CA1320703C - Microwave carton - Google Patents
Microwave cartonInfo
- Publication number
- CA1320703C CA1320703C CA000595056A CA595056A CA1320703C CA 1320703 C CA1320703 C CA 1320703C CA 000595056 A CA000595056 A CA 000595056A CA 595056 A CA595056 A CA 595056A CA 1320703 C CA1320703 C CA 1320703C
- Authority
- CA
- Canada
- Prior art keywords
- carton
- top panel
- panel
- along
- flap
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
- B65D5/42—Details of containers or of foldable or erectable container blanks
- B65D5/54—Lines of weakness to facilitate opening of container or dividing it into separate parts by cutting or tearing
- B65D5/545—Lines of weakness to facilitate opening of container or dividing it into separate parts by cutting or tearing for opening containers formed by erecting a "cross-like" blank
- B65D5/5455—Lines of weakness to facilitate opening of container or dividing it into separate parts by cutting or tearing for opening containers formed by erecting a "cross-like" blank the lines of weakness being provided in a closure hinged to an edge of the container body
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Cartons (AREA)
- Package Specialized In Special Use (AREA)
Abstract
MICROWAVE CARTON
ABSTRACT OF THE DISCLOSURE
A carton of unitary structure which is adapted for heating food, especially frozen food, in a microwave oven. An openable removable top flap for the carton is formed by partially scoring the outer and inner surfaces of the top panel and providing slit lines or foraminating the front flap. The slit lines or foraminations in the front flap, preferably herringbone slit lines formed into the surface of the carton, extend from locations at a top flap crease in the top panel to positions adjacent a lifting tab portion provided at the free edge of the front flap. A pair of spaced apart lower score lines are formed in the inner surface of the top panel along the crease line forming the folding edges of the side flaps and along the back flap, whereas a pair of spaced apart upper score lines in the outer surface are closely spaced apart from and in parallel with but wider spread apart than the upper score lines.
ABSTRACT OF THE DISCLOSURE
A carton of unitary structure which is adapted for heating food, especially frozen food, in a microwave oven. An openable removable top flap for the carton is formed by partially scoring the outer and inner surfaces of the top panel and providing slit lines or foraminating the front flap. The slit lines or foraminations in the front flap, preferably herringbone slit lines formed into the surface of the carton, extend from locations at a top flap crease in the top panel to positions adjacent a lifting tab portion provided at the free edge of the front flap. A pair of spaced apart lower score lines are formed in the inner surface of the top panel along the crease line forming the folding edges of the side flaps and along the back flap, whereas a pair of spaced apart upper score lines in the outer surface are closely spaced apart from and in parallel with but wider spread apart than the upper score lines.
Description
132~3 MICROWAVE CARTON
FIELD OF THE I~ ENT_ON
The present invention relates in general to cartons, and more particularly, relates to a carton of unitary structure which is adapted for heatiny food, especially frozen food, in a microwa~e oven.
In recent years, microwave ovens have assumed an important position in the ~itchens of numerous homeowners, inasmuch as they enable foods, various kinds of foods, s~ch as fro~en food consisting of vegetables and even complete meals to be quickl~l an~
convenlently heated and/or cooked in microwave ovens.
~n particular, modern homemakers who frequently prepare meals for a household while concurrently being employed in a full-time job in industry or ccmmerce, have recognized the convenience of microwave cooking and heating of frozen foods and the like. However, in order to do so, some labor-intensive steps must be undertaken. In essence, the food must be removed from the package, irrespective as to whether it is constituted of a plastic or paperboard carton or a foil tray, arranged in a dish transparent to microwaves-and possessing the necessary strength and then heated in the microwave oven. This step is necessary since various objects, such as aluminum foil trays or other metal receptacles containing the food cannot be employed in microwave ovens; whereas other types of cartons are not suitable for the retention of liquids.
On the other hand, cartons which are designed to hold liquids, utilize adhesives, which when subjected to the heat of the microwave oven frequently produce off-tastes and generate off-odors in the foods.
~-' . ~ ~
~ 32~0~
DISCUSSION OF THE PRIOR ART
In order to improve upon the structure and the convenience in the utilization of microwave cartons, particularly cartons which can ~e opened prior to and/or during the cookiny sequence to enable access to the carton contents, and then reclosed so as to e~fect~vely seal in t~.e food, various types of microwave cartons have been developed in the art.
Thus, Ielmini U.S. Patent 4,687,104 discloses a lo microwave carton possessing a top and front flap structure with parallel spaced inner and outer score lines to define openable and recloseable top and ~ront flap portions through the formation of tearable joints.
The top flap portion is confiyured to allow for the lS retention of a full-strength U-shaped top surface to enable lifting of the carton and contents therein without affecting the integrity of the carton structure. This type of carton, while enabling ~he heating of foods in a microwave oven, does not enable the sealing reclosure of the front flap portion because of the incorporation of the parallel spaced tear joint lines, and moreover, in one embodiment, includes a tab-receiving slit in the sidewall thereof which will permit liquids to escape from the carton during the heating of the carton contents in a microwave oven.
~eroszek U.S. Patent 4,594,492 pertains to a microwave pac~age in the nature of a carton which incorporates a structure for browning foods in the carton when cooked in a microwave oven. There is no disclosure of a carton which allows for the resealing thereof prior to or after heating the carton contents in the oven so as to inhibit the egress of any liquids from the carton.
