BLANKS, TRAYS, AND ASSOCIATED METHODS FOR HOLDING FOOD PRODUCTS
20250376292 ยท 2025-12-11
Inventors
Cpc classification
B65D5/2047
PERFORMING OPERATIONS; TRANSPORTING
B65D5/24
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65D5/56
PERFORMING OPERATIONS; TRANSPORTING
B65D5/20
PERFORMING OPERATIONS; TRANSPORTING
B65D5/24
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A tray for holding one or more food products includes a plurality of panels extending at least partially around the interior of the tray, the plurality of panels including a central panel and a plurality of side panels in at least partial face-to-face contact with respective portions of the central panel, the plurality of panels arranged to form a tray bottom, a sidewall extending upwardly from the tray bottom, and a flange extending outwardly from the sidewall, each panel of the plurality of panels having a laminate structure, the laminate structure including a base layer and a barrier layer, the plurality of side panels positioned at least partially reinforcing the flange 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 the interior of the tray, the plurality of panels comprising a central panel and a plurality of side panels in at least partial face-to-face contact with respective portions of the central panel, the plurality of panels arranged to form a tray bottom, a sidewall extending upwardly from the tray bottom, and a flange extending outwardly from the sidewall, each panel of the plurality of panels comprising a laminate structure, the laminate structure comprising a base layer and a barrier layer, the plurality of side panels positioned at least partially reinforcing the flange of the tray.
2. The tray of claim 1, wherein the central panel comprises a central portion and a marginal portion extending at least partially around the central portion, the central portion of the central panel at least partially forming the tray bottom and the sidewall of the tray.
3. The tray of claim 2, wherein each side panel of the plurality of side panels is in at least partial face-to-face contact with the marginal portion of the central panel to at least partially form and reinforce the flange of the tray.
4. The tray of claim 3, wherein each side panel of the plurality of side panels is in at least partial face-to-face contact with the central portion of the central panel to at least partially form and reinforce the sidewall of the tray.
5. The tray of claim 4, wherein each side panel of the plurality of side panels at least partially form and reinforce the tray bottom of the tray.
6. The tray of claim 2, wherein the central panel further comprises a plurality of corner portions, the plurality of corner portions at least partially forming respective corners of a plurality of corners of the tray.
7. The tray of claim 6, wherein the plurality of corner portions comprises a respective plurality of lines of weakening facilitating formation of the respective corners of the plurality of corners of the tray.
8. The tray of claim 2, wherein the plurality of side panels comprises a first side panel and a second side panel.
9. The tray of claim 8, wherein the plurality of side panels further comprises a third side panel and a fourth side panel.
10. The tray of claim 9, wherein each side panel of the plurality of side panels have a generally tapered configuration.
11. The tray of claim 9, wherein the tray further comprises a plurality of corner gussets foldably connected to the central panel, each corner gusset of the plurality of corner gussets foldably connected to a respective side panel of the plurality of side panels.
12. The tray of claim 11, wherein at least one corner gusset of the plurality of corner gussets comprises a central portion and at least one outer portion foldably connected to the central portion of the at least one corner gusset, the central portion of the at least one corner gusset foldably connected to the central panel, the at least one outer portion of the corner gusset foldably connected to the respective side panel of the plurality of side panels.
13. The tray of claim 8, further comprising handle features, the handle features comprising a plurality of handle flaps forming a plurality of handles, each handle repositionable between a first position, in which each handle is at least partially coextensive with a respective side panel of the plurality of side panels, and a second position, in which each handle is separated from the respective side panel of the plurality of side panels.
14. The tray of claim 13, wherein each handle flap is foldably connected to the respective side panel of the plurality of side panels.
15. The tray of claim 13, wherein each handle flap is foldably connected to the central panel.
16. A blank for forming a tray for holding one or more food products, the blank comprising: a plurality of panels for extending at least partially around the interior of the tray formed from the blank, the plurality of panels comprising a central panel and a plurality of side panels for being positioned in at least partial face-to-face contact with respective portions of the central panel when the tray is formed from the blank, the plurality of panels for being arranged to form a tray bottom, a sidewall extending upwardly from the tray bottom, and a flange extending outwardly from the sidewall when the tray is formed from the blank, each panel of the plurality of panels comprising a laminate structure, the laminate structure comprising a base layer and a barrier layer, the plurality of side panels for being positioned at least partially reinforcing the flange of the tray formed from the blank.
17. The blank of claim 16, wherein the central panel comprises a central portion and a marginal portion extending at least partially around the central portion, the central portion of the central panel for at least partially forming the tray bottom and the sidewall of the tray formed from the blank.
18. The blank of claim 17, wherein each side panel of the plurality of side panels is for being positioned in at least partial face-to-face contact with the marginal portion of the central panel to at least partially form and reinforce the flange of the tray formed from the blank.
