Tray for food products and related systems and methods

Abstract

The present application discloses a tray for holding one or more food products, the tray comprising a first portion comprising a plurality of panels, the panels comprising a central panel and a plurality of lower side panels foldably connected to the central panel. The tray further includes a second portion engaged with the first portion, the second portion including a plurality of panels including a flanged panel and a plurality of upper side panels foldably connected with the flanged panel, the plurality of upper side panels and the plurality of lower side panels attached so as to form a plurality of sidewalls of the tray.

Description

[0001] Cross - reference to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 422,625, filed on November 4, 2022; U.S. Provisional Patent Application No. 63 / 455,485, filed on March 29, 2023; and U.S. Provisional Patent Application No. 63 / 464,781, filed on May 8, 2023.

[0003] References Cited

[0004] U.S. Provisional Patent Application No. 63 / 422,625 (filed on November 4, 2022), U.S. Provisional Patent Application No. 63 / 455,485 (filed on March 29, 2023), U.S. Provisional Patent Application No. 63 / 464,781 (filed on May 8, 2023), and U.S. Design Patent Application No. 29 / 906,128 (filed on October 21, 2023) are each incorporated herein by reference in their entirety as if set forth herein in full. Technical Field

[0005] The present invention relates to blanks, containers, trays, structures, and various features, and methods for forming containers from blanks. In some embodiments, the present invention relates to trays formed from multiple mating parts. Summary of the Invention

[0006] According to one aspect, the present invention generally relates to a tray for holding one or more food items, the tray including a first portion that includes a plurality of panels, the panels including a center panel and a plurality of lower side panels foldably connected to the center panel. The tray further includes a second portion that engages the first portion, the second portion including a plurality of panels, the panels including a flange panel and a plurality of upper side panels foldably connected to the flange panel, the plurality of upper side panels and the plurality of lower side panels being attached to form a plurality of side walls of the tray.

[0007] According to another aspect, the present invention generally relates to a combination of blanks for forming a tray for holding one or more food items, the combination including a first blank that includes a plurality of panels, the panels including a center panel and a plurality of lower side panels foldably connected to the center panel. The combination further includes a second blank that is configured to engage the first blank when the tray is formed from the combination of blanks, the second blank including a plurality of panels, the panels including a flange panel and a plurality of upper side panels foldably connected to the flange panel, the plurality of upper side panels and the plurality of lower side panels being for attachment to form a plurality of side walls of the tray formed from the combination of blanks.

[0008] According to another aspect, the present invention generally relates to a method of forming a tray for holding one or more food items, the method comprising: obtaining a first blank comprising a plurality of panels including a center panel and a plurality of lower side panels foldably connected to the center panel; and obtaining a second blank comprising a plurality of panels including a flange panel and a plurality of upper side panels foldably connected to the flange panel. The method further comprises forming a first portion of the tray from the first blank, forming a second portion of the tray from the second blank, and attaching the plurality of upper side panels and the plurality of lower side panels to form a plurality of sidewalls of the tray.

[0009] Those skilled in the art will appreciate the above and other advantages and benefits of the various additional embodiments by reading the following detailed description of the embodiments with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] By convention, the various features of the drawings discussed below are not necessarily drawn to scale. The dimensions of the various features and elements in the drawings may be enlarged or reduced to more clearly depict embodiments of the present invention.

[0011] Figure 1 is a plan view of a first blank for at least partially forming a tray for holding food items, according to a first exemplary embodiment of the present invention.

[0012] Figure 2 is a plan view of a second blank for at least partially forming a tray for holding food items, according to a first exemplary embodiment of the present invention.

[0013] Figure 3 is a schematic view of an apparatus for processing blanks and / or trays that can be used with exemplary embodiments of the present invention.

[0014] Figure 4 is, according to a first exemplary embodiment of the present invention, formed from Figure 1 and Figure 2 a perspective view of a tray formed from the blanks.

[0015] Figure 5 is Figure 4 another perspective view of the tray.

[0016] Figure 6 is a plan view of a first blank for at least partially forming a tray for holding food items, according to a second exemplary embodiment of the present invention.

[0017] Figure 7 is a plan view of a second blank for at least partially forming a tray for holding food items, according to a second exemplary embodiment of the present invention.

[0018] Figure 8 is a perspective view of a tray formed from a blank of Figure 6 and Figure 7 in accordance with a second exemplary embodiment of the present invention.

[0019] Figure 9 is a plan view of a first blank for at least partially forming a tray for holding food in accordance with a third exemplary embodiment of the present invention.

[0020] Figure 10 is a plan view of a second blank for at least partially forming a tray for holding food in accordance with a third exemplary embodiment of the present invention.

[0021] Figure 11 is a perspective view of a tray formed from a blank of Figure 9 and Figure 10 in accordance with a third exemplary embodiment of the present invention.

[0022] Figure 12 is Figure 11 another perspective view of the tray.

[0023] Figure 13 is a plan view of a first blank for at least partially forming a tray for holding food in accordance with a fourth exemplary embodiment of the present invention.

[0024] Figure 14 is a plan view of a second blank for at least partially forming a tray for holding food in accordance with a fourth exemplary embodiment of the present invention.

[0025] Figure 15 is a perspective view of a tray formed from a blank of Figure 13 and Figure 14 in accordance with a fourth exemplary embodiment of the present invention.

[0026] Figure 16 is Figure 15 another perspective view of the tray.

[0027] In all the figures, corresponding parts are denoted by corresponding reference numerals. DETAILED DESCRIPTION

[0028] Various aspects of the present invention can be further understood by reference to the accompanying drawings. For simplicity, the same reference numerals may be used to introduce the same features. It should be understood that in the case where multiple similar features are introduced, not all of these features must be marked on each figure. It should also be understood that the various components used to form the structure may be interchanged. Thus, although only certain combinations are shown herein, many other combinations and configurations are hereby contemplated.

[0029] The tray according to the present invention is capable of accommodating a variety of different-shaped items. For purposes of illustration, and not for purposes of limiting the scope of the present invention, the following detailed description presents items that are at least partially disposed on or within a structural embodiment, such as food items.

[0030] The items can include food items such as cereals, granola, trail mix, candies, pasta, dried fruits, nuts, agricultural products (such as fruits, vegetables, salads, etc.), or any other food items such as liquid or powder food or beverage products. In other embodiments, the items can be non-food products (such as detergents, cat litter, etc.) without departing from the present invention.

[0031] In this specification, the terms "interior", "inner", "exterior", "outer", "lower", "bottom side", "upper", and "top" denote orientations determined relative to a tray that is fully upright and vertical.