3 ~ 3 Smith U.S. Patent 3,167,238 discloses a recloseable carton which incorporates top and front flap portions which are opena~le by separation Cro~ ~he remaining carton along tear lines and formations. The carton may then be reclosed by tucking in of the separated ~ront flap portion behind a front carton pane' ~lthough this carton is basically recloseable, it is of an adhesively-sealed configuration which is not readily adaptable for use i.n the heating or cooking lo of foods therein in a microwave oven.
SUMMARY OF ~HE I~VENTION
Accordingly, the present invention contemplates the provision of a carton which is adapted for the heating and cooking of foods directly in the carton in a microwave oven in the absence of any leaking, producing off-tastes or generating off-odors in the foods which would be unpalatable to a consumer.
The carton is constituted from a unitary carton blank materlal incorporating a bottom carton portion and a top carton portion. The carton bottom portion has a general~y rectangular bottom panel, side panels extending from the periphery of the bottom panel and web corners being provided between adjacent side panels. The side panels and web corners are folded upwardly, preferably along creases or fold lines which are formed in the carton material, such as to produce a food or product-receiving carton bottom structure. The side panels and web corners are preferably folded, heated and sealed then filled with product.
Optionally, the side panels and web corners may be temporarily maintained in this folded condition while the carton bottom structure is being filled with ~132~7~33 product through the provision of suitable cooperating tabs and notches formed in the side panels and web corners; for instance, such as has been developed by the Kliklok Corporation, Greenwich, Connecticut.
The top carton portion i.ncludes a rectangular top which is adapted to cover the rectangular bottom panel, and extends from and is hingedl~ connect2d with an outer edge of one of the side panels. The top carton portion includes side flaps extending from opposite edges of the periphery of the top panel at both sides of the hinged edge thereof with the bo~tom side panel, and a front flap. After filling the carton bottom structure wi~h the food product which is to be cooked or heated, the top panel is folded down over the carton bottom structure and the flaps are folded over and contacted against the surfaces of adjacent panels. One of the contacting surfaces of the carton material is coated with a waterproof, heat-sealable coating so as to facilitate the flaps to be heat-sealed to the side panels in a manner well known in the carton heat sealing technology.
An openable, removable top flap for the carton is formed by partially scoring the outer and inner surfaces or the top panel and providing slit lines or foramlnations in the front flap. The slit lines or foraminations in the front flap, preferably herringbone slit lines formed into the surface of the carton, extend from locations at a top flap crease in the top panel to positions adjacent a lifting tab portlon 3Q provided at the free edge of the front flap. A pair of spaced-apart lower score lines are formed in the inner surface of the top panel of the carton, whereas a pair of spaced-apart upper score lines in the outer surface are closely spaced apart from and in parallel with but wider spread apart than the lower score lines. The score lines extend along the top panel, with the first and second upper score lines extending along the creases forming the foldlng or folded edges of the side flaps then ~eing angled towards each other as they approach the rear side panel connecting the top panel to the bottom panel then along the crease formlny the folding edge of the top panel and the rear side panel, where the first and second upper score lines connect, said score lines extending along the folding edges in a non-continuous fashion in the form of perforated cut scores, and generally parallel to and spaced apart ~ro~
the lower score lines over a major pcrtion of the top panel, and then being angled towards each other towards the front flap until the outside surface or upper score lines meet the foraminations in the front panel and wherein said score lines which angle away from and extend between the folded edges are continuous, said parallel score lines providing a frangible tear path so that upon lifting of the lifting tab, the front flap and top tear in-the region between the foraminations and the score lines facilitate the top flap to be lifted up away from the carton top panel, exposing the contents of the carton to view, or to be removed entirely to provide easy access.
A primary advantage of the invention resides in that a user can readily heat and/or cook the food product in the microwave while the food remains in the carton. ~he user is afforded convenient and full access to the entire contents of the carton, by merely lifting the top flap, without destroying or adversely affecting the structural integrity of the carton.
~, .
6 11 3~07~3 Although the top flap overlies or covers a substantial portion of the carton bottom structure, liftincJ or removing the top flap by separation of the score lines and foraminations does not substantiall~ impair the structural integritv of the carkon, and allows it to be easily reclosed. When the entire top flap is re~oved, the t iangular corners whlch re.~ain provide additional structural support for the carton.
The employment of "herringbone" foraminations or slit lines in the separating lines for the detachable portion of the front flap, allows the latter to be readily tucked in behind the side portions of the remaining front flap upon reclosing the carton. This forms a secure latching and sealing action, preventing an inadvertent opening of the reclosed carton during continued heating in the microwave oven and during subse~uent handling prior to its intended reopening for dispensing the heated food contained therein.
Accordingly, it is a primary object of the present invention to provide a novel microwave carton facilitating the heating of a food product contained therein in a microwave oven.
Another objec~ of the invention resides in the provision of a carton as described herein incorporatin~
a flap structure which allows for the ready and simple reclosing of the carton subsequent to opening thereof to gain access to the carton contents.
Reference may now be had to the following detailed description of preferred embodiments of the inventive microwave carton showing the advantageous and ~2~37~3 novel features thereof, taken in conjunction with the accompanying drawings; in which:
Figure 1 illustrates a flat carton blank for p~oducing the microwave carton pursuant to the invention;
Figure 2 illustrates a perspective vie~ of the assembled microwave carton in a partially opened condition showing the exposed carton interior;
Figure 3 illustrates a perspective view of the assembled microwave carton with the top portion completely removed;
Figure 4 illustrates a flat carton blank for producing the microwave carton showing access from the side of the carton; and Figure 5 illustrates a flat carton blank showing the base of the carton at the corners with tab and notch fasteners for the initial filling of the carton with product.
