Multiple pastry box

A container assembly for carrying display-packaged delicate baked goods includes a container having opposing side walls interconnected with opposing end walls, a bottom interconnected with each of the side and end walls, a top, and an interior. A retaining tray has at least one aperture therein, and is removably received in the container interior. The retaining tray is dimensioned such that the container side and end walls restrict movement of the retaining tray in a direction perpendicular to the container side and end walls. The retaining tray includes at least one spacing member extending therefrom and spacing the retaining tray from an underlying surface. A display package includes a pan portion and a top removably secured to the pan portion. The pan portion includes a projection extending outwardly therefrom, and is removably received within the aperture until the projection contacts the retaining tray. The projection is disposed on the pan portion such that the display package is suspended from the retaining tray within the aperture above the underlying surface, thereby restricting the display package from movement in a direction perpendicular to the container side and end walls and in a direction toward the bottom of the container.

FIELD OF THE INVENTION
 The present invention relates to containers and, more particularly, to
 containers for the storage and transportation of baked goods.
 DESCRIPTION OF THE RELATED ART
 Baked goods, such as pastries, cakes, and pies, are delicate items which
 are easily damaged during the shipping and handling thereof Furthermore,
 such baked goods are known as "impulse" items because a consumer often
 purchases baked goods without the prior intention of so doing. In order to
 increase the likelihood of creating the impulse to buy within the
 consumer, baked goods are prominently and attractively displayed in a
 high-traffic area of a retail establishment. The buying impulse is created
 by appealing to the consumer's senses of sight and smell. Aesthetics are a
 critical factor in the creation within the consumer of the impulse to
 purchase a baked good. An aesthetically appealing baked good is much more
 likely to create the buying impulse within a consumer than an
 unattractively displayed baked good or one with degraded aesthetics. The
 aesthetics of baked goods can be negatively impacted due to their delicate
 nature. Thus, it is desirable to preserve and protect the aesthetic
 quality of baked goods.
 Many bakeries supply baked goods to a number of geographically-dispersed
 customers such as restaurants and retail outlets. The distribution channel
 may include, for example, a central bakery which produces large quantities
 of baked goods. The baked goods are then placed in shipping containers for
 distribution, and delivered to the customer location by, for example, a
 delivery truck. Once at the customer location, the shipping containers
 which contain the baked goods are then carried by hand or upon a wheeled
 cart from the delivery truck to a location within the retail outlet.
 During transportation from the bakery to the customer, the shipping
 containers may be stacked one on top of another, and are likely to
 encounter relatively rough handling which may result in the baked goods
 suffering some degradation in aesthetic quality.
 Various individual display packages have been developed which enable the
 aesthetic display of an individual baked good at the point of sale by
 affording the consumer a relatively unobstructed view of the contents of
 the package. However, the individual display packages do not effectively
 protect baked goods during the distribution thereof from the central
 bakery to the customer location. The protective properties of the typical
 individual display package are sacrificed in order to achieve the desired
 aesthetic or display qualities. Such individual display packages may not
 be stacked one on top of another, nor may they be packed in quantity
 within a shipping container, without damaging the display package or the
 baked goods therein which, in turn, degrades the aesthetics of the baked
 good. Therefore, baked goods are typically packaged in small quantities.
 Very delicate baked goods, such as pastries, tend to be packaged
 individually. Even the individually packaged baked goods, however, still
 require very careful handling if their aesthetic appeal is to be
 preserved.
 Even with careful handling, the individual display packages may shift
 within the delivery truck or within shipping containers during
 distribution. Such shifting often results in damage to the baked goods or
 in damage to the individual display packages. Damage to either the baked
 good or its display package degrades the overall attractiveness of the
 display of the baked good, reduces the aesthetic quality thereof, and
 therefore reduces the likelihood of creating the buying impulse within a
 consumer.
 The above factors result in various inefficiencies within the distribution
 channel. Valuable delivery truck space is wasted due to an inability to
 stack boxes. Other examples of such inefficiencies include the additional
 hours of labor required to accomplish delivery due to the small quantities
 of baked goods contained in each package, an increased number of trips are
 required to deliver a given quantity of baked goods, and the special care
 which must be taken by a delivery person in order to minimize damage to
 the baked goods. Furthermore, due to damage in transit and delivery,
 shrinkage occurs from the amount of product which leaves the central
 bakery to the amount of product which reaches the customer in saleable
 condition and without loss of aesthetic quality. Such inefficiencies all
 result in higher operating costs and lower profits.
 Therefore, what is needed in the art is a shipping container which enables
 the shipment of a relatively large quantity of delicate baked goods and
 which protects the baked good from damage. Furthermore, what is needed in
 the art is a shipping container which enables the shipment of a relatively
 large quantity of individually display-packaged delicate baked goods and
 which preserves the aesthetic appearance of the baked good and its
 individual display package.