[0032] As described herein, the tray can be formed from multiple overlapping panels, end flaps, and / or other portions of a blank. These panels, end flaps, and / or other portions of the blank can be designated in terms of relative to each other, such as "first", "second", "third", etc., in a sequential or non-sequential manner without departing from the present invention.

[0033] Figure 1 Shows the outer surface 101 of a base blank or first blank 103 for forming a base portion or first tray portion 105 of a tray 110 according to a first exemplary embodiment of the present invention.

[0034] As shown, the blank 103 has a longitudinal direction LI and a transverse direction L2. In the illustrated embodiment, the blank 103 has a base panel or bottom panel or center panel 111. The blank 103 can also include a plurality of lower side end flaps or lower side panels 113 that are foldably connected to the center panel 111 at respective transverse fold lines 115A, inclined fold lines 115B, longitudinal fold lines 115C, inclined fold lines 115D, transverse fold lines 115E, inclined fold lines 115F, longitudinal fold lines 115G, and inclined fold lines 115H.

[0035] As shown, each side panel 113 can include a respective base portion 117 and a respective distal portion 119 that are foldably connected to the respective base portion 117 at respective transverse fold lines 121A, inclined fold lines 121B, longitudinal fold lines 121C, inclined fold lines 121D, transverse fold lines 121E, inclined fold lines 121F, longitudinal fold lines 121G, and inclined fold lines 121H.

[0036] Although the central panel 111 is shown as having a generally octagonal configuration with eight side panels foldably connected thereto, it should be understood that the central panel 111 can have different configurations in which different corresponding numbers of side panels are foldably connected thereto without departing from the invention.

[0037] Reference Figure 2 , the outer surface 201 of a crown blank or second blank 203 for forming the crown portion 205 or second portion 205 of the tray 110 is shown in the figure.

[0038] As shown, the blank 203 can have a longitudinal axis L1, a transverse axis L2, and a top panel or flange panel 211 that generally forms the perimeter of the blank 203 so as to extend at least partially around a central opening 212 into which a plurality of panels of the blank 203 and the second portion 205 / tray 110 extend. As shown, the outer perimeter length of the flange panel 211 can be greater than the outer perimeter length of the central panel 111.

[0039] The blank 203 can also include a plurality of upper side end flaps or upper side panels 213 that are foldably connected to the flange panel 211 at respective transverse fold lines 215A, inclined fold lines 215B, longitudinal fold lines 215C, inclined fold lines 215D, transverse fold lines 215E, inclined fold lines 215F, longitudinal fold lines 215G, and inclined fold lines 215H.

[0040] In the illustrated embodiment, each upper side panel 213 can have a generally trapezoidal configuration and include at least one hole 217 formed therein at least partially, and the hole 217 can at least partially interrupt the respective fold lines 215A, 215B, 215C, 215D, 215E, 215F, 215G, 215H. In some embodiments, one or more holes 217 can be provided for at least partially receiving one or more machine components during the formation of the tray 110 and / or for providing visibility of tray components exposed from behind the lower side panels 213.

[0041] Also as shown, adjacent lower upper panels 213 can be at least partially separated from each other at respective inclined cuts 218 that extend into the flange panel 211.

[0042] Additionally referring Figures 3 - 5 , the formation of the tray 110 by the mating of the first blank 103 and the second blank 203 will be described according to an exemplary embodiment.

[0043] For example, the first blank 103 can be inverted such that its outer surface 101 is positioned on the support surface and its inner surface is positioned facing upward. A plurality of lower side panels 113 can be folded at respective fold lines 115A, 115B, 115C, 115D, 115E, 115F, 115G, 115H into a generally upright relationship with the central panel 111 so as to at least partially form a first portion 105 of the tray 110.

[0044] Simultaneously or thereafter, the second blank 203 can be positioned above the first blank 103 / first portion 105, and the upper side panels 213 can be folded downward relative to the flange panel 211 at respective fold lines 215A, 215B, 215C, 215C, 215D, 215E, 215F, 215G, 215H so as to at least partially form a second portion 205 of the tray 110.

[0045] In such an arrangement, the upper side panels 213 can be positioned to at least partially face-to-face contact with the respective lower side panels 113 so as to form respective side walls 219 of the tray 110, which side walls 219 at least partially surround and extend along the interior 107 of the tray 110. In some embodiments, the respective side panels 113, 213 can be adhesively bonded to each other using an adhesive such as glue. As shown, adjacent side walls among the plurality of side walls 219 can be arranged inclined relative to each other.

[0046] This joining of the first portion 105 of the tray 110 and the second portion 205 of the tray 110 can cause respective distal portions 119 of the respective lower side panels 113 to fold relative to respective base portions 117 of the respective lower side panels 113 at respective fold lines 121A, 121B, 121C, 121D, 121E, 121F, 121G, 121H and at least partially face-to-face contact respective portions of the inner surface of the flange panel 211 (e.g., the surface facing the support surface). In some embodiments, this positioning of the respective distal portions 119 can be achieved before the first portion 105 and the second portion 205 of the tray 110 are joined.

[0047] In this regard, the distal portions 119 of the respective lower side panels 113 can cooperate with the flange panel 211 so as to form a reinforcing flange 221 of the tray 110, in which a plurality of layers of material at least overlap so as to form the flange 221, e.g., for strength, rigidity, etc. As shown, the flange panel 211 extends outwardly from the panels 113, 213, e.g., away from the interior 107 of the tray 110. The flange panel 211 can be arranged in a generally spaced-apart and parallel relationship with the central panel 111.

[0048] It should be understood that the formation structure of the tray 110 can be achieved by applying an adhesive such as glue one or more times. For example, the adhesive can be applied one or more times between one or more corresponding lower side panels 113 and one or more corresponding upper side panels 213. As another example, the adhesive can be applied one or more times between one or more corresponding distal portions 119 of the lower side panel 113 and one or more corresponding portions of the flange panel 211, so that the distal portion 119 of the lower side panel 113 provides additional attachment points with the flange panel 211 / second portion 205 of the tray 110, in order to fix the first portion 105 and the second portion 205 of the tray 110 together, and to maintain the relative positions of the side wall 219 and the flange 221 of the tray.

[0049] It should be understood that one or more features of the tray 110 can be optionally arranged, sized, and / or set without departing from the present invention.

