Packaged Food Product

Abstract

A packaged food product may incorporate an angled back card to improve stability by providing an enlarged footprint when the package is standing upright, i.e., vertically oriented. The angled back card can provide a wider base of support between the front of the product and the back card to improve the ability of the package to be self-supporting in an upright position, i.e., to stand up reliably on a shelf without leaning on other structures for external support. The package may be generally dumbbell-shaped as viewed from the front and/or from other angles, and may comprise a center portion that is narrower and/or shallower than adjacent end portions. This may facilitate handling of the product by the consumer and also may help to provide the product with an impactful appearance and theme at retail when the product is viewed from the front and/or from other angles. The product may include high-protein food items, consistent with the theme established by the shape, and may include prominently-displayed information about the protein content of the food items.

Claims

1. A method of providing a packaged food product, comprising: (a) forming a tray with a flange and at least one cavity having an angled rear surface; (b) placing a food product in the tray; (c) placing a film over the tray; (d) sealing the food product in at least one cavity; (e) placing a rigid angled back card on the angled rear surface in a position that will enable the packaged food products to be stably self-supporting in an upright orientation on a generally horizontal surface with an edge of the flange contacting the generally horizontal surface, and with the back card extending down and away from the angled rear surface to contact the generally horizontal surface; and (f) repeating steps (a) through (e) to form a plurality of additional packaged food products.

2. The method of claim 1 wherein steps (a) through (f) are performed in line.

3. The method of claim 1 wherein the trays are pre-formed off line.

4. The method of claim 1 wherein the tray includes an upper compartment having a rear surface, a lower compartment having a rear surface, and an intermediate compartment having a rear surface, the upper and lower compartments having substantially the same depth, and wherein placing a food product in the tray comprises placing the tray in a horizontal position with the tray resting on the rear surfaces of the upper and lower compartments prior to placement of the angled back card on the angled rear surface.

5. A method of packaging a food product in a high-speed commercial packaging operation and thereafter displaying the food product in a retail setting, comprising: (a) forming a tray with a flange and at least one cavity having an angled rear surface; (b) placing a food product in the package; (c) placing a film over the tray; (d) sealing the food product in at least one cavity; (e) placing a rigid angled back card on the angled rear surface; repeating steps (a) through (e) to form a plurality of additional packaged food products; and (g) standing a plurality of the packaged food products upright in a retail display such that each of the packaged food products is stably self-supporting in an upright orientation on a generally horizontal surface with an edge of the flange contacting the generally horizontal surface, and with the back card extending down and away from the angled rear surface to contact the generally horizontal surface.

6. The method of claim 5 wherein the tray comprises an upper cavity and at least one lower cavity, the lower cavity having the angled rear surface, the method further comprising placing a portion of the back card into a notch on the upper cavity.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0033] FIG. 1 is a perspective view of a packaged food product in accordance with a first embodiment;

[0034] FIG. 2 is a front elevation view thereof;

[0035] FIG. 3 is a rear elevation view thereof;

[0036] FIG. 4 is a right side elevation view thereof;

[0037] FIG. 5 is a left side elevation view thereof;

[0038] FIG. 6 is a top plan view thereof;

[0039] FIG. 7 is a bottom plan view thereof;

[0040] FIG. 8 is a right side elevation view of a packaged food product in accordance with a second embodiment;

[0041] FIG. 9 is a perspective view thereof;

[0042] FIG. 10 is a right side elevation view of the packaged food product of FIG. 1;

[0043] FIG. 11 is a right side elevation view of a third embodiment;

[0044] FIG. 12 is a right side elevation view of a fourth embodiment;

[0045] FIG. 13 is a right side elevation view of a fifth embodiment;

[0046] FIG. 14 is a perspective view of a sixth embodiment;

[0047] FIG. 15 is a rear elevation view thereof;

[0048] FIG. 16 is a rear elevation view of a seventh embodiment which is similar to that of FIG. 14 except as shown;

[0049] FIG. 17 is an isometric view of an eighth embodiment;

[0050] FIG. 18 is a right side cross-sectional elevation view of the tray of FIG. 1;

[0051] FIG. 19 is an isometric view of a ninth embodiment;

[0052] FIG. 20 is an isometric view of a tenth embodiment identical to that of FIG. 14, but with a transparent lid;

[0053] FIG. 21 is a flow chart illustrating a method of making and displaying packaged food products;

[0054] FIG. 22 is a perspective view of an eleventh embodiment;

[0055] FIG. 23 is a front elevation view thereof;

[0056] FIG. 24 is a right side elevation view thereof;

[0057] FIG. 25 is a right side elevation view of a twelfth embodiment.