19. The blank of claim 18, wherein each side panel of the plurality of side panels is for being positioned in at least partial face-to-face contact with the central portion of the central panel to at least partially form and reinforce the sidewall of the tray formed from the blank.
20. The blank of claim 19, wherein each side panel of the plurality of side panels is for being positioned at least partially forming and reinforcing the tray bottom of the tray formed from the blank.
21. The blank of claim 17, wherein the central panel further comprises a plurality of corner portions for at least partially forming respective corners of a plurality of corners of the tray formed from the blank.
22. The blank of claim 21, wherein the plurality of corner portions comprises a respective plurality of lines of weakening.
23. The blank of claim 17, wherein the plurality of side panels comprises a first side panel and a second side panel.
24. The blank of claim 23, wherein the plurality of side panels further comprises a third side panel and a fourth side panel.
25. The blank of claim 24, wherein each side panel of the plurality of side panels have a generally tapered configuration.
26. The blank of claim 24, wherein the tray further comprises a plurality of corner gussets foldably connected to the central panel, each corner gusset of the plurality of corner gussets foldably connected to a respective side panel of the plurality of side panels.
27. The blank of claim 26, wherein at least one corner gusset of the plurality of corner gussets comprises a central portion and at least one outer portion foldably connected to the central portion of the at least one corner gusset, the central portion of the at least one corner gusset foldably connected to the central panel, the at least one outer portion of the corner gusset foldably connected to the respective side panel of the plurality of side panels.
28. The blank of claim 23, further comprising handle features, the handle features comprising a plurality of handle flaps for forming a plurality of handles when the tray is formed from the blank, each handle repositionable between a first position when the tray is formed from the blank, in which each handle is at least partially coextensive with a respective side panel of the plurality of side panels, and a second position when the tray is formed from the blank, in which each handle is separated from the respective side panel of the plurality of side panels.
29. The blank of claim 28, wherein each handle flap is foldably connected to the respective side panel of the plurality of side panels.
30. The blank of claim 28, wherein each handle flap is foldably connected to the central panel.
31. A method of forming a tray for holding one or more food products, the method comprising: obtaining a blank comprising a plurality of panels, the plurality of panels comprising a central panel and a plurality of side panels, each panel of the plurality of panels comprising a laminate structure, the laminate structure comprising a base layer and a barrier layer; positioning the plurality of panels extending at least partially around an interior of the tray; positioning the plurality of side panels in at least partial face-to-face contact with respective portions of the central panel; arranging the plurality of panels to form a tray bottom, a sidewall extending upwardly from the tray bottom, and a flange extending outwardly from the sidewall; and at least partially reinforcing the flange of the tray with the plurality of side panels.
32. The method of claim 31, further comprising press-forming the blank to at least partially form the tray.
33. The method of claim 32, comprising positioning the plurality of side panels in at least partial face-to-face contact with respective portions of the central panel prior to press-forming the blank.
34. The method of claim 33, wherein the central panel comprises a central portion and a marginal portion extending at least partially around the central portion, and the blank is press-formed such that the central portion of the central panel at least partially forms the tray bottom and the sidewall of the tray extending upwardly from the tray bottom.
35. The method of claim 34, comprising positioning each side panel of the plurality of side panels in at least partial face-to-face contact with the marginal portion of the central panel such that the blank is press-formed such that each side panel of the plurality of side panels at least partially forms and reinforces the flange of the tray extending outwardly from the sidewall.
36. The method of claim 35, comprising positioning each side panel of the plurality of side panels in at least partial face-to-face contact with the central portion of the central panel to at least partially form and reinforce the sidewall of the tray.
37. The method of claim 36, comprising positioning each side panel of the plurality of side panels at least partially forming and reinforcing the tray bottom of the tray.
38. The method of claim 34, wherein the central panel further comprises a plurality of corner portions, the plurality of corner portions press-formed to at least partially form respective corners of a plurality of corners of the tray.
39. The method of claim 38, wherein the plurality of corner portions comprises a respective plurality of lines of weakening facilitating formation of the respective corners of the plurality of corners of the tray.
40. The method of claim 34, wherein the plurality of side panels comprises a first side panel and a second side panel.
41. The method of claim 40, wherein the plurality of side panels further comprises a third side panel and a fourth side panel.
42. The method of claim 41, wherein each side panel of the plurality of side panels have a generally tapered configuration.
43. The method of claim 41, wherein the tray further comprises a plurality of corner gussets foldably connected to the central panel, each corner gusset of the plurality of corner gussets foldably connected to a respective side panel of the plurality of side panels.