DETAILED DESCRIPTION
Referring to Figures 1 to 3, carton 10 includes, in general, a carton bottom structure 12 and a carton top structure 14 which, when assembled, is used to contain a product, for instance, a food such as a frozen vegetable, dinner, etc., in the carton for direct heating and cooking within the carton in a microwave oven (not shown).
The bottom structure 12 includes a rectangular bottom panel 16 defined by periphery 18. Side panels 20, 22, 24, 26 respectively extend from each side of periphery 18, while web corners 28, 30, 32, 34 extend between the respective adjacent side panels at the corners 36 of bottom panel 16. Crease lines are formed 8 ~ 3 2 ~ ~ ~ 3 at the intersections of bo-ttom panel 16 and side panels 20 to 26 along the periphery 18 and at -the intersection ~0 of its web corners with the side panels so as to bend inwardly from -the outer surface 38 of carton 10.
S A diagonal crease 42 is formed in each of the web corners from the corners 36 of bottom panel 16 so as to assist in the folding in thereof during the formation of the assembled carton, as shown in Figure 2.
The bottom portion or structure of the carton is maintained in the form of a box-like, food-containing configuration by the use of heat-sealing after assembly and prior to filling of carton 10, as shown in Figures 2 and 3.
In Figure 5, the side panels 20a to 26a and web corners 28a to 34a are temporarily maintained in a folded condition while the carton bottom structure 12a, with i-ts bottom panel 16a defined by periphery 18a, is being filled with product through the provision of suitable cooperation tabs and notches formed in the side panel of the web corners. Crease lines are formed at the intersections of bottom panel 16a and side panels 20a to 26a along the periphery 18a and at the intersection 40a of its web corners with the side panels so as to bend inwardly from the outer surface 38a of carton 10. ~ diagonal crease 42a is formed in each of the web corners from ~he corners 36a of bottom panel 16a so as to assist in the folding in thereof during the formation of the assembled carton. Each web corner 28a to 34a includes a notch 46 and a notch flap 48 formed along the outer periphery of the web corners.
A T-shaped tab 50 is formed along the outer edge of each of side panels 22a and 26a adjacent its respective ~L3~703 notch 46. Notches 46, notch flaps 48 and tabs 50, which constitute tab and notch fas~eners, are used to temporarily keep the base portion 16a ~olded in a rood-containing configuration.
The top carton structure 1~ includes a rectangular top panel 62 having peripheral edges 54, 66, 68 and 70, respecti.vely. A front flap 76 extends from the edge 70, all of the edges 64 to 70 being creased to facilitate the folding thereof. The top panel 62 includes first and second (upper) score lines 80, 82 extending partially through the outer surface and third and fourth (lower) scoxe lines 84, 86 extending partially through the inner surface thereof. The score lines extend along the top panel with the fi.rst 80 and second 82 upper score lines extending along the creases which form the folding edges 68, 64 of the side flaps 72 and 74, respectively, then being angled towards each other along score lines 105' as they approach the rear side panel 20 which connects the top panel 62 and bottom panel 16, then along crease 66 which forms the folding edge of the top panel where first and second score lines 80 and 82 connect. Firs-t and second score lines 80 and 82 e~tend along the folding edges in a non-continuous fashion in the form of perforated cut scores and are generally parallel to and spaced apart rrom the third and fourth lower score lines 84 and 86 over a major portion of the top panel. ~s the score lines approach the front flap 76, the score lines 80 and 82 are angled towards each other and along score lines 105' towards the front flap 76, until the upper score lines 80 and 82 meet the foraminations 96 and 98 in front flap 76. The score lines 105', which angle 10 1320~0~
away from and extend between the folded edges 68 and 64, are generally continuous. The first and third score lines 80, 84 and the second and four-th score lines 32, 86 are in parallel with each other and are offset by a spacing to form a tear distance 90, thereby defining an openable removable top flap 92. The utilization of perforated cut scores, which onl~
partiall~ score the outer and inner surfaces of the top panel, prevents delamination along the edges where the carton is folded.
In another embodiment of the present invention as shown in Figure 4, the top carton structure 14a includes a rectangular top panel 62a having peripheral edges 64a -through 70a respectively. ~ fron-t flap 72a extends from edge 64a, a rear flap 74a extends from edge 68a and a side flap 76a extends from edge 70a, all of the edges 64a to 70a being creased to facilitate folding thereof. The top panel 62a includes a first outer score line 80a extending partially through the outer surface and a second (inner) score line 84a extending partially through the inner surface. The score lines 80a and 84a extend along the top panel, with the first outer score line 80a extending along creases 70a and 66a which form the respective folding edges of the side flap 76a and side panel 20 which in turn connects the top panel 62a and bottom or opposite panel 16, then score line 80a is angled along score lines 105a' as it approaches the rear flap 74a, and follows crease 68a which forms the folding edge of rear flap 74a. First outer score line 80a extends along the folding edges 66a, 68a and 70a in a non-continuous fashion in the form of perforated cut scores and is generally parallel to and spaced apart from the second 11 ~ 3 2 0 l ~ ~
inner score line 84a over a major portion of the top panel 62a. As the score line 80a approaches the front flap 72a along edges 66a and 70a respectively, the score line 80a is angled along score lines 105a' towards the front flap 72a, until the outer score line 80a meets the foraminations 9~a and 96a in front flap 72a. The score lines 105a', which angle away from and extend between the folded edges 66a and 70a, are generally continuous. The first outer score line 80a and the second inner score line 84a are in parallel with each other and are offset by a spacing to form a tearing distance 90a, thereby defininy an openable removable top panel 92a. In this embodiment, the front flap 72a is hingedly connected wi-th the top panel along edge 64a and not edge 70a (as in Figure 1).
