Patent Description:
As it is known, trays made of paper material are commercially available and consist of a flat laminar element having a plurality of perforated seats, each of which is intended to receive a corresponding paper ramekin in engagement. In detail, the ramekins made of paper are made from a flat sheet of paper material which has been deep-drawn to a three-dimensional configuration. The ramekins are inserted into the holes of the flat laminar element at an outer perimeter edge, e.g. by means of glue. Such containers, although capable of holding food products, are not free of limitations and drawbacks. In particular, the Applicant has found that some containers are made by means of complex manufacturing processes that require long production times and that produce large amounts of paper waste, both during the production of the laminar element and during the production of each of the ramekins.

A further example of a container is described in Italian patent application No.<CIT>, comprising a first laminar support in paper material arranged parallel to and in engagement with a second laminar support in paper material. Each laminar support has a top surface on which there are respective through cuts delimiting a central portion of circular shape. It has to be noted how the through notches of the first support are aligned with the through notches of the second support along a vertical axis. A rotating operation of each of the central portions of the first and second supports with respect to the top surface, determines the central portion of each support to be moved away from the respective top surface to allow the creation of a containment structure. Specifically, the containment structure is inwardly delimited by the central portion and laterally delimited by ribs defined by the paper material interposed between two adjacent through notches. It has to be noted how, due to the circular shape of the central portion, it is possible to create a three-dimensional structure following the execution of a single deformation step of the first and second laminar supports. Document <CIT> shows a similar food container.

Although such containers allow food products to be effectively housed, the Applicant has noted that this solution has limitations and drawbacks. In particular, such containers can only be made with a base portion having a circular shape, preventing the housing of food products having an oval or prismatic shape with a polygonal base.

The aim of the present invention is therefore to solve at least one of the drawbacks and/or limitations of the previous solutions.

A first objective of the present invention is to provide a container that can be manufactured with few and simple operations.

A further purpose of the present invention is to provide a container that offers the possibility of being easily transported by automatic means.

A further aim of the present invention is to provide a container with a small encumbrance in order to optimise transport volumes and costs.

It is also the purpose of the present invention to provide a container having a simple and compact structure that can be realised quickly and cheap; in particular, it is the purpose of the present invention to realise a container that does not require the substantial modification of the common equipment used today for making standard type containers.

A further purpose of the present invention is to provide a container made of paper material fully recyclable.

These purposes and others, which will appear more fully in the course of this description, are essentially achieved by a food container of the type according to the following claims.

Some embodiments of the invention will be described herein with reference to the accompanying drawings, which are provided for illustrative purposes only and are therefore not limiting:.

With reference to the enclosed figures, a container for the housing and transport of food products, in particular sweet products, has been collectively denoted by <NUM>. The container <NUM> comprises a first and a second support 2a, 2b made of paper material and presenting one or more containment structures 3a, 3b. It has to be noted how each of said supports is made separately and subsequently coupled. The first and second supports 2a, 2b are structurally identical to each other; in the following, reference will therefore be made only to the first support 2a to describe the common features to the first and second supports 2a, 2b.

The first support 2a may comprise at least one (and generally a plurality) of containment structures 3a, each having a base portion 4a, a top portion 5a delimiting an opening 6a for insertion of the food product and a lateral portion 7a emerging from the base portion 4a and connecting to the top portion 5a.

The containment structure 3a is made in one piece from the same sheet of paper material, i.e. the base portion 4a, the top portion 5a and the side portion 7a are made of piece and joined seamlessly. From the point of view of making, the support structure 3a is made by deformation starting from a sheet of flat paper material of the type shown in <FIG>. In particular, <FIG> shows the first support 2a die-cut from a semi-finished product made unrolled, for example, from a roll of paper material on which one or more through notches 12a are defined. The notches 12a develop from a peripheral zone towards a central zone of the sheet of flat paper material around a central zone to define the base portion 4a of the support structure 3a.

The curvilinear through notches 12a are adjacent to each other, distinct and spaced apart, each presenting a clockwise or counterclockwise course about an axis <NUM> orthogonal to the first support 2a. Each passing notch extends along a substantially curved trajectory presenting concavity facing the respective base portion 4a. In particular, each through notch 12a extends in interposition between an attachment end 12a' defined at the periphery of the first support 2a and a base end 12a" defined at the base portion 4a. The extension of the through-notches 12a defines a length of ribs 8a, the latter subsequently detailed.

It has further to be noted how the through notches 12a are spaced apart by a variable amount proceeding from the attachment end 12a' of the first support 2a approaching the base end 12a'. In other words, the distance between two adjacent through-slots 12a is a minimum of between <NUM> and <NUM>, optionally between <NUM> and <NUM>. More specifically, the ratio of the minimum distance between two adjacent through notches 12a at the coupling end 12a' to the minimum distance between two adjacent through slots at the base end 12a" is between <NUM> and <NUM>, optionally between <NUM> and <NUM>.