44. The method of claim 43, wherein at least one corner gusset of the plurality of corner gussets comprises a central portion and at least one outer portion foldably connected to the central portion of the at least one corner gusset, the central portion of the at least one corner gusset foldably connected to the central panel, the at least one outer portion of the corner gusset foldably connected to the respective side panel of the plurality of side panels.
45. The method of claim 40, further comprising handle features, the handle features comprising a plurality of handle flaps forming a plurality of handles, each handle repositionable between a first position, in which each handle is at least partially coextensive with a respective side panel of the plurality of side panels, and a second position, in which each handle is separated from the respective side panel of the plurality of side panels.
46. The method of claim 45, wherein each handle flap is foldably connected to the respective side panel of the plurality of side panels.
47. The method of claim 45, wherein each handle flap is foldably connected to the central 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.
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[0037] Corresponding parts are designated by corresponding reference numbers throughout the drawings.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0038] Various aspects of the disclosure may be understood further by referring to the figures. For purposes of simplicity, like numerals may be used to describe like features. It will be understood that where a plurality of similar features are depicted, not all of such features necessarily are labeled on each figure. It also will be understood that the various components used to form the constructs may be interchanged. Thus, while only certain combinations are illustrated herein, numerous other combinations and configurations are contemplated hereby.
[0039] Constructs such as 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 at least partially disposed upon or within the construct embodiments.
[0040] The articles can include, but are not limited to, fresh food products such as meat products (e.g., ground meat, sliced meat, diced meat, sausage, cured meat, etc.), fish products, fast food products, take-out products, meal leftovers, and the like, or any combination thereof. Examples of such products can include pastries (e.g., filled or frosted pastries), breads, fruit bars, French toast sticks, fish, chicken (such as chicken nuggets, chicken strips, chicken fingers, etc.), popcorn, peanuts, candy, French fries (such as waffle fries, steak fries, shoestring fries, curly fries, etc.), sandwiches, pizza, calzone, turnover, burrito, or any other food product that may be provided for consumption by a consumer. In this specification, the terms inner, interior, outer, exterior, lower, bottom, upper, and top indicate orientations determined in relation to fully erected and upright constructs such as trays.
[0041] As described herein, constructs such as trays may be formed by multiple overlapping panels, end flaps, and/or other portions of blanks. Such panels, end flaps, and/or other portions of the blanks can be designated in relative terms to one another, e.g., first, second, third, etc., in sequential or non-sequential reference, without departing from the disclosure.
[0042] Referring to
[0043] As shown, the laminate structure 102 can include a base layer 104 comprising a composite material 106 and a barrier layer 108 laminated to the base layer 104 and comprising a barrier material 110.
[0044] The composite material 106 can comprise a paper or paperboard product such as kraft paper, parchment, clay-coated paperboard, solid bleached board (SBB) paperboard, solid bleached sulphate (SBS) paperboard, Kraft line paperboard, cardboard, or another suitable material that may be degradable, compostable, and/or repulpable. In some embodiments, the base layer 104 can be comprised of composite material 106 in a thickness of between and including about 0.010 inches and about 0.015 inches, for example about 0.012 inches, though a different arrangement can be provided without departing from the disclosure.
[0045] The barrier material 110 can comprise a polymeric material, for example, polyethylene terephthalate (PET). In some embodiments, the barrier material 110 can be provided to form a barrier layer 108 with a thickness of between about 45 gauge and about 50 gauge, for example, about 48 gauge, though the barrier material 110 can have a different configuration and/or arrangement without departing from the disclosure.
[0046] The laminate structure 102 can be formed by arranging the base layer 104 and the barrier layer 108 in respective overlapping relation. Such an arrangement can be provided through lamination processes that include, for example, rollers and nips, chemical deposition, the application of one or more adhesives, etc.
[0047] In some embodiments, the laminate structure 102 can be provided in a different arrangement. For example, in some embodiments, the laminate structure 102 can be provided with two barrier layers 108, one of each laminated on opposite sides of the base layer 104.
[0048] Referring additionally to
[0049] As shown, the blank 203 can have a longitudinal axis L1, a lateral axis L2, and one or more panels. In the illustrated embodiment, the blank 203 can include a base panel or bottom panel or main panel or central panel 221 foldably connected to a pair of side panels 223 (broadly, first side panel and second side panel) at respective longitudinal fold line 225.
[0050] The central panel 221, as shown, can include a central portion 227 and a marginal portion 229 extending at least partially around the periphery thereof. Respective corner portions 231 of the central panel 221 can be at least partially defined proximate respective pluralities of lines of weakening 233 that include respective lateral, longitudinal, and oblique lines of weakening in series adjacent and approximating the curvature of respective curved free edges of the central panel 221.
[0051] In the illustrated embodiment, the respective pluralities of lines of weakening 233 extend inwardly from a respective curved free edge of the central panel 221 toward the central portion 227 thereof.