An additional feature of the present invention is the ability to remove substantially the entire top panel of the carton thereby allowing complete access to the contents therein as shown in Figures 2 and 3. This is accomplished by the first and second upper score lines 80 and 82 and the third and fourth lower score lines 84 and 86, which run parallel to each other, extending along folding edges 64, 66, and 68, and which are angled towards rear side panel 20 and also towards the front flap 76. The score lines form the tear distance 90, and extend along the sides of the top panel 14 and across the rear side panel 20 opposite the front flap 76, leaving triangular segments 105 remaining at each corner segment of the carton as shown in Figures 2 and 3. The triangular segments 105, which remain after the entire top panel is removed, are designed to provide additional structural support to the carton (105a in the Figure 4 embodiment).
~321)7~
A center flap portion 9~ of the Eront flap 76 is hingedly connected with the top panel alon~ edge 70 (similarly, center flap portion 94a of front flap 72a is hingedly connected therewith along edge 64a in the Figure 4 embodiment), and includes a pair of diverging slit lines or "herringbone" foraminations 96, 98, ~hich extend from a lifting tab 100 formed at the free edge of center flap portion 94 bet~een slit lines 96, 98 towards the respective tear distances 90 between the score lines 80, 84 and 82, 86 so as to join therewith. Thus, separation along lines 96, 98 and then along the tear distances 90 will provide access to the carton contents. Cutouts 102 may be formed on both sides of the tab 100 to facilitate gripping of the latter by a user during opening of the carton.
Upon reclosing of the carton 10, the lifting tab 100 is inserted between the side portions of the front flap 76 which are still attached so as to cause the "herringbone" foraminations 96, 98, and particularly the curved portions 104, to latchingly engage there~ith and to maintain the top flap 62 in a sealingly carton-closing condition.
A similar arrangement is shown in Figure 4, which illustrates a removable top ~lap 92a, lifting tab lOOa, cutouts 102a, and curved portions 104a of front flap 72a.
In order to form the microwave carton lO, the carton blan~ shown in Figure l is folded, for instance, by an automatic folding machine. The side panels 20 to 26 and web corr.ers 23 to 34 are folded up from the outer surface of carton bottom panel 16. When the side panels are generally perpendicular to the inner surface ~ 320703 ~3 of the bottom panel 16, the side panels and web corners are heat-sealed, as shown in Figure 3, to maintain the bottom container structure 12 in its Lolded, box-like, product-containing configuration. Food product is then filled into the bottom structure 12 and the top structure 14 is folded over until the top panel 62 is located generally in parallel with bottom structure 16.
Side flaps 72, 74 and front flap 76 are folded over until they lie in contact with the adjoining side panels. Inasmuch as the external surface of the carton is covered with a water-repellant, heat-sealable coating, the side flaps 72, 74 and portions of the front flap 76 outside of the cen-ter flap portion 94 are sealed to the side panels 26, 22 and 2~, respectively by the application of heat.
While there have been shown and described what are considered to be preferred embodiments of the invention, it will of course be understood that various modifications and changes in form or detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention be not limited to the exact form and detail herein shown and described, nor to anything less than the whole of the invention herein disclosed as hereinafter claimed.
FIELD OF THE I~ ENT_ON
The present invention relates in general to cartons, and more particularly, relates to a carton of unitary structure which is adapted for heatiny food, especially frozen food, in a microwa~e oven.
In recent years, microwave ovens have assumed an important position in the ~itchens of numerous homeowners, inasmuch as they enable foods, various kinds of foods, s~ch as fro~en food consisting of vegetables and even complete meals to be quickl~l an~
convenlently heated and/or cooked in microwave ovens.
~n particular, modern homemakers who frequently prepare meals for a household while concurrently being employed in a full-time job in industry or ccmmerce, have recognized the convenience of microwave cooking and heating of frozen foods and the like. However, in order to do so, some labor-intensive steps must be undertaken. In essence, the food must be removed from the package, irrespective as to whether it is constituted of a plastic or paperboard carton or a foil tray, arranged in a dish transparent to microwaves-and possessing the necessary strength and then heated in the microwave oven. This step is necessary since various objects, such as aluminum foil trays or other metal receptacles containing the food cannot be employed in microwave ovens; whereas other types of cartons are not suitable for the retention of liquids.
On the other hand, cartons which are designed to hold liquids, utilize adhesives, which when subjected to the heat of the microwave oven frequently produce off-tastes and generate off-odors in the foods.
~-' . ~ ~
~ 32~0~
DISCUSSION OF THE PRIOR ART
In order to improve upon the structure and the convenience in the utilization of microwave cartons, particularly cartons which can ~e opened prior to and/or during the cookiny sequence to enable access to the carton contents, and then reclosed so as to e~fect~vely seal in t~.e food, various types of microwave cartons have been developed in the art.
Thus, Ielmini U.S. Patent 4,687,104 discloses a lo microwave carton possessing a top and front flap structure with parallel spaced inner and outer score lines to define openable and recloseable top and ~ront flap portions through the formation of tearable joints.
The top flap portion is confiyured to allow for the lS retention of a full-strength U-shaped top surface to enable lifting of the carton and contents therein without affecting the integrity of the carton structure. This type of carton, while enabling ~he heating of foods in a microwave oven, does not enable the sealing reclosure of the front flap portion because of the incorporation of the parallel spaced tear joint lines, and moreover, in one embodiment, includes a tab-receiving slit in the sidewall thereof which will permit liquids to escape from the carton during the heating of the carton contents in a microwave oven.