 SUMMARY OF THE INVENTION
 The present invention provides a multiple pastry box which permits the
 packing and shipping of a quantity of individually display-packaged
 pastries within a single carton, and which protects the pastries and the
 individual display packages from damage, thereby preserving their
 aesthetic quality.
 The invention comprises, in one form thereof, a container assembly,
 including a container having opposing side walls interconnected and spaced
 apart by opposing end walls, a bottom interconnected with the side and end
 walls, a top, and an interior. A retaining tray defines at least one
 aperture and is removably received in the container interior. The
 retaining tray is dimensioned such that the container side and end walls
 restrict movement of the retaining tray in a direction perpendicular to
 the container side and end walls. The retaining tray includes at least one
 spacing member extending therefrom and spacing the retaining tray a
 predetermined distance from an underlying surface. A display package
 includes a pan portion and a top removably secured to the pan portion. The
 pan portion includes at least one projection extending outwardly
 therefrom, and is removably received within the aperture until the
 projection contacts the retaining tray. The projection is disposed on the
 pan portion such that the display package is suspended from the retaining
 tray within the aperture and above the underlying surface, thereby
 restricting the display package from movement in a direction perpendicular
 to the container side and end walls and in a direction toward the bottom
 of the container.
 An advantage of the present invention is that the display-packages are
 restricted from horizontal displacement during packaging, handling and
 transport.
 Another advantage of the present invention is that the display packages are
 restricted from vertical movement during packaging, handling and
 transport.
 Yet another advantage of the present invention is that the aesthetic
 quality of the display packages is preserved during packaging, handling
 and transport.
 A still further advantage of the present invention is that a large quantity
 of display packages containing delicate baked goods may be shipped within
 one container without degraded aesthetics.

Corresponding reference characters indicate corresponding parts throughout
 the several views. The exemplification set out herein illustrates one
 preferred embodiment of the invention, in one form, and such
 exemplification is not to be construed as limiting the scope of the
 invention in any manner.
 DETAILED DESCRIPTION OF THE DRAWINGS
 Referring now to the drawings and particularly to FIG. 1, there is shown a
 multiple pastry box 10 including container 12, retainer trays 14a and 14b,
 and display packages 16.
 Container 12 includes opposing side walls 20, 22, end walls 24, 26, bottom
 28 and a top portion having two side flaps 30, 32 and two end flaps 34,
 36, all of which conjunctively define box interior 38. Container 12 is
 closed by folding end flaps 34, 36 inward toward the interior 38 until the
 flaps are substantially parallel with bottom 28. Then, side flaps 30, 32
 are likewise folded inward toward box interior 38 until they are
 substantially parallel with bottom 28. The side flaps 30, 32 will thus
 overlie end flaps 34, 36. The side flaps 30, 32 form a junction
 therebetween which extends the entire length of the top of container 12.
 The container 12 can then be securely closed by, for example, applying
 tape over side flaps 30, 32. The tape preferably is applied such that it
 covers the junction or intersection of flaps 30, 32, thereby joining the
 flaps together along a substantial length of the junction formed
 therebetween, and then extends onto end walls 24, 26. Container 12 is
 opened by cutting or removing the tape and reversing the process described
 above, i.e., the side flaps 30, 32 are folded out relative to interior 38
 and, thereafter, the end flaps 34, 36 are also folded out relative to
 interior 38, thereby rendering accessible any contents previously placed
 in interior 38. The bottom 28 of container 12 can, for example, be formed
 of flaps similarly to the top or, alternatively, formed of a solid
 one-piece construction. Container 12 is formed of, for example, corrugated
 cardboard or other suitable material, and is dimensioned to contain a
 predetermined number of baked goods.
 Retainer trays 14a and 14b are of substantially identical construction and,
 therefore, only retainer tray 14a will be described in detail, such
 description being equally applicable to retainer tray 14b. Referring now
 to FIG. 2, retainer tray 14a includes planar top member 40, side walls 42,
 44, and end walls 46, 48. Retainer tray 14a is designed to fit snugly
 within container 12 and is therefore dimensioned such that there is only a
 slight clearance between retainer side walls 42, 44 and container side
 walls 20, 22, and between retainer end walls 46, 48 and container end
 walls 24, 26. The minimal clearance between the side and end walls of
 retainer tray 14a and the container side and end walls 42, 44 and 46, 48,
 respectively, ensures retainer tray 14a will not be displaced in the
 horizontal plane when disposed in interior 38 of container 12. Retainer
 tray 14a is constructed of, for example, corrugated cardboard, paperboard,
 or, alternatively, injection molded plastic. Retainer tray 14a may be
 constructed by the folding or forming of one piece of, for example,
 cardboard or paperboard, or may be constructed of separate pieces of
 material attached or connected together.
