66 hingedly coupled to a first end of the third panel 56, and a fourth bottom flap 68 hingedly coupled to a first end of the fourth panel 58. The bottom flaps 62, 64, 66, 68 cooperate with each other to form the bottom 25 of the sleeve 16. The bottom flaps 62, 64, 66, 68 are each hingedly coupled to the respective panels 52, 54, 56, 58 along fold lines 61. The fold lines 61 can be formed by perforations, scored marks, or the like, for example. In certain embodiments, the second bottom flap 64 and the third bottom flap 66 can include securement tabs 69 hingedly coupled thereto to facilitate formation of the bottom 25 of the sleeve 16. Although, it is understand additional securement tabs 69 can be included on any of the bottom flaps, as desired.
The blank 50 further includes the flaps 40a, 40b, 40c as described hereinabove. The first flap 40a is hingedly coupled to a second end of the first panel 52, the second flap 40b is hingedly coupled to a second end of the second panel 54, and the third flap 40c is hingedly coupled to a second end of the third panel 56. The flaps 40a, 40b, 40c are each hingedly coupled to the respective panels 52, 54, 56 along fold lines 41. The fold lines 41 can be formed by perforations, scored marks, or the like, for example. The retaining tab 48 is formed in the first flap 40a and is defined by a portion of the fold line 41 and a perforated line 41a.
A top panel 70 configured to form the cover 20 of the shell 16 is hingedly coupled to a second end of the fourth panel 58 along a fold line 71. The fold line 71 can be formed by perforations, scored marks, or the like, for example. The top panel 70 is divided into a first section 72, a second section 74, a third section 76, and a fourth section 78. The sections 72, 74, 76, 78 are hingedly coupled to each other along fold lines 81. The fold lines 81 can be formed by perforations, scored marks, or the like, for example.
The first section 72 is disposed adjacent the fold line 71 and forms the top wall 21 of the cover 20. The first section 72 includes the aperture 24 and the pair of slits 34 for receiving the pair of tabs 32 formed therein. In certain embodiments, the first section 72 additionally includes a knock-out portion 80 for forming the slot 22 of the cover 20 of the shell 16. The knock-out portion 80 is disposed adjacent the fold line 71 and is defined by a portion of the fold line 71 and a perforated line 82. However, it is understood, the knock-out portion 80 can be disposed at any portion of the top panel 70 as desired and can be configured to be completely removed or hingedly coupled to the first section 72.
The second section 74, the third section 76, and the fourth section 78 form the partitions 30a, 30b, 30c, respectively. The third section 76 and the fourth section 78 each extend laterally from opposing sides of the first section 72. An engagement tab 90 is hingedly coupled to each of the third section 76 and the fourth section 78 along fold lines 91. The engagement tabs 90 are configured to facilitate formation of the cover 20. The second section 74 extends from the edge of the first section 72 opposing the fold line 71. Each of the third section 76 and the fourth section 78 has a substantially constant width. A first end of each of the third section 76 and the fourth section 78 adjacent the panels 52, 54, 56, 58 is tapered, wherein the width decreases at a constant rate towards the panels 52, 54, 56, 58. The tapered first end militates against an interference of the third sub-section 76 and the fourth sub-section 78 with the respective flaps 40b, 40c.
The second section 74 is divided into a first sub-section 84 adjacent the first section 72, a second sub-section 86, and a third sub-section 88. The sub-sections 84, 86, 88 are hingedly coupled to each other along perforated fold lines 92. The first sub-section 84 and the third sub-section 88 each have a width substantially equal to a second end of the third section 76 and the fourth section 78. The second sub-section 86 is disposed intermediate the first sub-section 84 and the third sub-section 88 and has a width substantially equal to a thickness of the engagement tabs 90. The pair of tabs 32 extend outwardly from a distal edge of the third sub-section 88. The third sub-section 88 includes a recess 93 formed intermediate the pair of tabs 32 in the distal edge of the third sub-section 88. It is understood the top panel 70 can include other configurations as desired. For example, the top panel 70 can include any number of sections and sub-sections to form the cover 20.
To assemble the shell 16 from the blank 50, the sidewalls 26a, 26b, 26c, 26d are formed by folding the panels 52, 54, 56, 58 along the fold lines 51 and securing the securement tab 59 to the first panel 52. The bottom flaps 62, 64, 66, 68 are folded along the fold lines 61 and cooperate with each other to form the bottom 25 of the sleeve 16. The flaps 40a, 40b, 40c are folded along the fold lines 41 to converge inwardly with respect to the shell 16. The top panel 70 is then manipulated to form the cover 20 of the shell 16.
