Patent Publication Number: US-2019185202-A1

Title: Container with Surface Features

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application No. 62/599,292, filed on Dec. 15, 2017. 
    
    
     INCORPORATION BY REFERENCE 
     The disclosure of U.S. Provisional Patent Application No. 62/599,292, filed on Dec. 15, 2017, is hereby incorporated by reference for all purposes as if presented herein in its entirety. 
     BACKGROUND OF THE DISCLOSURE 
     The present disclosure generally relates to containers for holding at least one food product, blanks for forming such containers, and methods of forming such containers. In one embodiment, the present disclosure relates to a container having surface features for maintaining one or more properties of a food product. 
     SUMMARY OF THE DISCLOSURE 
     In one aspect of the disclosure, a container for holding at least one article comprises a lid and a tray extending at least partially around an interior of the container, and the lid is foldably connected to the tray. The tray comprises a material having an outer layer defining an exterior surface of the container and an inner layer defining an interior surface of the container. The interior surface comprises surface features for supporting the at least one article, the surface features comprise a plurality of protrusions, and adjacent protrusions of the plurality of protrusions define respective channels of a plurality of channels. 
     In another aspect of the disclosure, a blank for forming a container for holding at least one article comprises a lid portion foldably connected to a tray portion, and the lid portion and the tray portion are for forming a lid and a tray extending at least partially around an interior of the container formed from the blank. The tray portion comprises a material having an outer layer defining an exterior surface of the blank and an inner layer defining an interior surface of the container, the interior surface comprises surface features for supporting the at least one article, the surface features comprise a plurality of protrusions, and adjacent protrusions of the plurality of protrusions define respective channels of a plurality of channels. 
     In another aspect of the disclosure, a method of forming a container for holding at least one article comprises obtaining a blank for forming a container for holding at least one article, the blank comprising a lid portion foldably connected to a tray portion, the tray portion comprises a material having an outer layer defining an exterior surface of the blank and an inner layer defining an interior surface of the blank. The interior surface comprises surface features for supporting the at least one article, the surface features comprise a plurality of protrusions, and adjacent protrusions of the plurality of protrusions define respective channels of a plurality of channels. The method further comprises forming a lid from the lid portion of the blank and forming a tray from the tray portion of the blank, the lid and the tray extend at least partially around an interior of the container. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures. It is within the scope of the present disclosure that the above-discussed aspects be provided both individually and in various combinations. 
       According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure. 
         FIG. 1  is a plan view of an exterior surface of a blank for forming a container according to an exemplary embodiment of the disclosure. 
         FIG. 2  is a plan view of an interior surface of the blank of  FIG. 1 . 
         FIG. 3  is a schematic cross-sectional view of a portion of the blank as shown in  FIG. 2 , showing surface features on the interior surface of the blank. 
         FIG. 4  is a perspective view of a partial folding operation of a container formed from the blank of  FIG. 1  according to an exemplary embodiment of the disclosure. 
         FIG. 5  is a perspective view of a container formed from the blank of  FIG. 1  in an open configuration. 
         FIG. 6  is a schematic cross-sectional view of a portion of the container of  FIG. 5  and supporting a food product. 
         FIG. 7  is a perspective view of the container of  FIG. 5  in a closed configuration. 
     
    
    
     Corresponding parts are designated by corresponding reference numbers throughout the drawings. 
     DETAILED DESCRIPTION 
     Containers according to the present disclosure can accommodate articles of numerous different shapes. In this specification, the terms “lower,” “bottom,” “upper,” “top,” “front,” and “back” indicate orientations determined in relation to fully erected containers. As described herein, containers may be formed by multiple overlapping portions, panels, walls, and/or end flaps. Such portions, panels, walls, and/or end flaps may be designated in relative terms to one another, e.g., “first”, “second”, “third”, etc., in sequential or non-sequential reference, without departing from the disclosure. 