[0052] Similarly, each side panel 223 can include a central portion 235 and a marginal portion 237 extending at least partially therearound. Respective corner portions 239 of the side panels 223 can be at least partially defined proximate respective pluralities of lines of weakening 241 that include respective lateral, longitudinal, and oblique lines of weakening in series adjacent and approximating the curvature of respective curved free edges of the respective side panel 223, with the respective lines of weakening extending inwardly thereof toward the central portion 235.
[0053] It will be understood that, prior to further processing, the respective side panels 223 of the blank 203 can be folded at the respective fold line 225 into at least partial face-to-face contact with the central panel 221. In such an arrangement, the corner portions 239 of the side panels 223 can be generally aligned with the respective corner portions 231 of the central panel 221.
[0054] Turning to
[0055] In the illustrated embodiment, the male forming member 139 and the female forming member 141 can be arranged so as to be movable relative to one another, e.g., such that one or both of the male forming member 139 and the female forming member 141 can be configured to move toward and/or away from the other of the male forming member 139 and the female forming member 141.
[0056] In this regard, the blank 203 can be positioned between the male forming member 139 and the female forming member 141 on one or more supporting structures. One or more of the forming members 139, 141 can be drawn together/approximated toward one another such that one or more of the protruding surface features of the male forming member 139 urges a portion of the blank 203 into the corresponding recessed feature of the female forming member 141. Such action of the forming apparatus 137 can cause at least partial deformation/and or reconfiguration of the blank 203 into the tray 205.
[0057] Referring additionally to
[0058] The sidewall 245 of the tray 205 can extend to a rim or flange 247 extending outwardly from the sidewall 245 and positioned in generally spaced and planar relation with the tray bottom 243.
[0059] The rim or flange 247 can be at least partially formed from the marginal portion 229 of the central panel 221 and the respective marginal portions 237 of the respective side panels 223 overlapped thereupon.
[0060] In this regard, when the tray 205 is formed from the blank 203 in the manner described above, the respective pluralities of lines of weakening 233, 241 can facilitate at least partial deformation, such as stretching, of the respective overlapped corner portions 231, 239 to form corners 249 of the tray 205 along the flange 247.
[0061] Furthermore, the respective central portions 235 of the respective side panels 223 can be positioned overlapping respective portions of the central portion 227 of the central panel 221 to at least partially form respective portions of the flange 247, the sidewall 245, and the tray bottom 243. Such overlapping arrangement of the respective side panels 223 can at least partially reinforce the flange 247, the sidewall 245, and the tray bottom 243, e.g., so as to provide resistance to deformation such as bending, flexing, bowing, buckling, etc.
[0062] Turning to
[0063] Such an overlapping arrangement of panels of the tray 205 formed from the laminate structure 102 can thus provide a superior tray structure that can include increased strength due to the multi-ply arrangement thereof, as well as enhanced barrier properties at least partially due to the contacting relationship of the barrier layer 108 associated with the central panel 221 and the barrier layer 108 associated with the respective side panel 223.
[0064] In this regard, the tray 205 can receive one or more food products in the interior 207 thereof, and can have a relatively increased resistance to failure due to the multi-ply arrangement of the tray 205. Furthermore, fluids incidental to one or more food products in the interior 207 of the tray 205, for example, runoff, blood, juices, moisture due to condensation, seasonings, food additives or treatments, etc., can have an increased resistance to egress from the interior 207 of the tray 205 to an exterior environment due to the contacting relationship of the barrier layer 108 associated with the central panel 221 and the barrier layer 108 associated with the respective side panel 223, which can minimize, inhibit, prevent, and/or otherwise avoid the passage of fluids thereby.
[0065] It will be understood that, in some embodiments, an upper surface of the flange 247 of the tray 205 can present a plurality of engagement/support surfaces for engaging/supporting a covering or lidding film, e.g., a plastic or other polymeric film, or other covering structure. In one embodiment, the lidding film can be provided as a polymeric layer that at least partially deforms in the presence of a heat source, e.g., a heat sealable film. The lidding film can thus be positioned extending across a top opening of the tray 205 in contact with one or more surfaces of the flange 247 to cover the interior 207 of the tray 205 and maintain one or more conditions of the food products held therein, e.g., freshness, ripeness, moisture content, etc. It will be understood that the lidding film can minimize, inhibit, and/or prevent the passage of one or more materials into the interior 207 of the tray 205, for example, condensation or other moisture, insects or other pests, dirt, debris, etc. In some embodiments, the tray 205 can be provided together with the lidding film and one or more food products as a package.
