TRAY FOR FOOD PRODUCTS

Abstract

A tray for holding one or more food products includes a plurality of panels extending at least partially around an interior of the tray, the plurality of panels including a bottom panel, a plurality of side panels foldably connected to the bottom panel, a plurality of corner panels foldably connected to a respective side panel and at least partially forming a plurality of gussets, at least one handle activation panel foldably connected to a respective side panel, and at least one handle panel foldably connected to the respective side panel and separable from the at least one handle activation panel at a cut, and handle features including the at least one handle panel, the at least one handle panel positionable extending outwardly from a respective panel of the plurality of panels to form at least one handle of the tray.

Claims

1. A tray for holding one or more food products, the tray comprising: a plurality of panels extending at least partially around an interior of the tray, the plurality of panels comprising a bottom panel, a plurality of side panels foldably connected to the bottom panel, a plurality of corner panels foldably connected to a respective side panel of the plurality of side panels and at least partially forming a plurality of gussets of the tray, at least one handle activation panel foldably connected to a respective side panel of the plurality of side panels, and at least one handle panel foldably connected to the respective side panel of the plurality of side panels and separable from the at least one handle activation panel at a cut; and handle features comprising the at least one handle panel, the at least one handle panel positionable extending outwardly from a respective panel of the plurality of panels to form at least one handle of the tray.

2. The tray of claim 1, wherein the at least one handle panel is repositionable between a downwardly folded position and the outwardly extending position to provide the at least one handle reconfigurable between an activated configuration and an inactivated configuration.

3. The tray of claim 2, wherein the at least one handle activation panel is in at least partial face-to-face contact with the respective side panel of the plurality of side panels.

4. The tray of claim 3, wherein the at least one handle panel is positionable in generally planar relation with the at least one handle activation panel when the at least one handle panel is in the downwardly folded position.

5. The tray of claim 4, wherein the at least one handle panel is positionable in at least partial face-to-face contact with the respective side panel of the plurality of side panels when the handle is in the inactivated configuration.

6. The tray of claim 5, wherein the at least one handle activation panel is a first handle activation panel, the at least one handle panel is a first handle panel, the at least one handle is a first handle, the respective side panel of the plurality of side panels is a first side panel and the plurality of side panels further comprises a second side panel, the plurality of panels further comprises a second handle activation panel foldably connected to the second side panel, a second handle panel foldably connected to the second side panel, and the handle features further comprise a second handle at least partially formed by the second handle panel.

7. The tray of claim 6, wherein each gusset of the plurality of gussets comprises a respective first corner panel of the plurality of corner panels in at least partial face-to-face contact with a respective second corner panel of the plurality of corner panels.

8. The tray of claim 7, wherein the plurality of side panels further comprises a third side panel and a fourth side panel, the plurality of gussets comprises a first gusset, a second gusset, a third gusset, and a fourth gusset, the first gusset is foldably connected to each of the first side panel and the third side panel, the second gusset is foldably connected to each of the first side panel and the fourth side panel, the third gusset is foldably connected to each of the fourth side panel and the second side panel, and the fourth gusset is foldably connected to each of the second side panel and the third side panel.

9. The tray of claim 8, wherein each of the first gusset and the fourth gusset are in at least partial face-to-face contact with the third side panel and each of the second gusset and the third gusset are in at least partial face-to-face contact with the fourth side panel.

10. A blank for forming a tray for holding one or more food products, the blank comprising: a plurality of panels for at least partially around an interior of the tray formed from the blank, the plurality of panels comprising a bottom panel, a plurality of side panels foldably connected to the bottom panel, a plurality of corner panels foldably connected to a respective side panel of the plurality of side panels and for at least partially forming a plurality of gussets of the tray formed from the blank, at least one handle activation panel foldably connected to a respective side panel of the plurality of side panels, and at least one handle panel foldably connected to the respective side panel of the plurality of side panels and separable from the at least one handle activation panel at a cut; and handle features comprising the at least one handle panel, the at least one handle panel positionable extending outwardly from a respective panel of the plurality of panels to form at least one handle of the tray formed from the blank.

