Abstract:
The present invention relates to a multiple part, quadrate container used for refrigerated and frozen dough intermediates that provides portion control for the consumer. More particularly, the present invention is a paperboard container sized and configured to receive one or more individual dough intermediates containing packages. The dough intermediates are contained or packaged in envelopes, sleeves, tube, cans or films that may include the ability to sequester or scavenge gas released by the dough. By incorporating a package within a package, a portion control arrangement is provided that gives the consumer added convenience.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS  
         [0001]    None.  
         FIELD OF THE INVENTION  
         [0002]    The present invention relates to a multiple part, quadrate container used for refrigerated and frozen dough intermediates that provides portion control for the consumer. More particularly, the present invention provides an external paperboard container sized and configured to receive one or more individual dough intermediates containing packages. The dough intermediates are contained or packaged in envelopes, sleeves, tube, cans or films that may include the ability to sequester or scavenge gas released by the dough. By incorporating a package within a package, a portion controlled structure is provided giving additional convenience to the consumer.  
         BACKGROUND OF THE INVENTION  
         [0003]    Dough packaging can be quite expensive and even complex in that the package has to be able to withstand the pressures of the gases that build up from raw or uncooked dough. The amount of gases that can build up in the dough are dependent upon a number of conditions including the type and amount of yeast used in the dough, the temperature at which the dough is stored and the like. The resulting pressure of the gas build up can be significant and can even cause small explosions of the containers in which the dough is stored. As such, packing of dough intermediates or raw dough has been generally focused on containers that can withstand a significant amount of pressure and are airtight.  
           [0004]    One of the preferable current packaging arrangements has taken the form of cans, which in addition to being more expensive than other packages are also significantly more complicated to produce, pack, ship and even use. In addition to the problems of potential explosion caused by the build up of gas in the can, the gas build up may contribute to other undesirable circumstances which may cause the can to become disfigured. That is, the gas accumulation causes the can to bubble or swell up, which is unappealing to consumers and creates difficulties for the retailer as the cans become difficult, if not impossible to stack. This situation often results in the can then being returned to the manufacturer which obviously creates a significant expense. If a recurring problem, the relationship with the retailer can become strained and the customer disenfranchised with product offering.  
           [0005]    Dough packaging can also experience a problem known as syruping in which liquid from the dough seeps or wicks out through the dough can which can create a sticky mess on the exterior of the packaging, making the product unsaleable.  
           [0006]    Another drawback with dough cans is that they can be confusing and even difficult to open. Current packaging requires the user to peel away an outer liner and then attempt to split the can along one of the exposed seems. If the die used in the fabrication of the can has not completely cut through the material to form the seem, then the can may not open causing the user to rely on a knife or other utensil to free the dough from the can this situation may create unnecessary hazards to the user. Alternatively, when pressure has built up in the can, the can may burst open unexpectedly after the user has removed the outer liner, thus startling the consumer. In the former situation, the consumer is frustrated with the difficulty in opening the product and in the latter, the consumer is leery about opening another canned dough product.  
           [0007]    Other packaging for raw dough or dough intermediates has included plastic films or tubes for products such as cookie dough and the like. Here, the plastic film is applied directly to the cookie dough log as the cookie dough log is extruded from the forming apparatus. The ends of the plastic tubes are then crimped and banded to seal the container. While plastic films overcome some of the drawbacks that cans suffer from, such as the film can accommodate a limited expansion due to gas build up and is relatively inexpensive, the films are not suitable for all raw dough applications and packaging requirements or completely overcome all of the previous drawbacks. The plastic films can also burst if the gas build up is excessive. The gas build up can also cause the crimped ends to become undone thus exposing the dough to the atmosphere and contamination. Unfortunately, the crimped ends of the tubes also create wasted product in that the ends of the dough log have a crinkled or pinched appearance, which is aesthetically unappealing, leading the consumer to discard the material found in the respective ends.  
