Note: Descriptions are shown in the official language in which they were submitted.
CA 02308558 2000-OS-16
CASE 20322
PACKAGING SYSTEM FOR MEAL KIT
Field of the Invention
S The present invention relates generally to a packaging system for a meal kit
that
includes multiple, ready to eat food items and a beverage. In particular, the
invention relates
to a container that includes an outer carton and a removable inner Garner
tray. The invention
also relates to a method of assembling and packaging the food items and
beverage container
of the meal kit.
Background of the Invention
Pre-packaged meal kits which include multiple food items that require a
minimal
amount of consumer preparation and allow for quick assembly of the food items
have become
increasingly popular. Generally, a meal kit contains various ready to eat food
items to
provide an essentially complete meal. Typical food items include farinaceous
food products,
meat products, cheese, sauces or dips, and dessert items.
The food items may be individually pre-packaged in film wrap, pouches or
containers
having removable lids. The consistency of certain of these food items is more
delicate such
that the food items may be easily crushed, crumbled or otherwise deformed. For
example,
chips may crumble into smaller pieces and breadsticks may be deformed by a
heavy item
placed on it. It is desirable to arrange the multiple, pre-packaged food items
in a container in
such a way as to limit movement of the food items during shipping and handling
to prevent
damage to the food items and improve the visual presentation of the meal kit.
It is known to
contain the food items in a main tray made of plastic, or other rigid
material, and having one
or more compartments. Such main trays provide a compact container for the
various food
items.
To provide a more complete and convenient meal kit, it is desirable to include
a
beverage with the food items. Packaging the beverage container, which may be
larger and
heavier than many or all of the food items, in the meal kit may be a problem.
If the food
items and beverage container are not contained in generally stable positions,
the beverage
container may damage the food items and may obstruct a consumer's view of the
food items
in the meal kit container. Thus, it is desirable to isolate the beverage
container from the food
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items. Because of the larger size of the beverage container, it may not be
feasible or
economical, however, to provide a container having a separate compartment for
the beverage
container.
Moreover, certain food items, such as pizza crusts, breadsticks and nacho
chips, also
S present packaging problems. These food items may be pre-packaged in larger-
sized packages
that are essentially as long and/or as wide as the meal kit container itself.
As a result, it may
be difficult, if not impossible, to utilize a mufti-compartment container with
such food items
and still maintain the desired compact size of the container and overall meal
kit.
There remains a need for a compact, compartmentalized packaging system for use
with a meal kit that includes multiple, pre-packaged food items and a beverage
container.
Summary of the Invention
In accordance with the invention, there is provided a packaging system for a
meal kit
that includes multiple, prepackaged food items and a beverage container. The
packaging
system generally comprises an outer container and an inner, carrier tray
having a single
compartment and disposed within the outer container. One or more ready to eat
food items
are disposed in the inner carrier tray. These food items are arranged in one
or more layers. A
beverage container also is disposed within the outer container adjacent the
inner carrier tray
between a side wall of the inner carrier tray and an opposing side wall of the
outer carton.
The inner carrier tray mechanically isolates the food items from the beverage
container when
assembled within the outer container.
The outer container comprises generally upstanding front, back and first and
second
side walls, and the inner carrier tray comprises generally upstanding front
and back walls and
generally upstanding first and second side walls. The walls of the inner
carrier tray may
extend outwardly at an angle. The bottom wall of the carrier tray is generally
planar and may
include one or more cut outs for receiving food items. The carrier tray also
may include legs
or tabs extending downwardly from the bottom wall. The front wall, side wall
and first side
wall of the inner tray engagably contact the front, back and first side wall
of the outer
container to limit lateral movement of the inner carrier tray within the outer
carton. The outer
container further comprises a lid having at least one opening cut from the
lid. The inner tray
maintains the position of the food items and the beverage container relative
to the openings in
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the lid to allow a consumer to view the food items and beverage container when
the lid is in a
closed position and the outer carton is sealed closed.
The invention further relates to a method of assembling a meal kit of ready to
eat food
and beverage items comprising individually packaging two or more ready to eat
food items,
assembling the food items in a carrier tray by arranging the food items in one
or more layers
within the carrier tray, providing an outer container having a lid, assembling
a beverage
container within the outer container, assembling the carrier tray with food
items adjacent the
beverage container, where the beverage container is disposed between and
engagably
contacting a wall of the carrier tray and an opposing wall of the outer
container, and sealing
the lid of the outer container.
