Material-saving pizza box and blank

Abstract

A pizza box and blank comprising one or more of the features of (1) a unique cover-locking structure comprising (a) a tab extending from a front end edge of a panel of a side wall structure and (b) a tab engaging edge disposed in or on the cover, and (2) a unique cover side flap structure comprising a structure similar to that shown in Correll U.S. Pat. No. 6,547,125 except with the minimum height of the cover side flaps being substantially less than the maximum height of the rear wall and/or side wall panels of the box blank, thereby providing a possible way to mate two adjacent blanks during the manufacturing process. The advantage of the first feature is a cover-locking structure that provides material savings along with ease of use and secure cover closure. The advantage of the second feature is cost savings.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to my application Ser. No. 09/950,112, entitled “Material-saving Food Carton,” filed Sep. 10, 2001, now U.S. Pat. No. 6,547,125 B2 granted Apr. 15, 2003.

This application is a continuation-in-part application of my application Ser. No. 10/784,381 filed Feb. 23, 2004, which is a continuation-in-part application of application Ser. No. 10/431,984 filed May 8, 2003.

FEDERALLY SPONSORED RESEARCH

Not Applicable

SEQUENCE LISTING OR PROGRAM

Not Applicable

FIELD OF THE INVENTION

This invention relates to packaging in general and in particular, but not by way of limitation, to boxes and box blanks for food products such as pizza and the like.

BACKGROUND OF THE INVENTION

Each year thousands of pizza businesses sell millions of hot pizzas for delivery and carry-out. The success of these businesses depends to an extent on the cost and functionality of the boxes used for packaging the product. Ideally, these boxes should be cost-effective and easy to use.

The instant invention pertains to a blank and box that contains several structural enhancements that are applicable to a prior invention of mine disclosed in Correll U.S. Pat. No. 6,547,125 granted Apr. 15, 2003, and entitled “Material-saving Food Carton.” As such, the structure of the instant invention is quite similar to that of Correll '125, with deviations occurring in the particular areas of structural innovation. The preferred embodiment of the invention disclosed in this prior patent happens to be a non-fastened, non-rectangular, some-slanting-wall box having a full-length cover panel. In conclusion, where applicable the essential material of the disclosure, discussion, and terminology contained within U.S. Pat. No. 6,547,125 is included herein by this reference thereto.

One of the ways of reducing the amount of material required for making a box blank is to design the blank so that it can be oriented 180 degrees to an adjacent similar blank and then mated (or nested) along the adjacent sides of the two blanks. This technique has been done for decades within the packaging industry. Three examples include Lighter U.S. Pat. No. 2,435,283 granted Feb. 3, 1948; Correll U.S. Pat. No. 5,381,949 granted Jan. 17, 1995; and Correll U.S. Pat. No. 5,713,509 granted Feb. 3, 1998. Each of these patents shows a blank having a cover side flap that has a shorter height than the side wall of the blank, thereby allowing one blank to be oriented 180 degrees to a similar adjacent blank and then mated together for manufacture.

The prior art also discloses Deiger U.S. Pat. No. 4,919,326 granted Apr. 24, 1990; Philips et al. U.S. Pat. No. 5,702,054 granted Dec. 30, 1997; and Correll U.S. Pat. No. 6,206,277 granted Mar. 27, 2001. Each of these patents discloses a particular type of structure comprising a side wall attached to a bottom panel, a corner panel attached to an end of the side wall, a connector panel attached to a bottom edge of the corner panel, an end wall panel attached to the bottom panel, and an end flap attached to an end of the end wall panel and also to the connector panel.

Philips et al., in particular, depicts the structure of the pizza box and box blank currently in use by Domino's Pizza.

Each of the above-cited prior art has a particular drawback. Specifically, Lighter, Correll '949, and Correll '509 disclose how to mate adjacent blanks of a particular structure but do not disclose how to mate adjacent blanks having a structure similar to that of the current Domino's Pizza pizza box blank (i.e., the structure of Philips et al. '054).

Deiger, Philips et al., and Correll '277 disclose how to create a non-slanting end wall on a box having a structure similar that of the current Domino's Pizza pizza box, but do not disclose how to create a material-saving inward-slanting end wall. Further, they do not disclose how to save material by mating adjacent blanks having a structure similar to that of the Domino's Pizza pizza box blank.

In addition, Correll U.S. Pat. No. 5,381,949 granted Jan. 17, 1995, and Correll U.S. Pat. No. 5,713,509 granted Feb. 3, 1998, also disclose adjacent nesting blanks. However, they do not disclose how to mate adjacent blanks having a structure similar to that of Philips et al. '054.

In addition to material savings derived from nesting of adjacent blanks, it would be desirable to have a cover-locking structure that requires only a minimal amount of extra material to incorporate into a box blank and also is easy to operate and maintains a reasonably tight cover closure after repeated opening-and-reclosings of the box.

Philips et al. discloses a cover-locking structure comprising a tab at opposing ends of a cover front flap with the projections engaging with slits at opposing ends of the front wall structure. The height of the cover front flap is substantially the same height as that of the front wall of the box. This cover-locking structure is relatively material-efficient and easy to use. However, it tends to be undependable in that after the box is opened and reclosed once or twice the tabs tend to no longer engage securely with the slits at the ends of the front wall structure. This cover-locking structure is currently in use on the Domino's Pizza pizza box.

