The present invention relates to the container industry. More particularly, it is well suited for use as a food take-out and delivery article. For example, it is ideal as a pizza take-out or delivery article. Pizza take-out and delivery is a multi-billion dollar industry. The growth of the business has kept pace with the development of suitable containers for carrying the pizza.
The modem pizza take-out or delivery article such as that used by the large retail chain stores is, in many ways, the ideal take-out or delivery system. In order to be an ideal system, the boxes must possess a combination of traits. The boxes must keep the pizza warm, be sturdy enough to with stand the delivery process, and bye inexpensive to manufacture. Boxes known in the art achieve each of these characteristics. One example is that disclosed in U.S. patent #5,702,054.
Although boxes found in the art are nearly ideal take-out/ delivery vehicles for getting the product to the customer, none successfully address post delivery customer needs. More specifically, most containers found in art present a disposal problem. Pizza boxes are typically larger than indoor household trash receptacles. In order to dispose of the box, customers must crush or tear the box in order to reduce its size so that it may easily fit into a household trash receptacle. Additionally, the box is typically too large to easily fit into the household refrigerator for storing leftover pizza.
The subject of several patents is the improvement of the typical pizza box to help alleviate these shortcomings. For example,
Other patents address both ease of disposal and the need to have a box that can accommodate multiple volumes. U.S. Patent #5,071,062 discloses a box incorporating perforated score lines so that the top portion may be ripped off while the bottom portion of the box is retained and folded into a second enclosed box structure for the storage of left over pizza. U.S. Patent #6,375,066 discloses a how design incorporating transverse perforation lines through the lid and bottom portions of the box and an additional fold line which together facilitate breaking the box in two and folding the open end shut for use as a secondary storage container. U.S. Patent #7,051,919 discloses a box incorporating perforations and score lines, which facilitate the removal of multiple pieces of the original box and the folding of the remainder of the box into a tapered box structure for the storage of leftover pizza. However, each of these designs utilizes extensive perforations and score lines that weaken certain areas of the box structure to facilitate removal of portions and subsequent folding. Further, each are complex and difficult for the consumer to master. Because these perforations and score lines are present during the delivery process, these box designs are structurally weaker than the typical pizza box used in the art that does not incorporate such means. Additionally, none of the pizza boxes that are disclosed in the foregoing patents are designed to hold an entire half pizza for storage of leftovers
The present invention overcomes the shortcomings of the prior art and provides an easily disposable box that may also be used as a storage container for holding leftovers. The present invention most preferably utilizes a pull-tab cord design as the primary means of weakening the box structure for disposal (herein generally also referred to a divisional means) that facilitates separating the overall box into two portions. However, perforations may be used as a substitute for the pull-tab cord. Further, perforations may be used in addition and in conjunction with the pull-tab cord in order to facilitate cleaner edges when the box is tom apart and or to reduce the effort required to tear the box in two. Depending upon the exact placement of the pull-tab cord, the halves may or may not be equal in size. Further, the resulting open ends of one or both of the resulting halves may incorporate a small number of preformed score lines and or perforations that facilitate folding the open end shut, thereby forming a second closed box structure. In a preferred embodiment of the present invention, one portion of the split box is sized so that when the open end is folded shut, the closed box is essentially half the volume of the original box. By most preferably utilizing a destructive pull-tab cord design instead of extensive preformed perforations as the primary means of weakening the box structure for disposal, the structural integrity of the box is not significantly weakened as compared to the typical box until the customer chooses to pull the tab in order to dispose of the box or store leftovers.
The most preferable embodiment of the present invention utilizes, as divisional means, a pull-tab connected to a cord running against or within the box so that when the consumer pulls it, the cord cuts or tears the box material similar to that found in the art and used to open some mailing containers. This weakens the structure of the box so that the box may easily be separated into two pieces. However, a row of perforations may be utilized as divisional means instead of the pull-tab cord means. The pull-tab allows the consumer to get a secure grip on the cord in order to pull it. In the preferred embodiment, the pull-tab is defined by perforations of the box adjacent to the sides of the cord and or at one end of the cord, but in other embodiments may include an additional piece of material attached to the cord for the consumer to grip. The cord may be made using any material of sufficient strength to tear the box material when pulled. Typically, the cord is made of a plastic polymer material. In one preferred embodiment of the present invention, the cord is made of polyethylene. In another preferred embodiment of the present invention, the cord is made of a woven fibrous material. Several tear tape products are available on the marker and some of these are suitable for use in this box structure. The box may be constructed of any material of sufficient strength for use as a container that may be cut or form by the cord material. In the Preferred embodiment, the box is made of a corrugated paper cardboard material. in yet another embodiment, the corrugated paper material is coated with a water repellant substance such as a wax or a plastic coating found in the art in order to maintain the freshness of the leftovers.
