Molded paper pulp pizza box

Abstract

An apparatus for containing a hot food product for delivery. The apparatus comprises a box member formed of molded paper pulp having a first predetermined shape and a first predetermined size. The box member has a base portion and a wall portion each of the base portion and the wall portion have an interior surface and an exterior surface. A plurality of raised portions having a second predetermined shape are disposed on the interior surface of the base portion. Such raised portions cover greater than 50 per cent of the interior surface of the base portion of the box member. A molded paper pulp lid member is engageable with the box member. The lid member has a second predetermined shape and a second predetermined size and has both an interior surface and an exterior surface. There is at least one closure means having a first portion formed on the lid member and a second portion formed on the box member for closing such box after such hot food product is placed therein.

Description

FIELD OF THE INVENTION

The present invention relates, in general, to a pizza box, and, more particularly, the present invention relates to a pizza box that is made of molded paper pulp.

BACKGROUND OF THE INVENTION

Corrugated paper material that is currently used for pizza delivery boxes tends to become soggy and to lose some of its structural strength after absorbing greasy drippings and steam condensation. A corrugated box also absorbs moisture emanating from hot, steaming pizza as it emerges from the oven. As a result, the top portion begins to droop a bit and some retailers use a small plastic piece on top of the pizza to hold the top up so that it does not touch the pizza toppings. Most pizza that is made available through retailers are circular in shape yet the pizza its transported in a square shaped box because of limitations of the die-cut corrugated paper box-making process. This mismatch in shape introduces unnecessary air around the hot product that leads to additional heat loss. Moreover, the mismatch allows the pizza to slide around in the box which can lead to loss of toppings and a messy pizza and box.

It should be noted that molded paper in environmentally responsible. Molded paper packaging is made from 100% recycled paper and a result is itself entirely recyclable and compostable. It can also be made from easy to renew resources like sugarcane pulp, weed pulp and wood chip pulp. Companies with a commitment to environmental issues show their support by packaging in molded paper. Molded paper also complies with the rigorous European Community packaging directive which mandates recycled packaging content.

A typical twelve inch corrugated paper box that is currently used in pizza deliveries cost the pizza retailer 35 to 40 cents at a bulk rate. A molded paper pulp pizza delivery box could be made for 30 to 50% less. In addition, cost for the raw materials for molded paper pulp products are generally more stable compared to corrugated paperboard or EPS. Further, using a circular delivery box creates a more secure packaging with less heat loss.

Thus, it would be advantageous if there were a pizza delivery box available that was made of molded paper pulp that would not is only be cheaper to produce but could be made in a circular form that would be more conducive for the delivery of a round pizza and also be packaged in a box that is not only made of recycled paper but is in itself entirely recyclable.

SUMMARY OF THE INVENTION

In a first aspect the present invention provides an apparatus for containing a hot food product for delivery. The apparatus comprises a box member formed of molded paper pulp having a first predetermined shape and a first predetermined size. The box member has a base portion and a wall portion each of the base portion and the wall portion have an interior surface and an exterior surface. A plurality of raised portions having a second predetermined shape are disposed on the interior surface of the base portion. Such raised portions cover greater than 50 per cent of the interior surface of the base portion of the box member. A molded paper pulp lid member is engageable with the box member. The lid member has a second predetermined shape and a second predetermined size and has both an interior surface and an exterior surface. There is at least one closure means having a first portion formed on the lid member and a second portion formed on the box member for closing such box after such hot food product is placed therein.

OBJECTS OF THE INVENTION

It is, therefore, one of the primary objects of the present invention to provide a pizza delivery box that is made of molded paper pulp.

Another object of the present invention is to provide a pizza delivery box that is made in a circular form.

Still another object of the present invention is to provide a pizza delivery box that is cheaper to make than present corrugated paper boxes.

Yet another object of the present invention is to provide a pizza delivery box that has excellent heat insulation.

Another object of the present invention is to provide a pizza delivery box that is far superior in handling greasy, oily products such as pizza than is the present corrugated paper boxes.

Still another object of the present invention is to provide a pizza delivery box that has better stackability than currently used boxes.

Yet another object of the present invention is to provide a pizza delivery box that does not require assembling.

Another object of the present invention is to provide a pizza delivery box that has an embossed design.

