Abstract:
A hot pizza box is formed of corrugated cardboard and includes an aluminum liner for the top, bottom, front, back and side panels to help retain heat within the box. A second aluminum liner may be located within the corrugated material of the box either above or below the corrugated material in the box panels. An alternative pizza box is formed of resilient material having interior and exterior members enclosing a cavity. A formed aluminum panel is located in the cavity. The bottom panel of the box has a central aperture penetrating the interior member. The aluminum panel has an opening formed to align with the aperture and a series of channels extends from the opening to edges of the panels. The aperture serves to channel heat from the pizza to the opening in the bottom panel and through the channels to the panels and tabs of the pizza box.

Description:
RELATED APPLICATION 
       [0001]    The instant application is a Continuation-in-Part of Provisional Patent Application Ser. No. 62/285,176 filed on Oct. 22, 2015 and claims priority to the filing date thereof and incorporates the disclosure of the application in its entirety. 
     
    
     FIELD OF INVENTION 
       [0002]    This invention relates to the field of packaging, and more specifically to heat-retaining boxes for pizza and other food products. 
       BACKGROUND OF THE INVENTION 
       [0003]    Pizza has long been provided carry out and delivery in cardboard or paperboard boxes. While such boxes are inexpensive to make and easy to use, they will only keep the pizza at a desirable eating temperature for a short time. The present invention addresses this problem with two designs for a pizza box that will substantially maintain the serving temperature of the pizza for an extended time. 
         [0004]    An example of a pizza container invention developed to address the rapid cooling problem associated with carry out and pizza delivery includes U.S. Pat. No. 9,162,808 which discloses an insulated take home food container. The present invention relates to a laminate of metallic or non-metallic heat reflective film, either flat or in a manner to create air pockets, utilized to increase the holding time a food stays warm in the container. The container can have flat surface or dividing walls depending on the use of the box. 
         [0005]    It is an objective of the present invention to provide a pizza box suitable for carry out and delivery use that will maintain the pizza at an elevated temperature for an extended period of time. It is a further objective to provide a box that is inexpensive to make and efficient to use. It is a still further objective of the invention to provide a box that can be stored and shipped in a flattened configuration. It is yet a further objective to provide such a box that is quickly and easily assembled from flat configuration into a box. Finally, it is an objective of the present invention to provide a box that can be manufactured from easily recycled materials or that can be recycled for additional uses. 
         [0006]    While some of the objectives of the present invention are disclosed in the prior art, none of the inventions found include all of the requirements identified. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention addresses all of the deficiencies of prior art dispensers for hot pizza boxes and satisfies all of the objectives described above. 
         [0008]    (1) A hot pizza box providing the desired features may be constructed from the following components. A bottom panel is provided. The bottom panel is sized and shaped to support a pizza. A front panel is provided. The front panel is attached to a front edge of the bottom panel along a first perforation line. A first bottom side panel is provided. The first bottom side panel is attached to a first side edge of the bottom panel along a second perforation line. A second bottom side panel is provided. The second bottom side panel is attached to a second side edge of the bottom panel along a third perforation line. A back panel is provided. The back panel is attached to a back edge of the bottom panel along a fourth perforation line. A first back panel seal is provided. The first back panel seal is attached to a first end of the first bottom side panel at a fifth perforation line. A second back panel seal is provided. The second back panel seal is attached to a first end of the second bottom side panel at a sixth perforation line. 
         [0009]    A top panel is provided. The top panel is attached at a back edge to the back panel along a seventh perforation line. A first top side panel is provided. The first top side panel is attached to a first side edge of the top panel along an eighth perforation line. A second top side panel is provided. The second top side panel is attached to a second side edge of the top panel along a ninth perforation line. A first lid reinforcing tab is provided. The first lid reinforcing tab is attached to a first end of the first top side panel along a tenth perforation line. A second lid reinforcing tab is provided. The second lid reinforcing tab is attached to a first end of the second top side panel along an eleventh perforation line. A lid front panel is provided. The lid front panel attached to a front edge of the top panel along a twelfth perforation line. A lid front panel securing portion is provided. The lid front panel securing portion is attached to the lid front panel along thirteenth and fourteenth parallel perforation lines. 
