Abstract:
A portable, stackable, all-in-one, combustible fuel package composed of a carton without internal structure and containing a fire starting material and charcoal or other combustible material, a one-piece carton blank for forming the carton, and methods of assembling and using the carton and its components to provide a heat source are provided. The carton blank is a simple design for easy assembly of the carton. The container maintains the firestarter separate from the charcoal material and allows direct access to the firestarter for its removal from the container. The carton includes selectively deployable legs structured to raise the carton off of a surface sufficient for placement of the firestarter under the carton and allow air flow to the base of the container to maintain the burning of the firestarter and charcoal material inside the container. In use, the firestarter is removed from the carton, the legs are deployed to raise said carton, the firestarter is positioned beneath the carton and between the legs, the firestarter is lit and allowed to burn the carton and kindle the charcoal housed inside. The charcoal package can be conveniently used for barbecuing at tailgating parties and other outdoor events with no need for lighter fluid or cleanup.

Description:
FIELD OF THE INVENTION 
     This application relates generally to outdoor cooking products, and more particularly to a carton containing a firestarter and combustible material for use in outdoor cooking and barbecuing. 
     BACKGROUND OF THE INVENTION 
     Typically, charcoal briquettes are purchased in bulk in a large bag. A portion of briquettes is removed, generally saturated with a combustible liquid (typically a petroleum distillate), then ignited. Transferring charcoal briquettes from the bag to the grill, and arranging them on the grill can be messy, and use of a starter fluid that must be stored poses a potential fire hazard. Some efforts have been made to impregnate the charcoal briquettes with a combustible liquid to avoid the need for a separate starter fluid. However, this is expensive to make, emits volatile organic compounds in the manufacturing process, emits an offensive odor when cooking and can impart a bad taste to the food being cooked. To avoid the mess and inconvenience, combustible packages have been described that contain the charcoal in an effort to minimize handling and positioning of the charcoal for burning. 
     For example, U.S. Pat. No. 2,834,661 (Chaplin) and U.S. Pat. No. 2,955,029 (Foote) describe two-part containers molded from pulp having an inside wall that forms a central chimney. As the walls of the chimney section burn, the charcoal is fed into the center. The packages include ribs or recesses to provide an air passage underneath the package. 
     U.S. Pat. No. 3,031,277 (Strauss) discloses a complicated multipart fire kindling device made of a container with a complicated fuel insert, and charcoal or other fuel loaded into the container. 
     U.S. Pat. No. 4,460,377 (Kalil) discloses a container with a complex structure including an upper compartment containing charcoal or other combustible material, and a lower compartment containing a paraffin wax firelighter. A central flue extends from the lower chamber through the upper chamber. 
     U.S. Pat. No. 4,953,533 (Witt) describes a complexly shaped combustible package for outdoor grilling having a central chimney, and an unspecified ignitor that is lit with a fuse. 
     U.S. Pat. No. 5,186,721 (Campana) describes a fuel package in which an inorganic ignitor with a wick element, which produces a thermite reaction, is positioned inside the container with the charcoal. 
     A drawback of the foregoing fuel packages is that they require multiple separate components, central chimneys, or complicated structure for forming the package. The packages are complex, costly, have low efficacy, and present manufacturing problems and safety hazards. The irregular external shapes and other structural characteristics limit the useful visible or printing space on the package, or preclude the use of an overwrap, either of which might be used to provide advertising and coupon space. When an igniting material is packaged inside the container in contact with the charcoal, there is a danger that the ignitor material will accidentally ignite, presenting a hazard during shipping or storage. Where no ignitor is provided, some sort of starter fluid is likely needed as the burning of the cardboard structures, in and of themselves, are not likely to provide sufficient fuel to get the charcoal to a state suitable for cooking. Many of these packages are also irregularly shaped. This precludes tight stacking of multiple packages for shipping and display purposes. 
     Therefore, it would be desirable to provide a charcoal package with improved features that overcome the shortcomings of other fuel packages. 
