Patent Publication Number: US-2021178721-A1

Title: Food carton insert and methods for providing multiple food compartments in a food container

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Patent Application 62/947,143 filed Dec. 12, 2019, the contents of which are hereby incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The presently disclosed subject matter relates generally to carry-out food containers and more particularly to a food carton insert and methods for providing multiple food compartments in a food container. 
     BACKGROUND 
     Various products are known to be purchased by consumers which require a container for ease of transport. For example, in the food and grocery industry it is common to place food items in individual carry-out/to-go food containers. There may be certain drawbacks to commonly used carry-out food containers. For example, often the carry-out food container provides one compartment only for holding food. Consequently, when multiple food items are placed in the food container, the one compartment offers no means for keeping the multiple food items separate. 
     SUMMARY 
     This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Further, the claimed subject matter is not limited to implementations that solve any or all disadvantages noted in any part of this disclosure. 
     According to at least one embodiment of the disclosed subject matter, a method of making a food carton insert, including: providing a substantially continuous sheet of paperboard having a first end and a second end opposite the first end; folding the paperboard at a first fold line at a 90-degree angle in a first direction; folding the paperboard at a second fold line at a 180-degree angle in a second direction being opposite the first direction; folding the paperboard at a third fold line at a 90-degree angle in the first direction for creating a divider between the first fold line and the third fold line, thereby creating a first food compartment left of the divider and a second food compartment right of the divider. 
     According to at least another embodiment of the disclosed subject matter, the method of making a food carton insert further includes wherein the third fold line fold is folded after the second fold line fold, which is folded after the first fold line fold. 
     According to at least another embodiment of the disclosed subject matter, the method of making a food carton insert further includes applying adhesive to one or two opposing panels of the paperboard extending from the second fold line, and applying pressure to adhere the two opposing panels together. 
     According to at least another embodiment of the disclosed subject matter, the method of making a food carton insert further includes indenting or scoring the first fold line and the third fold line on a top side of the paperboard. 
     According to at least another embodiment of the disclosed subject matter, the method of making a food carton insert further includes indenting or scoring the second fold line on a bottom side of the paperboard. 
     According to at least another embodiment of the disclosed subject matter, the method of making a food carton insert further includes perforating one of more of the fold lines of the paperboard. 
     According to at least another embodiment of the disclosed subject matter, the method of making a food carton insert further includes: folding the paperboard at a fourth fold line at a 90-degree angle in the first direction; folding the paperboard at a fifth fold line at a 180-degree angle in the second direction; folding the paperboard at a sixth fold line at a 90-degree angle in the first direction for creating a second divider between the fourth fold line and the sixth fold line, thereby creating a third food compartment right of the second divider. 
     According to at least another embodiment of the disclosed subject matter, the method of making a food carton insert further includes: folding the paperboard at a seventh fold line at a 90-degree angle in the first direction; folding the paperboard at an eight fold line at a 180-degree angle in the second direction; folding the paperboard at a ninth fold line at a 90-degree angle in the first direction for creating a third divider between the seventh fold line and the ninth fold line, thereby creating a fourth food compartment right of the third divider. 
     According to at least another embodiment of the disclosed subject matter, the method of making a food carton insert further includes: placing the food carton insert into a food carton or container; placing food in one or more of the compartments; closing the food carton or container. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing, as well as the following Detailed Description of preferred embodiments, is better understood when read in conjunction with the appended drawings. For the purposes of illustration, there is shown in the drawings exemplary embodiments; however, the presently disclosed subject matter is not limited to the specific methods and instrumentalities disclosed. 
         FIG. 1  illustrates a perspective view of an example of the presently disclosed food carton insert for providing multiple food compartments in a food container, which is a three-compartment food carton insert. 
         FIG. 2  illustrates a perspective view of the three-compartment food carton insert shown in  FIG. 1  installed in a food carton or container. 
         FIG. 3  illustrates a plan view of the three-compartment food carton insert shown in  FIG. 1  in a flat pre-folded configuration. 
         FIG. 4  illustrates a plan view of a four-compartment food carton insert. 
         FIG. 5  illustrates a perspective view of yet another example of the presently disclosed food carton insert for providing multiple food compartments in a food container, which is a two-compartment food carton insert according to a simplest configuration. 
         FIG. 6  illustrates a perspective view of the two-compartment food carton insert shown in  FIG. 5  installed in a food carton or container. 