Another box closure structure is disclosed in Keefe, Jr. et al. U.S. Pat. No. 6,749,106 B2 granted Jun. 15, 2004. It discloses a relatively complex cover-locking structure consisting of a tab extending from a front end edge of each of a pair of corner panels attached to a front end of side wall panels. Further, the front wall of the box contains openings for receiving the tabs. The engagement of the tabs with these openings serves to hold the corner panels and attached side wall panels in upright or vertical position. Still further, there is a flap attached to the top edge of the front wall. Finally, there are cover diagonal flaps attached to front diagonal edges of the cover panel. These cover flaps wrap around the ends of the front wall flap when the box is closed and, thereby, hold the cover in closed disposition.

Several comments relative to the above-described box closure structure are in order. First, the width of the front wall flap is substantially the same as the height of the front wall. Therefore, there is no material savings over the current Domino's Pizza box (or the Philips et al. box). Second, it appears that this particular structure would be cumbersome and time-consuming when erecting the blank into a box and also when closing up the box after loading it with pizza. Third, the tabs extending from the front edge of the corner panels serve to hold the corner panel and side wall in place as opposed to holding the cover in place. Finally, it appears that it would be complex for consumers to figure out how to manipulate this cover-locking structure for opening and closing the box.

In conclusion, it would be highly desirable to provide a pizza box and blank that overcomes the above-cited drawbacks and further enhances the box blank disclosed in Correll U.S. Pat. No. 6,547,125, and, thereby, satisfies the need for further material savings and ease of use. Nothing in the prior art does that. However, my invention does.

SUMMARY OF THE INVENTION

In accordance with the presently preferred embodiment, my invention is a box and/or blank that can incorporate one or more of the following features:

• • 1) A unique cover-locking structure comprising (a) a tab projecting from a front end edge of a panel of a side wall structure and (b) a tab engaging edge disposed in or on a cover of the box and which engages with the tab, thereby acting to hold the cover in a closed disposition; and
  • 2) A unique cover side flap structure comprising a structure similar to that shown in Correll U.S. Pat. No. 6,547,125 except with the minimum height of the cover side flaps being substantially less than the maximum height of the rear wall and/or side wall panels of the box blank, thereby providing a possible way to mate two adjacent blanks during the manufacturing process.

My invention typically would be used for packaging relatively flat food products such as pizza; however, it could take other forms and be used for other purposes, as well.

A complete understanding of the invention can be obtained from the detailed description that follows.

OBJECT AND ADVANTAGES

A main object of the instant invention is to enhance the box and blank disclosed in Correll U.S. Pat. No. 6,547,125 entitled “Material-saving Food Carton” and make it more material-efficient and easier to use.

The advantages of my invention are as follows:

1) A first advantage of my invention is a cover-locking structure that provides material savings along with ease of use and secure cover closure after repeated box opening-and-reclosings.

2) A second advantage of my invention is cost savings for the box manufacturer and/or pizzeria owner without any attendant operational inconvenience or deterioration of package integrity. This results, in part, from the shortened-height cover side flaps and the ability to invert and mate adjacent blanks in manufacture.

Further objects and advantages of the invention will become apparent from consideration of the following detailed description, related drawings, and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of multiple units of a preferred embodiment of the box blank.

FIG. 2 is a perspective view of a box erected from the blank.

FIG. 3 is a plan view of an enlarged portion of a blank having a flip-tab opening.

FIG. 4 is a plan view of an enlarged portion of a blank having an alternate configuration of flip-tab opening.

LIST OF REFERENCE NUMERALS

Within a drawing, closely related components have the same number but different alphabetic suffixes. Between drawings, like reference numerals designate corresponding parts.

• 10 blank of the preferred embodiment
• 10a blank of the preferred embodiment
• 12 box of the preferred embodiment
• 20 bottom panel
• 22 rear wall
• 24 rear wall fold line
• 30 side wall structure
• 32 side wall panel
• 34 side wall fold line
• 36 front corner panel
• 37 fold line
• 38 connector panel
• 39 fold line (bottom edge of corner panel)
• 40 front end edge of corner panel
• 44 rear end of side wall panel
• 46 tab
• 48a top edge portion of side wall panel
• 48b top edge portion of side wall panel
• 50 front wall structure
• 52 front wall
• 54 front wall fold line
• 55 end flap
• 56 end flap fold line
• 57 connector panel fold line
• 58 top edge of front wall
• 60 cover
• 62 cover panel
• 64 cover panel fold line
• 65 tab engaging edges
• 66 cover front flap
• 68 cover front flap fold line
• 69 bottom edge of cover front flap
• 70 cover side flap structure
• 72 cover side flap
• 74 cover side flap fold line
• 75 front end of cover side flap
• 76 corner flap
• 78 corner flap fold line
• 82 lower edge of corner flap
• 84a lower edge portion of cover side flap
• 84b lower edge portion of cover side flap
• 95 height of rear wall
• 96 height of cover front flap
• 97 height of front wall
• 98 minimum height of cover side flap (a.k.a. predetermined minimum height)
• 99 maximum height of side wall panel
• 102 flip-tab
• 104 hole or knock-out
• 106 alternate flip-tab

DETAILED DESCRIPTION OF A PRESENTLY PREFERRED EMBODIMENT

Referring now to the drawings, there is illustrated a presently preferred embodiment of the instant invention in the format of a one-piece blank and, correspondingly, in the format of an inward-slanting-wall box created from the blank.