[0050] In some embodiments, a composite material and / or a polymer material sheet (such as a lining) can be applied to one or more portions of the interior 107 of the tray 110, for example, to prevent leakage, to maintain one or more sanitary conditions of one or more foods contained therein, to increase the lifespan of the tray 110 in the presence of fluid, etc. In these embodiments, the fixed engagement of the first portion 105 and the second portion 205 of the tray 110 (such as by engaging the distal portion 119 of the corresponding lower side panel 113 with the corresponding portion of the flange panel 211) can minimize, inhibit, prevent, and / or otherwise avoid the accidental separation of the lining from the tray 110. In some embodiments, such a lining L can be at least partially maintained in the engagement relationship between the first tray portion 105 and the second tray portion 205 of the tray 110.

[0051] In this regard, the blanks 103, 203 and / or the trays 110 formed from them can be provided with a lining L, which lining L includes a plastic layer, such as polyethylene, polyethylene terephthalate (PET) material or any other thermoplastic material, or a bioplastic, such as a vegetable oil or starch-based plastic. In one embodiment, such a lining can include polyethylene, which can be softened and fused to the blanks 103, 203 / trays 110. In an alternative embodiment, the lining for attachment to the blanks 103, 203 / trays 110 can include PET or a similar material, which is at least partially attached to the blanks 103, 203 / trays 110 through a heat-sealing layer (e.g., a heat-formable sealant-grade clear polyester packaging film, such as Mylar® XMPOL12 available from DuPont Teijin Films U.S. Limited Partnership of Hopewell, Virginia, or any suitable heat-formable sealant or adhesive, any suitable heat- or pressure-activated adhesive, or any other suitable material), where the PET lining can be more suitable for uses that require heating the container in an oven.

[0052] Such a lining can be at least partially attached to the blanks 103, 203 / trays 110 for positioning in contact with one or more foods held in the tray 110 (e.g., during heating). In one embodiment, after heating the food, the blanks 103, 203 / trays 110 and the accompanying lining L can be separated to allow for the separate recycling of the blanks 103 and the lining. Optionally, the blanks 103, 203 and the trays 110 formed from them can be provided separately from the lining.

[0053] In Figure 3 In the exemplary embodiment schematically shown, the blanks 103, 203 / trays 110 or their folded configurations can be arranged on the lower die 15 of the system 17, and a lining material or sheet material 19 (such as a polyethylene or PET web) can be supplied from a supply roll 21 above the blanks 103, 203 / trays 110. The upper die 23 has a heater plate surface 25, which heater plate surface 25 has a PTFE coating, such as a Teflon® coating available from The Chemours Company of Wilmington. Alternatively, the heater plate surface 25 can have a coating of any suitable material, or the coating can be omitted. As Figure 3As shown schematically, the upper mold 23 can include a plurality of holes or ducts 27 in the heater plate surface 25 for applying vacuum and / or air pressure to the sheet 19. The lower mold 15 and / or the upper mold 23 including the ducts 27 and / or the heater plate 55 can be otherwise shaped, arranged, positioned, and / or constructed without departing from the present invention. For example, the heater plate 25 can be omitted and heat can be alternatively applied to the sheet 19 (e.g., by a hot air stream).

[0054] In the illustrated embodiment, the lower mold 15 can hold the blanks 103, 203 / tray 110 above the cavity 14 in the lower mold 15 while supporting the blanks 103, 203 / tray 110. An initial vacuum can be applied to the ducts 27 to pull the diaphragm sheet 19 upward against the upper mold 23, and the upper mold 23 can be heated to a suitable temperature to soften the diaphragm sheet 19 and / or activate the heat-sealing layer. Instead of or in addition to the initial vacuum, air pressure below the diaphragm sheet 19 can be employed with a similar or the same effect. Subsequently, the diaphragm sheet 19 can be pressed downward (e.g., by air pressure applied by the ducts 27 and / or vacuum applied from below the blank 103 / tray 105).

[0055] The air pressure can cause the diaphragm sheet 19 to move toward the blanks 103, 203 / tray 110, and the lower mold 15 can support the blanks 103, 203 / tray 110 when the diaphragm sheet 19 is applied to one or more portions of the blanks 103, 203 / tray 110 to form the liner L. In one embodiment, after the liner L is applied to the blanks 103, 203, the liner L can help hold the tray 110 in its tray shape. In one embodiment, the tray 110 can be ejected from the lower mold 15 and conveyed away from the forming tool, e.g., on a conveyor.

[0056] In one embodiment, the tray 110 can be formed from the blanks 103, 203 and the liner L can be applied to the tray 110 at a much higher rate than a system that forms the tray 110 separately from the blanks 103, 203 and then places the formed tray 110 into the lower mold 15. In one example, the tray 110 of this embodiment can be formed from the blanks 103, 203 and the liner L together at a rate of about 500 trays per minute. The tray 110 can be formed in other ways without departing from the present invention. For example, the tray 110 can be formed from the blanks 103, 203 before the liner L is applied (e.g., before engaging the lower mold 15).

[0057] Reference Figure 6 , shows the outer surface 301 of the base blank or first blank 303 for forming the base portion or first tray portion 305 of the tray 310 according to a second exemplary embodiment of the present invention.

[0058] As shown, the blank 303 has a longitudinal direction LI and a transverse direction L2. In the illustrated embodiment, the blank 303 includes a plurality of panels that extend at least partially around the interior 307 of the tray 310, and the plurality of panels can include a base panel or a bottom panel or a center panel 311.

[0059] As shown, the center panel 311 can have an irregular but skew-symmetric 10-sided arrangement, although it can be provided with sides of uneven length so as to have an overall generally linear cross-sectional profile. It should be understood that the center panel 311 can have different arrangements without departing from the present invention.

[0060] The blank 303 and the plurality of panels of the first tray portion 305 / tray 310 formed therefrom can include a plurality of lower panels, and these lower panels include corresponding pairs of side panels 313, 315, 317, 319, 321 that are positioned in a relative relationship along the center panel 311.

[0061] As shown, each side panel 313 can include: a respective base portion 323 that is foldably connected to the center panel 311 at a respective transverse fold line 325; and a respective distal portion 327 that is foldably connected to the respective base portion 323 at a respective transverse fold line 329.

[0062] The side panel 315 can include: a respective base portion 331 that is foldably connected to the center panel 311 at a respective inclined fold line 333; and a respective distal portion 335 that is foldably connected to the respective base portion 331 at a respective transverse fold line 337.

[0063] Similarly, the side panel 317 can include: a respective base portion 339 that is foldably connected to the center panel 311 at a respective inclined fold line 341; and a respective distal portion 343 that is foldably connected to the respective base portion 339 at a respective inclined fold line 345.