11. The blank of claim 10, wherein the at least one handle panel is repositionable between a folded position and the outwardly extending position to provide the at least one handle reconfigurable between an activated configuration and an inactivated configuration when the tray is formed from the blank.

12. The blank of claim 11, wherein the at least one handle activation panel is a first handle activation panel, the at least one handle panel is a first handle panel, the at least one handle is a first handle when the tray is formed from the blank, the respective side panel of the plurality of side panels is a first side panel and the plurality of side panels further comprises a second side panel, the plurality of panels further comprises a second handle activation panel foldably connected to the second side panel, a second handle panel foldably connected to the second side panel, and the second handle panel is for forming a second handle when the tray is formed from the blank.

13. The blank of claim 12, wherein each gusset of the plurality of gussets comprises a respective first corner panel of the plurality of corner panels in at least partial face-to-face contact with a respective second corner panel of the plurality of corner panels.

14. The blank of claim 13, wherein the plurality of side panels further comprises a third side panel and a fourth side panel, the plurality of gussets comprises a first gusset, a second gusset, a third gusset, and a fourth gusset, the first gusset is foldably connected to each of the first side panel and the third side panel, the second gusset is foldably connected to each of the first side panel and the fourth side panel, the third gusset is foldably connected to each of the fourth side panel and the second side panel, and the fourth gusset is foldably connected to each of the second side panel and the third side panel.

15. A method of forming a tray for holding one or more food products, the method comprising: obtaining a blank, the blank comprising a plurality of panels comprising a bottom panel, a plurality of side panels foldably connected to the bottom panel, a plurality of corner panels foldably connected to a respective side panel of the plurality of side panels, at least one handle activation panel foldably connected to a respective side panel of the plurality of side panels, at least one handle panel foldably connected to the respective side panel of the plurality of side panels and separable from the at least one handle activation panel at a cut, and handle features comprising the at least one handle panel; positioning the plurality of panels extending at least partially around an interior of the tray; positioning the plurality of corner panels at least partially forming a plurality of gussets of the tray; and forming a handle from the at least one handle panel such that the at least one handle panel is positionable extending outwardly from a respective panel of the plurality of panels.

16. The method of claim 15, wherein the at least one handle panel is repositionable between a downwardly folded position and the outwardly extending position to provide the at least one handle reconfigurable between an activated configuration and an inactivated configuration.

17. The method of claim 16, wherein the at least one handle activation panel is in at least partial face-to-face contact with the respective side panel of the plurality of side panels.

18. The method of claim 17, wherein the at least one handle panel is positionable in generally planar relation with the at least one handle activation panel when the at least one handle panel is in the downwardly folded position.

19. The method of claim 18, wherein the at least one handle panel is positionable in at least partial face-to-face contact with the respective side panel of the plurality of side panels when the handle is in the inactivated configuration.

20. The method of claim 19, wherein the at least one handle activation panel is a first handle activation panel, the at least one handle panel is a first handle panel, the at least one handle is a first handle, the respective side panel of the plurality of side panels is a first side panel and the plurality of side panels further comprises a second side panel, the plurality of panels further comprises a second handle activation panel foldably connected to the second side panel, a second handle panel foldably connected to the second side panel, and the method further comprises forming a second handle from the second handle panel.

21. The method of claim 20, wherein positioning the plurality of corner panels comprises positioning a respective first corner panel of the plurality of corner panels in at least partial face-to-face contact with a respective second corner panel of the plurality of corner panels.

22. The method of claim 21, wherein the plurality of side panels further comprises a third side panel and a fourth side panel, the plurality of gussets comprises a first gusset, a second gusset, a third gusset, and a fourth gusset, the first gusset is foldably connected to each of the first side panel and the third side panel, the second gusset is foldably connected to each of the first side panel and the fourth side panel, the third gusset is foldably connected to each of the fourth side panel and the second side panel, and the fourth gusset is foldably connected to each of the second side panel and the third side panel.

