Thermoformed bakery package

Abstract

A trifold thermoformed package with a bottom portion, a top portion and an internal portion integrally formed from a single sheet of thermoformable material. The top and bottom portions are arranged in a clamshell configuration and can be selectively closed about a first living hinge to cooperatively define an internal space for receiving items to be packaged. The internal portion is configured to fold about second living hinge into the package between the top portion and the bottom portion to form a shelf upon which items can be placed, thereby allowing two layers of items to be contained in the same package without direct stacking. The top portion may be joined to one edge of the bottom portion along a first living hinge and the internal portion may be joined to a second edge of the bottom portion along a second living hinge disposed opposite the first living hinge.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 
     
         1 . A thermoformed package comprising:
 a bottom portion, a top portion and an internal portion integrally formed from a single sheet of thermoformable material;   the bottom portion having a floor panel, a bottom sidewall extending from the floor panel and a bottom flange extending outwardly from the bottom sidewall, the bottom flange extending at least partially about the periphery of the bottom sidewall to form a bottom shoulder;   the top portion having a top panel, a top sidewall extending from the top panel and a top flange extending outwardly from the top sidewall, the top portion joined to the bottom portion by a first living hinge, the first living hinge configured to allow the top portion and the bottom portion to be selectively closed to define an internal space;   the internal portion having a peripheral edge joined to the bottom portion by a second living hinge, the internal portion configured to be selectively folded onto the bottom shoulder to form a shelf within the internal space between the top portion and the bottom portion, the shelf dividing the internal space into a bottom region capable of packaging a first layer of items and a top region capable of packaging a second layer of items.   
     
     
         2 . The package of  claim 1  wherein the internal portion has a peripheral lip generally corresponding in size and shape with the bottom shoulder, whereby the peripheral lip overlies the bottom shoulder when the package is closed. 
     
     
         3 . The package of  claim 2  wherein the internal portion includes a rail closely fitted into the bottom portion inwardly of the bottom shoulder when the internal portion is folded, the rail extending into the bottom portion along the bottom sidewall. 
     
     
         4 . The package of  claim 3  wherein at least one of the top flange and bottom flange includes a recess corresponding with the peripheral lip. 
     
     
         5 . The package of  claim 3  wherein the internal portion corresponds in size and shape with the bottom portion, whereby the internal portion closes the bottom portion providing separation between the top region and the bottom region. 
     
     
         6 . The package of  claim 5  wherein the bottom flange has a periphery and the internal portion has a periphery smaller than the bottom flange periphery. 
     
     
         7 . The package of  claim 6  wherein the bottom portion and the top portion include closing features that are interfitted when the package is closed. 
     
     
         8 . The package of  claim 7  wherein the closing features are disposed outwardly of the periphery of the internal portion, whereby the closing features of the top portion can be interfitted with the closing features of the bottom portion even when the internal portion is folded into the bottom portion. 
     
     
         9 . The package of  claim 8  wherein the top portion and the bottom portion are generally rectangular, and the closing features extend along short sides of the top portion and the bottom portion. 
     
     
         10 . A thermoformed package for bakery items comprising:
 a bottom portion, a top portion and an internal portion thermoformed from a single sheet, the bottom portion and top portion joined along a first living hinge and being movable about the first living hinge between an open state and a closed state, when in the closed state the bottom portion and the top portion cooperatively defining an internal space;   the bottom portion and the internal portion joined along a second living hinge, the internal portion being movable about the second living hinge between an unfolded state and a folded state, when in the folded state the internal portion is disposed between the bottom portion and the top portion forming a shelf dividing the internal space into a top region and a bottom region;   the bottom portion having a floor panel, a bottom sidewall extending from the floor panel and a bottom flange extending outwardly from the bottom sidewall, the bottom flange extending at least partially about the periphery of the bottom sidewall;   the top portion having a top panel, a top sidewall extending from the top panel and a top flange extending outwardly from the top sidewall, the top flange extending at least partially about the periphery of the top sidewall;   the internal portion having a peripheral lip disposed between the bottom flange and the top flange; and   wherein the bottom floor provides a first surface configured to support a first layer of packaged bakery items and the shelf provides a second surface configured to support a second layer of packaged bakery items.   
     
     
         11 . The package of  claim 10  wherein at least one of the top flange and the bottom flange includes a recess capable of receiving the peripheral lip. 
     
     
         12 . The package of  claim 10  wherein the internal portion includes a rail closely fitted into the bottom portion inwardly of the bottom flange when the internal portion is in the folded state, the rail extending into the bottom portion along the bottom sidewall. 
     
     
         13 . The package of  claim 10  wherein the bottom flange includes a bottom shoulder, the peripheral lip of the internal portion generally corresponding in size and shape with the bottom shoulder, whereby the peripheral lip overlies the bottom shoulder when the package is in the closed state. 
     
     
         14 . The package of  claim 13  wherein the peripheral lip extends around the full perimeter of the internal portion and the bottom shoulder extends around the full perimeter of the bottom portion. 
     
     
         15 . The package of  claim 13  wherein the bottom flange has a peripheral edge and the internal portion has a peripheral edge smaller than the bottom flange peripheral edge. 
     
     
         16 . The package of  claim 10  wherein the bottom portion and the top portion include closing features that are interfitted when the package is in the closed state. 
     
     
         17 . The package of  claim 16  wherein the closing features are disposed outwardly of the peripheral edge of the internal portion, whereby the closing features of the top portion can be interfitted with the closing features of the bottom portion even when the internal portion is folded into the bottom portion. 
     
     
         18 . The package of  claim 17  wherein the top portion and the bottom portion are generally rectangular, and the closing features extend along short sides of the top portion and the bottom portion. 
     
     
         19 . A thermoformed package for bakery items comprising:
 a bottom portion, a top portion and an internal portion thermoformed from a single sheet, the bottom portion and top portion joined along a first living hinge and being movable about the first living hinge between an open state and a closed state, when in the closed state the bottom portion and the top portion cooperatively defining an internal space;   the bottom portion and the internal portion joined along a second living hinge, the internal portion being movable about the second living hinge between an unfolded state and a folded state, when in the folded state the internal portion is disposed between the bottom portion and the top portion forming a shelf dividing the internal space into a top region and a bottom region;   the bottom portion having a floor panel, a bottom sidewall extending from the floor panel and a bottom flange extending outwardly from the bottom sidewall, the bottom flange extending at least partially about the periphery of the bottom sidewall;   the top portion having a top panel, a top sidewall extending from the top panel and a top flange extending outwardly from the top sidewall, the top flange extending at least partially about the periphery of the top sidewall;   the internal portion having a peripheral lip disposed between the bottom flange and the top flange, the top flange and the bottom flange sandwiching the peripheral lip; and   wherein the bottom floor provides a first surface capable of supporting a first layer of packaged bakery items and the shelf provides a second surface capable of supporting a second layer of packaged bakery items, the floor panel including a first plurality of contours configured to seat a plurality of packaged bakery items, the internal portion including a second plurality of contour configured to a seat a plurality of packaged bakery items.   
     
     
         20 . The package of  claim 19  wherein the first plurality of contours includes a plurality of generally circular contours each configured to individually retain a donut; and
 wherein the second plurality of contours includes a plurality of generally circular contours each configured to individually retain a donut.