THERMOFORMED BAKERY PACKAGE

A trifold thermoformed package with a bottom portion, a top portion and an internal portion integrally formed from a single sheet of thermoformable material. The top and bottom portions are arranged in a clamshell configuration and can be selectively closed about a first living hinge to cooperatively define an internal space for receiving items to be packaged. The internal portion is configured to fold about second living hinge into the package between the top portion and the bottom portion to form a shelf upon which items can be placed, thereby allowing two layers of items to be contained in the same package without direct stacking. The top portion may be joined to one edge of the bottom portion along a first living hinge and the internal portion may be joined to a second edge of the bottom portion along a second living hinge disposed opposite the first living hinge.

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Description
FIELD OF THE INVENTION

The present invention relates to thermoformed packaging and, more particularly, to thermoformed packages suitable for bakery and other similar items.

BACKGROUND OF THE INVENTION

Donuts and similar bakery items are commonly sold in a range of different packages. Some of these packages are manufactured from cardboard or paperboard. For example, many conventional donuts packages are formed by folding a die-cut paperboard blank into the desired rectangular shape. Paperboard and cardboard packages suffer from a number of shortcomings. For example, typical paperboard and cardboard packages have limited strength and they are not easily formed into contoured shapes that can provide the desired level of structural integrity. Further, liquids, including oils and greases, associated with the food items can seep into cardboard and paperboard. This not only has a negative aesthetic impact, but it can reduce the strength of the paperboard/cardboard and potentially causing a package failure. Paperboard and cardboard are opaque and do not allow the packaged items to be seen. As a result, paperboard and cardboard packages are often manufactured with windows that are covered with a transparent film. The addition of windows and transparent films not only increases cost, but it can also negatively affect the structural integrity of the package.

Thermoformed packages are also used regularly in packaging donuts and similar bakery items. Thermoformed packages provide a number of important benefits compared to paperboard and cardboard packages. For example, thermoformed packages overcome the principle shortcomings of paperboard/cardboard packages discussed above. Thermoformed packages do not absorb liquids, oils and greases like paperboard. They are, therefore, not subject to weaking when contacting liquids, such as oils and greases. Further, thermoformed materials can be transparent allowing the consumer to view the contents and can be formed with integral contours that provide the desired structural integrity.

With these types of packages, the size and shape of the package is selected to accommodate the desired number of donuts or similar bakery items. For example, the width and depth of the package is selected to allow the donuts or similar bakery items to be placed in the package in a single layer. It is generally considered undesirable to stack donuts and similar bakery items atop one another within a package for various reasons. For example, these types of products are typically relatively soft and the bottom products upon which other products are stacked are susceptible to crushing. In addition, if products are stacked they may be contaminated by glazes, frostings and other foodstuff on adjacent items. This may affect the taste, appearance and aesthetic appeal of the packaged items. Given the general preference to avoid stacking donuts and similar bakery items, the packages (both paperboard and thermoformed packages) can become increasingly unwieldy and awkward as they are designed as increasingly larger rectangles to package more and more products.

In view of the foregoing, there is need for an improved thermoformed package capable of packaging donuts and similar bakery items without stacking of packaged items.

SUMMARY OF THE INVENTION

The present invention provides a trifold thermoformed package with a bottom portion, a top portion and an internal portion that are integrally formed from a single sheet of thermoformable material. The top and bottom portions are arranged in a clamshell configuration and can be selectively closed to cooperatively define an internal space for receiving items to be packaged. In one embodiment, the internal portion is configured to fold into the package between the top portion and the bottom portion to form a shelf upon which items can be placed, thereby allowing two layers of items to be contained in the same package without direct stacking.

In one embodiment, the top portion is joined to one edge of the bottom portion along a first living hinge and the internal portion is joined to a second edge of the bottom portion along a second living hinge. The first edge and the second edge may be disposed on opposite sides of the bottom portion.

In one embodiment, the bottom portion includes a peripheral shoulder configured to receive and support the peripheral edges of the internal portion when the internal portion is folded into the interior of the package. The peripheral shoulder may extend partially or entirely around the periphery of the bottom portion. The peripheral shoulder may be continuous or discontinuous.

In one embodiment, the internal portion includes a peripheral rail configured to fit closely into the peripheral shoulder when the internal portion is folded into the interior of the package. The peripheral rail may extend partially or entirely around the periphery of the internal portion. The peripheral rail may be continuous or discontinuous. If desired, the peripheral rail may be configured to be coextensive with the peripheral shoulder when the internal portion is folded into the interior of the package.