[0066] In this regard, the reinforcement of the flange 247 provided by the at least partial overlapping arrangement of the respective side panels 223 can at least partially maintain a generally flat and outward arrangement of the flange 247, for example, under tensile and/or compresses stresses generated by the engagement of the lidding film with the flange 247. Furthermore, in high-moisture content environments, the reinforcement of the flange 247 by the side panels 223 can at least partially maintain an integrity of the flange 247 in the presence of moisture.
[0067] With additional reference to
[0068] For example, and as shown, the central panel 221 and side panels 223 can be reoriented to generally extend along the longitudinal axis L1, e.g., such that the side panels 223 are foldably connected to the central panel 221 at respective lateral fold lines 225.
[0069] In this regard, and with additional reference to
[0070] Turning to
[0071] The blank 403 and tray 405 formed therefrom can include additional side panels foldably connected thereto, such that a side panel is foldably connected to each side of the central panel 221. In the illustrated embodiment, a pair of side panels 423 (broadly, first side panel and second side panel) can be foldably connected to the central panel 221 at respective lateral fold lines 425.
[0072] Each side panel 423 can include a central portion 435 and a marginal portion 437 extending at least partially therearound. Respective corner portions 439 of the side panels 423 can be at least partially defined proximate respective pluralities of lines of weakening 441 that include respective lateral, longitudinal, and oblique lines of weakening in series adjacent and approximating the curvature of respective curved free edge portions of the corner portions 439 of the respective side panel 423, with the respective lines of weakening extending inwardly thereof toward the central portion 435.
[0073] In the illustrated embodiment, the side panels 423 can have an at least partially triangular configuration at portions extending away from the corner portions 439 thereof, e.g., so as to have a generally tapered configuration.
[0074] With continued reference to
[0075] In the illustrated embodiment, the side panels 451 can have an at least partially triangular configuration at portions extending from the corner portions 459 thereof, e.g., so as to have a generally tapered configuration. As shown, the side panels 451 can taper to a respective blunted or flat free edge 461.
[0076] With additional reference to
[0077] For example, the respective side panels 423 of the blank 403 can be folded at the respective fold lines 425 into at least partial face-to-face contact with the central panel 221. In such an arrangement, the corner portions 439 of the side panels 423 can be generally aligned with the respective corner portions 231 of the central panel 221. Further, the respective side panels 451 can be folded at the respective fold lines 453 into at least partial face-to-face contact with the central panel 221 such that the respective corner portions 459 thereof are generally aligned with the respective corner portions 231 of the central panel 221. In such an arrangement, the free edges of the side panels 423, 451 can be in general alignment such that the side panels 423, 451 substantially overlie, e.g., in at least partial face-to-face contact with, the exterior surface 401 of the central panel 221.
[0078] The blank 403 can be positioned between the male forming member 139 and the female forming member 141 of the forming apparatus 137 (
[0079] In this regard, the tray 405 can be formed from plurality of panels extending at least partially around an interior 407 thereof, with the central portion 227 of the central panel 221 at least partially forming a tray bottom 443 and a sidewall 445 extending upwardly therefrom.
[0080] The sidewall 445 of the tray 405 can extend to a rim or flange 447 extending outwardly from the sidewall 445 and positioned in generally spaced and planar relation with the tray bottom 443.
[0081] The rim or flange 447 can be at least partially formed from the marginal portion 229 of the central panel 221 and the respective marginal portions 437, 457 of the respective side panels 423, 451 overlapped thereupon such that the respective marginal portions 437, 457 of the respective side panels 423, 451 at least partially reinforce the flange 447.
[0082] In this regard, when the tray 405 is formed from the blank 403 in the manner described above, the respective pluralities of lines of weakening 233, 441 can facilitate at least partial deformation, such as stretching, of the respective overlapped corner portions 231, 439, 459 to form corners 449 of the tray 405 along the flange 447.
[0083] Furthermore, the respective central portions 435, 455 of the respective side panels 423, 451 can be positioned overlapping respective portions of the central portion 227 of the central panel 221 to at least partially form and reinforce respective portions of the sidewall 445 and/or tray bottom 443.
[0084] The tray 405 can thus be formed with advantages and functionality similar to that described above with respect to the trays 205, 305. It will be understood that the blank 403 and/or the tray 405 formed therefrom can have a different configuration without departing from the disclosure.
[0085] It will be understood that, in some embodiments, an upper surface of the flange 447 of the tray 405 can present a plurality of engagement/support surfaces for engaging/supporting a covering or lidding film. In some embodiments, the tray 405 can be provided together with the lidding film and one or more food products as a package.
[0086] In this regard, the reinforcement of the flange 447 provided by the at least partial overlapping arrangement of the respective side panels 423, 451 can at least partially maintain a generally flat and outward arrangement of the flange 447, for example, under tensile and/or compresses stresses generated by the engagement of the lidding film with the flange 447. Furthermore, in high-moisture content environments, the reinforcement of the flange 447 by the side panels 423, 451 can at least partially maintain an integrity of the flange 447 in the presence of moisture.
