Abstract:
A folded pizza box is formed from a lay flat blank for retaining, transporting and serving hot pizza. The blank includes an arrangement of end panels, side panels and lid panels foldable relative to a bottom panel such that, in the erected box, the lid panels overlap and are interlocked with the end panels by frictionally engaged detents. The side panels slant upwardly and inwardly from the bottom panel to add rigidity and save material for the carton. The end panels flare upwardly and outwardly from the bottom panel to prevent shifting of stacked boxes. The lid panels each have less width than the bottom panel and do not extend completely across the width of a box erected from the blank.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S)  
       [0001]     This application claims priority to U.S. Patent Application Ser. No. 60/602,991, filed on 19 Aug. 2004, which is hereby incorporated by reference hereinto. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Technical Field of the Invention  
         [0003]     The present invention relates generally to containers for storing and handling product, and more particularly to containers made from a corrugated paperboard blank for retaining, transporting and serving food, especially pizza.  
         [0004]     2. Brief Description of the Related Art  
         [0005]     Pizza businesses make and sell millions of hot pizzas for delivery and carryout. The success of these businesses depends to an extent on the cost and functionality of the folded boxes utilized in packaging the pizza product. Ideally, it is recognized that these boxes should be inexpensive, easy to use, stackable, rigid, and crush-resistant.  
         [0006]     Some prior art boxes employ inward-slanting wall constructions in an effort to conserve manufacturing costs, or rely on foldable blanks capable of being manufactured in nested and inverted configuration in order to achieve a minimum of material consumption and to attain maximum stacking strength. Certain cartons employ various rigid cover structures and avoid the use of any tabs projecting above their cover structure so as to allow stacking of multiple cartons one on top of the other. The top and bottom surfaces of these boxes are generally flat and smooth, whereby they tend to slide on top of one another when stacked.  
         [0007]     The construction of prior art folded pizza boxes requires several steps in their use. These steps include pre-erecting the boxes, stacking empty pre-erected boxes on a shelf, removing a pre-erected box from the shelf and opening the pre-erected box, removing a pizza from an oven and placing it on a counter surface for cutting, and after cutting the pizza transferring it from the counter surface to the opened box, and then re-closing the box.  
         [0008]     Conventional pizza boxes have a large one-piece lid that pivots from one side between open and closed positions. This large lid interferes with adjoining structures and makes it awkward to gain access to the pizza.  
         [0009]     Several drawbacks are inherently unavoidable in using the prior art boxes to package pizza. For example, previous box designs require a substantial amount of labor to pre-erect the boxes, place a pizza on a surface to cut it, transfer the cut pizza to the box, and re-close the box. This extra handling of the pizza also results in increased risk of contamination of the pizza. Moreover, the pizza starts cooling during the cutting process, which is undesirable to the consumer. Additionally, the construction of conventional pizza boxes makes it difficult for the consumer to serve the pizza from the box, or to cut the pizza while it is in the box.  
         [0010]     It should also be appreciated that once a pizza is boxed, it is important to let the moisture out of the carton to prevent soggy pizza. Prior art pizza cartons generally accomplish this task by venting the carton through seams or gaps between the end walls or sidewalls and the cover structure, or through other vent holes formed in the carton surface.  
         [0011]     Mindful of such prior art structures and their use, there is a need for a pizza box that meets the strength and ventilation requirements and uses a minimum amount of material in its construction, is easy to erect, requires minimal handling of the pizza at the food preparation site, and enables the consumer to easily gain access to and serve pizza from the box, and/or to cut the pizza while it is in the box.  
         [0012]     Applicant met these needs in its prior copending application filed on 10 Jun. 2004 and the present application represents an improvement over and variation of the box disclosed and claimed in that application.  
       SUMMARY OF THE INVENTION  
       [0013]     The box of the invention is inexpensive, meets the strength and ventilation requirements of pizza boxes, uses a minimum amount of material in its construction, is easy to erect, requires minimal handling of the pizza at the food preparation site, and enables the consumer to easily gain access to and serve pizza from the box, and/or to cut the pizza while it is in the box.  