In one embodiment, the bottom portion, the top portion and the internal portion are configured to divide the interior of the package into top and bottom regions of approximately the same height, thereby facilitating packaging of multiple layers of items in both the top region and the bottom region. In alternative embodiments, the bottom portion, the top portion and the internal portion may be configured to provide top and bottom regions of different heights, which may be useful, for example, in packaging different items in the bottom region and the top region.

In one embodiment, the package is configure specially for use in packaging donuts and similar items. In such embodiments, the bottom portion may include contours configured to receive individual packaged items. For example, a bottom configured to receive one layer of three generally circular donuts may include three generally circular contours—one for each donut. The circular contours may be arranged in a line one adjacent to another. In this embodiment, the internal portion may be configured to support a second layer three generally circular donuts. To that end, the internal portion may include three generally circular contours-again, one for each donut. The number of contours may vary to correspond with the number of donuts.

The present invention provides a simple and effective thermoformed package having an integral shelf capable of dividing the interior of the package into top and bottom regions. The shelf allows two layers of items to be packaged without stacking the packaged items one atop the other, which reduces the risk of crushing and helps to prevent against cross-contamination. The bottom portion, top portion and internal portion are integrally joined, which avoids the need to maintain separate inventories of top, bottom and internal portions. Similarly, the use of living hinges facilitates accurate folding of the various portions and helps to ensure proper alignment. When included, the peripheral shoulder and peripheral rail help to seat the internal portion in the bottom portion and provide the package with enhanced structural integrity. The package can also be provided with contours that separately and individually support packaged items. The contours can further help to maintain the packaged items in the desired condition during shipping and handling.

These and other features of the invention will be more fully understood and appreciated by reference to the description of the embodiments and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a package in accordance with an embodiment of the present invention in the opened conditioned.

FIG. 2 is a perspective view of the thermoformed package in a partially closed condition.

FIG. 3 is a perspective view of the thermoformed package in the closed condition.

FIG. 4 is a top view of the open package.

FIG. 5 is a front view of the open package.

FIG. 6 is a top view of the closed package.

FIG. 7 is a front view of the closed package.

FIG. 8 is a side view of the closed package.

FIG. 9A is a first sectional view of the closed package taken along line IX-IX of FIG. 6.

FIG. 9B is an enlarged view of Area 9B of FIG. 9A.

FIG. 9C is an enlarged view of Area 9C of FIG. 9A.

FIG. 10A is a second section view of the closed package taken along line X-X of FIG. 6.

FIG. 10B is an enlarged view of Area 10B of FIG. 10A.

FIG. 10C is an enlarged view of Area 10C of FIG. 10A.

FIG. 11 is a sectional view taken through two stacked packages showing the nesting features.

Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.

DESCRIPTION OF CURRENT EMBODIMENTS

A package assembly 10 in accordance with an embodiment of the present invention is shown in FIGS. 1-4. The package 10 generally includes a bottom portion 12, a top portion 14 and an internal portion 16 that are integrally formed from a sheet of thermoformable material. The bottom portion 12 and top portion 14 are arranged in a clamshell configuration and are selectively closable to cooperatively define an internal space for receiving items to be packaged. The internal portion 16 is configured to fold into the package 10 between the top portion 14 and the bottom portion 12 to divide the internal space and form a shelf upon which items can be placed, thereby allowing two layers of items to be contained in the same package without direct stacking the packaged items. This configuration may be particularly beneficial in packaging two layers of donuts and other similar items that might be negatively affected if stacked directly one atop the other.

Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s).

As noted above, the present invention provides a package 10 capable of packaging two layers of items without the need to stack packaged items one atop the other. The package 10 is of a one-piece construction having a bottom portion 12, a top portion 14 and an internal portion 16. The top and bottom portions 12 and 14 cooperatively define an internal space for packaging items, such as donuts and other similar items. The internal portion 16 divides the interior space into a bottom region 60 and a top region 62, and provides an internal shelf upon which the second layer of items can be placed. FIG. 1 shows the package 10 in the open condition. FIG. 2 shows the package 10 in a partially closed condition with the internal portion 16 folded into the upper open end of the bottom portion 12. FIG. 3 shows the package 10 in the closed condition.

