Title of Invention: CUPCAKE CONTAINER WITH INTEGRATED COLLAR ALL FORMED FROM A COMMON CARDBOARD BOX BLANK
Abstract: 
A cupcake container that folds from a flattened orientation to an erect orientation. The container is formed from a single cardboard box blank including an integrated collar, which is raised over a bottom panel by two legs. The integrated collar has at least one circular opening into which a cupcake base is fitted. The front and top panels form an aperture closed by a polymer film to allow viewing of the contents of the container.

Detailed Description: 

BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a cupcake container for the display, sale and transport of a decorated cupcake.
2. Discussion of Related Art
A conventional box for holding cupcakes has a folded, patterned box into which is fitted an insert that has openings suited to hold cupcakes. The folded box is formed from a cardboard box blank that is cut in accordance with a box pattern and has appropriately scored fold lines where the patterned cardboard box blank folds into the shape of the box. The folded box may have a portion of the top and front cut to form a large opening for viewing the contents of the folded box. The large opening may be closed by securing a piece of polymer film or foldable plastic to a periphery of box surrounding the large opening, that is, onto an underside of the top and onto a backside of the front. Glue may be used to secure the plastic to the box.
The insert, which is formed from another cardboard box blank, has a rectangular or square shape with one or more circular openings each sized to accommodate insertion of the base of a cupcake. Each of the circular openings is preferably widened by two smaller stress relief cutouts or recesses, which are in the form of semi-circles that are located substantially diametrically opposite each other. Further, each side of the rectangular or square shape of the insert has a scored fold line with corners from the scored fold line out removed so that the four sides of the insert may fold down along the for scored fold lines and fit in the folded box.
Typically, the folded, patterned box is shipped in a flattened, stowed condition and the folded, patterned insert is shipped in a flattened, stowed condition. After their arrival, typically at the point of use/sale, the folded, patterned box needs to be erected into its deployed condition by unfolding it from its flattened condition into the box shape. The insert is folded along its scored lines and fitted into the erected box shape.
It is, however, desirable to avoid the need for storing the two types of items (folded, patterned boxes and the inserts) separately in their flattened conditions since separate storage takes up more storage space than would common storage. It is further desired to avoid the need to bring the insert to the erected box shape for insertion at the point of use/sale. It is also desired to avoid the risk of a miscount or loss in delivery of the separate items as may occur with separate deliveries since the number of folded, patterned boxes is supposed to match the number of inserts. It is further desired to apply an inked pattern or graphics to the cardboard box blank in a single printing run to help ensure consistency in print quality as opposed to printing different cardboard box blanks in separate printing runs (such as for the folded, patterned box and for the insert). It is also preferred to cut and score fold lines in the cardboard box blank for forming the entire box rather than doing so separately, i.e., one for the folded, patterned box and another for the insert. It is also desired that the cupcake be retained in position within the folded, patterned box to enable adding frosting, icing and other food embellishments to the top of the cupcake with the container open.
SUMMARY OF THE INVENTION
One aspect of the invention resides in a container for at least one cupcake that is folded from a flattened condition to an erect condition that forms a box shape having a panel within. The panel has at least one opening each sized to accommodate retaining and embracing a base of an associated cupcake in position.
Preferably, the box has a transparent window for viewing the contents of the container, namely the at least one cupcake.
Another aspect of the invention resides in a structure formed from a cardboard box blank having a plurality of scored fold lines and having adhered portions arranged so that the structure is movable between a flattened orientation and an erect orientation with folds occurring at each of the scored fold lines in the erect orientation. The structure is self-standing in the erect orientation in an upright position. The cardboard box blank defines panels connected to each other in succession by associated ones of the plurality of scored fold lines. The panels include in succession a front, a bottom, a mediate spacer leg, an integrated collar, and a distal spacer leg, the distal leg being friction fit against the front in the erect orientation, the distal leg having a distal edge that is against the bottom as the distal leg is friction fit against the front.
A further aspect of the invention resides in adhered portions that include portions of two glue tabs that are adhered to a support panel and to the bottom respectively. The two glue tabs are connected to two corner panels respectively by associated ones of additional scored fold lines and arranged so that with the structure in the erect orientation and upright position, an underside of the structure includes portions of surfaces of each of the two glue tabs, the two corner flaps, the support panel and the bottom. The additional scored fold lines are positioned to bend from a substantially unbent position with the structure in an erect orientation to a substantially bent position with the structure in the flattened orientation.
In addition, the panels may include first and second sets of the panels, the first set of panels having in succession a tuck tab, a top, the front, the bottom, the mediate spacer leg, the integrated collar, and the distal spacer leg, the second set having in succession a glue flap, a rear, a right sidewall, the front and a left sidewall. Each of the first and second sets has the front in common with each other. The rear is connected to a support panel by one of the plurality of scored fold lines. The left and right sidewalls are connected to associated corner flaps by associated ones of the plurality of scored fold lines.