         FIG. 7  illustrates a flow diagram of an example of a method of making the presently disclosed food carton insert for providing multiple food compartments in a food container. 
         FIG. 8  illustrates a flow diagram of an example of a method of using the presently disclosed food carton insert for providing multiple food compartments in a food container. 
     
    
    
     DETAILED DESCRIPTION 
     The presently disclosed subject matter now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the presently disclosed subject matter are shown. Like numbers refer to like elements throughout. The presently disclosed subject matter may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Indeed, many modifications and other embodiments of the presently disclosed subject matter set forth herein will come to mind to one skilled in the art to which the presently disclosed subject matter pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the presently disclosed subject matter is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. 
     In some embodiments, the presently disclosed subject matter provides a food carton insert and methods for providing multiple food compartments in a food container. The presently disclosed food carton insert may be easily installed in an existing food carton or container. For example, the presently disclosed food carton insert may be used for rendering one large compartment of an existing food carton or container into multiple food compartments. 
     Referring now to  FIG. 1  is a perspective view of an example of the presently disclosed food carton insert  100  for providing multiple food compartments in a food container, which in this non-limiting example is shown as a three-compartment food carton insert  100 . Notably,  FIG. 1  depicts a three-compartment food carton insert  100 , though the dotted lines in the middle insert allow for the possibility that numerous additional compartments  115  may be envisioned. Similarly,  FIG. 2  allows for the possibility of additional compartments  115  and/or a longer food carton  200 . 
     Food carton insert  100  may be formed from a continuous panel  110  that is foldable. When folded, foldable panel  110  may provide multiple food compartments  115  separated by dividers  120 . The dividers  120  are formed of a folded portion of panel  110 . In the example of the three-compartment food carton insert  100 , food carton insert  100  may include three food compartments  115  (e.g., food compartments  115 A,  115 B,  115 C) separated by two dividers  120  (e.g., dividers  120 A,  120 B). 
     Panel  110  may be formed, for example, of paperboard. Paperboard is a thick, paper-based material used, for example, for packaging. Paperboard is the broad name that refers to different qualities, or grades, of paper-based packaging material. Further, the paperboard forming panel  110  may be made of solid unbleached sulfate (SUS®) paperboard and may further including a coating, such as a clay coating. However, any suitable paperboard or other material may be used and may include any suitable coating or no coating. More details of a panel  110  for forming a three-compartment food carton insert  100  are shown and described hereinbelow with reference to  FIG. 3 . 
     Referring now to  FIG. 2  is a perspective view of the three-compartment food carton insert  100  shown in  FIG. 1  installed in a food carton (or container)  200 . Food carton (or container)  200  may be any type of disposable or non-disposable container, such as, but not limited to, a paperboard container, a Styrofoam container, a plastic container, a glass container, a metal container, and the like. 
     In the example shown in  FIG. 2 , food carton (or container)  200  may be a disposable paperboard food carton (e.g., carry-out/to-go food container). In this example, food carton (or container)  200  may be a substantially rectangular food carton that may include a bottom panel  210 , four side panels  212 , closure flaps  214 , and corner gussets  216 . Together, the bottom panel  210 , the four side panels  212 , and the closure flaps  214  form a single inner compartment  218 . Three-compartment food carton insert  100  is sized to fit within inner compartment  218  of food carton (or container)  200 . For example, three-compartment food carton insert  100  may be easily placed in the space of inner compartment  218 , thereby rendering the one large space of inner compartment  218  into multiple (e.g., three) food compartments (e.g., food compartments  115 A,  115 B,  115 C). 
     In the example of the three-compartment food carton insert  100 , three food items (e.g., tacos, hotdogs, etc.) may be placed in food carton (or container)  200  and wherein three-compartment food carton insert  100  provides a means for keeping the three food items separate. 
     Food carton (or container)  200  is not limited to a substantially rectangular shape. Food carton (or container)  200  may be of a number of overall general shapes including, but not limited to, square, rectangular, pyramidal, triangular, circular, oval, or any other suitable shape. Accordingly, the footprint of any food carton insert  100  may be designed to correlate to any shape of food carton (or container)  200 . 
     Referring now to  FIG. 3  is a plan view of the three-compartment food carton insert  100  shown in  FIG. 1  and  FIG. 2  in a flat unfolded configuration. With respect to forming, for example, paperboard products, this flat unfolded configuration may also be referred to as a “blank.” The precise width and length of panel  110  depends on the number of dividers  120  to be provided and the size of the floor (e.g., bottom panel  210 ) of the container in which it will be used. In this example, panel  110  may include two dividers  120  and is sized to fit within a container whose floor may be about 5.5 inches wide and about 7.75 inches long. 