           [0008]    In addition, the use of tubes is not acceptable from a customer prospective for such things as biscuits, rolls, buns, pastries, bread sticks and the like as the pressure of the tube has a tendency to compact or crush the dough products before they are frozen or the tubes do not provide sufficient support to the intermediates. That is, an extruded rope of cookie dough creates a relatively rigid supporting structure for filling a plastic tube as the density of the dough is relatively rigid. However, if one put biscuits or rolls in a tube, the tube would likely be flaccid or flimsy and cause handling difficulties.  
           [0009]    Paperboard containers have been used in a number of packaging applications, including in the packaging of materials that release gas while in the package, such as coffee and fruits and vegetables. U.S. Pat. No. 6,451,423 discloses one such example and describes the use of a polymeric matrix, which may be coated or laminated onto a paperboard as well as other substrates.  
           [0010]    In each of the foregoing examples, the consumer is required to either use the entire contents of the package or in the alternative, use only that portion of the package that is required and then repackage the remaining portion of the product for use at a later time. As home produced packaging is not as effective as packaging provided by the manufacturer, the remaining product will likely stale over time, causing it to be discarded.  
           [0011]    However, heretofore multiple part convenient to use, portion controlled containers, whether coated with a substance or not, have not been used in the packaging of refrigerated and frozen raw dough or dough intermediates. This may be due to the fact that refrigerated and frozen dough products are stored in refrigerators or freezers and moisture generally builds up due to condensation caused by the regular opening and closing of the appliances.  
           [0012]    What is needed therefore is a portion controlled packaging arrangement for refrigerated and frozen raw dough that is convenient to use and overcomes the drawbacks of the foregoing arrangements.  
         BRIEF SUMMARY OF THE INVENTION  
         [0013]    The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention.  
           [0014]    In one preferred embodiment of the present invention a quadrate container for refrigerated and frozen doughs is described and includes a generally planar element for enclosing a packaged dough intermediate. The generally planar element has first and second side edges and first and second ends. The first and second ends being substantially parallel to one another and substantially perpendicular to the first and second sides and the generally planar element has first and second faces.  
           [0015]    The generally planar element has at least first, second and third lines of weakness disposed in the generally planar element and substantially parallel to the first and second sides. First and second fold lines are provided and formed in the generally planar element and run longitudinally of the generally planar element and parallel to one another, and spaced from the first and second ends. A sealing flap is provided adjacent one of the first and second sides and substantially parallel to one of the first and second sides for holding the generally planar element in a folded configuration.  
           [0016]    First, second, third and fourth panels are provided in the generally planar element and are disposed between the first and second sides. The first panel is defined by the area between one of the first and second sides and the first line of weakness. The second panel is defined by the area between the first line of weakness and the second line of weakness. The third panel is defined by the area between the second line of weakness and the third line of weakness. The fourth panel is defined by the area between the third line of weakness and one of the first and second sides.  
           [0017]    The quadrate container of the present invention is provided with at least one preformed container that is sized and configured to hold the dough intermediate and sized and configured to fit within the generally planar element when in said folded configuration to create a portion controlled container for refrigerated and frozen doughs.  
           [0018]    Other embodiments of the present invention include the use of additional preformed containers that can fit within the quadrate container when folded. Such other containers include alternate raw dough intermediate containers, such as dough cans, envelopes, tubes and sleeves as well as containers for sauces, spreads, dips and the combinations thereof.  
           [0019]    A further embodiment of the present invention relates to a multiple part container for use with refrigerated and frozen dough. The multiple part container includes a first container having a first internal volume and constructed of a first material and at at least a second container having a second internal volume and constructed of a second material distinct from the first material. The second internal volume is less than the first internal volume and the second container is sized and configured to fit within the first container. The second container is sized and configured to receive at least one dough intermediate to create a portion controlled container for refrigerated and frozen doughs.  
           [0020]    Additional embodiments include the use of a third container disposed within the first container. The third container can have similar or equivalent dimensions with that of the second container or the third container can have an internal volume that is distinct from each of the first and second containers. In addition, the third container can be used for dough intermediates or other items such as dips, spreads, sauces and combinations or the like.  
