Containers for sandwiches and blanks for containers for sandwiches

Abstract

A substantially triangular prism-shaped container for a food product, such as a sandwich, comprises: first and second rectangular walls 2, (3, fig. 1A) each with two long sides and two short sides, se

Description

Field of the Invention The invention relates to containers for a food product such as a sandwich, blanks for containers and partially assembled containers, which can be further formed by a user. The invention relates particularly to compostable containers and / or biodegradable containers incorporating windows. Background to the Invention Triangular prism-shaped containers for a food product such as a sandwich are well known. However, these often suffer from the following defects: • Prior art packaging often requires non-biodegradable, non-compostable layers of plastics; • Certain prior art packs must be transported in a fully assembled (or formed) state which creates considerable difficulty for transporting; • The prior art packs may be difficult to assemble at the filling station and often require adhesives to be applied at that stage. Embodiments of the invention seek to address at least some of these drawbacks. Summary of the Invention In a first broad independent aspect, the invention provides a blank for forming a substantially triangular prism-shaped container for a food product, such as a sandwich, the blank comprising a first substantially rectangular wall with two long sides and two short sides; a second substantially rectangular wall with two long sides and two short sides; the first substantially rectangular wall being separated from the second substantially rectangular wall by a fold line; a substantially rectangular lid with two long sides and two short sides being secured to either said first or second rectangular wall; two side walls formed by at least two substantially triangular portions; and wherein the side walls extend from the second rectangular wall and are secured by respective flanges to the first substantially rectangular wall; whereby the pack may be transported flat as a partially formed container. This configuration is particularly advantageous because the blank is configured in such way that it can be partially formed allowing it to be transported flat and rapidly deployed on site for filling with food produce such as a sandwich or a wrap. Furthermore, in certain embodiments, the container may be easily formed by either a user or a machine without the use of additional adhesives at the point of filling the pack. In a subsidiary aspect, the lid comprises two laterally extending flanges and the side walls further comprise at least one slot arranged in each side wall to receive at least a portion of the lid's laterally extending flanges. This configuration is particularly advantageous as it allows the lid to be substantially interlocked into the side walls without requiring additional adhesive to secure the laterally extending flanges to the side walls. This is particularly advantageous in terms of ease of assembly. In a further subsidiary aspect, the lid's laterally extending flanges comprises a first and a second portion; the second portion being located in an outward most position and being relatively reduced in dimensions compared to the first portion. This is particularly advantageous in order to facilitate the insertion of the flanges into the side walls. In a further subsidiary aspect, the side walls comprise two triangular portions which are bisected by a fold line and the slot extends across the fold line. This configuration is particularly advantageous for large scale production whilst at the same time being advantageous for rapid deployment during the filling process of the packs. In a further subsidiary aspect, the lid comprises a window of cellulose material and the blank comprises a board which consists of only biodegradable card and blister coating. This allows the pack to be fully composed of readily biodegradable and / or compostable material. In a further subsidiary aspect, the lid comprises a longitudinally extending flange which may be secured to one of said substantially rectangular wall when assembled whilst said lid is secured to the other side wall by a fold line or hinge. This configuration is particularly advantageous for enclosing the contents of the pack whilst at the same time providing improved evidence of tampering with the packs when on display. In a further subsidiary aspect, one of the walls which is located at the opposite end of the blank relative to the flange of said lid, said wall comprises a further flange which is located at the opposite end of the blank to the flange of said lid; whereby when said oppositely located flanges are brought together and secured together these form an upwardly extending handle. In a second broad independent aspect, the invention provides a substantially triangular prism-shaped container for a food product, such as a sandwich, comprising: a first substantially rectangular wall with two long sides and two short sides; a second