Food Spill Catching and Serving Device

(1) Field of the Invention

The present invention relates to an improved food spill catching device which can be worn by a person in a moving vehicle to catch the food spills and which is also useful as a serving tray. In particular the present invention relates to a device which can be mass produced at low cost.

(2) Prior Art

My U.S. Pat. No. 4,887,315 describes the prior art. Generally the prior art does not describe a device like that of the present invention.

In my U.S. Pat. No. 4,887,315, I described a preferred unitary preform which was folded to assemble the device. The tray produced performs very well; however, because of the unusual shape of the preform there is considerable wastage of material (paper or plastic) upon cutting.

It is therefore an object of the present invention to provide an improved food spill catching and serving device which minimizes the loss of material in forming the device. Further, it is an object of the present invention to provide a device which can be produced in high volume and at low cost. These and other objects will become increasingly apparent by reference to the following description and the drawings.

FIG. 1 is a perspective view of the food spill catching and serving device 10 of the present invention as a food serving tray, particularly illustrating the device in a closed condition with a cut-away portion showing a hamburger 100 inside.

FIG. 2 is a perspective view of the opened device 10 of FIG. 1 with the hamburger 100 removed, particularly illustrating the folded straps 12 in a tray 10c.

FIG. 3 is a perspective view illustrating a cover tray portion 10b of the device 10 removed from a container tray portion 10c.

FIG. 4 is a perspective view of the tray portion 10c of FIG. 3 assembled as the food spill catching device 10 with the straps 12 in their extended position from the tray portion 10c for attaching around the neck of a person.

FIG. 5 is a schematic plan view of an apparatus for assembling the food spill catching device 10, particularly illustrating separate lines 200, 300 and 300a for cutting, assembling and forming the trays 10b and 10c and the straps 12.

FIG. 6 is a cross-section along line 6-6 of FIG. 5 showing male-female molds unit 205 for compressing the folded straps 12 and trays 10b and 10c together until a glue holding the straps 12 in the tray 10c has set. The trays 10b and 10c provide a standard double bottom clamshell container.

The present invention relates to a protective device for collecting food spills adapted to be positioned on a front body portion of a person in an upper chest area to catch the spills from the mouth of the person which comprises: a rigid tray having a bottom, a front side away from the body portion, a back side adjacent to the upper chest area and opposite ends connecting the sides and the bottom to form the tray with a recess inside the tray for catching spills; and a separate strap means mounted across the bottom of the tray in the recess and adjacent the opposite ends of the tray, which strap means extends to and fastens round the neck of the person, wherein in use food falls from the mouth by gravity into the recess in the tray.

Further, the present invention relates to a method for collecting food spills while seated in a moving vehicle which comprises: providing a protective device adapted to be positioned on a front body portion of a person in an upper chest area which comprises a rigid tray having a bottom, a front side away from the body portion, a back side adjacent the upper chest area and opposite ends connecting the sides and the bottom to form the tray with a recess inside the tray for catching the spills; and a separate strap means mounted on the bottom of the tray in the recess and adjacent the opposite ends of the tray, which strap means extends to and fastens around the neck of the person, wherein in use food falls by gravity from the mouth into the tray while the person is seated in the moving vehicle; mounting the device around the neck using the strap means; collecting the food spills in the recess in the tray; and removing the strap means from around the neck after use.

Finally the present invention relates to a method for providing a protective device for collecting food spills adapted to be positioned on a front body portion of a person in an upper chest area to catch the spills from the mouth of the person which comprises: a rigid tray having a bottom, a front side away from the body portion, a back side adjacent to the upper chest area and opposite ends connecting the sides and the bottom to form the tray with a recess inside the tray for catching spills; and a separate strap means mounted across the bottom of the tray in the recess and adjacent the opposite ends of the tray, which strap means extends to and fastens around the neck of the person, wherein in use food falls from the mouth by gravity into the recess in the tray which comprises: providing a first conveyor line for multiple of the trays; providing a second conveyor line for multiple of the strap means; and mounting the strap means in the recess in the tray at a junction of the first and second conveyor lines.

The straps and tray are formed separately and then assembled. This is in contrast to the preferred unitary preform shown in my U.S. Pat. No. 4,887,315. The result is a considerable savings in material because of reduced wastage.

