Flexible tray and method of transporting and storing manufactured ice shapes

Abstract

A packaging assembly for transporting and storing ice includes a tray having a base portion and a plurality of compartments formed on the base portion configured to receive at least one piece of ice, optionally manufactured by a multi-day freeze process followed by shaping and three-dimensional machine cutting. Each compartment includes an opening formed on the base portion of the packaging assembly, a bottom portion substantially parallel to the base portion, at least one sidewall having a first end and a second end, the at least one sidewall connecting the base portion to the bottom portion, and at least one volume strip formed in a respective at least one sidewall. The plurality of compartments are formed as at least one of a circular frustum, a square frustum, and a rectangle frustum.

Claims

1. A packaging assembly for transporting and storing ice, the packaging assembly comprising: a tray having a substantially planar base portion; a plurality of compartments each formed on the base portion and configured to receive at least one piece of ice, wherein each compartment includes: an opening formed on and substantially planar with the base portion; a bottom portion substantially parallel to the base portion; at least one sidewall having a first end and a second end, the at least one sidewall connecting the base portion at the first end to the bottom portion at the second end via a curved portion, wherein an entire perimeter of the first end of the at least one sidewall is substantially flush with the base portion, wherein each of the at least one sidewall is angled such that each compartment of the plurality of compartments has a first dimension at the first end that is larger than a second dimension at the second end; and a plurality of volume strips formed in an outer surface of the at least one sidewall, wherein each of the plurality of volume strips extending linearly from the base portion to the curved portion and not extending into the curved portion, wherein the plurality of volume strips are evenly distributed around the entirety of the at least one sidewall, wherein the plurality of volume strips are uniform with one another; and a substantially planar cover in contact with the base portion, wherein the cover is configured to be removably attached to the base portion and seal the opening of each of the plurality of compartments.

2. The packaging assembly of claim 1, wherein the at least one sidewall is formed as a circular frustum so that the first end has a diameter larger than a diameter of the second end.

3. The packaging assembly of claim 2, wherein the second end of the sidewall is connected to the bottom portion at an angle that is greater than 90°.

4. The packaging assembly of claim 3, wherein the second end of the sidewall is connected to the bottom portion at an angle that is between about 91° and about 99°.

5. The packaging assembly of claim 4, wherein the angle is about 94°.

6. The packaging assembly of claim 1, wherein each compartment includes four sidewalls so that each compartment is formed as at least one of a square frustum and a rectangle frustum.

7. The packaging assembly of claim 6, wherein the second end of each sidewall is connected to the bottom portion at an angle that is greater than 90°.

8. The packaging assembly of claim 7, wherein the second end of the sidewall is connected to the bottom portion at an angle that is between about 91° and about 99°.

9. The packaging assembly of claim 8, wherein the angle is about 93°.

10. The packaging assembly of claim 1, wherein the tray and the plurality of compartments are formed as one-piece using a recyclable polypropylene.

11. The packaging assembly of claim 1, wherein the packaging assembly includes four compartments.

12. The packaging assembly of claim 1, wherein the cover is hermetically sealed against the at least one compartment via at least one heat seal.

13. The packaging assembly of claim 1, wherein the volume strips are formed as parallel ridges extending from the first end of the sidewall to the second end of the sidewall and protrude outwardly from an outer surface of the sidewall.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1A is a schematic top view of the example packaging according to an example embodiment of the present invention.

(2) FIG. 1B is a schematic section view of the example packaging according to an example embodiment of the present invention.

(3) FIG. 1C is a schematic side view of the example packaging according to an example embodiment of the present invention.

(4) FIG. 1D is a perspective view of the example packaging according to an example embodiment of the present invention.

(5) FIG. 1E is a schematic side view of the example packaging according to an example embodiment of the present invention.

(6) FIG. 2A is a schematic top view of the example packaging according to an example embodiment of the present invention.

(7) FIG. 2B is a schematic section view of the example packaging according to an example embodiment of the present invention.

(8) FIG. 2C is a schematic side view of the example packaging according to an example embodiment of the present invention.

(9) FIG. 2D is a perspective view of the example packaging according to an example embodiment of the present invention.

(10) FIG. 2E is a schematic side view of the example packaging according to an example embodiment of the present invention.

(11) FIG. 3A is a schematic top view of the example packaging according to an example embodiment of the present invention.

(12) FIG. 3B is a schematic section view of the example packaging according to an example embodiment of the present invention.

(13) FIG. 3C is a schematic side view of the example packaging according to an example embodiment of the present invention.