         [0014]     The pizza box of the present invention is formed from a paperboard blank that may be left flat at the food preparation site, and upon which a pizza may be placed directly from the oven so that it can be cut on the flattened box, after which the box can be closed. This eliminates steps in the handling of the pizza, reduces the risk of contamination, and minimizes cooling of the pizza. It also speeds the process of preparing and packaging the pizza.  
         [0015]     To attain these advantages, the box of the invention is formed from a blank that includes a substantially rectangular bottom panel, a pair of opposed end wall panels foldably connected to opposite ends of the bottom panel, a pair of opposed side wall panels foldably connected along a first edge to opposite sides of the bottom panel, and a pair of lid panels foldably connected to a second, free edge of the side wall panels. Each lid panel has a width less than the width of the bottom panel, and cooperating detents on the lid panels and end panels releasably hold the lid panels closed in a box erected from the blank.  
         [0016]     In a first form of the present invention, the lid panels in their closed position are supported at opposite edges on the end walls of the box, and in a second form the lid panels have depending slotted or notched flaps at their opposite ends which mate with slots or notches in the box end walls to support the lid. Both of these variations improve the crush strength of the lid.  
         [0017]     The blank is supplied flat to the food preparer, who stores it flat until it is needed. The flat blank is then retrieved from a stack of the flat blanks and laid on a counter or other surface, and a cooked pizza is moved from the oven directly onto the flat blank. The pizza may then be cut while it is resting on the bottom panel of the blank. After the pizza is cut, the end walls are folded upwardly to an approximately vertical orientation, and the side walls are then folded up and the lid panels are folded inwardly and down over the top of the box, engaging the detents to hold the box in erected position.  
         [0018]     In the first form of the invention, the detents comprise locking tabs projecting upwardly from the upper edge of the end walls, and cooperating slots in opposite end edges of the lid panels. In a first variation of this form, there are two locking tabs on each end wall, with a cooperating slot in each end edge of each lid panel. In a second variation of this form, only one locking tab is provided on each end wall, and one cooperating slot is in only one end edge of each lid panel.  
         [0019]     In the second form of the invention, the detents comprise down-turned flaps on opposite end edges of the lid panels, with at least one generally V-shaped slot or notch in a lower edge of the flaps, and cooperating generally V-shaped slots or notches in an upper edge of each end wall arranged so that the notches in the flaps engage with the notches in the end walls when the lid panels are in their closed position, with portions of the flaps overlapping and interwoven with portions of the end walls to frictionally hold the lid panels closed. The closing process in this form of the invention is designed to take advantage of the natural motions of the hands and fingers of the worker when setting up the box, and the box can be quickly and easily set up from a flat blank without lifting it from the work surface. This eliminates the need to pre-erect the box, a process that adds additional work elements and often consumes space in the pizza preparation area.  
         [0020]     In a preferred construction, opposite end edges of the end wall panels are inwardly inclined, whereby when the side wall panels are folded upwardly against these end edges they are slightly inwardly inclined. This reduces the size of the blank and also ensures that the pizza is tightly contained within the box.  
         [0021]     Further, the lid panels slightly overhang the end walls, and the detent slots may be located near the overhanging edge of the lid panels so that when the locking tabs on the end walls are engaged in the slots, the end walls are slightly outwardly inclined. This permits the bottom of one erected box to be received between the upwardly projecting locking tabs of another box when they are stacked on top of one another, thereby preventing sliding of the upper box over the top of the lower box. Also, and as noted previously, with this arrangement the opposite edges of the panels are supported on top of the end walls, improving the crush strength of the lid.  
         [0022]     The locking tabs and slots may be positioned so that multiple, side-by-side, contiguous blanks can be simultaneously cut on a multiple out die, with the locking tabs on one blank cut from the edge of the adjacent blank, thereby reducing the overall blank size and amount of waste material and thus reducing cost.  
         [0023]     The blank size for the various forms of the box of the invention is 2% to 15% smaller than the blank size of conventional boxes.  
         [0024]     Because the box of the invention can be folded from its blank with the pizza in place, it enables the worker to place the pizza directly on the box after baking. This eliminates the extra steps of placing the pizza on the counter or cutting surface and re-scooping the cut pizza to place it into a pre-erected box. In other words, the pizza can be placed directly onto the flat blank for cutting, followed by folding of the box. This reduces the amount of labor and increases the speed of packaging the pizza. It also reduces heat loss and possible contamination that occurs when the pizza is placed on a separate cutting surface.  