[0064] As shown, each side panel 319 can include: a respective base portion 347 that is foldably connected to the center panel 311 at a respective longitudinal fold line 349; and a respective distal portion 351 that is foldably connected to the respective base portion 347 at a respective longitudinal fold line 353.

[0065] The side panel 321 can include: a respective base portion 355 that is foldably connected to the center panel 311 at a respective inclined fold line 357; and a respective distal portion 359 that is foldably connected to the respective base portion 355 at a respective inclined fold line 361.

[0066] The blank 303 and the tray portion 305 / tray 310 formed therefrom can also include a plurality of end flaps that are foldably connected to respective ones of the plurality of panels / side panels.

[0067] In the illustrated embodiment, the plurality of end flaps can include corner end flaps 363 that are foldably connected to respective base portions 331 of respective side panels 315 at respective inclined fold lines 365.

[0068] The corner end flap 367 can be foldably connected to a respective base portion 339 of a respective side panel 317 at a respective inclined fold line 369, and another corner end flap 371 can be foldably connected to an opposite edge of the respective base portion 339 of the respective side panel 317 at a respective inclined fold line 373.

[0069] Similarly, the corner end flap 375 can be foldably connected to a respective base portion 355 of a respective side panel 321 at a respective inclined fold line 377, and another corner end flap 379 can be foldably connected to an opposite edge of the respective base portion 355 of the respective side panel 321 at a respective inclined fold line 381.

[0070] Reference Figure 7 , shows an outer surface 401 of a crown blank or second blank 403 for forming a crown portion or second portion 405 of the tray 310.

[0071] As shown, the blank 403 can have a longitudinal axis L1, a transverse axis L2, and a top panel or flange panel 411 that generally forms a perimeter of the blank 403 so as to extend at least partially around a central opening 412 into which a plurality of panels of the blank 403 and the second portion 405 / tray 310 extend.

[0072] In the illustrated embodiment, the flange panel 411 can have a configuration that is generally complementary to the center panel 311 described above, although it should be understood that the flange panel 411 can have a different configuration without departing from the invention. As shown, the flange panel 411 can have an outer perimeter length that is greater than that of the center panel 311.

[0073] The blank 403 and the tray portion 405 / tray 310 formed therefrom can include a plurality of side panels extending into the central opening 412, and these side panels include corresponding pairs of side panels 413, 415, 417, 419, 421 positioned in a relative relationship along the flange panel 411.

[0074] The side panel 413 can be foldably connected to the flange panel 411 at a corresponding transverse fold line 423, the side panel 415 can be foldably connected to the flange panel 411 at a corresponding inclined fold line 425, the side panel 417 can be foldably connected to the flange panel 411 at a corresponding inclined fold line 427, the side panel 419 can be foldably connected to the flange panel 411 at a corresponding longitudinal fold line 429, and the side panel 421 can be foldably connected to the flange panel 411 at a corresponding inclined fold line 431.

[0075] Although the side panels 413, 415, 417, 419, 421 have a configuration that is generally complementary to the corresponding side panels 313, 315, 317, 319, 321, it should be understood that one or more of the side panels 413, 415, 417, 419, 421 can have a different configuration without departing from the present invention.

[0076] Additionally referring Figure 8 , the formation of the tray 310 by the cooperation of the first blank 303 and the second blank 403 will be described according to an exemplary embodiment.

[0077] The first blank 303 can be inverted, for example, such that its outer surface 301 is on a support surface and its inner surface faces upward. A plurality of lower side panels 313, 315, 317, 319, 321 can be folded at corresponding fold lines 325, 333, 341, 349, 357 into a relationship that is generally upright with respect to the central panel 311.

[0078] Then, the second blank 403 can be positioned above the first blank 303 / first portion 305, and the upper side panels 413, 415, 417, 419, 421 can be folded downward relative to the flange panel 411 at corresponding fold lines 423, 425, 427, 429, 431 so as to at least partially form the second portion 405 of the tray 310.

[0079] In such an arrangement, the lower side panels 313, 315, 317, 319, 321 can be positioned to at least partially face-to-face contact with the corresponding upper side panels 419, 417, 415, 413, 421, so as to form corresponding side walls 433 / 435, 437 / 439, 441 / 443, 445 / 447, 449 / 451 of the tray 310 that at least partially extend around the interior 307 of the tray 310. In some embodiments, the corresponding side panels 313, 315, 317, 319, 321, 419, 417, 415, 413, 421 can be bonded to each other using an adhesive such as glue. As shown, adjacent side walls among the plurality of side walls 433, 435, 437, 439, 441, 443, 445, 447, 449, 451 can be arranged to be inclined relative to each other.

[0080] This engagement of the first portion 305 of the tray 310 and the second portion 405 of the tray 110 can cause the distal portions 327 of the corresponding side panels 313 to fold outward at the corresponding fold lines 329 (e.g., above and away from the central panel 311, extending outward in a generally spaced-apart and parallel relationship), can cause the distal portions 335 of the corresponding side panels 317 to fold outward at the corresponding fold lines 337, can cause the distal portions 343 of the corresponding side panels 317 to fold outward at the corresponding fold lines 345, can cause the distal portions 351 of the corresponding side panels 319 to fold outward at the corresponding fold lines 353, and can cause the distal portions 359 of the corresponding side panels 321 to fold outward at the corresponding fold lines 361, so as to at least partially form the first portion 305 of the tray 310.

[0081] In this regard, the distal portions 327, 335, 343, 351, 359 of the corresponding lower side panels 313, 315, 317, 319, 321 can cooperate with the flange panels 411 of the upper portion 405 to form a reinforcing flange 463 of the tray 310, wherein the multi-layer materials at least overlap to form the flange 463, for example, for strength, stiffness, etc. As shown, the flange panels 411 extend outwardly away from the panels 313, 315, 317, 319, 321, 419, 417, 415, 413, 421, for example, away from the interior 307 of the tray 310. The flange panels 411 can be arranged in a generally spaced-apart and parallel relationship with the central panel 311.

[0082] Moreover, the inner surfaces of the corresponding corner end flaps 363 can be positioned to at least partially face-to-face contact with a part of the corresponding base portion 323 of the corresponding adjacent side panel 313. It should be understood that this positioning of one or both of the corner end flaps 363 can include at least partially folding at the corresponding fold line 365 relative to the corresponding base portion 331 of the corresponding side panel 315.

