Dual Purpose Pie Carton

Abstract

A carton suitable for both shipping and displaying an item, particularly a bake good, such as a pie, is disclosed. The carton includes a top panel a bottom panel, first and second side panels and first and second end panels. According to an embodiment, a detachable panel section is provided in the top panel and the first side panel, and a substantially transparent film is attached to an underside of the top panel and the first side panel behind the detachable panel section. The carton may be opened to remove the item contained therein for cooking or preparation. The carton can be converted to a display configuration by completely detaching the detachable panel section from a remainder of the carton such that the transparent film forms a display window. When the carton is in its display configuration, the item may be placed in the carton such that the item is visible through the display window.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/095,140, filed on Sep. 8, 2008, the entire disclosure of which is incorporated herein by reference.

BACKGROUND

The disclosure relates to a carton for shipping and displaying a food item.

Baked goods, such as frozen or refrigerated pies are often shipped to a store or restaurant in shipping cartons, and then removed from the cartons for baking in the store or restaurant. After being baked, the baked goods are placed in display cartons for display and sale in the store or restaurant. The use of separate boxes for shipping and display results in increased cost and waste.

It is therefore desirable to provide a carton that is suitable for both shipping and display of a baked good.

SUMMARY

A carton for shipping and displaying a food item, such as a baked good, is disclosed. More specifically, the carton can be suitable for shipping and displaying a pie. The carton can be converted from a first configuration for storing and/or shipping a food item to a second configuration for displaying the food item. A blank assembly for forming the carton, a method of for forming the carton from the blank assembly, and a method of preparing a food item for sale using the carton are also disclosed.

According to an embodiment, a carton can comprise a bottom panel, a top panel, a first side panel, a second side panel, a first end panel formed by a first top end flap and a first bottom end flap, the first top end flap and the first bottom end flap being folded in overlapping relationship, and a second end panel. The first top end flap can comprise at least one tab and the first bottom end flap can comprise at least one cutout. The carton can be converted from a first configuration in which the first top end flap and the first bottom end flap are adhesively secured together such that the first end panel is closed, to a second configuration in which the first top end flap and the first bottom end flap are not adhesively secured together and the at least one tab is inserted in the at least one cutout such that the first end panel is closed.

According to an embodiment a carton can comprise a bottom panel, a top panel, a first side panel, a second side panel, a first end panel, a second end panel; and a detachable panel section in at least one of the top panel, the first side panel, the second side panel, the first end panel and the second end panel. The detachable panel section can be defined by a tear pattern. A substantially transparent film can be positioned behind the detachable panel section.

According to an embodiment, a carton blank assembly can include a blank comprising a bottom panel, a first side panel foldably connected to the bottom panel, a top panel foldably connected to the first side panel, and a second side panel foldably connected to the top panel. The blank can further comprise a first bottom end flap foldably connected to the bottom panel, a first top end flap foldably connected to the top panel, a second bottom end flap foldably connected to the bottom panel and comprising at least one cutout, and a second top end flap foldably connected to the top panel and comprising at least one tab. Adhesive can be disposed on either the first bottom end flap or the first top end flap.

The first top end flap and the first bottom end flap can be folded in overlapping relationship and releasably, adhesively secured together with the adhesive. The at least one tab can be inserted in the at least one cutout to secure the first top end flap and the first bottom end flap together when the first top end flap and the first bottom end flap are not adhesively secured together.

According to an embodiment, a carton blank assembly can include a carton blank comprising a bottom panel, a first side panel foldably connected to the bottom panel, a top panel foldably connected to the first side panel, a second side panel foldably connected to the top panel, a plurality of end flaps, and a detachable panel section defined by a tear pattern in the blank. The assembly can include a substantially transparent film attached to an underside of the blank and disposed behind the detachable top panel section.

