Curved Bottom Taco Shell

The invention relates generally to taco shells, and more specifically to taco shells having a non-planar base and non-planar sidewalls.

Background of the Invention

Conventional taco shells are formed from a circular tortilla, which is bent and then cooked, for example by baking, in order to form a shell that is generally rigid and holds its generally U-shaped configuration so that it can be filled with a taco filling for consumption. Before cooking, the tortilla is placed in a mold which folds the tortilla about a longitudinal axis to form a pair of opposed and spaced apart planar side walls. The side walls are interconnected by a base having a generally semi-circular cross-section to thereby define a channel in which the taco filling, such as lettuce, beans, cooked meat, poultry, or the like, is placed. Consequently, the taco shell is not stable in a vertical, upright position and must be laid on one of its sides to prevent the taco shell from tipping over. However, when the taco shell is on its side, the taco shell can no longer hold the taco filling, which falls out through the open mouth of the taco shell.

In order to hold taco shells upright, various taco shell holders have been devised. Typically, the taco shell holder has a body with a wide base and a taco shell receiving opening in which the taco shell sits while it is filled and from which it is subsequently removed for consumption. However, the taco shell holders are not edible and, therefore, generate a significant amount of waste. Furthermore, in the fast- food-take-out environment, taco shell holders make it difficult to package the taco shell when the taco shell is filled with taco shell filling.

One solution to this problem has been proposed in International Publication Number WO 2004/043154 applied for by The Pillsbury Company (hereinafter referred to as the "Pillsbury Application"), the disclosure of which is hereby expressly incorporated by reference. The Pillsbury Application teaches modifying the conventional taco shell, which has planar side walls, to include a generally planar base. Although somewhat effective,

square bottom taco shells are not without problems. For instance, flat based taco shells have heretofore not provided the stability or strength desired by taco shell retailers and manufactures due to the high stress concentration factors associated with the sharp corners at the base of the taco shell as the planar sidewalls transition to the planar base. Furthermore, due to the variation in the surface topology of taco shells, the flat base shell does not provide coplanar support points and, instead, provides a plurality of support points at different elevations which causes the taco shell to be unstable when it is supported by its base. Further, the flat bottom and substantially perpendicular sidewalls provides an unaesthetic and unappetizing appearance. Further still, the flat base and flat sidewalls do not fit well in the palm of one's hand. Additionally, the flat bottom does not provide proper drainage from the taco. Therefore, juices from the meat and vegetables accumulate on the flat bottom, saturating the bottom, resulting in the weakening of same and providing an unappetizing, soggy texture and unpleasant taste to the base of the taco shell.

Another solution has been proposed in U.S. Patent No. 5,993,871 issued to Beehler (hereinafter referred to as "Beehler"), the disclosure of which is hereby expressly incorporated by reference. Referring to Figure 1 of this application, a cross-sectional view of the Beehler taco shell is shown. Although effective, the Beehler taco shell is not without its problems. For instance, the Beehler taco shell 100 includes flat, planar side walls 102 which are linear in cross-section along their entire height. The flat, planar side walls 102 are abruptly transitioned to a bottom wall 104 of the taco shell 100 via sharp radiused connecting members 106 having radiuses in a "range of about 12/128 ^th of an inch to about 26/12S" ¹ of an inch for a regular sized taco shell." It has been found that this abrupt transition of a flat, planar side wall via sharply radiused connecting members 106 weakens the structural integrity of the taco shell 100 along the length of the connecting members 106, often resulting in failures, in the forms of cracks and breaks, along the length of the connecting members 106, and most often along the transition line between the flat, planar side walls 102 and the connecting members 106.

Further, it has been found that the center rib 108 of the Beehler taco shell does not provide a sufficiently steep slope to promote adequate drainage of the taco fillings. Accordingly, the bottom of the Beehler taco shell is prone to becoming soggy, which results in the weakening of the taco shell 100 and provides an unpleasant taste and texture to one consuming the taco

shell 100. The Beehler taco has a slope having a rise to run ratio of about 1 :4 or less. Further still, it has been found that the planar side walls of the Beehler taco shell do not provide an ergonomic fit relative to a user's hand, and therefore it is not easily and comfortably handled during eating or preparation.

Consequently, there exists a need for a taco shell which is self supporting and can assume a generally upright position so that the taco filling will generally remain in the taco shell, which is less prone to breakage, which provides improved base drainage, which has an improved ergonomic fit within a user's hand, is easier to manufacture, and/or which is less expensive to produce.

