Note: Descriptions are shown in the official language in which they were submitted.
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FOOD PACKAGING INSERT AND SYSTEM
REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority under 35 U.S.C.
119(e) of United States provisional application serial number 62/423273 filed
on
November 16, 2016, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The embodiments described herein relate generally to a
packaging insert for use with a food container to retain heat, reduce
moisture, resist oil
stains, and/or provide other desired characteristics. The packaging inserts
generally
include a structural support made from e.g., folding carton board or
corrugated board
combined with one or more treated layers. A treated layer may comprise, e.g.,
a
coating, laminated foil, laminated film, metalized film, or sputter coated
paper.
[0003] At least some known containers are used for storing and/or
transporting a heated or cooled food product therein in which the container is
formed
in a manner so as to provide one or more desired characteristics such as,
e.g., heat
retention. However, specially constructing containers to have desired
properties may
limit their flexibility (in terms of the number of applications they are
suitable for) and
may also entail significant additional expense.
[0004] As such, it would be desirable to provide one or more inserts
that can be used in connection with a variety of containers and placed
therein, under a
food item, to provide one or more desired properties. Such inserts can be used
at a
much lower cost, and inserts can be made of a wide variety of materials that
cannot be
used during normal corrugation. Such inserts also allow the same container to
be
altered for many applications, depending on the insert used, reducing the
required
inventory for multiple applications.
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BRIEF DESCRIPTION OF THE INVENTION
[0005] In one aspect, a food packaging insert includes a support
member including a sheet of corrugated material. The support member defines an
upper
surface and a lower surface. The insert further includes at least one treated
layer
disposed on one of the upper surface and the lower surface. The food packaging
insert
is insertable into a food container and configured to provide one or more
desired
properties to the food container.
[0006] The sheet of corrugated material can include a sheet of single
faced corrugated board.
[0007] The sheet of single faced corrugated board can define a
plurality of flutes on the upper surface of the support member. The at least
one treated
layer can be disposed on the lower surface of the support member.
[0008] The at least one treated layer can include a metalized film.
[0009] The metalized film can include a metalized polyester film.
[0010] The one or more desired properties can include moisture
control.
[0011] According to another aspect, a food packaging system includes
a food container having a base portion and a closeable lid, and a packaging
insert
insertable into the base portion. The packaging insert includes a support
member and
at least one treated layer disposed on one of the support member's upper or
lower
surfaces. The support member includes a sheet of corrugated material. The
packaging
insert is configured to provide one or more desired properties to the food
container.
[0012] The sheet of corrugated material can include a sheet of single
faced corrugated board.
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[0013] The sheet of single faced corrugated board can define a
plurality of flutes on the upper surface of the support member. The at least
one treated
layer can be disposed on the lower surface of the support member.
[0014] The at least one treated layer can include a metalized film.
[0015] The metalized film can include a metalized polyester film.
[0016] The one or more desired properties can include moisture
control.
[0017] The food container can be a pizza box and the one or more
desired properties can include preserving the crunchiness or crispiness of a
pizza stored
within the pizza box
[0018] According to another aspect, a method of using a food
packaging system includes placing an insert into the base portion of a food
container
beneath a pizza and closing the closeable lid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Figures 1-6 show exemplary embodiments of the systems and
inserts described herein.
[0020] Figure 1 is a perspective view of a food packaging system
including an insert and a food container, according to one embodiment of the
present
invention.
[0021] Figure 2 is a perspective view of the system of Figure 1,
showing the insert placed within the tray or base portion of the food
container.
[0022] Figure 3 is a perspective view of the insert of Figure 1.
[0023] Figure 4 is atop view of the insert of Figure 1.
[0024] Figure 5 is a bottom view of the insert of Figure 1.
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[0025] Figure 6 is a side view of the insert of Figure 1.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The following detailed description illustrates the disclosure by
way of example and not by way of limitation. The description clearly enables
one
skilled in the art to make and use the disclosure, describes several
embodiments,
adaptations, variations, alternative, and use of the disclosure, including
what is
presently believed to be the best mode of carrying out the disclosure.
[0027] Referring to FIG. 1 there is shown a first embodiment of a food
packaging system 10 that includes a packaging insert 12 that is insertable
into an
interior of a food container 14 (as shown in FIG. 2). In the illustrated
embodiment,
food container 14 is a conventional pizza box including a tray portion 16 and
a closeable
lid 18. The insert 12 can be placed over the interior surface of container's
base panel
20. One or more food items (not shown) such as a pizza can then be placed
directly
onto an upper surface 22 of insert 12, and the container's lid 18 can then be
closed.
[0028] Figures 3-6 show a variety of views of an insert 12. In the
illustrated embodiment, insert 12 is generally flat or planar, and square or
rectangular
in shape, and sized so as to fit snugly within container 14 over base panel
20. However,
inserts can be made in a variety of shapes and sizes. For example, in an
alternative
embodiment, insert could be circular in shape and sized so as to correspond to
the
underside of a pizza. Insert 12 has an upper surface 22 and a lower surface
24. In use,
lower surface 24 is placed downwardly in face-contacting relationship with the
upper
surface of base panel 20. Upper surface 22 is positioned facing up so as to
receive one
or more food items placed thereupon.
Insert 12 comprises a structural support 28 and one or more treated
layers 30 on the insert's lower and/or upper surfaces. In the illustrated
embodiment,
insert 12 comprises a single treated layer 30 defined on the insert's lower
surface 24.