According to an embodiment, a method of preparing a food item for sale can comprise transporting the food item to a location in a carton comprising a bottom panel, a top panel, a first side panel, a second side panel, a first end panel, and a second end panel. The first end panel can be formed by a top end flap and a bottom end flap, wherein the top end flap and the bottom end flap are folded in overlapping relationship and secured together by an adhesive bond. The method can comprise breaking the adhesive bond and opening the first end panel after transporting the carton to the location, removing the food item from the carton after opening the first end panel, cooking the food item after removing the food item from the carton, placing the food item inside the carton after cooking the food item, and, after placing the food item inside the carton, reclosing the first end panel by inserting at least one tab of the top end flap in a corresponding cutout in the bottom end flap.

According to an embodiment, a method of preparing a food item for sale can comprise transporting the food item to a sale location in a carton comprising a bottom panel, a top panel, a first side panel, a second side panel, a first end panel, a second end panel, a detachable panel section, and a substantially transparent film positioned behind the detachable panel section. The detachable panel section can be defined by a tear pattern and can be located in at least one of the top panel, the first side panel, the second side panel, the first end panel and the second end panel. The method can further comprise detaching the detachable panel section after transporting the food item to the sale location such that the food item can be viewed through the substantially transparent film.

Those skilled in the art will appreciate the above features and advantages, as well as additional features and advantages upon reading the following detailed description with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a blank for forming a carton according to an embodiment.

FIG. 2 is a perspective view of a partially erected structure formed from the blank of FIG. 1.

FIG. 3 is a perspective view of a fully erected carton formed from the blank of FIG. 1, wherein the carton is in a shipping or storage configuration.

FIGS. 4-6 illustrate a process of opening the carton of FIG. 3 for removing one or more items from the carton.

FIG. 7 shows the carton in a reclosed configuration for containing one or more items that have been placed in the carton.

FIG. 8 illustrates the detachment of a detachable portion of a top panel of the carton.

FIG. 9 shows the carton in a display configuration, upon detachment of the detachable portion from the carton.

DETAILED DESCRIPTION

FIG. 1 shows an outer face of a blank 1 for forming a carton 200 (FIGS. 2-8), according to an embodiment of the invention. The blank 1 includes a bottom panel 10, a first side panel 20 foldably connected to the bottom panel 10 by a fold line 14, a top panel 30 foldably connected to the first side panel 20 by a fold line 22, and a second side panel 40 foldably connected to the top panel 30 by a fold line 34. The blank 1 further includes a first bottom end flap 50 and a second bottom end flap 70 foldably connected to opposite ends of the bottom panel 30 by respective fold lines 16, 18, and a first top end flap 60 and a second top end flap 80 foldably connected to opposite ends of the top panel 30 by respective fold lines 36, 38. Fastening tabs 64 are foldably connected to a free end of the first top end flap 60 by a fold lines 62. First and second side end flaps 100, 110 are foldably connected to first ends of the first and second side panels 20, 40, respectively by respective fold lines 26, 46. Third and fourth side end flaps 120, 130 are foldably connected to second ends of the first and second side panels 20, 40, respectively, along fold lines 28, 48. A side flap 140 is foldably connected to an outer edge of the bottom panel 10 by a fold line 12.

The fold lines 12, 14, 16, 18, 22, 26, 28, 34, 36, 38, 46, 48, 62 may be crease lines, perforated crease lines, perforated lines, crease-cut lines or score lines, for example. Fold lines 36, 38 may include respective arc-shaped cut line segments 36a, 38a, which form vents in the carton 200 for venting steam from the carton 200 when a warm baked good is placed in the carton 200.

The first and second top end flaps 60, 80 are configured for attachment to the first and second bottom end flaps 50, 70, respectively, in a fully erected carton 200 (FIGS. 3-9). The first bottom end flap 50 includes adhesive regions 52 for adhesive attachment of the first top end flap 60 to the first bottom end flap 50. The adhesive regions 52 each include a perimeter cut pattern 54 and a pattern of perforated lines 56 within the cut pattern 54. The cut pattern 54 may extend partially, for example about 50%, through the thickness of the blank 1. The pattern of perforated lines 56 may also extend partially, such as about 30%, through the thickness of the blank. Adhesive may be applied directly on the adhesive regions 52, or on the inner side of the first top end flap 60. The cut patterns 54 and patterns of perforated lines 56 promote stronger attachment of the first top end panel 60 to the first bottom end panel 50. According to another embodiment (not shown), the adhesive regions 52 may be formed on the first top end flap 60 instead of the first bottom end flap 50.