23. The method of claim 22, further comprising positioning each of the first gusset and the fourth gusset in at least partial face-to-face contact with the third side panel and positioning each of the second gusset and the third gusset in at least partial face-to-face contact with the fourth side panel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.

[0009] FIG. 1 is a plan view of an exterior surface of a blank used to form a tray according to an exemplary embodiment of the disclosure.

[0010] FIG. 2 is a perspective view of a tray formed from the blank of FIG. 1 according to an exemplary embodiment of the disclosure with handle panels in a folded position.

[0011] FIG. 3 is a perspective view of the tray of FIG. 2 with the handle panels in an outwardly extending position according to an exemplary embodiment of the disclosure.

[0012] FIG. 4 is a perspective view of the tray of FIG. 3 with a food product held in an interior thereof according to an exemplary embodiment of the disclosure.

[0013] Corresponding parts are designated by corresponding reference numbers throughout the drawings.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0014] Trays according to the present disclosure can accommodate articles of numerous different shapes. For the purpose of illustration and not for the purpose of limiting the scope of the disclosure, the following detailed description describes articles such as food products. In some embodiments, articles described herein can be fruits such as tomatoes (e.g., cherry tomatoes, etc.), berries (e.g., blueberries, raspberries, blackberries, strawberries, etc.), apples, oranges, tangerines, clementines, lemons, limes, cherries, etc. In another embodiment, articles described herein can be product packages, containers, bottles, cans, etc., that are at least partially disposed within the tray embodiments. In some embodiments, articles described herein can be food products that may be provided in discrete portions, for example, chicken nuggets, chicken strips, French fries, chips, and/or other food items that can commonly be referred to as finger foods. Such food products can also include sandwiches or the like, for example, chicken sandwiches, hamburgers, tacos, burritos, etc. In some embodiments, articles described herein can be food products that are arranged as prepared foods or prepared meals that can include one or more portions of a dish ready to be heated and served to a customer. In some embodiments, the articles can be used for packaging food and beverage products, for example. Packaged articles can be made from materials suitable in composition for packaging the particular food or beverage item, and the materials include, but are not limited to, glass; aluminum and/or other metals; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and Nylon; composite materials; and the like, or any combination thereof.

[0015] The articles described herein can include different types of food or beverage products, containers thereof, and/or having different shapes, without departing from the disclosure. In this specification, the terms lower, bottom, upper, and top indicate orientations determined in relation to fully erected and upright trays. As described herein, trays can be formed from blanks by overlapping multiple panels, portions, and/or end flaps. Such panels, portions and/or end flaps may be designated herein in terms relative to one another, e.g., first, second, third, etc., in sequential or non-sequential reference, without departing from the disclosure.

[0016] FIG. 1 is a plan view of an exterior surface 101 of a blank, generally indicated at 103, used to form a tray 105 (FIG. 2) according to an exemplary embodiment of the disclosure. In some embodiments, the blank 103 comprises paperboard (e.g., solid bleached sulphate folding boxboard), or other suitable material that can be recyclable and/or suitable for use in an oven (not shown).

[0017] The blank 103 can be formed from a single ply of material, such as but not limited to paperboard, cardboard, paper, a polymeric sheet, and/or a laminate that includes more than one layer. In some embodiments, the blank 103 can include a microwave interactive layer (not shown) such as is common in MicroRite containers available from Graphic Packaging International of Atlanta, GA. The microwave interactive layer can be commonly referred to as, or can have as one of its components, a susceptor, a foil, a microwave shield, or any other term or component that refers to a layer of material suitable for shielding microwave energy and/or causing heating in a microwave oven.

