TRAY WITH REINFORCEMENT FEATURES

Abstract

A tray may include a base panel, a front panel foldably connected to the base panel and including a front rim panel with a first end portion, and a side panel foldably connected to the base panel and including a side rim panel with a second end portion. A secondary panel may be foldably connected to the base panel and positioned between the front panel and the side panel. The secondary panel may include a corner rim panel at a distal region. The corner rim panel, the front rim panel, and the side rim panel may cooperate to form a contiguous rim that may extend along the front panel, the secondary panel, and the side panel. The first end portion and the second end portion may overlap the corner rim panel to reinforce the rim at the corner region.

Claims

1. A tray comprising: a base panel; a front panel foldably connected to the base panel and including a front rim panel at a distal region, the front rim panel having a first end portion; a side panel foldably connected to the base panel and including a side rim panel at a distal region, the side rim panel including a second end portion; a secondary panel foldably connected to the base panel and positioned between the front panel and the side panel, the secondary panel having a corner rim panel positioned at a distal region; and wherein the corner rim panel, the front rim panel, and the side rim panel cooperate to form a contiguous rim that extends along the front panel, along the secondary panel, and along the side panel, and wherein the first end portion and the second end portion overlap the corner rim panel.

2. The tray of claim 1, wherein the front panel includes a first intermediate flap foldably connected to the front panel and wherein the first intermediate flap is folded into at least a partial face-to-face alignment with the secondary panel.

3. The tray of claim 2, wherein the side panel includes a second intermediate flap foldably connected to the side panel and wherein the second intermediate flap is folded into at least a partial face-to-face alignment with the secondary panel.

4. The tray of claim 1, wherein the front panel includes a first reinforcement tab foldably connected to the first end portion and wherein the first reinforcement tab is folded into at least a partial face-to-face alignment with the secondary panel.

5. The tray of claim 4, wherein the side panel includes a second reinforcement tab foldably connected to the second end portion and wherein the second reinforcement tab is folded into at least a partial face-to-face alignment with the secondary panel.

6. The tray of claim 1, the tray further comprising a back panel foldably connected to the base panel and including a back rim panel at a distal region, the back rim panel having a third end portion, wherein the side panel further includes a fourth end portion and wherein the secondary panel is a first secondary panel having a first corner rim, the tray further comprising a second secondary panel foldably connected to the base panel and positioned between the back panel and the side panel, the second secondary panel having a second corner rim panel positioned at a distal region, wherein the second corner rim panel, the back rim panel, and the side rim panel cooperate to form a contiguous rim that extends along the back panel, along the second secondary panel, and along the side panel, and wherein the third end portion and the fourth end portion overlap the second corner rim panel.

7. The tray of claim 1, further comprising a denesting lug extending outwardly from one of the front panel or the side panel.

8. The tray of claim 7, wherein the first end portion is defined by a notch adjacent the denesting lug.

9. The tray of claim 8, wherein the denesting lug is a first denesting lug and the notch is a first notch, the tray comprises a second denesting lug and the second end portion is defined by a second notch adjacent the second denesting lug.

10. The tray of claim 9, wherein the front panel includes a first intermediate flap foldaby connected to the front panel, the first intermediate flap is folded into at least a partial face-to-face alignment with the secondary panel, the side panel includes a second intermediate flap foldably connected to the side panel and wherein the second intermediate flap is folded into at least a partial face-to-face alignment with the secondary panel.

11. The tray of claim 10, wherein the first denesting lug is separated from the first intermediate flap at a first cut, and wherein the second denesting lug is separated from the second intermediate flap at a second cut.

12. A blank for forming a tray, the blank comprising: a base panel; a front panel foldably connected to the base panel and including a front rim panel at a distal region, the front rim panel having a first end portion; a side panel foldably connected to the base panel and including a side rim panel at a distal region, the side rim panel including a second end portion; a secondary panel foldably connected to the base panel and positioned between the front panel and the side panel, the secondary panel having a corner rim panel positioned at a distal region; and wherein the corner rim panel, the front rim panel, and the side rim panel cooperate to form a contiguous rim that extends along the front panel, along the secondary panel, and along the side panel, and wherein the first end portion and the second end portion overlap the corner rim panel when the tray is formed from the blank.

13. The blank of claim 12, wherein the front panel includes a first intermediate flap foldably connected to the front panel and wherein the first intermediate flap is folded into at least a partial face-to-face alignment with the secondary panel when the tray is formed from the blank.

14. The blank of claim 13, wherein the side panel includes a second intermediate flap foldably connected to the side panel and wherein the second intermediate flap is folded into at least a partial face-to-face alignment with the secondary panel when the tray is formed from the blank.