         [0025]     The box of the invention is also more convenient to use by consumers, since the full size top panel found on conventional boxes has been split in half, making it easier to gain access to and serve pizza from the box. Additionally, in the serving form the box lies flat and this aids in the folding of the box for disposal. Conventional pizza boxes must be broken down for disposal. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0026]     The foregoing, as well as other objects and advantages of the invention, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like reference characters designate like parts throughout the several views, and wherein:  
         [0027]      FIG. 1  is a top perspective view of a first embodiment of the pizza box according to the invention.  
         [0028]      FIG. 2  is a top plan view of a blank for making the box of  FIG. 1 .  
         [0029]      FIG. 3  is a top perspective view of the box of  FIG. 1 , shown with the lid panels open.  
         [0030]      FIG. 4  is a top perspective view of a plurality of the boxes of  FIG. 1  in stacked relationship.  
         [0031]      FIG. 5  is a top perspective view of a second embodiment of the box of the invention.  
         [0032]      FIG. 6  is a top perspective view of the box of  FIG. 5 , with one of the lid panels open.  
         [0033]      FIG. 7  is a top plan view of a blank for making the box of  FIG. 5 .  
         [0034]      FIG. 8  is a top perspective view of a plurality of the boxes of  FIG. 5  in stacked relationship.  
         [0035]      FIG. 9  is a top perspective view of a third embodiment of the box of the invention.  
         [0036]      FIG. 10  is a top perspective view of the box of  FIG. 9  with one lid panel open.  
         [0037]      FIG. 11  is a top plan view of a blank for making the box of  FIG. 9 .  
         [0038]      FIG. 12  is a top plan view of a pair of the blanks of  FIG. 11 , depicting how plural blanks can be cut on a multiple out die to achieve a saving in material.  
         [0039]      FIG. 13  is a top perspective view of a fourth embodiment of the box of the invention.  
         [0040]      FIG. 14  is a top perspective view of the box of  FIG. 13 , showing the lid panels in partially closed position and depicting how the notched end flaps on the lid panels interengage with the notched end walls.  
         [0041]      FIG. 15  is a top plan view of a blank for making the box of  FIG. 14 .  
         [0042]      FIG. 16  is a top plan view of an alternate blank for making the box of  FIG. 14 , wherein the side walls of a box erected from the blank are inwardly inclined. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0043]     The first embodiment of the box of the invention is indicated at  10  in  FIGS. 1-4 . This box comprises a bottom wall  11  with opposed end walls  12  and  13  foldably connected to opposite ends thereof, opposed side walls  14  and  15  foldably connected to opposite sides thereof, and partial lid panels  16  and  17  foldably connected to the respective side walls.  
         [0044]     Locking tabs  18 ,  19  and  20 ,  21  project laterally outwardly from respective opposite side edges of each lid panel, and have outwardly divergent opposite side edges  22  and a rounded outer end  23 . A pair of spaced apart, parallel cuts  24  and  25  extend a short distance into the respective lid panels from approximately the center of each locking tab, perpendicular to the side edges of the lid panels, and a transverse cut  26  connects the cuts  24  and  25  at their outer ends, forming a short bendable tab  27  lying in the plane of the respective lid panel at each locking tab, with the free end of the tabs spaced slightly outwardly of the associated lid panel side edge.  
         [0045]     Raised projections  28  and  29  extend upwardly from the top edge of each end wall  12  and  13  in positions to be in aligned registry with the locking tabs when the lid panels are in closed position. Shaped slots  30  and  31  are formed through the projections approximately in line with the height of the top edge of the respective end wall, and a short latching tab  32  projects downwardly from the top center of each slot.  
         [0046]     The free outer edge of each lid panel is stepped or offset at its center, defining a wider leading edge  33  and a recessed edge  34 , said edges being connected by an angled shoulder  35 .  
