U.S. patent application number 10/428282 was filed with the patent office on 2003-12-11 for corrugated paperboard dishware and cookware.
Invention is credited to Calpino, Barry T., Porchia, Jose.
Application Number | 20030226882 10/428282 |
Document ID | / |
Family ID | 29715257 |
Filed Date | 2003-12-11 |
United States Patent
Application |
20030226882 |
Kind Code |
A1 |
Porchia, Jose ; et
al. |
December 11, 2003 |
Corrugated paperboard dishware and cookware
Abstract
Disposable dishware and cookware may be constructed from
corrugated paperboard. The corrugated paperboard provides voids
filled with air to serve as a natural insulation barrier. In so
doing the contents held by the dishware are maintained at a desired
temperature longer without transferring temperature to the user.
The voids may also serve as conduits or plenums to communicate hot
air away from the cookware and thus provide for use at elevated
temperatures.
Inventors: |
Porchia, Jose; (Milwaukee,
WI) ; Calpino, Barry T.; (Racine, WI) |
Correspondence
Address: |
S.C. JOHNSON & SON, INC.
1525 HOWE STREET
RACINE
WI
53403-2236
US
|
Family ID: |
29715257 |
Appl. No.: |
10/428282 |
Filed: |
May 2, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60377825 |
May 3, 2002 |
|
|
|
Current U.S.
Class: |
229/403 ;
229/404; 229/406; 229/939 |
Current CPC
Class: |
B65D 81/34 20130101;
B65D 65/403 20130101; B65D 3/22 20130101; B65D 81/3869
20130101 |
Class at
Publication: |
229/403 ;
229/404; 229/406; 229/939 |
International
Class: |
B65D 003/22 |
Claims
What is claimed is:
1. An insulated, food container manufactured from cellulosic
materials, comprising: a bottom wall; and an upstanding outer wall
attached to the bottom wall and defining an interior space, the
outer wall including an inner layer, an outer layer, and a
corrugated layer between the inner layer and outer layer defining
voids, the interior space being insulated from the atmosphere by
the outer wall and the voids in the corrugated layer.
2. The container of claim 1, wherein the container is one of a
frusto-conical and cylindrical shape.
3. The container of claim 2, further including a liquid impermeable
coating on the inner layer.
4. The container of claim 1, further including a lid.
5. The container of claim 1, wherein the container is substantially
parallelepiped in shape.
6. The container of claim 1, wherein the voids contain air, the air
being able to circulate within each void.
7. The container of claim 1, wherein the voids contain foam
styrene.
8. The container of claim 1, wherein the walls are
compressible.
9. The container of claim 1, wherein the bottom wall includes a
first layer, a second layer, and a corrugated layer between the
two.
10. The container of claim 1, wherein the outer wall further
includes a second corrugated layer.
11. An insulated container manufactured from cellulosic materials,
comprising: a bottom wall; an upstanding outer wall attached to the
bottom wall and defining a mouth and an interior space, the outer
wall including a corrugated layer and at least one substantially
planar layer attached to the corrugated layer, the corrugated layer
including a plurality of flutes forming voids in cooperation with
the planar layer.
12. The container of claim 11, wherein the voids contain air.
13. The container of claim 11, wherein the voids contain foam
styrene.
14. The container of claim 11, further including a second planar
layer, the corrugated layer being positioned between the first and
second planer layers.
15. The container of claim 11, further comprising a removable cap
adapted to seal the mouth.
16. The container of claim 14, further including a second
corrugated layer.
17. The container of claim 16, wherein the first and second
corrugated layers include flutes provided at different
amplitudes.
18. The container of claim 16, wherein the first and second
corrugated layers include flutes provided at different
frequencies.
19. The container of claim 16, wherein the first and second
corrugated layers include flutes provided at different
wavelengths.
20. The container of claim 16, wherein the first and second
corrugated layers include flutes which are out-of-phase with one
another.
21. The container of claim 19, wherein the flutes are 180.degree.
out-of-phase.
22. A method of cooking a foodstuff, comprising: disposing a
foodstuff in container manufactured of cellulosic materials, the
container including a bottom wall and an upstanding outer wall, the
outer wall including an inner layer, an outer layer, and a
corrugated layer between the inner layer and outer layer defining
voids; and warming the foodstuff within the container.
23. The method of claim 22, wherein the foodstuff is warmed to a
temperature than exceeds 500.degree. F.
24. The method of claim 23, wherein the foodstuff is warmed to a
temperature that exceeds 451.degree. F.