DETAILED DESCRIPTION

[0058] In a first embodiment, illustrated in FIG. 1-7, there is provided a packaged food product 40 that comprises a rigid thermoformed tray 42 comprising one or more cavities or compartments, specifically an upper compartment 44, an intermediate compartment 46, and a lower compartment 48; and a lid 50 sealed to the tray. Food products 52, 54 and 56 (shown in FIG. 4) are disposed within the cavities.

[0059] Each cavity has one or more side walls and a rear wall. A back card 58 extends along and beyond coplanar rear walls 60 and 62 of the intermediate and lower compartments. The back card 58 is oriented so that so that the packaged food product is capable of being displayed on edge with the bottom end 64 of the flange 66, and the bottom end 68 of the back card 58 stably supporting the packaged food product on a horizontal surface 70 (FIG. 4).

[0060] The bottom end 68 of the back card extends downward and rearward from the rear surface of the bottom compartment to provide an enlarged footprint for the packaged food product. The rear walls 60, 62 and back card 58 may be oriented at an angle of 5 to 40 or 15 to 30 relative to the flange 66. The back card 58 has a portion of reduced width behind the middle compartment.

[0061] The back card 58 has front surface portions flush against and affixed by adhesives and/or other means to the angled rear walls 60 and 62 of the intermediate and lower compartments. The back card further has an upper end 72 abutting a bottom wall 74 of the upper compartment. The bottom wall of the upper compartment may have a stabilizing surface 76 such as a shallow groove or a shelf, shown in FIG. 12, engaging the upper end or another portion of the back card. In other embodiments, an example of which is illustrated in FIGS. 8 and 9, a portion of the back card 58 may extend upward beyond the upper cavity and may have an opening 104 above the upper cavity to facilitate hanging the packaged food product from a peg. Alternatively, the back card may extend laterally beyond the tray and have an opening to facilitate pegging of the product.

[0062] Some or all of the compartments 44, 46 and 48 may be gas flushed to reduce or eliminate oxygen therein. The lid may comprise a flexible film having moisture-barrier and oxygen-barrier properties.

[0063] To facilitate handling and to communicate information or a thematic concept, the product of claim 1 has a generally dumbbell-shaped front surface 80, with the middle cavity 46 being narrower and shallower than the upper and lower cavities. In keeping with the concept of the product, the front surface has information 108 prominently displayed thereon which may refer to protein content, e.g., the words Protein Pack, or to the amount of protein contained in the product. The food product may comprise one or more proteinaceous food products such as diced cheese 52, diced meats 54 and nuts 56 that in the aggregate contain a significant amount of protein. By way of example and not by way of limitation, the amount of protein in some embodiments may be, e.g., about 5 to 20 grams; about 12 to 14 grams; or about 13 grams, and the amount of protein may be communicated by text and/or graphics prominently displayed on the front surface 80, or otherwise included on the package. Other text, graphics, colors, etc. may also be included on any of the package surfaces to provide brand information, ingredient information, nutritional information, to make the package attractive, or for other reasons.

[0064] In some embodiments, the mass of the food product in the upper compartment may be less than the mass of the food product in the lower compartment to enhance stability. In other embodiments, the mass of the food product in the upper compartment may be equal to or greater than the mass of the food product in the lower compartment, and the angled back card may provide sufficient stability notwithstanding the higher center of gravity associated with this arrangement.