     More specifically in this example, panel  110  (in blank form) may have an overall width of about 5 5/16 inches and an overall length of about 14 3/32 inches. Certain portions of panel  110  correspond to food compartments  115 A,  115 B,  115 C and certain other portions of panel  110  correspond to dividers  120 A,  120 B. For example and in order, a portion  130  corresponds to food compartment  115 A, portions  132  and  134  correspond to divider  120 A, a portion  136  corresponds to food compartment  115 B, portions  138  and  140  correspond to divider  120 B, and a portion  142  corresponds to food compartment  115 C. 
     Wherein panel  110  (in blank form) is foldable to form the finished product, the various portions are defined by certain fold lines. For example, a fold line  150  is the boundary between portion  130  and portion  132 , a fold line  152  is the boundary between portion  132  and portion  134 , a fold line  154  is the boundary between portion  134  and portion  136 , a fold line  156  is the boundary between portion  136  and portion  138 , a fold line  158  is the boundary between portion  138  and portion  140 , and a fold line  160  is the boundary between portion  140  and portion  142 . 
     In each embodiment of the panel  110  (in blank form), the panel  110  may define a first end  111 A opposite a second end  111 B. 
     In this example, and referring still to  FIG. 3 , the length of each of the portions  130 ,  136 , and  142  may be about 2 17/32 inches. Further, the length of each of the portions  132 ,  134 ,  138 , and  140  may be about 1⅝ inches. 
     Fold line  150 , fold line  152 , and fold line  154  may be used to form divider  120 A. Accordingly, fold lines  150  and  154  may be considered the lower fold lines of divider  120 A, while fold line  152  may be considered the upper fold line of divider  120 A. Likewise, fold line  156 , fold line  158 , and fold line  160  may be used to form divider  120 B. Accordingly, fold lines  156  and  160  may be considered the lower fold lines of divider  120 B, while fold line  158  may be considered the upper fold line of divider  120 B. 
     Referring now to  FIG. 4  is a plan view of another example of the presently disclosed food carton insert  100  in a flat pre-folded configuration for providing multiple food compartments in a food container, which is a four-compartment food carton insert  100 . In the example of the four-compartment food carton insert  100 , food carton insert  100  may include four food compartments  115  (e.g., food compartments  115 A,  115 B,  115 C,  115 D) separated by three dividers  120  (e.g., dividers  120 A,  120 B,  120 C). The four-compartment food carton insert  100  may be installed in food carton (or container)  200 . 
     Four-compartment food carton insert  100  may be easily placed in the space of inner compartment  218 , thereby rendering the one large space of inner compartment  218  into multiple (e.g., four) food compartments (e.g., food compartments  115 A,  115 B,  115 C,  115 D). For example, four food items (e.g., tacos, hotdogs, etc.) may be placed in food carton (or container)  200  and wherein four-compartment carton insert  100  provides a means for keeping the four food items separate. 
     Again, the precise width and length of panel  110  depends on the number of dividers  120  to be provided and the size of the floor (e.g., bottom panel  210 ) of the container in which it will be used. In this example, panel  110  includes three dividers  120  and is sized to fit within a container whose floor may be about 5.5 inches wide and about 7.75 inches long. 
     More specifically in this example, panel  110  (in blank form) may have an overall width of about 5 5/16 inches and an overall length of about 17 5/16 inches. Certain portions of panel  110  correspond to food compartments  115 A,  115 B,  115 C,  115 D and certain other portions of panel  110  correspond to dividers  120 A,  120 B,  120 C. For example and in order, a portion  130  corresponds to food compartment  115 A, portions  132  and  134  correspond to divider  120 A, a portion  136  corresponds to food compartment  115 B, portions  138  and  140  correspond to divider  120 B, a portion  142  corresponds to food compartment  115 C, portions  144  and  146  correspond to divider  120 C, and a portion  146  corresponds to food compartment  115 D. 
     Wherein panel  110  (in blank form) is foldable to form the finished product, the various portions are defined by certain fold lines. For example, a fold line  150  is the boundary between portion  130  and portion  132 , a fold line  152  is the boundary between portion  132  and portion  134 , a fold line  154  is the boundary between portion  134  and portion  136 , a fold line  156  is the boundary between portion  136  and portion  138 , a fold line  158  is the boundary between portion  138  and portion  140 , a fold line  160  is the boundary between portion  140  and portion  142 , a fold line  162  is the boundary between portion  142  and portion  144 , a fold line  164  is the boundary between portion  144  and portion  146 , and a fold line  166  is the boundary between portion  146  and portion  148 . 