[0083] Continue to refer to Figures 6 - 8 such that the inner surface of the respective corner end flap 367 can be positioned to be at least partially face-to-face in contact with a portion of the respective base portion 331 of the respective adjacent side panel 315. Similarly, the inner surface of the respective corner end flap 371 can be positioned to be at least partially face-to-face in contact with a portion of the respective base portion 347 of the respective adjacent side panel 319. It should be understood that such positioning of one or more of the respective corner end flaps 367, 371 can include at least partial folding at the respective folding lines 369, 373 at the respective base portions 339 of the respective side panels 317.

[0084] Similarly, the inner surface of the respective corner end flap 375 can be positioned to be at least partially face-to-face in contact with a portion of the respective base portion 347 of the respective adjacent side panel 319. The inner surface of the respective corner end flap 379 can be positioned to be at least partially face-to-face in contact with a portion of the respective base portion 323 of the respective adjacent side panel 313. It should be understood that such positioning of one or more of the respective corner end flaps 375, 379 can include at least partial folding at the respective folding lines 377, 381 at the respective base portions 355 of the respective side panels 321.

[0085] The aforementioned positioning of the corner end flaps 363, 367, 371, 375, 379 can at least partially cover the gap (e.g., seam) between the respective adjacent side panels 313, 315, 317, 319, 321 that are substantially abutting or otherwise proximate, and can at least partially block the leakage of fluid contents (e.g., seasonings, condensates, runoff, etc.) associated with the food within the interior 307 of the tray 310.

[0086] Moreover, the corner end flaps 363, 367, 371, 375, 379 being positioned to overlap the respective side panels 313, 315, 317, 319, 321 can strengthen the respective side walls 433, 435, 437, 439, 441, 443, 445, 477, 449, 451, e.g., such that a double-layer structure is provided at such overlapping portions to avoid, for example, bending, flexing, other undesirable deformations, etc.

[0087] In some embodiments, a composite material and / or a polymer material sheet, such as the liner L, can be applied, for example, to one or more portions of the interior 307 of the tray 310 to prevent leakage, to maintain one or more sanitary conditions of one or more foods contained therein, to increase the lifespan of the tray 310 in the presence of fluids, etc. In some embodiments, the fastening engagement of the first portion 305 and the second portion 405 of the tray 310 can minimize, prohibit, prevent, and / or otherwise avoid the accidental separation of the liner from the tray 310. In some embodiments, such a liner L can be at least partially maintained in an engagement relationship between the first tray portion 305 and the second tray portion 405 of the tray 310. It should be understood that the liner can be applied in the manner described above with respect to the blanks 103, 203 and / or the trays 110 formed therefrom and as Figure 3 schematically shown in

[0088] to the blanks 303, 403 and / or the trays 310 formed therefrom.

[0089] It should be understood that one or more features of the tray 310 can be optionally arranged, sized, and / or provided without departing from the present invention.

[0090] For example, according to an alternative exemplary embodiment of the present invention, the blank and the tray formed therefrom can be without side panels 331, 417 and related features, wherein the center panel 311 is correspondingly arranged such that the tray has a generally shape of a four-sided tray with four angled corners.

[0091] Referring Figure 9 to

[0092] FIG.

[0093] shows the outer surface 501 of a base blank or first blank 503 for forming a base portion or first tray portion 505 of a tray 510 according to a third exemplary embodiment of the present invention.

[0094] The plurality of panels of the blank 503 and the first tray portion 505 / tray 510 formed from the blank 503 can include a plurality of upper side panels, which include corresponding pairs of side panels 513, 517 positioned in a relative relationship along the central panel 511. The side panel 513 can be foldably connected to the central panel 511 at corresponding inclined fold lines 515, and the side panel 517 can be foldably connected to the central panel 511 at corresponding inclined fold lines 519.

[0095] As shown, each of the side panels 513, 517 can include a corresponding inclined weakening line 521 that extends at least partially along the side panels 513, 517 to facilitate the formation of the first tray portion 505 of the tray 510, as further described herein.

[0096] Reference Figure 10 , the outer surface 601 of the crown blank or second blank 603 for forming the crown portion or second portion 605 of the tray 510 is shown.

[0097] As shown, the blank 603 can have a longitudinal axis LI, a transverse axis L2, and a top panel or flange panel 611 that generally forms the perimeter of the blank 603 to extend at least partially around a central opening 612, into which the plurality of panels of the blank 603 and the second portion 605 / tray 510 extend.

[0098] In the illustrated embodiment, the flange panel 611 can have a configuration that is generally complementary to the central panel 511 described above, but it should be understood that the flange panel 611 can have different configurations without departing from the present invention. As shown, the flange panel 611 can have an outer peripheral length greater than that of the central panel 511.

[0099] The blank 603 and the tray portion 605 / tray 510 formed therefrom can include a plurality of side panels that extend into the central opening 612, which include a plurality of circumferentially arranged side panels 613 that are positioned to extend into the central opening 612.

[0100] As shown, each of the side panels 613 can be foldably connected to the flange panel 611 at corresponding weakening lines 615A, 615B, 615C, 615G, 615E, 615F, 615G, 615H, 615I, 615J, 615K, 615L, 615M, 615N, 615P, 615Q. Additionally, each of the side panels 613 can be at least partially separated from an adjacent side panel 613 at a corresponding inclined cutout.

[0101] Additionally referring Figure 11 and 12, the formation of the tray 510 by the cooperation of the first blank 503 and the second blank 603 will be introduced according to the exemplary embodiments.

[0102] The first blank 503 can be inverted, for example, such that its outer surface 501 lies on the support surface and its inner surface faces upward. The plurality of lower side panels 513, 517 can be folded at the respective fold lines 515, 519 into a relationship substantially perpendicular to the central panel 511.

[0103] In this arrangement, the side panels 513, 517 can be at least partially flexed, bent, etc. at the respective weakening lines 521, where the side panel 517 overlaps, for example, at least partially face-to-face with the respective transverse edge portions of the adjacent side panel 513.

[0104] Then, the upper side panels 613 of the second blank 603 can be folded downward relative to the flange panel 615 at the respective fold lines 615A - 615Q so as to at least partially form the second part 605 of the tray 510. In this regard, the upper side panels 613 can be positioned to at least partially face-to-face contact the respective upper edge portions of the corresponding lower side panels 513, 517.

[0105] In this arrangement, the upper side panels 613 can be positioned to at least partially face-to-face contact the corresponding lower side panels 513, 517 so as to form the respective side walls 665, 667, 669, 671 of the tray 510, which at least partially surround the interior 507 of the tray 510 and extend. In some embodiments, the corresponding side panels 513, 517, 613 can be bonded to each other using an adhesive such as glue. As shown, adjacent side walls among the plurality of side walls 665, 667, 669, 671 can be arranged to extend relative to each other along a common curvature line substantially.