         [0010]    The hot pizza box is formed of corrugated cardboard or paperboard. The bottom panel, front panel, first and second bottom side panels, back panel, first and second back panel seals, and top panel have an aluminum lining on interior surfaces of the panels and seals. The pizza box is formed by folding the front panel to be orthogonal to the bottom panel, folding the first and second back panel seals to be orthogonal to the first and second bottom side panels, respectively, folding the first and second bottom side panels to be orthogonal to the bottom panel, folding the first and second lid reinforcing tabs to be orthogonal to the first and second top side panels, respectively, folding the first and second top side panels to be orthogonal to the top panel, folding the a lid front panel to be orthogonal to the top panel, folding the lid front panel securing portion over the first and second lid reinforcing tabs and securing it frictionally to an interior surface of the top panel, folding the back panel to be orthogonal to the bottom panel and folding the top panel to be orthogonal to the back panel, thereby forming a closed pizza box. 
         [0011]    (2) In a variant of the invention, the bottom panel, front panel, first and second bottom side panels, back panel, first and second back panel seals, and top panel further include a second layer of aluminum located between interior and exterior surfaces of the corrugated cardboard or paperboard. 
         [0012]    (3) In another variant, the second layer of aluminum is located between the interior surface of the corrugated cardboard or paperboard and a corrugated layer of paper within the corrugated cardboard or paperboard. 
         [0013]    (4) In still another variant, the second layer of aluminum is located between the exterior surface of the corrugated cardboard or paperboard and a corrugated layer of paper within the corrugated cardboard or paperboard. 
         [0014]    (5) In yet another variant, at least one interruption in the fourth perforation line is provided. The at least one interruption is formed as a first cut through the back panel parallel to and spaced downwardly from the fourth perforation line and connected to the fourth perforation line by second and third cuts orthogonal to the first cut and the fourth perforation line, the first cut reduces the effort required to fold the back panel to be orthogonal to the bottom panel. 
         [0015]    (6) In a further variant, at least one vent opening is provided. The vent opening is located in either of the top panel or the bottom panel. 
         [0016]    (7) In still a further variant, at least one securing protrusion is provided. The first securing protrusion extends outwardly from a distal edge of the lid front panel securing portion and is adapted to facilitate frictionally securing the lid front panel securing portion to the interior surface of the top panel. 
         [0017]    (8) In yet a further variant, an alternative hot pizza box includes the following components. A bottom panel is provided. The bottom panel is sized and shaped to support a pizza. A front panel is provided. The front panel is attached to a front edge of the bottom panel along a first perforation line. A first bottom side panel is provided. The first bottom side panel is attached to a first side edge of the bottom panel along a second perforation line. A second bottom side panel is provided. The second bottom side panel is attached to a second side edge of the bottom panel along a third perforation line. A back panel is provided. The back panel is attached to a back edge of the bottom panel along a fourth perforation line. A first back panel seal is provided. The first back panel seal is attached to a first end of the first bottom side panel at a fifth perforation line. A second back panel seal is provided. The second back panel seal is attached to a first end of the second bottom side panel at a sixth perforation line. 
         [0018]    A top panel is provided. The top panel is attached at a back edge to the back panel along a seventh perforation line. A first top side panel is provided. The first top side panel is attached to a first side edge of the top panel along an eighth perforation line. A second top side panel is provided. The second top side panel is attached to a second side edge of the top panel along a ninth perforation line. A first lid reinforcing tab is provided. The first lid reinforcing tab is attached to a first end of the first top side panel along a tenth perforation line. A second lid reinforcing tab is provided. The second lid reinforcing tab is attached to a first end of the second top side panel along an eleventh perforation line. A lid front panel is provided. The lid front panel attached to a front edge of the top panel along a twelfth perforation line. A lid front panel securing portion is provided. The lid front panel securing portion is attached to the lid front panel along thirteenth and fourteenth parallel perforation lines. 
         [0019]    The hot pizza box is formed of resilient material and has an exterior member and an interior member. The members are spaced apart to form an interior cavity. The bottom panel has a central aperture. The aperture penetrates only the interior member. The bottom panel, front panel, first and second bottom side panels, back panel, first and second back panel seals, and top panel have a formed aluminum panel located between the interior member and the exterior member. 