15. The blank of claim 12, wherein the front panel includes a first reinforcement tab foldably connected to the first end portion and wherein the first reinforcement tab is folded into at least a partial face-to-face alignment with the secondary panel when the tray is formed from the blank.

16. The blank of claim 15, wherein the side panel includes a second reinforcement tab foldably connected to the second end portion and wherein the second reinforcement tab is folded into at least a partial face-to-face alignment with the secondary panel when the tray is formed from the blank.

17. The blank of claim 12, the blank further comprising a back panel foldably connected to the base panel and including a back rim panel at a distal region, the back rim panel having a third end portion, wherein the side panel further includes a fourth end portion and wherein the secondary panel is a first secondary panel having a first corner rim, the tray further comprising a second secondary panel foldably connected to the base panel and positioned between the back panel and the side panel, the second secondary panel having a second corner rim panel positioned at a distal region, wherein the second corner rim panel, the back rim panel, and the side rim panel cooperate to form a contiguous rim that extends along the back panel, along the second secondary panel, and along the side panel, and wherein the third end portion and the fourth end portion overlap the second corner rim panel when the tray is formed from the blank.

18. The blank of claim 12, further comprising a denesting lug extending outwardly from one of the front panel or the side panel.

19. The blank of claim 18, wherein the first end portion is defined by a notch adjacent the denesting lug.

20. The blank of claim 19, wherein the denesting lug is a first denesting lug and the notch is a first notch, the tray comprises a second denesting lug and the second end portion is defined by a second notch adjacent the second denesting lug.

21. The blank of claim 20, wherein the front panel includes a first intermediate flap foldably connected to the front panel, the first intermediate flap is folded into at least a partial-face-to-face alignment with the secondary panel when the tray is formed from the blank, the side panel includes a second intermediate flap foldably connected to the side panel and wherein the second intermediate is folded into at least partial face-to-face alignment with the secondary panel when the tray is formed from the blank.

22. The blank of claim 21, wherein the first denesting lug is separated from the first intermediate flap at a first cut and wherein the second denesting lug is separated from the second intermediate flap at a second cut when the tray is formed from the blank.

23. A method for forming a tray, the method comprising: receiving a blank that includes a base panel, a front panel foldably connected to the base panel and including a front rim panel at a distal region, the front rim panel having a first end portion, a side panel foldably connected to the base panel and including a side rim panel at a distal region, the side rim panel including a second end portion, and a secondary panel foldably connected to the base panel and positioned between the front panel and the side panel, the secondary panel having a corner rim panel positioned at a distal region; forming a tray from the blank; and forming a contiguous rim of the tray that extends along the front panel, along the secondary panel, and along the side panel, and wherein the first end portion and the second end portion overlap the corner rim panel.

24. The method of claim 23, wherein the front panel of the blank includes a first intermediate flap foldably connected to the front panel and wherein forming the tray from the blank comprises folding the first intermediate flap into at least a partial face-to-face alignment with the secondary panel.

25. The method of claim 24, wherein the side panel of the blank includes a second intermediate flap foldably connected to the side panel and wherein forming the tray from the blank further involves folding the second intermediate flap into at least a partial face-to-face alignment with the secondary panel.

26. The method of claim 23, wherein the front panel of the blank includes a first reinforcement tab foldably connected to the first end portion and wherein forming the tray from the blank comprises folding the first reinforcement tab into at least a partial face-to-face alignment with the secondary panel.

27. The method of claim 26, wherein the side panel of the blank includes a second reinforcement tab foldably connected to the second end portion and wherein forming the tray from the blank further involves folding the second reinforcement tab into at least a partial face-to-face alignment with the secondary panel.

28. The method of claim 23, wherein tray formed from the blank includes a denesting lug extending outwardly from one of the front panel or the side panel.

29. The method of claim 28, wherein the first end portion is defined by a notch adjacent the denesting lug.

30. The method of claim 29, wherein the denesting lug is a first denesting lug and the notch is a first notch, the tray comprises a second denesting lug and the second end portion is defined by a second notch adjacent the second denesting lug.

31. The method of claim 30, wherein the front panel includes a first intermediate flap foldaby connected to the front panel, wherein forming the tray from the blank comprises folding the first intermediate flap into at least a partial face-to-face alignment with the secondary panel, the side panel includes a second intermediate flap foldably connected to the side panel and wherein forming the tray from the blank further comprises folding the second intermediate flap into at least a partial face-to-face alignment with the secondary panel.

32. The method of claim 31, wherein forming the tray from the blank comprises separating the first denesting lug from the first intermediate flap at a first cut, and separating the second denesting lug from the second intermediate flap at a second cut.

