MULTIPLE LEVEL CARTON BOX ASSEMBLY FOR PIZZA OR THE LIKE
The invention for which we wish to obtain a patent, is a multiple level carton box assembly, that is an embodiment of several vertically engaged interlocking parallel levels of carton boxes (trays), horizontally arranged in a series of one on top of the other, enabling the base (floor) of each carton box to act as a serving tray and also to become the cover of the adjacent box (tray) below. The carton boxes (trays) of our multiple level carton box assembly are secured (interlocked) to each other by means of vertical interlocking tongues extending above the front - back side walls of each carton box (tray) which penetrate the slits-slots of the base of the adjacent carton box (tray) above thus creating an embodiment, interlocking and stabilizing the multiple level carton box assembly in place and securing it against shifting, sliding, separation, bouncing or any other movement during transport. The multiple level carton box assembly is closed by only one cover which is placed on the uppermost carton box (tray) of the assembly, where the vertical interlocking tongues extend above the front - back side walls ready to engage and interlock the cover to the embodiment for the distribution of pizza, other takeaway foods and pastry.
Single level carton boxes for the distribution of pizza have been in the market since long ago. It has been established however, that with the use of such single-level boxes there is considerable waste of material, time and money. Furthermore, it is also established that the transport of a single pizza, requires its own separate box as well as time for its assembly. Particularly, we have researched the United States patent no. 4984734, date of patent January 15, 1991, of inventor Kenneth J. Zion, which requires an excessive amount of cardboard for the construction of each carton box and furthermore, the locking device of the carton boxes to one another is not safe for two reasons. First, because the locking flaps simply surround the adjacent carton box above without penetrating its base and therefore there is no stability in the stack, and second because the size of the flaps is not sufficient to withstand the weight and the heat from the pizza in the boxes above. This second fault is also evident in the design of the top cover which does not have any slots through which the flaps can slide to secure the cover which therefore can easily slide off with any vibration or movement during transport. The multiple level carton box assembly of our invention has both vertically interlocking "tongues" which penetrate the base of the adjacent box (tray) above and stabilize the assembly against shifting, sliding, separation, bouncing or any other movement and horizontal supporting
semicircular 'tongues" which allow each carton box (tray) to withstand the weight and the heat of the pizza in the adjacent carton box (tray) above without touching or crushing the pizza in the carton box (tray) below. The multiple level carton box assembly requires only one cover on the uppermost carton box (tray). This cover locks in place by the penetration of the vertically interlocking tongues of the uppermost carton box (tray) into the respective slits-slots on the cover thus securing the entire embodiment.
The advantages of our multiple level carton box assembly are as follows: First: Financial and ecological benefits. A conventional single carton box with its individual cover, requires 3,240 cm2 of cardboard. In our invention, a carton box of the same capacity requires 2,850cm2 of cardboard that is 390cm2 less cardboard or savings of 12%. For an order of two pizzas the conventional pizza carton boxes require 6,480 cm2 of cardboard while our multiple level carton box assembly, due to the use of a single cover, drops to 4,605cm2, a difference of 1,875cm2, that is savings of 29%. With a three-box multiple level carton box assembly (order of three pizzas), we have savings of 34% while with a four-box multiple level carton box assembly (order of four pizzas) the savings reach 37%. Furthermore, our invention achieves time saving in its assembly of up to 60%> compared to that of conventional packaging. The savings in material result in cost reduction in the production of the multiple level carton box assembly which passes on to the business owner of pizza parlors or other food establishments and in turn to the consumer. Thus a chain of double financial benefit is achieved, since less material means less quantity of natural resources being used (wood) and a decrease in the quantity of disposable material being produced with all the environmental advantages that result thereof. Second: Storage benefits Because the carton boxes (trays) of the multiple level carton box assembly are stored flat (open), thousands of carton boxes (trays) can be stored in the place of business requiring very little storage space while box assembly is extremely simple and fast for whatever number of carton boxes (trays) may be required. Third: Production benefits The manufacturer constructing the flat cut outs for the carton boxes (trays) of the multiple level carton box assembly does not need large storage space during production because the size of the cardboard cut out for each carton box (tray) is much less than that of conventional pizza boxes due to the fact that the cover is a separate component. There is also no waste of material nor large volumes of left over scraps for disposal.