~eroszek U.S. Patent 4,594,492 pertains to a microwave pac~age in the nature of a carton which incorporates a structure for browning foods in the carton when cooked in a microwave oven. There is no disclosure of a carton which allows for the resealing thereof prior to or after heating the carton contents in the oven so as to inhibit the egress of any liquids from the carton.
3 ~ 3 Smith U.S. Patent 3,167,238 discloses a recloseable carton which incorporates top and front flap portions which are opena~le by separation Cro~ ~he remaining carton along tear lines and formations. The carton may then be reclosed by tucking in of the separated ~ront flap portion behind a front carton pane' ~lthough this carton is basically recloseable, it is of an adhesively-sealed configuration which is not readily adaptable for use i.n the heating or cooking lo of foods therein in a microwave oven.
SUMMARY OF ~HE I~VENTION
Accordingly, the present invention contemplates the provision of a carton which is adapted for the heating and cooking of foods directly in the carton in a microwave oven in the absence of any leaking, producing off-tastes or generating off-odors in the foods which would be unpalatable to a consumer.
The carton is constituted from a unitary carton blank materlal incorporating a bottom carton portion and a top carton portion. The carton bottom portion has a general~y rectangular bottom panel, side panels extending from the periphery of the bottom panel and web corners being provided between adjacent side panels. The side panels and web corners are folded upwardly, preferably along creases or fold lines which are formed in the carton material, such as to produce a food or product-receiving carton bottom structure. The side panels and web corners are preferably folded, heated and sealed then filled with product.
Optionally, the side panels and web corners may be temporarily maintained in this folded condition while the carton bottom structure is being filled with ~132~7~33 product through the provision of suitable cooperating tabs and notches formed in the side panels and web corners; for instance, such as has been developed by the Kliklok Corporation, Greenwich, Connecticut.
The top carton portion i.ncludes a rectangular top which is adapted to cover the rectangular bottom panel, and extends from and is hingedl~ connect2d with an outer edge of one of the side panels. The top carton portion includes side flaps extending from opposite edges of the periphery of the top panel at both sides of the hinged edge thereof with the bo~tom side panel, and a front flap. After filling the carton bottom structure wi~h the food product which is to be cooked or heated, the top panel is folded down over the carton bottom structure and the flaps are folded over and contacted against the surfaces of adjacent panels. One of the contacting surfaces of the carton material is coated with a waterproof, heat-sealable coating so as to facilitate the flaps to be heat-sealed to the side panels in a manner well known in the carton heat sealing technology.
An openable, removable top flap for the carton is formed by partially scoring the outer and inner surfaces or the top panel and providing slit lines or foramlnations in the front flap. The slit lines or foraminations in the front flap, preferably herringbone slit lines formed into the surface of the carton, extend from locations at a top flap crease in the top panel to positions adjacent a lifting tab portlon 3Q provided at the free edge of the front flap. A pair of spaced-apart lower score lines are formed in the inner surface of the top panel of the carton, whereas a pair of spaced-apart upper score lines in the outer surface are closely spaced apart from and in parallel with but wider spread apart than the lower score lines. The score lines extend along the top panel, with the first and second upper score lines extending along the creases forming the foldlng or folded edges of the side flaps then ~eing angled towards each other as they approach the rear side panel connecting the top panel to the bottom panel then along the crease formlny the folding edge of the top panel and the rear side panel, where the first and second upper score lines connect, said score lines extending along the folding edges in a non-continuous fashion in the form of perforated cut scores, and generally parallel to and spaced apart ~ro~
the lower score lines over a major pcrtion of the top panel, and then being angled towards each other towards the front flap until the outside surface or upper score lines meet the foraminations in the front panel and wherein said score lines which angle away from and extend between the folded edges are continuous, said parallel score lines providing a frangible tear path so that upon lifting of the lifting tab, the front flap and top tear in-the region between the foraminations and the score lines facilitate the top flap to be lifted up away from the carton top panel, exposing the contents of the carton to view, or to be removed entirely to provide easy access.
A primary advantage of the invention resides in that a user can readily heat and/or cook the food product in the microwave while the food remains in the carton. ~he user is afforded convenient and full access to the entire contents of the carton, by merely lifting the top flap, without destroying or adversely affecting the structural integrity of the carton.
~, .
6 11 3~07~3 Although the top flap overlies or covers a substantial portion of the carton bottom structure, liftincJ or removing the top flap by separation of the score lines and foraminations does not substantiall~ impair the structural integritv of the carkon, and allows it to be easily reclosed. When the entire top flap is re~oved, the t iangular corners whlch re.~ain provide additional structural support for the carton.
The employment of "herringbone" foraminations or slit lines in the separating lines for the detachable portion of the front flap, allows the latter to be readily tucked in behind the side portions of the remaining front flap upon reclosing the carton. This forms a secure latching and sealing action, preventing an inadvertent opening of the reclosed carton during continued heating in the microwave oven and during subse~uent handling prior to its intended reopening for dispensing the heated food contained therein.
Accordingly, it is a primary object of the present invention to provide a novel microwave carton facilitating the heating of a food product contained therein in a microwave oven.
Another objec~ of the invention resides in the provision of a carton as described herein incorporatin~
a flap structure which allows for the ready and simple reclosing of the carton subsequent to opening thereof to gain access to the carton contents.