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 a blank for at least partially forming a tray according to a first embodiment of the disclosure.

[0010] FIG. 2 is a schematic elevation view of a tray formed from the blank of FIG. 1, according to an embodiment of the disclosure.

[0011] FIG. 3 is another schematic elevation view of the tray of FIGS. 1 and 2.

[0012] FIG. 4 is an enlarged perspective view of a portion of the tray of FIGS. 1-3.

[0013] FIG. 5 is a plan view of a blank for forming a tray according to a second embodiment of the disclosure.

[0014] FIG. 5A is an enlarged view of a portion of the blank of FIG. 5.

[0015] FIG. 6 is a schematic elevation view of a tray formed from the blank of FIG. 5 according to an embodiment of the disclosure.

[0016] FIG. 7 is another schematic elevation view of the tray of FIG. 5.

[0017] FIG. 8 is an enlarged perspective view of a portion of the tray of FIG. 5.

[0018] Corresponding parts are designated by corresponding reference numbers throughout the drawings.

DETAILED DESCRIPTION

[0019] The present disclosure relates generally to various aspects of containers, constructs, trays, materials, packages, elements, and articles, and methods of making such containers, constructs, trays, materials, packages, elements, and articles. Although several different aspects, implementations, and embodiments are disclosed, numerous interrelationships between, combinations thereof, and modifications of the various aspects, implementations, and embodiments are contemplated hereby. In one illustrated embodiment, the present disclosure relates to forming a container or tray for holding food items or various other articles. However, in other embodiments, the container or tray can be used to form other non-food containing articles or may be used for heating or cooking.

[0020] Trays described herein can be used for holding one or more articles such as food products, e.g., portioned retail food products that can include one or more of cookies, crackers, cakes, pastries, candies, nuts, popcorn, trail mix, gum, etc. In some embodiments, the articles can include frozen or non-frozen food products that can be provided in discrete portions, for example, pizza, chicken nuggets, French fries, onion rings, mozzarella sticks, chips, popcorn, other finger foods, etc. In embodiments, other types of articles that can include food products and/or non-food products can be placed in the tray for service to a customer. In some embodiments, such products can be contained in additional packaging and then placed in the tray. The tray could be otherwise shaped and arranged and could be used to hold other products and/or articles in similar or different environments without departing from the disclosure.

[0021] The trays described herein can include attachment, reinforcement, or denesting features. These features can be associated with the corners of the trays. The trays can include a base panel and a set of main panels foldably connected to the base panel. Secondary panels that are positioned between adjacent main panels are also foldably connected to the base panel. Each main panel can include a main rim panel at a distal end. The main rim panels can include a central portion and two end portions. Similarly, each secondary panel can include a corner rim panel at a distal end. The corner rim panels can cooperate with the main rim panels of neighboring main panels to form a contiguous rim. Each corner rim panel can overlap with two adjacent end portions, reinforcing the rim at the corners. The main panels can further include intermediate flaps or attachment tabs for securing the main panels to the secondary panels. Additionally, the main panels can further include reinforcement tabs or denesting tabs.

[0022] FIG. 1 illustrates an exterior surface 101 of a blank 103 for at least partially forming a tray 105 other container according to a first exemplary embodiment of the disclosure.

[0023] In the illustrated embodiment, the blank 103 can have a lateral axis L1, a longitudinal axis L2, and a plurality of panels for extending at least partially around an interior 107 (not shown in FIG. 1, see FIG. 4) of the tray 105.

[0024] In the illustrated embodiment, the plurality of panels can include a central panel or base panel 121, a side panel 123 (broadly, first side panel) foldably connected to the base panel 123 at a longitudinal fold line 125, a side panel 127 (broadly, first side panel) foldably connected to the bottom panel 121 at a longitudinal fold line 129, a front panel 131 foldably connected to the base panel 121 at a lateral fold line 133, and a back panel 135 foldably connected to the base panel 121 at a lateral fold line 137.

[0025] The plurality of panels can also include secondary panels 139, 141, 143, 145 (broadly, first, second, third, and fourth secondary panels) foldably connected to the base panel 121 at respective oblique fold lines 147, 149, 151, 153. In the illustrated embodiment, the side panels 123, 127 can be positioned opposed to one another across the base panel 121 along the lateral axis L1, and the front panel 131 and back panel 135 can be positioned opposed to one another across the base panel 121 along the longitudinal axis L2.

[0026] In this regard, the secondary panel 139 can be positioned between the side panel 123 and the front panel 131, the secondary panel 141 can be positioned between the front panel 131 and side panel 127, the secondary panel 143 can be positioned between the side panel 127 and back panel 135, and the secondary panel 145 can be positioned between the side panel 123 and the back panel 135.