         [0047]     To erect the box of  FIG. 1 , the opposite side walls  13  and  14  are first folded upwardly, followed by inward folding of the lid panels and interengagement of the angled shoulders  35 , whereby the leading edge of one lid panel overlaps the recessed edge of the other. This holds the lid panels in place until the end walls can be erected, and serves to reinforce the lid against collapse when a force is applied on top of it. The end walls  11  and  12  are then folded upwardly, with the locking tabs  18 ,  19  and  20 ,  21  being inserted through the slots  30  and  31 . As the tabs  18 ,  19  and  20 ,  21  are being inserted through the slots, the latching tabs  32  slide along the top of the bendable tabs  27 , causing them to flex downwardly until the latching tab passes the free end of the bendable tab, at which time the bendable tab springs back up, latching behind the latching tab  32 . This arrangement securely holds the box in its erected position until it is desired to open it, at which time slight downward pressure can be exerted on top of the lid panels just behind the projections  28  and  29 , thereby releasing the latching tabs and enabling the end walls  13  and  14  to be folded downwardly and the lid panels opened.  
         [0048]     The overlapped and interlocked free outer edges of the lid panels, and the secure engagement of the locking tabs in the slots formed in the end walls results in increased strength and resistance to collapse of the lid when a force is exerted on it.  
         [0049]     It will be noted that the opposite side edges  35  and  36  of the end walls are upwardly convergent or angled inwardly. Thus, the side walls will be inwardly inclined when are folded upwardly against these angled edges. This arrangement permits less material to be used in the construction of the box and also more closely constrains the pizza or other product placed in the box.  
         [0050]     Additionally, the opposite end edges  37  and  38  of the side walls are slightly outwardly divergent or outwardly angled, whereby the end walls are outwardly inclined and the top of the box has a slightly greater length dimension than the bottom, enabling the bottom of an upper box to fit between the projections  28  and  29  of a lower box so that the boxes can be more stably stacked than conventional boxes.  
         [0051]     Further, it will be noted that the projections  28  and  29  and the associated slots  30  and  31  on one end wall are offset relative to the projections and slots on the opposite end wall. Similarly, the locking tabs  18 ,  19  and  20 ,  21  on the respective lid panels are correspondingly offset. Thus, in the manufacture of the blank, the locking tabs on one blank can be cut from the edge of an adjacent blank, as depicted with a different blank in  FIG. 12 , resulting in a saving in material.  
         [0052]     The second embodiment of the box of the invention is indicated at  40  in  FIGS. 5-8 . In this embodiment, the lid panels  41  and  42  are wider than the bottom wall  43 , whereby the lid panels slightly overhang the end walls  44  and  45  in an erected box. In addition, the locking tabs  46 ,  47  and  48 ,  49  project upwardly from the upper edge of the end walls, and the slots  50  and  51  for receiving the locking tabs are formed in the outer end edges of the lid panels. The free outer edges  52  of the lid panels are straight, rather than offset as in the first embodiment, and when the lid panels are in closed position the free edges of the lid panels overlap one another. In this form of the invention the opposite side edges  53  and  54  of the lid panels are supported on top of the end walls, lending further strength to the construction. In all other respects, with the exception of the omission of the cuts  24 ,  25  and  26 , bendable tabs  27 , and latching tabs  32 , this form of the invention is the same as the previously described embodiment, e.g., the opposite side walls  55  and  56  are inwardly inclined due to the convergent side edges  57  and  58  on opposite side edges of the end walls, and the distance between the upwardly projecting locking tabs  46 ,  47  and  48 ,  49 , respectively, is greater than the width of the bottom so that the bottom of an upper box can fit between the locking tabs of a lower box. Also, the end walls are slightly outwardly inclined due to the placement of the slots  50  and  51  near the outer edges of the extended lid panels.  
         [0053]     The third embodiment of the invention is indicated generally at  60  in  FIGS. 9-12 . This form of the invention is virtually identical to the second embodiment described above, except that one of the locking tabs and its associated slot is omitted from each end of the box. Thus, there is only one latching tab  61  and associated slot  62  associated with each lid panel, with the locking tab and associated slot for the respective lid panels being located on opposite ends of the box and on opposite sides of the box centerline. As in the previous embodiment, when the lid panels are in their closed position the free outer edges of the lid panels overlap one another. This double thickness along the centerline of the box effectively forms a beam that reinforces the lid against collapse when pressure is applied on it.  