     In this example and referring still to  FIG. 4 , the length of each of the portions  130 ,  136 ,  142 , and  148  may be about 1 57/64 inches. Further, the length of each of the portions  132 ,  134 ,  138 ,  140 ,  144 , and  146  may be about 1⅝ inches. 
     Fold line  150 , fold line  152 , and fold line  154  may be used to form divider  120 A. Accordingly, fold lines  150  and  154  may be considered the lower fold lines of divider  120 A, while fold line  152  may be considered the upper fold line of divider  120 A. Likewise, fold line  156 , fold line  158 , and fold line  160  may be used to form divider  120 B. Accordingly, fold lines  156  and  160  may be considered the lower fold lines of divider  120 B, while fold line  158  may be considered the upper fold line of divider  120 B. Likewise, fold line  162 , fold line  164 , and fold line  166  may be used to form divider  120 C. Accordingly, fold lines  162  and  166  may be considered the lower fold lines of divider  120 C, while fold line  164  may be considered the upper fold line of divider  120 C. 
     Referring now to  FIG. 5  is a perspective view of yet another example of the presently disclosed food carton insert  100  for providing multiple food compartments in a food container, which is a two-compartment food carton insert  100  according to a simplest configuration. In the example of the two-compartment food carton insert  100 , food carton insert  100  may include two food compartments  115  (e.g., food compartments  115 A,  115 B) separated by one divider  120 . Two-compartment food carton insert  100  may be easily placed in the space of inner compartment  218 , as depicted in  FIG. 6 , thereby rendering the one large space of inner compartment  218  into multiple (e.g., two) food compartments (e.g., food compartments  115 A,  115 B). For example, two food items (e.g., tacos, hotdogs, etc.) may be placed in food carton (or container)  200  and wherein two-compartment carton insert  100  provides a means for keeping the two food items separate. 
     The descriptions herein of the two-compartment, three-compartment and four-compartment food carton inserts  100  may be easily used by one skilled in the art to additionally create, without undue experimentation, five-compartment, six-compartment, and/or seven or more-compartment food carton inserts  100 . The panels  110  of  FIGS. 3 and 4  would be extended to allow for additional food compartments  115 , dividers  120  and additional fold lines, so that an insert  100  may be constructed. 
     Referring now to  FIG. 7  is a flow diagram of an example of a method  300  of making the presently disclosed food carton insert  100  for providing multiple food compartments in a food container. Method  300  may include, but is not limited to, the following steps. 
     At a step  310 , the presently disclosed food carton insert is provided in a flat unfolded configuration (in blank form). In one example, the paperboard panel  110  (in blank form) that corresponds to the three-compartment food carton insert  100 , as shown in  FIG. 3 , is provided. In another example, panel  110  (in blank form) that corresponds to the four-compartment food carton insert  100 , as shown in  FIG. 4 , is provided. In yet another example, panel  110  (in blank form) that corresponds to the two-compartment food carton insert  100 , as show in  FIG. 5 , is provided. In other examples, other panels  110  (in blank form) that correspond to five or more compartment food carton inserts  100  are provided. 
     At a step  315 , fold operations are performed on panel  110  in any predetermined fold order. In one example, and referring now to panel  110  (in blank form) shown in  FIG. 3 , a 90-degree fold is performed at fold line  150 , in a first direction, then a 180-degree fold is performed at fold line  152 , in a second direction opposite the first direction, then a 90-degree fold is performed at fold line  154 , in the first direction, then a 90-degree fold is performed at fold line  156 , in the first direction, then a 180-degree fold is performed at fold line  158 , in the second direction, and then a 90-degree fold is performed at fold line  160 , in the first direction. In one example, the folded panels (e.g.,  132 ,  134 ) may be glued, taped, or otherwise adhered together to hold in the folded configuration to form the dividers (e.g.  120 A). An adhesive may be applied to one or both of the opposing panels (e.g.,  132 ,  134 ) and pressure may be applied to the two opposing panels (e.g.,  132 ,  134 ) so that the adhesive may adhere the two opposing panels (e.g.,  132 ,  134 ) together. 