Fourth: The side walls of each carton box (tray) of the multiple level assembly have a meticulously designed construction and reinforcements to
support the base of the adjacent carton box (tray) above thus eliminating the possibility of bending of the base due to the weight of the pizza because each base rests firmly on the rigid folding corners, the side walls as well as on horizontal semicircular "tongues" and vertical interlocking tongues of the adjacent carton box (tray) below which provide additional support. Fifth: Minimal time for assembly
The store owner does not need to assemble the carton boxes (trays) of the multiple level carton box assembly in advance but simply to place the pizza on each base, raise the side walls, fold the corners and with very little pressure stabilize them by entering the small "teeth" on the edges of the corners into the proper slots on the base of the carton box (tray) whereupon the carton box (tray) is ready to receive the top which is also the base of the adjacent carton box (tray) above and thus repeat this simple process until the desired number of levels is achieved and finally with a single cover close and lock the entire multiple level carton box assembly forming a rigid embodiment.
Sixth: Distribution benefits
With the successive placing of pizzas in multiple level carton boxes (trays), maintenance of satisfactory temperature levels is achieved, so that the orders are delivered to the consumer at satisfactory temperature levels because there are side ventilation holes on each carton box (tray) which help maintain the desired temperature steady and prevent sogging. Seventh: Serving benefits Serving becomes easy because the base of each carton box of the multiple level carton box assembly acts as a tray with no space taken up by the cover since the cover can be simply lifted off and discarded because the cover is a separate component not attached to the base as is the case in conventional pizza boxes where the base and cover are one component. In the multiple level assembly with the lifting of each carton box the one underneath remains open as a tray, etc.
Eighth: Stability of the shape and surface of pizza
Each carton box (tray) of the multiple level carton box assembly interlocks safely into the base of the adjacent carton box (tray) above thus creating an embodiment, preventing distortion of the stack due to the presence of vertically interlocking tongues which penetrate and interlock into slits-slots, slots on the base of the adjacent box (tray) above thus securing all carton boxes (trays) of the multiple level assembly in place. Furthermore, the rigid folding corners and the horizontal semicircular tongues ensure excellent surface resting of each carton box (tray) on top of the other preventing bending or collapsing of the carton boxes trays (above) and maintaining the pizza flat.
Ninth: Stacking two or more orders.
With our multiple level carton box assembly, two or more orders can be combined for delivery, stacked vertically so that the cover of each order acts as a divider for the next order above also securing the separate orders from shifting, sliding during transport by the extending above the cover vertical interlocking tongues which lock into the slits-slots on the adjacent base of the carton box (tray) of the next order above. Tenth: Variety of shapes, sizes and material
Our multiple level carton box assembly allows for; choice of any geometric shape of box (square, rectangular, hexagonal, octagonal even triangular). Choice of any desired size.
Besides corrugated cardboard, any other material which can be cut and bent to take the shape of a box can be used.
The above characteristics are the "avant-garde" of our invention giving our multiple level carton box assembly a uniqueness which we have arduously worked for, aiming to provide a beneficial packaging alternative to the entire industry of production and distribution of pizza as well as other food products and pastry.
DESCRIPTION OF THE CARTON BOX COMPONENTS
All component numbers refer to FIGURE 1 unless otherwise stated.