Reference may now be had to the following detailed description of preferred embodiments of the inventive microwave carton showing the advantageous and ~2~37~3 novel features thereof, taken in conjunction with the accompanying drawings; in which:
Figure 1 illustrates a flat carton blank for p~oducing the microwave carton pursuant to the invention;
Figure 2 illustrates a perspective vie~ of the assembled microwave carton in a partially opened condition showing the exposed carton interior;
Figure 3 illustrates a perspective view of the assembled microwave carton with the top portion completely removed;
Figure 4 illustrates a flat carton blank for producing the microwave carton showing access from the side of the carton; and Figure 5 illustrates a flat carton blank showing the base of the carton at the corners with tab and notch fasteners for the initial filling of the carton with product.
DETAILED DESCRIPTION
Referring to Figures 1 to 3, carton 10 includes, in general, a carton bottom structure 12 and a carton top structure 14 which, when assembled, is used to contain a product, for instance, a food such as a frozen vegetable, dinner, etc., in the carton for direct heating and cooking within the carton in a microwave oven (not shown).
The bottom structure 12 includes a rectangular bottom panel 16 defined by periphery 18. Side panels 20, 22, 24, 26 respectively extend from each side of periphery 18, while web corners 28, 30, 32, 34 extend between the respective adjacent side panels at the corners 36 of bottom panel 16. Crease lines are formed 8 ~ 3 2 ~ ~ ~ 3 at the intersections of bo-ttom panel 16 and side panels 20 to 26 along the periphery 18 and at -the intersection ~0 of its web corners with the side panels so as to bend inwardly from -the outer surface 38 of carton 10.
S A diagonal crease 42 is formed in each of the web corners from the corners 36 of bottom panel 16 so as to assist in the folding in thereof during the formation of the assembled carton, as shown in Figure 2.
The bottom portion or structure of the carton is maintained in the form of a box-like, food-containing configuration by the use of heat-sealing after assembly and prior to filling of carton 10, as shown in Figures 2 and 3.
In Figure 5, the side panels 20a to 26a and web corners 28a to 34a are temporarily maintained in a folded condition while the carton bottom structure 12a, with i-ts bottom panel 16a defined by periphery 18a, is being filled with product through the provision of suitable cooperation tabs and notches formed in the side panel of the web corners. Crease lines are formed at the intersections of bottom panel 16a and side panels 20a to 26a along the periphery 18a and at the intersection 40a of its web corners with the side panels so as to bend inwardly from the outer surface 38a of carton 10. ~ diagonal crease 42a is formed in each of the web corners from ~he corners 36a of bottom panel 16a so as to assist in the folding in thereof during the formation of the assembled carton. Each web corner 28a to 34a includes a notch 46 and a notch flap 48 formed along the outer periphery of the web corners.
A T-shaped tab 50 is formed along the outer edge of each of side panels 22a and 26a adjacent its respective ~L3~703 notch 46. Notches 46, notch flaps 48 and tabs 50, which constitute tab and notch fas~eners, are used to temporarily keep the base portion 16a ~olded in a rood-containing configuration.
The top carton structure 1~ includes a rectangular top panel 62 having peripheral edges 54, 66, 68 and 70, respecti.vely. A front flap 76 extends from the edge 70, all of the edges 64 to 70 being creased to facilitate the folding thereof. The top panel 62 includes first and second (upper) score lines 80, 82 extending partially through the outer surface and third and fourth (lower) scoxe lines 84, 86 extending partially through the inner surface thereof. The score lines extend along the top panel with the fi.rst 80 and second 82 upper score lines extending along the creases which form the folding edges 68, 64 of the side flaps 72 and 74, respectively, then being angled towards each other along score lines 105' as they approach the rear side panel 20 which connects the top panel 62 and bottom panel 16, then along crease 66 which forms the folding edge of the top panel where first and second score lines 80 and 82 connect. Firs-t and second score lines 80 and 82 e~tend along the folding edges in a non-continuous fashion in the form of perforated cut scores and are generally parallel to and spaced apart rrom the third and fourth lower score lines 84 and 86 over a major portion of the top panel. ~s the score lines approach the front flap 76, the score lines 80 and 82 are angled towards each other and along score lines 105' towards the front flap 76, until the upper score lines 80 and 82 meet the foraminations 96 and 98 in front flap 76. The score lines 105', which angle 10 1320~0~
away from and extend between the folded edges 68 and 64, are generally continuous. The first and third score lines 80, 84 and the second and four-th score lines 32, 86 are in parallel with each other and are offset by a spacing to form a tear distance 90, thereby defining an openable removable top flap 92. The utilization of perforated cut scores, which onl~
partiall~ score the outer and inner surfaces of the top panel, prevents delamination along the edges where the carton is folded.