     To aid the manufacturing process, the panels  110  (in blank form) may be indented, perforated and/or scored along one or more fold lines  150 ,  152 ,  154 ,  156 ,  158 ,  160 ,  162 ,  164 ,  166 . If indented and/or scored along multiple fold lines  150 ,  152 ,  154 ,  156 ,  158 ,  160 ,  162 ,  164 ,  166 , one side of the panel  110  (in blank form) may be indented and/or scored for one or more of the panels  150 ,  154 ,  156 ,  160 ,  162 ,  166 , and on an opposite side of the panel  110  (in blank form) one or more of the remaining panels  152 ,  158 ,  164  may be indented and/or scored, thereby ensuring that the indentions and/or scores appropriately aid the folding in the corresponding direction. 
     Referring now to  FIG. 8  is a flow diagram of an example of a method  400  of using the presently disclosed food carton insert  100  for providing multiple food compartments in a food container. Method  400  may include, but is not limited to, the following steps. 
     At a step  410 , any configuration of the presently disclosed food carton insert  100  is provided along with any food carton or container. In one example, the two-compartment food carton insert  100  shown in  FIG. 7  is provided along with food carton (or container)  200 . In another example, the three-compartment food carton insert  100  shown in  FIG. 1  is provided along with food carton (or container)  200 . In another example, the four-compartment food carton insert  100  shown in  FIG. 4  is provided along with food carton (or container)  200 . In other examples, other panels  110  (in blank form) that correspond to two or five or more compartment food carton inserts  100  are provided. 
     At a step  415 , the presently disclosed food carton insert  100  is placed into the food carton or container. In one example, the three-compartment food carton insert  100  is placed inside food carton (or container)  200  as shown in  FIG. 2 . In another example, the four-compartment food carton insert  100  is placed inside food carton (or container)  200  as shown in  FIG. 5 . In other examples, other panels  110  (in blank form) that correspond to two or five or more compartment food carton inserts  100  are placed inside food cartons (or containers)  200 . 
     At a step  420 , food items may be place into the food compartments of the presently disclosed food carton insert  100 . In one example, and referring to the three-compartment food carton insert  100  and food carton (or container)  200  shown in  FIG. 2 , three tacos are placed in three-compartment food carton insert  100 . For example, one taco or hotdog is placed in food compartment  115 A of three-compartment food carton insert  100 . Then, another taco or hotdog is placed in food compartment  115 B of three-compartment food carton insert  100 . Then, another taco or hotdog is placed in food compartment  115 C of three-compartment food carton insert  100 . In other examples, placement of food items may occur in four-compartment, two-compartment or other inserts  100 . 
     At a step  425 , the food carton or container is closed. In one example, the closure flaps  214  of food carton (or container)  200  are closed. 
     Following long-standing patent law convention, the terms “a,” “an,” and “the” refer to “one or more” when used in this application, including the claims. Thus, for example, reference to “a subject” includes a plurality of subjects, unless the context clearly is to the contrary (e.g., a plurality of subjects), and so forth. 
     Throughout this specification and the claims, the terms “comprise,” “comprises,” and “comprising” are used in a non-exclusive sense, except where the context requires otherwise. Likewise, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items. 
     For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing amounts, sizes, dimensions, proportions, shapes, formulations, parameters, percentages, quantities, characteristics, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about” even though the term “about” may not expressly appear with the value, amount or range. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are not and need not be exact, but may be approximate and/or larger or smaller as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art depending on the desired properties sought to be obtained by the presently disclosed subject matter. For example, the term “about,” when referring to a value can be meant to encompass variations of, in some embodiments ±100%, in some embodiments ±50%, in some embodiments ±20%, in some embodiments ±10%, in some embodiments ±5%, in some embodiments ±1%, in some embodiments ±0.5%, and in some embodiments ±0.1% from the specified amount, as such variations are appropriate to perform the disclosed methods or employ the disclosed compositions. 
     Further, the term “about” when used in connection with one or more numbers or numerical ranges, should be understood to refer to all such numbers, including all numbers in a range and modifies that range by extending the boundaries above and below the numerical values set forth. The recitation of numerical ranges by endpoints includes all numbers, e.g., whole integers, including fractions thereof, subsumed within that range (for example, the recitation of 1 to 5 includes 1, 2, 3, 4, and 5, as well as fractions thereof, e.g., 1.5, 2.25, 3.75, 4.1, and the like) and any range within that range. 
     Although the foregoing subject matter has been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be understood by those skilled in the art that certain changes and modifications can be practiced within the scope of the appended claims.