The integrated collar is integrated into the cupcake container and has an opening in communication with two stress relief recesses. The two stress relief recesses extend outwardly from the opening from locations of the opening that are substantially diametrically opposite each other.
In the erect orientation, the distal leg being friction fit against a portion of an inside surface of the front that is clear of the common aperture, the distal leg having a distal edge that is against a topside of the bottom as the distal leg is friction fit against the portion of the inside surface of the front.



BRIEF DESCRIPTION OF THE DRAWING
For a better understanding of the present invention, reference is made to the following description and accompanying drawings, while the scope of the invention is set forth in the appended claims.
FIG. 1 is a schematic diagram of a cardboard box blank for making a cupcake container to hold a single cupcake according to the invention as well as a polymer film closing a window of the cardboard box blank.
FIG. 2 is flattened view of the front, top and side of the cupcake container formed from the cardboard box blank of FIG. 1 and glued where needed to keep the cupcake container together when erected.
FIG. 3 is a flattened view of the rear, bottom and remaining side of the cupcake container of FIG. 2.
FIG. 4 is an isometric view of the cupcake container of FIGS. 2-3, shown partially erected with its bottom panel deployed but its integrated collar is yet to be deployed;
FIG. 5 is an isometric view of the top of the cupcake container of FIG. 4, but further erected with the retaining panel deployed as well and with one of the two dust flaps folded in preparation for closing the cover or lid.
FIG. 6 is an isometric view of top, front and right side of the cupcake container of FIG. 2, fully erected with its cover or lid closed.
FIG. 7 is an isometric view of the bottom, rear and left side of the cupcake container of FIG. 6.
FIG. 8 is a schematic diagram of a die cut for a cardboard box blank suited for a dual cupcake holder suited to retain two cupcakes in a spaced relation from each other when erected.
FIG. 9 is an isometric view of the dual cupcake container with the cardboard box blank of FIG. 8 folded appropriately into an erect position with its lid open and with appropriate panels glued to each other in a like manner to that for the single cupcake container embodiment of FIGS. 1-7.



DETAILED DESCRIPTION OF THE INVENTION
Turning to FIG. 1, a cardboard box blank 10 for a cupcake container 20 (FIGS. 2-7) is shown that has a window 22 closed by a transparent plastic sheet 22A, such as a polymer film. The transparent plastic sheet 22A is attached to the periphery of the window 22, which extends along the backside of a front wall 12 and the underside of a top panel 18. A tuck tab 24 extends from a free edge of the top panel 18. In addition to the front wall 12 and the top panel 18, the cardboard box blank 10 has a rear wall 14, a pair of sidewalls 16A, 16B and a bottom panel 30. Dust flaps 26A, 26B extend from a free edge of the sidewalls 16A, 16B respectively.
The cupcake container 20 may be of an auto bottom, tuck top box style.
The bottom panel 30 extends from the front wall 12 and preferably constitutes the full size of the container bottom. A mediate spacer leg 32 extends from the bottom panel 30 and an integrated collar 34 integrally extends from the mediate spacer leg 32 to serve as a cupcake spacer panel and is integrated with the rest of the cupcake container 20. A distal spacer leg 36 extends from the integrated collar 34 and has the same height H as the mediate spacer leg 32. When fully assembled, the mediate spacer leg 32 and the distal spacer leg 36 are substantially in parallel planes, preferably friction fit between the front and rear walls 12, 14 so as to exert some level of pressure against the front and rear walls 12, 14.
The integrated collar 34 is provided with a generally circular aperture 40, which is also generally centered on the integrated collar 34. The aperture 40 preferably has stress relief cutouts or recesses 42 located substantially diametrically opposite each other in the form of semi-circles that project outward from the aperture 40. In the case of the cupcake container 20 being formed to hold only a single cupcake, the integrated collar 34 preferably has the generally circular aperture 40 centrally located so that when the cupcake is retained in the generally circular aperture 40, the integrated collar 34 centers the cupcake in the integrated collar 34. In the case of the cupcake container being formed to retain multiple cupcakes, the integrated collar 34 has a plurality of generally circular apertures 40 arranged preferably in a manner rendering them substantially equidistant from each other to the nearest side of the integrated collar panel.
The rear panel 14 has a support panel 44 extending therefrom, and the adjacent sidewall 16A has a bottom corner panel 46 that includes a glue tab 48 extending therefrom. Similarly, the sidewall 16B has a bottom corner panel 50 extending therefrom, with a glue tab 52. The sidewall 14 also has a glue flap 54.