[0018] As described further herein, the blank 103 includes handle features for forming handles 109 (broadly, first handle or second handle) of the tray 105 formed from the blank 103. In some embodiments, the handle features and handles 109 formed therefrom can provide an outwardly-extending structure of the tray 105 by which a user can grasp the tray 105 to lift, carry, move, etc., the tray 105. Such an upper structure of the tray 105 can be particularly advantageous, for example, in situations in which food products are heated, e.g., in a conventional or microwave oven, or deposited into the tray 105 in a heated condition, such that it is desirable to have one or more handles extending away from the interior 107 of the tray 105 in which such heated items are positioned so as to minimize, reduce, inhibit, and/or prevent the transfer of heat from the interior 107 of the tray 105 to the user's hands and/or fingers.

[0019] As shown, the blank 103 has a longitudinal axis L1 and a lateral axis L2 and includes a plurality of panels for extending at least partially around an interior 107 of the tray 105 when the tray 105 is formed from the blank 103. The panels can include a bottom panel 121, a first side panel 123 (broadly, second side panel or third side panel or fourth side panel) foldably connected to the bottom panel 121 at a lateral fold line 125, a second side panel 127 (broadly, first side panel or third side panel or fourth side panel) foldably connected to the bottom panel 121 at a lateral fold line 129, a third side panel 131 (broadly, first side panel or second side panel or fourth side panel) foldably connected to the bottom panel 121 at a longitudinal fold line 133, and a fourth side panel 135 (broadly, first side panel or second side panel or third side panel) foldably connected to the bottom panel 121 at a longitudinal fold line 137.

[0020] The blank 103 can also include a plurality of end flaps/corner panels/corner flaps foldably connected to respective panels of the plurality of panels of the blank 103. In the illustrated embodiment, the corner panels can include, in clockwise relation: a first corner panel 139 (broadly, respective first corner panel or respective second corner panel) foldably connected to the side panel 123 at an oblique fold line 141; a second corner panel 143 (broadly, respective first corner panel or respective second corner panel) foldably connected the side panel 121 at an oblique fold line 145 and to the third side panel 131 at an oblique fold line 147; a third corner panel 149 (broadly, respective first corner panel or respective second corner panel) foldably connected to the third side panel 131 at an oblique fold line 151; a fourth corner panel 153 (broadly, respective first corner panel or respective second corner panel) foldably connected to the third corner panel 149 at an oblique fold line 155 and foldably connected to the second side panel 127 at an oblique fold line 157; a fifth corner panel 159 (broadly, respective first corner panel or respective second corner panel) foldably connected to the second side panel 127 at an oblique fold line 161; a sixth corner panel 163 (broadly, respective first corner panel or respective second corner panel) foldably connected to the fifth corner panel 159 at an oblique fold line 165 and foldably connected to the fourth side panel 135 at an oblique fold line 167; a seventh corner panel 169 (broadly, respective first corner panel or respective second corner panel) foldably connected to the fourth side panel 135 at an oblique fold line 171; and an eighth corner panel 173 (broadly, respective first corner panel or respective second corner panel) foldably connected to the seventh corner panel 169 at an oblique fold line 175 and foldably connected to the first side panel 123 at an oblique fold line 177.

[0021] As described further herein, adjacent corner panels (e.g., foldably connected corner panels) of the plurality of corner panels of the blank 103 and tray 105 can together form gussets of the blank 103 and tray 105 formed therefrom, and relative portions of each gusset can be arranged in at least partial overlapping and/or face-to-face contact upon formation of the tray 105. In some embodiments, adjacent corner panels of the blank 103/tray 105 can be devoid of a foldable connection.

[0022] In particular, the corner panels 139, 143 can form a gusset 111 foldably connected to each of the side panels 123, 131 at the respective fold lines 141, 147, the corner panels 149, 153 can together form a gusset 113 foldably connected to each of the side panels 131, 127 at the respective fold lines 151, 157, the corner panels 159, 163 can together form a gusset 115 foldably connected to each of the side panels 127, 135 at the respective fold lines 161, 167, and the corner panels 169, 173 can together form a gusset 117 foldably connected to each of the side panels 135, 123 at the respective fold lines 171, 177.

