Abstract:
A musical pizza box includes a box material foldable into a pizza box having a lid hingedly attached to a base and a pizza box audio module. The pizza box audio module preferably includes a speaker, a microchip board capable of receiving a microchip mounted on the microchip board, at least one power source, electrical wiring electrically connecting the speaker, the microchip board, and the power source, and an activation mechanism. When the box material is folded to form the pizza box, the microchip is mounted to the microchip board, and the lid is moved from a closed state to an opened state, the activation mechanism is triggered to cause any recorded audio message stored on the microchip to be emitted by the speaker. Methods of manufacturing a musical pizza box and methods of advertising are also disclosed.

Description:
REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims one or more inventions which were disclosed in Provisional Application No. 61/669,067, filed Jul. 7, 2012, entitled “MUSICAL PIZZA BOX”. The benefit under 35 USC §119(e) of the United States provisional application is hereby claimed, and the aforementioned application is hereby incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The invention pertains to the fields of advertising and packaging. More particularly, the invention pertains to packaging including audio messages. 
         [0004]    2. Description of Related Art 
         [0005]    Carry-out or delivery pizza is a popular consumer food product and is often served at parties or small gatherings. Carry-out or delivery pizza is also especially popular in association with particular events, such as birthdays and sporting events, especially the Super Bowl® football game each year. 
         [0006]    Carry-out or delivery pizza is conventionally transported in a pizza box. Pizza boxes are conventionally made of corrugated cardboard. Although numerous different designs are known in the art,  FIG. 1  shows a common basic conventional pizza box  10  prior to being folded. Dashed lines represent fold lines to form a folded pizza box. Two side flaps  14  and a front flap  16  extend from the lid  12 . The lid  12  is separated from the bottom  18  by a back wall  17 . Two side walls  20  and a front wall, which is formed by an inner front wall  22  and an outer front wall  24  when the pizza box is folded, extend from the bottom  18 . Tabs  28  on the back ends of the side walls  20  insert in front of the back wall  17  and tabs  26  on the front ends of the side walls  20  insert between the front walls  22 ,  24  in forming the folded pizza box. 
         [0007]      FIG. 2  shows the pizza box  10  of  FIG. 1  in a folded, opened state with the lid open.  FIG. 3  shows the pizza box  10  in a folded, closed state with the lid closed. In addition to the basic features shown in  FIG. 1  through  FIG. 3 , pizza boxes may have additional holes, flaps, or tabs to make the pizza box sturdier, easier to open or close, or better at housing the pizza during transportation of the pizza from the pizza restaurant to the home of the consumer. 
         [0008]    Pizza boxes are also often conventionally used to display advertisements directed to the consumer of the pizza, either by directly printing the advertisement on the box, or by attaching a paper flyer advertisement to the box. Often, this advertising is ignored, with the message not getting to the pizza purchaser or consumer. 
         [0009]    Greeting card music modules are conventionally placed in greeting cards to output recorded audio when the greeting card is open. The recorded audio is conventionally prerecorded and conventionally includes music or part of a song, although recordable greeting cards are also available such that the buyer can record their own audio message on the music module prior to giving the greeting card to the intended recipient. 
         [0010]      FIG. 4  shows schematically a prior art pre-recorded greeting card music module  30 . The module  30  includes a backing  32 , a microchip board  34  mounted on the backing  32 , at least one power source  36 , wiring  38 , a speaker  40 , and an activation mechanism  42 . The power source  36  is preferably one or more button batteries. The power source  36  provides power to the microchip board  34  and to the speaker  40  by way of the wiring  38 . The activation mechanism  42  in  FIG. 4  is mechanical. The activation mechanism  42  includes a tab, which, when pulled away from the microchip board  34 , allows the electrical circuit to be closed, thereby activating the audio recorded on the microchip board  34  to be outputted by the speaker  40 . 
         [0011]      FIG. 5  shows schematically a prior art recordable greeting card audio module  50 . In addition to the elements of a pre-recorded greeting card music module, the recordable greeting card audio module  50  also includes a microphone  52 , at least one record button  54 , a replay button  56 , and a key  58 . To record audio on the audio module, the user first removes the key  58 , which is typically made of clear plastic and inserted under a latch or one of the batteries, to begin. The user then presses and holds down the record button  54  and any produced audio is received by the microphone  52  and recorded on the microchip of the microchip board  34 . The recordable greeting card audio module  50  has two record buttons  54 , which must be simultaneously pressed to begin recording, although the recordable greeting card audio module  50  may alternatively only have a single record button. In some designs, the recordable greeting card audio module includes a visual or auditory signal indicating when the maximum recording time has been reached. The user may then replay the audio recording by activating a replay button  58 , when present, or by engaging the activation mechanism  42 . The activation mechanism  42  in  FIG. 5  is mechanical. Additional wiring  38  provides electrical communication between the microphone  52 , the record buttons  54 , the replay button  56 , and the other electronics of the device. 
