Clamshell food container with sauce holder and carton blank therefor

• US 7,631,800 B2
• Filed: 11/30/2007
• Issued: 12/15/2009
• Est. Priority Date: 11/30/2007
• Status: Active Grant

• Current Assignee: Pactiv Packaging Incorporated (Pactiv)
• Original Assignee: Dopaco Incorporated (Graeme Richard Hart, MBA)
• Inventors: Sievers, Deanna Dixon, Cai, Liming
• Primary Examiner(s): Elkins; Gary E
• Application Number:
  US11/987,429
• Publication Number:
  US 20090140032A1
• Time in Patent Office: 746 Days
• Field of Search: 229/120.18, 229/120.13, 229/120.21, 229/904, 229/114, 206561-565
• US Class Current: 229/120.18
• CPC Class Codes: B65D 5/5021 Integral elements for containers formed by folding-up portions connected to a central panel from all sides
• CPC Class Codes: B65D 5/667 Lids in the form of an inverted tray
• CPC Class Codes: Y10S 229/904 Compartmented fast food holder or lap tray

Abstract

A clamshell container and sauce holder for receiving a sauce container is constructed from a one-piece carton blank cut and scored to facilitate erection into a clamshell container with top and bottom portions hingedly connected along a common fold line. A bottom portion of the container includes an upper flat section extending inwardly from a bottom side wall, an integral support and a base member including a tuck flap for positioning the upper flat section. In addition, an opening is defined in the upper flat section for holding a sauce container.

Claims

1. A clamshell food container with a dipping sauce holder, said container comprising:

a one-piece flat sheet of carton material cut and scored to facilitate erection into a box-like structure;

said clamshell food container including a first common fold line, and a top and a bottom hingedly connected along said common fold line to form a clamshell type structure;

said top including a flat top portion, a plurality of top fold lines and a plurality of top side walls integrally connected to said flat top portion by said plurality of top fold lines and a plurality of connecting tabs connecting said plurality of top side walls one to another to maintain said top in an open box-like structure;

said bottom including a flat bottom portion having a tuck flap slit formed therein, a plurality of bottom fold lines and a plurality of bottom side walls integrally connected to said bottom portion by said plurality of bottom fold lines, a plurality of tabs connecting said plurality of bottom side walls one to another to maintain said bottom in an erect position in the form of an open box-like structure;

one of said bottom side walls including an upper flat section extending inwardly from one of said bottom side walls, and an integral vertical wall extending down to said flat bottom portion for supporting said flat section generally parallel to said flat bottom portion, and an integral generally horizontal base member juxtaposed on said flat bottom portion, and a tuck flap formed in said vertical wall and folded down and into said tuck flap slit for folding and positioning said vertical wall;

said upper flat section including a dipping sauce holder adapted to hold a sauce container within an area bounded by one of said bottom side walls, said vertical wall, said flat bottom portion and said flat section;

wherein said top and bottom of said container are hingedly connected at the back of said carton and said one of said bottom side walls is at the front of said container opposite from the back of said container; and

wherein said flat top portion forms a cover for the sauce container by contacting a top of a sauce container.

2. A clamshell container according to claim 1 which includes an E-Z lock mechanism.

3. A clamshell container according to claim 2 in which the E-Z lock mechanism includes a male member extending outwardly from said flat section and in which one of said top side walls includes a member receiving slit.

4. A clamshell container according to claim 1 in which a separate part of said flat cover portion of a sauce holder is operable separately to provide access to a sauce holder without separating the top and bottom of the container.

5. A clamshell container according to claim 1 in which said top includes a forwardly slanted surface portion.

6. A clamshell container according to claim 1 in which said top includes a pair of curved score lines which converge toward the front of the container.

7. A clamshell container according to claim 1 in which one of said top side walls includes a cut out along a fold line in an upper portion thereof and in which said upper flat section includes a forwardly extending male protrusion for fitting into said cut out to form an E-Z lock mechanism.

8. A one-piece carton blank of stiff resilient and foldable sheet material adapted to be folded into a clamshell type container for a food product and sauce holder, said blank including a plurality of fold lines and a central lid-forming portion having front, rear and side walls closure panels each being foldably connected by one of said plurality of fold lines to said central lid, a central tray-forming portion having a tuck flap slit and front, rear and side wall closure panels foldably connected to said central tray, and said rear wall closure panel of said lid portion hingedly connected to said rear wall closure panel of said tray by one of said plurality of fold lines to join said central lidforming portion and said tray portion to thereby provide a closeable structure, a plurality of end glue flaps, a first pair of which extend from said rear closure panel of said central lid and a second pair from said rear closure panel of said tray, a third pair of which extend from said front closure panel of said central lid and a fourth pair of which extend from said front closure panel of said tray;

an upper tray section including a cut out sauce holder for receiving a sauce container, a support for said upper tray section and a foldable base member for said base extending from said front closure panel of said tray and separated from said front closure panel of said tray portion and from one another by one of said fold lines that are parallel to one another; and

said support including a tuck flap, and wherein said support and said tuck flap are positioned and dimensioned so that the tuck flap fits into said tuck flap slit in said central tray and said support supports and positions said upper tray parallel with said central tray and with said foldable base member juxtaposed on said central tray and wherein said upper portion of said first closure panel of said tray portion including an elongated cut to thereby form a forwarding extending first closure member extending outwardly from said upper tray when assembled into a clamshell container, and said front closure panel of said central lid including a longitudinal cut from a second forwardly extending closure member in said central lid for engaging said first closure member to maintain said container in a closed portion.

9. A one-piece carton blank according to claim 8 in which said side closure panels of said central lid and said central tray define curved edges that converge from said rear panel closure panels and said front panel closure members.

10. A one-piece closure blank according to claim 9 in which said fold lines forming said side closure panels are curved in a similar manner to the curved edges of said side closure panels.