In addition to the various objects and advantages of the invention which have been described in some specific detail above it should be noted that various other objects and advantages of the present invention will become more readily apparent to those persons who are skilled in the relevant art from the following more detailed description, particularly when such description is taken in conjunction with the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of the top of a pizza delivery box and a lid according to an embodiment of the invention.

FIG. 2 is a is a perspective view of the bottom of a pizza delivery box.

FIG. 3 is a cross section of the lid member shown in FIG. 1 taken across the line III-III.

FIG. 4 is a cross section of the box member shown in FIG. 1 taken across the line IV-IV.

FIG. 5 is a top perspective view of the top of a pizza delivery box showing the lid connected to the base portion of the box.

FIGS. 6A and 6B are perspective views of the pizza delivery box showing one means of closure.

FIGS. 7A and 7B are perspective views of the pizza delivery box showing an alternate closure means.

BRIEF DESCRIPTION OF THE PRESENTLY PREFERRED AND VARIOUS ALTERNATIVE EMBODIMENTS OF THE INVENTION

Prior to proceeding with the more detailed description of the present invention it should be noted that, for the sake of clarity, identical components which have identical functions have been designated by identical reference numerals throughout the several views illustrated in the drawings.

In a first aspect the present invention provides an apparatus, generally designated 10, for containing a hot food product for delivery. It is within the scope of the invention that the apparatus 10 could be used for transporting various hot food products; however, the main hot food product that the invention is designed for is for the delivery of pizza, since pizza is by far the product that is most widely thought of when one thinks of home delivery. The apparatus 10 comprises a box member 2 formed of molded paper pulp and having a first predetermined shape and a first predetermined size. The box member 2 has a base portion 4 and a wall portion 6, each of the base portion 4 and the wall portion 6 have an interior surface and an exterior surface.

A plurality of raised portions 8 having a second predetermined shape are disposed on the interior surface of the base portion 4. Such raised portions 8 cover greater than 50 per cent of the interior surface of the base portion 4 of the box member 2. A molded paper pulp lid member 12 is engageable with the box member 2. The lid member 12 has a second predetermined shape and a second predetermined size and has both an interior surface and an exterior surface. Such lid member 12 when placed on top of the box member 2 has a substantially flat top surface 13 and a downwardly extending wall portion 15.

There is at least one closure means, generally designated 20, having a first portion formed on the lid member 12 and a second portion formed on the box member 2 for closing such box 2 after such hot food product is placed therein.

Such box member 2 and such lid member 12 can be formed as separate entities; however, in a presently preferred embodiment of the invention such molded paper pulp lid member 12 is hingedly connected along one edge thereof to a corresponding edge of said box member 2. Having the lid member 12 and the box member 2 formed as a single unit means that there will not have to be any assembly after the box is filled, one simply has to fold over the lid member and close it on top of the box member 2 and the apparatus 10 is ready for delivery. Further, having the lid member 12 attached to the box member 2 makes it easy to stack the units one on top of another which takes up a minimum amount of space.

Outer portions of each of the plurality of raised portions 8 are disposed a predetermined distance away from an outer periphery of the interior surface of the base member 4 of box member 2. It is also presently preferred that the plurality of raised portions 8 be uniformly disposed on the interior surface of the box member 2. It is also presently preferred that such plurality of raised portions 8 be substantially triangular in shape.

The outer surface of the box member 2 has raised portions 14, these raised portions 14 correspond to the area 16 between the outer periphery of the interior surface of the box member 2 and the outer portion of the plurality of raised portions 8 and further correspond to the area 18 between each uniformly disposed raised portion 8 on the interior surface of the box member 2. Such raised portions 14 on the outer surface of the box member 2 are designed for creating air pockets between the box member 2 and a supporting surface.

Such first predetermined shape of such box member can be one of substantially circular, hexagonal, octagonal and rectangular. It is presently preferred that such first predetermined shape is substantially circular primarily because the apparatus 10 is designed for the delivery of pizza and the circular shape would correspond to the common shape of pizzas. With the circular shape there is next to no wasted space in the apparatus and thereby there is less chance of the pizza sliding around in the container as can be the case with a rectangular box. Further, the first predetermined size would be the size of the pizza to be contained therein. That is, the box would be a size sufficient to contain a 12 inch pizza or there could be a smaller box for the delivery of a 9 inch pizza and so on.