25. The method of claim 22, further comprising placing a cap on the
container prior to cooking the foodstuff.
26. A method of evenly cooling a foodstuff, comprising: disposing a
foodstuff within a container, the container having an outer wall
including an outer layer, an inner layer, and a corrugated layer
between the inner layer and outer layer defining voids; placing the
container in an atmosphere cooler than the temperature of the
foodstuff; and allowing the heat of the foodstuff to dissipate
within the voids of the outer wall and to the atmosphere.
27. The method of claim 26, further comprising freezing the
foodstuff.
28. The method of claim 27, further comprising allowing the outer
wall to slightly compress under the expansion of the foodstuff due
to freezing.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This non-provisional application claims the priority
benefits of provisional U.S. patent application Ser. No.
60/377,825, filed on May 3, 2002.
FIELD OF THE DISCLOSURE
[0002] The disclosure generally relates to dishware and cookware
and, more particularly, relates to disposable dishware and
cookware.
BACKGROUND OF THE DISCLOSURE
[0003] Disposable dishware is widely used. For example, paper
plates are ubiquitous at such events as picnics, barbecues and many
other social gatherings. Paper cups are used for everything from
in-home drinks to dentists offices to fast food restaurants. Milk
cartons and restaurant take-out packages are often made of paper
material coated with a fluid impermeable layer.
[0004] One difficulty associated with such items, however, is
related to insulation. Taking a paper cup as an example, their use
is somewhat limited when it comes to maintaining the temperature of
the drink held therein. Coffee is often sold in disposable cups,
but typically in the form of Styrofoam, or the like. Not only is it
desirable to keep the contents warm and/or cold, but it is also
desirable to limit dissipation of such temperature to the hand of
the user. As a result, various after market devices have been
introduced and been met with substantial commercial success. Foam
coolers sized to correspond to the outer dimension of the cup are
currently sold and provide a snug and insulative fit. Cardboard
rings are often provided by coffee shops for fitting around the
outside of the paper coffee cup to thereby provide an added barrier
to limit heat transference to the hand of the users. However, both
such solutions add additional apparatus to the process at both
added expense and user burden.
[0005] Paper cookware is even more limited. As such items must be
exposed to high temperatures, the paper is limited to applications
which will not exceed its combustion point, approximately
450.degree. F. Moreover, cookware such as pans and plates are often
subjected not only to high temperatures, but below freezing
temperatures as well. Paper is limited in this regard as well in
that as the food contained within the dish freezes, it often
expands due to the water contained therein, and the paper is of
insufficient strength to withstand the forces of expansion. Ice
cream cartons, for example, are therefore often oversized provided
with reinforcing ribs or expansion joints to address such
issues.
[0006] In light of the foregoing shortcomings, the use of paper in
dishware and cookware has been less than fully exploited. Even
though the paper itself is relatively inexpensive and lends itself
to disposability and recycling, such limitations have prevented the
breadth of disposable cookware options available to the consuming
public, and required use of more expensive, and less than optimal,
metals and the like.
SUMMARY OF THE DISCLOSURE
[0007] In accordance with one aspect of the disclosure, disposable
paper based dishware and cookware are provided. The paper based
dishware may be provided in the form of a cup formed from
corrugated paperboard. The corrugations of the paperboard create
voids which serve as an insulation layer between the user and the
cup contents. The paper based cookware may be provided in the form
of a pan formed from corrugated paperboard as well. The corrugation
of the paperboard not only creates voids which may be filled with
air or another insulating material, but also serve as cooling
conduits or pseudo-chimneys enabling heat to dissipate from the
paper to the air within the voids and ultimately to be directed
away from the cookware.
[0008] In accordance with another aspect of the disclosure, an
insulated food container is disclosed which comprises a bottom
wall, and an upstanding outer wall attached to the bottom wall
having an interior space. The outer wall includes an inner layer,
an outer layer, and a corrugated layer between the inner layer and
outer layer defining voids with the interior space being insulated
from the atmosphere by the outer wall and the voids in the
corrugated layer.
[0009] In accordance with another aspect of the disclosure, an
insulated container manufactured from cellulosic materials is
disclosed which comprises a bottom wall and an upstanding outer
wall attached to the bottom wall in defining a mouth and an
interior space. The outer wall includes a corrugated layer and at
least one substantially planar layer attached to the corrugated
layer. The corrugated layer includes a plurality of flutes forming
voids in cooperation with the planar layer.