         [0054]     As seen in  FIG. 12 , multiple blanks  60 A,  60 B,  60 C and  60 D can be produced on a multiple out die, with the tabs  61  on one blank being cut from the edge of an adjacent blank, forming a void or recess  62  which can aid in ventilating the box.  
         [0055]     The fourth embodiment of the invention is indicated at  70  in  FIGS. 13-15 . In this form of the invention the locking tabs and associated slots are omitted, and instead, flaps  71  and  72  extend downwardly from opposite ends of each lid panel  73  and  74 , and generally V-shaped notches  75  in the lower edges of the flaps engage with similar V-shaped notches  76  in the upper edge of the end walls  77  and  78  to frictionally hold the lid panels closed. The notches  75  are located nearer to the free outer edge of the respective lid panels, defining a relatively long flap  79  adjacent the hinged edge of the lid panel, and a relatively short flap  80  adjacent its free outer edge. In use, the long flaps  79  extend downwardly against the outer surface of the associated end wall, and the short flaps  80  extend downwardly against the inner surface of the end wall. The free outer edges of the lid panels extend slightly beyond the short flap, defining a narrow lip or overhang  81  that overlaps with the corresponding edge on the other lid panel when the lid panels are closed. This also results in setting the short flap slightly back from the free outer edge of the lid panel, whereby when the lid panels are in their closed position there is no interference between the flap and the confronting edge of the opposite lid panel.  
         [0056]      FIG. 16  depicts a blank  90  for making a box substantially the same as that shown in  FIGS. 13-15 , except that the opposite side edges  91  and  92  of the end walls  93  and  94  are upwardly convergent, and the end edge  96  of the longer flaps  97  on the lid panels  98  and  99  is angled parallel to the respective edge  91 ,  92 . Thus, in a box (not shown) erected from this blank, the opposite side walls  100  and  101  are inwardly inclined, and the edge  96  of the flaps  97  conforms to the shape of the lower corners of the ends of the box.  
         [0057]     A box embodying the present invention is formed from a blank typically constructed of corrugated paperboard but may otherwise be fabricated of other suitable foldable materials. The intended use for this carton is for the retention, storage and serving of pizza. However, it should be understood that the invention is not restricted in use and may have broader applications for containment of other articles.  
         [0058]     In use, an article such as a pizza taken directly from an oven, is positioned and cut upon the bottom panel of the box while the box remains flat on a supporting surface. The flat orientation of the box facilitates cutting of the pizza without damage to or interference from its end and side walls, it being understood that the bottom panel and box are sized to accommodate the pizza. Once the box has been closed around the pizza, it is ready for delivery to or pick up by a customer. The box can be used by the customer to serve the pizza, either by opening both lid panels, or by opening a single lid panel, or by laying the box completely flat.  
         [0059]     The lid panels interlock with the end walls and overlap one another to reinforce each other and provide strength to the top of the box. It should be appreciated that when boxing hot pizza, it is important to let moisture escape from the box to prevent a soggy product. While some moisture is released by the seams or gaps between the inside surfaces of the walls and the lateral edges of the lid panels, the lower portions of the tab-receiving openings are sized and shaped to further allow for venting of the moisture. With this design, the box is able to retain sufficient heat to keep the pizza at a desirable temperature while preventing condensation from forming thereon.  
         [0060]     From the foregoing, it should be understood that the preferred use of the blank facilitates a highly efficient and economic food packaging operation in comparison with prior art pizza packaging. Use of the present invention eliminates the prior art handling steps of pre-erecting a box, stacking multiple pre-erected boxes on a shelf, removing a pre-erected box from the shelf, opening the pre-erected box, placing the pizza on a counter surface for cutting after removing it from the oven, moving the cut pizza (which may have since cooled) to the open box and then re-closing the box. In addition, loading the pizza directly from the oven reduces labor costs, speed packaging, and prevents potential contamination of the pizza from the counter surface.  
         [0061]     While the invention has been described with reference to preferred embodiments, those skilled in the art will appreciate that certain substitutions, alterations and omissions may be made without departing from the spirit thereof. Accordingly, the foregoing description is meant to be exemplary only and should not be deemed limitative on the scope of the invention set forth in the following claims.