To form the cover 20, the second section 74, the third section 76, and the fourth section 78 are folded along fold lines 81 towards the sidewalls 26a, 26b, 26c, 26d. The third section 76 and the fourth section 78 form the second partition 30b and the third partition 30c, respectively. The engagement tabs 90 are then folded along fold lines 91 towards each other to abut an inner surface of the second section 74 at the first sub-section 84 thereof. The second section 74 is folded upon itself along the fold lines 91 to envelope the engagement tabs 90 and form the first partition 30a. The second section 74 envelopes the engagement tabs 90 so the first sub-section 84 is substantially parallel to the third sub-section 88 and the second sub-section 86 is substantially perpendicular to the first sub-section 84 and the third sub-section 88. The pair of tabs 32 cooperate with the pair of slits 34 to maintain the second section 74 in a position enveloped about the engagement tabs 90 to form and reinforce the first partition 30a. The recess 93 of the third sub-section 88 cooperates with the first sub-section 84 to form the depression 44 in the first partition 30a of the cover 20.
Once formed, the cover 20 can then be folded about the fold line 71 to move from the open position to the closed position as desired. The retaining tab 48 can be detached along the perforated line 41a to position the retaining tab 48 in a position extending outwardly from the first sidewall 26a and the first flap 40a of the sleeve 16. The knock-out portion 80 of the blank 50 can be separated along the perforated lines 82 and folded along the fold line 71 to form the slot 22 for receiving the utensil 15.
To assemble the container assembly 10, the receptacle 12 is positioned within the insulation layer 14 so that the insulation layer 14 either partially or entirely envelopes the receptacle 12. The sleeve 16 can be stored flat and easily opened by forming and securing the bottom 25. The receptacle 12 and insulation layer 14 are positioned within the sleeve 16 so the sleeve 16 covers a substantial portion of the receptacle 12 and insulation layer 14. The flaps 40a, 40b, 40c are folded about the fold lines 41 and are urged to an inwardly converging position to engage with the mouth 17 of the receptacle 12 or the lid 19. The cover 20 is moved from the open position to the closed position so that the mouth 17 and the lid 19 are received through the aperture 24 formed therein. As the cover 20 moves from the open position to the closed position, the inner surface 45 of the first partition 30a contacts the retaining tab 48 and applies force thereto. The force applied to the retaining tab 48 causes the retaining tab 48 to pivot about the fold line 41 and fold against the outer surface of the first sidewall 26a of the sleeve 16. In the closed position, the retaining tab 48 is received in the depression 44 of the cover 20. The edge 49 of the retaining tab 48 engages the perimeter surface 43 of the depression 44 to prevent the cover 20 from moving towards the open position and maintain the cover 20 in the closed position. Additionally, in certain embodiments, the substantially linear portion 23b of the rim 23 engages with the mouth 17 and/or the lid 19 to maintain the cover 20 in the closed position.
Each of the ends of the handle 36 are inserted through a respective slot 38 formed in the second sidewall 26b and the third sidewall 26c so that the container assembly 10 can be easily and safely transported. The utensil 15 can be inserted through the slot 22.
In application, the receptacle 12 is filled with a food product such as hot soup. The mouth 17 of the receptacle 12 facilitates quick transfer of the food product to the receptacle 12. The lid 19 is coupled to the receptacle 12 to close the opening 18. Advantageously, the insulation layer 14 insulates the food product within the receptacle 12 thereby facilitating a minimal temperature drop over a period of time such as the time of travel from the food retailers to a designated delivery event location. The sleeve 16 further facilitates insulation and provides a portable containing means for transporting food products. The configuration of the sleeve 16 is durable and easy to assemble.
In non-limiting examples, the container assembly 10 can militate against a temperature drop of more than 5-10 degrees Fahrenheit per hour. In certain embodiments, a kit can be provided, manufactured, or sold that includes at least one blank 50 for forming the shell 16, at least one insulation layer 14, and at least one receptacle 12. The kit can include the blank 50 unassembled, fully assembled or partially assembled as the shell 16. The kit can also include the utensil 15, the handle 36, and other component desired for transporting the food product.
It is understood that the container assembly 10 can be assembled either prior to filling the receptacle 12 with the liquid or semi-liquid food product or after filling the receptacle 12 with the liquid or semi-liquid food product. In certain embodiments, the container assembly 10 can be pre-assembled and packaged in bulk shippers and delivered in units of six or twelve, for example, to the food retailers, restaurants, caterers, etc.
According to this embodiment, the retail food providers only are required to remove the lid 19, fill the receptacle 12 with the food product, replace the lid 19, and provide the take-out, delivery, or catered service.
As illustrated in
In the embodiment illustrated, a second end of each of the third section 76 and the fourth section 78 opposing the first end adjacent the panels 52, 54, 56, 58 is also tapered, wherein the width increases at a constant rate away from the panels 52, 54, 56, 58 towards the fold line 91. The tapered second end of each of the third section 76 and the fourth section 78 accommodates an increase in the width of the first sub-section 84 and the third sub-section 88. It is understood the width of third section 76 and the fourth section 78 can be constant or varying at any portion thereof. For example, the width of the third section 76 and the fourth section 78 can decrease at a constant rate from the fold line 91 to the fold line 71.
The edge 42 of the first flap 40a is substantially arcuate as described hereinabove with reference to
From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.
