GB2428234A

GB2428234A - Wedge shaped snack food container

Info

Publication number: GB2428234A
Application number: GB0514374A
Authority: GB
Inventors: Gary Orsman
Original assignee: St Neots Packaging Ltd
Current assignee: St Neots Packaging Ltd
Priority date: 2005-07-13
Filing date: 2005-07-13
Publication date: 2007-01-24
Anticipated expiration: 2025-07-13
Also published as: GB2428234B; GB0514374D0

Abstract

The container is made from a blank and comprises a generally rectangular back wall 4 that is joined at the sides by two triangular side walls 10, 10'. The side walls have each a flap 12, 12' depending there from, which can be folded, one over the other, in overlapping fashion to form the base wall of the container. The lid 14 can have a window 20 and a tab 18. Flanges 2, 16, 16' and 16'' are folded in a direction outwards of the container and serve to seal the lid 14. The container can be lined with a polyethylene layer, which, when the container is heated, can melt partially to seal the lid to the flanges.

Description

1 2428234 Title: Snack Food Container

Field of the Invention

The present invention relates to a wedge-shaped snack food container formed from a blank made from cardboard, paper or a similar foldable material, and to a method of preparing the snack food container.

Background of the Invention

The snack food industry is rapidly growing due to the increased consumption of take-away food and pre-prepared meals. Sandwiches are a convenient pre-prepared food which are widely available from various outlets.

Most sandwiches are diagonally cut to provide two triangular slices which are often sold in a triangular package. The sandwiches are placed next to one another in the package, usually with the longest side of the sandwich facing uppermost such that prospective consumers may observe the sandwich filling prior to purchase.

The packaging for sandwiches is often constructed from clear plastics material which may have a paper or cardboard label provided within the package, or a label adhered to the outer surface of the packaging.

However, such packaging has the disadvantage that it must be formed from the plastics material prior to placing the food inside. Furthermore, this type of packaging is usually not biodegradable or recyclable.

The provision of sandwich packaging prepared from paper or card material is disclosed in, for example, GB 2,391,212 and W002/346299. However, such packaging is typically structurally weak.

Further, a problem with such packaging is leakage of the sandwich filling. More especially, oily or fatty sandwich fillings (e.g. mayonnaise or the like) may frequently cause the formation of unappetising grease stains on the paper or card packaging.

Use of plastics material for food packaging usually allows for gas-tight sealage of foodstuffs, which prevents the packaged food from dehydrating and preserves freshness.

In contrast, existing card packaging allows for gas flow exchange through the packaging, leading to dehydration and curling of sandwiches.

In various embodiments the present invention aims to overcome or reduce one or more of the aforementioned problems.

Summary of the Invention

In a first aspect the invention provides a wedge-shaped container for snack-food, the container comprising card or other foldable material and being formed from a flat blank having a generally rectangular back wall, the two elongate sides of the back wall each being joined by a hinged fold to a respective side wall, a first foldable flap which forms a base wall of the container when the container is assembled, and a second foldable, flap of substantially similar dimensions as the first flap, such that when the container is assembled the second flap forms a second layer or thickness over or under substantially all of the base wall of the container.

Preferably the first and second foldable flaps are generally rectangular. Desirably the first foldable flap is provided attached to a first side wall and the second foldable flap is provided attached to a second side wall. In the assembled container the two side walls are each preferably essentially triangular, more especially essentially right-angled triangles, preferably isosceles triangles.

For present purposes the second flap is considered to form a second layer or thickness over or under substantially all of the base wall if the second flap has an overlap with at least 60% of the surface of the first flap, preferably at least 70%, more preferably at least 80%, and most preferably at least 90%. The double thickness of the base of the container, provided by the overlap, confers increased rigidity to the packaging. In addition, the double base layer helps to reduce leakage of the contents of the packaging, and help prevent the appearance of greasy stains on the outside of the container, and reduces gas flow through the container, reducing dehydration of the sandwiches and preserving freshness.

Desirably the blank further comprises a generally rectangular lid portion. This may be joined, typically by a hinged fold, to any suitable portion of the blank. Preferably the lid portion is attached by a hinged fold to the longest edge of one of the triangular side walls.

Advantageously the lid comprises a window portion formed from a transparent or translucent material, such that a snack food inside the container can be viewed by a prospective consumer when the container is assembled. A preferred material for the transparent or translucent portion of the lid is a biodegradable substance, such as a cornstarch film. In one embodiment of the present invention, the window portion may extend over substantially the entire length of the lid, although the window portion may cover a shorter length of the lid.

In a preferred embodiment, the invention provides a snack food container having a lid comprising a window portion, which window portion comprises a transparent or translucent film which is substantially free of folds or creases, especially transverse folds or creases. This enables a prospective consumer to see clearly the food inside the container, especially a sandwich filling. Preferably the window portion extends over at least 35% of the area of the lid, more preferably over at least 40% and most preferably over at least 45 % of the area of the lid.