In another embodiment of the present invention as shown in Figure 4, the top carton structure 14a includes a rectangular top panel 62a having peripheral edges 64a -through 70a respectively. ~ fron-t flap 72a extends from edge 64a, a rear flap 74a extends from edge 68a and a side flap 76a extends from edge 70a, all of the edges 64a to 70a being creased to facilitate folding thereof. The top panel 62a includes a first outer score line 80a extending partially through the outer surface and a second (inner) score line 84a extending partially through the inner surface. The score lines 80a and 84a extend along the top panel, with the first outer score line 80a extending along creases 70a and 66a which form the respective folding edges of the side flap 76a and side panel 20 which in turn connects the top panel 62a and bottom or opposite panel 16, then score line 80a is angled along score lines 105a' as it approaches the rear flap 74a, and follows crease 68a which forms the folding edge of rear flap 74a. First outer score line 80a extends along the folding edges 66a, 68a and 70a in a non-continuous fashion in the form of perforated cut scores and is generally parallel to and spaced apart from the second 11 ~ 3 2 0 l ~ ~
inner score line 84a over a major portion of the top panel 62a. As the score line 80a approaches the front flap 72a along edges 66a and 70a respectively, the score line 80a is angled along score lines 105a' towards the front flap 72a, until the outer score line 80a meets the foraminations 9~a and 96a in front flap 72a. The score lines 105a', which angle away from and extend between the folded edges 66a and 70a, are generally continuous. The first outer score line 80a and the second inner score line 84a are in parallel with each other and are offset by a spacing to form a tearing distance 90a, thereby defininy an openable removable top panel 92a. In this embodiment, the front flap 72a is hingedly connected wi-th the top panel along edge 64a and not edge 70a (as in Figure 1).
An additional feature of the present invention is the ability to remove substantially the entire top panel of the carton thereby allowing complete access to the contents therein as shown in Figures 2 and 3. This is accomplished by the first and second upper score lines 80 and 82 and the third and fourth lower score lines 84 and 86, which run parallel to each other, extending along folding edges 64, 66, and 68, and which are angled towards rear side panel 20 and also towards the front flap 76. The score lines form the tear distance 90, and extend along the sides of the top panel 14 and across the rear side panel 20 opposite the front flap 76, leaving triangular segments 105 remaining at each corner segment of the carton as shown in Figures 2 and 3. The triangular segments 105, which remain after the entire top panel is removed, are designed to provide additional structural support to the carton (105a in the Figure 4 embodiment).
~321)7~
A center flap portion 9~ of the Eront flap 76 is hingedly connected with the top panel alon~ edge 70 (similarly, center flap portion 94a of front flap 72a is hingedly connected therewith along edge 64a in the Figure 4 embodiment), and includes a pair of diverging slit lines or "herringbone" foraminations 96, 98, ~hich extend from a lifting tab 100 formed at the free edge of center flap portion 94 bet~een slit lines 96, 98 towards the respective tear distances 90 between the score lines 80, 84 and 82, 86 so as to join therewith. Thus, separation along lines 96, 98 and then along the tear distances 90 will provide access to the carton contents. Cutouts 102 may be formed on both sides of the tab 100 to facilitate gripping of the latter by a user during opening of the carton.
Upon reclosing of the carton 10, the lifting tab 100 is inserted between the side portions of the front flap 76 which are still attached so as to cause the "herringbone" foraminations 96, 98, and particularly the curved portions 104, to latchingly engage there~ith and to maintain the top flap 62 in a sealingly carton-closing condition.
A similar arrangement is shown in Figure 4, which illustrates a removable top ~lap 92a, lifting tab lOOa, cutouts 102a, and curved portions 104a of front flap 72a.
In order to form the microwave carton lO, the carton blan~ shown in Figure l is folded, for instance, by an automatic folding machine. The side panels 20 to 26 and web corr.ers 23 to 34 are folded up from the outer surface of carton bottom panel 16. When the side panels are generally perpendicular to the inner surface ~ 320703 ~3 of the bottom panel 16, the side panels and web corners are heat-sealed, as shown in Figure 3, to maintain the bottom container structure 12 in its Lolded, box-like, product-containing configuration. Food product is then filled into the bottom structure 12 and the top structure 14 is folded over until the top panel 62 is located generally in parallel with bottom structure 16.
Side flaps 72, 74 and front flap 76 are folded over until they lie in contact with the adjoining side panels. Inasmuch as the external surface of the carton is covered with a water-repellant, heat-sealable coating, the side flaps 72, 74 and portions of the front flap 76 outside of the cen-ter flap portion 94 are sealed to the side panels 26, 22 and 2~, respectively by the application of heat.
While there have been shown and described what are considered to be preferred embodiments of the invention, it will of course be understood that various modifications and changes in form or detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention be not limited to the exact form and detail herein shown and described, nor to anything less than the whole of the invention herein disclosed as hereinafter claimed.
Claims (5)
1. A microwave carton which is constructed from a unitary carton blank, said carton comprising:
a carton bottom structure including a substantially rectangular bottom panel, side panels extending from the periphery of said bottom panel and web corners extending between the side panels, crease lines formed along the periphery of said bottom panel, at the intersection of the web corners with the sides and centrally along the web corners to enable folding of the side panels normally of the bottom panel so as to provide a liquid-containing carton bottom structure;
a substantially rectangular carton top structure including a top panel which is integrally connected along a first edge with an outer edge of one of said side panels and being dimensioned to overlie the bottom structure;
a front flap extending from a second edge of said top panel opposite said first edge;
side flaps foldably connected to side edges of said top panel along crease lines located between said first and second edges;
tearable joints extending along said top panel, with first and second upper score lines extending along the crease lines which foldably connect the side flaps to the top panel, then being angled towards each other as they approach the side panel which connects the top panel to the bottom panel then along a crease which foldably connects said top panel to the side panel which connects the top panel to the bottom panel where the first and second upper score lines connect, said upper score lines extending along said foldable connection in a non-continuous fashion in the form of perforated cut scores and generally parallel to and spaced apart from third and fourth lower cut score lines over a major portion of the top panel, said upper and lower score lines also being angled towards each other towards said front flap, said upper score lines meeting foraminations in the front flap, and wherein said angled score lines are continuous, said spacing apart of the upper and lower score lines forming a tearing distance therebetween over a portion of said top panel; and wherein, the front flap, which is integral with and hinged to the second edge of said top panel, includes a lifting tab, which is formed centrally at the free edge of said front flap, and foraminations which extend between said lifting tab and said tearable joints in said top panel.