The first bottom end panel 50 also includes cutouts 58 configured to receive the fastening tabs 64 when the adhesive bond between flaps 50, 60 is broken in the erected carton 200, as will be described later.

The second bottom end flap 70 includes an adhesive region 72 for adhesive attachment of the second top end flap 80 to the second bottom end flap 70. The adhesive region 72 includes a pattern of perforated lines 74. The pattern of perforated lines 74 may extend partially, for example about 30%, through the thickness of the blank 1. Adhesive may be applied directly on the adhesive regions 72, or on the inner side of the second top end flap 80.

The first and second side end flaps 100, 110 may include respective notches or cut-outs 102, 112, which effectively remove a part of the flaps 100, 110 so that the flaps 100, 110 do not cover or interfere with the slots 58 in flap 50 when the flaps 100, 110 are folded in the erected carton 200.

The side flap 140 is configured for attachment to the second side panel 40. An adhesive region 142 may be provided in the side flap 140 to secure the side flap 140 to the second side panel 40.

The panels 10, 20, 30, 40 and flaps 50, 60, 70, 80, 100, 110, 120, 130, 140 may be constructed of a paperboard or cardboard material, for example. However, other suitably rigid, durable and foldable materials may be employed.

The blank 1 includes a detachable panel section 150. The detachable panel section 150 includes a detachable top panel portion 30a in the top panel 30 and a detachable side panel portion 20a in the first side panel 20 foldably connected to the section 30a along the fold line 22. The detachable panel section 150 is defined by a tear pattern 152 extending within the top panel 30 and the first side panel 20. In the exemplary embodiment of FIG. 1, the tear pattern 152 is substantially rectangular, which results in the panel section 150 having a substantially rectangular shape. However other configurations and shapes are envisioned for the tear pattern 152 and the detachable panel section 150. For example, it is possible for the panel section 150 to extend into the first top end panel 60, the second top end panel 80 or the second side panel 40, or any one or combination of the panels 20, 30, 40, 60, 80.

As will be described later in more detail, the panel section 150 is configured to be removed from the carton 200 (FIG. 8) to place the carton 200 in a display configuration (FIG. 9), such that the detachable top panel portion 30a and the detachable side panel portion 20b are separated from the top panel 30 and side panel 20, respectively, leaving a non-detachable top panel portion 30b and a non-detachable side panel portion 20b with the carton 200. A cut-away corner section 155 having a free edge 156 may be provided in the detachable top panel portion 30a between adjacent end points 152a, 152b of the tear pattern 152. The cut-away corner section 155 is formed by gap or opening 157 between the detachable top panel section 30a and the non-detachable top panel section 30b and enables gripping of the detachable top panel portion 30a.

Still referring to FIG. 1, a substantially transparent, flexible film 158 is attached to the undersides of the top panel 30 and the first side panel 20 and disposed behind the detachable top panel and side panel portions 30a, 20a. The film 158 is visible in the area of the opening 157 in the shipping carton 200 (FIG. 3) and renders at least a portion of the interior of the carton 200 visible to a user or consumer. The film 158 may be adhesively or otherwise attached to the top panel 30 and the first side panel 20 at the non-detachable top and side panel portions 30b, 20b, and is preferably not attached to the detachable top and side panel portions 30a, 20a. In alternate embodiments in which the detachable panel section extends into other panels of the blank 1, the film 158 should extend behind such panels and be attached to the blank 1 around the detachable panel section 150.