substantially rectangular wall with two long sides and two short sides; the first substantially rectangular wall being separated from the second substantially rectangular wall by a fold line; a substantially rectangular lid with two long sides and two short sides being secured to either said first or second rectangular wall; and which when closed forms a triangular prismshaped container; and two side walls formed by at least two substantially triangular portions; wherein the side walls extend from the second rectangular wall and are secured by respective flanges to the first substantially rectangular wall. In a subsidiary aspect, the lid comprises two laterally extending flanges and the side walls further comprise at least one slot arranged in each side wall to receive at least a portion of the lid's laterally extending flanges. In a further subsidiary aspect, the lid comprises a longitudinally extending flange which is secured by a label to one of the substantially rectangular walls when the container is formed whilst the lid is secured to the opposite wall by a fold line or hinge. In a further subsidiary aspect, the two triangular portions of the side walls are bisected by a fold line and the slot extends across the fold line. In a further subsidiary aspect, the lid comprises a window of transparent cellulose material and the board of the container consisting of biodegradable card and blister coating. In a further subsidiary aspect, the lid comprises a longitudinally extending flange which is secured by a label to the first substantially rectangular wall. In a further subsidiary aspect, one of the walls further comprises a flange which is located at the opposite side of the container to where the flange of said lid is provided; whereby when said oppositely located flanges are brought together and secured together these form an upwardly extending handle. Brief Description of the Drawings Figure 1 shows a blank in accordance with a first embodiment. Figure 1A shows the embodiment of figure 1 in a plan perspective view. Figure 2 shows a perspective view of a partially formed or assembled container from the blank. Figure 3 shows a perspective view of a partially assembled (or formed) container formed from the blank of the first embodiment, which can be stacked and supplied to a customer in a partially formed configuration. Figures 4 -6 show perspective views of a detailed view of a partially assembled (or formed) container in accordance with a first embodiment. Figure 7 shows a perspective view of a closed container formed from the blank which when assembled adopts the form of a triangular prism-shaped pack with a front window in its lid. Figure 8 shows a plan view of a further embodiment of the invention. Detailed Description of the Figures Figure 1 and 1A show a blank referenced generally as 1 with first and second substantially rectangular walls 2, 3, first and second side walls 4, 5 and a lid 6 which, when fully constructed, forms a substantially triangular prism-shaped container shown in Figure 7. The first substantially rectangular wall 2 has two long sides and two short sides, and the second substantially rectangular wall 3 has two long sides and two short sides. The side wall 4 is preferably formed by two substantially triangular portions, wherein, as shown in figure 2 and 3, the triangular portions of the side wall can be folded by a hinge fold line 21 outwards onto one another when the container is partially constructed. The side wall 5 is preferably formed by two substantially triangular portions, where the triangular portions of the side wall can be folded along a hinge fold line 23 outwards onto one another when the blank is partially assembled as shown in figures 2 and 3. Preferably, the two further triangular portions of each side wall are substantially the same size as each other. The two further triangular portions of each side wall are configured to be folded onto one another outwards when the container is partially assembled and stacked (as shown on Fig.3). In a preferred embodiment, the rectangular walls and side walls are formed as a continuous sheet. Preferably, the rectangular walls and side walls include no lamination whatsoever and may advantageously be formed solely of a blister coating on the inside with a carton board on the outside. Each of side walls 4, 5 further comprises laterally protruding flanges 7, 8 adjacent to the side walls and separated from the outermost triangular portions by hinge fold lines 22 and 24. These laterally extending flanges are configured to receive on their external surface (as shown in figure 2) adhesive to secure the side walls 4 and 5 to the rectangular wall 2 as shown in figures 2 and 3. This allows the partially assembled pack to be transported flat and unfolded for filling with sandwiches or the like and thereafter closing without employing anything but a single label between flange 11 and the external surface of the rectangular wall 2. This is particularly advantageous to provide a visible label to immediately show whether any tampering of the pack has taken