Brief Description of the Drawings
FIG. 1 is a perspective view of a container embodying the invention, with the
lid of
the outer carton open to show a carrier tray located within the outer carton;
FIG.2 is a perspective view of a meal kit in which food and beverage items are
assembled within the container of FIG.1;
FIG. 3 is an exploded perspective view of the meal kit of FIG. 2;
FIG. 4 is a front elevational view of the meal kit of FIG. 2 with the front
wall of the
outer carton and the front wall of the carrier tray removed to show the
contents of the meal
kit;
FIG. 5 is a top plan view of a blank from which the carrier tray of FIG. 1 may
be
formed;
FIG. 6 is a top plan view of a blank for forming a carrier tray in accordance
with a
second embodiment of the invention;
FIG. 7 is a top plan view of a blank for forming a carrier tray in accordance
with a
third embodiment of the invention;
FIG. 8 is a top plan view of a blank for forming a carrier tray in accordance
with a
fourth embodiment of the invention; and
FIG. 9 is a top plan view of a blank for forming a carrier tray in accordance
with a
fifth embodiment of the invention.
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Detailed Description of the Preferred Embodiment
The present invention generally is embodied in a packaging system 10 for a
meal kit
11 of ready to eat food and beverage items. In the illustrated embodiment, as
shown in FIG.
1, the packaging system 10 generally comprises an outer carton 12 and an inner
carrier tray 14
S removably disposed within the carton 12. The outer carton 12 is of a
generally rectilinear
construction and is formed of paperboard. The carton 12 has two side walls 18,
front wall 20,
back wall 22 and bottom wall 24. A lid 16 is pivotably moveable between open
and closed
positions along the intersection 25 of the lid 16 and the back wall 22.
The carrier tray 14 of generally rectilinear construction is disposed within
the interior
26 of the carton 12 and provides two separate compartments 37 and 38 in the
interior 26. As
shown also in FIGS. 3 and 4, the open-top carrier tray has a planar bottom
wall 28, side walls
30 and 32, and front and back walls 34 and 36. The dimensions of the carrier
tray are smaller
than those of the interior 26 such that when the carrier tray 14 is disposed
in the carton 12, the
two compartments 37 and 38 result. In this respect, the lengths of the side
walls 30 and 32
1 S are approximately the same as the lengths of the side walls 18 of the
outer carton 12. The
lengths of the front and back walls 34 and 36, however, are shorter than the
lengths of the
front and back walls 20 and 22 of the carton 12. The height of the walls of
the carrier tray 14
also is shorter than the height of the walls of the carton 12 to provide
clearance at the top of
the carrier tray 14 with respect to the lid 16.
As shown in FIGS. 2 and 3, the meal kit 11 generally includes at least two pre-
packaged, ready to eat food items 40, 41, 42 and 43 and a beverage container
46. The food
items may be packaged in pouches, wrapped in a film, contained in a cup having
a removable
lid or the like. The food items may include a farinaceous food, one or more
sauces or dips,
and a dessert food. Examples of farinaceous foods include bread sticks, pizza
crusts, nacho
chips and the like. Examples of sauces or dips include cheese sauce, salsa,
pizza sauce and
the like. Examples of dessert foods include candy pieces, cookies and the
like. Other pre-
packaged food items, such as shredded cheese and proteinaceous items (e.g.,
meat products),
may also be included in the meal kit. The beverage container 46 may be a can
of any chosen
beverage, such as soda, juice or other drink, a box or plastic bottle of the
chosen beverage and
the like. If desired, other components may also be included in the meal kit.
Such other
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components include, for example, utensils or other implements to assist with
assembling the
food items, spices, napkins and the like.