FIG. 2 shows a partially erected carton 2 formed from the blank 1. In this configuration, the blank 1 is folded such that the top panel 30 and bottom panel 10 extend substantially parallel to each other, the first and second side panels 20 extend substantially parallel to each other, substantially perpendicular to the top and bottom panels 30, 10, and a rear end panel 280 extends substantially perpendicular to the top and bottom panels 30, 10 and the first and second side panels 20, 40. The rear end panel 280 is formed by the second top end panel 80 and second bottom end panel 70, which are folded such that second the top end panel 80 overlaps the second top end panel 70 and is attached to the adhesive region 72.

In the partially erected carton 2 as configured in FIG. 2, the first and second side panels 20, 40 are folded with respect to the top panel 30 along the fold lines 22, 34, respectively, and the bottom panel 10 is folded with respect to the first side panel 20 along the fold line 14. The side flap 140 is folded inwardly along the fold line 12 inside of the side panel 40, so as to extend substantially parallel to the side panel 40, and is optionally adhesively attached to the underside of the side panel 40 via the adhesive region 142, for reinforcing the side panel 40. The first and second side end flaps 100, 110 are folded inwardly along the fold lines 26, 46, respectively, so as to extend transversely to the first and second side panels 20, 40. The third and fourth side end flaps 120, 130 are folded inwardly along the fold lines 28, 48, respectively, so as to extend transversely to the first and second side panels 20, 40. The second top end flap 80 and the second bottom end flap 70 are folded over the third and fourth side end flaps 120, 130 along the fold lines 38, 18 to form the rear end panel 280, such that second the top end flap 80 overlaps the second bottom end flap 70. The second top end flap 80 is attached to the adhesive region 72 on the second bottom end flap 70, thereby forming the second end panel 280. The first top end flap 60, the first bottom end flap 50, and the first and second side end flaps 100, 110 are not folded inward and are positioned such that the partially erected structure 2 has an open front end 4, thereby providing access to the interior 6 of the partially erected structure 2.

An item I to be stored within the fully erected carton 200 (FIGS. 3-8) may be placed in the interior 6 of the partially erected carton 2 through the open front end 4 prior to storage and/or shipping. In particular, the item I may be an uncooked or unprepared food item, such as a frozen or refrigerated pie, or the item may be a ready-to-eat food item.

FIG. 3 shows the fully erected carton 200 formed from the blank 1, wherein the carton 200 is in a configuration for shipping or storing the item I (omitted from FIG. 3) therein. According to an embodiment of the invention, the configuration of FIG. 3 is suitable for storing and/or shipping the item I after the item I has been placed in the partially erected structure 2. The carton 200 in the configuration of FIG. 3 is configured similarly to the partially erected carton 2, except that the carton 200 includes a front end panel 260 formed by the first top end panel 60 and the first bottom end panel 50, and extending substantially parallel to the rear end panel 280. In the configuration of FIG. 3, the first and second side end flaps 100, 110 are folded inwardly along the fold lines 26, 36, respectively, so as to extend transversely to the first and second side panels 20, 40. The first top end flap 60 and the first bottom end flap 50 are folded over the first and second side end flaps 100, 110 along the fold lines 36, 16, such that first the top end flap 60 overlaps the first bottom end flap 50. The first top end flap 60 is attached to the adhesive regions 52 on the first bottom end flap 50, thereby forming the front end panel 260. Thus, the carton 200 fully encloses the item I.

FIGS. 4-6 illustrate a manner in which the carton 200 can be opened from the configuration of FIG. 3. Referring to FIG. 4, the first top end flap 60 can be detached from the first bottom end flap 50 by pulling the fastening tabs 64 outward and upward in the direction U so as to break the adhesive bond between the adhesive regions 52 and the first top end flap 60. Thereafter, as shown in FIGS. 5 and 6, the top and bottom end flaps 60, 50 and the first and second side end flaps 100, 110 can be folded outward to open the carton 200, and the item I can be removed. For example, when the item I (not shown in FIGS. 4-5) is a frozen, uncooked or unprepared food item, such as a pie, the item I can be removed from the carton 200 for cooking or other preparation.