     SUMMARY OF THE INVENTION 
     These and other objects and advantages are achieved in a self-contained fuel package made of a carton containing a fire starting material and charcoal or other combustible material, a carton blank for forming the carton, and methods of assembling and using the carton and its components to prepare a heat source for cooking. 
     The carton includes a pair of foldable legs underneath the carton. The underside of the carton preferably includes vent holes, or a perforated or thin center section, between the legs to permit access to the charcoal by a flame, and air flow into the container. In use, the legs of the box are folded out and into position, and a solid firestarter product placed between the legs under the center of the carton, and lit. The flame then consumes the carton and kindles the charcoal while the firestarter expends itself. 
     Advantageously, the integrated package provides a portable, all-in-one, charcoal package that can be used on a non-igniting support surface, frame or rack, for fast and easy barbecuing in the backyard, tailgating in the middle of a parking lot at a sporting event, or at any number of locations and events. It eliminates the need for additional items for the consumer to transport to a location, and the problem of purchasing goods in different units. It also eliminates the need for liquid lighter fluid, pre-allocation of charcoal, and the need to carry out or dispose of leftover charcoal after the cookout if less than a full bag is used. The single-use carton fires up fast, provides a simple burn, is entirely consumed, and eliminates messy clean-ups. The package eliminates the need for direct handling of charcoal, which is contained within the carton. The carton and its contents are readily ignitable and will form a suitable bed of coals for cooking. The carton blank is a simple design that is easily assembled into the carton. The carton itself is stackable on a pallet, and allows for easy shipping and space-saving, in-store stacking of the product. Moreover, the simple shape of the carton lends itself to direct printing or otherwise permits the use of an overwrap that can be used for advertising, coupons or the like. The carton also preferably includes structure to maintain the ignitor or the firestarter securely in the carton and separate from the charcoal or other combustible material during storage and shipping, and allow the firestarter to be readily removed from the carton for use. The carton is easy to convert from its storage/shipping form to its “fire-starting” form. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Throughout the following views, reference numerals will be used on the drawings, and the same reference numerals will be used throughout the several views and in the description to indicate same or like parts of the invention. 
     FIG. 1 is perspective view of an embodiment of a blank used to form the carton in accordance with the invention; 
     FIG. 2 is a perspective view of the blank of FIG. 1, showing the second sidewall panel  26  being folded to form a carton; 
     FIG. 3 is a perspective view of the blank of FIG. 1, showing the second sidewall panel  26  attached to the front side panel  20 ; 
     FIG. 4 is a perspective view of the blank of FIG. 3, showing the flaps  52 ,  54  folded inward into the carton; 
     FIG. 5 is a perspective view of the blank of FIG. 4, showing the base panels  38 ,  40  and the top panels  34 ,  36  folded outward; 
     FIG. 6 is a perspective view of the blank of FIG. 5, showing the first base panel  38  folded onto the carton; 
     FIG. 7 is a bottom plan view of the view of the blank of FIG. 7 showing the second base panel  40  folded onto the first base panel  38 ; 
     FIG. 8 is a bottom plan view of the blank/carton of FIG. 7, showing the leg extensions  102 ,  104  folded and secured onto the second base panel  40 ; 
     FIG. 9 is a bottom plan view of the blank/carton of FIG. 8, showing the flaps  52 ,  54  folded inward into the carton; 
     FIG. 10 is a bottom plan view of the blank/carton of FIG. 9, showing the first top panel  34  folded onto the carton  12 ; 
     FIG. 11 is a top plan view of the carton formed from the blank  10  of FIGS. 1-10, showing the second top panel  36  folded onto the first top panel  34 ; 
     FIG. 12 is a perspective view of the carton in FIG. 11; 
     FIG. 13 is a bottom plan view of the carton of FIG. 12, showing the folding of the leg extensions  102 ,  104 ; 
     FIG. 14 is a bottom plan view of the carton of FIG. 13, showing the leg extensions  102 ,  104  secured in the longitudinal grooves  86 ,  88  to form the leg support members  116 ,  118 ; 
     FIG. 15 is a perspective view of the carton of FIG. 14, showing the second top panel  36  lifted up to expose the firestarter  15 ; 
     FIG. 16 is a perspective view of the carton of FIG. 15, showing removal of the second top panel  36  from the carton; 
     FIG. 17 is a perspective view of the carton of FIG. 16, placed on a grill  122  with the firestarter  15  placed underneath; and 
     FIG. 18 is a perspective view of an embodiment of a kit  14  incorporating the carton of FIG.  12  and other items. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The carton of the present invention can be constructed from a carton blank that is cut and scored as one piece. An embodiment of a carton blank  10  is shown in FIG. 1, and a carton  12  assembled from the blank  10  is shown in FIGS. 12-16. 