[0106] In this regard, the upper side panels 613 can extend downward from the flange panel 611 of the upper part 605, and the flange panel 611 forms a flange or reinforcing flange 663 of the tray 510. As shown, the flange panel 611 extends outward from the panels 513, 517, 613, for example, away from the interior 607 of the tray 610. The flange panel 611 can be arranged in a relationship substantially spaced apart and parallel to the central panel 511.

[0107] The aforementioned positioning of the lower side panels 513, 517 can at least partially cover the gap (such as a seam) between the corresponding adjacent side panels 513, 517 that are normally in contact or otherwise close to each other, and can at least partially prevent the leakage of fluid contents (such as seasonings, condensates, runoffs, etc.) associated with the food in the interior 507 of the tray 510.

[0108] Moreover, the positioning of side panels 513, 517 can, for example, strengthen the corresponding side walls 665, 667, 669, 671 so as to provide a double-layer structure at such overlapping portions to avoid, for example, bending, flexing, other undesired deformations, etc.

[0109] In some embodiments, a composite material and / or a polymer material sheet (such as liner L) can be applied to one or more portions of the interior 507 of tray 510 so as to, for example, prevent leakage, to maintain one or more sanitary conditions of one or more foods contained therein, to increase the lifespan of tray 510 in the presence of fluids, etc. In some embodiments, the fastening engagement of the first portion 505 and the second portion 605 of tray 510 can minimize, prohibit, prevent, and / or otherwise avoid the accidental separation of the liner from tray 510. In some embodiments, such a liner L can be at least partially maintained in an engagement relationship between the first tray portion 505 and the second tray portion 605 of tray 510. It should be understood that the liner can be applied to blanks 503, 603 and / or trays 510 formed therefrom in the manner described above with respect to blanks 103, 203, 303, 403 and / or trays 110, 310 and as Figure 3 schematically illustrated therein.

[0110] In some embodiments, it should be understood that the formation configuration of tray 510 can be achieved by applying an adhesive such as glue one or more times.

[0111] It should be understood that one or more features of tray 510 can be optionally arranged, sized, and / or provided without departing from the present invention.

[0112] Reference Figure 13 is made to FIG., which shows the outer surface 701 of a base blank or first blank 703 for forming a base portion or first tray portion 705 of a tray 710 according to a fourth exemplary embodiment of the present invention.

[0113] As shown, blank 703 has a longitudinal direction LI and a transverse direction L2. In the illustrated embodiment, blank 703 includes a plurality of panels for at least partially surrounding and extending around the interior 707 of tray 710, and these panels can include a base panel or bottom panel or center panel 711.

[0114] As shown, center panel 711 can have a four-sided (substantially square or rectangular) arrangement, but it should be understood that center panel 711 can have different arrangements without departing from the present invention.

[0115] The blank 703 and the multiple panels of the first tray portion 705 / tray 710 formed therefrom can include multiple lower side panels, which include corresponding pairs of side panels 713, 717 positioned in a relative relationship along the center panel 711, wherein the side panel 713 is foldably connected to the center panel 711 at a corresponding inclined fold line 715, and the side panel 717 is foldably connected to the center panel 711 at a corresponding inclined fold line 719.

[0116] As shown, each of the side panels 713, 717 can include a corresponding inclined weakening line 721 that extends at least partially along the side panels 713, 717 to facilitate the formation of the first tray portion 705 of the tray 710, as further described herein. In some embodiments, one or more of the side panels 713, 717 can include multiple additional weakening lines along the upper edge portion.

[0117] The blank 703 and the tray portion 705 / tray 710 formed therefrom can also include multiple end flaps foldably connected to the corresponding panels / side panels among the multiple panels / side panels.

[0118] In the illustrated embodiment, the multiple end flaps can include corner end flaps 723, 727 that are at least partially foldably connected to the corresponding side panels 713 at corresponding inclined fold lines 735, 729 and corner end flaps 731, 735 that are at least partially foldably connected to the corresponding side panels 713 at corresponding inclined fold lines 733, 737.

[0119] Reference Figure 14 , the outer surface 801 of the crown blank or second blank 803 for forming the crown portion or second portion 805 of the tray 710 is shown in the figure.

[0120] As shown, the blank 803 can have a longitudinal axis L1, a transverse axis L2, and a top panel or flange panel 811 that generally forms the perimeter of the blank 803 to extend at least partially around a central opening 812, and the multiple panels of the blank 803 and the second portion 805 / tray 710 extend into the central opening 812.

[0121] In the illustrated embodiment, the flange panel 811 can have a generally circular arrangement with one or more pairs of diametrically opposed flat edges, although the flange panel 811 can have different configurations without departing from the present invention. As shown, the flange panel 811 can have an outer peripheral length greater than that of the center panel 711.

[0122] The blank 803 and the tray portion 805 / tray 710 formed therefrom can include a plurality of side panels extending into the central opening 812, and these side panels include a plurality of circumferentially arranged side panels 813 positioned to extend into the central opening 812.

[0123] As shown, each side panel 813 can be foldably connected to the flange panel 811 at corresponding weakened lines 815A, 815B, 815C, 815G, 815E, 815F, 815G, 815H, 815I, 815J, 815K, 815L, 815M, 815N, 815P, 815Q. Additionally, each side panel 813 can be at least partially separated from an adjacent side panel 813 at a corresponding angled cut.

[0124] Additionally referring Figures 15 - 16 to, the formation of the tray 710 by the cooperation of the first blank 703 and the second blank 803 will be described according to an exemplary embodiment.

[0125] The first blank 703 can be inverted, for example, such that its outer surface 701 is on a support surface and its inner surface faces upward. A plurality of lower side panels 713, 717 can be folded at corresponding fold lines 715, 719 into a generally upright relationship with the central panel 711.

[0126] In this arrangement, the side panels 713, 717 can be at least partially flexed, bent, etc. at corresponding weakened lines 721, where the inner surface of the side panel 717 overlaps (e.g., at least partially face-to-face contact) the outer surface of corresponding corner end tabs 723, 727, 731, 735 extending from the corresponding side panel 713. This movement of the corner end tabs 723, 727, 731, 735 can include at least partial folding at corresponding fold lines 725, 729, 733, 737.