In the illustrated embodiment, the package 10 is generally rectangular. However, the shape of package 10 may vary from application to application. In this embodiment, the bottom portion 12 generally includes a somewhat rectangular bottom floor panel 40, a bottom sidewall 42 extending upwardly from the periphery of the floor panel 40 and a bottom flange 44 extending outwardly from the top of the bottom sidewall 42. The upper extent of the bottom portion 12 defines a mouth 46 providing access to the interior space defined by the bottom floor panel 40 and the bottom sidewall 42. Similarly, the top portion 14 generally includes a somewhat rectangular top cover panel 50, a top sidewall 52 extending downwardly from the periphery of the top cover panel 50 and a top flange 54 extending outwardly from the bottom of the top sidewall 52. The lower extent of the top portion 14 (when folded into the closed position) defines a mouth 56 providing access to the interior space defined by the top cover panel 50 and the top sidewall 52.

The bottom portion 12 and top portion 14 may include mating features that help to align and potentially interlock the bottom portion 12 and the top portion 14 when the package 10 is closed. For example, the bottom portion 12 may include one or more upright ribs 70 and the top portion 14 may define one or more corresponding channels 72 configured to interfit with the ribs 70. The size, shape and configuration of the ribs 70 and channels 72 may be varied to control the amount of force required to close and open the package 10. If desired, the ribs 70 and channels 72 may be shaped to provide a snap-lock. For example, the head of each rib 70 and the base of each channel 72 may be enlarged slightly to bias the ribs 70 into fully seated engagement with the channels 72. Other snap-locking or interlocking features may be incorporated into the ribs 70 and channels 72. In the illustrated embodiment, the ribs 70 and channels 72 extend along the short edges of the package 10 and partially into the long edges of the package 10 leaving substantial gaps along the long edges of the package 10 for the internal portion 16 to extend. In alternative embodiments, the rib(s) 70 and channel(s) 72 may extend partially or entirely around the periphery of the package 10, and they may be continuous or discontinuous. If desired, the rib(s) 70 may be essentially coextensive with the channel(s) 72 when the package 10 is closed.

In this embodiment, the bottom sidewall 42 and the top sidewall 52 are of approximately the same size, such that the bottom portion 12 and the top portion 14 each define about one half of the overall height of the package 10. The relative heights of the bottom portion 12 and the top portion 14 may, however, vary from application to application. For example, the relative heights may vary when the items packaged in the bottom region 60 are of a different height than the items packaged in the top region 62.

In the illustrated embodiment, the bottom portion 12 and the top portion 14 are arranged in a clamshell configuration. More specifically, the top portion 14 is joined along one edge to the bottom portion 12 by a first living hinge 18 (or primary living hinge). The first living hinge 18 may extend along substantially the full length of one side of the bottom portion 12 and the top portion 14 as shown in FIG. 2. However, the length of the first living hinge 18 may vary from application to application. The first living hinge 18 may be continuous or discontinuous, as desired. As shown in FIG. 3, the first living hinge 18 of the illustrated embodiment is formed by cutting a discontinuous line between the bottom portion 12 and the top portion 14. The discontinuous line results in a plurality of small lands 24 that bridge between the bottom portion 12 and the top portion 14. The number, size and shape of the lands 24 may be varied from application to application to provide the first living hinge 18 with the desired characteristics.

Similarly, the internal portion 16 is joined along one edge to the bottom portion 12 by a second living hinge 20 (or secondary living hinge). The first living hinge 18 and the second living hinge 20 may extend along opposite sides of the bottom portion 12. In the illustrated embodiment, the package 10 is generally rectangular with a pair of long edges and a pair of short edges. As shown, the living hinges 18 and 20 extend along opposed long edges of the package 10. Alternatively, the second living hinge 20 may be located along a different edge of the package 10. For example, the second living hinge 20 may be located along an edge adjacent to the edge of the first living hinge 18. The second living hinge 20 may extend along substantially the full length of the bottom portion 12 and the top portion 14 as shown in FIG. 2. However, as with the first living hinge 18, the length of the second living hinge 20 may vary from application to application. The second living hinge 20 may be continuous or discontinuous, as desired. Referring again to FIG. 3, the second living hinge 20 of the illustrated embodiment is formed by cutting a discontinuous line between the bottom portion 12 and the internal portion 16. The discontinuous line results in a plurality of small lands 28 that bridge between the bottom portion 12 and the internal portion 16. The number, size and shape of the lands 28 may be varied from application to application to provide the second living hinge 20 with the desired characteristics.