The instant invention comprises, in large part, improvements intended for use in the box and blank disclosed in Correll U.S. Pat. No. 6,547,125 granted Apr. 15, 2003. As such, the structure of the instant invention is quite similar to that of Correll '125, with deviations occurring in the particular areas of structural innovation. Therefore, where applicable the essential material of the disclosure, discussion and terminology contained in Correll '125 is hereby included herein by this reference thereto. In addition, some of the appended claims are written in Jepson-type format wherein the prior art structure cited in the claim is referred to as a “prior-patent-disclosed combination of components.” As used herein, the phrase “prior-patent-disclosed combination of components” refers to blank or box components that have been previously described or disclosed within U.S. Pat. No. 6,547,125 (which was published Mar. 13, 2003).

The preferred embodiment is created from corrugated board; however, other foldable materials can be used, as well. The intended use for the embodiment is for erecting into a pizza box. However, it will be appreciated, as the description proceeds, that my invention may be realized in different embodiments and used in differing applications.

FIG. 1 shows a first blank 10 and a second blank 10a oriented at 180 degrees to blank 10. Even though only a partial section of blank 10a is depicted, this blank is of identical structure to that of blank 10. FIG. 2 shows a fully-erected pizza box 12 created from blank 10. Referenced components are labeled in FIG. 1, particularly on the left side of the drawing; selected components are labeled in other Figures. Corresponding parts between drawings share a same reference numeral.

It is noted that the presently preferred embodiment of the invention is bilaterally symmetrical (i.e., having identical left and right sides). Therefore, pairs of opposing like components are to be found, with one item of the pair on each side of the blank or box. For simplicity of labeling, both components of an opposing pair bear the same reference numeral. In some cases, for illustrative simplicity, only one item of a pair of opposing like components is numerically labeled. Where this occurs, it is to be understood that the discussion applies to both components of the pair, even though only one of the components is numerically labeled in the drawings.

Structure of the Embodiment

Referring in particular to FIG. 1 which shows blank 10, there is a bottom panel 20, a rear wall 22 hingedly attached to bottom panel 20 at a rear wall fold line 24, and opposing left and right side wall structures 30.

Each side wall structure 30 comprises a side wall panel 32 hingedly attached to bottom panel 20 at a side wall fold line 34 and disposed substantially perpendicular to rear wall 22, a front corner panel 36 hingedly attached to a front end of side wall panel 32 at a fold line, a connector panel 38 hingedly attached to a bottom edge 39 of front corner panel 36 at a fold line (also depicted by numeral 39) and to bottom panel 20 at a fold line 37. Side wall panel 32 has a free rear end 44 that is obliquely disposed, or at an acute angle, to side wall fold line 34. In addition, side wall panel 32 has a top edge comprising a plurality of top edge portions including top edge portions 48a and 48b. It is noted that top edge portion 48a is disposed parallel to side wall fold line 34 and top edge portion 48b is disposed non-parallel to fold line 34. Finally, it is noted that front corner panel 36 has a front end edge 40 and a tab 46 projecting from front end edge 40 and disposed coplanar to the remainder of corner panel 36. As such, panel 36 happens to be a tab-holding panel. As used herein, the term “tab-holding panel” refers to any panel (or flap) that has a tab, or tab-like projection, projecting from an edge of the panel.

A front wall structure 50 comprises a front wall 52 hingedly attached to bottom panel 20 at a front wall fold line 54 and left and right end flaps 55 hingedly attached to respective left and right ends of front wall 52 at an end flap fold line 56 and to connector panel 38 at a connector panel fold line 57. Front wall 52 has a top edge 58 that is free of attachment.

Several important features are noted regarding fold lines 56, 57. First, end flap fold line 56 is disposed at an obtuse angle to front wall fold line 54. Second, end flap fold line 56 is disposed at an acute angle to connector panel fold line 57. Third, connector panel fold line 57 is approximately aligned with front wall fold line 54.

The optimal disposition of these fold lines, or the sizes of these angles, depends on several factors, including the type of corrugated board used in making the blank and the degree of inward-slanting angle desired on front wall 52 of the box. Therefore, for any given box the determination of the optimal disposition of the fold lines, or the degree of angle between fold lines, is typically derived from testing, a function easily accomplished by any box designer skilled in the art. However, as a guide, it is noted that in the drawing of the preferred embodiment, the angle between fold line 56 and fold line 54 is approximately ninety nine degrees and the angle between fold line 56 and fold line 57 is approximately seventy six degrees. These angles are the recommended starting points for any testing which might be undertaken.

A cover 60 comprises a full-length cover panel 62 hingedly attached to rear wall 22 at a cover panel fold line 64, a cover front flap 66 hingedly attached to a front edge of cover panel 62 at a cover front flap fold line 68, and left and right cover side flap structures 70. Cover front flap 66 has a bottom edge 69.

It is further noted that cover 60 has a pair of first and second tab engaging edges 65. As illustrated in FIG. 2, when blank 10 is erected into box 12, tabs 46 engage with tab engaging edges 65 to hold cover 60 in a closed disposition. In the preferred embodiment, each tab engaging edge 65 results from, or is a part of, an opening or “hole” that is disposed in cover front flap 66 and has a top edge of the opening bordering cover panel 62. In FIG. 1 the opening is shown as a rectangular “hole” or a “knock-out” in the board. However, it is possible for the opening to take other shapes and configurations, particularly in the blank format.