 Side walls 42, 44 of retainer tray 14a are substantially perpendicular to
 top planar member 40. Likewise, end walls 46, 48, are substantially
 perpendicular to planar member 40. Side walls 42, 44 and end walls 46, 48
 enable stacking of one retainer tray on top of another. When the retainer
 trays are stacked one on top of another, side walls 42, 44 and end walls
 46, 48 create a vertical separation 49 between the respective planar
 members 40 of each retainer tray. The height of side walls 42, 44 and end
 walls 46, 48 determines the vertical separation or space 49 created
 between the respective planar top members of the stacked retainer trays.
 Planar member 40 defines, for example, six apertures 50a, 50b, 50c, 50d,
 50e and 50f therein. Apertures 50a-50f are, for example, substantially
 cylindrical in shape, each being dimensioned to receive and support one of
 display packages 16. In general, the shape of the aperture corresponds to
 the shape of the package 16.
 Display packages 16 include a pan portion 70, cover 72 and flange 74. Pan
 70 includes a closed bottom portion 76 and an open top portion 78. Flange
 74 is integral with pan 70 and extends radially-outward therefrom. Flange
 74 is disposed, for example, near the open top portion 78 of pan 70. Cover
 72 is removably secured to the open top portion 78 of pan 70 by use of,
 for example, projections (not shown) which snap through complementary
 features (not shown) in pan 70. Alternatively, cover 72 can be constructed
 in a way, or from a material, which renders it elastically deformable.
 Cover 72 can then be removably secured to pan 70 by elastic deformation
 over a complementary feature such as, for example, a ridge or ring (not
 shown) formed around the open top 78 of pan 70. Display packages 16 are,
 for example, cylindrical in shape, having a slightly outward flare, and
 are constructed of, for example, a transparent plastic in order to
 aesthetically display a baked good contained therein.
 Flange 74 is disposed, for example, around the entire perimeter of pan 70
 proximate to the open top 78 thereof. Apertures 50a-50f are dimensioned to
 receive pan 70 of display package 16. However, flange 74 extends radially
 outward from pan 70 such that flange 74 does not pass through apertures
 50a-50f . Rather, flange 74 interferes with the outer perimeter of
 apertures 50a-50f and rests on flat planar member 40 of retainer tray 14.
 Thus, pans 70 are suspended from planar member 40 within apertures 50a-50f
 by their respective flanges 74. When the retainer trays are stacked, the
 portion of the pan 70 below flange 74 is disposed between the stacked
 retainer trays 14a and 14b, within the space 49 created by side walls 42,
 44 and end walls 46, 48. The vertical separation or space 49 between the
 stacked retainer trays 14a, 14b can be adjusted by changing the height of
 side walls 42, 44 and/or end walls 46, 48 during manufacture thereof.
 Thus, various depths of pans 70 and various heights of covers 72 can be
 accommodated. Furthermore, virtually any size or shape of pan 70 can be
 accommodated by changing the shape and dimensions of apertures 50a-50f.
 In use, container 12 is supplied to an end user in, for example, a
 ready-to-use form, or in a flat or condensed form requiring some assembly.
 When supplied in a flat or condensed form efficiencies of shipping are
 realized. When containers 12 are supplied in the flat or condensed form,
 the top end and side flaps, and a bottom are pre-cut and creased to
 simplify assembly of container 12. Assembly is accomplished by closing the
 bottom 28 of container 12. Bottom 28 is closed, for example, by a
 procedure similar to that described above for the closing of top flaps
 30-36. Bottom end flaps (not shown) are folded inward until the end flaps
 are substantially perpendicular to end and side walls 24, 26 and 20, 22,
 respectively. Bottom side flaps (not shown) are then folded inward, over
 the bottom end flaps, until the bottom side flaps are substantially
 perpendicular to the end and side walls 24, 26 and 20, 22, respectively.
 The bottom of container 12 is then closed by, for example, applying tape
 to the junction formed between the bottom side flaps and then onto end
 walls 20, 22. Container 12 is thus ready to receive display-packaged
 backed goods for delivery.
 Retainer trays 14a and 14b may also be supplied in a pre-formed or in a
 flat or condensed form. If supplied in the flat or condensed form, side
 walls 42, 44 and end walls 46, 48 are pre-cut and creased to simplify
 assembly. Furthermore, interlocking features (not shown) are also
 pre-formed in the flat for retainer trays 14a and 14b, further simplifying
 assembly thereof. Assembly of retainer tray 14a is accomplished by folding
 side walls 42, 44 until they are substantially perpendicular to planar
 member 40. End walls 44, 46 are likewise folded, in the same direction as
 side walls 42, 44, until they are substantially perpendicular to planar
 member 40. The end walls 44, 46 and side walls 42, 44 are interconnected
 by, for example, tape or an interlocking feature integral therewith.