     According to one exemplary embodiment of the disclosure,  FIGS. 1 and 2  show a blank  13  for forming a container  15  ( FIG. 5 ) according to an exemplary embodiment of the disclosure, with  FIG. 1  showing an exterior surface  10  of the blank and  FIG. 2  showing an interior surface  11  of the blank  13 . As described herein, the container  15  comprises a tray  17  and a reclosable lid  19  foldably connected to the tray  17 . The illustrated container  15  is suitable for holding one or more articles such as one or more food products F ( FIG. 6 ), for example, a pizza, calzone, sandwich, roll, and/or any other food item, e.g., for storage, transport, and/or delivery to a customer. In this regard, in one embodiment, the container  15  can be broadly referred to as a pizza box. Other types of food products, which may or may not be provided with additional packaging, can be placed in the container  15  for storage, transport, and/or delivery to a customer without departing from the disclosure. As described further herein, the interior surface  11  of the blank  13  includes surface features  21  for accommodating the food product F and/or maintaining a property of the food product F. As the interior surface  11  of the blank  13  forms the interior surface  16  ( FIG. 4 ) of the container  15 , the surface features  21  are provided on a portion of the container  15  facing an interior  23  ( FIG. 4 ) of the container  15 . The container  15  could be otherwise shaped and arranged and/or could be used to hold other products and/or articles in similar or different environments without departing from the disclosure. For example, the container  15  could be configured in any suitable configuration for carrying a heated food product without departing from the disclosure. 
     As shown in  FIG. 1 , the blank  13  has a longitudinal axis L 1  extending generally in the direction of the length of the blank  13  and a lateral axis L 2  extending generally in the direction of the width of the blank  13 . The blank  13 , as shown, includes a lid portion  25  for forming the lid  19  of the container  15  and a tray portion  26  for forming the tray  17  of the container  15 . In one embodiment, the lid portion  25  and the tray portion  26  are separate sections of material that are joined, e.g., glued, adhered, bridged, or taped, to name a few, to form the blank  13 . In another embodiment, the lid portion  25  and the tray portion  26  are sections of a unitary blank  13 . The exterior surface  10  of the blank  13  can be substantially smooth or planar, and can receive one or more visual indicia, for example, graphics and/or text. In one embodiment, the exterior surface  10  of the blank  13  can be substantially devoid of surface features. 
     Still referring to  FIG. 1 , as shown, the lid portion  25  of the blank  13  includes a top panel  27 , a first lid side flap  29  foldably connected to the top panel  27  at a longitudinal fold line  31 , a second lid side flap  33  foldably connected to the top panel  27  at a longitudinal fold line  35 , and a lid front flap  37  foldably connected to the top panel  27  at a lateral fold line  39 . As illustrated, a first back flap  41  is foldably connected to the first lid side flap  29  at a lateral fold line  43 , and a second back flap  45  is foldably connected to the second lid side flap  33  at a lateral fold line  47 . As also shown, curved cuts  32  can be provided that interrupt portions of the respective fold line  21 ,  35  to define tabs  34  in the lid portion  25 . 
     The tray portion  26  of the blank  13 , as shown, includes a bottom panel  49 , a first tray side flap  51  foldably connected to the bottom panel  49  at a longitudinal fold line  53  and a second tray side flap  55  foldably connected to the bottom panel  49  at a longitudinal fold line  57 . A back panel  59  is foldably connected to the bottom panel  49  at a lateral fold line  61 , and a tray front flap  63  is foldably connected to the bottom panel  49  at a lateral fold line  65 . As illustrated, the back panel  59  is foldably connected to the top panel  27  at a longitudinal fold line  67  such that the lid portion  25  of the blank  13  is foldably connected to the tray portion  26  of the blank  13  via the back panel  59  at the longitudinal fold line  67 . As shown, a cut  68  can interrupt a portion of the fold line  67 . In one embodiment, the back panel  59  is at least partially defined by two respective longitudinal cuts  42 ,  44  between the back panel  59  and a respective back flap  41 ,  45  of the lid portion  25  of the blank  13 . 