As illustrated in FIG. 3 which shows a partial section of a cover panel of a blank, an opening in cover front flap 66 can result from, or be formed by, a flip-tab 102; that is, a tab that “flips open” when the blank is erected into a box or, specifically, when cover front flap 66 is folded perpendicular to cover panel 62. The result of this configuration is (a) a “hole” that provides a tab engaging edge for engaging with tabs 46 and (b) flip-tab 102, which remains coplanar to cover panel 62 in the box format and, thereby, projects forward from the front edge of the cover panel. This configuration tends to conceal or hide the hole that provides the tab engaging edge.

An alternate configuration of flip-tab is illustrated in FIG. 4. This Figure, which shows a partial section of a cover panel of a blank, depicts a flip-tab and hole combination, wherein the tab engaging edge results from a “hole” created by the combination of knock-out 104 and a flip-tab 106. With this, after the blank is erected into a box and the flip-tab “flips open,” the hole becomes larger. The result of this configuration is that flip-tab 106 does not extend as far past the front wall of the box as does flip-tab 102 of the prior example but still hides the hole that provides the tab engaging edge. The position, size, shape, and configuration of the holes that produce the tab engaging edges should be such that they provide an optimal degree of engagement with tabs 46. This optimal degree of engagement depends on several factors including type of corrugated board used in making the blank and the degree of inward-slanting angle used on front wall 52 of the box. Therefore, the optimal degree of engagement is determined through trial-and-error testing, a function easily performed by any competent packaging designer skilled in the art.

Each cover side flap structure 70 comprises a cover side flap 72 hingedly attached to a side edge of cover panel 62 at a cover side flap fold line 74 that's disposed perpendicular to rear wall 22. The cover side flap has a front end 75 that is free of attachment. It also has a lower edge comprising a plurality of lower edge portions 84a and 84b. It is noted that lower edge portion 84a is disposed parallel to cover flap fold line 74 and lower edge portion 84b is disposed non-parallel to fold line 74.

Side flap structure 70 further comprises a free-swinging corner flap 76 hingedly attached to a rear end of cover side flap 72 at a corner flap fold line 78. It is noted that corner flap fold line 78 is disposed at an obtuse angle to cover side flap fold line 74. The exact degree of the angle is whatever is needed to achieve the desired degree of inward-slanting angle for rear wall 22. (Specifically, in the drawing of the preferred embodiment the angle between fold line 74 and fold line 78 happens to be 112 degrees.) Due to structural differences between boxes, such as differences in type of corrugated board, the final determination of this angle may require testing, a function easily accomplished by any competent box designer skilled in the art.

It is also noted that corner flap 76 has a lower edge 82 that is non-aligned with lower edge portions 84a and 84b of cover side flap 72. The determination of the optimal angle between lower edge 82 and fold line 78 will also likely require trial-and-error testing. The optimal angle is whatever retains cover side flap 72 in a proper (vertical) position after blank 10 has been folded into box 12. (Specifically, in the drawing of the preferred embodiment, this angle is 90 degrees.)

At this point, several panel heights are noted. Specifically, rear wall 22 has a height 95. Cover front flap 66 has a height 96. Front wall 52 has a height 97. Cover side flap 72 has a minimum height 98. And side wall panel 32 has a maximum height 99. The minimum height of cover side flap 72 is the distance between fold line 74 whatever portion of the lower edge of the side flap (i.e., 84a/b) that is closest to the fold line. Put another way, it is the length of the shortest distance between the lower edge and the fold line. The maximum height of side wall panel 32 is the distance between fold line 34 and whatever portion of the top edge of the side wall panel (i.e., 48a/b) that is farthest from the fold line. Alternatively put, it is the length of the longest distance between the top edge and the fold line.

It is further noted that minimum height 98 of cover side flap 72 is substantially less than maximum height 99 of side wall panel 32. This feature enables multiple adjacent blanks to be mated during manufacture for material savings. Minimum height 98 is also substantially less than rear wall height 95 and front wall height 97.

Although not indicated with reference numerals, it is noted that in addition to maximum height 99 of side wall panel 32, the wall panel also has a minimum height. This minimum height of wall panel 32 is the distance between fold line 34 and whatever portion of the top edge of the side wall panel (i.e., 48a/b) that is closest to the fold line. Further it is noted that in addition to minimum height 98 of cover side flap 72, the side flap also has a maximum height. This maximum height of side flap 72 is the distance between fold line 74 and whatever portion of the lower edge of the side flap (i.e., 84a/b) that is farthest from the fold line. As regards both side wall 32 and cover side flap 72, the minimum height is substantially less than the maximum height.

For clarity of definition, it is noted that a beveled end or beveled corner section of a cover side flap does not constitute a portion of the lower edge of that side flap. Further, a beveled end or beveled corner section of a wall panel does not constitute a portion of the top edge of the wall panel.

In a five centimeter (two-inch) high pizza box in a format resembling that of the preferred embodiment, cover front flap height 96 will be shorter than front wall height 97 by approximately twelve millimeters (one-half inch).

The dimensional relationships cited in the preceding paragraphs are described in the appended claims by the terms “substantially less” and “substantially shorter.” As used in the claims, the term “substantially less” means “at least ten percent shorter” and the term “substantially shorter” means “at least five percent shorter.” The term “a substantial portion” means “at least twenty percent.”