It has further to be noted how the through notches 12a delimit the perimeter of the base portion 4a and define a surface extension of the latter; in fact, as for example shown in <FIG>, the base portion is inscribed by the through notches 12a. The through notches further define a shape of the base portion 4a, which may be curvilinear or polygonal.

The base portion 4a may have an elongated shape extending along a predetermined direction of development Y (e.g. a shape symmetrical with respect to said axis of development Y). In detail, a portion of the base 4a having an oval shape has been shown in the accompanying figures; however, the possibility of making through notches 12a in such a way as to make a portion of the base 4a having a rectangular, square, regular polygon or star shape is not excluded. As a matter of fact, further embodiments of the invention shown in <FIG>, respectively present base portions 4a having a square, rectangular and star shape. In particular, respective first supports 2a having a single base portion 4a are shown, however, an embodiment of first supports 2a having a plurality of first base portions 4a, each of which is capable of realising a respective first containment structure 3a is not excluded. As shown in the accompanying figures, the base portion 4a is offset by an angle α with respect to a reference axis X orthogonal to the axis <NUM>, lying on an ideal plane parallel to the top surface 5a, as well as passing through the centre of the base portion 4a and parallel to a side (formerly major) of the respective support 2a, 2b. In detail, the angular offset between the development direction Y of the base portion 4a of the first support 2a and the reference axis X is between <NUM>° and <NUM>°, optionally between <NUM>° and <NUM>°, wherein said angle α is measured on the ideal plane.

Referring now to the configuration shown in <FIG> in which the first support 2a is in engagement with the second support 2b, the base portion 4a of the first support 2a is angularly offset with respect to the base portion 4b of the second support 2b, wherein said angular offset is measured in interposition between the development direction X of the base portion of the first support 2a and a respective development direction X' of the base portion of the second support 2b.

In particular, the base portions 4a, 4b, of the first and second supports 2a, 2b respectively, can be offset by an angle between <NUM>° and <NUM>°, optionally between <NUM>° and <NUM>°. In fact, the two supports 2a, 2b are superimposed asymmetrically, i.e. by tilting them one on top of the other along the smaller common side from the configuration in <FIG>. In this way, the respective base portions 4a, 4b are not perfectly overlapped, but are offset from each other by twice the angle between the previously mentioned X and Y axes (see also <FIG>).

The first and second supports 2a, 2b are further movable at least between a first and a second operative position. In particular, in the first operative position, the base portions of the first and second supports 2a, 2b respectively lie substantially parallel to the respective top portion 5a, 5b, defining a configuration of minimum vertical container size (equal to the thickness of the two sheets). In this operative position, the base portion 4a of the first support is at least partially superimposed on the base portion 4b of the second support 2b, defining an superimposition area <NUM>. In other words, the base portion 4a of the first support 2a does not correspond with the base portion 4b of the second support 2b. The base portion 4a of the first support 2a is only partially superimposed on the base portion 4b of the second support 2b: the superimposition area has a smaller surface area than the surface area of the base portion of the first or second support 2a, 2b. In the specific example, the two ovoid portions are respectively inclined by the angle α with respect to the straight sides of the respective supports. A first ovoid base portion will be inclined by an angle α, the other by an angle of -a.

In the second operative position, the base portions of the first and second supports 2a, 2b, respectively, emerge in moving away from the respective top portion, defining a vertical size configuration greater than the minimum vertical size configuration. In the second operative position, the surface extension of the superimposition area is substantially equal to the surface extension of the base portion of the first or second support 2a, 2b. In fact, the base portions of the first and second support 2a, 2b are completely superimposed. In fact, the first base portion 4a will undergo in the movement a partial rotation of an angle -a, while the first base portion 4b will undergo in the movement a partial rotation of an angle +a: the two opposing rotations will lead the two base portions to coincide, i.e. to have their own superimposed axis of symmetry Y.

During the transition of the first and second support 2a, 2b from the first to the second operative position, it is possible to switch from a flat sheet to the three-dimensional structure of the containment structure while maintaining the integrity of the support and without the need for separation and recoupling of the parts. The containment structure is therefore in one piece and is derived from a flat paper/board sheet.

In the second operative position of the first and second supports 2a, 2b, the base portion 4a is spaced with respect to the top portion 5a by a predetermined depth measured along the axis <NUM> and proportional to the extent of the through slots 12a. In other words, the ratio of the extension of each through notch <NUM> along the predetermined trajectory to the depth of the base portion 4a is between <NUM> and <NUM>, optionally between <NUM> and <NUM>.

The movement of the first support 2a from the first to the second operative position involves the arrangement of the material interposed between the through-slots 12a of the first support 2a in a three-dimensional configuration to define ribs 8a that are distinct and spaced apart.

Specifically, the ribs 8a lie on an ideal curved surface defining the lateral portion 7a, each extending in interposition between the top surface and the base portion 4a and spaced apart from each other by through openings. Each rib 8a also has a predetermined variable angular extension proceeding from the top portion 5a approaching the base portion 4a, between <NUM>° and <NUM>°, optionally between <NUM>° and <NUM>°.