Typically, a foldable flange is provided on the outer edges of one or more (preferably all) of the side walls, back wall and the base (i.e. those edges which are not hinged to another part of the packaging). Conveniently in assembling the container, the flanges are folded outwards (away from the body of the container) and the lid may be adhered to flanges, thus forming a seal and closing the snack food container.

In a preferred embodiment, all or at least part of one side of the card or other foldable material (which side forms the inner surface of the assembled container) is provided with a polyethylene coating. When heated, the coating partially melts. Accordingly, the polyethylene-coated card can be heated to seal the lid to the flanged portions of the side and back walls and the base.

In one embodiment of the present invention, a tab is provided on the lid, preferably at one corner thereof. Conveniently, pressure may be applied to the tab by the consumer to separate the lid from the body of the container, thus opening the container and allowing removal of the food by the consumer.

In a preferred embodiment a container in accordance with the invention consists entirely of biodegradable material. The container of the present invention is inexpensive and disposable.

Preferably, the snack food container of the present invention is used to hold one or more diagonally cut sandwich slices. Typically the snack food packaging is designed to hold two diagonally cut sandwich slices. Alternatively, the snack food packaging may be designed to hold three or four diagonally cut sandwich slices. The dimensions of the blank can be adjusted appropriately in a manner which will be apparent to those skilled in the art.

In accordance with one embodiment of the present invention, the sandwich slices may be placed on the inner surface of one of the side walls and the packaging may be folded and assembled around the sandwich. Alternatively, the packaging may be folded prior to the insertion of the sandwich. In either event, the lid is sealed as a last step, once the sandwich is placed inside the container.

Conveniently, the container blank may be stored in a flat conformation prior to use, thus minimising the space required to store the packaging.

In one embodiment, the outer surface of the packaging may be coloured and/or printed with labelling. In another embodiment, the outer surface of the packaging may be laminated.

Yet another advantage of the container of the present invention is that it provides, in preferred embodiments, a configuration which leads itself to processing on an automated production line. More specifically the container can be readily held in an open, assembled configuration, with the lid open, and then transferred to an insertion configuration (in which, for example, a sandwich may more readily be introduced into the container) without requiring any human manipulation.

Typically the container can be held in open, assembled configuration simply by application of gentle pressure, e.g. by holding the container between two pinch belts or rollers.

Preferably this pressure is applied to the respective apices of the side walls at or near (i.e. within 3cm, preferably within 2cm, most preferably within 1cm) the point where they contact the back wall and base. This allows one side wall to be readily opened outwards by the simple expedient of a projecting finger or the like, passage of the container past the finger causing a resistance to the advance of the side wall which is forced outwards, opening the container into an insertion configuration.

Desirably, once opened into this insertion configuration, the container may be deposited into another belt or line, preferably having grooves, apertures, recesses or the like being so shaped and dimensioned as to accept the container and retain it in the insertion configuration. The containers are then advanced past a packing station, at which the contents are inserted into the container. This will normally be done by human operatives, but in principle this step too could also be automated.

The container may then be advanced past another finger or projection to return it to the open assembled configuration, and past a cam, fmger or the like to close the lid. With the lid closed, the container may be advanced to a heating station to seal the lid to the rest of the container. In this way, partial opening of the container (to facilitate insertion of the foodstuff) and its closure can be performed in an entirely automated manner.

In accordance with a second aspect, the present invention provides a method of producing a snack food container in accordance with the first aspect defined above.

Detailed Description of the Invention

The invention will be further described by way of illustrative example, and with reference to the following drawings wherein: Figure 1 shows a blank from which a snack food container in accordance with the invention can be formed; Figure 2 is a perspective view of a snack food container in accordance with the invention in an assembled, open configuration; and Figure 3 is a perspective view of a snack food container in accordance with the invention in an assembled, closed configuration.

With reference to Figure 1, a blank (2) is shown from which a wedgeshaped snack food container may be formed. The blank is predominantly made from cardboaid and comprises a generally rectangular back wall (4) having two elongate side edges (6, 6') and two short edges (8, 8'). The elongate side edges (6, 6') and short edges (8, 8') are approximately 12cm and 7cm in length, respectively. Generally triangular side walls (10, 10') are provided. One of the side walls (10) is provided with a first foldable, generally rectangular flap (12), having a length of about 12cm and a width of about 7cm, which forms a base wall of the container when assembled. The second side wall (10') is provided with a second foldable, generally rectangular flap (12'), of dimensions substantially similar to those of the first flap (12). The triangular side wall (10) is attached to a lid (14) via a fold line provided along the longest edge (11) of the side wall (10). The longest edge (11) of the side wall (10) is approximately 17cm in length. Flange portions (16, 16', 16") are provided on the outer edges of the side wall (10'), back wall (4) and flap (12). In assembling the container, the flanges (16, 16', 16") are folded outwards (i.e. away from the body of the container) and the lid (14) may be adhered to the flanges (16, 16', 16"), thus forming a seal and closing the container. The flange portions (16, 16', 16") are approximately 1cm wide.