[0087] Turning to
[0088] In this regard, and with additional reference to
[0089] Turning to
[0090] The blank 603 and tray 605 formed therefrom can include additional side panels foldably connected thereto, such that a side panel is foldably connected to each side of the central panel 221. In the illustrated embodiment, a pair of side panels 623 (broadly, first side panel and second side panel) can be foldably connected to the central panel 221 at respective lateral fold lines 625.
[0091] Each side panel 623 can include a central portion 635 and respective corner portions 639 at least partially defined proximate respective pluralities of lines of weakening 641 that include respective lateral, longitudinal, and oblique lines of weakening in series adjacent and approximating the curvature the corner portions 639, with the respective lines of weakening extending inwardly thereof toward the central portion 635.
[0092] A pair of side panels 651 (broadly, third side panel and fourth side panel) can be foldably connected to the central panel 221 at respective longitudinal fold lines 653. Each side panel 651 can include a central portion 655 and respective corner portions 657 at least partially defined proximate respective pluralities of lines of weakening 659 approximating the curvature the corner portions 641, with the respective lines of weakening extending inwardly thereof toward the central portion 655.
[0093] With additional reference to
[0094] For example, the respective side panels 623 of the blank 603 can be folded at the respective fold line 625 into at least partial face-to-face contact with the central panel 221. In such an arrangement, the corner portions 639 of the side panels 623 can be generally aligned with the respective corner portions 231 of the central panel 221. Further, the respective side panels 651 can be folded at the respective fold line 653 into at least partial face-to-face contact with the central panel 221 such that the respective corner portions 657 thereof are generally aligned with the respective corner portions 231 of the central panel 221.
[0095] The blank 603 can be positioned between the male forming member 139 and the female forming member 141 of the forming apparatus 137 (
[0096] In this regard, the tray 605 can be formed from plurality of panels extending at least partially around an interior 607 thereof, with the central portion 227 of the central panel 221 at least partially forming a tray bottom 643 and a sidewall 645 extending upwardly therefrom.
[0097] The sidewall 645 of the tray 605 can extend to a rim or flange 647 extending outwardly from the sidewall 645 and positioned in generally spaced and planar relation with the tray bottom 643.
[0098] The rim or flange 647 can be at least partially formed from the marginal portion 229 of the central panel 221 and the respective portions of the respective side panels 623, 651 overlapped thereupon such that the side panels 623, 651 at least partially reinforce the flange 647.
[0099] In this regard, when the tray 605 is formed from the blank 603 in the manner described above, the respective pluralities of lines of weakening 233, 641, 657 can facilitate at least partial deformation, such as stretching, of the respective overlapped corner portions 231, 639, 657 to form corners 649 of the tray 605 along the flange 647.
[0100] Furthermore, the respective portions the respective side panels 623, 651 can be positioned overlapping respective portions of the central portion 227 of the central panel 221 to at least partially form and reinforce respective portions of the sidewall 645. In the illustrated embodiment, the side panels 623, 651 can be dimensioned so as to terminate at or above the central panel 221 so as to avoid overlap or substantial overlap with the central panel 221. It will be understood that one or more of the side panels 623, 651 can overlap the central panel 221 without departing from the disclosure.
[0101] The tray 605 can thus be formed with advantages and functionality similar to that described above with respect to the trays 205, 305, 405, 505. It will be understood that the blank 603 and/or the tray 605 formed therefrom can have a different configuration without departing from the disclosure.
[0102] It will be understood that, in some embodiments, an upper surface of the flange 647 of the tray 605 can present a plurality of engagement/support surfaces for engaging/supporting a covering or lidding film. In some embodiments, the tray 605 can be provided together with the lidding film and one or more food products as a package.
[0103] In this regard, the reinforcement of the flange 647 provided by the at least partial overlapping arrangement of the respective side panels 623, 651 can at least partially maintain a generally flat and outward arrangement of the flange 647, for example, under tensile and/or compresses stresses generated by the engagement of the lidding film with the flange 647. Furthermore, in high-moisture content environments, the reinforcement of the flange 647 by the side panels 623, 651 can at least partially maintain an integrity of the flange 647 in the presence of moisture.
[0104] Turning to
[0105] The blank 703 and tray 705 formed therefrom can include additional side panels foldably connected thereto, such that a side panel is foldably connected to each side of the central panel 221. In the illustrated embodiment, a pair of side panels 723 (broadly, first side panel and second side panel) can be foldably connected to the central panel 221 at respective lateral fold lines 725. Furthermore, a pair of side panels 751 (broadly, third side panel and fourth side panel) can be foldably connected to the central panel 221 at respective longitudinal fold lines 753.