[0027] A plurality of rim panels can also be foldably connected to a respective panel of the plurality of panels of the blank 103 and the tray 105 formed therefrom, e.g., such that each rim panel of the plurality of panels is foldably connected to a panel of the plurality of panels.

[0028] As shown, the plurality of rim panels can include a side rim panel 155 foldably connected to the side panel 123 at a longitudinal fold line 157. As shown, the side rim panel 155 can have a central portion 159 generally coextensive with the side panel 123, and respective end portions 161, 163 extending longitudinally past respective ends of the side panel 123.

[0029] Similarly, a side rim panel 165 can be foldably connected to the side panel 127 at a longitudinal fold line 168, and can have a central portion 167 generally coextensive with the side panel 127, and respective end portions 169, 171 extending longitudinally past respective ends of the side panel 127.

[0030] With continued reference to FIG. 1, a front rim panel 173 can be foldably connected to the front panel 131 at a lateral fold line 175. As shown, the front rim panel 173 can have a central portion 177 generally coextensive with the front panel 131, and respective end portions 179, 181 extending laterally past respective ends of the front panel 131.

[0031] Similarly, a back rim panel 183 can be foldably connected to the back panel 135 at a lateral fold line 185. As shown, the back rim panel 183 can have a central portion 187 generally coextensive with the back panel 135, and respective outer portions 189, 191 extending laterally past respective ends of the back panel 135.

[0032] The plurality of rim panels of the blank 103 and the tray 105 formed therefrom can also include a corner rim panel 193 foldably connected to the secondary panel 139 at a fold line 195, a corner rim panel 197 foldably connected to the secondary panel 141 at a fold line 199, a corner rim panel 201 foldably connected to the secondary panel 143 at a fold line 203, and a corner rim panel 205 foldably connected to the secondary panel 145 at a fold line 207.

[0033] Each fold line 195, 199, 203, 207, as shown, can have the form of a pair of intersecting oblique fold line segments so as to have a slightly V-shaped arrangement, though it will be understood that one or more of the fold lines 195, 199, 203, 207 can have a different arrangement, for example, a straight oblique arrangement, without departing from the disclosure.

[0034] With continued reference to FIG. 1, the plurality of end flaps of the blank 103 and the tray 105 formed therefrom can include a plurality of attachment end flaps or intermediate flaps foldably connected to a respective panel of the plurality of panels. As shown, the plurality of attachment end flaps can include a first attachment end flap 209 foldably connected to the side panel 123 at a lateral or oblique fold line 211 and a second attachment end flap 213 foldably connected to the side panel 123 at a lateral or oblique fold line 215.

[0035] An attachment end flap 217 can be foldably connected to the side panel 127 at a lateral or oblique fold line 219, and an attachment end flap 221 can be foldably connected to the side panel 127 at a lateral or oblique fold line 223.

[0036] As shown, the plurality of attachment end flaps can include a first attachment end flap 225 foldably connected to the front panel 131 at a longitudinal or oblique fold line 227, and a second attachment end flap 229 foldably connected to the front panel 131 at a longitudinal or oblique fold line 231.

[0037] Similarly, a first attachment end flap 233 can be foldably connected to the back panel 135 at a longitudinal or oblique fold line 235, and a second attachment end flap 237 can be foldably connected to the back panel 135 at a longitudinal or oblique fold line 239.

[0038] Still referring to FIG. 1, a plurality of reinforcement tabs can be foldably connected to a respective rim panel of the plurality of rim panels and can be separably connected to/separated from a respective panel of the plurality of panels.

[0039] As shown, a reinforcement tab 241 can be foldably connected to the end portion 161 of the side rim panel 155 at an oblique fold line 243, and can be separably connected to/separable from the side panel 123 at an oblique cut 244. Similarly, a reinforcement tab 245 can be foldably connected to the end portion 163 of the side rim panel 155 at an oblique fold line 247, and can be separably connected to/separable from the side panel 123 at an oblique cut 246.

[0040] A reinforcement tab 249 can be foldably connected to the end portion 169 of the side rim panel 165 at an oblique fold line 251, and can be separably connected to/separable from the side panel 127 at an oblique cut 252. Similarly, a reinforcement tab 253 can be foldably connected to the end portion 171 of the side rim panel 165 at an oblique fold line 255, and can be separably connected to/separable from the side panel 127 at an oblique cut 256.