In the illustrated embodiment, the bottom portion 12 includes a peripheral shoulder 30 configured to receive and support the internal portion 16 when the internal portion 16 is folded into the interior of the package 10. The peripheral shoulder 30 may extend partially or entirely around the periphery of the bottom portion 12. The peripheral shoulder 30 may be continuous or discontinuous. As perhaps best shown in FIGS. 1 and 4, the peripheral shoulder 30 of the illustrated embodiment is a generally planar surface that extends around the bottom portion 12 just outwardly of the mouth the bottom portion 12.

As noted above, the internal portion 16 is configured to fold into the interior of the package 10. In the illustrated embodiment, the internal portion 16 is, when folded disposed at the interface of the bottom portion 12 and the top portion 14. More specifically, the illustrated internal portion 16 includes a peripheral lip 74 that extends about the periphery of the internal portion 16 and, when the package 10 is closed, is sandwiched between interfacing surfaces of the bottom portion 12 and the top portion 14. In the illustrated embodiment, the peripheral lip 74 is generally continuous having narrow regions 80 and 82 corresponding with the ribs 70 and channels 72, and wider regions 84 and 86 corresponding with the spaces between the ribs 70 and channels 72. As shown in FIG. 3, the wider region 86 on the inside edge of the peripheral lip 74 is joined to the bottom portion 12 by the second living hinge 20 and more particularly by the lands 28 that bridge between the bottom portion 12 and the internal portion 16. The illustrated peripheral lip 74 is generally planar corresponding in shape with corresponding planar regions of the interfacing surfaces of the bottom portion 12 and the top portion 14. The size, shape and configuration of the peripheral lip 74 may vary from application to application.

The top portion 14 and/or the bottom portion 12 may be contoured to closely accommodate the peripheral lip 74 of the internal portion 16. For example, in the illustrated embodiment, the top portion 14 includes a shallow recess 76 generally corresponding in depth and shape with the peripheral lip 74 (See FIGS. 9B-C and 10B-C). When the package 10 is closed, the peripheral lip 74 occupies the void provided by the recess 76. As a result, the recess 76 allows the interfacing surfaces of the bottom portion 12, the top portion 14 and the internal portion 16 to close flat against each other when the package 10 is closed. In alternative embodiment, the recess 76 may have other size, shapes and configurations, and may be eliminated altogether in some applications.

The internal portion 16 may also be configured to partially fit down into the mouth of the bottom portion 12. In the illustrated embodiment, the internal portion 16 includes a downwardly extending peripheral rail 78 that is disposed inwardly from the peripheral lip 74, and is configured to fit closely along the bottom sidewall 42. The peripheral rail 78 may be continuous or discontinuous, but in the illustrated embodiment is continuous extending entirely around the internal portion 16. The peripheral rail 78 not only provides some interlock between the internal portion 16 and the bottom portion 12, but it also provides additional structural integrity to the internal portion 16. The size, shape and configuration of the peripheral rail 78 may vary from application to application.

The relative size and shape of the bottom portion 12, top portion 14 and internal portion 16 may vary from application to application depending in large part on the items to be packaged. In the illustrated embodiment, the package 10 is configured to package two layers of donuts. In this context, the bottom portion 12, the top portion 14 and the internal portion 16 are configured to divide the interior of the package 10 into top and bottom regions 60, 62 of approximately the same height, thereby facilitating the support of one layer of donuts on bottom floor panel 40 and a second layer of donuts on the shelf formed by the internal portion 16. In alternative embodiments, the bottom portion 12, the top portion 14 and the internal portion 16 may be configured to provide top and bottom regions of different heights, which may be useful, for example, in packaging items of different size and/or shape in the bottom region and the top region.

In the illustrated embodiment, the package 10 is intended for use in packaging donuts and other similar bakery items. In this embodiments, the bottom portion 12 includes contours configured to receive and separately support a number of individual packaged items. For example, the bottom floor panel 40 is formed with three generally circular contours 90, each shaped to separately and individually support a generally circular donut. The circular contours 90 may be arranged in a line one adjacent to another or in any other desired arrangement. In the illustrated embodiment, the internal portion 16 is configured to support a second layer three generally circular donuts. As a result, the illustrated internal portion 16 includes three generally circular contours 92—again, one for each donut to be packaged. The size and shape of the package 10 and the number and arrangement of contours 92 may be varied to correspond with the desired number of donuts to be packaged in the package 10. For example, a package may be configured to package a dozen donuts by doubling the width of the package and forming six contours in the bottom floor panel and six contours in the internal portion. The size, shape, number, arrangement and configuration of contours in the bottom portion 12 and the internal portion 16 may be varied depending on the configuration of the package and the size, shape and number of items to be packaged. The contours may also be specially configured to provide the bottom portion 12 and the internal portion 16 with the desired structural integrity. For example, the depth, width, shape and arrangement of contours may be selected to not only support the packaged items, but also to reinforce the package against bending under load.