As can be seen in FIG. 2, end flaps 55 extend diagonally inward from front wall 52 and contain cover front flap 66 between them. Corner panels 36 extend diagonally forward from side wall panels 32 and front end 40 is adjacent to, or even abuts, cover front flap 66. Connector panels 38 overlie bottom panel 20. Cover side flaps 72 are disposed exterior to side wall panels 32 (hence they're sometimes called exterior cover side flaps).

Although not seen in FIG. 2, it is noted that in the box format corner flaps 76 are perpendicular to the cover side flaps 72 and disposed between rear end 44 of side wall panel 32 and rear wall 22. Lower edge 82 of corner flap 76 contacts bottom panel 20, thereby holding cover side flaps 72 in vertical or erected disposition. It is noted that this configuration is accomplished in spite of the fact that minimum height 98 of cover side flaps 72 is substantially less than height 95 of rear wall 22.

In the Philips et al. '054 box the height of the cover front flap is the same length as the height of the front wall. However, it is noted that in my invention height 96 of cover front flap 66 is substantially shorter than height 97 of front wall 52, thereby effecting a significant material savings.

Mating of Multiple Blanks During Manufacture

FIG. 1, which shows identical blanks 10 and 10a oriented at 180 degrees to one another, depicts the configuration of multiple units of the preferred embodiment in a mated configuration for efficient manufacture. Even though only a partial section of blank 10a is depicted, this blank is of identical structure to that of blank 10. Further, in the drawing a small gap exists between the blanks. This gap is provided for clarity of illustration. In the actual manufacture of these blanks this gap would likely not exist and, instead, the adjacent edges of the blanks probably would be in contact with one another. (However, in the preferred embodiment, a small knock-out would exist between corner flaps 76 of the adjacent blanks.) Specifically, lower edge 84a/b of cover side flap 72 of each blank contacts, or is disposed adjacent to, top edge 48a/b of side wall panel 32 of the other blank. It is further noted that the furthermost extremities at each end of each blank (constituted by bottom edge 69 of cover front flap 66 and top edge 58 of front wall 52) are aligned with the furthermost extremities of the adjacent blank.

Method for Erecting the Blank into the Box Any method used for erecting the blank of Philips et al. '054 patent or Correll '125 patent into a box can be used for erecting the preferred embodiment into a box.

Specifically, the following method can be used, which is highly efficient.

First, position the blank so that it's horizontal and with the inside surface up and cover front flap 66 next to the abdomen.

Second, with your hands placed near the rear end of cover side flaps 72, simultaneously fold cover side flaps 72 inward and, with your index fingers, fold rear corner flaps 76 inward.

Third, while keeping your hands in that position (i.e., at the rear end of cover side flaps 72) and while holding the cover side flaps upright, with your fingers pull rear wall 22 upright.

Fourth, fold bottom panel 20 downward to about halfway closed.

Fifth, fold side wall panels 32 inward and position them interior to cover side flaps 72 and then fold bottom panel 20 down until the box is almost all the way closed.

Sixth, turn the partially-erected box to a vertical position with front wall structure 50 up.

Seventh, open cover panel 62 about three inches and then, with your index fingers, push both front corner panels 36 inward. This will cause front wall structure 50 to assume an upright position.

Eighth, fold cover front flap 66 down and tuck it between end flaps 55 and close the box completely. This step can sometimes be most easily executed with the rear end of the box held against a surface. This can be accomplished by either (a) holding the box vertically with the rear end resting on a table or (b) holding the box horizontally with the rear end held against your abdomen.

When sliding cover front flap 66 into closed disposition (or between end flaps 55), bottom edge 69 of flap 66 slides over and past tabs 46. Once cover panel 62 is in closed disposition, tabs 46 engage with tab engaging edges 65, or, specifically, with the lower edge of the “hole” that provides tab engaging edges 65 in the preferred embodiment, thereby holding cover 60 in closed disposition. Further, when tabs 46 are of the proper size and configuration, bottom edge 69 of cover front flap 66 will slide easily past the tabs and the tabs will readily engage with tab engaging edges 65. The result will be that cover 60 will be held in place in the closed disposition but can be easily opened with a reasonable amount of upward lifting force. If, during trial-and-error testing, it should turn out that it is difficult to close the cover onto the box or that the cover should not have the proper amount of cover closure resistance, simply adjust the size, shape, and/or position of tabs 46 (and/or perhaps the size and location of tab engaging edges 65) until the desired degree of resistance is achieved.

Definition of Key Terms

Certain terms are used in the appended claims for describing the invention. To insure clarity of meaning those terms are now specifically defined as used herein.

An “inward-slanting wall” is a wall disposed at an acute angle to a bottom panel.

An “inward-slanting-wall box” is a box having at least one wall disposed at a substantially acute angle to the bottom panel of the box.

A “free-swinging” flap or panel is one that is attached to only one other flap or panel after the blank has been erected into a box. An example is corner flap 76.

A “tab engaging edge” is any portion of an edge of the board (e.g., corrugated board) that forms the cover of the box and that engages with a tab disposed at a front end edge of a panel of a side wall structure of the box. Example embodiments of a tab engaging edge include (a) an edge created by an opening or hole in the cover front flap (illustrated in the preferred embodiment of the instant invention) and (b) an edge created by an outward projection or tab along an end edge of the cover front flap.

A “minimum height of a cover side flap” is the length of the shortest distance between the lower edge of the flap and the cover side flap fold line joining the flap to a cover panel, this “shortest distance” existing at a narrowest point between the fold line and the lower edge of the flap. For specificity of definition, it is noted that a beveled end or beveled corner section of a cover side flap does not constitute a portion of the lower edge of that side flap.