 Once assembled, retainer tray 14a is placed within interior 38 of container
 12. Then, pans 70 of display packages 16, which contain finished or
 partially finished baked goods, are then placed into a respective one of
 apertures 50a-50f. The covers 72 may have already been attached to pans
 70, or may be attached at this point. Display packages 16 are received
 within a respective one of apertures 50a-50f until flange 74 contacts the
 outside perimeter of that respective aperture and/or planar member 40,
 thereby preventing any further downward displacement of display package
 16. Thus, display package 16 is suspended by flange 74 within a respective
 aperture from planar member 40. The portion of pan 70 below flange 74 is
 disposed in the space 49 formed by the separation created between planar
 member 40 and the bottom of container 12 by side walls 42, 44 and/or end
 walls 46, 48 of retainer tray 14a. The minimal clearance between retainer
 side walls 42, 44 and container side walls 20, 22, and between retainer
 end walls 46, 48, and container end walls 24, 26, respectively, ensures
 retainer tray 14a will not be displaced in a direction perpendicular to
 side and end walls 20, 22, and 24, 26, respectively, when disposed in
 interior 38 of container 12. The placement of display package 16 within a
 respective one of apertures 50a-50f ensures display package 16 will not be
 displaced in a direction perpendicular to side and end walls 20, 22, and
 24, 26, respectively. Furthermore, the suspension of display package 16 by
 flange 74 from retaining tray 14a prevents the downward displacement of
 display package 16.
 A second retainer tray 14b is then assembled and placed into container 12.
 Side walls 42, 44 and/or end walls 46, 48 of retainer tray 14b act to
 vertically space apart the respective planar members 40 of retainer tray
 14a and retainer tray 14b. Pans 70 and/or display packages 16, containing
 finished or partially finished baked goods, are then placed within a
 respective one of apertures 50a-50f of retainer tray 14b. The spacing
 between retainer tray 14a and 14b is chosen such that display packages 16
 within retainer tray 14a, prevented from downward displacement by flanges
 74, are further prevented from upward movement by the overlying retainer
 tray 14b and/or the display packages 16 contained therein.
 This process of placing retainer trays into container 12 and placing pans
 70 and/or display packages 16 into the apertures of the retainer tray is
 repeated until container 12 has reached its capacity. Container 12 is then
 closed as described above.
 In the embodiment shown, the top of container 12 is shown as being integral
 with container 12 and including flaps 30-36. However, it is to be
 understood that the top of container 12 may be alternatively formed as one
 piece of material integral with, or separate from, container 12.
 Apertures 50a-50f, in the embodiment shown, are shown and described as
 being cylindrical in shape. However, it is to be understood that the
 apertures may be of virtually any shape which corresponds to the
 particular display package being placed therein.
 In the embodiment shown, container 12 and retainer trays 14a, 14b, are
 shown and described as being constructed of cardboard and/or paperboard.
 However, it is to be understood that container 12 and retainer trays 14a,
 14b can be alternatively constructed out of, for example, injection molded
 plastic, sheet metal, or virtually any other suitable material.
 In the embodiment shown, Flange 74 is shown and described as disposed
 proximate to the open top 78 of pan 70 of display package 16. However, it
 is to be understood that flange 74 may be disposed at other points along
 the outside of pan 70. Furthermore, flange 74 is disclosed as being
 disposed around the entire perimeter of pan 70. It is to be understood
 that flange 74 can be disposed around only a portion of the perimeter of
 pan 70 and still perform its intended function. Moreover, flange 74 may
 alternatively be formed as simple projections or stubs extending radially
 outward from pan 70.
 Cover 72 of pan 70 is, in the embodiment shown, disclosed as including
 projections (not shown) which snap into corresponding features (not shown)
 on pan 70, or as elastically snapping over a ridge disposed proximate to
 open top 78 of pan 70. However, it is to be understood that cover 72 may
 also be configured to elastically deform or snap over flange 74.
 Furthermore, cover 72 may include a portion of or form a portion of flange
 74.
 While this invention has been described as having a preferred design, the
 present invention can be further modified within the spirit and scope of
 this disclosure. This application is therefore intended to cover any
 variations, uses, or adaptations of the present invention using the
 general principles disclosed herein. Further, this application is intended
 to cover such departures from the present disclosure as come within the
 known or customary practice in the art to which this invention pertains
 and which fall within the limits of the appended claims.