a carton bottom structure including a substantially rectangular bottom panel, side panels extending from the periphery of said bottom panel and web corners extending between the side panels, crease lines formed along the periphery of said bottom panel, at the intersection of the web corners with the sides and centrally along the web corners to enable folding of the side panels normally of the bottom panel so as to provide a liquid-containing carton bottom structure;
a substantially rectangular carton top structure including a top panel which is integrally connected along a first edge with an outer edge of one of said side panels and being dimensioned to overlie the bottom structure;
a front flap extending from a second edge of said top panel opposite said first edge;
side flaps foldably connected to side edges of said top panel along crease lines located between said first and second edges;
tearable joints extending along said top panel, with first and second upper score lines extending along the crease lines which foldably connect the side flaps to the top panel, then being angled towards each other as they approach the side panel which connects the top panel to the bottom panel then along a crease which foldably connects said top panel to the side panel which connects the top panel to the bottom panel where the first and second upper score lines connect, said upper score lines extending along said foldable connection in a non-continuous fashion in the form of perforated cut scores and generally parallel to and spaced apart from third and fourth lower cut score lines over a major portion of the top panel, said upper and lower score lines also being angled towards each other towards said front flap, said upper score lines meeting foraminations in the front flap, and wherein said angled score lines are continuous, said spacing apart of the upper and lower score lines forming a tearing distance therebetween over a portion of said top panel; and wherein, the front flap, which is integral with and hinged to the second edge of said top panel, includes a lifting tab, which is formed centrally at the free edge of said front flap, and foraminations which extend between said lifting tab and said tearable joints in said top panel.
2. A carton as claimed in Claim 1, wherein a surface of the carton includes a water-repellant coating for withstanding the temperatures encountered during microwave cooking.
3. A carton as claimed in Claim 1, wherein the top panel is substantially totally removable.
4. A microwave carton which is constructed from a unitary carton blank; said carton comprising a carton bottom structure including a substantially rectangular bottom panel; side panels extending from the periphery of said bottom panel and web corners extending between said side panels, crease lines formed along the periphery of said bottom panel, at the intersection of the web corners with the side panels and centrally along the web corners to enable folding of the side panels normally of the bottom panel so as to provide a liquid-containing carton bottom structure;
a substantially rectangular carton top structure including a top panel which is integrally connected along a first edge with an outer edge of one of said side panels and being dimensioned to overlie the bottom structure;
a front flap extending from a second edge of said top panel adjacent said first edge;
a side flap foldably connected to the top panel along crease lines adjacent the front flap, and a rear flap foldably connected to said top panel along crease lines opposite the front flap;
tearable joints extending along said top panel, with a first outer score line extending along the crease lines which foldably connect said side flap and said side panel to said top panel t then being angled towards the rear flap then along the crease line which foldably connects said rear flap to said top panel, said score line extending along said foldable connections in a non-continuous fashion in the form of perforated cut scores, and being generally parallel to and spaced apart from a second inner cut score line over a major portion of the top panel, said score line also being angled towards said front flap until the outer score line meets formations in the front flap and wherein said angled score lines are continuous, said spacing apart of the outer and inner score lines forming a tearing distance therebetween over a portion of said top panel; and wherein the front flap, which is integral with and hinged to the second edge of said top panel, includes a lifting tab which is formed centrally at the free edge of said front flap and foraminations extending between said lifting tab and said tearable joints in said top panel.
a substantially rectangular carton top structure including a top panel which is integrally connected along a first edge with an outer edge of one of said side panels and being dimensioned to overlie the bottom structure;
a front flap extending from a second edge of said top panel adjacent said first edge;
a side flap foldably connected to the top panel along crease lines adjacent the front flap, and a rear flap foldably connected to said top panel along crease lines opposite the front flap;
tearable joints extending along said top panel, with a first outer score line extending along the crease lines which foldably connect said side flap and said side panel to said top panel t then being angled towards the rear flap then along the crease line which foldably connects said rear flap to said top panel, said score line extending along said foldable connections in a non-continuous fashion in the form of perforated cut scores, and being generally parallel to and spaced apart from a second inner cut score line over a major portion of the top panel, said score line also being angled towards said front flap until the outer score line meets formations in the front flap and wherein said angled score lines are continuous, said spacing apart of the outer and inner score lines forming a tearing distance therebetween over a portion of said top panel; and wherein the front flap, which is integral with and hinged to the second edge of said top panel, includes a lifting tab which is formed centrally at the free edge of said front flap and foraminations extending between said lifting tab and said tearable joints in said top panel.
5. A carton as claimed in Claim 1 or 4, wherein said foraminations comprise herringbone-shaped slit lines in said front flap.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US07/192,262 US4919785A (en) | 1988-04-28 | 1988-04-28 | Microwave carton |
US192,262 | 1988-04-28 |
Publications (1)
Publication Number | Publication Date |
---|---|
CA1320703C true CA1320703C (en) | 1993-07-27 |
Family
ID=22708935
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA000595056A Expired - Lifetime CA1320703C (en) | 1988-04-28 | 1989-03-29 | Microwave carton |
Country Status (2)
Country | Link |
---|---|
US (1) | US4919785A (en) |
CA (1) | CA1320703C (en) |
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Also Published As
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US4919785A (en) | 1990-04-24 |
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