The cupcake container 20 is assembled into its flattened condition of FIG. 2 from the box blank 10 of FIG. 1 by gluing areas A, A′ together to join the rear wall 14 and the sidewall 16B and by gluing the areas B, B′ together to join the bottom corner flap 46 and the support panel 44. Glue areas C, C′ are glued together to join the bottom corner panel 50 with the bottom panel 30.
In the flattened condition of FIGS. 2 and 3, the cupcake container 20 has its rear wall 14 overlying the sidewall 16A with its dust flap 26A extending upwardly and the sidewall 16B overlies the front wall 12, with the bottom panel 30 and the integrated collar 34 extending upwardly adjacent the top panel 18. The support panel 44 and the corner bottom panels 46 and 50 fold upwardly within the flattened container 12 in a manner indicative of conventional auto bottom box structure.
Turning to FIG. 4, the cupcake container 20 is shown in a partially erect orientation and is folded to provide a generally rectangular shape. The bottom panel 30 is folded downwardly into its operative position to fully occupy the bottom of the cupcake container 20. The integrated collar 34 extends upwardly from the bottom panel 30 and adjacent the rear wall 14. In this condition, the mediate spacer leg 32 is folded at fold line 60 (FIG. 1) and extends upwardly adjacent the rear wall 14.
Turning to FIG. 5, the integrated collar 34 is folded downwardly into the cupcake container 20, with the fold being at the fold line 62 (see FIG. 1). Also in FIG. 4, the distal leg 36 is folded downwardly at the fold line 64 (see FIG. 1) so that the distal leg 36 engages the bottom of he cupcake container 20 and preferably exerts pressure against the inside facing surface of the front wall 12 beneath the window 22.
The integrated collar 34 is deployed to extend across the inside of the cupcake container 20 and spaced from the bottom panel 30. The generally circular aperture 40 and its relief cutouts or recesses 42 together configure the cupcake container 20 for receiving a base of a cupcake through the aperture 42 in a manner that allows the underside of the base of the cupcake to be supported on the topside of the bottom panel 30.
The integrated collar 34 holds or retains the cupcake in position spaced apart from the front, rear and sidewalls of the cupcake container 20 and also frictionally retains the cupcake against vertical movement within the cupcake container 20 by being friction fit into the generally circular aperture 40. The relief or recesses 42 provide some level of resiliency to accommodate variations in the dimension of the base of the cupcake yet facilitating the edge of the generally circular aperture 40 to frictionally engage the base of the cupcake. The bottom panel 30 prevents crumbs or icing bits from sifting through the bottom of the cupcake container 20. In addition, the two dust flaps 26A, 26B are shown folded outwardly, but the two dust flaps 26A, 26B are to be folded inwardly instead in preparation for the top panel 18, which serves as a lid or cover of the container 20, closing the container.
Turning to FIGS. 6 and 7, the cupcake container 20 is shown in a closed condition, with the top panel 18 closing the upper end opening of the cupcake container 20. The tuck tab 24 is inserted adjacent the rear panel 14 and retains the cupcake container in its closed condition. The window 22 is positioned across from the front wall 12 and the top panel 18 for viewing the cupcake. The underside of the cupcake container in the erect position can be seen to be constituted by a portion of the bottom panel 30, a portion of the support panel 44, the two corner panels 46, 50 and the two glue tabs 48, 52.
All the scored fold lines are folded when the cupcake container 20 is in an erect orientation, except for the scored fold lines between the glue tabs 48, 52 and the two corner panels 46, 50 since those two scored fold lines are substantially flat with the cupcake container 20 in the erect position. However, those two scored fold lines bend with the cupcake container 20 in the flattened position. There are two pairs of substantially diametrically opposite scored fold lines that form the four corner edges between the front, rear and two sidewalls. One of the pairs flatten when the cupcake holder 20 is in a flattened orientation and the remaining pair bends further.
The foregoing structure provides a cupcake container 20 that allows the cupcake to be seen and holds the cupcake in position so that handling of the container does not damage its icing and decoration. The cupcake container 20 is provided as an auto bottom tuck top style box, but other box styles may be used instead with the integrated collar panel as described above. The integrated collar 34 may be considered to be an integrated collar, that is, integrated with the remainder of the cupcake container 29.
Turning to FIG. 8, a cardboard box blank 50 is shown to accommodate retaining two cupcakes when fully erected into a dual cupcake box having the same cutouts, scored fold lines and glued portions as in the embodiment of FIGS. 1-6 except that there are two cupcake apertures 40A, 40B with associate pairs of stress relief cutouts 42A, 42B to retain two cupcakes and the dimension of the dual cupcake box is necessarily larger to accommodate retaining in position inside two cupcakes.