In order to function properly, the cord must be security attached to the box material. In one embodiment, polymer glue is used to attach the cord to the box, but any means of sufficient strength known in the art may be used to attach the cord to the box. In one particular embodiment, the cord is attached to the inner surface of the box. In another particular embodiment, the cord is attached to the outside surface of the box. In another particular embodiment, the cord is inserted within the box material. In embodiments wherein the box is constructed of corrugated material, the cord may run either parallel or perpendicular to the direction of corrugations. In yet another embodiment, the cord may comprise multiple layers, and be attached to both the inner and outer surface of the box. In yet another embodiment, the cord may comprise multiple layers, and be attached to both the inner surface of the box and be inserted within the box material. In yet another embodiment, the cord may comprise multiple layers, and be attached to both the outer surface of the box and be inserted within the box material.
Perforations may be added along either or both sides of the cord in order to reduce the effort required to rip the box or to help generate smoother edges along the rip. Further, perforations may be utilized without the cord, either singly or in multiple rows.
The Lines of Perforation may be comprised of any perforation found in the art. In one particular embodiment, the Lines of Perforation are comprised of elongated perforations situated at an angle between zero and ninety-degrees in relation to the Cord. In the most preferred embodiment, the Lines of Perforation are comprised of perforations that include two elongated cuts situated at essentially ninety-degrees to one another, and connected to one another in order to essentially generate a single perforation. In yet another particular embodiment of the present invention, a pair of parallel Lines of Perforation is utilized without the Cord. This embodiment is particularly desirable if the material composing the box has sufficient strength for the strip between the Lines of Perforation to be tom out with minimal breakage.
In a preferred embodiment of the present invention, the open end of at least one of the portions of the reduced first box structure includes additional score lines and of perforations as means for facilitating closure of the open end, generating the second box. In general removable sections and closing tabs are arranged so as to imitate the intact, original box wall structure when possible. This facilitates formation of a second box that is very strong and opens and closes well Further, this design is more intuitive for the consumer to use because the intact, original box wall structure can be used as a guide for the proper assembly of the second box. Several embodiments of the present invention utilizing closing means, which particularty point out the features of such means, are illustrated in the Best Mode portion of this application.
In summary, the present invention provides for a sturdy delivery vehicle that incorporates means for reducing the difficulty of disposal. Further, in a preferable embodiment, the split box is designed so the end may be folded closed, generating a sturdy storage container that may be used to store leftovers. Further, in a most preferable embodiment, the splint box is designed so the end may be folded closed, generating a sturdy storage container that may be used to store a full half pizza of leftovers. Box designs incorporating the present invention are easy to use and economical to manufacture.
The present invention may best be described by example. Preferred embodiments of the present invention and two further examples are illustrated. The Best Mode is set out in Example 7. In all illustrations, a solid line represents a cut. A line with large dashes represents folds in the box structure that are most preferably but not necessarily scored using perforations or cuts. Lines denoted by small dashes represent lines that are perforated or otherwise weakened so that the consumer may tear the box material along the line. Lines denoted by small dots represent latent fold lines along which the box is folded to close the open end of the split box. These lines may be scored using perforations or indentations. Alternatively, they may be left un-scored. Lines denoted by dashes perpendicular to the length of the box represent the location of the cord.
EXAMPLE 1:
In order to easily dispose of the box or prepare the box for storing leftovers, the consumer grasps the Pull-Tab, and pulls the Cord, thereby ripping or cutting the box along the Cord line. The box may then be separated by tearing the box along the perforation parallel to and in line with the cord line in the Lower Front Wall. In an alternative embodiment, the Cord is extended, and the Pull-Tab is placed on the outer edge of the Lower Front Wall. In this alternative embodiment, a perforation parallel to and in line with the Cord line is unnecessary.
Once the box is separated into two pieces, both pieces may be disposed of directly, or alternatively, the open end of the large piece may be folded closed, forming a second sturdy container structure (Second Box). The open end is folded shut as follows. Removable Section A and Removable Section B are torn out of the box along the perforations. The Front Closing Tab and the Rear Closing Tab are folded up towards the Bottom after separating them from the Lower Front Wall and Back Wall along the perforations. The open edge of the Top is folded in along Latent Fold Line B. The open edge of the Bottom is folded in along Latent Fold Line A white in one embodiment; the Front Closing Tab is inserted between the leaves of the Lower Front Wall. In another embodiment, the Front Closing Tab is folded inward similar to the Rear Closing Tab. In yet another particular embodiment, the Front Closing Tab and Removable Section A are left connected and both are folded inwards similar to the Rear Closing Tab. In this example of a preferred embodiment of the present invention, one edge of the Front Closing Tab is angled in order to facilitate insertion between the leaves of the Lower Front Wall. Other embodiments of the present invention may feature a Front Closing Tab without such an angle.