           [0021]    These and other objects of the invention will become clear from an inspection of the detailed description of the invention and from the appended claims.  
           [0022]    Publications, patents and patent applications are referred to throughout this disclosure. All references cited herein are hereby incorporated by reference.  
           [0023]    There are a number of permutations possible for each of the foregoing embodiments and one with skill in the art would readily recognize such variations. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0024]    These, as well as other objects and advantages of this invention, will be more completely understood and appreciated by referring to the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings, of which:  
         [0025]    [0025]FIG. 1 depicts a front view of the generally planar element which when folded forms the quadrate container of the present invention;  
         [0026]    [0026]FIG. 2 illustrates the back or second face of the generally planar element which when folded forms the quadrate container of the present invention;  
         [0027]    [0027]FIG. 3 shows a front elevation of an unfilled quadrate container after the generally planar element has been assembled into its folded configuration;  
         [0028]    [0028]FIG. 4 illustrates one embodiment of a preformed container suitable for holding the raw dough or dough intermediate which is sized and configured to fit within the quadrate container after the generally planar element has been assembled into is folded configuration;  
         [0029]    [0029]FIG. 4A provides a further illustration of a cut away of an additional internal or second container to fit within the first quadrate container;  
         [0030]    [0030]FIG. 5 illustrates the quadrate container of the present invention having a number of preformed containers positioned internally of the quadrate container and visible though a cut out in the generally planar element to demonstrate the portion control feature of the present invention;  
         [0031]    [0031]FIG. 6 is a view of an alternate assembly of the quadrate container in which no cutout is provided;  
         [0032]    [0032]FIG. 7 is an end view of the quadrate container showing various preformed dough intermediate containers disposed therein. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0033]    The present invention is now illustrated in greater detail by way of the following detailed description, but it should be understood that the present invention is not to be construed as being limited thereto.  
         [0034]    The present invention is a novel, multiple part, portion controlled container for refrigerated and frozen raw dough or dough intermediates for use in retail and wholesale establishments. The container of the present invention provides convenience and simplicity for the user as well as potentially economic advantages to the manufacturer.  
         [0035]    As used herein the term “dough intermediate” or “dough intermediates” refers to a dough that is required to undergo one or more treatment steps, such as baking, cooking, frying or the like before the dough is ready for human or animal consumption. The intermediate is generally in an uncooked or raw form.  
         [0036]    As used herein the term “portion control” refers to the ability to select variable serving sizes of the product.  
         [0037]    Turning now to FIG. 1, the generally planar element is depicted by reference numeral  10 . The generally planar element  10  has a first panel  1 , second panel  13 , third panel  15  and fourth panel  17 . The first panel  11  has first and second faces  12  and  14 , respectively. The first panel  11  is provided with end flaps  16  and  18 , which extend from the longitudinally extending end edges  28  and  38  of the first panel  11 . First panel  11  is also provided with a sealing flap  20 , which is connected to the first panel  11  along transversely extending side edge  24 . The sealing flap  20  is provided with a sealing means  22 , such as a line of adhesive, so as to seal the generally planar element  10  in its folded configuration (see FIGS. 3 and 4). The sealing flap  20  is moveable about a line of weakness  26  so that it can be brought into sealing engagement with fourth panel  17 . A suitable adhesive may include a hot melt, permanent adhesive, or a pressure sensitive permanent adhesive, which seals without the application of heat, or a cold glue.  
         [0038]    The end flaps  16  and  18  are foldable about lines of weakness  40  and  32  so as to form part of the end closure of the generally planar element when assembled into is final folded configuration. End flap  16  is provided with a longitudinally extending end edge  42  and end flap  18  is provided with a longitudinally extending end edge  30 .  
         [0039]    The first panel  11  is thus defined by the area including the longitudinally extending ends  28  and  38  and transversely extending sides  26  and  34 . The area of first panel  11  also includes the area of first and second end tabs  16  and  18  thus pushing out the longitudinally extending sides to end edge  30  and  42  or portions of the total sides of the generally planar element  10  illustrated by reference numerals  19  and  21 .  
