MEAL-KIT PREPARATION AND SHIPPING SYSTEM

Abstract

A meal-kit delivery package includes a meal-kit shipping container dimensioned to accommodate any number of meal-kit bags to be shipped to a customer. The meal-kit shipping container also accommodates at least one additional meal ingredient, and any number of shipping materials. For example, the shipping materials can include a liner, a cooling component such as, ice or a cold pack, a first cushioning layer such as, bubble wrap and/or chipboard, and a second cushioning layer. The shipping container may also include a lid or other sealing device to enclose the contents within the shipping container. Each of the meal-kit bags is constructed from a semi-rigid material to accommodate placement of the meal ingredients therein while maintaining a loading configuration where a first side surface and a second side surface of the meal-kit bag maintains a generally vertical orientation.

Claims

1. A meal-kit bag, comprising: a plurality of surfaces, including: (i) a lower surface; (ii) a first side surface having first edge connected to a first portion of the lower surface; and (iii) a second side surface having a first edge connected to a second portion of the lower surface, wherein the first side surface and the second side surface are connected to form a volume by way of: (i) a first connection between an upper portion of the first side surface and an upper portion of the second side surface; (ii) a second connection between a first lateral portion of the first side surface and a first lateral portion of the second side surface; and (iii) a third connection between a second lateral portion of the first side surface and a second lateral portion of the second side surface; wherein the first side surface includes an opening disposed below the upper portion of the first side surface to enable access to the volume; wherein one or more of the plurality of surfaces includes a plurality of vents to maintain a level of carbon dioxide within the volume below a threshold associated with storing produce; wherein each of the plurality of surfaces is constructed from a semi-rigid material to accommodate placement of a plurality of meal ingredients therein while maintaining a loading configuration where the first side surface and the second side surface of the meal-kit bag maintains a generally vertical orientation.

2. The meal-kit bag of claim 1, wherein the lower surface, the first edge of the first side surface, and the first edge of the second side surface form a gusset to provide a resting base while the meal-kit bag is in the loading configuration.

3. The meal-kit bag of claim 1, wherein the upper portion of the first side surface and the upper portion of the second side surface form a top portion having at least two layers, the top portion defining a handle therethrough.

4. The meal-kit bag of claim 1, wherein the meal-kit bag is formed from a single sheet of semi-rigid material having a thickness between approximately 0.5 mil and approximately 6 mil.

5. The meal-kit bag of claim 1, wherein the meal-kit bag is constructed from at least one of an oriented polypropylene and a cast polypropylene.

6. The meal-kit bag of claim 1, wherein at least one of the first side surface and the second side surface forms a storage pocket.

7. A meal-kit delivery package, comprising: a plurality of meal-kit bags, each adapted to store a plurality of meal ingredients therein, each of the plurality of meal-kit bags comprising a lower surface having a first portion and a second portion, a first side surface having a first edge connected to the first portion of the lower surface and an opening, and a second side surface having a first edge connected to the second portion of the lower surface, wherein one or more of the lower surface, the first side surface, and the second side surface includes a plurality of vents to maintain a level of carbon dioxide within the volume below a threshold associated with storing produce; a meal-kit shipping container for accommodating the plurality of meal-kit bags, at least one additional meal ingredient, and a plurality of shipping materials; wherein each of the plurality of meal-kit bags is constructed from a semi-rigid material to accommodate placement of the plurality of meal ingredients therein while maintaining a loading configuration where the first side surface and the second side surface of each of the plurality of meal-kit bags maintains a generally vertical orientation.

8. The meal-kit delivery package of claim 7, wherein each of the plurality of meal-kit bags includes a gusset formed by the first side surface, the second side surface, and the lower surface to provide a resting base while each of the plurality of meal-kit bags is in the loading configuration.

9. The meal-kit delivery package of claim 7, wherein the each of the plurality of meal-kit bags is constructed from a single sheet of semi-rigid material.