FIG. 7 shows the carton 200 in a reclosed configuration after the first top end flap 60 has be detached from the first bottom end flap 50 as shown in FIGS. 4, 5 and 6. In the case of an item I that has been removed from the carton 200 in the configuration of FIG. 6, the item I can later be returned to the carton 200, for example after baking cooking or other preparation, and the carton 200 can then be reclosed in the configuration of FIG. 7. In the reclosed configuration, the first and second side end flaps 100, 110 are folded inwardly along the fold lines 26, 36, respectively, so as to extend transversely to the first and second side panels 20, 40. The first top end flap 60 and the first bottom end flap 50 are folded over the first and second side end flaps 100, 110 along the fold lines 36, 16, such that first the top end flap 60 overlaps the first bottom end flap 50. The first top end flap 60 is fastened to the first bottom end flap 50 by the fastening tabs 64, which are inserted in the cutouts 58 in the bottom end flap 50, thereby reforming the front end panel 260. Thus, the carton 200 fully encloses the item I. As illustrated in FIGS. 3-9, the cut line segments 36a, 38a form vents in the erected carton 200 which serve to vent steam from the carton 200 when the item I is a warm baked item, such as a pie.

FIGS. 8 and 9 illustrate the manner in which the carton 200 can be converted into a display configuration for displaying the item I. As shown in FIG. 8, the detachable panel section 150 can be detached from the remainder of the carton 200 along the tear pattern 152 by gripping the free edge 156 of the cut-away corner section 155, and pulling the detachable panel section 150 up and away from the remainder of the carton 200 in the direction Y. As shown in FIG. 9, upon completely detaching the detachable panel section 150 from the remainder of the carton 200, the carton 200 is converted to the display configuration. In the display configuration, the detachable top and side panel portions 30a, 20a are removed and the non-detachable top and side panel portions 30b, 20b remain with the carton, surrounding the film 158. Because the film 158 is substantially transparent, the film 158 forms a display window in the side panel 20 and the top panel 30, through which the item I (omitted from FIG. 9) is visible while the carton 200 is closed. The display configuration of the carton 200 is particularly useful for displaying the item I contained therein in a retail location. It is noted that, alternatively, the detachable panel section 150 can first be detached from the carton 200, and the item I can thereafter be placed in the carton 200 for display.

The foregoing disclosure provides illustrative embodiments of the invention and is not intended to be limiting. As understood by those of skill in the art, the overall invention encompasses other embodiments not specifically enumerated herein. For example, although the carton 200 is shown in the form of a parallelpipedal box, it can alternatively be shaped differently, and likewise the detachable panel section 150 and the associated film 158 can be shaped and arranged differently (e.g., a carton may include multiple separate detachable panel sections that are inwardly covered by a film, or respectively inwardly covered by multiple separate films). As an additional example, the fastening tabs 64 and cutouts 58 that receive the fastening tabs may be reduced or increased in number, may be arranged differently and/or may be replaced with any other suitable attachment mechanism(s).

Claims

1. An assembly for forming a carton, the assembly including:

a carton blank comprising a bottom panel, a first side panel foldably connected to the bottom panel, a top panel foldably connected to the first side panel, a second side panel foldably connected to the top panel, a plurality of end flaps, and a detachable panel section defined by a tear pattern in the blank; and

a substantially transparent film attached to an underside of the blank and disposed behind the detachable top panel section.

2. The assembly of claim 1, wherein the detachable panel section comprises a detachable top panel portion disposed in the top panel.

3. The assembly of claim 1, wherein the detachable panel section comprises a cut-away corner section configured to enable gripping of the detachable panel section.

4. The assembly of claim 1, wherein the detachable panel section is disposed in at least one of the top panel, the first side panel, the second side panel, the first top end flap and an end flap of the plurality of end flaps.

5. The assembly of claim 1, wherein:

the plurality of end flaps comprises a top end flap foldably connected to the top panel and a bottom end flap foldably connected to the bottom panel; and

the top end flap and the bottom end flap are configured to be selectively attached to each other and selectively detached from each other for closing and opening the carton, respectively.