     In the illustrated embodiment, the tray portion  26  of the blank  13  comprises a first gusset panel  69  that is foldably connected to the bottom panel  49  at an oblique fold line  71 . A second gusset panel  77  is foldably connected to the bottom panel  49  at an oblique fold line  79  in the blank  13 . A first gusset side flap  83  is foldably connected to the first tray side flap  51  at a lateral fold line  85  and is foldably connected to the first gusset panel  69  at a longitudinal fold line  73 . A second gusset side flap  87  is foldably connected to the second tray side flap  55  at a lateral fold line  89  and is foldably connected to the second gusset panel  77  at a longitudinal fold line  81 . As shown, the tray portion  26  of the blank  13  comprises a first gusset front flap  91  foldably connected to the first gusset panel  69  at a lateral fold line  75  and foldably connected to the tray front flap  63  at a longitudinal fold line  93  that can be interrupted by one or more cuts. The tray portion  26  also includes a second gusset front flap  95  foldably connected to the second gusset panel  77  at a lateral fold line  82  and foldably connected to the tray front flap  63  at a longitudinal fold line  97  that can be interrupted by one or more cuts. As illustrated, the fold lines  71 ,  73 ,  75  can be arranged to intersect each other, and the fold lines  79 ,  81 ,  82  can be arranged to intersect each other. As also shown, lateral cuts  52  can be provided on the respective first tray side flap  51  and the second tray side flap  55 , a longitudinal cut  64  can be provided on a portion of the tray front flap  63 , and oblique cuts  50  can be provided on the bottom panel  49 . The blank  13  can have a different arrangement of panels, flaps, fold lines and/or cuts without departing from the disclosure. 
     Referring to  FIGS. 1-3 , the blank  13  and the container  15  are formed from a material  100  that defines the outer surface  12  and the interior surface  11  with the surface features  21 . In this regard, the material  100  can include an outer layer  101  and an inner layer  103  that includes surface features  21 . The outer layer  101  and the inner layer  103  can be joined, for example, with an adhesive such as glue, or can be otherwise laminated. The material  100  can include additional layers without departing from the disclosure. In one embodiment, the material  100  can be formed of a single layer of material that includes the surface features  21  on one side thereof. In one embodiment, the outer layer  101  can be a linerboard and the inner layer  103  can be corrugated sheet, for example, a fluted sheet, such that the material  100  can broadly be referred to as a single-faced structure. In such an arrangement, one side of the inner layer  103  is devoid of a liner, linerboard, or other covering adjacent the surface features  21 . In one embodiment, the outer layer  101  is a relatively thin layer having a first thickness T 1  (e.g., paper or any other suitable corrugated liner) and the inner layer  103  is a layer (e.g., paperboard or other suitable corrugated medium) that has a second thickness T 2  that is greater than the thickness T 1  of the outer layer  101 . Alternatively, the material of the outer layer  101  and the inner layer  103  could have the same thickness without departing from the disclosure. Also, the outer layer  101  and/or inner layer could comprise any suitable material (e.g., Kraft container board, coated paperboard, uncorked paperboard, paper, etc.) without departing from the disclosure. 
     As shown, the inner layer  103  has a waveform shape with the surface features  21  including a plurality of protrusions  105  spaced apart by respective channels  107  disposed and/or defined between and/or separating adjacent protrusions  105 . As shown, each respective channel  107  can include substantially the entire region of the inner layer  103  between each respective adjacent protrusion  105  such that respective channels  107  parallel with respective protrusions  105 . The protrusions  105  and channels  107  can have the same or similar lengths, or can have differing lengths without departing from the disclosure. 
     In this regard, the protrusions  105  and the channels  107  can form an alternating pattern such as that in a wave pattern, for example, a sinusoidal wave pattern. In this regard, the protrusions  105  and the channels  107  can form a pattern of the material  100  that can broadly be referred to as a single-face corrugated material or ribbed material. As shown, the channels  107  can extend longitudinally, or can have a different orientation, such as a laterally-extending or obliquely-extending orientation. In one embodiment, one or more of the protrusions  105  and/or the channels  107  can have a different cross-sectional configuration, for example, a configuration that is at least partially square, rectangular, triangular, or ovoid in cross-section. The protrusions  105  and/or the channels  107  could have other shapes without departing from the disclosure. 
     As shown, the protrusions  105  can have a hollow cross-sectional configuration, for example, such that a chamber  108  is defined between each protrusion  105  and the outer layer  101 . In an alternative embodiment, the inner layer  103  can be configured such that the protrusions  105  have a substantially solid cross-sectional configuration such that no chamber is defined between the protrusions  105  and the outer layer  101 . In the illustrated embodiment, each protrusion  105 , as shown, has a curved configuration that presents an upper-facing or food-contacting surface  109  for supporting one or more food products F ( FIG. 6 ). In this regard, the protrusions  105  can be configured with a curvature that extends toward the outer layer  101 , e.g., such that each protrusion  105  has a convex configuration relative to the outer layer  101 . In one embodiment, the protrusions  105  can have a concave or other configuration. While the protrusions  105  have been illustrated with the substantially similar configuration shown, one or more protrusion  105  can have a different configuration, for example, a cross-sectional configuration that is at least partially square, rectangular, triangular, or ovoid in cross-section, without departing from the disclosure. 