         [0020]    The pizza box is formed by folding the front panel to be orthogonal to the bottom panel, folding the first and second back panel seals to be orthogonal to the first and second bottom side panels, respectively, folding the first and second bottom side panels to be orthogonal to the bottom panel, folding the first and second lid reinforcing tabs to be orthogonal to the first and second top side panels, respectively, folding the first and second top side panels to be orthogonal to the top panel, folding the a lid front panel to be orthogonal to the top panel, folding the lid front panel securing panel over the first and second lid reinforcing tabs and securing it frictionally to an interior surface of the top panel, folding the back panel to be orthogonal to the bottom panel and folding the top panel to be orthogonal to the back panel, thereby forming a closed pizza box. 
         [0021]    (9) In another variant of the invention, the formed aluminum panel further includes a mating recess. The recess is sized and shaped to align with the aperture in the bottom panel; 
         [0022]    (10) In still another variant, the formed aluminum panel further includes a series of channels. The channels are adapted to augment heat flow from the aperture to distal ends of the aluminum panel, thereby distributing heat to the panels and seals of the pizza box. 
         [0023]    (11) In yet another variant, at least one interruption is provided in the fourth perforation line. The at least one interruption is formed as a first cut through the back panel parallel to and spaced downwardly from the fourth perforation line. The first cut is connected to the fourth perforation line by second and third cuts orthogonal to the first cut and the fourth perforation line, the first cut reduces the effort required to fold the back panel to be orthogonal to the bottom panel. 
         [0024]    (12) In a further variant, at least one vent opening is provided. The vent opening is located in either of the top panel or the bottom panel. 
         [0025]    (13) In still a further variant, at least one securing protrusion is provided. The first securing protrusion extends outwardly from a distal edge of the lid front panel securing portion. A first receiving notch is provided. The first receiving notch penetrates only the interior member of the top panel and is located and adapted to receive frictionally the first securing protrusion. 
         [0026]    (14) In yet a further variant, second and third receiving notches are provided. The second and third receiving notches penetrate the top panel and are located and adapted to receive frictionally inner edges of the first and second lid reinforcing tabs. 
         [0027]    (15) In a final variant of the invention, at least one first bottom side panel securing tab and at least one second bottom side panel securing tab are provided. The first and second bottom side panel securing tabs extend upwardly to form the first and second bottom side panels, respectively. At least one first bottom side panel receiving notch and at least one second bottom side panel receiving notch are provided. The first and second bottom side panel receiving notches penetrate the top panel and are located and adapted to receive frictionally the first and second bottom side panel securing tabs, respectively, thereby securing the top panel over the bottom panel. 
         [0028]    An appreciation of the other aims and objectives of the present invention and an understanding of it may be achieved by referring to the accompanying drawings and the detailed description of a preferred embodiment. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0029]      FIG. 1  is a plan view of the exterior surface of a punched and perforated cardboard blank which is folded to form a first embodiment of the invention; 
           [0030]      FIG. 2  is a plan view of the interior surface of the  FIG. 1  embodiment illustrating an aluminum coating on the interior surface of the pizza box to be formed; 
           [0031]      FIG. 2A  is a cross-sectional view of the  FIG. 1  embodiment illustrating the second layer of aluminum disposed between the interior surface of the cardboard and the corrugated paper; 
           [0032]      FIG. 2B  is a cross-sectional view of the  FIG. 1  embodiment illustrating the second layer of aluminum disposed between the exterior surface of the cardboard and the corrugated paper; 
           [0033]      FIG. 3  is a plan view of the exterior surface of a punched and perforated cardboard blank which is folded to form a second embodiment of the invention; 
           [0034]      FIG. 4  is a plan view of the interior surface of the  FIG. 3  embodiment illustrating a heat flow aperture in the interior surface panel of the pizza box to be formed; 