Support member 28 can be formed from a generally flat or planar sheet of
corrugated
board or folding carton board. Alternatively, support member 28 can be formed
from
cardboard, plastic, fiberboard, paperboard, foamboard, corrugated paper,
and/or any
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suitable material known to those skilled in the art and guided by the
teachings herein
provided. In the illustrated embodiment, support member 28 is formed from a
single
faced corrugated board comprising a flat linerboard 32 adhered to a corrugated
medium
32 that defines a plurality of flutes 33. Any suitable flute size can be used
such as, e.g.,
A flute, B flute, C flute, D flute, or E flute. The fluted side of support
member 28
defines the top surface 22 of insert 12. Support member 28 is configured to
provide
structural support and rigidity to insert 12. In addition, the upward-facing
flutes 33 of
support member 28 may allow moisture to escape from the food item, thereby
reducing
sogginess. Support member 28 also acts as a layer of isolation / insulation
between the
food item and the base panel 20 and outside environment. Thus, support member
28
may facilitate heat retention while also reducing the risk that moisture or
oil soaks or
through bottom panel 20 of container 12. Moisture and/or oil that escapes from
the
food item may be absorbed into the material of support member 28. In addition,
or
alternatively, moisture and/or oil from the food item may collect in channels
defined by
flutes 33.
[0029] Treated layer 30 may comprise, e.g., a coating, laminated foil,
laminated film, metalized film, or sputter coated paper. Exemplary materials
from
which treated layer 30 may be formed include, but are not limited to, aluminum
foil
(with or without a protective coating), metalized polymer films (such as
oriented
polypropylene, polyethylene terephthalate, nylon, polyethylene, cast
polypropylene,
polyester, and/or polyvinyl chloride), metalized paper, and/or non-metalized
polymer
films. In the preferred embodiment, treated layer 30 is a metalized polyester
(met-PET)
film laminated to the liner side /lower surface of support member 28.
Empirical testing
has shown that the use of an insert with a met-PET film laminated to the lower
surface
of a single faced corrugated support member may provide at least some heat
retention
benefit to a pizza box as compared to a pizza box using a control insert which
included
no lamination. Unexpectedly, the addition of a met-PET laminated film was also
found
to provide a significant benefit in terms of reducing the retained moisture in
the pizza
and increasing the pizza's crispiness or crunchiness. Surprisingly, this
benefit was
obtained even after the pizza was left in the box for an extended period of
time (e.g., 35
minutes). Finally, the addition of a met-PET laminated film was shown to
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moisture from leaking through the bottom of the pizza box. Moisture was
observed
trapped at the interface between the support member and met-PET laminated
film.
[0030] One exemplary method of using the system will now be
described. The food container 14 is opened and insert 12 is placed, with its
top surface
22 facing up, into the interior of the tray portion 16 over the base panel 20.
In certain
embodiments, insert 12 may simply rest on base panel 20 without being secured
thereto.
In other embodiments, however, glue or other adhesive can be used to secure
insert 12
to base panel 20. In other embodiments, insert 12 can be sized so as to be
friction fit
within the tray portion 16. In still other embodiments, other attachment means
can be
used to secure insert within tray portion 16. A food item such as a pizza is
then placed
onto the top surface 22 of insert 12 and the lid 18 is shut to close the
container 14.
[0031] In an example embodiment, an insert and/or the food container
with which it is used can include at least one marking thereon including,
without
limitation, indicia that communicates the product, a manufacturer of the
product and/or
a seller of the product. For example, the marking may include printed text
that indicates
a product's name and briefly describes the product, logos and/or trademarks
that
indicate a manufacturer and/or seller of the product, and/or designs and/or
ornamentation that attract attention. In another embodiment, the insert and
container
are void of markings, such as, without limitation, indicia that communicates
the
product, a manufacturer of the product and/or a seller of the product.
Furthermore, the
container may have any suitable size, shape and/or configuration, i.e., any
suitable
number of sides having any suitable size, shape and/or configuration as
described
and/or illustrated herein. In one embodiment, the container includes a shape
that
provides functionality, such as a shape that facilitates packaging a food
item, a shape
that facilitates transporting the container, and/or a shape that facilitates
stacking and/or
arrangement of a plurality of containers. Similarly, the insert may have any
suitable
size, shape and/or configuration, such as a size and shape that facilitates
insertion into
a corresponding food container and/or a size and shape that facilitates
stacking and/or
arrangement of a plurality of inserts.
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[0032] In the exemplary embodiment, an insert is provided with only
a single treated layer on the insert's lower surface. However, in other
embodiments,
one or more treated layers may be provided on the upper and/or lower surfaces.
In the
exemplary embodiment, a single insert is used with the food container.
However, in
other embodiments, two or more inserts may be used having identical or
different
properties and may be, for example, stacked on top of another. In the
exemplary
embodiment, an insert is placed in the base of a food container underneath a
food item.
However, in other embodiments, one or more inserts may be placed over the food
item
and, for example, affixed to the interior surface of the container's lid. In
the exemplary
embodiment, the support member is formed from a single faced corrugated board.
In
other embodiments, the support member may be formed from, for example, a
single
wall, double wall, or triple wall corrugated board. In the exemplary
embodiment, a
food container is a conventional pizza box such as one formed from corrugated
fiberboard. In other embodiments, one or more inserts may be used in
combination
with, for example, a pizza box made from a blank that includes a heat-
reflective film
adhered thereto.
[0033] Although specific features of various embodiments of the
invention may be shown in some drawings and not in others, this is for
convenience
only. In accordance with the principles of the invention, any feature of a
drawing may
be referenced and/or claimed in combination with any feature of any other
drawing.
[0034] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person skilled in
the art to
practice the invention, including making and using any devices or systems and
performing any incorporated methods. The patentable scope of the invention is
defined
by the claims, and may include other examples that occur to those skilled in
the art.
Such other examples are intended to be within the scope of the claims if they
have
structural elements that do not differ from the literal language of the
claims, or if they
include equivalent structural elements with insubstantial differences from the
literal
language of the claims.
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