     Each channel  107 , as shown, has a curved configuration that can support, for example, portions of food products F, at a vertical position spaced above and away from the outer layer  101 . In this regard, each channel  107  has a curvature that extends away from the outer layer  101 , e.g., such that each channel  107  has a concave configuration relative to the outer layer  101 . While the channels  107  have been illustrated with the substantially similar configuration shown, one or more channels  107  can have a different configuration, for example, a cross-sectional configuration that is at least partially square, rectangular, triangular, or ovoid in cross-section, without departing from the disclosure. In this regard, the arrangement of the surface features  21  is such that a plurality of food-contacting surfaces  109  is provided spaced apart from one another, e.g., by respective channels  107 . 
     Referring additionally to  FIG. 4 , formation of the container  15  from the blank  13  will be described according to one exemplary method of the disclosure. Formation of the lid  19  can proceed by folding the first lid side flap  29  at the fold line  31 , folding the second lid side flap  33  at the fold line  35 , and folding the lid front flap  37  at the fold line  39 , all to respective substantially upright, e.g., substantially perpendicular, configurations relative to the top panel  27 . Similarly, formation of the tray  17  can proceed by folding the first tray side flap  51  at the fold line  53 , folding the second tray side flap  55  at the fold line  57 , folding the back panel  59  at the fold line  61 , and folding the tray front flap  63  at the fold line  65 , all to respective substantially upright configurations relative to the bottom panel  49 . In this regard, portions of the blank  13  are folded to at least partially extend around the interior  23  of the container  15 . 
     Still referring to  FIG. 1 , and referring additionally to  FIG. 5 , the respective first back flap  41  and second back flap  45  can be folded at the respective fold lines  43 ,  47  into substantially perpendicular relation with the respective first lid side flap  29  and second lid side flap  33  and into at least partial overlapping relation with the back panel  59 , for example, into at least partial face-to-face contact with the back panel  59 . Such arrangement of the first back flap  41  and the second back flap  45  adjacent the back panel  59  can, for example, provide reinforcement during opening and closing of the lid  19 . In one embodiment, the first back flap  41  and the second back flap  45  can be joined to the back panel  59 , for example, with an adhesive such as glue. As also shown, the respective gusset panels  69 ,  77  can be folded at the respective oblique lines of weakening  71 ,  79  into overlapping relation, e.g., at least partial face-to-face contact, with the bottom panel  49 . The folding of the first gusset panel  69  as described above draws the first gusset side flap  83  to at least partially fold at the fold line  73  into substantially upright relation with respect to the bottom panel  49  and to at least partially fold at the fold line  85 . Such folding of the first gusset panel  69  also draws the first gusset front flap  91  to at least partially fold at the fold line  75  into substantially upright relation to the bottom panel  49  and to at least partially fold at the fold line  93 , thus forming a first gusset  111  with the first gusset side flap  83  and the first gusset front flap  91  disposed in oblique relation with both the first tray side flap  51  and the tray front flap  63 . Similarly, the folding of the second gusset panel  77  as described above draws the second gusset side flap  87  to at least partially fold at the fold line  81  into substantially upright relation to the bottom panel  49  and to at least partially fold at the fold line  89 . Further, such folding of the second gusset panel  77  and draws the second gusset front flap  95  to at least partially fold at the fold line  82  into substantially upright relation to the bottom panel  49  and to at least partially fold at the fold line  97 , thus forming a second gusset  113  with the second gusset side flap  87  and the second gusset front flap  95  are disposed in oblique relation with both the second tray side flap  55  and the tray front flap  63 . The above-described folding of the gusset panels  69 ,  77  may occur at a different point during formation of the container  15  without departing from the disclosure. In one embodiment, the gussets  111 ,  113  can provide a visually-distinctive appearance of the container  15  and/or can facilitate interengagement of a container with another container, a shipping structure, and/or a storage structure. In addition, at least a portion of the top panel  27  can protrude over one or both of the gussets  111 ,  113 , for example, to provide a surface or ledge by which a user can engage and lift the lid  19  from the tray  17 . 