[0023] With continued reference to FIG. 1, the handle features of the blank 103 and tray 105 formed therefrom for forming a handle 109 of the tray 105 can include a first handle activation panel 179 (broadly, second handle activation panel) foldably connected to the third side panel 131 at a longitudinal fold line 181, and a second handle activation panel 183 (broadly, first handle activation panel) foldably connected to the fourth side panel 135 at a longitudinal fold line 185.

[0024] Each handle activation panel 179, 183, as shown can include and/or be associated with a respective handle panel 187 (broadly, first handle panel or second handle panel) at least partially separable therefrom at a respective cut 189 that intersects the respective fold line 181, 185. Accordingly, each handle panel 187 can be foldably connected to the respective side panel 131, 135 at a portion of the respective fold line 181, 185.

[0025] As shown, each cut 189 can have a generally bracket-shaped configuration, with a generally longitudinal segment that intersects a respective pair of generally oblique or generally lateral segments. The respective longitudinal segments can transition to the respective oblique or lateral segments at respective curved portion of the respective cut 189. It will be understood that one or both of the cuts 189 can have a different configuration without departing from the disclosure.

[0026] Each cut 189/handle panel 187 can intersect a respective access opening 191 formed by a respective cut in the respective handle activation panel 179, 183. While the access openings 191 are shown as having a generally semicircular configuration, it will be understood that one or both of the access openings 191 can have a different configuration without departing from the disclosure.

[0027] It will be understood that the handle features of the blank 103 and the tray 105 formed therefrom can include one or both of the handle panels 187 and associated features. In some embodiments, the handle features of the blank 103 and tray 105 formed therefrom can include one or both of the handle activation panels 179, 183 and associated features.

[0028] Turning now to FIGS. 2-4, formation of the tray 105 from the blank 103 according to an exemplary embodiment of the disclosure will be described.

[0029] The blank 103 can be positioned with the exterior surface 101 facing downwardly, for example, on a supporting surface such as a conveyor, bedplate, table, etc., and with an interior surface of the blank 103 (e.g., on a plane opposite the exterior surface 101) facing upwardly.

[0030] The side panels 123, 127, 131, 135 can be at least partially folded upwardly at the respective fold lines 125, 129, 133, 137 into an at least partially upright relationship with the bottom panel 121. In some embodiments, the panels 123, 127, 131, 135 can be obliquely arranged relative to the bottom panel 121 such that the tray 105 can have a generally downwardly tapering configuration.

[0031] The aforementioned movement of the side panels 123, 127, 131, 135 can cause the respective gussets 111, 113, 115, 117 to activate, e.g., reconfigure. For example, the corner panels 139, 143 can fold relative to one another at the fold line 145 into at least partial face-to-face contact and can further fold at the respective fold lines 141, 147 such that the corner panel 139 is positioned in at least partial face-to-face contact with the side panel 123 and such that the corner panel 143 is exposed facing outwardly on the gusset 111.

[0032] Similarly, the corner panels 149, 159 can fold relative to one another at the fold line 155 into at least partial face-to-face contact and can further fold at the respective fold lines 151, 157 such that the corner panel 153 is positioned in at least partial face-to-face contact with the side panel 127 and such that the corner panel 149 is exposed facing outwardly on the gusset 113.

[0033] The corner panels 159, 163 can fold relative to one another at the fold line 165 into at least partial face-to-face contact and can further fold at the respective fold lines 161, 167 such that the corner panel 159 is positioned in at least partial face-to-face contact with the side panel 127 and such that the corner panel 163 is exposed facing outwardly on the gusset 115.

[0034] The corner panels 169, 173 can fold relative to one another at the fold line 175 into at least partial face-to-face contact and can further fold at the respective fold lines 171, 177 such that the corner panel 173 is positioned in at least partial face-to-face contact with the side panel 123 and such that the corner panel 169 is exposed facing outwardly on the gusset 117.