[0106] Respective corner gussets 755 can be foldably connected to respective corners of the central panel 221 of the blank 703 and tray 705 formed therefrom at respective oblique fold lines 757.
[0107] Each gusset 755, as shown, can include a central portion 759 at least partially interrupted by a notch 761, a first outer portion 763 foldably connected to the central portion 759 at an oblique fold line 765, and a second outer portion 767 foldably connected to the central portion 759 at an oblique fold line 769.
[0108] The respective first outer portion 763, as shown, can be foldably connected to a respective side panel 723, 755 at a respective oblique fold line 771, and the respective second outer portion 767 can be foldably connected to a respective side panel 723, 751 at a respective oblique fold line 773. In this regard, each gusset 755 can be foldably connected to a respective side panel 723, 751 as well as to a respective portion of the central panel 221. In some embodiments, the respective outer portion 763, 767 can be considered a portion of a respective adjacent side panel 723, 751, for example, at least partially delineated by a respective fold line 771, 773.
[0109] As shown, respective pluralities of lines of weakening 741 can be provided along corner portions of the blank 703 and the tray 705 formed therefrom, with each of the pluralities of lines of weakening 741 extending at least partially across a respective corner gusset 755 and respective portions of respective adjacent side panels 723, 751.
[0110] With additional reference to
[0111] For example, the respective side panels 723 of the blank 703 can be folded at the respective fold line 725 into at least partial face-to-face contact with the central panel 221 and the respective side panels 751 can be folded at the respective fold line 753 into at least partial face-to-face contact with the central panel 221.
[0112] Simultaneously or thereafter, the respective corner gussets 755 can be actuated. The central portion 759 of the respective gussets 755 can be folded at the respective fold lines 757 into at least partial face-to-face contact with respective portions of the central panel 221, and the respective first outer portions 763 can be folded at the respective fold lines 765, 771 into at least partial face-to-face contact with each of the respective central portion 759 and a respective side panel 723, 751. Similarly, the respective second outer portions 767 can be folded at the respective fold lines 769, 773 into at least partial face-to-face contact with each of the respective central portion 759 and a respective side panel 723, 751.
[0113] The blank 703 can be positioned between the male forming member 139 and the female forming member 141 of the forming apparatus 137 (
[0114] In this regard, the tray 705 can be formed from plurality of panels extending at least partially around an interior 707 thereof, with the central portion 227 of the central panel 221 at least partially forming a tray bottom 743 and a sidewall 745 extending upwardly therefrom.
[0115] The sidewall 745 of the tray 705 can extend to a rim or flange 747 extending outwardly from the sidewall 745 and positioned in generally spaced and planar relation with the tray bottom 743.
[0116] The rim or flange 747 can be at least partially formed from the marginal portion 229 of the central panel 221 and the respective portions of the respective side panels 723, 751 and the corner gussets 755 overlapped thereupon.
[0117] In this regard, when the tray 705 is formed from the blank 703 in the manner described above, the respective pluralities of lines of weakening 233, 741 can facilitate at least partial deformation, such as stretching, of respective corner portions 231 of the central panel 221 and respective portions of the respective side panels 723, 751 and corner gussets 755 overlapped thereupon to form corners 749 of the tray 705 along the flange 747.
[0118] Furthermore, the respective portions the respective side panels 723, 751 can be positioned overlapping respective portions of the marginal portion 229 of the central panel 221 to at least partially form and reinforce respective portions of the flange 749. In the illustrated embodiment, the side panels 723, 751 can be dimensioned so as to terminate at or above the central panel 221 so as to avoid overlap or substantial overlap with the sidewall 745 and/or the tray bottom 743. It will be understood that one or more of the side panels 723, 751 can overlap the sidewall 745 and/or the tray bottom 743 without departing from the disclosure.
[0119] The tray 705 can thus be formed with advantages and functionality similar to that described above with respect to the trays 205, 305, 405, 505, 605. It will be understood that the blank 703 and/or the tray 705 formed therefrom can have a different configuration without departing from the disclosure.
[0120] It will be understood that, in some embodiments, an upper surface of the flange 747 of the tray 705 can present a plurality of engagement/support surfaces for engaging/supporting a covering or lidding film. In some embodiments, the tray 705 can be provided together with the lidding film and one or more food products as a package.
[0121] In this regard, the reinforcement of the flange 747 provided by the at least partial overlapping arrangement of the respective side panels 723, 751 can at least partially maintain a generally flat and outward arrangement of the flange 747, for example, under tensile and/or compresses stresses generated by the engagement of the lidding film with the flange 747. Furthermore, in high-moisture content environments, the reinforcement of the flange 747 by the side panels 723, 751 can at least partially maintain an integrity of the flange 747 in the presence of moisture.