One side of the card (which forms the inner surface of the assembled container) is provided with a polyethylene coating. After assembly, the region of the container wherein the lid (14) is in contact with the flanges (16, 16', 16") is heated to partially melt the polyethylene coating such that the lid (14) is adhered to the flanges (16, 16', 16"), thus closing and sealing the container.

A corner of the lid is provided with a tab (18) which projects beyond the body of the container when assembled. To open the packaging, the consumer lifts the tab and applies pressure to release the lid from the body of the container.

The lid (14) is provided with a window portion (20) formed from a transparent or translucent material, such as a cornstarch film. The transparent film protects the contents of the packaging whilst allowing a prospective consumer to view the interior of the container.

A double thickness of packaging material is provided at the base by the overlap of two flaps (12, 12') provided at the ends of the triangular side walls (10, 10'). There is also a smaller flap (22) provided at the short end of the back wall (4). The provision of a double thickness of packaging material over substantially all of the base of the container has the advantages of providing rigidity to the packaging, protecting against leakage of the contents of the packaging, and reducing air flow through the packaging and concomitant dehydration of the foodstuff. A portion (24) of the first flap (12) is glued to the smaller flap (22) and another portion of the first flap (12) glued to the second flap (12'), in order to hold the container in the assembled configuration.

The container is ideally suited to holding a diagonally cut sandwich, wherein two parts of a sandwich are placed next to each other within the packaging. The dimensions of the assembled container (and hence of the unfolded blank) are selected to accommodate the sandwich. The sandwich is placed onto the inner surface of one of the side walls and the packaging is assembled by folding along the relevant fold lines. The packaging is then sealed and the enclosed sandwich is then placed on display for sale.

Figure 2 is a perspective view of the snack food container in an assembled, open configuration. The wedge shaped container is formed from a blank and when assembled, the container has a double thickness at its base formed from the overlap of two flaps (12, 12'). The container is provided with a lid (14). Foldable flanges (16, 16', 16") are provided on the outer edges of the side wall (10'), back wall (4) and flap (12). In assembling the container, the flanges (16, 16', 16") are folded outwards.

Figure 3 is a perspective view of a snack food container in an assembled, closed configuration One side of the card (which forms the inner surface of the container) is provided with a polyethylene coating. Once assembled, the region of the container wherein the lid (14) is in contact with the flanges (16, 16', 16") is heated sufficiently to cause the polyethylene coating to partially melt such that the lid (14) is adhered to the flanges (16, 16', 16"), thus closing and sealing the container.

The container shown in the drawings may conveniently be transferred between an open, assembled configuration and an insertion configuration in an automated maimer. For example, the container may be held in a first conveyance between two pinch belts or rollers which pinch the side walls near their respective apices at or near the point where they contact the back wall and base, with the lid (14) open, the aperture of the container preferably facing upwards or towards the direction of travel of the container (or at any intermediate position therebetween). A finger or projection contacting the side wall (10') will force the side wall (10') to open outwards as the container advances, typically causing the side wall (10') and attached flap 12' to rotate through approximately 90 , causing the container to adopt an insertion configuration.

Conveniently the container may at this juncture be transferred to a second belt or other conveyance, typically situation below the pinch belts or rollers and running at an angle thereto (e.g. perpendicular). Advantageously the container is dropped or deposited onto the second belt or other conveyance, which is preferably provided with a plurality of grooves, apertures, recesses or the like which are so shaped and dimensioned as to accept a container and retain it in the insertion configuration. In this configuration the container is advanced past a packing station at which a sandwich or other snack food is placed into the container. Advancement of the container past further suitably positioned fingers or projections: returns the container to the open, assembled configuration; and closes the lid.

The lid is then heat-sealed to the rest of the container at a sealing station.

Claims

1049.00/S CLAIMS

1. A wedge-shaped container for snack-food, the container comprising card or other foldable material and being formed from a flat blank having a generally rectangular back wall, the two elongate sides of the back wall each being joined by a hinged fold to a respective side wall, a first foldable flap which forms a base wall of the container when the container is assembled, and a second foldable flap of substantially similar dimensions as the first flap, such that when the container is assembled the second flap forms a second layer or thickness over or under substantially all of the base wall of the container.

: * s.

2. The wedge-shaped container of claim I wherein the first and second foldable flaps are **..

*.... generally rectangular. S...