[0010] In accordance with another aspect of the disclosure, a
method of cooking a food stuff is disclosed which comprises
disposing a food stuff in a container manufactured in cellulosic
materials, and warming the food stuff within the container. The
container may include a bottom wall and upstanding outer wall with
the outer wall including an inner layer, an outer layer, and a
corrugated layer between the inner layer and the outer layer
defining voids.
[0011] In accordance with yet another aspect of the disclosure, a
method of evenly cooling a food stuff is disclosed which comprises
disposing of food stuff within a container, placing the container
in an atmosphere cooler than the temperature of the food stuff, and
allowing the heat of the food stuff to dissipate within voids of
the outer wall and to the atmosphere. The container may include an
outer wall including an outer layer, an inner layer, and a
corrugated layer between the inner layer and the outer layer
defining the voids.
[0012] These and other aspects and features of the disclosure will
become more apparent upon reading the following detailed
descriptions when taken in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is an isometric view of a disposable cup constructed
in accordance with the teachings of the disclosure;
[0014] FIG. 2 is an isometric view of a cap for the disposable
cup.
[0015] FIG. 3 is an isometric view of the cup and cap
assembled.
[0016] FIG. 4 is cross-sectional view of the cup of FIG. 1, taken
along line 4-4 of FIG. 1;
[0017] FIG. 5 is an isometric view of a disposable pan constructed
in accordance with the teachings of the disclosure;
[0018] FIG. 6 is a cross-sectional view of the pan of FIG. 3, taken
along line 6-6 of FIG. 3; and
[0019] FIG. 7 is a cross-sectional view of an outer wall having
more than one corrugated layer.
[0020] While the disclosure is susceptible to various modifications
and alternative constructions, certain illustrative embodiments
thereof have been shown in the drawings and will be described below
in detail. It should be understood, however, that there is no
intention to limit the disclosure to the specific forms disclosed,
but on the contrary, the intention is to cover all modifications,
alternative constructions, and equivalents falling within the
spirit and scope of the disclosure.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0021] Referring now to the drawings, and with specific reference
to FIGS. 1-3, a disposable dish constructed in accordance with the
teachings of the disclosure is generally referred to by reference
numeral 20. While the dish 20 is depicted in the form of a cup in
FIG. 1, it is to be understood that dish could be provided in any
other form wherein insulation properties are desirable such as, but
not limited to plates, bowls, saucers, servers, casseroles,
platters, and the like.
[0022] The cup 20 may include a frustoconical outer wall 22 closed
by a base 24. The outer wall 22 need not be frustoconical in shape
but could be any number of other shapes including, but not limited
to, straight conical, angular, or the like. The cup 20 may further
include a brim 26 defining a mouth 28 for access to an interior
space 30 for holding foodstuffs or drinks such a coffee, tea, soda,
etc. The cup 20 may be provided with a lid 32 adapted to
substantially close off the mouth 28 upon fitting to the cup, and
which may include a relatively small port 34, or reclosable flap
(not shown) to allow for access to the liquid contained within the
cup 20 when the lid 32 is mounted to the cup 20.
[0023] Turning now to FIG. 4, the cup 20 is illustrated in
cross-section. As shown therein, the outer wall 22 may be formed
from corrugated paperboard. More specifically, the outer wall 22
may include an inner layer 36, and outer layer 38, and a layer 40
of corrugations or flutes 42 traveling longitudinally from the base
24 to the brim 26. In so doing, the corrugations 42 form a
plurality of voids 44. The voids 44 may be filled with air which by
itself serves as a temperature barrier or insulation layer
inhibiting transfer of heat and/or cold from the interior space 30
to and from the atmosphere 46. The voids 44 could, alternatively,
be filled with some other insulative material such as, but not
limited to, foam styrene, to further enhance the insulative
properties of the cup 20. The base 24 can also be formed of similar
corrugated paperboard.
[0024] In further alternative embodiments, the outer wall 22 may
include one or more additional layers of corrugated material to
provide even more insulative capability. Such layers could be of
various depth and spacing. The corrugations also could travel
circumferentially around the cup 20, as opposed to longitudinally.
The various layers of corrugations could also be configured in
differing or alternating orientations, or be provided at differing
or alternating dimensions.
[0025] By manufacturing the cup 20 from corrugated paperboard, the
cost of the cup 20 is maintained at sufficiently low level so as to
be disposable. Moreover, the use of cellulosic material makes the
cup easily recyclable. The use of corrugated paperboard affords a
built-in insulation feature removing the need for aftermarket
accessories such as coolers or slip-on protective coats.
[0026] As indicated above the use of corrugated paperboard is not
limited to dishware according the teachings of this disclosure.