place whilst on display on the shelves without requiring any adhesive handling at the sandwich filling station or in the preparation area. Each of the side walls 4, 5 further comprises slots 9,10 positioned substantially between the two triangular portions 21 and 23 of each side wall. Preferably, the slots extend across the fold lines 21 and 23. In an optional configuration, the slots are positioned substantially perpendicularly to the hinge lines 22 and 24. The lid 6 is substantially rectangular and further comprises a flange 11 which extends from the lid 6. When the blank 1 is assembled into its substantially triangular prism-shaped configuration, the flange 11 facilitates the closure of the formed container, remaining outside the outer surface of the first substantially rectangular wall 2, as best shown in Figure 7. The lid 6 has two side flanges 12, 13 extending from both sides. Each of the flanges have narrower tab portions 14 and 15. Preferably, the flange 12 and the tab portion 14 have one common linear border 30 with the side which is nearer to flange 11, and the opposite side border 31 is formed of two lines extending from one another at an obtuse angle thus allowing the upper tab portion to more readily be located within slot 9 as shown in figures 6 and 7. Similarly, flange 13 also incorporates a tab portion 15 which has a common linear border at the side which is nearer to the flange 11 of the lid, whilst the opposite side border 32 is formed of two lines extending from one another at an obtuse angle thus allowing the upper tab portion 15 to more readily be located within slot 10 as shown in figures 6 and 7. The pack may thus be rapidly closed without using additional adhesive materials. The blank 1 further comprises an aperture defining a window 16, which in Figure 1 is also substantially rectangular. The window may be formed of transparent or translucent, i.e. ‘see-through’, material and may be confined to the lid. Preferably, the window 16 extends from the outer flange 11, i.e. from the joint between the lid 6 and flange 11 through almost the entirety of the lid 6. In a preferred embodiment, shown in Figure 1, the sheet of see-through material extends around the aperture of window 16 and on one side covers a portion of the surface of flange 11 (shown by dash lines). In a preferred embodiment, the window 16 is secured to the blank 1 by heat sealing. In an alternative embodiment, the window 16 occupies substantially the entire surface of the lid 7 or can be prolonged to the joint of the lid with wall 3 (i.e. line 18). In further embodiments, the window may be partially in the lid and partially in one of the rectangular walls. In a preferred embodiment, the rectangular walls and side walls are formed as a continuous sheet. Preferably, the rectangular walls and side walls include no lamination whatsoever and may advantageously be formed solely of a blister coating on the inside with a carton board on the outside. The first and second substantially rectangular walls 2 and 3 are joined together by a hinged fold 17 located at their adjacent long side. The second substantially rectangular wall 3 is joined with the lid 6 by a hinged fold 18 located at their adjacent long side. The side wall 4 is joined with the rectangular wall 3 by a hinged fold 19 located at the short side of wall 3, to which the side wall 4 is adjacent. The side wall 5 is joined to the rectangular wall 3 and separated therefrom by a hinged fold 20 located at the opposite side of the hinge fold 19. Flange 12 is adjacent to lid 6 and separated therefrom by a hinged fold 25. Flange 13 is adjacent to lid 6 and separated therefrom by a hinged fold 26. Flange 11 which extends from the lid 6 is adjacent to the lid by a hinged fold 27. The mentioned fold lines may be perforated, although it is preferred that none of the joints are actually perforated. The fold lines may be formed by scoring the board, i.e by forming partial longitudinal troughs to define clear lines for bending the material into shape. Lid 6 creates a front wall in the fully formed container (as further shown in figures 6 and 7) and comprises a wide enough window 16 to show the contents of the container which are typically food produce such as sandwiches, wraps etc. Window 16 may be formed of a compostable material, such as cellulose or a cellulose-based material, so that the recyclability of the blank 1 is improved. Preferably, the window 16 is biodegradable within 12 to 18 weeks. The sheet of window 16 may comprise a liquid-impermeable membrane. Figure 2 shows a partially assembled container formed from the blank 1 of figure 1 and describes in detail how it is formed. Side walls 4 and 5 are folded respectively along lines 21 and 23. Glue strips or points may be added to flanges or flaps 7 and 8, and the rectangular wall 2 may be folded along line 17 over glue strips on flanges 7 and 8, whereby the rectangular wall 2 is fixed relative to these strips as shown in figure 3. Hence, when the container is partially assembled, flanges 7 and 8 are located inside the cavity of the