(14) FIG. 3D is a perspective view of the example packaging according to an example embodiment of the present invention.

(15) FIG. 3E is a schematic side view of the example packaging according to an example embodiment of the present invention.

(16) FIG. 4A is a schematic top view of the example packaging according to an example embodiment of the present invention.

(17) FIG. 4B is a schematic section view of the example packaging according to an example embodiment of the present invention.

(18) FIG. 5A is a schematic top view of the example packaging according to an example embodiment of the present invention.

(19) FIG. 5B is a schematic section view of the example packaging according to an example embodiment of the present invention.

(20) FIG. 6A is a schematic top view of the example packaging according to an example embodiment of the present invention.

(21) FIG. 6B is a schematic section view of the example packaging according to an example embodiment of the present invention.

DETAILED DESCRIPTION

(22) Various features and advantageous details are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. It should be understood, however, that the detailed description and the specific examples, while indicating embodiments, are given by way of illustration only, and not by way of limitation. Various substitutions, modifications, additions, and/or rearrangements will be apparent to those of ordinary skill in the art from this disclosure.

(23) In the following description, numerous specific details are provided to provide a thorough understanding of the disclosed embodiments. One of ordinary skill in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

(24) In an example embodiment, transportation and storage of handcrafted ice may be accomplished using a packaging assembly, as shown in FIGS. 1D, 2D, and 3D. Packaging assemblies include compartments for storing individual pieces of handcrafted ice that may be placed inside a compartment. Once placed inside a compartment, the handcrafted ice may be sealed inside the packaging assembly using a removable cover. For example, the cover may hermetically seal handcrafted ice inside packaging assembly. After transportation of the handcrafted ice is complete, the handcrafted ice may be stored inside packaging assembly until needed. Once needed, a portion of the removable cover covering a particular compartment may be removed so as to expose the handcrafted ice. A force may then be applied to remove the handcrafted ice. For example, a force may be applied to a bottom portion of the compartment which causes the handcrafted ice to dislodge from its compartment. Alternatively, a force may be applied to a bottom portion of the compartment which causes the sidewalls of the compartment to deform which causes the handcrafted ice to dislodge from its component.

(25) For example, the packaging assembly may be designed as a disposable packaging assembly, so that once the handcrafted ice has been removed from the packaging assembly, the packaging assembly may be disposed of and/or recycled.

(26) The rigidity of the packaging assembly and its compartments is selected to ensure that the desirable characteristics of the handcrafted ice, e.g., clarity, shape, absence of cracks, etc., are maintained during transportation, storage, and removal from the packaging assembly. For example, the composition of the packaging assembly is selected to ensure that the humidity, temperature, and transpiration of the handcrafted ice is controlled during transportation, storage, and removal. For example, a suitable plastic material may be used which acts as a barrier to maintain the humidity and temperature inside the compartment.

(27) To facilitate the removal of the handcrafted ice from a compartment, the configuration of a compartment can be selected to ensure that the handcrafted ice is removed without causing damage to the ice. Sidewalls of the compartments may connect to a bottom portion of the compartment at a specific angle. For example, the sidewalls may connect to the bottom portion at an angle greater than 90°. For example, the sidewalls may connect to the bottom portion at an angle in the range of about 91° to about 99°, and preferably in a range of about 93° to about 94°. In this manner, when a force is applied to the bottom portion of the compartment, the handcrafted ice can easily be removed. Furthermore, when a force is applied to the bottom portion of the compartment that causes the sidewalls to deform, the handcrafted ice will not be damaged.

(28) To protect the handcrafted ice during transportation, storage, and removal while still facilitating removal of the handcrafted ice, the bottom portions and corners of the compartments may be thicker than the sidewalls of the compartments. For example, the sidewall may have a thickness in a range of 1.0 mm to 2.0 mm, preferably in a range of 1.25 to 1.75; the portion that connects the sidewall to the bottom may have a thickness in a range of 4 mm to 6 mm, preferably in a range of 4.75 mm to 5.25 mm; and the bottom portion may have a thickness in a range of 4 mm to 6 mm, preferably in a range of 4.75 mm to 5.25 mm. For example, the sidewall may have a thickness of 1.5 mm; the portion that connects the sidewall to the bottom portion may be 5 mm; and the bottom portion may have a thickness of 5 mm.