         [0012]      FIG. 6  shows a prior art light-activated greeting card music module  60 . Instead of a mechanical activation mechanism, the module  60  is activated when the light sensor  62  attached to the microchip board  34  is exposed to light. The light sensor conducts electricity only when exposed to sufficient light, which allows the electrical circuit to be closed, thereby activating the audio recorded on the microchip to be outputted by the speaker  40 . 
       SUMMARY OF THE INVENTION 
       [0013]    A musical pizza box includes a box material foldable into a pizza box having a lid hingedly attached to a base; and a pizza box audio module. The pizza box audio module preferably includes a speaker, a microchip board capable of receiving a microchip mounted on the microchip board, at least one power source, electrical wiring electrically connecting the speaker, the microchip board, and the power source, and an activation mechanism. When the box material is folded to form the pizza box, the microchip is mounted to the microchip board, and the lid is moved from a closed state to an opened state, the activation mechanism is triggered to cause any recorded audio message stored on the microchip to be emitted by the speaker. Methods of manufacturing a musical pizza box and methods of advertising are also disclosed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  shows a prior art pizza box prior to being folded. 
           [0015]      FIG. 2  shows the prior art pizza box of  FIG. 1  in a folded, opened state. 
           [0016]      FIG. 3  shows the prior art pizza box of  FIG. 1  in a folded, closed state. 
           [0017]      FIG. 4  shows schematically a prior art pre-recorded greeting card music module. 
           [0018]      FIG. 5  shows schematically a prior art recordable greeting card music module. 
           [0019]      FIG. 6  shows schematically a prior art light-activated greeting card music module. 
           [0020]      FIG. 7  shows a side view of a portion of a pizza box with an audio module between outer layers of the corrugated cardboard. 
           [0021]      FIG. 8  shows a side view of a portion of a pizza box with an audio module embedded into the corrugated cardboard from the top. 
           [0022]      FIG. 9  shows a side view of a portion of a pizza box with an audio module attached to an outside surface of the corrugated cardboard. 
           [0023]      FIG. 10  shows a top view of a portion of a pizza box with a light-activated audio module between outer layers of the corrugated cardboard. 
           [0024]      FIG. 11  shows preferred locations for a light-activated audio module on a pizza box. 
           [0025]      FIG. 12  shows preferred locations for a mechanically-activated audio module on a pizza box. 
           [0026]      FIG. 13  shows a preferred location for a mechanically-activated audio module fully installed on a folded pizza box. 
           [0027]      FIG. 14  shows schematically an audio module with an insertable microchip module in an embodiment of the present invention. 
           [0028]      FIG. 15  shows schematically shows a recordable pizza box audio module in an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0029]    Pizza boxes are brought into millions of homes and businesses throughout the year, often for special occasions. A pizza box provides the opportunity to deliver advertisements, marketing materials, or simply a message or special greeting to consumers of carry-out or delivery pizza. When the customer purchases the pizza and opens the pizza box, they are treated to music or a greeting, which may include a personalized message to the customer, such as “Happy Birthday” or the like. The opening of the box preferably engages the sound-producing device to play the desired message or greeting. The sound-producing device may be activated, for example, by a photo sensor or a box hinge opening detection mechanism. The sound-producing device is referred to herein as an audio module. 
         [0030]    A musical pizza box includes an audio module that is activated to play recorded audio when the pizza box is opened by lifting the lid of the pizza box. The audio module is preferably de-activated when the pizza box is closed and re-activated each time the pizza box is opened, as long as the battery or batteries hold sufficient charge. In some embodiments, the audio is pre-recorded prior to installation of the audio module on the pizza box. In other embodiments, the audio module is recordable and the audio is recorded after the musical pizza box has been assembled. The recorded audio may be any recorded audio, including, but not limited to, any pre-recorded song or music, which may be for a specific purpose or occasion, a pre-recorded advertisement, which may be for an event, a company, including the pizza restaurant itself, a consumer product, or custom recorded audio recorded by the pizza restaurant or a buyer or consumer of the pizza. 
         [0031]    In some embodiments, the audio is a combination of a pre-recorded message and an optional customizable message. In some such embodiments, the pizza chain has a pre-recorded message recorded on the audio modules installed in the pizza boxes. When the pizza boxes are delivered to a local franchisee, the local franchisee may add their own recorded message or even personalize the message for the particular customer. 