6. The assembly of claim 5, comprising

at least one tab in the top end flap; and

at least one cutout in the bottom end flap, wherein the top end flap and the bottom end flap are configured to be folded in overlapping relationship and releasably, adhesively secured together with adhesive; and the at least one tab is configured to be inserted in the at least one cutout to secure the first top end flap and the first bottom end flap together when the top end flap and the bottom end flap are not adhesively secured together.

7. The assembly of claim 1, comprising at least one cut line segment configured to form a vent in the carton.

8. The assembly of claim 7, wherein the at least one cut line segment comprises a cut line segment formed in a fold line between one of the plurality of end flaps and the top panel.

9. A carton comprising:

a bottom panel;

a top panel;

a first side panel;

a second side panel;

a first end panel;

a second end panel; and

a detachable panel section in at least one of the top panel, the first side panel, the second side panel, the first end panel and the second end panel, the detachable panel section being defined by a tear pattern; and

a substantially transparent film positioned behind the detachable panel section.

10. The carton of claim 9, wherein the detachable panel section is located in the top panel.

11. The carton of claim 10, wherein the detachable panel section comprises a cut-away corner section configured to enable gripping of the detachable panel section.

12. The carton of claim 9, wherein the detachable panel section is located in at least one of the top panel, the first side panel, the second side panel, the first end panel and the second end panel.

13. The carton of claim 9, comprising at least one vent opening for releasing steam from the carton.

14. The carton of claim 13, wherein the at least one vent opening comprises a cut line segment in a fold line between the first end panel and the top panel and/or a cut line segment formed in a fold line between the second end panel and the top panel.

15. The carton of claim 9, wherein:

the first end panel comprises a first top end flap foldably connected to the top panel and a first bottom end flap foldably connected to the bottom panel; and

the first top end flap and the first bottom end flap are configured to be selectively attached to each other and selectively detached from each other for closing and opening the carton, respectively.

16. The carton of claim 15, comprising

at least one tab in the top end flap; and

at least one cutout in the bottom end flap, wherein the top end flap and the bottom end flap are configured to be folded in overlapping relationship and releasably, adhesively secured together with adhesive; and the at least one tab is configured to be inserted in the at least one cutout to secure the first top end flap and the first bottom end flap together when the top end flap and the bottom end flap are not adhesively secured together.

17. The carton of claim 9, wherein the carton is configured to contain a pie.

18. A method of preparing a food item, comprising:

transporting the food item to a location in a carton comprising a bottom panel, a top panel, a first side panel, a second side panel, a first end panel, a second end panel, and a detachable panel section and a substantially transparent film positioned behind the detachable panel section, wherein the detachable panel section is defined by a tear pattern and is located in at least one of the top panel, the first side panel, the second side panel, the first end panel and the second end panel; and

after transporting the food item to the sale location, detaching the detachable panel section such that the food item can be viewed through the substantially transparent film.

19. The method of claim 18, comprising:

opening the carton after transporting the food item to the sale location;

removing the food item from the carton after opening the carton;

cooking the food item after removing the food item from the carton;

placing the food item inside the carton after cooking the food item; and

reclosing the first end panel after placing the food item inside the carton.

20. The method of claim 19, wherein:

the first end panel comprises a top end flap and a bottom end flap configured to be folded in overlapping relationship;

opening the first end panel comprises breaking an adhesive bond between the top end flap and the bottom end flap; and

reclosing the first end panel comprises inserting at least one tab of the top end flap in a corresponding cutout in the bottom end flap.

21. The method of claim 18, comprising placing the carton on display after detaching the detachable panel section.

22. The method of claim 18, wherein the carton comprises at least one vent opening configured to vent steam from the carton.

23. The method of claim 18, wherein detaching the detachable panel section comprises gripping a cut-away corner section of the detachable panel section and pulling the detachable panel section.

24. The method of claim 18, wherein the food item is a pie.