           [0035]      FIG. 5  is a plan view of the formed aluminum panel disposed between interior and exterior paperboard panels of the box; 
           [0036]      FIG. 5A  is a close-up partial plan view of the formed aluminum panel illustrating the flow of heat into the channels from the opening; 
           [0037]      FIG. 6  is a perspective view of the assembled pizza box of the  FIG. 3  embodiment; 
           [0038]      FIG. 7  is a cross-sectional view of the bottom portion of the  FIG. 3  embodiment taken along the line  7 - 7 ; 
           [0039]      FIG. 8  is a cross-sectional view of the lid portion of the  FIG. 3  embodiment taken along the line  8 - 8 ; and 
           [0040]      FIG. 9  is a cross-sectional view of the  FIG. 3  embodiment taken along the lines  7 - 7  and  8 - 8  with the pizza box closed. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0041]    (1)  FIGS. 1-2  illustrate a hot pizza box  10  providing the desired features that may be constructed from the following components. A bottom panel  14  is provided. The bottom panel  14  is sized and shaped to support a pizza. A front panel  18  is provided. The front panel  18  is attached to a front edge  22  of the bottom panel  14  along a first perforation line  26 . A first bottom side panel  30  is provided. The first bottom side panel  30  is attached to a first side edge  34  of the bottom panel  14  along a second perforation line  38 . A second bottom side panel  42  is provided. The second bottom side panel  42  is attached to a second side edge  46  of the bottom panel  14  along a third perforation line  50 . A back panel  54  is provided. The back panel  54  is attached to a back edge  58  of the bottom panel  14  along a fourth perforation line  62 . A first back panel seal  66  is provided. The first back panel seal  66  is attached to a first end  70  of the first bottom side panel  30  at a fifth perforation line  74 . A second back panel seal  78  is provided. The second back panel seal  78  is attached to a first end  82  of the second bottom side panel  42  at a sixth perforation line  86 . 
         [0042]    A top panel  90  is provided. The top panel  90  is attached at a back edge  94  to the back panel  54  along a seventh perforation line  98 . A first top side panel  102  is provided. The first top side panel  102  is attached to a first side edge  106  of the top panel  90  along an eighth perforation line  110 . A second top side panel  114  is provided. The second top side panel  114  is attached to a second side edge  118  of the top panel  90  along a ninth perforation line  122 . A first lid reinforcing tab  126  is provided. The first lid reinforcing tab  126  is attached to a first end  130  of the first top side panel  102  along a tenth perforation line  134 . A second lid reinforcing tab  138  is provided. The second lid reinforcing tab  138  is attached to a first end  142  of the second top side panel  114  along an eleventh perforation line  146 . A lid front panel  150  is provided. The lid front panel  150  IS attached to a front edge  154  of the top panel  90  along a twelfth perforation line  158 . A lid front panel securing portion  162  is provided. The lid front panel securing portion  162  is attached to the lid front panel  150  along thirteenth  166  and fourteenth  170  parallel perforation lines. 
         [0043]    The hot pizza box  10  is formed of corrugated cardboard  174  or paperboard (not shown). The bottom panel  14 , front panel  18 , first  30  and second  42  bottom side panels, back panel  54 , first  66  and second  78  back panel seals, and top panel  90  have an aluminum lining  178  on interior surfaces of the panels  182 ,  186 ,  190 ,  194 ,  198 ,  202  and seals  206 ,  210 . The pizza box  10  is formed by folding the front panel  18  to be orthogonal to the bottom panel  14 , folding the first  66  and second  78  back panel seals to be orthogonal to the first  30  and second  42  bottom side panels, respectively, folding the first  30  and second  42  bottom side panels to be orthogonal to the bottom panel  14 , folding the first  126  and second  138  lid reinforcing tabs to be orthogonal to the first  102  and second  114  top side panels, respectively, folding the first  102  and second  114  top side panels to be orthogonal to the top panel  90 , folding the a lid front panel  150  to be orthogonal to the top panel  90 , folding the lid front panel securing portion  162  over the first  126  and second  138  lid reinforcing tabs and securing it frictionally to an interior surface  202  of the top panel  90 , folding the back panel  54  to be orthogonal to the bottom panel  14  and folding the top panel  90  to be orthogonal to the back panel  54 , thereby forming a closed pizza box  10 . 