     The carton  12  can be combined with materials for igniting and starting a fire, and sold as an integrated unit or kit  14  for generating a cooking fire, as shown in FIG.  18 . The kit  14  preferably includes the carton, a solid fire starting material  15  (FIG. 15 removably held in the carton for igniting the carton and the charcoal, and a single meal quantity of a combustible material  16  such as charcoal, charcoal briquettes, wood, coke, or other solid carbonaceous combustible material  16 , in a combustible packaging  17  and contained within the carton. The charcoal or other combustible material  16  can also be provided in a container  17   a  and packaged separately from the carton  12 . The kit  14  may also include instructions  18  for setting up the carton and its components for igniting the unit to prepare it for cooking. For example, as shown, a removable overwrap  18   a  with written instructions and/or illustrations on one side showing the set-up of the carton and its components, and coupons, advertising or other information imprinted on the same side or the underside, can be attached around the carton. Instructions for the set-up and other information can also be printed directly on the carton. The kit  14  can further include one or more additional articles  19  such as matches, a grill or rack, hotpads, grilling utensils, dishware and tableware. 
     The carton  12  is made of a combustible material having sufficient rigidity to maintain the shape of the erected carton, while supporting the contents of the carton. The carton  12  is preferably made of paperboard or corrugated cardboard, that will burn completely with little or no residue remaining so that clean up is not required. Most preferably, the carton is made from pressed paperboard. 
     Advantageously, the firestarter  15  is a solid shape article that is composed of an organic material that is made of materials that provide a safe, combustible starter without fuses, volatile solvents, or “super hot” burning chemicals such as magnesium compounds. The firestarter can be readily ignited and maintain a burn to effectively ignite the carton and kindle the charcoal. A preferred firestarter is a pressed article composed of paraffin wax mixed with wood shavings, fine wood chips, saw dust, paper pulp, wood pulp, and the like. 
     In a method of preparing a cooking fire with the present packaging, a combustible packaging or carton  12  containing charcoal or other combustible material  16  is selected; a fire starter  15  is removed from a position proximate the packaging; a plurality of legs are deployed to raise the packaging; the firestarter  15  is positioned beneath the packaging and between the legs; the firestarter is lit; and the lit firestarter is allowed to burn the packaging and correspondingly kindle the charcoal. 
     An example of a carton blank  10  for forming the carton  12 , is shown in FIG.  1 . The carton blank  10  includes four side panels  20 ,  22 ,  24 ,  26  foldably connected to form the sidewalls of the erected carton  12  (FIG.  15 ). The side panels include a front side panel  20 , a back side panel  24 , and first and second sidewall panels  22 ,  26 . Each of the side panels has four sides or edges designated as a, b, c, d. The first sidewall panel  22  is positioned between the front side panel  20  and the back side panel  24 , and is foldably connected along opposing sides  22   a ,  22   c  to side  20   c  of the front side panel  20  and side  24   a  of the back side panel  24 . The second sidewall panel  26  is positioned adjacent to the back side panel  24 , and is foldably connected along side  26   a  to side  24   c  of the back side panel  24 . In erecting carton  12 , side  26   c  of the second sidewall panel  26  is attached to side  20   a  of the front side panel  20  (FIGS.  2  and  3 ). The two panels  20 ,  26  can be joined by any suitable means, including adhering an adhesive strip  30  over a tab or flap  32  that is foldably connected along side  20   a  of the front side panel  20 . 