Object of the Invention

It is an object of the invention to provide a curved bottom taco shell that ameliorates some of the disadvantages and limitations of the known art or at least provides the public with a useful choice.

Summary of the Invention

One embodiment of a taco shell formed in accordance with the present invention is disclosed. The taco shell includes a longitudinal axis, a pair of spaced apart sidewalls, and a bottom wall. Each sidewall may have a curved bottom portion and an upper portion, wherein at least the curved bottom portion of each sidewall curves inward toward the opposing sidewall as the sidewall approaches a bottom of the taco shell. The bottom portion may have a height greater than about 1.5 cm or 10% of a maximum height of the sidewalls, which ever is less. The bottom wall connects and extends between the bottom portion of each of the sidewalls. The sidewalls and bottom wall define a channel adapted to receive edible items. The bottom wall may be non-planar in shape such as to have a cross-sectional profile taken perpendicular to the longitudinal axis that is generally configured in a wave pattern having at least two troughs and one crest. The spaced apart sidewalls are each connected to one of the troughs such that the curved bottom portion of the sidewall is an

- A - extension of the trough. The two troughs are adapted to support the taco shell in a self- supporting and upright manner upon a planar and level support surface.

A slope of the areas of the bottom wall extending between the crest and the two troughs may exceed a rise to run ratio of 1 :3.5 to promote drainage. The upper portion of each of the sidewalls may be substantially planar in shape, though alternately they may be curved. The curvature of the bottom portion of each sidewall may increase as the bottom portion approaches its respective trough until the curvature of the bottom portion is equal to the curvature of the trough as the sidewall intersects the bottom wall, proving a smooth transition between the two structures.

An alternate embodiment of a taco shell having a longitudinal axis is disclosed. The taco shell may include a pair of sidewalls, each sidewall being non-planar in shape. The taco shell may also include a bottom wall extending between and spacing apart the sidewalls from one another. The pair of spaced apart sidewalls and bottom wall may define a channel adapted to receive edible items. The bottom wall may be non-planar in shape such as to have a cross-sectional profile taken perpendicular to the longitudinal axis to form a wave pattern having at least two troughs and one crest. Each of the spaced apart sidewalls may be connected to one of the troughs. The two troughs may be adapted to support the taco shell in a self-supporting and upright manner upon a planar and level support surface.

The sidewalls may include a curved bottom portion that has a height that extends above a height of an apex of the crest of the bottom wall by at least a distance equal to half an amplitude of the wave pattern. A slope of the bottom wall extending between the crest and the two troughs may exceed a rise to run ratio of 1:3 to promote drainage.

Brief Description of the Drawings

The invention will now be described, by way of example only, by reference to the accompanying drawings:

Figure 1 is a cross-sectional view of a prior art taco shell formed in accordance with the teachings of U.S. Patent No. 5,993,871 issued to Beehler;

Figure 2 is a front elevation view of one embodiment of a taco shell formed in accordance with the present invention; and Figure 3 is an isometric view of the taco shell of Figure 2.

Detailed Description of the Preferred Embodiment

The following description will describe the invention in relation to preferred embodiments of the invention, namely a taco shell. The invention is in no way limited to these preferred embodiments as they are purely to exemplify the invention only and that possible variations and modifications would be readily apparent without departing from the scope of the invention.

Referring to Figure 2, one embodiment of a taco shell 200 formed in accordance with the present invention is shown. The taco shell 200 includes a pair of non-planar side walls 202 and 204 and a base or bottom wall 206. The bottom wall 206 connects and extends between the sidewalls, spacing them from one another. The pair of spaced apart sidewalls 202 and 204 in combination with the bottom wall 206 define a channel 208 adapted to receive edible items, a few suitable examples being a meat filling, lettuce, tomato, onions, etc. The spacing between the sidewalls 202 and 204 may be constant along the height of the taco shell, increase, or decrease, or a combination thereof, though most preferably the spacing increases along the entire height. Preferably, the sidewalls 202 and 204 are angled substantially perpendicular to the support surface 224 so as to be at an angle relative to the support surface 224 of between 85 and 120 degrees.