Such apparatus 10 further can include a thin laminating film 22 that is disposed on at least the interior surface of the box member 2 and the lid member 12. Such laminating film 22 could also be disposed on the exterior surface of the box member 2 and the lid member 12.

As more clearly seen in FIG. 4 in cross section, the wall portions 6 of box member 2 further include a ridge member 24. The ridge member 24 extends outwardly from the wall portion 6. Similarly, as seen in FIG. 3, the lid member 12 includes a ridge member 26 that extends outwardly from the wall portion 15 of the lid member. The ridge member 24 on the box member 2 mates with the corresponding ridge member 26 on the lid member 12.

The closure means 20 includes a groove 28 that is disposed on an upper surface of the ridge member 24 and extends an entire perimeter of the ridge member 24. The closure means 20 also includes a rounded projection 32 disposed on a lower surface of the lid member 12 and extends the entire perimeter of the ridge member 26 for engagement with the groove 28 disposed on ridge member 24 of the wall portion 6 of the box member 2 for securing the lid member 12 to the box member 2 thereby reducing any heat loss when transporting such pizza.

The ridge member 24 of the box member further includes a lip portion 34 disposed on an outer periphery of the ridge member 24, such lip portion 34 is disposed on an outer edge of the groove 28. Similarly the ridge member 26 of the lid member 12 further includes a lip portion 36 disposed on the outer periphery of the ridge member 26 of the lip member 12. The lip portion 36 is disposed on an outer edge of the projection 32, such lip portion 36 of the lid member 12 is engageable with the lip portion 34 of the ridge member 24 of the wall portion 6 of the box member 2.

The ridge member ridge member 24 on the box member 2 further includes a projection 42 that extends outwardly therefrom. The projection 42 is disposed on a radially opposed portion of the boxmember 2 from the portion of the box member 2 where the hingedly connected lid member 12 is attached. The projection 42 on the box member includes at least one slit 46 disposed in the projection 42.

Similarly, the ridge member 26 of the lid member 12 further includes a projection 44 that extends outwardly therefrom. This projection 44 engages the at least one slit 46 in the projection 42 on the box member 2.

In an alternate embodiment, as seen in FIGS. 1, 7A and 7B, such projection 42 on the box member 2 includes two slits 46 disposed in the projection 42. The two slits 46 are spaced equidistant on the projection 42. To correspond to the two slits 46 in this embodiment such projection 44 on the lid member 12 includes two separate projections 44 for engagement with the two slits 46 disposed on the box member 2.

Thus, the present invention provides a pizza delivery box 10 is that is made of molded paper. Such molded paper uses the latest advances in food grade molded pulp technology to significantly improve the way pizza is presented and transported for delivery. The invention capitalizes on advances in molded paper pulp technology whereby food-grade packaging can now be developed from 100% post-consumption paper pulp. Compared to currently used corrugated paper boxes the innovation appreciably reduces the per-piece cost of packaging, while delivering a product with excellent heat insulation, moisture absorption and structural strength. Such a product is actually far superior in handling greasy, oily products like pizza. Additionally the “molded” nature of packaging allows distinct branding opportunities like “molded-in-logos” or attractive design patterns making the product a good vehicle to push brand distinction.

The pulp-molding process is a very low cost manufacturing process and after use, the material is 100% biodegradable. The round die-cut corrugated boxes are transported as flat shapes and must be assembled prior to use in delivery. The new design will reduce the effort required and the time needed. The molded paper pulp forms stack up exceptionally well (with minimal empty space between packaging), thereby using less space at the delivery counter compared to assembled corrugated boxes that do not stack well and retain empty interior space. Using the circular delivery box will also create a more secure and better heat-retaining packaging. Other attractive and optimal shapes and forms may be produced according to manufacturer specifications.

The structural elements of the lid of the molded paper pulp delivery box design allow for placement of an outer branding sticker and will also provide physical strength to the most vulnerable area of the lid. The molded box features raised surfaces or slices that create air pockets between the hot, oven-baked pizza box and the supporting surface (like a table) below, thereby reducing the rate of heat loss. A molded-in hinge, seal or flap that provides safe and secure closure to the box can join the upper and lower box portions yet various options are available to offer proper sealing and thus prevent heat loss.

While a presently preferred embodiment and alternate embodiments of the present invention have been described in detail above, it should be understood that various other adaptations and/or modifications of the invention can be made by those persons who are particularly skilled in the art without departing from either the spirit of the invention or the scope of the appended claims.