[0122] Turning to
[0123] In the illustrated embodiment, the blank 803 and tray 805 formed therefrom can further include handle features that can include a respective handle flap 843 foldably connected to the central panel 221 at a respective portion of the fold line 225 and separable from the respective side panel 223 at a respective generally U-shaped or bracket-shaped cut 845.
[0124] With additional reference to
[0125] As shown in
[0126] The handles 847 can be reconfigured/repositioned to a second or activated position/configuration, as shown in
[0127] In this regard, the handles 847 of the tray 805 can be activated to provide convenient gasping surfaces for a user to engage and lift the tray 805. In the event that food products, for example, hot food products, can be provided in the interior 207 of the tray 805, the handles 847 can provide additional spacing between a user's hands and the hot contents of the interior 207 of the tray 805, which can avoid discomfort on the part of the user when moving the tray 805, for example, from a heating source or filling/serving location to a second location, e.g., a location in which the contents of the tray 805 are to be consumed or further served.
[0128] The tray 805 can thus be formed with advantages and functionality similar to that described above with respect to the trays 205, 305, 405, 505, 605, 705. It will be understood that the blank 803 and/or the tray 805 formed therefrom can have a different configuration without departing from the disclosure.
[0129] It will be understood that, in some embodiments, an upper surface of the flange 247 of the tray 805 can present a plurality of engagement/support surfaces for engaging/supporting a covering or lidding film. In some embodiments, the tray 805 can be provided together with the lidding film and one or more food products as a package.
[0130] In this regard, the reinforcement of the flange 247 provided by the at least partial overlapping arrangement of the respective side panels 223 can at least partially maintain a generally flat and outward arrangement of the flange 247, for example, under tensile and/or compresses stresses generated by the engagement of the lidding film with the flange 247. Furthermore, in high-moisture content environments, the reinforcement of the flange 247 by the side panels 223 can at least partially maintain an integrity of the flange 247 in the presence of moisture.
[0131] Turning to
[0132] In the illustrated embodiment, the blank 903 and tray 905 formed therefrom can further include handle features similar to that described above with regard to the blank 803 and tray 805 formed therefrom. In this regard, the blank 903 and tray 905 formed therefrom can include the handle flaps 843 for forming the respective handles 847.
[0133] Each handle flap 843 of the blank 903 and tray 905 formed therefrom, as shown, can be separably connected to the respective side panel 223 at the respective cut 845, but can be foldably connected to the respective side panel 223 at a respective longitudinal fold line 945 spaced apart from the respective fold line 225.
[0134] With additional reference to
[0135] As shown in
[0136] The handles 847 can be reconfigured/repositioned to a second or activated position/configuration, as shown in
[0137] The tray 905 can thus be formed with advantages and functionality similar to that described above with respect to the trays 205, 305, 405, 505, 605, 705, 805. It will be understood that the blank 903 and/or the tray 905 formed therefrom can have a different configuration without departing from the disclosure.
[0138] It will be understood that, in some embodiments, an upper surface of the flange 247 of the tray 905 can present a plurality of engagement/support surfaces for engaging/supporting a covering or lidding film. In some embodiments, the tray 905 can be provided together with the lidding film and one or more food products as a package.
[0139] In this regard, the reinforcement of the flange 247 provided by the at least partial overlapping arrangement of the respective side panels 223 can at least partially maintain a generally flat and outward arrangement of the flange 247, for example, under tensile and/or compresses stresses generated by the engagement of the lidding film with the flange 247. Furthermore, in high-moisture content environments, the reinforcement of the flange 247 by the side panels 223 can at least partially maintain an integrity of the flange 247 in the presence of moisture.
[0140] It will be understood that the blanks and trays described herein can have a different configuration and/or arrangement without departing from the disclosure.
[0141] In general, the blanks described herein may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, sheet plastics or any other material having properties suitable for enabling the container to function at least generally as described above. The blanks can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blanks may then be coated with a varnish to protect information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.
[0142] 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 of 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 tear lines to be replaced with a continuous slit, 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.
[0143] In accordance with the exemplary embodiments, 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 or depressed 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. In situations where cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line.
[0144] The above embodiments may be described as having one or more panels adhered together by glue during erection of the tray embodiments. The term glue is intended to encompass all manner of adhesives commonly used to secure tray panels in place, and is not intended to exclude heat, chemical, or frequency bonding techniques.
[0145] The foregoing description of the disclosure illustrates and describes various embodiments. As various changes could be made in the above construction without departing from the 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. Furthermore, the scope of the present disclosure covers various modifications, combinations, alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are within the scope of the disclosure 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.