(29) To protect the handcrafted ice during transportation, storage, and removal and to facilitate the removal of the handcrafted ice, volume strips may be formed in the compartments. These volume strips may be formed in the sidewalls of the compartments and increase the rigidity of the compartment so as to facilitate removal of the handcrafted ice. Additionally, the volume strips enable and promote airflow around the surfaces of the handcrafted ice. Airflow around the handcrafted ice during transportation, storage, and removal is particularly advantageous, as it allows for enhanced humidity and transpiration control and prevents the handcrafted ice from adhering to the compartment, which facilitates removal of the handcrafted ice.

(30) In addition to protecting the handcrafted ice during transportation, storage, and removal, forming equally spaced volume strips on the outer surface of the compartments saves costs associated with shipping the packaging assembly, as the volume strips facilitates and increases the amount of packaging assemblies that can be stacked on top of each other. For example, the volume strips may be formed as ridges formed on the outer surface of a compartment. For example, the volume strips may be equally spaced on the outer surface of the compartment.

(31) FIGS. 1A-1E illustrate an example packaging assembly 100. FIG. 1A is a schematic top view of packaging assembly 100. Packaging assembly may have width 110 and length 111 and include compartments 101-104 formed on base 150 of packaging assembly 100. As shown in FIG. 1A, compartments 101-104 may be arranged on base 150 in a symmetrical pattern, and packaging assembly 100 may be configured to have up to four compartments. For example, compartments 101-104 may be circular and formed to receive spherical shaped handcrafted ice. For example, compartments 101-104 may be configured to receive spherical shaped handcrafted ice having a diameter in the range of 2″ to 3″, preferably in a range of 2.25″ to 2.75.″ In an example embodiment, the spherical shaped handcrafted ice may have a diameter of 2.5″.

(32) FIG. 1B is a schematic section view of line 1B-1B, shown in FIG. 1A. Compartments 103 and 104, as shown in FIG. 1B may include bottom portion 160, sidewalls 161, and opening 162. Sidewalls 161 extend from base portion 150 to bottom portion 160. In an example embodiment, the connection between sidewalls 161 and bottom portion 160 may be formed as fillet 119.

(33) As shown in FIG. 1B, sidewalls 161 of compartments 101-104 may connect to bottom portion 160 at angle 117. For example, angle 117 may be greater than 90°. For example, the angle 117 may be in the range of about 91° to about 99°, preferably in the range of about 92° to about 95°, and more preferably in a range of about 93° to about 94°. In one example, angle 117 is 94°.

(34) As shown in FIG. 1B, opening 162 of compartment 104 may have a dimension of 114, and bottom portion 160 of compartment 104 may have a dimension 113. Compartment 104 may be formed as a circular frustum such that dimension 114 is larger than dimension 113. It has been found that a circular frustum shaped compartment that has an angle of 94° between a sidewall and a bottom portion is particularly advantageous for the transportation, storage, and removal of a handcrafted piece of ice.

(35) As shown in FIGS. 1A, 1C, 1D, and 1E, compartments 101-104 may include volume strips 118 formed on an outer surface of compartments 101-104. For example, volume strips 118 may be formed as ridges outwardly extending from compartments 101-104 outer surface. Volume strips 118 may also be equally spaced on the outer surface of compartments 101-104.

(36) FIGS. 2A-2E illustrate an example packaging assembly 200. FIG. 2A is a schematic top view of packaging assembly 200. Packaging assembly may have width 210 and length 211 and include compartments 201-204 formed on base 250 of packaging assembly 200. As shown in FIG. 2A, compartments 201-204 may be arranged on base 250 in a symmetrical pattern, and packaging assembly 200 may be configured to have up to four compartments. For example, compartments 201-204 may be square shaped and formed to receive cubed shaped handcrafted ice. For example, compartments 201-204 may be configured to receive cubed shaped handcrafted ice having a length in a range of 1″ to 3″, preferably in a range of 1.5″ to 2.5;″ a height in a range of 1″ to 3″, preferably in a range of 1.5″ to 2.5;″ and a width of in a range of 1″ to 3″, preferably in a range of 1.5″ to 2.5;″ In an example embodiment, the cubed shaped handcrafted ice may have a length of 2″, height of 2,″ and a width of 2″.

(37) FIG. 2B is a schematic section view of line 2B-2B, shown in FIG. 2A. Compartments 203 and 204, as shown in FIG. 2B may include bottom portion 260, sidewalls 261, and opening 262. Sidewalls 262 extend from base portion 250 to bottom portion 260. In an example embodiment, the connection between sidewalls 261 and bottom portion 260 may be formed as fillet 219

(38) As shown in FIG. 2B, sidewalls 261 of compartments 201-204 may connect to bottom portion 260 at angle 217. For example, angle 217 may be greater than 90°. For example, the angle 217 may be in the range of about 91° to about 99°, preferably in the range of about 92° to about 95°, and more preferably in a range of 93° to 94°. In one example, angle 217 is 93°.