In the illustrated embodiment, the bottom portion 12 and the top portion 14 include nesting features that facilitate stacking of packages 10 one atop the other. More specifically, in the illustrated embodiment, the top portion 14 includes a pair of generally semi-circular lugs 96 that extend upwardly from the cover panel 50, and the bottom portion 12 includes a pair corresponding semi-circular channels 98 recessed inwardly from the floor panel 40. As shown, the illustrated nesting features are coaxial with and generally correspond in shape with portions of the contours 90, 92. In use, packages 10 can be nested by fitting the channels 98 of one package 10 onto the lugs 96 of the underlying package 10 (See FIG. 11). The number, size, shape and configuration of nesting features may vary from application to application. In some applications, the nesting features may be eliminated.

The bottom portion 12 and the top portion 14 may be provided with pull tabs intended to assist in opening the package 10. For example, in the illustrated embodiment, the bottom portion 12 includes tabs 88 that extend outwardly from the corners of the bottom flange 44 and the top portion 14 includes tabs 89 that extend outwardly from the corners of the top flange 54. As shown, the tabs 88 and 89 are disposed on the corners opposite the first living hinge 18. The tabs 88 and 89 of this embodiment are configured to only partially overlap, thereby allowing a user to easily grasp the non-overlapping portions of the tabs 88 and 89, and pull them away from one another to separate the bottom portion 12 and the top portion 14 to open the package 10 about the first living hinge 18. The number, size, shape and configuration of tabs may vary from application to application. In some applications, the tabs may be eliminated.

The present invention is intended for use in manufacturing recyclable or disposable packages used as point-of-sale or point-of-purchase packaging. The package 10 may be manufactured from conventional thermoformable materials, such as PET, RPET, PVC or other similar polymers, using generally conventional thermoforming equipment with molds, tools and/or fixtures configured to implement the present invention. The thickness of the thermoformable material may vary from application to application, but in those embodiment intended for point-of-purchase or point-of-sale packaging, the material may have a nominal thickness in the range of 10-15 mils (0.010-0.015 inch).

The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.

Claims

1. A thermoformed package comprising:

a bottom portion, a top portion and an internal portion integrally formed from a single sheet of thermoformable material;
the bottom portion having a floor panel, a bottom sidewall extending from the floor panel and a bottom flange extending outwardly from the bottom sidewall, the bottom flange extending at least partially about the periphery of the bottom sidewall to form a bottom shoulder;
the top portion having a top panel, a top sidewall extending from the top panel and a top flange extending outwardly from the top sidewall, the top portion joined to the bottom portion by a first living hinge, the first living hinge configured to allow the top portion and the bottom portion to be selectively closed to define an internal space;
the internal portion having a peripheral edge joined to the bottom portion by a second living hinge, the internal portion configured to be selectively folded onto the bottom shoulder to form a shelf within the internal space between the top portion and the bottom portion, the shelf dividing the internal space into a bottom region capable of packaging a first layer of items and a top region capable of packaging a second layer of items.

2. The package of claim 1 wherein the internal portion has a peripheral lip generally corresponding in size and shape with the bottom shoulder, whereby the peripheral lip overlies the bottom shoulder when the package is closed.

3. The package of claim 2 wherein the internal portion includes a rail closely fitted into the bottom portion inwardly of the bottom shoulder when the internal portion is folded, the rail extending into the bottom portion along the bottom sidewall.

4. The package of claim 3 wherein at least one of the top flange and bottom flange includes a recess corresponding with the peripheral lip.

5. The package of claim 3 wherein the internal portion corresponds in size and shape with the bottom portion, whereby the internal portion closes the bottom portion providing separation between the top region and the bottom region.

6. The package of claim 5 wherein the bottom flange has a periphery and the internal portion has a periphery smaller than the bottom flange periphery.

7. The package of claim 6 wherein the bottom portion and the top portion include closing features that are interfitted when the package is closed.

8. The package of claim 7 wherein the closing features are disposed outwardly of the periphery of the internal portion, whereby the closing features of the top portion can be interfitted with the closing features of the bottom portion even when the internal portion is folded into the bottom portion.

9. The package of claim 8 wherein the top portion and the bottom portion are generally rectangular, and the closing features extend along short sides of the top portion and the bottom portion.