The bottom wall 206 is preferably non-planar in shape such as to have a cross-sectional profile taken perpendicular to the longitudinal axis of the taco shell 200 that is generally in a wave pattern having two troughs 210 and 212 and one crest 214. The sidewalls 204 and 206 are each connected to one of the troughs 210 or 212. Preferably, the sidewalls 204 and 206 each include a curved lower portion 216 and 218 and a planar upper portion 220 and 222. Preferably, the curved lower portions 216 and 218 are coupled to the bottom wall 206 so as to be an extension of the trough 210 and 212 to which they are coupled to. Preferably, the curved lower portions 216 and 218 have a height 226 extending up from a support surface 224 of at least 1 cm, or even greater heights such as greater than about 1.5, 2, 2.5, 3,

or 3.5 cm. Stated in other terms, preferably, the curved lower portions 216 and 218 have a height 226 extending up from the support surface 224 of at least 1.5 times an amplitude 228 of the wave pattern of the bottom wall 206, or even greater heights such as greater than about 1.6, 1.7, 1.8, 1.9, or 2 times the amplitude 228. Stated in yet other terms, preferably, the curved lower portions 216 and 218 have a height 226 that is at least 10% of the overall height 230 of the side walls, or even greater heights such as heights that are greater than about 15%, 20%, or 25% of the overall height 230 of the sidewalls.

Preferably, the curved lower portions 216 and 218 increase in curvature as they approach the troughs 210 and 212 such that a gentle transition is provided between the sidewalls 202 and 204 and the bottom wall 206. This gentle transition has been found to increase the structural integrity of the taco shell 200, while also enhancing its appearance, and providing a more ergonomical fit in the palm of a user's hand during eating and handling. Preferably, the lower portions 216 and 218 of the sidewalls 202 and 204 are curved outward from one another so as to give the sidewalls 202 and 204 a somewhat clam-shell appearance.

Although the upper portions 232 and 234 of the sidewalls 202 and 204 are illustrated and described as being substantially planar, it is noted that they may alternately be curved. Further, although it is noted that the sidewalls 202 and 204 are shown with lower curved portions which are curved about a substantially horizontal axis, it should be noted that the sidewalls 202 and 204 may also be curved about a substantially vertical axis to increase the structural integrity of the sidewalls 202 and 204.

Preferably, the sloped portions 236 and 238 of the bottom wall 206 extending from the crest 214 to the troughs 210 and 212 have a slope which promotes the rapid drainage of food juices from their surface, for instance slopes having rise to run ratios steeper than about 1 :4, or even ratios of even steeper slopes, such as those steeper than about 1 :3.5, 1 :3.25, 1 :3, or 1:2.75. By using slopes of these magnitudes, rapid drainage can be achieved, keeping the bottom wall 206 dry, crisp, strong, and tasty.

Preferably the amplitude of the wave pattern of the bottom wall 206 is greater than a predetermined distance, a few suitable examples being greater than 0.5 cm, 0.75 cm, or 1 cm. Preferably the overall height 230 of the sidewalls is greater than a predetermined height, the predetermined height being preferably greater than about 3 cm, 4 cm or 5 cm. The width of

the bottom wall 206 is greater than a predetermined width, the predetermined width being greater than about 2 cm, 2.5 cm, 3 cm, or 3.5 cm. Preferably, the taco shell 200 is formed form a substantially circular tortilla having a predetermined diameter, the predetermined diameter preferably exceeding about 10 cm, 12 cm, or 14 cm. Preferably the tortilla is formed in a mold to assume the shape illustrated in Figure 2, and then cooked, for example by baking.

Preferably, the elongate troughs 210 and 212 are adapted to support the taco shell 200 in a self-supporting and upright manner upon a planar and level support surface 224. As best seen by referring to Figures 2 and 3, the troughs 210 and 212 form a pair of generally parallel, elongate, lines of support 240 and 242 for contact with the support surface 224. By providing line bearing contact surfaces 240 and 242, potential instability from variations in the surface topology of the taco shell 200, which result from the course or granular nature of the tortilla substrate, is removed and taco shell 200 provides a substantially stable taco shell 200. These parallel lines of support 240 and 242 permit the taco shell 200 to be self supporting and stable upon a substantially planar and level support surface 224 in an upright manner.

Advantages

The illustrated and described taco shell provides one or more of the following advantages over previously developed taco shells: a) the enhancement of the structural integrity of the taco shell; b) the enhancement of the drainage ability of the base of the taco shell; c) an improved appearance; d) a reduction in a rate of structural failure of the taco shell; e) enhancement in the taco shell's ability to resist absorption of filling juices; f) increase ease of manufacture; g) improved ergonomic fit relative to a user' s hand; and h) reduced production costs.

Variations

Throughout the description of this specification, the word "comprise" and variations of that word such as "comprising" and "comprises", are not intended to exclude other additives, components, integers or steps.

It will of course be realised that while the foregoing has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is hereinbefore described.