3. The wedge-shaped container of claim 1 or 2 wherein the first foldable flap is provided attached to a first side wall and the second foldable flap is provided attached to a second sidewall.

4. The wedge-shaped container of any one of claims 1, 2 or 3 wherein, in the assembled container, the two side walls are each essentially triangular.

5. The wedge-shaped container of claim 4 wherein the two side walls are essentially right- angled triangles.

6. The wedge-shaped container of claim 4 or 5 wherein the two side walls are isosceles triangles.

7. The wedge-shaped container of any one of the preceding claims wherein the second flap has an overlap with at least 60% of the surface of the first flap.

8. The wedge-shaped container of any one of the preceding claims wherein the second flap has an overlap with at least 70% of the surface of the first flap.

9. The wedge-shaped container of any one of the preceding claims wherein the second flap has an overlap with at least 80% of the surface of the first flap.

10. The wedge-shaped container of any one of the preceding claims wherein the second flap has an overlap with at least 90% of the surface of the first flap.

11. The wedge-shaped container of any one of the preceding claims comprising a generally rectangular lid portion.

12. The wedge-shaped container of claim 11 wherein the lid is joined by a hinged fbld to any suitable portion of the blank. S... S... S * S...

13. The wedge-shaped container of claim 11 or 12 wherein the lid is attached by a hinged * fold to the longest edge of an essentially tangular side wall.

* . *

14. The wedge-shaped container of any one of claims 11 to 13 wherein the lid comprises a * window portion fomied from a transparent or translucent mateaI, such that a snack-food inside the container can be viewed by a prospective customer when the container is assembled.

15. The wedge-shaped container of claim 14 wherein the transparent or translucent portion of the lid is formed from a biodegradable substance, such as a cornstarch film.

16. The wedge-shaped container of claim 14 or 15 wherein the window portion extends over substantially the entire length of the lid.

17. The wedge-shaped container of any one of claims 14 to 16, wherein the window extends over at least 35% of the area of the lid.

18. The wedge-shaped container of any one of claims 14 to 17, wherein the window extends over at least 40% of the area of the lid.

19. The wedge-shaped container of any one of claims 14 to 18, wherein the window extends over at least 45% of the area of the lid.

20. The wedge-shaped container of any one of the preceding claims wherein a foldable flange is provided on the outer edges of one or more of the side walls, back wall and the base.

21. The wedge-shaped container of claim 20 wherein a foldable flange is provided on the outer edges of all of the side walls, back wall and the base.

::::.

22. The wedge-shaped container of claim 20 or 21 wherein the flanges are folded outwards, away from the body of the container.

23. The wedge-shaped container of claim 22 wherein the lid is adhered to the flanges, thus forming a seal and closing the snack food container. I * *

*

24. The wedge-shaped container of any of the preceding claims wherein all or at least pa of one side of the card or other foldable material, which forms the inner surface of the assembled container, is provided with a polyethylene coating.

25. The wedge-shaped container of claim 24 wherein the coating partially melts upon heating.

26. The wedge-shaped container of claim 24 or 25 wherein the polyethylenecoated card is heated to seal the lid to the flanged portions of the side and back walls and the base.

27. The wedge-shaped container of any of the preceding claims wherein a tab is provided on the lid.

28. The wedge-shaped container of any one of the preceding claims wherein the container consists entirely of biodegradable material.

29. The wedge-shaped container of any one of the preceding claims wherein the container is designed to hold one or more diagonally cut sandwich slices.

30. The wedge-shaped container of claim 29 wherein the sandwich slices are placed on the inner surface of one of the side walls and the packaging is folded and assembled around the sandwich.

31. The wedge-shaped container of claim 30 wherein the packaging is folded prior to insertion of the sandwich.

:

32. The wedge-shaped container of any one of claims 29 to 31 wherein the lid is sealed as a : : ::* last step, once the sandwich is placed inside the container.

*

33. The wedge-shaped container of any one of the preceding claims wherein the container blank may be stored in a flat confonnation prior to use, thus minirnising the space required to store the packaging.

34. The wedge-shaped container of any one of the preceding claims wherein the outer surface of the packaging is coloured and/or printed with labelling.

35. The wedge-shaped container of any one of the preceding claims wherein the outer surface of the packaging is laminated.

36. The wedge-shaped container of any one of the preceding claims wherein the container provides a configuration which lends itself to processing on an automated production line, where the container is readily held in an open, assembled configuration, with the lid open, and then transferred to an insertion configuration without requiring any human manipulation. t4-.

37. A method of producing a wedge-shaped container in accordance with any one of the preceding claims.

38. A wedge-shaped container as hereinbefore described and with reference to the accompanying drawings. * S. *5S* S... S... *0 ** * . S * ** * * S *