[0065] The product is preferably sized and shaped so that it has good handling characteristics. To this end, the tray 42 in some embodiments has a height h of 3 in. to 10 in., or 6 in. to 7 in.; a maximum width of 2 to 5 in., or 3 to 4 in.; a reduced central width W.sub.2; a depth d.sub.1 of about 1 in. to 4 in., or 2 in. to 3 in.; and a reduced central depth d.sub.2 that is less than d.sub.1. The back card 58 in some embodiments extends downward and rearward from the lower compartment, in some embodiments providing the product with an increased depth d.sub.3 which is greater than d.sub.1 at its bottom. In some embodiments, each of the upper and lower compartments 44 and 48 has a width W.sub.3, and the middle compartment has a reduced width W.sub.4 which is less than W.sub.3. In the interest of promoting stability, the flange width W.sub.5and flange return dimension W.sub.6(shown in FIG. 18) are both preferably fairly small. In some embodiments, the flange width W.sub.5 may be, e.g., 5 to 6 mm., and the flange return dimension W.sub.6 may be, e.g., 0 to 5 mm. or 2 to 3 mm.

[0066] FIGS. 8 and 9 illustrate an embodiment which is similar to that of FIG. 1 except as noted below. In the embodiment of FIGS. 8 and 9, the back card 58 extends upward over and beyond the upper compartment 44 across its entire width, and peg openings 104 are provided in the lid 50, flange 66 and back card 58. In other similar embodiments, the back card may extend vertically beyond the upper edge of the flange, and a single peg opening may be provided in the back card only. Also, the width of the back card may be reduced near its upper end in other embodiments.

[0067] FIG. 10 illustrates an embodiment similar to that of FIG. 1, except that the depth of the lower compartment 48 in the embodiment of FIG. 10 is less than that of the upper compartment 44, and the depth of the product at its bottom, i.e., the distance from a plane defined by a front surface of the flange to the bottom/rearward end 68 of the back card is equal to the depth of the upper compartment 44. The configuration of FIG. 10 may facilitate compact stacking and display of food products 40 in upright, flat or other orientations. For example, a stack of horizontally oriented products like that shown in FIG. 10 may be more stable, absent significant deflection of the back card due to stacking loads. However, the stability of the embodiment of FIG. 10 may not be as great as that of the embodiment of FIGS. 1-7 due to the decreased depth at the bottom or base. Also, prior to attachment of the back card, if the tray of FIG. 10 is resting on the rear wall 82 of upper compartment 44 and rear wall 62 of lower compartment 48, the flange 66 will not be horizontal, which may complicate high speed filling and sealing of the trays.

[0068] As shown in FIG. 13, the back card need not be adhered to both the intermediate and lower compartments 46 and 48, but rather may be adhered only to the intermediate compartment 46, and may be spaced from the lower compartment 48.

[0069] FIGS. 14, 15 and 20 illustrate a multipack packaged food product that comprises first and second trays 42 similar to those described above, each comprising a flange 66 and at least one cavity. The means for enclosing the food products within the cavities may comprise a first film lid hermetically sealed to the flange of the first tray and a second film lid hermetically sealed to the flange of the second tray. Alternatively, or additionally, the means for enclosing the food products within the cavities may include a single opaque (FIG. 14) or transparent (FIG. 20) film lid 84 having a first portion 88 covering the first tray and a second portion 90 covering the second tray. Provision of a transparent lid, as shown in FIG. 20, provides an advantage in that it may enable the underlying trays, food products contained therein, and/or graphics, text, etc. on underlying surfaces, to be viewed therethrough. The film lid 84 may have an area of weakness 86 such as a perforation to facilitate separation of the first portion from the second portion.

[0070] In multipack embodiments, the back card 58 may comprise a single back card having a first portion 92 engaging the first tray and a second portion 94 engaging the second tray, with an area of weakness 96 between the first and second portion to facilitate separation of the first portion from the second portion. The area of weakness 96 may comprise a removable strip of material defined by a pair of parallel vertical perforations 98. A portion of one or more of the back cards may extend upward beyond the upper cavity and may have an opening above the upper cavity to facilitate hanging the packaged food product from a peg.

[0071] FIGS. 16 and 17 illustrate further embodiments which are similar to that of FIGS. 14 and 15 except as noted below.

[0072] In the embodiment of FIG. 16, a hang tab 100 with a peg opening 104 is provided on an extension 102 of removable strip 96, extending upward between the upper compartments 44. The hang tab 100 may have an enlarged head to facilitate handling and provide additional strength and durability at around the opening.