10. The meal-kit delivery package of claim 7, wherein each of the plurality of meal-kit bags further comprises a sealing mechanism adapted to restrict the plurality of meal ingredients from being removed via the opening.

11. The meal-kit delivery package of claim 7, wherein each of the plurality of meal-kit bags further comprises a plurality of vents to maintain a level of carbon dioxide within the meal-kit bag below a threshold associated with storing produce.

12. The meal-kit delivery package of claim 7, wherein each of the plurality of meal-kit bags further comprises a handle defined by the second portion of the first side surface and the second portion of the second side surface.

13. The meal-kit delivery package of claim 7, wherein the semi-rigid material has a thickness of approximately 2 mil.

14. The meal-kit delivery package of claim 7, wherein each of the plurality of meal-kit bags is constructed from at least one of an oriented polypropylene and a cast polypropylene.

15. The meal-kit delivery package of claim 7, further comprising at least one instructional card disposed in the meal-kit shipping container, the at least one instructional card including information for the plurality of meal-kit bags.

16. A method of preparing a meal-kit delivery package, comprising: providing a plurality of meal-kit bags, each adapted to store a plurality of meal ingredients therein, each of the plurality of meal-kit bags comprising a lower surface having a first portion and a second portion, a first side surface having a first edge connected to the first portion of the lower surface and an opening, and a second side surface having a first edge connected to the second portion of the lower surface, wherein one or more of the lower surface, the first side surface, and the second side surface includes a plurality of vents to maintain a level of carbon dioxide within the volume below a threshold associated with storing produce; providing a meal-kit shipping container for accommodating the plurality of meal-kit bags, at least one additional meal ingredient, and a plurality of shipping materials; placing each of the meal-kit bags in a vertical loading orientation, wherein the first side surface and the second side surface maintain a generally vertical configuration and a portion of the lower surface rests on a loading surface; loading each of the meal-kit bags with a first ingredient used to prepare a meal; transporting each of the meal-kit bags while maintaining the vertical loading orientation; loading each of the meal-kit bags with at least a second ingredient used to prepare the meal; transporting each of the meal-kit bags while maintaining the vertical loading orientation; and placing each of the meal-kit bags in the meal-kit shipping container in the vertical loading orientation.

17. The method of claim 16, further comprising the step of sealing each of the plurality of meal-kit bags via a sealing mechanism to restrict the plurality of meal ingredients from being removed via the opening.

18. The method of claim 16, further comprising the step of unfolding each of the plurality of meal-kit bags to form a gusset at the lower surface, the first portion of the first side surface, and the first portion of the second side surface.

19. The method of claim 16, further comprising the step of placing a plurality of additional ingredients and a plurality of shipping components into the meal-kit shipping container.

20. The method of claim 19, wherein the step of placing the plurality of shipping components into the meal-kit shipping container comprises placing at least one of a coolant, a cushioning device, and a structural element into the meal-kit shipping container.

21. The method of claim 16, further comprising the step of disposing at least one instructional card in the meal-kit shipping container while maintaining the vertical loading orientation, the at least one instructional card including information for the plurality of meal-kit bags.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The above needs are at least partially met through the provision of the meal-kit preparation and shipping system described in the following detailed description, particularly when studied in conjunction with the drawings, wherein:

[0010] FIG. 1 illustrates a perspective view of an example meal-kit delivery package in accordance with various embodiments;

[0011] FIG. 2A illustrates a perspective view of a first side surface of an example meal-kit bag in accordance with various embodiments;

[0012] FIG. 2B illustrates a perspective view of a second side surface of the example meal-kit bag of FIG. 2A in accordance with various embodiments;

[0013] FIG. 2C illustrates a bottom plan view of a lower surface of the example meal-kit bag of FIGS. 2A and 2B in accordance with various embodiments;

[0014] FIG. 3 illustrates a front elevation view of the example meal-kit bag of FIGS. 2A-2C in accordance with various embodiments;