container, contacting with the inner surface of wall 2. These may be adhered securely by any appropriate method including heat sealing. Preferably, biodegradable glue, adhesive tape, or strips may be placed at least partially over flanges 7 and 8. Figure 3 shows a partially assembled container formed from the blank of Figure 1, which is stackable and flat by its nature and thereby ideally suited for transporting flat to the location where operators or machines will fill the packs. Wall 2 lies over wall 3, and side walls 4 and 5 are stacked along lines 21 and 23 respectfully outside the inner cavity of the container. In the partially formed container, the side walls 4, 5 are joined to the wall 2 along lines 22 and 24. The folded side walls 4, 5 of the partially formed container comprise slots 9, 10. Figure 4 shows a partially formed container from the blank 1 and the inner cavity of the container created by rectangular walls 2,3 and side walls 4, 5. The container can be formed with high velocity by a user or machine in a few simple steps. To form the container, one options is to press on the side walls 4, 5, namely, along the lines 21 and 23 to thereby cause the rectangular walls to separate and reveal the main food produce receiving inner cavity of the container which is located between the walls 2, 3 and side walls 4, 5. Figure 5 shows a partially formed container formed from the blank 1 of Figure 1 in the opened form, when the lid 6 is opened. The lid 6 with the window 16 creates a front panel of the container. The flanges 12, 13, and 11 are folded along the lines 25, 26 and 27 respectfully. The lid 6 is lifted into its closing position by folding along the pre-formed fold line 18. The inner cavity of the container is created by the walls 2, 3 and side walls 4, 5, the formed cavity being retained once the flanges 13 and 14 are inserted into their respective slots 9 and 10 and thereafter flange 11 being secured by a simple sticker against the outside surface of wall 2. Figure 6 shows a nearly assembled container formed from the blank 1 of figure 1, which is partially closed, to show the details of the assembled container and how it might be used. Lid 6 spans from the hinged fold of long side 18 of the second rectangular wall 3 to a position adjacent to the outer long side 28 of the first rectangular wall 2. Namely, the detailed location of flanges 14 and 15 is shown by: flange 12 being inserted into the slot 9, located in the side wall 4, in such a way, that the tab 14 (not shown in Fig.6) of flange 12 remains inside the inner cavity of the container, and the other part of flange 12 id located outside the side wall, covering it; flange 13 being inserted into the slot 10, located in the side wall 5, in such a way, that the tab 15 of flange 13 remains inside the inner cavity of the container, and the other part of flange 13 is located outside the side wall, covering it (not shown in figure 6). Flanges 12 and 13 are adjacent to the lid 6, hence, lifting the lid 6 provides the opening and closing of the formed container. The formed container could be closed by inserting flanges 12 and 13 into the slots 9 and 10 respectfully, and also the container may be opened by tearing a label (not shown) affixed between flange 11 and the outer surface of wall 2 and in addition by removing flanges 12 and 13 from slots 9 and 10, allowing the moving of the lid 6 into the configuration as shown in figure 5. Figure 7 shows an assembled container formed from the blank 1 of figure 1, in the closed form which would be typical of the configuration for containing and displaying a sandwich on a shelf. Tab 15 lies fully inside the inner cavity of the container in the closed position. Flange 11 lies fully on the outer surface of the wall 2 in the closed position where it would be fixed into position by a label (not shown). The window 16 on the front wall allows the user to see the full contents of the container when the container is fully closed for the display and sale of the filled pack. The flange 11 can be fixed on the outer surface of the wall 2 by any of the known means which allow the container as a whole to be fully biodegradable, such as round biodegradable label. Usefully, such a label can also contain information about the contents, such as branding, nutritional, expiry date or allergy-related information. Embodiments of the packs are particularly advantageous as they can also be particularly suited for a packing machine to grab, glue and fold the blank 1 in a swift and efficient manner. After being transported in a flat partially assembled form as in the configuration of figure 3, an operator or a machine may rapidly fold the pack as in figures 4 and 5 to receive the food produce and to allow it to be sealed ready for presentation to customers as in figures 6 and 7. Figure 8 shows a further embodiment in which wall 2 has a flange 32 which is sized and shaped to collaborate with flange 11. These flanges may be secured together with a label of the kind described above in order to form a handle for securely picking up the pack once assembled.