1, 2, 3, 4. Folding corners with teeth 1 A, 2A, 3A, 4A respectively 1A. Tooth which is inserted in slot IB 2A. Tooth which is inserted in slot 2B 3A. Tooth which is inserted in slot 3B 4A. Tooth which is inserted in slot 4B 5. Carton box base (floor)
6, 8. Opposite side walls
6A, 6B, 8A, 8B. Folding inwards corner triangles of side walls covered by the folding corners 1, 2, 3, 4, for bracing of side walls
7, 9. Front-back side walls 7A, 7B, 9A, 9B. Folding inwards corner triangles of side walls covered by the folding corners 1, 2, 3, 4, for bracing of side walls
7C, 9C. Vertically interlocking "tongues" which penetrate slits-slots 7D, 9D respectively of base 5 of the adjacent box (tray) above 7G, 9G. Vertically interlocking "tongues" which penetrate slots 7H, 9H respectively of base 5 of the adjacent box (tray) above, FIGURE 11
7J, 9J. Vertically interlocking "tongues" which penetrate slots 7K, 9K respectively of base 5 of the adjacent box (tray) above, FIGURE 17 7E, 7F, 9E, 9F. Horizontal semicircular "tongues" which bend inwards at a right angle to the vertical side walls (parallel to the box base ) for support of the base above and to prevent bending of same
10. Round ventilation holes
11. Cover, FIGURE 2
11 A, 11B. Slits-slots of cover 11 where vertical interlocking tongues 7C, 9C of the uppermost carton box (tray) are inserted respectively 12. Another type of cover, FIGURE 3
12A, 12B. Slits-slots of cover 12 where vertical interlocking tongues 7C, 9C of the uppermost carton box (tray) are inserted respectively 12C,12D. Side flaps of cover 12 which bend downwards and are inserted inside the uppermost carton box (tray) of the assembly. To be noted that the size and shape of the flaps may vary according to the size, shape and use of the carton box (tray).
13. Cover, FIGURE 12, which accompanies box base of FIGURE 11 13A, 13B. Slots of cover 13, FIGURE 12, where vertical interlocking tongues 7G, 9G of the uppermost carton box (tray) are inserted respectively 14. Cover, FIGURE 18, which accompanies box base of FIGURE 17
14A, 14B. Slots of cover 14, FIGURE 18, where vertical interlocking tongues 7J, 9J of the uppermost carton box (tray) are inserted respectively
DESCRIPTION OF MULTIPLE LEVEL CARTON BOX ASSEMBLY
All component numbers refer to FIGURE 1 unless otherwise stated.
In FIGURE 1, we can observe the various components of the carton box (tray) of the multiple level carton box assembly, numbered as they appear on page 5, under the section titled "Description of the Carton Box Components".
Side walls 6, 7, 8, 9 must be bent (raised) vertically to the base of the carton box (tray), while triangles 6A, 6B, 7A, 7B, 8A, 8B, 9A, 9B are to be bent inwards along the side walls so as to be covered by folded corners 1, 2, 3, 4.
Corners 1, 2, 3, 4, are to be bent vertically to the base of the carton box (tray). Then they are to be folded in half along the double discontinuous lines.
The semicircular tongues 7E, 7F, 9E, 9F must be bent inwards vertically to the side walls so as to be in a horizontal position parallel to the base of the carton box (tray). The discontinuous lines on the figures show the places where the side walls, triangles and tongues bend (are folded).
Following the above clarifications, we will now proceed to describe how the multiple level carton box assembly is constructed.
FIGURE 1 shows the flat cut-out surface of the carton box (tray), before assembly, made of corrugated cardboard as 'it will be delivered from the manufacturer. We raise (bend vertically) the two opposite side walls 6, 8 and side wall 7 with our palms on corners 1, 4 and with our fingers we bend inwards triangles 6B, 7A, 7B, 8A. We then raise (bend) corners 1, 4, fold them in half inwards along the double discontinuous lines so as to cover triangles 6B, 7A, 7B, 8 A and we then press teeth 1 A, 4A into their respective slots IB, 4B on base 5 so that the folded corners are safely secured in place. We then raise the last side wall 9, and in the same manner, we bend inwards triangles 6A, 9B, 9A, 8B, we raise corners 2, 3 and fold them in half along the double discontinuous lines covering triangles 6 A, 9B, 9 A, 8B and we press teeth 2A, 3 A into their respective slots 2B, 3B on base 5. Finally, we bend the semicircular tongues 7E, 7F, 9E, 9F inwards so as to bring them to a horizontal position. The first carton box (tray) of the assembly is now constructed with its side walls rigidly secured to base 5. We continue to assemble the second, third, etc. carton boxes (trays) in the same manner.
Please note that the analytical description of the multiple level carton box assembly given in the preceding paragraph, in no way suggests that this is a time consuming process because in actuality the time required for the assembly of the carton box (tray) does not exceed 15 to 20 seconds, having placed the pizza in the box beforehand and repeating this simple process for as many carton boxes (trays) as necessary quickly, securely, safely but most of all economically.