Claims

1. An apparatus for containing a hot food product for delivery, said apparatus comprising;

(a) a box member formed of molded paper pulp having a first predetermined shape and a first predetermined size, said box member having a base portion and a wall portion each of said base portion and said wall portion having an interior surface and an exterior surface;

(b) a plurality of raised portions having a second predetermined shape disposed on said interior surface of said base portion, said raised portions covering greater than 50 per cent of said interior surface of said base portion of said box member;

(c) a molded paper pulp lid member engageable with said box member, said lid member having a second predetermined shape and a second predetermined size and having a substantially flat top portion and a wall portion each of said substantially flat top portion and said wall portion having an interior surface and an exterior surface; and

(d) at least one closure means having a first portion formed on said lid member and a second portion formed on said box member for closing said box after such pizza is placed therein.

2. The apparatus, according to claim 1, wherein said molded paper pulp lid member is hingedly connected along one edge thereof to a corresponding edge of said box member.

3. The apparatus, according to claim 1, wherein outer portions of each said plurality of raised portions are disposed a predetermined distance away from an outer periphery of said interior surface of said base member of box member.

4. The apparatus, according to claim 3, wherein said plurality of raised portions are uniformly disposed on said interior surface of said box member.

5. The apparatus, according to claim 4, wherein said outer surface of said box member has raised portions, said raised portions corresponding to an area between said outer periphery of said interior surface of said box member and said outer portion of said plurality of raised portions and further corresponding to an area between each uniformly disposed raised portion on said interior surface of said box member, said raised portions on said outer surface of said box member for creating air pockets between said box member and a supporting surface.

6. The apparatus, according to claim 1, wherein said first predetermined shape is one of substantially circular, hexagonal, octagonal and rectangular.

7. The apparatus, according to claim 6, wherein said first predetermined shape is substantially circular.

8. The apparatus, according to claim 1, wherein said apparatus further includes a thin laminating film disposed on at least said interior surface of said box member and said lid member.

9. The apparatus, according to claim 8, wherein said apparatus further includes said thin laminating film disposed on said exterior surface of said box member and said lid member.

10. The apparatus, according to claim 2, wherein said wall portions of said box member further includes a ridge member, said ridge member extending outwardly from said wall portion.

11. The apparatus, according to claim 10, wherein said closure means includes a groove disposed on an upper surface of said ridge member and extending an entire perimeter of said ridge member.

12. The apparatus, according to claim 11, wherein said lid member includes a ridge member extending outwardly from said wall portion of said lid member.

13. The apparatus, according to claim 12, wherein said closure means includes a rounded projection disposed on a lower surface of said ridge member of said lid member and extending an entire perimeter of said ridge member for engagement with said groove disposed on said ridge member of said wall portion of said box member for securing said lid member to said box member thereby reducing any heat loss when transporting such pizza.

14. The apparatus, according to claim 13, wherein said ridge member of said box member further includes a lip member disposed on an outer periphery of said ridge member, said lip member disposed on an outer edge of said groove.

15. The apparatus, according to claim 14, wherein said ridge member of said lid member further includes a lip member disposed on an outer periphery of said ridge member of said lip member, said lip member is disposed on an outer edge of said rounded projection, said lip member of said lid member engageable with said lip member of said ridge member of said wall portion of said box member.

16. The apparatus, according to claim 10, wherein said ridge member further includes a projection extending outwardly therefrom, said projection disposed on a radially opposed portion of said box member from said portion of said box member where said hingedly connected lid member is attached.

17. The apparatus, according to claim 16, wherein said projection on said box member includes at least one slit disposed in said projection.

18. The apparatus, according to claim 17, wherein said ridge member of said lid member further includes a projection extending outwardly therefrom, said projection for engaging said at least one slit in said projection on said box member.

19. The apparatus, according to claim 18, wherein said projection on said box member includes two slits disposed in said projection, said two slits being spaced equidistant on said projection.

20. The apparatus, according to claim 19, wherein said projection disposed on said lid member includes two separate projections for engagement with said two slits disposed on said box member.

21. The apparatus, according to claim 1, wherein said lid member and said box member are separate units.

22. The apparatus, according to claim 1, wherein said second predetermined shape of said raised portions are substantially triangular.