[0127] Then, the upper side panels 813 of the second blank 803 can be folded downward relative to the flange panel 811 at corresponding fold lines 815A - 815Q to at least partially form the second portion 805 of the tray 710. In this regard, the upper side panels 813 can be positioned to at least partially face-to-face contact the corresponding upper edge portions of the corresponding lower side panels 713, 717.

[0128] In this arrangement, the upper side panels 813 can be positioned to at least partially face-to-face contact with the corresponding lower side panels 713, 717 to form the respective side walls 865, 867, 869, 871 of the tray 710, which side walls 865, 867, 869, 871 at least partially surround and extend along the interior 707 of the tray 710. In some embodiments, the corresponding side panels 713, 717, 813 can be adhesively bonded to each other using an adhesive such as glue. As shown, adjacent side walls among the plurality of side walls 865, 867, 869, 871 can be inclined or perpendicular to each other.

[0129] This construction of the tray 710 provides a generally square or rectangular bottom profile that transitions along the side walls 865, 867, 869, 871 to a generally circular top profile.

[0130] In this regard, the upper side panels 813 can extend downward from the flange panel 811 of the upper portion 805, which flange panel 811 forms a flange or reinforcing flange 863 of the tray 710. As shown, the flange panel 811 extends outwardly from the panels 713, 717, 813, e.g., away from the interior 707 of the tray 710. The flange panel 811 can be arranged in a generally spaced-apart and parallel relationship with the center panel 711.

[0131] The aforementioned positioning of the lower side panels 813, 817 and the corner end flaps 723, 727, 731, 735 can at least partially cover the gaps (e.g., seams) between the corresponding adjacent side panels 713, 717 that are generally abutting or otherwise in proximity, and can at least partially prevent the leakage of fluid contents (e.g., seasonings, condensates, runoffs, etc.) related to the food within the interior 707 of the tray 710.

[0132] Moreover, the positioning of the side panels 713, 717 can strengthen the respective side walls 865, 867, 869, 871, e.g., such that a double-layer structure is provided at such overlapping portions to avoid, for example, bending, flexing, and other undesirable deformations.

[0133] In some embodiments, a composite material and / or a polymer material sheet, such as liner L, can be applied to one or more portions of the interior 707 of tray 710, for example, to prevent leakage, to maintain one or more sanitary conditions of one or more foods contained therein, to increase the lifespan of tray 710 in the presence of fluid, etc. In some embodiments, the secure engagement of the first portion 705 and the second portion 805 of tray 710 can minimize, inhibit, prevent, and / or otherwise avoid the accidental separation of the liner from tray 710. In some embodiments, such liner L can be at least partially maintained in an engagement relationship between the first tray portion 705 and the second tray portion 805 of tray 710. It should be understood that the liner can be applied in the manner described above with respect to blanks 103, 203, 303, 403, 503, 603 and / or trays 110, 310, 510 formed therefrom and as Figure 3 schematically illustrated therein to blanks 703, 803 and / or tray 710 formed therefrom.

[0134] In some embodiments, it should be understood that the formed configuration of tray 710 can be achieved by applying an adhesive, such as glue, one or more times.

[0135] It should be understood that one or more features of tray 710 can be optionally arranged, sized, and / or set without departing from the present invention.

[0136] Any feature of various embodiments of the present invention can be combined, replaced, or otherwise arranged with other features of other embodiments of the present invention without departing from the scope of the present invention. Moreover, it should be noted that the nested arrangement and / or features of the blanks and cartons of various embodiments can be included in a carton or blank having any carton style or panel configuration. The above carton styles and panel configurations are included by way of example.

[0137] A blank according to any embodiment of the present invention can be formed, for example, from coated cardboard and similar materials. For example, the inner side and / or the outer side of the blank can be coated with a clay coating. Then, products, advertisements, price codes, and other information or images can be printed on the clay coating. Then, the blank can be coated with a varnish to protect any information printed on the blank. The blank can also be coated with, for example, a moisture barrier layer on either or both of its sides. According to the above embodiments, the blank can be composed of cardboard of a certain caliper such that it is heavier and stiffer than ordinary paper. The blank can also be composed of other materials, such as cardboard, paperboard, or any other material having properties suitable for enabling the carton to function at least generally as described herein. The blank can also be laminated or coated with one or more sheet materials at selected panels or panel portions.

[0138] According to the above embodiments of the present invention, the fold line can be any substantially linear (although not necessarily straight) weakened form that is convenient to fold along it. More specifically (but not for the purpose of narrowing the scope of the present invention), the fold line includes: a score line, such as a line formed with a dull scoring tool, etc., which produces a crushed portion in the material along the desired weakened line; a cut, which locally extends into the material along the desired weakened line; and / or a series of cuts, which locally extend into the material and / or completely through the material along the desired weakened line; and various combinations of these features.

[0139] As an example, the tear line can include: a slit, which locally extends into the material along the desired weakened line; and / or a series of spaced slits, which locally extend into the material and / or completely through the material along the desired weakened line; 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 slits that completely extend through the material, where adjacent slits are slightly spaced apart to define a dent (e.g., a smaller, slightly bridging sheet of the material) between adjacent slits for temporarily connecting the material across the tear line generally. When tearing along the tear line, the dent is broken. The dent is typically a relatively small percentage of the tear line, alternatively, the dent can be omitted or torn from the tear line so that the tear line is a continuous cut line. That is, it is also within the scope of the present invention that each tear line will be replaced by a continuous slit, etc. For example, the cut line can be a continuous slit or can be wider than the slit without departing from the present invention.

[0140] The above embodiments can be described as causing one or more panels to be bonded together by glue during the erection of a cardboard box embodiment. The term "glue" will encompass all adhesives commonly used to hold the cardboard box panels in place.

[0141] The foregoing description of the present invention represents and describes various example embodiments. Various additions, variations, changes, etc. can be made to the example embodiments without departing from the spirit and scope of the present invention. All content included in the above description or shown in the drawings should be construed as illustrative rather than restrictive. Additionally, the present invention only represents and describes selected embodiments of the present invention, but the present invention can be used in various other combinations, variations, and environments, and can be varied or changed within the scope of the inventive concept expressed herein (commensurate with the above teachings) and / or within the skills or knowledge of the relevant field. Moreover, certain features and characteristics of the embodiments can be selectively interchanged and applied to other shown and unshown embodiments of the present invention.