[0015] FIG. 4A illustrates a left side elevation view of the example meal-kit bag of FIGS. 2A-3 in an unloaded configuration accordance with various embodiments;

[0016] FIG. 4B illustrates a left side elevation view of the example meal-kit bag of FIGS. 2A-4A in a loaded configuration in accordance with various embodiments;

[0017] FIG. 5 illustrates a front elevation view of the example meal-kit bag of FIGS. 2A-4B in a configuration prior to assembly in accordance with various embodiments; and

[0018] FIG. 6 illustrates a plan view of an example approach to preparing a meal-kit delivery package in accordance with various embodiments.

[0019] Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments. It will further be appreciated that certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. It will also be understood that the terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.

DETAILED DESCRIPTION

[0020] FIG. 1 depicts an example meal-kit delivery package 100, which may include a meal-kit shipping container 101 and any number of meal-kit bags 120, each of which is adapted to store a plurality of meal ingredients. The package 100 enables a meal-kit company to ship a plurality of meal-kits to a customer. Generally speaking, each of the meal-kit bags 120 includes an opening that can be easily sealed and unsealed (e.g., via a zipper mechanism), includes a handle enabling easy handling, and is constructed from a material that is rigid or semi-rigid in nature. The material gives the bags 120 a structure that allows packagers to easily fill the meal-kit bags 120 during the packaging process. That is, unlike typical bags that lack structure and consequently collapse when not being handled, the meal-kit bag 120 can be opened and positioned to remain open, enabling one or more packagers to easily fill the meal-kit bag 120 and place the meal-kit bag 120 within the container 101 after the meal-kit bag 120 has been filled.

[0021] The meal-kit shipping container 101 is dimensioned to accommodate the plurality of meal-kit bags 120 to be shipped to a customer. The meal-kit shipping container 101 may also accommodate at least one additional meal ingredient 108, and any number of shipping materials 102. For example, the shipping materials 102 can include a liner 104, a cooling component 106 (e.g., an ice or a cold pack), and any number of intermediate layers 110, 112 (e.g., bubble wrap and/or chipboard). The shipping container 101 may also include a lid or other sealing device 114 to enclose the contents within the shipping container 101.

[0022] In these examples, the liner 104 may be in the form of a single layer disposed on the bottom of the shipping container 101. However, in other examples, the liner 104 may include a number of surfaces that line some or all of the surfaces of the shipping container 101. For example, the liner 104 may form a cubic or prismatic shape having a total of six sides. Accordingly, the liner 104 may be composed of two separate pieces that cooperate to form the liner. Other examples are possible. The liner 104 may be constructed from a cost-effective, readily available, and/or insulative material such as cotton, denim, wool, plaster, and the like. Other examples are possible.

[0023] FIGS. 2A-5 depict various views of an example meal-kit bag 120. With reference to FIGS. 2A-2C, the example meal-kit bag 120 includes a first side surface 124 (see FIG. 2A), a second side surface 126 (see FIG. 2B), and a lower surface 122 (see FIG. 2C). The surfaces 122, 124, and 126 may be coupled at coupling regions 138 (shown in FIGS. 2A and 2B) to form a gusset. As shown in FIG. 2C, the lower surface 122 includes a first portion 122a that is connected to the first side surface 124 and a second portion 122b that is connected to the second side surface 126.

[0024] With reference to FIG. 2A, the first side surface 124 includes: (i) a first edge 124a connected to the first portion 122a of the lower surface 122 shown in FIG. 2C; (ii) an upper portion 124b; (iii) a first lateral portion 124c connected to the second side surface 126, and (iv) a second lateral portion 124d connected to the second side surface 126. The first side surface 124 may include vents 130 and an opening 128 that can be sealed by way of a sealing mechanism 128a. Further, a top portion 132 of the meal-kit bag 120 may be formed by a double layer of material comprised of the first side surface 124 and the second side surface 126. The top portion 132 may include a hole defining a handle 134.