[0035] Such activation of the gussets 111, 113, 115, 117 can cause adjacent side panels of the panels 123, 131, 127, 135 to draw closer together into generally abutting relation. However, the arrangement of the respective gussets 111, 113, 115, 117 can be such that a generally continuous surface is provided by the panels 121, 123, 127, 131, 135, 139, 143, 149, 153, 159, 163, 169, 173, e.g., so as to be generally devoid of seams or discontinuities. Such an arrangement can, in some embodiments, minimize, inhibit, prevent, and/or otherwise avoid inadvertent leakage or egress of material from the interior 107 of the tray associated with one or more food products, e.g., condensation, runoff, etc.

[0036] The handle activation panels 179, 183 can be folded downwardly at the respective fold lines 181, 185 into at least partial face-to-face contact with the respective side panels 131, 135. In this regard, in some embodiments, the handle activation panels 179, 183 can provide reinforcement to the side panels 131, 135. For example, the overlapping relationship of the handle activation panels 179, 183 and the respective side panels 131, 135 can provide a two-ply relationship that can minimize, inhibit, prevent, and/or otherwise avoid bending, bowing, buckling, creasing, tearing, other deformation, etc., of the side panel 131, 135, e.g., incidental to use.

[0037] FIG. 2 illustrates the handles 109 of the tray 105 in a folded or inactivated configuration in which the handle panels 187 are positioned folded generally downwardly and/or in at least partial face-to-face contact with the respective side panel 131, 135.

[0038] As shown in FIG. 3, the handles 109 can be reconfigured from the inactivated configuration to an outward or activated configuration in which the handle panels 187 can be separated from the respective handle activation panels 179, 183 at the respective cuts 189 and folded at the respective portions of the fold lines 181, 185 into an arrangement that is generally outwardly relative to the interior 107 of the tray 105. As described herein, an arrangement extending away from the interior 107 of the tray 105 can be one in which the handle panels 187 extend away from an aligned relationship over the bottom panel 121. In this regard, the handle panels 187 are repositionable between a downwardly folded position and an outwardly extending position to provide the handles 109 reconfigurable between the inactivated configuration and the activated configuration.

[0039] In some embodiments, the handle panels 187 can separate from the respective handle activation panels 179, 183 at the respective cuts 189 incidental to the aforementioned folding of the handle activation panels 179, 183 at the respective fold lines 181, 185. In some embodiments, the handle panels 187 can be separated by a user or machine component, for example, by engaging a free edge of the respective handle panel 187 exposed by the respective access opening 191 with a finger or machine component, and urging the respective handle panel 187 into the aforementioned arrangement.

[0040] The handle panels 187 are thus arranged as handles 109 in a freely extending and accessible relationship by which a user can grasp the handles 109, for example, with his or her fingers, and lift the handles 109 to lift, move, reposition, etc., the remainder of the tray 105 to which the handles 109 are attached. In some embodiments, the foldable connection of the handle panels 187 to the remainder of the tray 105 at the respective fold lines 181, 185 can allow the remainder of the tray 105 to allow for flexion/hinging/pivoting of the handles 109 at the respective fold lines 181, 185, for example, to provide stability of the tray 105 when being carried or moved. In some embodiments, the handles 109 can be provided so as to give the overall appearance and function of handles that are typically provided on a metal or ceramic pot or serving tray, to enhance a serving or dining experience, entice customers, etc.

[0041] It will be understood that the aforementioned arrangement of the tray 105 can be at least partially maintained with one or more applications of an adhesive such as glue.

[0042] With additional reference to FIG. 4, it will be understood that one or more articles such as one or more food products P can be positioned in the interior 107 of the tray 105 at one or more points during the formation thereof. In some embodiments, one or more food products P can be positioned in the interior 107 of the tray 105 prior to heating, for example, in a conventional or microwave oven.