         [0040]    The first panel  11  is connected to second panel  13  along transversely extending side edge  34 . The first panel  11  is foldable about a line of weakness  35  such that it may be folded into a relatively perpendicular configuration to that of the second panel  13 .  
         [0041]    Second panel  13  has first and second faces  50  and  52  and first and second end flaps  54  and  56 . The second panel  13  is connected to the first panel  11  along transversely extending side edge  34  and foldable about line of weakness  44 .  
         [0042]    End edge  56  is connected to second panel  13  along longitudinally extending end edge  60  and foldable about a longitudinally extending line of weakness  64 . End flap  56  has a longitudinally extending end edge  62 , which forms a portion of the end closure when the generally planar element  10  is assembled into its folded configuration. End flap  54  which is transversely opposite end flap  56  and is connected to second panel  13  along longitudinally extending side edge  70 . The end flap  54  is folded along longitudinally extending line of weakness  72  to aid in the formation of the end closure when the generally planar element  10  is assembled into is folded configuration.  
         [0043]    The area of the second panel  13  is defined by transversely extending sides  60  and  66  and longitudinally extending ends  60  and  70 . The area of the second panel  13 , may also include first and second end tabs  54  and  56  and hence the respective longitudinally extending edges  62  and  74  as well as portions of the total ends of the generally planar element  10  illustrated by reference numerals  19  and  21 .  
         [0044]    The second panel  13  is connected to the third panel  15  along transversely extending side edge  66  and is foldable about a transversely extending line of weakness  68 . As illustrated in FIG. 1, the second and third panels  13  and  15  respectively, are provided with a cut out area designated by reference numeral  58 . The cut out  58  is provided so that a prospective consumer can view the internal contents of the generally planar element  10  when in its folded configuration. It should however be understood, that the cut out  58  may be in only one panel or may extend into two, three or even all four panels of the present invention, depending on the particular configuration required by the manufacturer. Alternatively, no cut out may be provided in the configuration (see FIG. 6).  
         [0045]    The third panel  15  has first and second faces  80  and  82 , respectively, and is connected to the second panel  13  along a transversely extending side edge  76 . The third panel  15  is provided with first and second end tabs  84  and  86 . End tab  86  is connected to the third panel  15  along longitudinally extending edge  90  and foldable about a longitudinally extending line of weakness  94 . End tab  86  has a longitudinally extending end edge  88  that runs parallel to the longitudinally extending line of weakness  94  and longitudinally extending end edge  90 .  
         [0046]    The other end tab  84  is connected to the third panel  15  along longitudinally extending line of weakness  100 , which is coterminous with a side edge  96  of the third panel  15 . Second longitudinally extending side edge  98  of tab  84  is parallel to the longitudinally extending line of weakness  100 .  
         [0047]    The area of the third panel  15  is thus defined by transversely extending sides  76  and  92  and longitudinally extending ends  90  and  96 . In addition, the area of the third panel  17  may also include the area of the tabs  84  and  86  thereby extending to the longitudinally extending ends  88  and  98  of the tabs  84  and  86  as well as portions of the total ends of the generally planar element  10  illustrated by reference numerals  19  and  21 .  
         [0048]    The third panel  15  is connected to fourth panel  17  along a transversely extending side  92  and foldable about a transversely extending line of weakness  102  such that third panel  15 , when moved into position, is in a perpendicular position to both fourth panel  17  and second panel  13 , but parallel with first panel  11 .  
         [0049]    Fourth panel  17  is connected to the third panel along transversely extending side edge  104  and has first and second faces  110  and  112  respectively. The fourth panel  17  also has two end tabs  114  and  116 , which are transversely opposed to one another. End tab  116  is connected to the fourth panel  17  along a longitudinally extending line of weakness  120  on a first side and has a second side  118  defining the area of the tab  116 . The other tab  114  is connected to the fourth panel  17  along a longitudinally extending line of weakness  126  along a first side and has a second side end  130  offset from the first side in the transverse direction, and running parallel thereto.  