         [0044]    (2) In a variant of the invention, as illustrated in  FIGS. 2A and 2B , the bottom panel  14 , front panel  18 , first  30  and second  42  bottom side panels, back panel  54 , first  66  and second  78  back panel seals, and top panel  90  further include a second layer of aluminum  214  located between interior  218  and exterior  222  surfaces of the corrugated cardboard  174  or paperboard. 
         [0045]    (3) In another variant, as illustrated in  FIG. 2A , the second layer of aluminum  214  is located between the interior surface  218  of the corrugated cardboard  174  or paperboard and a corrugated layer of paper  226  within the corrugated cardboard  174  or paperboard. 
         [0046]    (4) In still another variant, as illustrated in  FIG. 2B , the second layer of aluminum  214  is located between the exterior surface  222  of the corrugated cardboard  174  or paperboard and a corrugated layer of paper  226  within the corrugated cardboard  174  or paperboard. 
         [0047]    (5) In yet another variant, as illustrated in  FIGS. 1 and 2 , at least one interruption  230  in the fourth perforation line  62  is provided. The at least one interruption  230  is formed as a first cut  234  through the back panel  54  parallel to and spaced downwardly from the fourth perforation line  62  and connected to the fourth perforation line  62  by second  238  and third  242  cuts orthogonal to the first cut  234  and the fourth perforation line  62 , the first cut  234  reduces the effort required to fold the back panel  54  to be orthogonal to the bottom panel  14 . 
         [0048]    (6) In a further variant, at least one vent opening  246  is provided. The vent opening  246  is located in either of the top panel  90  or the bottom panel  14 . 
         [0049]    (7) In still a further variant, at least one securing protrusion  250  is provided. The first securing protrusion  250  extends outwardly from a distal edge  254  of the lid front panel securing portion  162  and is adapted to facilitate frictionally securing the lid front panel securing portion  162  to the interior surface  202  of the top panel  90 . 
         [0050]    (8) In yet a further variant, as illustrated in  FIGS. 3-9 , an alternative hot pizza box  258 , includes the following components. A bottom panel  14  is provided. The bottom panel  14  is sized and shaped to support a pizza. A front panel  18  is provided. The front panel  18  is attached to a front edge  22  of the bottom panel  14  along a first perforation line  26 . A first bottom side panel  30  is provided. The first bottom side panel  30  is attached to a first side edge  34  of the bottom panel  14  along a second perforation line  38 . A second bottom side panel  42  is provided. The second bottom side panel  42  is attached to a second side edge  46  of the bottom panel  14  along a third perforation line  50 . A back panel  54  is provided. The back panel  54  is attached to a back edge  58  of the bottom panel  14  along a fourth perforation line  62 . A first back panel seal  66  is provided. The first back panel seal  66  is attached to a first end  70  of the first bottom side panel  30  at a fifth perforation line  74 . A second back panel seal  78  is provided. The second back panel seal  78  is attached to a first end  82  of the second bottom side panel  42  at a sixth perforation line  86 . 
         [0051]    A top panel  90  is provided. The top panel  90  is attached at a back edge  94  to the back panel  54  along a seventh perforation line  98 . A first top side panel  102  is provided. The first top side panel  102  is attached to a first side edge  106  of the top panel  90  along an eighth perforation line  110 . A second top side panel  114  is provided. The second top side panel  114  is attached to a second side edge  118  of the top panel  90  along a ninth perforation line  122 . A first lid reinforcing tab  126  is provided. The first lid reinforcing tab  126  is attached to a first end  130  of the first top side panel  102  along a tenth perforation line  134 . A second lid reinforcing tab  138  is provided. The second lid reinforcing tab  138  is attached to a first end  142  of the second top side panel  114  along an eleventh perforation line  146 . A lid front panel  150  is provided. The lid front panel  150  IS attached to a front edge  154  of the top panel  90  along a twelfth perforation line  158 . A lid front panel securing portion  162  is provided. The lid front panel securing portion  162  is attached to the lid front panel  150  along thirteenth  166  and fourteenth  170  parallel perforation lines. 