[0043] Accordingly, the tray 105 is provided with handle features for forming at least one handle 109 configured and arranged not only to allow a user to grasp the tray 105 in a convenient manner, but also to avoid discomfort or injury associated with close contact with one or more food products P in the interior 107 of the tray 105 that can be heated, e.g., so as to minimize, reduce, inhibit, and/or prevent the transfer of heat from the interior 107 of the tray 105 to the user's hands and/or fingers.

[0044] Any of the features of the various embodiments of the disclosure can be combined with, replaced by, or otherwise configured with other features of other embodiments of the disclosure without departing from the scope of this disclosure.

[0045] The blanks according to the present disclosure can be, for example, formed from coated paperboard and similar materials. For example, the interior and/or exterior sides of the blanks can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blank. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. In accordance with the above-described embodiments, the blank may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the trays, to function at least generally as described above. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.

[0046] In accordance with the above-described embodiments of the present disclosure, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features.

[0047] As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the spaced apart slits to be replaced with a continuous slit, a continuous score, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure. Also, a tear line can be a series of cut scores passing completely, or partially, through the material, that are separated by nicks.

[0048] The term glue is intended to encompass all manner of adhesives commonly used to secure tray panels in place.

[0049] Any of the blanks, trays, or other constructs of this disclosure may optionally include one or more features that alter the effect of microwave energy during the heating or cooking of a food item that is associated with the tray or other construct. For example, the blank, tray, container, or other construct may be formed at least partially from one or more microwave energy interactive elements (hereinafter sometimes referred to as microwave interactive elements) that promote heating, browning and/or crisping of a particular area of the food item, shield a particular area of the food item from microwave energy to prevent overcooking thereof, or transmit microwave energy towards or away from a particular area of the food item. Each microwave interactive element comprises one or more microwave energy interactive materials or segments arranged in a particular configuration to absorb microwave energy, transmit microwave energy, reflect microwave energy, or direct microwave energy, as needed or desired for a particular construct and food item.

[0050] In the case of a susceptor or shield, the microwave energy interactive material may comprise an electroconductive or semiconductive material, for example, a vacuum deposited metal or metal alloy, or a metallic ink, an organic ink, an inorganic ink, a metallic paste, an organic paste, an inorganic paste, or any combination thereof. Examples of metals and metal alloys that may be suitable include, but are not limited to, aluminum, chromium, copper, inconel alloys (nickel-chromium-molybdenum alloy with niobium), iron, magnesium, nickel, stainless steel, tin, titanium, tungsten, and any combination or alloy thereof.

[0051] Alternatively, the microwave energy interactive material may comprise a metal oxide, for example, oxides of aluminum, iron, and tin, optionally used in conjunction with an electrically conductive material. Another metal oxide that may be suitable is indium tin oxide (ITO). ITO has a more uniform crystal structure and, therefore, is clear at most coating thicknesses.

[0052] Alternatively still, the microwave energy interactive material may comprise a suitable electroconductive, semiconductive, or non-conductive artificial dielectric or ferroelectric. Artificial dielectrics comprise conductive, subdivided material in a polymeric or other suitable matrix or binder, and may include flakes of an electroconductive metal, for example, aluminum.

[0053] In other embodiments, the microwave energy interactive material may be carbon-based, for example, as disclosed in U.S. Pat. Nos. 4,943,456, 5,002,826, 5,118,747, and 5,410,135.

[0054] In still other embodiments, the microwave energy interactive material may interact with the magnetic portion of the electromagnetic energy in the microwave oven. Correctly chosen materials of this type can self-limit based on the loss of interaction when the Curie temperature of the material is reached. An example of such an interactive coating is described in U.S. Pat. No. 4,283,427.

[0055] The use of other microwave energy interactive elements is also contemplated. In one example, the microwave energy interactive element may comprise a foil or high optical density evaporated material having a thickness sufficient to reflect a substantial portion of impinging microwave energy. Such elements typically are formed from a conductive, reflective metal or metal alloy, for example, aluminum, copper, or stainless steel, in the form of a solid patch generally having a thickness of from about 0.000285 inches to about 0.005 inches, for example, from about 0.0003 inches to about 0.003 inches. Other such elements may have a thickness of from about 0.00035 inches to about 0.002 inches, for example, 0.0016 inches.