[0041] Further, a reinforcement tab 257 can be foldably connected to the end portion 179 of the front rim panel 173 at an oblique fold line 259, and can be separably connected to/separable from the front panel 131 at an oblique cut 260. Similarly, a reinforcement tab 229 can be foldably connected to the end portion 181 of the front rim panel 173 at an oblique fold line 263, and can be separably connected to/separable from the front panel 131 at an oblique cut 264.

[0042] Similarly, a reinforcement tab 265 can be foldably connected to the end portion 189 of the back rim panel 183 at an oblique fold line 267, and can be separably connected to/separable from the back panel 135 at an oblique cut 268. Similarly, a reinforcement tab 269 can be foldably connected to the end portion 191 of the back rim panel 183 at an oblique fold line 271, and can be separably connected to/separable from the back panel 135 at an oblique cut 272.

[0043] It will be understood with regard to the blank 103 and the tray 105 formed therefrom that one or more of the end portions 161, 163, 169, 171, 179, 181, 189, 191 of the respective rim panels 155, 165, 173, 183, the attachment end flaps 209, 213, 217, 221, 233, 237, and the reinforcement tabs 241, 245, 249, 253, 257, 261, 265, 269, can be attachment and/or reinforcement features of the blank 103 and tray 105 formed therefrom.

[0044] The blank 103 and tray 105 formed therefrom can additionally include product visibility features that can include one or more product visibility openings 273 at least partially defined in a respective panel 123, 127, 131, 135. Such openings 273 can provide for line of sight into an interior 107 of the tray 105 formed from the blank, can provide for ventilation and/or drainage, can be configured to at least partially receive and/or engage a respective machine element in the course of formation of the tray 105 from the blank 103, etc. It will be understood that a different number and/or arrangement of product visibility features could be provided without departing from the disclosure.

[0045] Turning to FIGS. 2-4, formation of a tray 105 from the blank 103 will be described and illustrated according to an exemplary embodiment of the disclosure, though it will be understood that the tray 105 could be formed through a different sequence to arrive at a similar construction without departing from the disclosure.

[0046] The blank 103 can be inverted, e.g., such that the exterior surface 101 thereof is positioned on a supporting surface and such that an interior surface thereof is positioned facing upwardly. The side panels 123, 127 can be at least partially folded at the respective fold lines 125, 129 into a generally upright arrangement relative to the base panel 121, and the front panel 131 and back panel 135 can be at least partially folded at the respective fold lines 133, 137 into a generally upright arrangement relative to the base panel 121.

[0047] Similarly, the secondary panel 139 can be at least partially folded at the fold line 147 into generally upright relation with the base panel 121, the secondary panel 141 can be at least partially folded at the fold line 149 into generally upright relation with the base panel 121, the secondary panel 143 can be at least partially folded at the fold line 151 into generally upright relation with the base panel 121, and the secondary panel 145 can be at least partially folded at the fold line 153 into generally upright relation with the base panel 121.

[0048] In such an arrangement, the attachment end flap 209 can be at least partially folded at the fold line 211 into at least partial face-to-face contact with the secondary panel 139, the attachment end flap 213 can be foldably connected at the fold line 215 into at least partial face-to-face contact with the secondary panel 145, the attachment end flap 217 can be at least partially folded at the fold line 219 into at least partial face-to-face contact with the secondary panel 141, and the attachment end flap 221 can be folded at the fold line 223 into at least partial face-to-face contact with the secondary panel 143.

[0049] Similarly, the attachment end flap 225 can be at least partially folded at the fold line 227 into at least partial face-to-face contact with the secondary panel 139, the attachment end flap 229 can be foldably connected at the fold line 231 into at least partial face-to-face contact with the secondary panel 141, the attachment end flap 233 can be at least partially folded at the fold line 235 into at least partial face-to-face contact with the secondary panel 145, and the attachment end flap 237 can be folded at the fold line 239 into at least partial face-to-face contact with the secondary panel 143.

[0050] The plurality of rim panels 155, 165, 173, 183, 193, 197, 201, 205 can be folded at least partially downwardly at the respective fold lines 157, 168, 175, 185, 195, 199, 203, 207 into at least partially overlapping relation to form a flange or rim 109 of the tray 105. As shown, the rim 109 can extend generally away, e.g., away from the interior 107 of the tray 105, relative to a sidewall 111 of the tray 105 formed by the plurality of panels 123, 127, 131, 135, 139, 141, 143, 145. In some embodiments, the rim 109 of the tray 105 can be in generally spaced and planar relation above the base panel 121.