A “minimum height of a wall” is the length of the shortest distance between the top edge of the wall and the fold line joining the wall to a bottom panel, this “shortest distance” existing at a narrowest point between the fold line and the top edge of the wall.

A “maximum height of a wall” is the length of the longest distance between the top edge of the wall and the fold line joining the wall to a bottom panel, this “longest distance” existing at a widest point between the fold line and the top edge of the wall, as measured perpendicularly to the fold line. For specificity of definition, it is noted that a beveled end or beveled corner section of a wall panel does not constitute a portion of the top edge of the wall panel.

A “maximum height of a cover side flap” is the length of the longest distance between the lower edge of the flap and the cover side flap fold line joining the flap to a cover panel, this “longest distance” existing at a widest point between the fold line and the lower edge of the flap, as measured perpendicularly to the fold line.

A “substantially acute angle” is considered herein to be an angle of 85 degrees or less.

A “substantially non-acute angle” is considered herein to be an angle greater than 85 degrees.

The term “substantially less” is considered herein to mean “at least ten percent shorter.”

The term “substantially shorter” is considered herein to mean “at least five percent shorter.”

The term “a substantial portion” means “at least twenty percent.”

“Obliquely disposed” refers to an edge, panel, line, or plane that is disposed neither parallel nor perpendicular to another edge, panel, line, or plane.

A “side wall structure” is a plurality of connected panels and/or flaps including at least one of the panels and/or flaps being a side wall attached to a side edge of the bottom panel of the box or blank.

A “front wall structure” is a plurality of connected panels and/or flaps including at least one of the panels and/or flaps being a front wall attached to a front edge of the bottom panel of the box or blank.

A “cover side flap structure” is a plurality of connected panels and/or flaps including at least one of the panels and/or flaps being a cover side flap attached to a side edge of the cover panel of the box or blank.

A “cover” is a plurality of connected panels and/or flaps including at least one of the panels and/or flaps being a cover panel attached to a top edge of at least one of the walls of the box or blank.

A “full-length cover panel” is a cover panel that's hingedly attached to a wall of the box and possessing a length sufficient to enable the cover panel to extend from that wall substantially all the way to an opposing wall structure.

A “tab-holding panel” is any panel (or flap) that has a tab, or tab-like projection, projecting from an edge of the panel. An example is corner panel 36 that has tab 46.

A “prior-patent-disclosed combination of components” refers to a combination of blank or box components (i.e., walls, panels, flaps, fold lines, etc.) that have been previously described or disclosed in my U.S. Pat. No. 6,547,125 (which was published Mar. 13, 2003).

The terms “box” and “carton” are synonymous and used interchangeably herein.

Within the drawing of blank 10, a fold line between component parts of the invention is depicted with a dashed line. The type of fold lines shown in the drawings are presently preferred but it will be appreciated that other methods known to those skilled in the art may be used. Within the context of this invention, a fold line can be created by a number of means such as, for example, by a crease or score in the board, by a series of aligned spaced short slits in the board, and by a combination of aligned spaced short and long slits. In some cases, when a longer slit is bounded on the ends by a series of shorter slits or a crease, the longer slit may be slightly offset in alignment from the shorter slits or crease for the purpose of creating a slot along the fold line when the blank is set up into a box. Such an offset slit may be referred to as a “slot-forming slit.” Nonetheless, the entire combination of long and short slits is considered to constitute a single fold line unless otherwise indicated. Also, as used herein the term “score” refers to a crease.

In addition, to create a fold line where one panel is folded 180 degrees to lay parallel on another panel, the fold line may constitute two narrowly-spaced parallel scores or series of aligned slits. In this case, the two narrowly-spaced parallel scores or series of aligned slits constitute a single fold line unless otherwise indicated.

In conclusion, as referred to herein, a fold line is any line, either real or imaginary, between two points on the blank or box along which the board is intended to be folded when the blank is being erected into a box or when the box is being manipulated as described herein.

CONCLUSION, RAMIFICATIONS, AND SCOPE

I have disclosed a pizza box and blank embodying one or more of the following structural features:

1) A unique cover-locking structure comprising (a) a tab extending from a front end edge of a panel of a side wall structure and (b) a tab engaging edge disposed in or on a cover of the box and which engages with the tab, thereby acting to hold the cover in a closed disposition; and

2) A unique cover side flap structure comprising a structure similar to that shown in Correll U.S. Pat. No. 6,547,125 except with the minimum height of the cover side flaps being substantially less than the maximum height of the rear wall and/or side wall panels of the box blank, thereby providing a possible way to mate two adjacent blanks during the manufacturing process.

The advantages of my invention are (1) a cover-locking structure that provides material savings along with ease of use and secure cover closure after repeated box opening-and-reclosings and (2) cost savings for the box manufacturer and/or pizzeria owner without any attendant operational inconvenience or deterioration of package integrity.

Within the foregoing discussion of the invention and in the appended claims, the labeling of any components by a numerical adjective (i.e., “first,” “second,” etc.) is for reference purposes only and does not denote any particular location of the components within the blank or box. Further, the term “hingedly attached” refers to two panels (or a panel and a flap) joined together at a fold line, and does not imply any degree of movability of the panels in the erected box format. Finally, the terms “box” and “carton” are synonymous and used interchangeably herein.