As also shown in FIG. 4, the carrier tray 14 rests on the bottom wall 24 of
the carton
12, as does the beverage container 46. The food items 40, 41, 42 and 43 are
disposed within
the carrier tray 14 and are arranged in layers. The beverage container 46 is
positioned
adjacent the carrier tray 14 and is nested between the side wall 32 of the
carrier tray 14 and
the side wall 18 of the carton 12. In providing two compartments 37 and 38,
the carrier tray
14 allows for separation of the food items 40, 41, 42 and 43 from the beverage
container 46
within the carton 12. By mechanically isolating the food items 40, 41, 42 and
43 from the
much heavier beverage container 46, the integrity of the food items, which
typically are
lighter and easily deformed or crumbled, may be better maintained. Shifting of
the
prepackaged food items 40, 41, 42 and 43 during shipping and handling of the
meal kit 11 is
thereby limited, as is rolling or other movement of the beverage container 46.
Significantly,
the upstanding side wall 32 of the carrier tray 14 between the food items and
the beverage
container prevents the beverage container from rolling on top of one or more
of the food
items.
Additionally, separating the food items 40, 41, 42 and 43 from the beverage
container
46 and limiting their movement in the respective compartments 37 and 38
improves the
presentation of the items contained in the meal kit 11. To allow a consumer to
view the
actual food items, the lid 16 may be provided with one or more cut outs 48.
The cut outs 48
may be of any size, shape and orientation to allow a consumer to view at least
the top layer of
food items and the beverage container through the closed lid 16 without
opening the carton
12. When the carton 12 is sealed closed, the carrier tray 14 helps to
stabilize the food items
and beverage container in position beneath cut outs 48 in the lid 16.
To provide two compartments 37 and 38 of appropriate dimensions, the carrier
tray 14
is offset to one side of the carton 12. The front and back walls 34 and 36 of
the carrier tray 14
engagably contact the front and back walls 20 and 22 of the carton 12,
respectively, to limit
transverse lateral movement of the carrier tray 14 within the carton 12.
Preferably, one side
wall 30 of the carrier tray 14 also engagbly contacts the corresponding side
wall 18 of the
carton 12. The beverage container 46 is disposed between, and engagably
contacts, the
opposite side wall 32 of the carrier tray 14 and the side wall 18 of the
carton 12. Movement
of both the carrier tray 14 and the beverage container 46 in a longitudinal
direction within the
interior 26 is limited.
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The carrier tray 14 also may be used to support and contain the food items
during
preparation and consumption. The carrier tray 14 is removed from the carton 12
upon
opening and the food items removed from the carrier tray 14. The food items
may be
assembled and prepared in the carrier tray 14 and may even be heated in a
microwave in the
carrier tray 14, if desired. The carrier tray 14 also serves as a container
from which the food
may be directly consumed. For example, in a pizza meal kit, the pizza crust is
placed in the
tray and the pizza sauce, cheese and other pizza ingredients are assembled on
top of the crust.
As another example, in a nachos meal kit, the chips are emptied into the
carrier tray 14 and
the cheese sauce is poured over the chips. In either example, the food may be
heated in the
carrier tray 14 using a microwave.
Referring now also to FIG. 5, the carrier tray 14 may be formed from single,
unitary
paperboard blank 49. To erect the carrier tray 14 from the blank 49, side wall
tabs 50 are
folded upwardly along fold lines 52. The side walls 30 and 32 are then folded
upwardly
along fold lines 54. Next, the front and back walls 34 and 36 are folded
upwardly along fold
lines 56. Finally, the side wall tabs 50 are secured with adhesive or the like
to the interior
surface 58 of the front and back walls 34 and 36. This assembly provides a
carrier tray 14
formed of a contiguous surface that will contain the food items, particularly
sauces and dips,
when the carrier tray 14 is utilized for preparation and eating of the food
items.
The side walls 30 and 32 and the front and back walls 34 and 36 of the carrier
tray 14
extend outwardly at an angle of at least about 0° to about 10°
and preferably from about 5° to
about 7° from a vertical plane. More preferably, the side walls extend
at an angle of about 7°
and the front and back walls extend at an angle of about 5°. When the
meal kit 11 is
assembled, at least a portion of the beverage container 46 preferably nests
under the
outwardly angling side wall 32. The angling of the side walls also facilitates
stacking (or
nesting) of assembled carrier trays 14 within one another during storage prior
to use in the
meal kit 11.
The blank from which the carrier tray 14 is formed preferably is comprised of
paperboard, and more preferably of solid bleach sulfate paperboard. Use of
solid bleach
sulfate paperboard for the carrier tray 14 limits odors (unpleasant or
otherwise) that may
result when the carrier tray is subjected to microwave heating. The paperboard
has a clay
coating on one surface, which, when assembled, is the interior surface of the
carrier tray 14
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The clay coating reduces absorption of moisture by the paperboard and reduces
sticking of
food items to the paperboard.