[0051] In such an arrangement, the corner rim panel 193 can be positioned in at least partial face-to-face contact with the end portion 179 of the front rim panel and the end portion 161 of the side rim panel 155 to form a contiguous rim, the corner rim panel 197 can be positioned in at least partial face-to-face contact with the end portion 181 of the front rim panel and the end portion 169 of the side rim panel 165 to form a contiguous rim, the top end flap 201 can be positioned in at least partial face-to-face contact with the end portion 171 of the side rim panel 165 and the end portion 191 of the back rim panel 183 to form a contiguous rim, and the top end flap 205 can be positioned in at least partial face-to-face contact with the end portion 189 of the back rim panel 183 and the end portion 163 of the side rim panel 155 to form a contiguous rim. As used herein, a contiguous rim is at least a portion of a rim that may be formed from one or more rim panels that are arranged to overlap and/or are in contact with one another.

[0052] Such formation of the rim 109 of the tray 105 can cause activation of one or more of the reinforcement tabs. The reinforcement tabs 241, 257 can at least partially separate from the respective panels (side panel 123, front panel 131) at the respective cuts 244, 260 and can at least partially fold relative to the respective rim panels (side rim panel 155, front rim panel 173) at the respective fold lines 243, 259 so as to be positioned in at least partial face-to-face contact with the secondary panel 139.

[0053] Similarly, the reinforcement tabs 261, 249 can at least partially separate from the respective panels (front panel 131, side panel 127) at the respective cuts 264, 252 and can at least partially fold relative to the respective rim panels (front rim panel 173, side rim panel 165) at the respective fold lines 263, 251 so as to be positioned in at least partial face-to-face contact with the side panel 141.

[0054] The reinforcement tabs 253, 269 can at least partially separate from the respective panels (side panel 127, back panel 135) at the respective cuts 256, 272 and can at least partially fold relative to the respective rim panels (side rim panel 165, back rim panel 183) at the respective fold lines 255, 271 so as to be positioned in at least partial face-to-face contact with the side panel 143.

[0055] Further, the reinforcement tabs 245, 265 can at least partially separate from the respective panels (side panel 123, back panel 135) at the respective cuts 246, 268 and can at least partially fold relative to the respective rim panels (side rim panel 155, back rim panel 183) at the respective fold lines 247, 267 so as to be positioned in at least partial face-to-face contact with the side panel 145.

[0056] Such an arrangement can be at least partially maintained with the application of one or more adhesives such as glue. In the illustrated embodiment, glue can be applied to the interior surface of one or more of the attachment end flaps 209, 213, 217, 221, 225, 229, 233, 237, the exterior surface 101 of one or more of the corner rim panels 193, 197, 201, 205, the exterior surface 101 of one or more of the secondary panels 139, 141, 143, 145, and the interior surface of one or more of the rim panels 155, 165, 173, 183.

[0057] The overlapping arrangement of the respective rim panels 155, 165, 173, 183, 193, 197, 201, 203 to form the rim 109 in concert with the respective reinforcement tabs 241, 245, 249, 253, 257, 261, 265, 269 extending downwardly from the rim 109 to the sidewall 111 and the connection of the panels 123, 127, 135, 131 to the secondary panels 139, 141, 143, 145 via the respective attachment end flaps 225, 229, 233, 237 provides a robust arrangement of the tray 105 in which the rim 109 is reinforced against unwanted deformation, for example, in the course of forces due to the loading of food products in the interior 107 of the tray 105, forces due to the application of a film or sealing member to the rim 109, forces incidental to manufacturing processes, e.g., supporting machine elements, etc.

[0058] For example, the reinforcement tabs 241, 257 extend downwardly from the overlapped rim panels 155, 173, 193 to provide a reinforced attachment to the side panel 139, the reinforcement tabs 229, 249 extend downwardly from the overlapped rim panels 165, 173, 197 to provide a reinforced attachment to the side panel 141, the reinforcement tabs 253, 269 extend downwardly from the overlapped rim panels 165, 183, 201 to provide a reinforced attachment to the side panel 143, and the reinforcement tabs 245, 265 extend downwardly from the overlapped rim panels 155, 183, 205 to provide a reinforced attachment to the side panel 145.

[0059] It will be understood that one or more features of the blank 103 and the tray 105 formed therefrom can have a different configuration and/or arrangement without departing from the disclosure.

[0060] For example, with additional reference to FIGS. 5 and 5A, a blank 303 for forming a tray 305 according to a second exemplary embodiment of the disclosure will be described.

[0061] The blank 303 and the tray 305 formed therefrom can have a configuration similar to the blank 103 and tray 105 formed thereof described above, with differences noted herein, and with like or similar features designated with like or similar reference numerals.

[0062] As shown, the blank 303 and the tray 305 formed therefrom can have the panels 123, 127, 131, 135, 139, 141, 143, 145, the rim panels 155, 165, 173, 183, 193, 197, 201, 205, and the attachment end flaps 209, 213, 217, 221, 225, 229, 233, 237.