The foregoing discussion has pertained mainly to packaging relatively flat food products such as pizza. However, it should be realized that my invention could be used for other purposes, as well.

The illustrated number, size, shape, type, placement, and function of components represent the presently preferred embodiment. However, it should be realized that many other combinations and configurations are possible within the scope of the invention.

In conclusion, while the above description contains precise terms and many specificities, these should not be construed as limitations on the scope of the invention but, rather, as exemplifications of the presently preferred embodiment thereof. Many other ramifications and variations are possible within the teachings and scope of the invention. For example, it is possible to omit fold line 37, thereby resulting in connector panel 38 being free of attachment to bottom panel 20. This structure is disclosed in my U.S. Pat. No. 5,806,755. Such a configuration could have the beneficial result of reducing the tendency for spring-back when panel 38 overlies bottom panel 20 (in the box format), thereby perhaps making it easier to fold blank 10 into box 12.

In short, the invention should not be limited to the disclosed embodiment and examples given but, on the contrary, should be determined by the appended claims and their legal equivalents. Thus, the scope of the claims is to be accorded the broadest interpretation so as to encompass all modifications and legally equivalent structures as is permitted under the law, including the doctrine of equivalents.

Claims

1. A box having a unique cover-locking structure, said box comprising:

a bottom panel,

a rear wall,

a cover comprising a cover panel attached to said rear wall, and

a side wall structure comprising a tab-holding panel;

wherein said side wall structure includes a tab projecting from a front end edge of said tab-holding panel and said cover has a tab engaging edge, said tab being engaged with said tab engaging edge, whereby the engagement of said tab with said tab engaging edge acts to hold said cover in a closed disposition.

2. A blank for a box having a unique cover-locking structure, said blank being of foldable material cut and scored to define:

a bottom panel,

a rear wall attached to said bottom panel,

a front wall structure opposing said rear wall and comprising a front wall attached to said bottom panel,

a side wall structure comprising a side wall panel attached to said bottom panel, a corner panel attached to a front end of said side wall panel and having a front end edge and a bottom edge, and a connector panel attached to the bottom edge of said corner panel, and

a cover comprising a cover panel attached to said rear wall and a cover front flap opposing said rear wall and attached to a front edge of said cover panel;

wherein said corner panel has a tab projecting from the front end edge and said cover has a tab engaging edge, said tab engaging edge being of a disposition and configuration to enable said edge to engage with said tab after said blank has been erected into a box.

3. The blank of claim 2 wherein:

said front wall structure further comprises an end flap attached to an end of said front wall and to said connector panel.

4. The blank of claim 2 wherein:

said front wall has a predetermined height and said cover front flap has a predetermined height and the predetermined height of said cover front flap is substantially less than the predetermined height of said front wall.

5. The blank of claim 2 wherein:

said front wall has a top edge free of attachment.

6. The blank of claim 2 wherein:

said cover further comprises a cover side flap structure comprising a cover side flap attached to said cover panel and having a lower edge and a corner flap attached to a rear end of said cover side flap and having a lower edge, at least a portion of the lower edge of said corner flap being disposed in non-alignment to a substantial portion of the lower edge of said cover side flap.

7. The blank of claim 2 wherein:

said cover further comprises a cover side flap structure comprising a cover side flap attached to said cover panel at a cover side flap fold line and having a lower edge, a substantial portion of said lower edge being disposed non-parallel to said cover side flap fold line.

8. The blank of claim 2 wherein:

said cover further comprises a cover side flap structure comprising a cover side flap attached to said cover panel and having a predetermined minimum height and said rear wall and said side wall panel each have a predetermined maximum height, the predetermined minimum height of said cover side flap being substantially less than the predetermined maximum height of at least one of said rear wall and said side wall panel.

9. A box having a unique cover-locking structure, said box comprising:

a bottom panel,

a rear wall,

a front wall structure opposing said rear wall and comprising a front wall,

a side wall structure comprising a side wall panel, a corner panel attached to a front end of said side wall panel and having a front end edge and a bottom edge, and a connector panel attached to the bottom edge of said corner panel, and

a cover comprising a cover panel attached to said rear wall and a cover front flap opposing said rear wall and attached to a front edge of said cover panel;

wherein said corner panel has a tab at the front end edge and said cover has a tab engaging edge and said tab is engaged with said tab engaging edge, whereby the engagement of said tab with said tab engaging edge acts to hold said cover in a closed disposition.

10. The box of claim 9 wherein:

said front wall structure further comprises an end flap attached to an end of said front wall and to said connector panel.

11. The box of claim 9 wherein:

said front wall has a predetermined height and said cover front flap has a predetermined height and the predetermined height of said cover front flap is substantially less than the predetermined height of said front wall.

12. The box of claim 9 wherein:

said front wall has a top edge free of attachment.

13. The box of claim 9 wherein:

said cover further comprises a cover side flap structure comprising a cover side flap attached to said cover panel at a cover side flap fold line and having a lower edge and a corner flap attached to a rear end of said cover side flap at a corner flap fold line, the lower edge of said cover side flap comprising a plurality of portions, at least one of the portions being disposed non-parallel to said cover flap fold line.