(39) As shown in FIG. 2B, opening 262 of compartment 204 may have a dimension of 214, and bottom portion 260 of compartment 204 may have a dimension 214. Compartment 204 may be formed as a square frustum such that dimension 214 is larger than dimension 213. It has been found that a square frustum shaped compartment that has an angle of 93° between a sidewall and a bottom portion is particularly advantageous for the transportation, storage, and removal of a handcrafted piece of ice.

(40) As shown in FIGS. 2A, 2C, 2D, and 2E, compartments 201-204 may include volume strips 218 formed on an outer surface of compartments 201-204. For example, volume strips 218 may be formed as ridges outwardly extending from compartments 201-204 outer surface. Volume strips 218 may also be equally spaced on the outer surface of compartments 201-204.

(41) FIGS. 3A-3E illustrate an example packaging assembly 300. FIG. 3A is a schematic top view of packaging assembly 300. Packaging assembly may have width 310 and length 311 and include compartments 301-304 formed on base 350 of packaging assembly 300. As shown in FIG. 3A, compartments 301-304 may be arranged on base 350 in a symmetrical pattern, and packaging assembly 300 may be configured to have up to four compartments. For example, compartments 301-304 may be rectangular shaped and formed to receive rectangular shaped handcrafted ice. For example, compartments 301-304 may be configured to receive rectangular shaped handcrafted ice having a length in a range of 4″ to 6″, preferably in a range of 4.5″ to 5.5;″ a height in a range of 0.75″ to 1.75″, preferably in a range of 1.0″ to 1.5;″ and a width of in a range of 0.75″ to 1.75″, preferably in a range of 1.0″ to 1.5;″ In an example embodiment, the cubed shaped handcrafted ice may have a length of 5″, height of 1.25,″ and a width of 1.25″.

(42) FIG. 3B is a schematic section view of line 3B-3B, shown in FIG. 3A. Compartment 304, as shown in FIG. 3B may include bottom portion 360, sidewalls 361, and opening 362. Sidewalls 362 extend from base portion 350 to bottom portion 360. In an example embodiment, the connection between sidewalls 361 and bottom portion 360 may be formed as fillet 319

(43) As shown in FIG. 3B, sidewalls 361 of compartments 301-304 may connect to bottom portion 360 at angle 317. For example, angle 317 may be greater than 90°. For example, the angle 317 may be in the range of about 91° to about 99°, preferably in the range of about 92° to about 95°, and more preferably in a range of 93° to 94°. In one example, angle 317 is 93°.

(44) As shown in FIG. 3B, opening 362 of compartment 304 may have a dimension of 314, and bottom portion 360 of compartment 304 may have a dimension 314. Compartment 304 may be formed as a rectangle frustum such that dimension 314 is larger than dimension 313. It has been found that a rectangle frustum shaped compartment that has an angle of 93° between a sidewall and a bottom portion is particularly advantageous for the transportation, storage, and removal of a handcrafted piece of ice.

(45) As shown in FIGS. 3A, 3C, 3D, and 3E, compartments 301-304 may include volume strips 318 formed on an outer surface of compartments 301-304. For example, volume strips 318 may be formed as ridges outwardly extending from compartments 301-304 outer surface. Volume strips 318 may also be equally spaced on the outer surface of compartments 301-304.

(46) FIG. 4A illustrate packaging assembly 100 with cover 400 applied to base 150, and FIG. 4B is a schematic section view of FIG. 4A. Cover 400 may be for example, a thermoplastic material. Cover 400 may be used to hermetically seal compartments 101-104. For example, cover 400 may be sealed via heat seals 410.

(47) FIG. 5A illustrate packaging assembly 200 with cover 500 applied to base 250, and FIG. 5B is a schematic section view of FIG. 5A. Cover 500 may be used to hermetically seal compartments 201-204. For example, cover 500 may be sealed via heat seals 510.

(48) FIG. 6A illustrate packaging assembly 300 with cover 600 applied to base 350, and FIG. 6B is a schematic section view of FIG. 6A. Cover 600 may be used to hermetically seal compartments 301-304. For example, cover 600 may be sealed via heat seals 610.

(49) The described example embodiments are understood to be embodiments of the invention that are applicable to all aspects of the invention, including compositions and methods.

(50) While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular embodiments of particular inventions. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

(51) Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products.

(52) Thus, particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims.

(53) The claims are not to be interpreted as including means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.