         [0050]    The fourth panel  17  is defined by transversely extending sides  104  and  124  and longitudinally extending first and second ends  122  and  128 . The fourth panel  17  may also include the area of end tabs  114  and  116  as well as portions of the total ends of the generally planar element  10  illustrated by reference numerals  19  and  21 .  
         [0051]    Transversely extending lines of weakness  35 ,  68  and  102  form the first, second and third lines of weakness and are generally disposed parallel to one another. A fourth line of weakness  24  is also disposed parallel to the first, second and third lines of weakness  35 ,  68  and  102  and is used where a sealing flap  20  is employed to complete the enclosure of the folded configuration as shown in FIGS. 3 and 4. The lines of weakness  35 ,  68  and  102  run parallel to the first and second sides  26  and  124  of the generally planar element  10 .  
         [0052]    Two generally parallel longitudinally extending lines of weakness are disposed in the generally planar element  10 . The first fold line is comprised of longitudinally extending fold lines  32 ,  64 ,  94  and  120  and spaced inwardly of a first side edge generally depicted by reference numeral  19 . The second fold line is comprised of longitudinally extending fold line  40 ,  72 ,  100  and  126  and is spaced inwardly of second side edge depicted generally by reference to numeral  21 .  
         [0053]    Turning now to FIG. 2, the second face  14 ,  52 ,  82  and  112  of each of the first  11 , second  13 , third  15  and fourth  17  panels are illustrated showing the reverse side of the generally planar element  10 .  
         [0054]    In one folding embodiment of the present invention for the generally planar element  10 , the final folded configuration of which is illustrated in FIG. 3, the fourth panel  17  is folded about transversely extending line of weakness  102  so that it is generally perpendicular to third panel  15 . The third panel  15  is folded about transversely extending line of weakness  68  so that the third panel is disposed generally perpendicularly to the second panel  13  and the fourth panel  17  is now in a parallel arrangement with the second panel  13 , forming a “C” shaped configuration. Finally, the first panel  11  is folded about transversely extending line of weakness  35  so that the first panel  11  is disposed generally perpendicularly to second panel  13  and in a parallel arrangement with third panel  15 . Then, sealing flap  20  is folded about transversely extending line of weakness  26  so as to contact the second face  112  of the fourth panel  17  to create a sealing engagement and close panels  11 ,  13 ,  15  and  17  into a generally rectangular configuration as seen in FIG. 3.  
         [0055]    Next, end tabs  54  and  56  of second panel  13  and end tabs  114  and  116  of fourth panel  17  are folded inwardly (towards the interior of the rectangle formed above) about longitudinally extending lines of weakness  64 ,  72 ,  120  and  126 , respectively so that they are generally perpendicular to the panels  13  and  17  from which they originate. Then, end tabs  16  and  18  and  84  and  86  are folded inwardly (as discussed above) about longitudinally extending lines of weakness  40 ,  32  and  100  and  90 , respectively so that they are generally perpendicular to the panels  11  and  15  from which the tabs extend. Thus, tabs  16 ,  18 ,  84  and  86  are disposed in an interlocking relationship with tabs  54 ,  56 ,  114  and  116  to form and end closure  23  of the carton as shown in FIG. 3.  
         [0056]    [0056]FIG. 3 illustrates the quadrate container  10  of the present invention in its folded configuration. The container  10  is provided with a cut out area  56  such that the potential customer can view the contents of the container.  
         [0057]    Turning now to FIG. 4, a depiction of preformed container  130  is shown. The preformed container  130  provides direct packaging contact with the raw dough or dough intermediate  140  and is chose for such direct food packaging. The preformed container may be a bag as shown in FIG. 4 that contains a plurality of raw dough pieces or intermediate or as illustrated in FIG. 4A an envelope or sleeve  131  that has only a couple of dough intermediates or raw dough pieces  140 . Each of the preformed containers  130  and  131  after filling are closed through use of a seam  142  or other closure means such as a clip, weld or the like. The bag, envelope or sleeve may be constructed from a polyester based material or other plastic or synthetic substances although other films are also suitable. The film should be sufficiently flexible to allow for some expansion of the contents due to the gas released by the raw dough or dough intermediates. Alternatively, the bag could be provided with a coating that scavenges the gas or a sachet which sequesters the gas to reduce the amount of internal pressure. In addition, the preformed container can also be provided with a vent so as to enable gas to escape from the interior of the container.  