14. An improved blank for an inward-slanting-wall box, said blank being of foldable material cut and scored to define the following prior-patent-disclosed combination of components:

a bottom panel,

a rear wall attached to said bottom panel and having a predetermined maximum height, opposing left and right side wall structures comprising (a) respective left and right side wall panels attached to said bottom panel at respective left and right side wall fold lines and each having a free rear end and a top edge and a predetermined maximum height,

(b) respective left and right corner panels attached to a front end of said left and right side wall panels and each having a front end edge and a bottom edge, and (c) respective left and right connector panels attached to the bottom edge of said left and right corner panels,

a front wall structure opposing said rear wall and comprising a front wall attached to said bottom panel at a front wall fold line, and

a cover comprising (a) a cover panel attached to said rear wall and (b) opposing left and right cover side flap structures comprising (i) respective left and right cover side flaps attached to said cover panel at respective left and right cover side flap fold lines and each having a lower edge and a predetermined minimum height and (ii) respective free-swinging left and right corner flaps attached to a rear end of said left and right cover side flaps at respective left and right corner flap fold lines and each having a lower edge, at least a portion of the lower edge of said left and right corner flaps being disposed in non-alignment to a substantial portion of the lower edge of said left and right cover side flaps, respectively;

wherein the improvement comprises the predetermined minimum height of said left and right cover side flaps being substantially less than the predetermined maximum height of at least one of the rear wall and the left and right side wall panels.

15. The blank of claim 14 wherein:

the improvement further comprises a substantial portion of the top edge of at least one of the side wall panels being disposed non-parallel to the side wall fold line associated with that side wall panel.

16. The blank of claim 14 wherein:

the improvement further comprises a substantial portion of the lower edge of at least one of the cover side flaps being disposed non-parallel to the cover side flap fold line associated with that cover side flap.

17. The blank of claim 14 wherein:

the improvement further comprises the top edge of each of said side wall panels comprising a plurality of top edge portions and the lower edge of each of said cover side flaps comprising a plurality of lower edge portions.

18. The blank of claim 14 wherein:

the improvement further comprises the top edge of each of said side wall panels comprising a plurality of top edge portions and the lower edge of each of said cover side flaps comprising a plurality of lower edge portions, wherein:

said plurality of top edge portions comprises a portion disposed parallel and a portion disposed non-parallel to the respective side wall fold line, and

said plurality of lower edge portions comprises a portion disposed parallel and a portion disposed non-parallel to the respective cover side flap fold line.

19. The blank of claim 14 wherein:

the improvement further comprises each of said left and right corner panels having a tab at the front end edge and said cover having first and second tab engaging edges.

20. The blank of claim 14 wherein:

said cover further comprises a cover front flap having a predetermined height and said front wall has a predetermined height, the predetermined height of said cover front flap being substantially less than the predetermined height of said front wall.

21. First and second box blanks formed from a single sheet of foldable material and disposed side-by-side, each of the blanks being cut and scored to define:

a bottom panel,

a rear wall attached to said bottom panel,

opposing left and right side wall structures comprising (a) respective left and right side wall panels attached to said bottom panel at respective left and right side wall fold lines and each having a free rear end, a top edge, and a predetermined maximum height, (b) respective left and right corner panels attached to a front end of said left and right side wall panels and each having a front end edge, and (c) respective left and right connector panels attached to a bottom edge of said left and right corner panels,

a front wall structure opposing said rear wall and comprising a front wall attached to said bottom panel at a front wall fold line, and

a cover comprising (a) a cover panel attached to said rear wall, (b) a cover front flap attached to a front edge of said cover panel, and (c) opposing left and right cover side flap structures comprising (i) respective left and right cover side flaps attached to said cover panel at respective left and right cover side flap fold lines and each having a lower edge and a predetermined minimum height and (ii) respective free-swinging left and right corner flaps attached to a rear end of said left and right cover side flaps at respective left and right corner flap fold lines and each having a lower edge, wherein the predetermined minimum height of each of said left and right cover side flaps is substantially less than the predetermined maximum height of said left and right side wall panels and at least a portion of the lower edge of said left and right corner flaps is disposed in non-alignment to a substantial portion of the lower edge of said left and right cover side flaps, respectively;

said first and second blanks being oriented at one hundred eighty degrees from each other and with the top edge of one of the side wall panels of the first blank disposed adjacent the lower edge of one of the cover side flaps of the second blank.

22. The first and second box blanks of claim 21 wherein:

a substantial portion of the top edge of at least one of the side wall panels of each blank is disposed non-parallel to the side wall fold line associated with that side wall panel.

23. The first and second box blanks of claim 21 wherein:

a substantial portion of the lower edge of at least one of the cover side flaps of each blank is disposed non-parallel to the cover side flap fold line associated with that cover side flap.

24. The first and second box blanks of claim 21 wherein:

the top edge of at least one of the side wall panels of the first blank comprises a plurality of top edge portions and the lower edge of at least one of the cover side flaps of the second blank comprises a plurality of lower edge portions.

25. The first and second box blanks of claim 21 wherein:

the top edge of at least one of the side wall panels of the first blank comprises a plurality of top edge portions and the lower edge of at least one of the cover side flaps of the second blank comprises a plurality of lower edge portions, wherein:

said plurality of top edge portions comprises a portion disposed parallel and a portion disposed non-parallel to the side wall fold line of said at least one of the side wall panels, and

said plurality of lower edge portions comprises a portion disposed parallel and a portion disposed non-parallel to the cover side flap fold line of said at least one of the cover side flaps.

26. The first and second box blanks of claim 21, wherein in each of the blanks:

each of said left and right corner panels has a tab at the front end edge and said cover has first and second tab engaging edges.