[0063] However, the blank 303 and tray 305 can have denesting features for at least partially providing separation between a tray 305 and a similar or identical tray 305 vertically stacked thereupon or therebelow.

[0064] For example, side rim panel 355 can have central portion 359 and respective end portions 361, 363 each at least partially defined by a respective notch 364 adjacent respective denesting tabs or denesting lugs 366 extending outwardly from the side panel 123. (For clarity, each denesting lug 366 is individually labeled in FIG. 5 as 366a, 366b, 366c, . . . , 366h). As shown, the denesting lugs 366 can be at least partially defined by a respective cut 362 that at least partially separates/makes separable the denesting lugs 366 from the adjacent attachment end flap 209, 213.

[0065] Similarly, side rim panel 365 can have central portion 367 and end portions 369, 371 at least partially defined by the respective notch 364 adjacent respective denesting lugs 366 extending outwardly from the side panel 127 that can be at least partially separated/separable from the respective adjacent attachment end flap 217, 221.

[0066] Front rim panel 373 can have central portion 377 and end portions 379, 381. As shown in FIG. 5A, end portion 379 is at least partially defined by the respective notch 364 adjacent respective denesting lug 366 extending outwardly from the front panel 131 that can be at least partially separated/separable from the respective adjacent attachment end flap 225.

[0067] Similarly, returning to FIG. 5, back rim panel 383 can have central portion 387 and end portions 389, 391 at least partially defined by the respective notch 364 adjacent respective denesting lugs 366 extending outwardly from the back panel 135 that can be at least partially separated/separable from the respective adjacent attachment end flap 233, 237.

[0068] Turning to FIGS. 6-8, the tray 305 can be formed from the blank 303 in a manner generally similar to that described above with respect to the formation of the tray 105 from the blank 103, except that the denesting lugs 366 extending outwardly from the respective panels 123, 127, 131, 135 can be exposed extending away from a sidewall 311 of the tray 305 so as to present engagement surfaces, for example, such that when the tray 305 is at least partially received in the interior 307 of a similar tray 305 therebelow, the denesting lugs 366 can extend outwardly to contact the sidewall 311 of the lower tray 305 to provide adequate spacing therebetween to minimize, inhibit, and/or prevent the trays 305 from becoming stuck together, for example, due to low or negligible tight tolerances in the sizes there therebetween that can result in an at least partial interference fit between the trays 305.

[0069] The tray 305 can provide advantages similar to those described above with respect to the tray 105 with regard to the reinforcement of the overlapping arrangement of rim panels 355, 365, 373, 383, 193, 197, 201, 205 to form a rim 309 similar to the rim 109.

[0070] It will be understood that one or more features of the blank 303 and the tray 305 formed therefrom could have a different configuration without departing from the disclosure.

[0071] 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.

[0072] In general, the blank may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blank can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carrier to function at least generally as described above. The blank 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.

[0073] 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 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.

[0074] In accordance with the exemplary embodiments, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding there along. 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.

[0075] In some embodiments, the tray may be formed according to alternative configurations that provide enhanced functionality and structural characteristics. The blank 103 may be modified to include additional features that facilitate improved performance in various applications.

[0076] In various embodiments, the rim panels 155, 165, 173, 183 may include sealing features that enhance the ability to apply overwrap films or lidding materials to the tray 105. These sealing features may be formed as raised beads or channels that provide controlled contact pressure when a sealing film is applied. The sealing features may extend continuously around the perimeter of the rim 109 to ensure uniform sealing performance.

[0077] In some embodiments, the corner rim panels 193, 197, 201, 205 may include modified geometries that provide enhanced corner strength. The corner rim panels may include curved transitions rather than angular transitions to distribute stress more effectively. The curved transitions may follow predetermined radii that optimize the balance between material usage and structural performance.

[0078] In various embodiments, the reinforcement tabs 241, 245, 249, 253, 257, 261, 265, 269 may include perforated separation lines rather than continuous cuts. The perforated separation lines may include alternating cut and tie segments that provide controlled separation force requirements. The tie segments may be sized to provide adequate retention during blank handling while allowing reliable separation during tray formation.

[0079] In some embodiments, the secondary panels 139, 141, 143, 145 may include specialized fold line configurations that enhance the structural integrity of the formed tray 105. The oblique fold lines 147, 149, 151, 153 may be positioned at predetermined angles relative to the lateral axis L1 and longitudinal axis L2 to optimize the folding characteristics during tray formation. The oblique fold lines may be oriented at angles ranging from approximately thirty degrees to approximately sixty degrees relative to the adjacent panel edges.