The vertical interlocking tongues 7C, 9C of the front - back side walls of each carton box (tray), are inserted and lock into slits-slots 7D, 9D respectively on base 5 of the adjacent carton box (tray) above so stabilizing the multiple level embodiment against movement or vibration of any kind while cover 11 , FIGURE 2, covers the uppermost carton box (tray) of the assembly and is stabilized by vertical interlocking tongues 7C, 9C extending above the uppermost carton box (tray) which are inserted into slits-slots
11 A, 1 IB respectively. Using cover 12, FIGURE 3, the vertical interlocking tongues 7C, 9C of the uppermost carton box (tray) are inserted into the slits-slots 12 A, 12B respectively while flaps 12C, 12D are bent downwards and inwards along side walls 6, 8 of the uppermost carton box (tray) of the assembly thus securing the embodiment completely. Holes 10, FIGURE 1, are used for ventilation purposes.
In FIGURE 11 , the vertical interlocking tongues 7G, 9G on the front - back side walls of each carton box (tray) have small indentations (cuts) on one side of the vertical interlocking tongues 7G, 9G in the same direction. These vertical interlocking tongues 7G, 9G, are inserted into slots 7H, 9H on base 5 of the adjacent carton box (tray) above and stabilize the assembly with a slight push sideways (shift). For this reason slots 7H, 9H are placed off center to allow the base 5 of the adjacent box above to be pushed sideways (shift) into vertical interlocking tongues 7G, 9G and lock and stabilize the embodiment of the multiple level carton box assembly for pizza, various other foods and pastry. Cover 13 of FIGURE 12 covers the uppermost carton box (tray) of the assembly and interlocks in place by a sliding motion (shift) of vertical interlocking tongues 7G, 9G into slots 13 A, 13B respectively of cover 13, FIGURE 12, which are placed off center so that the cover can shift and lock into place thus securing the embodiment completely.
All other components and numbers of FIGURE 11 are the same as those of FIGURE 1 with all box components numbered and described under section titled "Description of Carton Box Components" on page 5.
In FIGURE 17, the vertical interlocking tongues 7J, 9J on the front - back side walls of each carton box (tray) have small indentations (cuts) on opposite sides. These vertical interlocking tongues 7J, 9J, are inserted into slots 7K, 9K on base 5 of the adjacent carton box (tray) above and stabilize the assembly by rotation. For this reason slots 7K, 9K are placed off center in opposite directions to allow the base 5 of the adjacent carton box (tray) above to rotate into the vertical interlocking tongues, 7J, 9J and lock and stabilize the embodiment of the multiple level carton box assembly for pizza, various other foods and pastry. Cover 14 of FIGURE 18, covers the uppermost carton box (tray) of the assembly and interlocks into place by rotation of the vertical interlocking tongues 7J, 9J into slots 14A, 14B respectively of cover 14, FIGURE 18, which are placed off center in opposite directions so that the cover can rotate and lock into place thus securing the embodiment completely. All other components and numbers of FIGURE 17 are the same as those of FIGURE 1 , FIGURE 11 , with all box components numbered and described under section titled "Description of Carton Box Components" on page 5.
By referring to FIGURE 1, FIGURE 11, FIGURE 17, we surmise that the vertical interlocking tongues can be of three different types. The first type of interlocking tongues (7D, 9D), FIGURE 1, allows the adjacent carton box (tray) above to simply move on an up and down direction to interlock with the adjacent carton box (tray) below, the second type of interlocking tongues (7G, 9G), FIGURE 11, requires a sliding movement (shift) of the adjacent carton box (tray) above to interlock with the carton box (tray) below and the third type of interlocking tongues (7J, 9J), FIGURE 17, requires a rotating motion of the adjacent carton box (tray) above to interlock with the carton box (tray) below. The same applies to their respective types of covers (11, 12) FIGURES 2, 3, cover (13) FIGURE 12 , cover (14) FIGURE 18.