         [0058]    While FIGS. 4 and 4A illustrate bags, envelopes or sleeves, it should be understood that other preformed containers are also suitable for use with the present invention. These include, but are not limited to tubes, cans and other structures each of which should be sized and configured so as to fit within the generally quadrate container  10 . The tube or cans may be made of film, plastic material as described above or coated paperboard. Generally, the second or additional containers that fit within the quadrate container  10  are constructed of a material that is distinct from the quadrate container  10 , for the purposes of this section, paperboard and coated paperboard are distinct materials.  
         [0059]    In certain embodiments, preformed container(s)  130 ,  131  (if provided) will be a pouch that holds two biscuits or other products. In an exemplary embodiment of the present invention the package will have 4 pouches, each of the pouches  130  containing two biscuits, creating an eight-pack product (four pouches, each with two dough intermediates for a total of 8 dough intermediates in the quadrate container  10 ). The intent in providing such an arrangement is “portion control” for the consumer. That is, the consumer can use two biscuits while the remaining biscuits remain sealed in their original packaging, preserving the product for use at a later time. Obviously, there can be any number of preformed packages  130  contained within the container  10  or any number of dough intermediates provided within the preformed packages  130  of the present invention.  
         [0060]    [0060]FIG. 5 is provided for its depiction of the generally quadrate container  10  having one or more preformed containers  130  contained therein. FIG. 6 provides an alternate view of the generally quadrate container  10  without the cutout  56 .  
         [0061]    [0061]FIG. 7 provides a side view of the generally quadrate container  10  having the end flaps  16 ,  84  and  54  open to display more than one-preformed containers  131 ,  135  and  137 . In this representative example, it will be seen that there is an envelope  131 , a dough can  135  and a sauce, spread or dip container  137  provided along with the contents. This embodiment not only illustrates that different containers can be used with the present invention but also that the multiple types of internal containers can be inserted into the generally quadrate container  10  of the present invention.  
         [0062]    The generally quadrate container may also be provided with an external overwrap (not shown) as part of the packaging arrangement and of course may take forms other than generally quadrate, such as triangular. In any event, the container should be sufficiently large (have a sufficiently large interior volume) so as to be able to hold one or more internal raw dough preformed containers.  
         [0063]    The illustrations of FIGS. 5 and 7 show other embodiments of the present invention. That is, there can be a single or second dough intermediate container contained within the quadrate container  10 , or there can be multiple additional containers provided within the quadrate container  10  which provides the external or protective container. The second, third and possibly other containers may either all have the same size, or internal volume such as if each was packed with biscuits, rolls, buns, breadsticks or the like or the internal containers can each be of a different dimension or size or internal volume. However, the internal volume of the second and any additional containers are distinct from the internal volume of the first container. In addition, the external or first container is usually constructed of a different material such as a paperboard and the second, third or any additional containers (if any) maybe constructed of a material distinct from the first container. That is, the second or additional containers could be plastic or coated paperboard and the first container uncoated paperboard.  
         [0064]    In order to further illustrate the multiple package arrangement of the present invention one of the interior containers or second containers could contain rolls or biscuits and another container could hold breadsticks or dough for producing a loaf of bread, thus providing something of a complete meal concept. Alternatively, one or more of the additional containers could be used for dips, spreads, sauces and combinations thereof (see FIG. 7) to provide further satisfaction for the consumer.  
         [0065]    It will thus be seen according to the present invention a highly advantageous multiple part package for refrigerated and frozen dough intermediates or raw dough has been provided. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiment, that many modifications and equivalent arrangements may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products.