[0025] With reference to FIG. 2B, the second side surface 126 includes: (i) a first edge 126a connected to the second portion 122b of the lower surface 122 shown in FIG. 2C; (ii) an upper portion 126b; (iii) a first lateral portion 126c connected to the first lateral portion 124c of the first side surface 124; and (iv) a second lateral portion 126d connected to the second lateral portion 124d of the first side surface 124.

[0026] FIGS. 4A and 4B illustrate a side elevation view of the meal-kit bag 120. As shown, the first side surface 124 is joined to the second side surface 126, each of which is joined to the lower surface 122 to form a volume 121. The upper portion 126b of the second side surface 126 is connected to the upper portion 124b of the first side surface 124 to at least partially define the top portion 132. In some examples, the meal-kit bag 120 is constructed from a single sheet of semi-rigid material that is folded at specific locations. However, in other examples, any number of the surfaces 122, 124, 126 may be distinct components.

[0027] To form the volume 121, the surfaces 122, 124, and 126 shown in FIGS. 2A-2C are joined at three areas: (i) a first connection or coupling between the upper portion 124b of the first side surface 124 and the upper portion 126b of the second side surface 126; (ii) a second connection or coupling between the first lateral portion 124c of the first side surface 124 and a first lateral portion 126c of the second side surface 126; and (iii) a third connection or coupling between the second lateral portion 124d of the first side surface 124 and the second lateral portion 126d of the second side surface 126. The first, second, and the third connections or couplings may be of any form, for example, hermetic seals, adhesives, and the like. Other examples are possible.

[0028] In these examples, the lower surface 122, the first side surface 124, and the second side surface 126 are constructed from a semi-rigid material. This construction accommodates placement of any number of meal ingredients within the volume 121 formed by the surfaces 122, 124, 126, while maintaining a loading configuration where the first side surface 124 and the second side surface 126 maintains a generally vertical orientation. By generally vertical orientation, it is meant an angle formed with each of the first side surface 124 and the second side surface 126 relative to a horizontal plane (as well as the lower surface 122) denoted by a in FIG. 4A is between approximately 45 and approximately 90. It is understood that other non-generally vertical orientations of the surfaces 124, 126 are possible.

[0029] The surfaces 122, 124, 126 forming the meal-kit bag can be constructed from any number of materials such as oriented polypropylene (OPP) or cast polypropylene (CPP). Other examples are possible. In some examples, the thickness of the surfaces 122, 124, 126 is between approximately 0.5 mil and approximately 6 mil, and preferably, between approximately 1 mil and 3 mil to provide a sufficiently rigid, yet not overly structured bag. Other examples are possible.

[0030] As shown in FIGS. 2A and 3, the first side surface 124 includes an opening 128. The opening 128 is disposed at a position below the upper portion 124b (see FIG. 3) of the first side surface, and enables access to the volume 121. The opening 128 may be repeatedly sealable using a sealing mechanism 128a such as, a sliding seal (e.g., a zipper), an interlocking connection, a number of reusable adhesive surfaces, and the like. Other examples are possible.

[0031] The lower surface 122, first side surface 124, and/or the second side surface 126 may also define any number of vents 130 having any number of different shapes, sizes, and/or configurations. The vents 130 are sized to maintain a desired level of carbon dioxide within the volume 121 that is below a threshold associated with properly storing produce. For example, the vent or vents 130 may have a generally circular shape and may have a diameter between approximately 0.01 in and approximately 1.5 in. Other examples are possible. It is appreciated that the vent or vents 130 have a dimension that is small enough to restrict food products stored within the meal-kit bag 120 from exiting the volume 121 and located high enough from the bottom of the meal-kit bag 120 to contain any minor ingredient leaks that may occur therein. As an example, the vent or vents 130 may be disposed at a height that is approximately 25% to approximately 33% of the total height of the meal-kit bag. Other examples are possible.