Claims

1. A tray for holding one or more food items, the tray comprising: a first portion including a plurality of panels, the plurality of panels of the first portion including a central panel and a plurality of lower side panels foldably connected to the central panel; and a second portion joined to the first portion, the second portion including a plurality of panels, the plurality of panels of the second portion including a flange panel and a plurality of upper side panels foldably connected to the flange panel, the plurality of upper side panels and the plurality of lower side panels being attached to form a plurality of side walls of the tray.

2. The tray according to claim 1, wherein: the first portion of the tray is a base portion of the tray, and the second portion of the tray is a crown portion of the tray positioned above the base portion of the tray.

3. The tray according to claim 2, wherein: the flange panel extends at least partially around a central opening, and the plurality of upper side panels extend into the central opening.

4. The tray according to claim 3, wherein: the outer peripheral length of the flange panel is greater than the outer peripheral length of the central panel.

5. The tray according to claim 3, wherein: adjacent side walls among the plurality of side walls are disposed obliquely.

6. The tray according to claim 3, wherein: each of the plurality of lower side panels is at least partially curved.

7. The tray according to claim 6, wherein: the central panel has a square configuration.

8. The tray according to claim 3, wherein: corresponding upper side panels among the plurality of upper side panels are adhered to corresponding lower side panels among the plurality of lower side panels.

9. The tray according to claim 3, wherein: the flange panel extends away from the plurality of upper side panels and the plurality of lower side panels to form a reinforcing flange of the tray.

10. The tray according to claim 9, wherein: each of the plurality of lower side panels includes a corresponding base portion foldably connected to the central panel and a corresponding distal portion foldably connected to the corresponding base portion.

11. The tray according to claim 10, wherein: the corresponding distal portions of each of the plurality of lower side panels are positioned to at least partially face-to-face contact the flange panel to at least partially form the reinforcing flange of the tray.

12. The tray according to claim 9, wherein: the first portion of the tray further includes a plurality of corner end flaps foldably connected to corresponding ones of the plurality of lower side panels.

13. The tray according to claim 12, wherein: the corresponding corner end flaps are positioned to at least partially face-to-face contact a part of the corresponding one of the plurality of lower side panels to form a corresponding one of the plurality of side walls of the tray.

14. A combination of blanks for forming a tray for holding one or more food items, the combination comprising: a first blank including a plurality of panels, the plurality of panels of the first blank including a central panel and a plurality of lower side panels foldably connected to the central panel; and A second blank for joining with a first blank when a tray is formed from a combination of blanks, the second blank including a plurality of panels, the plurality of panels of the second blank including a flange panel and a plurality of upper side panels foldably connected to the flange panel, The plurality of upper side panels and the plurality of lower side panels are for attachment to form a plurality of side walls of a tray formed from a combination of blanks.

15. The combination according to claim 14, wherein: The flange panel extends at least partially around a central opening, and the plurality of upper side panels extend into the central opening.

16. The combination according to claim 15, wherein; the outer peripheral length of the flange panel is greater than the outer peripheral length of the central panel.

17. The combination according to claim 15, wherein: The plurality of upper side panels and the plurality of lower side panels are for attachment to form a plurality of side walls of a tray formed from a combination of blanks such that adjacent side walls among the plurality of side walls are disposed obliquely.

18. The combination according to claim 15, wherein: When a tray is formed from a combination of blanks, each lower side panel of the plurality of lower side panels is for at least partial bending.

19. The combination according to claim 18, wherein: The central panel has a square configuration.

20. The combination according to claim 15, wherein: The flange panel extends away from the plurality of upper side panels for forming a reinforcing flange of a tray formed from a combination of blanks.

21. The combination according to claim 20, wherein: Each lower side panel of the plurality of lower side panels includes a respective base portion foldably connected to the central panel and a respective distal portion foldably connected to the respective base portion.

22. The combination according to claim 21, wherein: The respective distal portion of each lower side panel of the plurality of lower side panels is for positioning in at least partial face-to-face contact with the flange panel to at least partially form a reinforcing flange of a tray formed from a combination of blanks.

23. The combination according to claim 20, wherein: The first blank further includes a plurality of corner end flaps foldably connected to respective lower side panels of the plurality of lower side panels.

24. The combination according to claim 23, wherein: The respective corner end flap is for positioning in at least partial face-to-face contact with a part of the respective lower side panel of the plurality of lower side panels to form a respective side wall of the plurality of side walls of a tray formed from a combination of blanks.

25. A method of forming a tray for holding one or more food items, the method comprising: Obtaining a first blank including a plurality of panels, the plurality of panels of the first blank including a central panel and a plurality of lower side panels foldably connected to the central panel; and Obtaining a second blank including a plurality of panels, the plurality of panels of the second blank including a flange panel and a plurality of upper side panels foldably connected to the flange panel; Forming a first part of the tray from the first blank; Forming a second part of the tray from the first blank; and Attach the plurality of upper side panels and the plurality of lower side panels so as to form a plurality of side walls of the tray.

26. The method according to claim 25, wherein: A first part of the tray is a base part of the tray, and a second part of the tray is a crown part of the tray positioned above the base part of the tray.

27. The method according to claim 26, wherein: The flange panel extends at least partially around the central opening, and the plurality of upper side panels extend into the central opening.

28. The method according to claim 27, wherein: The outer peripheral length of the flange panel is greater than the outer peripheral length of the central panel.

29. The method according to claim 27, wherein: Adjacent side walls among the plurality of side walls are arranged obliquely.

30. The method according to claim 27, further comprising: Causing each of the plurality of lower side panels to be at least partially bent.

31. The method according to claim 30, wherein: The central panel has a square configuration.

32. The method according to claim 27, further comprising: Adhering a corresponding upper side panel among the plurality of upper side panels to a corresponding lower side panel among the plurality of lower side panels.

33. The method according to claim 27, further comprising: Positioning the flange panel to extend away from the plurality of upper side panels and the plurality of lower side panels so as to form a reinforcing flange of the tray.

34. The method according to claim 33, wherein: Each of the plurality of lower side panels includes a corresponding base part foldably connected to the central panel and a corresponding distal part foldably connected to the corresponding base part.

35. The method according to claim 34, further comprising: Positioning the corresponding distal part of each of the plurality of lower side panels to be at least partially face-to-face with the flange panel so as to at least partially form a reinforcing flange of the tray.

36. The method according to claim 33, wherein: The first blank further includes a plurality of corner end flaps foldably connected to corresponding ones of the plurality of lower side panels.

37. The method according to claim 36, further comprising: Positioning a corresponding corner end flap to be at least partially face-to-face with a part of a corresponding one of the plurality of lower side panels so as to form a corresponding side wall among the plurality of side walls of the tray.

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