Cookware and serveware are also encompassed. As illustrated in FIG.
3, the cookware may be provided as a pan 50. While the following
description will be made with reference to the pan 50, it is to be
understood that the terms cookware and serveware, and the teachings
of this disclosure are applicable to many other forms including,
but not limited to, pots, skillets, woks, griddles, casseroles, and
the like.
[0027] The pan 50 may include a substantially rectangular outer
wall 52 having a closed and substantially planar bottom wall 53.
The outer wall 52 may terminate at an upper end 54 with a radially
outwardly extending lip 56. The lip 56 defines a mouth 58 providing
access to an interior space 60. A lid 62 may be provided to close
the pan 50 when desired. Moreover, the pan may include, while not
depicted in FIG. 3, a plurality of partitions to divide the pan 50
into individual compartments. Such a feature may be particularly
advantageous, for example, when heating or freezing a complete meal
with an entree in one compartment and side dishes in others.
[0028] As shown in FIG. 4, wherein the pan 50 is depicted in
cross-section, the construction of the pan 50 is similar to that of
the cup 20. More specifically, the outer wall 52 and bottom wall 53
may be constructed from corrugated paperboard. As with the cup 20,
the corrugated paperboard of the pan 50 may include an inner layer
64, an outer layer 66, and a layer 68 of corrugations 70
therebetween. The corrugations create voids 72 which may be filled
with air or another insulative material. If the voids 72 are filled
with air or some other thermally conductive material, the pan 50 is
able to withstand temperatures significantly higher than normal
paper products. Whereas normal paper combusts at approximately
451.degree. F., the inventors have found that a pan 50 constructed
in accordance with the teachings of the invention can withstand
temperatures in excess of 500.degree. F. In so doing, the pan 50 is
able to withstand temperatures in excess of the majority of baking
and cooking requirements of common dishes.
[0029] Not only can such a pan 50 withstand high temperatures and
thus be microwavable or ovenable, such a pan 50 can also be chilled
or frozen. This feature is provided, at least in part, by the
additional room afforded by the voids 72 provided between the
corrugations 70. Such voids allow for the inner layer 64 to
radially expand outwardly and compress the corrugations 70 into the
voids 72 as the matter held within the pan 50 freezes and
expands.
[0030] As with the dishware described above, the pan 50 may be
alternatively provided with more than one layer of corrugations, or
with corrugations of greater amplitude, frequency or wavelength.
Moreover, the multiple layers of corrugations may be provided in
alternating transverse directions, or at various degrees of
out-of-phase disposition. Multiple grades of cellulosic material
can also be used. In addition, if desired, the inner and/or outer
layers, respectively, can be coated with liquid impervious,
non-stick, or other compounds as well.
[0031] For example, as depicted in FIG. 7, an alternative
embodiment of a dishware outer wall is depicted in cross-section.
As shown therein, the outer wall 100 may include an inner layer
102, an outer layer 104, and an intermediate layer 106, and first
and second layers of corrugations 108 and 110 therebetween. Not
only does the wall 100 include multiple layers of corrugations, but
it will be further noted that the corrugations of the first and
second layers 108 and 110 are provided in different dimensions.
More specifically, the amplitudes, frequencies, and wavelengths of
the corrugations are different. For example, the corrugations or
flutes 112 of the first layer of corrugations 108 include a
wavelength of .beta. and amplitude of .gamma.. Whereas the flutes
114 of the second layer of corrugations 110 include a much shorter
wavelength of .beta.' and a much small amplitude of .alpha.'.
[0032] In order to form the shape of the cup 20 or pan 50, a
conventional thermoforming process can be used. In such a process,
paperboard, which has already been corrugated to have the desired
number of layers and corrugations of the desired shape and size, is
subjected to a thermoforming mold. First and second dies (not
shown) having a mating protrusion and cavity in the desired shape
are provided, with the corrugated paperboard being positioned
therebetween. The paper board is compressed between the dies under
heat and pressure sufficient to deform the paperboard into a shape
congruent with the dies. Upon retraction of the dies, the
paperboard retains the desired shape, whereupon the edges thereof
can be trimmed or otherwise finished for sale.
[0033] From the foregoing, one of ordinary skill in the art will
readily appreciate that corrugated paperboard dishware,
serveware,.and cookware can be constructed based on the teachings
of the present disclosure. Moreover, one of ordinary skill in the
art will understand that variations on the disclosed embodiments
can be produced without departing from the scope and protection
afforded by the disclosure.
* * * * *