[0032] As can be seen in FIGS. 4A and 4B, the upper portion 124b of the first side surface 124 and the upper portion 126b of the second side surface 126 may form a top portion 132 having at least two layers. The top portion 132 may define a handle 134 therethrough. This handle 134 can allow both packaging facility employees and customers to easily grasp a desired meal-kit bag for the purpose of preparing the meal-kit bag 120 for shipment, storage in a refrigerator, and/or other storage apparatus. By using a top portion 132 having at least two layers, a risk of tearing, ripping, and/or otherwise damaging the meal-kit bag 120 during the loading and/or handling process is mitigated due to the increased strength provided by the multiple layers.

[0033] As illustrated in FIGS. 4A and 4B, the meal-kit bag 120 maintains a loading, resting, and/or storage configuration whereby the first edge 124a of the first side surface 124 (and the first portion 122a of the lower surface 120) and the second edge 126a of the second side surface 126 (and the second portion 122b of the lower surface 122) act as points of contact with a generally horizontal plane. In other words, the first side surface 124, the second side surface 126, and the lower surface 122 cooperate to form a gusset to provide the stable loading base while the meal-kit bag 120 is in the loading, resting, and/or storage configuration. The horizontal plane can represent any number of environments, such as, a table or a conveyor system for filling the meal-kit bag 120, an intermediate layer for shipping the meal-kit delivery package 100, and a refrigerator shelf to accommodate and store the meal-kit bag 120. Because the meal-kit bag 120 is constructed from a semi-rigid material, the meal-kit bag 120 maintains its generally-triangular cross-sectional shape and will remain upright in order to be properly loaded, shipped, and stored in the aforementioned environments. Additionally, as illustrated in FIG. 4B, once the meal-kit bag has been loaded with meal ingredients 103, the lower surface 122 may also contact the horizontal plane. As such, the meal-kit bag 120 will be stable and remain upright, which, along with the sealing mechanism 128a, will reduce the occurrence of meal ingredients unintentionally exiting the volume 121 within the meal-kit bag 120.

[0034] As illustrated in FIG. 5, an example meal-kit bag 120 is constructed from a single sheet of semi-rigid material. The first side surface 124 of the meal kit bag 120 has an opening 128 and a sealing mechanism 128a pre-formed, thus particular details of this construction are not provided. The meal-kit bag 120 is formed by folding along the main midpoint line 136, and forming additional folds at a) the intersection of the first edge 124a of the first side surface 124 and the first portion 122a of the lower surface 122; and b) the intersection of the first edge 126a of the second side surface 126 and the second portion 122b of the lower surface 122. The meal-kit bag 120 can include any number of additional opposing folds to create a configuration where the edges 124a, 126a cooperate to create a generally elevated lower surface 122.

[0035] Upon folding the meal-kit bag 120, the upper portion 124b of the first side surface 124 and the upper portion 126b of the second side surface 126 will be aligned. Further, the first lateral portion 124c of the first side surface 124 and the first lateral portion 126c of the second side surface 126 will be aligned, and the second lateral portion 124d of the first side surface 124 and the second lateral portion 126d of the second side surface 126 will be aligned. The lower surface 122, the first side surface 124, and the second side surface 126 may then be coupled at these locations to define the volume 121. As previously stated, the surfaces may be coupled at these locations using any number of mechanisms such as, adhesives, sealants, bonding, and the like. Other examples are possible. Additionally, the lower surface 122, the first side surface 124, and the second side surface 126 may be coupled at coupling regions 138 in order to form the gusseted configuration.