[0080] In various embodiments, the attachment end flaps 209, 213, 217, 221, 225, 229, 233, 237 may include adhesive application zones that facilitate secure bonding during tray assembly. The adhesive application zones may be positioned along predetermined regions of each attachment end flap to ensure optimal contact with the corresponding secondary panels. The adhesive application zones may extend across substantially the entire surface area of each attachment end flap or may be limited to specific regions that provide adequate bonding strength.

[0081] In some embodiments, the product visibility openings 273 may include various geometric configurations that provide different functional characteristics. The product visibility openings may be circular, oval, rectangular, or polygonal in shape depending on the specific application requirements. The size and positioning of the product visibility openings may be optimized to provide adequate product visibility while maintaining the structural integrity of the respective panels 123, 127, 131, 135.

[0082] In various embodiments, the reinforcement tabs 241, 245, 249, 253, 257, 261, 265, 269 may include textured surfaces that enhance the adhesive bonding characteristics. The textured surfaces may be formed during the blank manufacturing process through embossing, scoring, or other surface treatment techniques. The textured surfaces may increase the effective bonding area between the reinforcement tabs and the secondary panels, thereby improving the overall structural performance of the tray 105.

[0083] In some embodiments, the corner rim panels 193, 197, 201, 205 may include alignment features that facilitate proper positioning during tray formation. The alignment features may be formed as raised beads, indentations, or other geometric features that provide tactile or visual guidance during the folding process. The alignment features may be positioned along the edges of the corner rim panels to ensure consistent overlap with the adjacent end portions of the main rim panels.

[0084] In various embodiments, the fold lines 195, 199, 203, 207 connecting the corner rim panels to the secondary panels may include stress relief features that prevent tearing during repeated folding operations. The stress relief features may be formed as small perforations, notches, or curved transitions at the intersection points of the V-shaped fold line segments. The stress relief features may distribute the folding stress over a larger area, thereby reducing the likelihood of material failure.

[0085] In some embodiments, the base panel 121 may include reinforcement ribs or channels that provide additional structural support for the tray 105. The reinforcement ribs may extend along predetermined paths across the base panel surface to distribute loading forces more effectively. The reinforcement ribs may be formed through embossing or scoring operations during the blank manufacturing process.

[0086] In various embodiments, the denesting lugs 366 may include chamfered or rounded edges that facilitate smooth separation between stacked trays 305. The chamfered edges may reduce the contact pressure between adjacent trays during denesting operations, thereby minimizing the force required to separate the trays. The chamfered edges may be formed at angles ranging from approximately fifteen degrees to approximately forty-five degrees relative to the lug surface.

[0087] In some embodiments, the notches 364 adjacent to the denesting lugs 366 may include variable depth configurations that accommodate different stacking requirements. The notch depth may be adjusted based on the expected stacking height and the desired separation force characteristics. Deeper notches may provide greater clearance for the denesting lugs while shallower notches may maintain more material for structural integrity.

[0088] In various embodiments, the cuts 362 that separate the denesting lugs 366 from the attachment end flaps may include controlled perforation patterns that provide predetermined separation forces. The perforation patterns may include alternating cut and tie segments with specific dimensional relationships that optimize the balance between blank handling integrity and reliable separation during tray formation. The tie segments may have widths ranging from approximately one millimeter to approximately three millimeters.

[0089] In some embodiments, the rim 109, 309 may include sealing channels that accommodate various types of lidding materials or overwrap films. The sealing channels may be formed as continuous grooves or raised beads that extend around the perimeter of the rim. The sealing channels may provide controlled contact pressure when sealing films are applied, thereby ensuring consistent sealing performance across the entire rim perimeter.

[0090] In various embodiments, the sidewall 111, 311 of the tray may include ventilation features that promote air circulation within the interior 107, 307. The ventilation features may be formed as small perforations, slots, or other openings that allow controlled air exchange while maintaining the structural integrity of the sidewall. The ventilation features may be particularly beneficial for applications involving fresh food products that require controlled atmospheric conditions.

[0091] In some embodiments, the blank 103, 303 may be manufactured from paperboard materials having specific caliper and density characteristics that optimize the folding and structural performance. The paperboard may have a caliper ranging from approximately twelve points to approximately twenty-four points, depending on the intended application and loading requirements. The paperboard may include recycled content while maintaining the necessary strength and folding characteristics.

[0092] The above embodiments may be described as having one or more panels adhered together by glue during erection of the carrier embodiments. The term glue is intended to encompass all manner of adhesives commonly used to secure carrier panels in place.

[0093] 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.