     The carton blank  10  also includes two overlaying top panels  34 ,  36 , and two overlaying base panels  38 ,  40 . Each of the top and base panels have four sides designated as a, b, c, d. The first top panel  34  is foldably connected along side  34   d  to side  20   b  of the front side panel  20 , and the second top panel  36  is foldably connected along side  36   d  to side  24   b  of the back side panel  24 . The first base panel  38  is foldably connected along side  38   b  to side  20   d  of the front side panel  20 , and the second base panel  40  is foldably connected along side  40   b  to side  24   d  of the back side panel  24 . 
     When the carton blank  10  is assembled into the erected carton, the two base panels  38 ,  40  are positioned over each other (FIGS.  5 - 7 ), and the two top panels  34 ,  36  are positioned over each other (FIGS. 9-12 and  15 ). Preferably, the carton blank  10  includes flaps  52 ,  54 , which are folded inward on the erected carton to provide support for the top panels and the base panels so that they do not collapse or sink into the interior  58  of the erected carton (FIGS.  5  and  9 ). 
     The first top panel  34  and the first base panel  38  can include a foldably connected flap  78 ,  80  along sides  34   d ,  38   b , respectively, for securing the panels to the carton  12 . As shown in FIGS. 9-10, when the first top panel  34  is folded onto the erected carton, the flap  78  is inserted into the carton at the fold along side  36   d  of the second top panel  36 . Likewise, the flap  80  of the first base panel  38  is inserted into the carton at the fold along side  40   b  of the second base panel  40  (FIGS.  5 - 6 ). To secure the second top panel  36  and the second base panel  40  to the carton, the panels include one or more tabs  44 ,  46 , that are inserted into slits  48 ,  50  in the fold along side  34   d  of the first top panel  34  and along side  38   b  of the first base panel  38  (FIGS. 6-7 and  10 - 11 ). 
     Optionally, the fold along side  36   d  of the second top panel  36  can be perforated so that the panel  36  can be easily removed from the carton  12  (FIG.  16 ). The second top panel  36  can also be perforated in a line  72  perpendicular to its hinged connection with the back side panel  24 , which allows the panel  36  to be separated into two halves, I and II (FIG.  1 ). 
     The first top panel  34  includes an opening  60  that is sized to removably retain a fire starting material or firestarter  15 . The firestarter can be carried in a container capable of holding the firestarter in place in the opening  60  or configured so as to ride in the opening by itself (FIGS.  15 - 16 ). The firestarter  15  is sized and shaped such that it can be inserted and securely held in the opening  60  of the first top panel  34 , and the second top panel  36  can be folded down flat onto the first top panel  34 . In use, the firestarter  15  is removed from the carton, placed underneath the carton  12 , and ignited (FIG.  17 ). The opening  60  thus serves a dual role in maintaining the firestarter away from the fuel  16  during storage/shipping, and as a vent to provide a drafting effect for effective kindling of the fuel inside the carton. 