The reduced size container may now be opened and closed as needed in a manner similar to the original full size container. When closed, the reduced size container is very sturdy and can be used to store leftovers conveniently.
EXAMPLE 2:
In addition to the features described in Example 1, this particular embodiment includes means for holding an additional item within the closed structure of the box such as dipping sauce. Separating the longitudinal edges from Lower Side Wall A and Back Bottom Tab A, then folding in towards the center of the Bottom of the box construct the Sauce Retainer. The additional container can then be placed into the corner of the box and secured by the Sauce Retainer.
EXAMPLE 3:
In order to easily dispose of the box or prepare the box for storing leftovers, the consumer grasps the Pull-Tab, and pulls the Cord, thereby ripping or cutting the box along the Cord line. The box is then easily separated into two pieces.
Once the box is separated into two pieces, both pieces may be disposed of directly, or alternatively, the open end of the large piece may be folded closed, forming a second sturdy container structure. The open end is folded shut as follows. The Removable Section is tom out along the perforations and removed from the box structure. The Front Closing Tab and the Rear Closing Tab are folded up towards the Top into an angle of essentially ninety degrees after separating them from the Upper Front Wall and Back Wall along the perforations. The open edge of the Bottom is folded in along the Lower Latent Fold Line towards the Bottom into an angle of essentially ninety degrees. The open edge of the Top is folded in along Latent Fold Line A folding along with it the Front Closing Tab and the Rear Closing Tab. The reduced size container may now be opened and closed as needed in a manner similar to the original full size container. When closed, the reduced size container is very sturdy and can be used to store leftovers conveniently.
EXAMPLE 4:
In addition to the features described in Example 1, in this particular embodiment the cord runs through the length of the box, which may simplify the manufacturing process. Further, in this particular embodiment, once the cord is pulled completely, the first box structure is torn completely in half, which eliminates the additional row of perforations parallel to and at the end of the Cord and the need to tear them. In the most preferable embodiment of this example, perforations are utilized beside the cord on the Lower Front Wall adjacent to Removable Section A in order to reduce the effort required to begin tearing the box.
EXAMPLE 5:
Once the pull-tab cord is pulled and the box is separated into two pieces, the open end of one of the pieces may be folded shut by folding the open edge of the Top down and inserting Locking Tab A into Slot A.
EXAMPLE 6:
However, in addition to the features described in Example 1, this particular embodiment utilizes perforations instead of the pull-tab cord. Therefore, in order to separate the box into two pieces, the box is torn along the Dividing Perforation.
In addition to the features described in Example 1, this particular embodiment utilizes perforations adjacent to the Cord in order to reduce the effort required to tear the box material and or facilitate a cleaner tom edge. In the most preferable embodiment, Lines of Perforation extend along both sides of the Cord along essentially the entire length of the box where no other specific type perforation is needed, as illustrated. However, in yet another embodiment, the Line of Perforation extending along the Cord adjacent to the side of the box that is not designed to be folded shut is eliminated. In yet another specific embodiment, the Line of Perforation extending along the Cord adjacent to the side of the box that is designed to be folded shut is eliminated. Further, this particular embodiment utilizes an Opening Hole for finger access in order to facilitate opening the closed box structure. Further, in this particular embodiment, a portion of the perforation across the front wall adjacent to the Pull-Tab is eliminated. This facilitates removal of Removable Section A along only one row of the perforations across the front wall, which facilitates insertion of the Front Closing Tab between the leaves of the Lower Front Wall.
EXAMPLE 8:
EXAMPLE 9.
EXAMPLE 10:
Each of the boxes depicted in the illustrations are simply examples including preferred embodiments of the present invention. Many other specific designs are possible without departing from the scope of the present invention which is defined by the claims. The location of the Cord May be moved in order to change the size or volume of the pieces of the slit box. Means for closing the open end similar to that disclosed in the illustrations may be added to both pieces of the split box instead of only one piece. Additionally, many minor changes may be made and details added to the box structure by those skilled in the art without departing from the scope of the present invention. Examples include but are not limited to: cuts or perforations along fold lines, small tabs designed to lock folded pieces in position, changes to the angle of certain edges to facilitate folding or closing, and changes to the relative scale of the parts of the structure. Each of these changes and details are commonly added to box structures by those skilled In the art.
The present invention has several key advantages when compared to the prior art. First, the utility of the box as a delivery vehicle is not compromised by the pull-tab cord design because the structural integrity of the box is not weakened until the consumer chooses to pull the tab. Once pulled, the box is easily broken into two conveniently disposable pieces. Second, the open end of the split box may be folded shut forming a sturdy storage container. Third, the present invention achieves its utility while retaining a simple design that is easy to use and economical to manufacture.
This list of references cited by the applicant is for the reader's convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.