DESCRIPTION OF ATTACHED FIGURES
FIGURE 1. Flat carton box (tray) surface (unassembled) as it will be manufactured Numbers are described under section titled "Description of Carton Box Components" on page 5
FIGURE 2. Cover 11 , with slits-slots 11 A, 1 IB
FIGURE 3. Cover 12 is a variation of cover 11 with slits-slots 12A, 12B and flaps 12C, 12D. To be noted that this particular size and shape of flaps is indicative only. The size and shape of the flaps may vary according to the geometric shape, size and use of the carton box (tray). FIGURE 4. Left-right side wall of carton box (tray) of FIGURE 1 FIGURE 5. Front-back side wall of carton box (tray) of FIGURE 1 FIGURE 6. Assembled single carton box (tray), uncovered FIGURE 7. Two-level carton box (tray) assembly, uncovered FIGURE 8. Single carton box (tray) with cover
FIGURE 9. Two-level carton box (tray) assembly, where slots on base 5 are numbered 7D, 9D and vertical interlocking tongues are numbered 7C, 9C. The vertical interlocking tongue 7C, shown with a discontinuous line, is inserted into slit-slot 7D on base 5 of the carton box (tray) above, while vertical interlocking tongue 7C, shown by a continuous line, is inserted into slit-slot 11B of cover 11. Vertical interlocking tongue 9C is inserted into slit-slot 9D on base 5 of the carton box (tray) above while vertical interlocking tongue 9C is inserted into slit-slot 11A of cover 11. FIGURE 10. Two-order assembly. (Double order R. Single order M) Separation cover 11 and top cover 11 on single order.
FIGURE 11. Flat cut out carton box (tray) surface (unassembled) with differently shaped vertical interlocking tongues than those of FIGURE 1. On the flat cut out carton box (tray) surface of FIGURE 11 the vertical interlocking tongues 7G, 9G have indentations (cuts) on one side into which slides (shifts) base 5 of the adjacent carton box (tray) above and locks in place to also form the cover of the carton box (tray) below. Slots 7H, 9H on base 5 of FIGURE 11 are placed off-center in the same direction to match the indentations (cuts) of the vertical interlocking tongues 7G, 9G of the adjacent carton box (tray) below so as to penetrate slots 7H, 9H of base 5 of the adjacent carton box (tray) above and slide (shift) to interlock in place.
Other than the difference in the shape of the vertical interlocking tongues 7G, 9G and the position of slots 7H, 9H, all other components and numbers are the same as those in FIGURE 1.
FIGURE 12. Cover 13 which solely accompanies the carton box (tray) type of FIGURE 11. This cover has slots 13 A, 13B placed off center on both sides in the same direction to match the position of the indentations (cuts) in the vertical interlocking tongues 7G, 9G so it can slide (shift) into slots 13 A, 13B and interlock in place.
FIGURE 13. Front -back side wall of carton box (tray) of FIGURE 11
FIGURE 14. Two-level carton box (tray) assembly and cover 13 before stacking
FIGURE 15. Stacking of the two carton boxes (trays) and cover 13 (order of two pizzas) showing how the vertical interlocking tongues 7G, 9G, slide into slots 7H, 9H, ready to be slided (shifted) in place to interlock the assembly.
FIGURE 16. Interlocked two-level carton box (tray) assembly with cover
13, as it appears after sliding (shifting) into place. FIGURE 17. Flat cutout carton box (tray) surface (unassembled) with differently shaped vertical interlocking tongues than those of FIGURE 1,
FIGURE 11.
On the flat cutout carton box (tray) surface of FIGURE 17 the vertical interlocking tongues 7J, 9J have indentations (cuts) in opposite directions into which rotates base 5 of the adjacent carton box (tray) above and interlock in place to also form the cover of the adjacent carton box (tray) below.
Slots 7K, 9K on base 5 of FIGURE 17 are placed off center in opposite directions to match the indentations (cuts) of the vertical interlocking tongues 7J, 9J of the adjacent box (tray) below so as to penetrate slots 7K,
9K of base 5 of the adjacent box (tray) above and rotate to interlock in place. Other than the difference in the shape of the vertical interlocking tongues 7J,
9J and the position of slots 7K, 9K, all other components and numbers are the same as those in FIGURE 1, FIGURE 11. FIGURE 18. Cover 14 which solely accompanies the carton box (tray) type of FIGURE 17. This cover has slots 14 A, 14B placed off center on both sides in the opposite direction to match the position of the indentations (cuts) in the vertical interlocking tongues 7J, 9J so it can rotate into slots 14A, 14B and interlock in place. FIGURE 19. Front side wall of carton box (tray) of FIGURE 17
FIGURE 20. Back side wall of carton box (tray) of FIGURE 17.