     Along each of the first and second base panels  38 ,  40 , is a foldably connected leg segment  102 ,  104 . As shown, the leg segments  102 ,  104  are connected along sides  38   a  and  40   a , respectively, but can also be positioned along sides  38   c  and  40   c , respectively. During storage and prior to use of the erected carton  12 , the leg segments  102 ,  104  are folded flat against the outer base panel  40  and secured together, for example, by a releasable adhesive tab  106  or other suitable means, as shown in FIG.  8 . Each of the first and second base panels  38 ,  40 , include two elongate slots  82 ,  84  and  86 ,  88 , and a center access area  92 ,  94 . The center access areas  92 ,  94 , can be in the form of vent holes as shown or a thin center section (not shown). The elongate slots  82 ,  84  and  86 ,  88  are positioned adjacent to and parallel with sides  38   a ,  38   c ,  40   a ,  40   c , respectively, and perpendicular to the fold along side  38   b  and  40   b . When the base panels  38 ,  40  are overlapped, in the erected carton  12 , the elongate slots ( 82  with  88 ,  84  with  86 ) and the center access sections ( 92  with  94 ) are aligned, as shown in FIGS. 5-7. In the use of the carton to ignite a fire, the leg segments  102 ,  104  are separated and folded along a score line  108 ,  110  (FIGS.  13 - 14 ), and the ends  112 ,  114  are inserted into the pair of elongate slots  82 / 88  and  84 / 86 , respectively, to provide a pair of leg support members  116 ,  118 . The leg supports  116 ,  118  are positioned underneath the carton  12 , such that center access sections  92 / 94  in the base panels are unobstructed. The center access areas permit direct access to the charcoal  16  by a flame from the firestarter  15  and air flow into the interior  58  of the carton  12  (FIG.  17 ). 
     Referring now to FIGS. 2-12, to form a carton  12  from the foregoing carton blank  10 , the four side panels  20 ,  22 ,  24 ,  26  are folded. The front side panel  20  is attached to the second sidewall panel  26 , for example, by adhering the adhesive tab  30  to the fold  32  of the front side panel  20  (FIGS.  2 - 3 ). The flaps  52 ,  54  of the first and second sidewall panels  22 ,  24  are folded inward (FIGS.  3 - 4 ). As depicted in FIGS. 5-6, the first base panel  38  is folded onto the carton, and the flap  80  is inserted into the carton adjacent the fold along side  40   b  of the second base panel  40 . The second base panel  40  is folded onto the first base panel  38  (FIG.  7 ), and secured to the carton by inserting the tabs  46  into the slits  50  located in the fold along side  20   d  of the front side panel  20 . The leg segments  102 ,  104  are folded underneath and flush against the outer base panel  40  of the carton, and the ends  112 ,  114  are secured to each other and/or to the surface of the second base panel  40  by a tab  106  (FIG.  8 ). A single use amount of charcoal briquettes  16  or other suitable combustible material can be placed inside the carton. Referring to FIGS. 9-10, the first top panel  34  is folded onto the carton and the flap  78  is inserted into the carton adjacent the fold along side  36   d  of the second top panel  36 . The fire starter material  15  is inserted into the opening  60  in the first top panel  34  (FIG.  15 ). The second top panel  36  is then folded onto the first top panel  34  and secured to the carton by inserting the tabs  44  into the slits  48  located in the fold along side  34   d  of the first top panel (FIGS.  11 - 12 ). The carton  12  is then ready for transport, further processing, storage, or shipment. 
     In use, the carton  12  is converted to a fire-starting assembly. The leg segments  102 ,  104  are separated from each other, folded underneath the carton along the score line  108 ,  110 , and the ends  112 ,  114  are secured into the adjacent elongate slot pairs  82 / 88  and  84 / 86  to form the support legs  116 ,  118  (FIGS.  13 - 14 ). The second top panel  36  is raised to expose the fire starter material  15  in the opening  60  of the first top panel  34  (FIGS.  15 - 16 ), and the firestarter  15  is removed and placed onto a surface such as a barbecue grill  122  (FIG.  17 ). The carton is placed over the firestarter, which is positioned under the center access areas  92 / 94  between the two legs  116 ,  118 , and the fire starting material is ignited. The second top panel  36  remains folded back, or is preferably removed (FIG.  16 ), so that the opening  60  in the first top panel  34  remains open to provide a draft effect to draw air through the carton. The height of the support legs  116 ,  118  are sufficient to place the underside of the carton  12  at a suitable distance from the fire starting material  15  to allow sufficient airflow for the flame to burn and ignite the carton  12  and the combustible material  16  inside. 
     The invention has been described by reference to detailed examples and methodologies. These examples are not meant to limit the scope of the invention. Variations within the concepts of the invention are apparent to those skilled in the art. The disclosures of the cited references throughout the application are incorporated by reference herein.