In the device of the present invention, the strap and tray can, if desired, be cut from different materials. These materials can have a different thickness and/or can be composed of a different material. Thus, for instance, the tray can be made of an expanded polystyrene and the straps can be made of cardboard. Generally the materials are disposable.

Preferably the strap is attached behind the neck. Various attachment means can be used; however, the least expensive is a tab on one strap and a receiving slot on the other strap.

Preferably the device also functions as a server for the food with top and bottom portions. Usually one of the portions is removed, such as by tearing a hinge in a "clam shell" type serving container and is discarded. Prior to use, the devices with the folded straps on the bottom of the trays are stacked for shipment and use.

Most usually the device is constructed for serving hamburgers and the like. In this event, the ratio of length to width between the sides is about equal.

FIGS. 1 to 4 show the assembled device 10. FIGS. 5 and 6 show the apparatus for assembling the device 10. As shown in FIG. 1, the device 10 is used to contain a hamburger 100 or like food to be dispensed to a customer, usually at a fast food restaurant. Conventionally the device 10 is hinged at 10a as shown in FIG. 2. As shown in FIG. 2, the device 10 includes two portions 10b and 10c. Portion 10c functions as a cover herein and portion 10b functions as the tray of the present invention. It will be appreciated that either portion 10b or 10c could be the tray portion 10b. Portion 10b includes a tab 10d which slides into slot 10e on the portion 10c. Each portion 10b and 10c includes tabs 10f (two shown) glued at each corner to form the portions 10b and 10c. The tabs 10f are glued to lateral sides 10g and 10h on each portion 10b and 10c. A front side 10i and a rear side 10j form the portion 10c along with a bottom 10k. The front and rear sides 10j and 10i are designated for convenience of explanation and could be reversed. The rear side 10i is positioned adjacent the chest area of the person. The description device 10 to this point is conventional and the trays 10b and 10c could also be made of molded polystyrene or other plastic material as is known to those skilled in the art.

As can be seen from FIGS. 2 and 3, straps 12 are folded inside the tray 10c. In this manner the straps 12 do not interfere with the food being served.

After the food is served, the portions 10b and 10c are separated along the hinge line 10a. This is accomplished easily if the hinge is perforated or has thin cross-section. The straps 12 are then unfolded from the bottom 10k of the tray 10c. As can be seen portion 12a (FIG. 4) of straps 12 is secured, preferably by gluing, to the bottom 10k of the tray 10c. The straps 12 have fold lines 12b (FIG. 4), 12c, 12d and 12e which are identical on each side of the straps 12. The straps 12 include a tab 12f which fits into slot 12g to hold the straps 12 around the neck of a person (not shown). The device 10 is then used and discarded when the use is complete.

FIGS. 5 and 6 show the apparatus for the manufacture of the device 10. FIG. 5 shows three conveyor lines 200, 300 and 300a. The conveyor line 200 conveys the boxboard 201 from a roll 202. A die cutter 203 stamps the preform 20 for the trays 10b and 10c. Glue is applied by applicator 204 in a position to secure tabs 10f. Glue is also applied by the applicator 204a to the preform 20 for securing the straps 12 in the portion of the preform 20 which will become the bottom 10k of the tray 10c.

Conveyor line 300 conveys cardboard 301 from roll 302 to a die cutter 303 which cuts the preform 30 for the straps 12 except the center portion 12a is left uncut from adjoining straps 12. The straps 12 are folded in a folding machine 304 to provide creases 12b to 12e. Glue is applied by applicators 307 so that the straps 12 remain folded. The preform 30 is moved to a second conveyor 300a where a cutter 305 severs the attachment at the center portion 12a. The single cut and folded strap 12 is then conveyed to line 200 where arm 306a of robot 306 mounts the folded strap onto the preform 20 at what will be the bottom 10k of the portion 10c. The preform 20 and folded strap 12 is then conveyed to a male-female molding unit 205 (FIG. 6) with male die 205a and female die 205b which forms the trays 10b and 10c and holds the tabs 10f and straps 12 in position until the glue is set. The device 10 is then removed from the mold unit 205 and can be stacked at station 206 for shipment. As can be seen, the present invention provides a means for readily and easily forming the device 10 without wasting cardboard in forming the straps 12. The resulting process produces little waste and is very fast and economical.

It is intended that the foregoing description be only illustrative and that the present invention be limited only by the hereinafter appended claims.