[0073] In the embodiment of FIG. 17, the back card extends upward over and beyond the upper compartments 44 across its entire width, and peg openings 104 are provided in the lid 50 and the back card 58.

[0074] FIG. 21 illustrates a method of packaging and displaying a food product in a high-speed commercial packaging operation comprising the following steps (a)-(f) 211-216:

[0075] (a) forming 211 a tray with a flange and at least one cavity having an angled rear surface;

[0076] (b) placing 212 a food product in the cavity;

[0077] (c) placing 213 a film over the tray;

[0078] (d) sealing 214 the food product in at least one cavity;

[0079] (e) placing 215 a rigid angled back card on the angled rear surface in a position that will enable the packaged food products to be stably self-supporting in an upright orientation on a generally horizontal surface with an edge of the flange contacting the generally horizontal surface, and with the back card extending down and away from the angled rear surface to contact the generally horizontal surface;

[0080] (f) repeating 216 steps (a) through (e) to form a plurality of additional packaged food products; and

[0081] (g) standing 217 a plurality of packaged food products upright in a retail display.

[0082] Step (b) may take place with the tray in a generally horizontal position, rotated 90 clockwise from the position of FIG. 4, with the rear of the tray resting on a conveyor.

[0083] Steps (a) through (f) may be performed in line in a single efficient high-speed commercial operation. Alternatively, one or more steps, such as forming the trays, may be performed off-line. Where the trays are formed off-line, they may be supplied to a filling and sealing line in stacks, nested together with stacking legs 106 (FIG. 19) provided to facilitate de-nesting.

[0084] Placing the rigid angled back card on the rear surface may comprise use of an adhesive or other means to affix the back card to the rear surface, and may further comprise affixing the back card to more than one compartment. In some embodiments, the tray may have two lower compartments with coplanar angled rear surfaces, and an upper compartment with a lower surface that has a stabilizing feature such as a notch, groove or shelf for receiving an upper end of the back card.

[0085] Additional steps, such as a gas-flush step, may be included in the process. The process may also include joining the packaged food products in pairs, wherein placing the rigid angled back card on the angled rear surface comprises placing a single rigid angled back card on rear surfaces of two trays.

[0086] After forming, filling and sealing the packages and attaching back cards, the resulting packaged food products may be transported to retail locations and placed on horizontal shelves in upright and vertical positions in which they are stable and self-supporting. Alternatively, they may displayed in other ways, e.g., on shelves in upright positions in which they lean on adjacent products or other structures; on shelves in flat or horizontal positions; or on pegs, suspended from a top or side hang tab in an upright or sideways position.

[0087] FIGS. 22-24 illustrate a further embodiment comprising a tray 42 for use in a packaged food product like that of FIG. 1. The tray 42 of FIGS. 22-24 includes an upper compartment 44, an intermediate compartment 46 and a lower compartment 48. The tray 42 is generally dumbbell-shaped and is otherwise similar to the tray of FIG. 1, except that (1) the tray is symmetrical about a horizontal axis, with its intermediate compartment 46 having a generally vertical back wall 60 and (2) the tray is wider than the tray of FIG. 1. Food packages employing the tray of FIGS. 22-24 may include a back panel, but will not necessarily include a back panel.

[0088] FIG. 25 illustrates a further embodiment similar to that of FIGS. 1-7, except that in the embodiment illustrated in FIG. 25, the back wall 82 of the upper compartment 44 has a generally planar surface 83 disposed in a plane that is tangent to the deepest portion of the bottom compartment 48. In this embodiment, the maximum depth of the upper compartment is equal to the maximum depth of the bottom compartment 48. That is, the distance from a plane defined by a front surface of the flange 66 to the rearmost portion of the bottom compartment 48 is equal to the distance from the same plane to the rearmost portion of the top compartment. This configuration may provide increased stability of the rigid thermoformed tray 42 during filling due to increased surface area being in contact with a conveyor. That is, if the tray is filled prior to attachment of the back card 58, with the tray being in a generally horizontal position on a conveyor or other supporting surface, the generally planar surface 83 provides increased contact area, to increase stability such that the tray is less susceptible to tipping, sliding, rocking or other undesirable movement relative to the conveyor or other supporting surface.