Claims

1. A blank for forming a substantially triangular prism-shaped container for a food product, such as a sandwich, the blank comprising:a first substantially rectangular wall with two long sides and two short sides;a second substantially rectangular wall with two long sides and two short sides;the first substantially rectangular wall being separated from the second substantially rectangular wall by a fold line;a substantially rectangular lid with two long sides and two short sides being secured to either said first or second rectangular wall;two side walls formed by at least two substantially triangular portions;wherein the side walls extend from the second rectangular wall and are secured by respective flanges to the first substantially rectangular wall; whereby the pack may be transported flat as a partially formed container.

2. The blank of claim 1, wherein the lid comprises two laterally extending flanges and the side walls further comprise at least one slot arranged in each side wall to receive at least a portion of the lid's laterally extending flanges.

3. The blank of either claim 1 or claim 2, wherein the lid’s laterally extending flanges comprises a first and a second portion; the second portion being located in outward most position and being relatively reduced in dimensions compared to the first portion.

4. The blank according to any one of the preceding claims, wherein the side walls comprise two triangular portions which are bisected by a fold line and the slot extends across the fold line.

5. The blank according to any one of the preceding claims, wherein the lid comprises a window of cellulose material and the blank comprises a board which consists of only biodegradable card and blister coating.

6. The blank of any one of the preceding claims, wherein the lid comprises a longitudinally extending flange which may be secured to one of said substantially rectangular wall when formed into a container whilst the lid is secured to the other side wall by a fold line or hinge.

7. The blank of claim 6, wherein one of the walls which is located at the opposite end of the blank relative to the flange of said lid, said wall comprises a further flange which is located at the opposite end of the blank to the flange of said lid; whereby when said oppositely located flanges are brought together and secured together these form an upwardly extending handle.

8. A substantially triangular prism-shaped container for a food product, such as a sandwich, comprising:a first substantially rectangular wall with two long sides and two short sides;a second substantially rectangular wall with two long sides and two short sides;the first substantially rectangular wall being separated from the second substantially rectangular wall by a fold line;a substantially rectangular lid with two long sides and two short sides being secured to either the first or second rectangular wall; and which when closed forms a triangular prismshaped container;two side walls formed by at least two substantially triangular portions;wherein the side walls extend from the second rectangular wall and are secured by respective flanges to the first substantially rectangular wall.

9. The container of claim 8, wherein the lid comprises two laterally extending flanges and the side walls further comprise at least one slot arranged in each side wall to receive at least a portion of the lid’s laterally extending flanges.

10. The container of either claim 8 or claim 9, wherein the lid comprises a longitudinally extending flange which is secured by a label to one of substantially rectangular walls whilst the lid is secured to the opposite wall by a fold line or hinge.

11. The container according to any one of claims 8 to 10, wherein the two triangular portions of the side walls are bisected by a fold line and the slot extends across the fold line.

12. The container according to any one of claims 8 to 11, wherein the lid comprises a window of cellulose material and the board of the container consisting of biodegradable card and blister coating.

13. The container according to any one of claims 8 to 12, wherein the lid comprises a longitudinally extending flange which is secured by a label to the first substantially rectangular wall.

514. The container according to claim 13, wherein one of the walls further comprises a flange which is located at the opposite side of the container to where the flange of said lid is provided; whereby when said oppositely located flanges are brought together and secured together these form an upwardly extending handle.1014

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