10. A thermoformed package for bakery items comprising:

a bottom portion, a top portion and an internal portion thermoformed from a single sheet, the bottom portion and top portion joined along a first living hinge and being movable about the first living hinge between an open state and a closed state, when in the closed state the bottom portion and the top portion cooperatively defining an internal space;
the bottom portion and the internal portion joined along a second living hinge, the internal portion being movable about the second living hinge between an unfolded state and a folded state, when in the folded state the internal portion is disposed between the bottom portion and the top portion forming a shelf dividing the internal space into a top region and a bottom region;
the bottom portion having a floor panel, a bottom sidewall extending from the floor panel and a bottom flange extending outwardly from the bottom sidewall, the bottom flange extending at least partially about the periphery of the bottom sidewall;
the top portion having a top panel, a top sidewall extending from the top panel and a top flange extending outwardly from the top sidewall, the top flange extending at least partially about the periphery of the top sidewall;
the internal portion having a peripheral lip disposed between the bottom flange and the top flange; and
wherein the bottom floor provides a first surface configured to support a first layer of packaged bakery items and the shelf provides a second surface configured to support a second layer of packaged bakery items.

11. The package of claim 10 wherein at least one of the top flange and the bottom flange includes a recess capable of receiving the peripheral lip.

12. The package of claim 10 wherein the internal portion includes a rail closely fitted into the bottom portion inwardly of the bottom flange when the internal portion is in the folded state, the rail extending into the bottom portion along the bottom sidewall.

13. The package of claim 10 wherein the bottom flange includes a bottom shoulder, the peripheral lip of the internal portion generally corresponding in size and shape with the bottom shoulder, whereby the peripheral lip overlies the bottom shoulder when the package is in the closed state.

14. The package of claim 13 wherein the peripheral lip extends around the full perimeter of the internal portion and the bottom shoulder extends around the full perimeter of the bottom portion.

15. The package of claim 13 wherein the bottom flange has a peripheral edge and the internal portion has a peripheral edge smaller than the bottom flange peripheral edge.

16. The package of claim 10 wherein the bottom portion and the top portion include closing features that are interfitted when the package is in the closed state.

17. The package of claim 16 wherein the closing features are disposed outwardly of the peripheral edge of the internal portion, whereby the closing features of the top portion can be interfitted with the closing features of the bottom portion even when the internal portion is folded into the bottom portion.

18. The package of claim 17 wherein the top portion and the bottom portion are generally rectangular, and the closing features extend along short sides of the top portion and the bottom portion.

19. A thermoformed package for bakery items comprising:

a bottom portion, a top portion and an internal portion thermoformed from a single sheet, the bottom portion and top portion joined along a first living hinge and being movable about the first living hinge between an open state and a closed state, when in the closed state the bottom portion and the top portion cooperatively defining an internal space;
the bottom portion and the internal portion joined along a second living hinge, the internal portion being movable about the second living hinge between an unfolded state and a folded state, when in the folded state the internal portion is disposed between the bottom portion and the top portion forming a shelf dividing the internal space into a top region and a bottom region;
the bottom portion having a floor panel, a bottom sidewall extending from the floor panel and a bottom flange extending outwardly from the bottom sidewall, the bottom flange extending at least partially about the periphery of the bottom sidewall;
the top portion having a top panel, a top sidewall extending from the top panel and a top flange extending outwardly from the top sidewall, the top flange extending at least partially about the periphery of the top sidewall;
the internal portion having a peripheral lip disposed between the bottom flange and the top flange, the top flange and the bottom flange sandwiching the peripheral lip; and
wherein the bottom floor provides a first surface capable of supporting a first layer of packaged bakery items and the shelf provides a second surface capable of supporting a second layer of packaged bakery items, the floor panel including a first plurality of contours configured to seat a plurality of packaged bakery items, the internal portion including a second plurality of contour configured to a seat a plurality of packaged bakery items.

20. The package of claim 19 wherein the first plurality of contours includes a plurality of generally circular contours each configured to individually retain a donut; and

wherein the second plurality of contours includes a plurality of generally circular contours each configured to individually retain a donut.
Patent History
Publication number: 20210130060
Type: Application
Filed: Nov 4, 2019
Publication Date: May 6, 2021
Inventors: Joshua C. Goad (Belmont, MI), George E. Raimer (Saranac, MI), Gordon L. Beach (Muskegon, MI)
Application Number: 16/672,890
Classifications
International Classification: B65D 75/24 (20060101); B65D 25/10 (20060101); B65D 85/36 (20060101); B65D 21/02 (20060101); B65D 43/16 (20060101);