     In the assembled and open configuration of the container  15  illustrated herein, a food product F ( FIG. 6 ) can be placed in the interior  23  of the container  15 , for example, resting upon the bottom panel  49 . 
     Referring additionally to the cross-sectional view of  FIG. 6  taken along the line  6 - 6  of  FIG. 5 , a portion of the bottom panel  49  comprised of the material  100  and supporting the food product F is illustrated. As described above, the inner layer  103  is devoid of a liner, linerboard, or other covering over the protrusions  105 . Accordingly, the food product F is supported on the surface features  21  of the interior surface  16  of the container  15  such that the food-contacting surfaces  109  of one or more of the protrusions  105  are in contact with the food product F and such that the food product F overlies one or more of the channels  107 . 
     In this regard, the surface features  21  provide a discontinuous surface along which the food product F is supported. In one embodiment, the food product F is a heated food product such that at least a portion of the heat H of the food product F can be transmitted to air in the channels  107 . In this regard, the channels  107  and the overlying food product F create spaces of heated air below the food product F such that at least a portion of the heat H of the food product F is maintained in one or more of the channels  107  and is in convective contact with the food item F, for example, to contribute to maintaining a condition such as the temperature of the food item F. Additionally, heat H in the channels  107  is inhibited or prevented from escaping into upper portions of the interior  23  of the container  15  to minimize, inhibit, and/or prevent heat losses from the food item F. In one embodiment, the one or more channels  107  beneath the food product F provide a degree of thermal insulation for the food product F that maintains the temperature of the heated food product F. It will be understood that one or more of the chambers  108  below the protrusions  105  can additionally or alternatively maintain heat H to minimize, inhibit, and/or prevent heat losses from the food item F and/or provide a degree of thermal insulation for the food product F as described above with regard to the channels  107 . 
     Furthermore, the channels  107  can support and/or capture a portion P of the food product F that may become separated from the food product F, for example, runoff from the food product F (e.g., oil or grease) or particulate from the food product F (e.g., crumbs) that falls into one or more of the channels  107 , for example, due to shifting and/or under the influence of gravity. The channels  107  can also support moisture from the environment in the interior  23  of the container  15  (e.g., vapor or condensation from steam). In this regard, the channels  107  can provide pathways for runoff, or drainage from the food product F and/or the surrounding environment, for example, to maintain a desired condition, e.g., crispness, minimization of grease buildup, minimization of pooling or soaking of liquids, etc., of the food product F. 
     Accordingly, and as described herein, the surface features  21  provide thermally insulative properties for the food product F and the container  15  as well as being configured for capturing and/or draining runoff and/or particulate from the food product F and/or moisture from the surrounding environment. Such advantages are provided by the configuration of the surface features  21 , which can provide ecological advantages and cost savings compared to, for example, conventional containers that lack such surface features. For example, because the inner layer  103  is devoid of a liner, linerboard, or other covering adjacent the surface features  21 , cost and materials savings are realized with respect to such liner, linerboard, or other covering. 
     Referring additionally to  FIG. 7 , the container  15  is illustrated in a closed condition, with the lid side flaps  29 ,  33  and the lid front flap  37  tucked into the interior  23  of the container  15  adjacent the respective tray side flaps  51 ,  55  and the tray front flap  63 . In this regard, the lid  19  and the tray  17  can together provide an enclosure, for example, to maintain a desired condition of the interior  23  of the container  15  or a food product F disposed therein. A user can selectively open the container  15  by lifting upwardly along a portion of the lid  19 , for example, a portion of the top panel  27  of the lid  19  extending over one or both of the gusset panels  69 ,  77  and/or one or more of the tabs  34  such that the lid  19  hingably raises relative to the tray  17  at the fold line  67 . 
     In general, the blanks described herein may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, sheet plastics or any other material having properties suitable for enabling the containers to function at least generally as described above. The blanks can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blanks may then be coated with a varnish to protect information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections. 
     As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type of tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the tear lines to be replaced with a continuous slit, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure. 
     In accordance with the exemplary embodiments, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed or depressed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features. In situations where cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line. 
     The above embodiments may be described as having one or more panels adhered together by glue during erection of the container embodiments. The term “glue” is intended to encompass all manner of adhesives commonly used to secure portions of the container in place, and is not intended to exclude heat, chemical, or frequency bonding techniques. 
     The foregoing description of the disclosure illustrates and describes various embodiments. As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are within the scope of the disclosure as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.