         [0052]    The hot pizza box  258  is formed of resilient material  262  and has an exterior member  266  and an interior member  270 . The members  266 ,  270  are spaced apart to form an interior cavity  274 . The bottom panel  14  has a central aperture  278 . The aperture  278  penetrates only the interior member  270 . The bottom panel  14 , front panel  18 , first  30  and second  42  bottom side panels, back panel  54 , first  66  and second  78  back panel seals, and top panel  90  have a formed aluminum panel  282  located between the interior  270  member and the exterior member  266 . 
         [0053]    The pizza box  258  is formed by folding the front panel  18  to be orthogonal to the bottom panel  14 , folding the first  66  and second  78  back panel seals to be orthogonal to the first  30  and second  42  bottom side panels, respectively, folding the first  30  and second  42  bottom side panels to be orthogonal to the bottom panel  14 , folding the first  126  and second  138  lid reinforcing tabs to be orthogonal to the first  102  and second  114  top side panels, respectively, folding the first  102  and second  114  top side panels to be orthogonal to the top panel  90 , folding the a lid front panel  150  to be orthogonal to the top panel  90 , folding the lid front panel securing portion  162  over the first  126  and second  138  lid reinforcing tabs and securing it frictionally to an interior surface  202  of the top panel  90 , folding the back panel  54  to be orthogonal to the bottom panel  14  and folding the top panel  90  to be orthogonal to the back panel  54 , thereby forming a closed pizza box  258 . 
         [0054]    (9) In another variant of the invention, the formed aluminum panel  282  further includes a mating recess  286 . The recess  286  is sized and shaped to align with the aperture  278  in the bottom panel  14 ; 
         [0055]    (10) In still another variant, the formed aluminum panel  282  further includes a series of channels  290 . The channels  290  are adapted to augment heat flow from the aperture  278  to distal ends  294  of the aluminum panel  282 , thereby distributing heat  326  to the panels  14 ,  18 ,  30 ,  42 ,  54 ,  90  and seals  66 ,  78  of the pizza box  258 . 
         [0056]    (11) In yet another variant, at least one interruption  230  in the fourth perforation line  62  is provided. The at least one interruption  230  is formed as a first cut  234  through the back panel  54  parallel to and spaced downwardly from the fourth perforation line  62  and connected to the fourth perforation line  62  by second  238  and third  242  cuts orthogonal to the first cut  234  and the fourth perforation line  62 , the first cut  234  reduces the effort required to fold the back panel  54  to be orthogonal to the bottom panel  14 . 
         [0057]    (12) In a further variant, at least one vent opening  246  is provided. The vent opening  246  is located in either of the top panel  90  or the bottom panel  14 . 
         [0058]    (13) In still a further variant, at least one securing protrusion  250  is provided. The first securing protrusion  250  extends outwardly from a distal edge  254  of the lid front panel securing portion  162 . A first receiving notch  298  is provided. The first receiving notch  298  penetrates only the interior member  270  of the top panel  90  and is located and adapted to receive frictionally the first securing protrusion  250 . 
         [0059]    (14) In yet a further variant, second  302  and third  306  receiving notches are provided. The second  302  and third  306  receiving notches penetrate the top panel  90  and are located and adapted to receive frictionally inner edges  310 ,  314  of the first  126  and second  138  lid reinforcing tabs. 
         [0060]    (15) In a final variant of the invention, at least one first bottom side panel securing tab  318  and at least one second bottom side panel securing tab  322  are provided. The first  318  and second  322  bottom side panel securing tabs extend upwardly to form the first  30  and second  42  bottom side panels, respectively. At least one first bottom side panel receiving notch  326  and at least one second bottom side panel receiving notch  330  are provided. The first  326  and second  330  bottom side panel receiving notches penetrate the top panel  90  and are located and adapted to receive frictionally the first  318  and second  322  bottom side panel securing tabs, respectively, thereby securing the top panel  90  over the bottom panel  14 . 
         [0061]    An appreciation of the other aims and objectives of the present invention and an understanding of it may be achieved by referring to the accompanying drawings and the detailed description of a preferred embodiment. 
         [0062]    The hot pizza boxes  10  and  258  have been described with reference to particular embodiments. Other modifications and enhancements can be made without departing from the spirit and scope of the claims that follow.