The paperboard preferably has a thickness of between about 0.016 and 0.022
inches,
and more preferably of about 0.018 inches. The paperboard has a stiffness of
at least about
160 Taber- MD or 87 Taber-CD, and more preferably at least about 200 Taber-MD
or 108
Taber-CD. The basis weight is between about 160 and about 240 pounds per 3000
square
feet.
The lid 16 of the carton 12 preferably is provided with conventional means for
retaining the lid 16 in closed position, as well as to facilitate opening. The
lid 16 also may be
provided with conventional features to permit re-closing of the lid 16. Such
means for
closing the carton 12 may include securing flaps 17 on the lid to the walls 18
and 20 of the
carton 12 with adhesive. Such means for opening may include providing a front
flap 19 by
which opening may be initiated and perforations along the lid 16 to complete
opening. A tear
strip, pull tab or the like also may be employed to facilitate opening.
Alternatively, the outer carton 12 and carrier tray 14 may be formed of other
suitable
materials such as a polymeric material or corrugated paperboard or cardboard,
such as B flute
corrugated.
The removable carrier tray 14 improves ease of assembly of the food items 40,
41, 42
and 43 and beverage container 46 in the carton 12 by allowing pre-assembly of
the food items
prior to final assembly of the meal kit 11. First, the food items 40, 41, 42
and 43 are
individually pre-packaged. The carrier tray 14 is assembled from the unitary
paperboard
blank 49. The outer carton 12 also is assembled.
Next, the packaged food items are arranged in one or more layers in the
carrier tray.
Preferably, the food items are arranged with the smaller packages and
containers on the
bottom layers) and the larger package containing the farinaceous food item on
the top. This
arrangement allows the farinaceous item to be viewed through the cut out 48 in
the lid 16, as
well as prevents smaller packages of food items from passing through the cut
out 48.
Next, the carrier tray 14 containing the pre-assembled food items is assembled
with
the beverage container 46 within the outer carton 12. Preferably, the beverage
container 46 is
deposited in the outer carton 12 prior to, but no later than consecutively
with, the carrier tray
14. Because the side walls 30, 32, 34 and 36 of the carrier tray 14 preferably
angle outwardly,
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the carrier tray 14 preferably is positioned above or adjacent to the beverage
container 46 as
the carrier tray 14 and beverage container 46 are deposited in the outer
carton 12. Such
positioning prevents the beverage container 46 from catching on the top edge
of the side wall
32 of the carrier tray 14.
Finally, after the various items are assembled in the outer carton 12, the lid
16 of the
outer carton 12 is secured in a closed position with adhesive or the like.
Alternatively, as shown in FIGS. 7-9, the carrier tray 14 may include
additional
features. The carrier tray 14 may include tab-like legs 60 extending
downwardly from the
corners (FIGS. 6-8) or from one or more locations along the side walls (FIG.
9). The carrier
tray 14 with legs 60 provides a raised bottom wall 28 beneath which food items
or other
components of the meal kit may be disposed. The raised bottom wall 28 also may
make the
food items more visible through the cut outs 48 in the lid 16 and may further
secure the
uppermost food item against the lid 16 to prevent smaller food items from
passing through
the cut out 48. The carrier tray 14 also may include one or more cut outs 62
at the bottom
wall 28 for receiving food items (FIGS. 8-9). These cut outs 62 are configured
to correspond
to the shape of the packaged food item disposed therein to allow the packaged
food item to be
placed in the cut out 68.
Numerous alternatives, modifications and variations to the packaging system
are
possible to improve the assembly and packaging of a meal kit that includes
multiple food
items and a beverage container. Thus, modifications and variations in practice
of the
invention are expected to be apparent to those skilled in the art upon
consideration of the
foregoing detailed description of the invention. Although a preferred
embodiment has been
described above and illustrated in the accompanying drawings, there is no
intent to limit the
scope of the invention to this or any other particular embodiment.
Consequently, any such
modifications and variations are intended to be included within the scope of
the following
claims, which further describe and point out the invention.
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