The cardboard box blank 10X of FIG. 8 is substantially the same as the cardboard box blank 10 of FIG. 1 aside from having a larger lengthwise dimension and having two cupcake apertures instead of just one. Sidewalls 16A, 16B are the same as are the dust flaps 26A, 26B, corner panels 46, 50, and glue tabs 48, 52 that extend from the sidewalls 16A, 16B. However, the front panel 12X, top panel 18X, rear panel 14X and bottom panel 30X are longer also than their counterparts in the cardboard box blank 10 of FIG. 1, namely, the front panel 12, top panel 18, rear panel 14, bottom panel 30 respectively. Also, the spacer leg 32X, the distal leg 26X, the tuck tab 24X and the support panel 44X are longer than their counterparts in the cardboard box blank 10 of FIG. 1, namely, spacer leg 32, distal leg 26, tuck tab 24 and support panel 44 respectively. The window 22X within the front panel 12X and top panel 18X is wider than its counterpart window 22 in the cardboard box blank 10 of FIG. 1 and is closed by a larger widthwise transparent sheet 22B such as a polymer film that is glued to the underside of the front and rear panels 12X, 18X at the peripheral region of the window 22X.
Turning to FIG. 9, the dimension of the cupcake container 56 that forms from the cardboard box blank 50 is necessarily larger to accommodate retaining in position inside two cupcakes instead of only one cupcake. The cupcake container 56 is shown in FIG. 9 in an erect condition with the cover or lid open.
The features, advantages and benefits of the single cupcake container 20 and dual cupcake container 20X with their respective integrated collars 34, 34X (cupcake spacer panels) are many:
Indulgent cupcakes displayed in an attractively designed cardboard box, as opposed to a plastic container, are suited to be purchased as a gift. Perhaps the perception among would be purchasers is that cupcakes displayed in a cardboard box are bakery fresh since bakeries typically package fresh bakery goods in cardboard boxes, but baked goods stored in plastic are done to preserve their shelf life and thus are either not as fresh or are of low quality.
The features, advantages and benefits of the cupcake container 20 or box with integrated collar 34 are many:
Indulgent cupcakes displayed in an attractively designed cardboard box, as opposed to a plastic container, are suited to be purchased as a gift. Perhaps the perception among would be purchasers is that cupcakes displayed in a cardboard box are bakery fresh since bakeries typically package fresh bakery goods in cardboard boxes, but baked goods stored in plastic are done to preserve their shelf life and thus are either not as fresh or are of low quality.
If the package does not restrain the cupcake from moving, the cupcake icing and decoration will become smeared against surfaces of the package to render the cupcake unsellable at full price.
Although a separate cupcake integrated collar can be inserted into a conventional cupcake box to keep the cupcake from moving and marring the icing, manual labor is needed to erect the integrated collar separately and then bring the integrated collar to the box in order to then place to integrated collar inside the box in its proper position.
Being that the integrated collar is separate item from the conventional cupcake box, the integrated collar must be manufactured and packaged separate from the conventional cupcake box and is then sold, shipped and stored as a separate stock keeping unit (SKU). Thus, there are two SKUs—one for the integrated collar and one for the rest of the cupcake container.
On the other hand, a cupcake box equipped with an integrated collar ensures that for every box there will be a integrated collar and only one SKU.
When the box is set up from its flattened orientation to its erect orientation, the integrated collar is set up at the same time, thus saving assembly time over that of conventional boxes that utilize separate integrated collars.
The integrated collar has an extended tab that rises upwardly from the print surface with the integrated collar panel assembled into its erect position. That extended tab offers an additional panel to be decoratively printed, which is lacking in the case of a conventional box having a separate integrated collar that has no such extended tabs that rise upwardly. Further, conventional separate integrated collars are not printed upon typically due to the added cost associated with performing an additional printing run. In the case of an integrated collar, however, all printing can be done in a single run across the cardboard box blank. Unlike the case for the conventional separate integrated collar manufacture, there is no additional board blank needed in the integrated collar manufacture with the cupcake box.
The cupcake container 20 has an unusually large waterfall style showcase window that takes up about as much room in the front as the front wall 12 cardboard and yet the cupcake container 20's integrity is not compromised from weakening by its significant presence. Instead, because of the integrated collar and the extra support it gives to the bottom border panel of the window (beneath the window 22), the large full front view waterfall window 22 might not be feasible due to support issues.
As can be appreciated by comparing the embodiment of the cupcake container of FIGS. 1-7 that holds a single cupcake with the cupcake container of FIGS. 8-9 that holds two cupcakes, the present invention may be applied to cupcake containers holding one or more cupcakes in a secure manner that avoids smearing of the cupcake icing or decoration during their transit or handling.
While the foregoing description and drawings represent the preferred embodiments of the present invention, it will be understood that various changes and modifications may be made without departing from the scope of the present invention.



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