         [0032]    In one embodiment, the recorded audio is all or part of the theme to the Monday Night Football® game television broadcast. In another embodiment, the recorded audio is all or part of the song “Happy Birthday”. In another embodiment, the recorded audio is all or part of the song “Thank You for Being a Friend”. 
         [0033]    Although the musical pizza box costs more than a conventional pizza box to manufacture, the audio module preferably adds less than a dollar per unit to the cost of the pizza boxes. In some embodiments, the pizza restaurant absorbs the additional cost. In other embodiments, the advertiser absorbs the additional cost. In yet other embodiments, the additional cost is passed on to the consumer, especially in the case of a recordable audio module for the consumer to record their own custom audio. 
         [0034]    The pizza box audio module may be any kind of audio module applied in any manner to a pizza box such that the audio module is activated to play recorded audio when the pizza box is opened by lifting the lid of the pizza box. 
         [0035]    In some embodiments, the pizza box audio module is mounted to the inside bottom surface of the pizza box. In other embodiments, the pizza box audio module is mounted to the inside top surface of the lid. In some embodiments, the pizza box audio module is mounted to the inside back surface of the pizza box. In other embodiments, the pizza box audio module is mounted to an outside surface of the pizza box. In yet other embodiments, the pizza box audio module is mounted between the layers of the corrugated cardboard. 
         [0036]      FIG. 7  shows a pocket  71  formed between the two outer layers  70 ,  72  of the corrugated cardboard of the pizza box  10  by removing only some of the corrugated layer  74 . The audio module  76  is then inserted into the pocket  71  to form the musical pizza box  80 . An adhesive may be used to maintain the module  76  in the pocket  71 . 
         [0037]      FIG. 8  shows a recess  73  formed by removing part of the top layer  70  and the top part of the corrugated layer  74 . The audio module  76  is then inserted from above into the recess  73  to form the musical pizza box  82 . An adhesive may be used to maintain the module  76  in the recess  73 . 
         [0038]      FIG. 9  shows the audio module  76  attached to the outer surface of the top layer  70  of the pizza box  10  to form the musical pizza box  84 . An adhesive may be used to attach the module  76  to the top layer  70 . 
         [0039]      FIG. 10  shows a top view of a light-activated audio module  78  inserted into a pocket  71  in the pizza box  10  to form the musical pizza box  86 . Although the audio module  78  is preferably fully inserted into the pocket  71 , preferably flush with an edge or a fold of the pizza box  10  as shown in  FIG. 10 , the light sensor  79  is exposed by removing a small portion of the top layer of the cardboard above where the light sensor  79  is located to form a window  75  to permit light to reach the light sensor  79  when the pizza box  10  is in an opened state. 
         [0040]    When the audio module is light-activated, the light-activated audio module may be mounted on any surface that is inside the pizza box when the pizza box is closed but visible when the pizza box is open.  FIG. 11  shows three preferred locations for a light-activated audio module  78 . The light-activated audio module  78  is most preferably mounted to face inward on the end of the front flap  16  of the lid  12 , as shown in  FIG. 11 . Alternatively, the light-activated audio module  78  is preferably mounted to face inward on the end of the left or right side flap  14  of the lid  12 . 
         [0041]    When the audio module is mechanically-activated, the mechanically-activated audio module is preferably mounted along a fold line of the back wall  17  of the pizza box  10 , as these are the two folds that move when the pizza box is opened. The mechanically-activated audio module  76  may be mounted in a pocket, in a recess, or to an outer surface, as shown in  FIG. 7  through  FIG. 9 . The tab  77  may be attached to an inside surface of the pizza box  10  or an outside surface. The tab  77  of the mechanically-activated audio module  76  is preferably attached to a different surface than where the main portion of the mechanically-activated audio module  76  is located, as shown in  FIG. 12 .  FIG. 12  shows four different preferred locations for the mechanically-activated audio module  76 . In one location, the mechanically-activated audio module  76  is mounted on or in the back wall  17  of the pizza box  10  with the tab  77  mounted to the lid  12  of the pizza box  10 . In another location, the mechanically-activated audio module  76  is mounted on or in the back wall  17  of the pizza box  10  with the tab  77  mounted to the bottom  18  of the pizza box  10 . In another location, the mechanically-activated audio module  76  is mounted on or in the lid  12  of the pizza box  10  with the tab  77  mounted to the back wall  17  of the pizza box  10 . In yet another location, the mechanically-activated audio module  76  is mounted on or in the bottom  18  of the pizza box  10  with the tab  77  mounted to the back wall  17  of the pizza box  10 . 