[0036] As illustrated in FIG. 6, an example approach 150 to preparing a meal-kit delivery package is provided. The illustrated approach depicts a factory or warehouse environment where the meal-kit delivery package 100 is manufactured. At a first station 152, any number of meal-kit bags 120 constructed in accordance with the foregoing description are provided and placed on a generally horizontal table and/or conveyor 151. Each of the meal-kit bags 120 is placed in the loading orientation whereby the first side surface 124 and the second side surface 126 maintain a generally vertical configuration. In some examples, each of the meal-kit bags 120 may need to be unfolded such that a gusset is formed by the lower surface 122, the first portion 124a of the first side surface 124, and the first portion 126a of the second side surface 126.

[0037] At the first station 152, each of the meal-kit bags 120 is loaded with at least one ingredient 103a used to prepare a meal via the opening 128. It is understood that the first station 152, any number of ingredients 103a may be loaded into each of the meal-kit bags.

[0038] Each of the meal-kit bags 120 are then transported to a second station 154, whereby additional ingredients 103b are loaded into the volume 121 via the opening 128. While maintaining the loading configuration, each of the meal-kit bags are transported to a third station 156 and placed into the meal-kit shipping container 101 in the vertical loading orientation. It is understood that there may be a delay between loading each of the meal-kit bags 120 with ingredients 103a, 103b and loading the meal-kit bags 120 into the meal-kit shipping container 101. The meal-kit bags 120 may be temporarily transported to a storage container (not shown) prior to being loaded into the meal-kit shipping container 101. Transportation to these intermediate locations may occur in an efficient manner because each of the meal-kit bags 120 is capable of standing in a generally vertical orientation, and can easily be grabbed via the handle 134. Further, it is understood that any number of stations may be used to load the meal-kit bag 120 and the meal-kit shipping container 101. Further, it is understood that any number of additional meal ingredients 108 (such as, for example meat products and other proteins) and shipping materials 102 (such as, for example coolants, cushioning devices, and other structural elements) may also be loaded at the third station 156 or any other station not illustrated.

[0039] In some examples, after all of the desired ingredients 103a, 103b have been loaded into the meal-kit bags but prior to loading the meal-kit bags 120 into the meal-kit delivery station, the meal-kit bags may be sealed via the sealing mechanism 128a. This seal acts to restrict the meal ingredients 103a, 103b from being removed from the volume 121 via the opening. Additionally, an instructional card 118 may be disposed in the meal-kit shipping container 101 while maintaining the vertical loading orientation.

[0040] In some examples, the meal-kit bag 120 may also include a storage pocket 140. In some examples, the storage pocket 140 may be formed by at least one of the first and second side surfaces 124, 126 by adding additional folds to the first and/or second side surfaces 124, 126. In other examples, the storage pocket 140 may be formed from an additional material that is coupled to one of the first and second side surfaces. The storage pocket 140 may be disposed on an outer side and/or an inner side (e.g., within the volume 121 of the meal-kit bag 120) of the first and second side surfaces 124, 126. The storage pocket 140 may be dimensioned to accommodate a placard containing cooking instructions, nutritional information, and/or any other additional information. In meal-kit packages 100 having a number of individual meals, by providing a location for this placard within or coupled to the particular meal-kit bag 120, a user will not need to spend time attempting to identify which instructions found within the shipping container 101 refer to a particular meal-kit bag 120.

[0041] Additionally, in some examples, any number of the meal-kit bags 120 may include partitions or dividers (not shown) which create physical barriers within the volume 121. These dividers may be constructed from any material and can be formed from discrete components or alternatively be formed as integral features of the meal-kit bag 120. These partitions may be used to provide particular locations for each of the meal-kit ingredients to avoid damaging other ingredients. Further the use of partitions may reduce overall loading times during the meal-kit bag 120 preparation, as it is not necessary to spend time rearranging ingredients in order to fit in the volume 121.

[0042] Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.

[0043] The patent claims at the end of this patent application are not intended to be construed under 35 U.S.C. 112(f) unless traditional means-plus-function language is expressly recited, such as means for or step for language being explicitly recited in the claim(s). The systems and methods described herein are directed to an improvement to computer functionality, and improve the functioning of conventional computers.