[0056] In some cases, microwave energy reflecting (or reflective) elements may be used as shielding elements where the food item is prone to scorching or drying out during heating. In other cases, smaller microwave energy reflecting elements may be used to diffuse or lessen the intensity of microwave energy. One example of a material utilizing such microwave energy reflecting elements is commercially available from Graphic Packaging International, Inc. (Atlanta, GA) under the trade name MicroRite packaging material. In other examples, a plurality of microwave energy reflecting elements may be arranged to form a microwave energy distributing element to direct microwave energy to specific areas of the food item. If desired, the loops may be of a length that causes microwave energy to resonate, thereby enhancing the distribution effect. Microwave energy distributing elements are described in U.S. Pat. Nos. 6,204,492, 6,433,322, 6,552,315, and 6,677,563, each of which is incorporated by reference in its entirety.

[0057] If desired, any of the numerous microwave energy interactive elements described herein or contemplated hereby may be substantially continuous, that is, without substantial breaks or interruptions, or may be discontinuous, for example, by including one or more breaks or apertures that transmit microwave energy. The breaks or apertures may extend through the entire structure, or only through one or more layers. The number, shape, size, and positioning of such breaks or apertures may vary for a particular application depending on the type of construct being formed, the food item to be heated therein or thereon, the desired degree of heating, browning, and/or crisping, whether direct exposure to microwave energy is needed or desired to attain uniform heating of the food item, the need for regulating the change in temperature of the food item through direct heating, and whether and to what extent there is a need for venting.

[0058] By way of illustration, a microwave energy interactive element may include one or more transparent areas to effect dielectric heating of the food item. However, where the microwave energy interactive element comprises a susceptor, such apertures decrease the total microwave energy interactive area, and therefore, decrease the amount of microwave energy interactive material available for heating, browning, and/or crisping the surface of the food item. Thus, the relative amounts of microwave energy interactive areas and microwave energy transparent areas may be balanced to attain the desired overall heating characteristics for the particular food item.

[0059] As another example, one or more portions of a susceptor may be designed to be microwave energy inactive to ensure that the microwave energy is focused efficiently on the areas to be heated, browned, and/or crisped, rather than being lost to portions of the food item not intended to be browned and/or crisped or to the heating environment. Additionally or alternatively, it may be beneficial to create one or more discontinuities or inactive regions to prevent overheating or charring of the food item and/or the construct including the susceptor.

[0060] As still another example, a susceptor may incorporate one or more fuse elements that limit the propagation of cracks in the susceptor, and thereby control overheating, in areas of the susceptor where heat transfer to the food is low and the susceptor might tend to become too hot. The size and shape of the fuses may be varied as needed. Examples of susceptors including such fuses are provided, for example, in U.S. Pat. No. 5,412,187, U.S. Pat. No. 5,530,231, U.S. Patent Application Publication No. US 2008/0035634A1, published Feb. 14, 2008, and PCT Application Publication No. WO 2007/127371, published Nov. 8, 2007, each of which is incorporated by reference herein in its entirety.

[0061] All dimensional information presented herein is intended to be illustrative of certain aspects, features, etc., of various embodiments of the disclosure, and is not intended to limit the scope of the disclosure. The dimensions of the blanks, containers, forming tools, features, or any other dimension, can be more or less than what is shown and described in this disclosure without departing from the scope of this disclosure and can be within the listed ranges of dimensions for each feature or outside the listed ranges of dimensions for each feature without departing from the scope of this disclosure.

[0062] The foregoing description of the disclosure illustrates and describes various exemplary embodiments. Various additions, modifications, changes, etc., could be made to the exemplary embodiments without departing from the spirit and scope of the disclosure. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.