In particular, as for example visible from <FIG> and <FIG>, each rib 8a has a variable angular extension progressively proceeding from the top portion to the base portion 4a along a direction parallel to the axis <NUM>. In other words, the ratio between the angular extension of each rib 8a at the top portion and the angular extension of the same rib 8a at the base portion 4a is between <NUM> and <NUM>, optionally between <NUM> and <NUM>.

As shown in <FIG>, the containment structure of the first support 2a is housed within the containment structure of the second support 2b, wherein the base portion 4a of the first support 2a is engaged, optionally exclusively in contact or proximity, with the base portion 4b of the second support 2b, wherein the ribs 8a of the first support 2a are superimposed on the ribs 8b of the second support 2b. In fact, the ribs 8a of the first support 2a are directed along an opposite winding direction from the ribs 8b of the second support 2b.

In other words, the ribs 8a of the first support and the ribs 8b of the second support 2b have an inclined course from the respective top portion to the respective base portion to define a lattice structure (see, for example, <FIG>).

It should also to be noted that the support and rigidity of the container is entirely dependent on the support and containment structures of the first and second support 2a, 2b, in this regard, the material constituting support <NUM> may be an appropriate cardboard, in particular with a grammage between <NUM> and <NUM> grams per m<NUM>.

Further, the first and second supports have their respective surfaces covered with a layer of plastic material, in particular, the surfaces of the first and second supports in contact with each other and at which they are engaged. As will be better described below, this layer of plastic material, allows the engagement between the first and second supports2a, 2b, and in particular of the bottom portions 4a, 4b, by means of heat-sealing.

It is also an object of the present invention to provide a method for making a container <NUM> for food products in accordance with the above description and/or in accordance with any one of the appended claims.

The method involves the steps of preparing a first and a second support 2a, 2b made from a single sheet of paper material performed on a single continuous sheet or on a pre-cut discrete sheet (<FIG>).

The method may thus provide for the superimposition of the first support 2a to the second support 2b, making it possible to realise the container in line with the first and second supports at least partially engaged with each other. In fact, as shown in <FIG>, when the first and second support 2a, 2b are superimposed, the notches 12a and 12b with opposing (clockwise/counter-clockwise) trends are partially superimposed one above the other at the superimposition area <NUM>, with the bottom portion 4b of the second portion 2b misaligned from the bottom portion 2a of the first support.

The method may comprise distinct deformation steps of the first and second supports to define respective containment structures 3a, 3b. In other words, the respective deformation steps comprise arranging the material interposed between the respective through notches 12a, 12b of the first and second supports 2a, 2b in a three-dimensional configuration to define the ribs 8a, 8b.

It has further to be noted how the deformation step of the first support is only partially executed at the same time as the deformation step of the second support 2b. In fact, the execution of the deformation step of the second support 2b, at least partially precedes the deformation step of the first support 2a, the execution of which is partially delayed.

In detail, the deformation step of the second support 2b includes the sub step of:.

The substep of rotating the base portion 4b of the second support 2b is executed simultaneously with the substep of pulling the same base portion 4b of the second support 2b. In fact, the mechanical organ in engagement with the base portion 4b simultaneously translates and rotates the same base portion 4b with respect to the axis <NUM>.

Claim 1:
Method for making a container for food products comprising the following steps:
- providing a first support (2a) made of flat paper sheet material comprising a predetermined number of through notches (12a) extended starting from a peripheral zone of the first support (2a) approaching a central zone of the same first support (2a) to define a base portion (4a) having a predetermined surface extension delimited by the through notches (12a),
- providing a second support (2b) made of flat paper sheet material comprising a predetermined number of through notches (12b) extended starting from a peripheral zone of the second support (2b) approaching a central zone of the paper sheet to define a base portion (4b) having a predetermined surface extension delimited by the through notches (12b),
- arranging the first support (2a) parallel to the second support (2b) and at least partly in contact with the latter in a manner such that the base portion (4a) of the first support (2a) is at least partly superimposed on the base portion (4b) of the second support (2b), defining a superimposition area having a surface size smaller than the surface extension of the base portion of the first or of the second support (2a, 2b),
- deforming the first support (2a) at the curvilinear through notches (12a) in order to define at least one three-dimensional containment structure (3a) having a top portion (5a) delimiting an insertion opening (6a) and a lateral portion (7a) which emerges from the base portion (4a) of the first support (2a) and is connected to the top portion (5a),
- deforming the second support (2b) at the curvilinear through notches (12b) in order to define at least one three-dimensional containment structure (3b) having a top portion (5b) delimiting an insertion opening (6b) and a lateral portion (7b) which emerges from the base portion (4b) of the second support (2b) and is connected to the top portion (5b),
wherein following the steps of deforming the first and the second support (2a, 2b), the surface size of the superimposition area is substantially equal to the surface extension of the base portion of the first or of the second support (2a, 2b).