         [0042]      FIG. 13  shows the mechanically-activated audio module  76  fully installed at a preferred location on a folded pizza box. The adhesive cover on the tab  77  has been removed and the adhesive strip on the tab  77  has been attached to the back wall  17  of the pizza box  10  such that when the pizza box goes from a closed state to an open state by opening the lid  12 , the tab  77  physically moves from an inactive position to an activated position to activate the audio module  76  to emit the pre-recorded audio. Depending on the mounting location of the audio module  76 , the tab  77  extends in going from the inactive position to the activated position and retracts in going from the activated position to the inactive position in some embodiments, such as when the tab  77  is attached to the inside of the back wall  17  in the position of  FIG. 13 . In other embodiments, the tab  77  retracts in going from the inactive position to the activated position and extends in going from the activated position to the inactive position in some embodiments, such as when the tab  77  is attached to the outside of the back wall in the position of  FIG. 13 . 
         [0043]    In some embodiments, the pizza box audio module is a conventional greeting card music module. In other embodiments, the pizza box audio module is specifically designed for application to a pizza box. The audio module preferably includes a housing surrounding the electronics to prevent them from being damaged by the environment after installation into a pizza box. In some embodiments, the audio is pre-recorded and can not be changed. In other embodiments, the audio is recordable only once. In yet other embodiments, the audio is recordable and re-recordable. 
         [0044]      FIG. 14  shows a pizza box audio module  90  configured to receive a microchip  100  with the pre-recorded audio. The audio module  90  includes a housing  92  covering most of the electronics, but the housing  92  includes a window  94  to provide access to a mounting location  96  on the microchip board  34  for the microchip  100 . The microchip  100  snaps into the mounting location  96  such that the electrical leads  101 ,  102  on the microchip  100  are in contact with the electrical leads  97 ,  98  of the mounting location  96  on the mounting board  34 . Although the audio module is shown as a mechanically-activated audio module in  FIG. 14 , the audio module  90  may alternatively be a light-activated audio module. This audio module design allows the audio module to be mounted to the pizza box prior to being sent to the pizza restaurant, such as at the manufacture location of the pizza box, while still allowing the pizza shop to insert customized pre-recorded audio for the musical pizza box. 
         [0045]      FIG. 15  shows a pizza box audio module  110  that is similar in design to the audio module  50  of  FIG. 5 . This audio module  110 , however, differs in that the module  110  is only recordable and re-recordable with the key  112  in a first position, as shown in  FIG. 15 . When the key  112  is pulled out to a second position, audio can no longer be recorded or re-recorded on the audio module  110 . In some embodiments, the key  112  has a first part made of an electrically conductive material, such as a metal, and a second part made of a non-conductive material, such as a plastic. When the first part is located under the battery, the record buttons  54  and replay button  56  allow a user to record audio, re-record audio, and replay the recorded audio. When the user is finished recording, the user may pull the key  112  such that the non-conductive part is located under the battery. The audio module  110  is then no longer recordable and only plays the last-recorded audio. This design allows the audio module to be mounted to the pizza box prior to being sent to the pizza restaurant, such as at the manufacture location of the pizza box, while still allowing the pizza shop to record customized audio for the musical pizza box that the customer can not erase or record over. 
         [0046]    Although the pizza box is preferably made of corrugated cardboard, the pizza box may be made of any material appropriate for containing and transporting a pizza. The pizza box material is preferably inexpensive and relatively lightweight, but sturdy enough to support the weight of a pizza and able to provide sufficient insulation to the pizza to keep the pizza warm during the transport time. In some embodiments, the pizza box material has a thickness greater than a thickness of the pizza box audio module. In other embodiments, however, the pizza box material has a thickness less than or equal to a thickness of the pizza box audio module. Although the corrugated cardboard is shown in the figures as having only a top layer, a bottom layer, and a single corrugated layer, any corrugated cardboard structure may be used within the spirit of the present invention, including, but not limited to, corrugated cardboard with multiple corrugated layers alternating with not-corrugated layers. In some embodiments, the corrugated cardboard is coated with a material to improve the water resistance or thermal insulation of the pizza box. 
         [0047]    The pizza box may have any dimensions appropriate for receiving and holding a pizza or part of a pizza. In one embodiment, the pizza box has a width and a depth of about  16  inches and a height of about two inches. Although the pizza box is shown as being rectangular in shape, a pizza box may have any shape appropriate for receiving and holding a pizza or part of a pizza, such as, for example, octagonal or triangular. Although the pizza box is shown with the lid being hingedly connected to the base, a pizza box may have a removable lid within the spirit of the present invention. In such embodiments, the pizza box music module is preferably light-activated. 
         [0048]    While the invention has been described with respect to pizza boxes, the present invention may alternatively be used on other boxes, including, but not limited to, candy boxes, cereal boxes, and snack boxes. 
         [0049]    Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. 
         [0050]    Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention.