Compartmented tray

Abstract

A tray for holding a plurality of food items, the tray comprising a plurality of panels including a central panel, a plurality of partition flaps foldably connected to each of the plurality of panels, and a plurality of end flaps foldably connected to each of the plurality of panels, the plurality of partition flaps and the plurality of end flaps overlapping to form a plurality of compartments of the tray.

Description

[Technical field]

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 159,015, filed March 10, 2021. [Background technology]

[0002] U.S. Provisional Application No. 63 / 159,015 filed March 10, 2021, U.S. Provisional Application No. 16 / 532,819 filed August 6, 2019, U.S. Provisional Application No. 62 / 851,932 filed May 23, 2019, U.S. Provisional Application No. 62 / 796,716 filed January 25, 2019, U.S. Provisional Application No. 62 / 715,520 filed August 7, 2018, U.S. Provisional Application No. 16 / 037,425 filed July 17, 2018, U.S. Provisional Application No. N filed March 28, 2018 The disclosures in U.S. Provisional Application No. 62 / 649,159, filed March 16, 2018, U.S. Provisional Application No. 62 / 643,914, filed July 20, 2017, U.S. Provisional Application No. 62 / 365,635, filed July 22, 2016, U.S. Application No. 12 / 992,131, filed February 11, 2011, and U.S. Application No. PCT / GB / 09 / 50506, filed March 13, 2009, are hereby incorporated by reference in their entirety for all purposes. Summary of the Invention [Problem to be solved by the invention]

[0003] FIELD OF THEINVENTION The present invention relates to blanks, containers, trays, structures, and various configurations and methods for forming containers from blanks. More specifically, the present invention relates generally to containers with multiple compartments. [Means for solving the problem]

[0004] The present disclosure, in one aspect, generally relates to a tray for holding a plurality of food items, the tray comprising a plurality of panels including a central panel, a plurality of partition flaps foldably connected to each of the plurality of panels, and a plurality of end flaps foldably connected to each of the plurality of panels, the plurality of partition flaps and the plurality of end flaps overlapping to form a plurality of compartments of the tray.

[0005] The present disclosure, in accordance with another aspect, generally relates to a blank for forming a tray for holding a plurality of food items, the blank comprising a plurality of panels including a central panel, a plurality of partition flaps foldably connected to each of the plurality of panels, and a plurality of end flaps foldably connected to each of the plurality of panels, the plurality of partition flaps and the plurality of end flaps overlapping to form a plurality of compartments of the tray formed from the blank.

[0006] The disclosure, in accordance with another aspect, generally relates to a method of forming a tray for holding a plurality of food items, comprising obtaining a blank having a plurality of panels including a central panel, a plurality of compartment flaps foldably connected to each of the plurality of panels, and a plurality of end flaps foldably connected to each of the plurality of panels, and overlapping the plurality of compartment flaps and the plurality of end flaps to form a plurality of compartments of the tray.

[0007] Those skilled in the art will appreciate the above advantages, as well as other benefits and advantages of various additional embodiments, upon reading the following detailed description of the embodiments with reference to the below-listed drawing figures.

[0008] In accordance with common practice, the various features of the drawings described below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly show the disclosed embodiments. Corresponding parts are designated by corresponding reference numerals throughout the drawings. [Brief description of the drawings]

[0009] [Figure 1] FIG. 2 is a plan view of a blank used to form a tray according to a first exemplary embodiment of the present application. [Diagram 2] 2 is a top perspective view of a tray formed from the blank of FIG. 1 according to a first exemplary embodiment of the present application. FIG. [Diagram 3] FIG. 3 is a bottom perspective view of the tray of FIG. 2. [Figure 4] FIG. 2 is a schematic diagram of an apparatus for forming a container in an exemplary embodiment of the present application. [Diagram 5] FIG. 2 is a plan view of a blank used to form a tray according to a second exemplary embodiment of the present application. [Figure 6] FIG. 6 is a top perspective view of a tray formed from the blank of FIG. 5 according to a second exemplary embodiment of the present application. [Figure 7] FIG. 7 is a bottom perspective view of the tray of FIG. 6.

[0010] The present disclosure relates generally to various aspects of containers, structures, trays, materials, packaging, elements, and articles, and methods of making such containers, structures, trays, materials, packaging, elements, and articles.

[0011] Although a number of different aspects, implementations, and embodiments are disclosed, numerous interrelationships between, combinations of, and modifications of the various aspects, implementations, and embodiments are contemplated herein.

[0012] In one embodiment shown, the present disclosure is directed to forming containers or trays for holding food or various other items, however, in other embodiments, the containers or trays may also be used to form other non-food items or may be used for heating or cooking.

[0013] 1 illustrates an exterior surface 101 of a blank 103 for forming a tray 105 (FIG. 2) or other container according to an exemplary embodiment of the present disclosure. In one embodiment, the blank 103 comprises paperboard (e.g., solid bleached sulfate folded corrugated paper) or other suitable material that is recyclable and / or suitable for use in an oven (not shown).

[0014] The blank 103 may be provided with a liner L comprising a plastic layer such as polyethylene, a 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 liner may comprise polyethylene that may be softened and fused to the blank 103.

[0015] In an alternative embodiment, the liner attached to the blank 103 comprises a heat seal layer (e.g., a thermoformable sealant grade clear polyester packaging film such as Mylar® XMPOL 12 available from DuPont Teijin Films US Partnership, Hopewell, Va., or any suitable thermoformable sealant or adhesive, any suitable heat or pressure activated adhesive, or any other suitable material), where a PET liner may be more suitable for uses requiring heating the container in an oven.

[0016] Such a liner may be at least partially attached to the blank 103 such that it is placed in contact with one or more food items held within the container 105 (e.g., during heating). In one embodiment, after the food items are heated, the blank 103 and attached liner L may be separated to allow both the blank 103 and the liner to be separately recycled.

[0017] The blank 103 may be formed from a single layer of material, such as, but not limited to, paperboard, cardboard, paper, a polymer sheet, and / or a laminate including two or more layers. In one embodiment, the blank 103 may include a microwave interactive layer (not shown), such as is typical of MicroLite® containers available from Graphic Packaging International, Atlanta, Georgia.

[0018] The microwave interactive layer may generally be one of a susceptor, a foil, a microwave shield, or any other term or component that refers to a layer of material suitable for shielding microwave energy and / or the source of heating in a microwave oven.

[0019] As shown in FIG. 1, the blank 103 has a longitudinal direction L1 and a transverse direction L2.

[0020] In the illustrated embodiment, the blank 103 has a central panel 111, a first side attachment panel 113 foldably connected to the central panel 111 at a transverse fold line 115, and a second side attachment panel 117 foldably connected to the central panel 111 at a transverse fold line 119.

[0021] As shown, the peripheral region of the central panel 111 may form the flange 120 of the blank 103 / container 105 .

[0022] The first compartment flap 121 and the second compartment flap 123 can be foldably connected to the central panel 111 at their respective longitudinal fold lines 125, 127 (broadly, their respective "first fold lines") and can be positioned within the outer edge of the central panel 111 to at least partially form the first compartment of the tray 105, and the first compartment flap 129 (broadly, the "third compartment flap") and the second compartment flap 131 (broadly, the "fourth compartment flap") can be positioned within the outer edge of the central panel 111 to be foldably connected to the central panel at their respective longitudinal fold lines 133, 135 (broadly, their respective "first fold lines") and form the second compartment of the tray 105.

[0023] The attachment tab 137 can be foldably connected to the first compartment flap 121 at a longitudinal fold line 139. The attachment tab 137 can be separable from the second compartment flap 123 at a notch 141 having one or more angles, diagonals, and / or curves, and the compartment flaps 121, 123 can be separable at a longitudinal notch 143 interrupted by the fold line 139. Also as shown, a pair of generally triangular shaped notches 145, 147 can be disposed in the central panel 111 on opposite sides of the compartment flaps 121, 123 and can be defined as respective free ends of the respective compartment flaps 121, 123.

[0024] Similarly, the attachment tab 149 may be foldably connected to the first compartment flap 129 at a longitudinal fold line 151, and the attachment tab 153 may be foldably connected to the second compartment flap 131 at a longitudinal fold line 155, with the attachment tabs 149, 153 being separable at a longitudinal notch 157. A pair of generally triangular shaped notches 159, 161 may be provided on opposite sides of the compartment flaps 129, 131 of the central panel 111 and may define respective free ends of each compartment flap 129, 131.

[0025] In this regard, the fold lines 125, 127, 133, 135 may be disposed along and / or across a portion of the respective slits 145, 147, 159, 161 and / or the respective openings in the central panel 111 formed by the slits 145, 147, 159, 161 and / or the compartment flaps 121, 123, 129, 131.

[0026] A plurality of end flaps are attached to each of the plurality of panels of the blank 103, including a first side end flap 163 (broadly, the "first end flap") foldably connected to the first side attachment panel 113 at a transverse fold line 165 (broadly, the "second fold line") and a second side end flap 167 (broadly, the "first end flap" or "second fold line") foldably connected to the first side attachment panel 113 at a transverse fold line 169 (broadly, the "second fold line"). or the "third end flap"), a first side end flap 171 (broadly, the "second end flap") foldably connected to the second side attachment panel 117 at a transverse fold line 173 (broadly, the "second fold line"), and a second side end flap 175 (broadly, the "second end flap" or the "fourth end flap") foldably connected to the second side attachment panel 117 at a transverse fold line 177 (broadly, the "second fold line"). In this regard, the fold lines 165, 169, 173, 177 can be spaced apart from the opening in the central panel 111 formed by the slits 145, 147, 159, 161 and / or the compartment flaps 121, 123, 129, 131.

[0027] As shown, the first side end flap 163 can include a base / side portion 179 foldably connected to the first side attachment panel 113 at a transverse fold line 165 and a distal / bottom portion 181 foldably connected to the base portion 179 at a transverse fold line 182. An attachment tab 183 can be foldably connected to the distal portion 181 of the end flap 163 at a longitudinal fold line 185.

[0028] The second side end flap 167 can include a base / side portion 187 foldably connected to the first side attachment panel 113 at a horizontal fold line 169 and a distal / bottom portion 189 foldably connected to the base portion 187 at a horizontal fold line 191.

[0029] Similarly, the first side end flap 171 may include a base / side portion 193 foldably connected to the second side attachment panel 117 at a lateral fold line 173 and a distal / bottom portion 195 foldably connected to the base 193 at a lateral fold line 197, as shown. An attachment tab 199 may be foldably connected to the distal portion 195 of the end flap 171 at a longitudinal fold line 201. The second side end flap 175 may include a base / side portion 203 foldably connected to the second side attachment panel 117. It includes a lateral fold line 117 and a distal / bottom portion 205 foldably connected to the base 203 at a lateral fold line 207.

[0030] 2 and 3, according to one embodiment, attachment panels 113, 117 may be folded at respective fold lines 115, 119 to provide at least partial face-to-face contact with respective portions of central panel 111. Compartment flap 121 / attachment tab 137 and compartment flap 123 may be separated at respective notches 141, 143 and folded downward at respective fold lines 125, 127 away from central panel 111. Similarly, compartment flap 129 / attachment tab 149 and compartment flap 131 / attachment tab 153 may be separated at notch 157 and folded downward at respective fold lines 133, 135 away from central panel 111.

[0031] The end flaps 163, 171 may be folded inwardly at respective fold lines 165, 173 to extend away from the central panel 111 toward engagement with the downwardly depending compartment flaps 121, 123. In this regard, respective edges or surfaces of the bases 179, 193 may intersect with edges or surfaces of the respective compartment flaps 121, 123.

[0032] Additionally, the distal portions 181, 195 are folded at their respective fold lines 182, 197 into a generally spaced apart and parallel arrangement with the respective edges or surfaces of the distal portions 181, 195 that intersect with the edges or surfaces of the respective compartment flaps 121, 123 and the central panel 111. In such a configuration, the attachment tabs 183, 199 associated with the end flaps 163, 171 can be folded at their respective fold lines 185, 201 into at least partial opposing contact with the compartment flap 123 to cover the space formed by separating the attachment tab 137 from the compartment flap 123, and the attachment tab 137 associated with the compartment flap 121 can be folded into at least partial opposing contact with the distal portions 181, 195 of the end flaps 163, 171, respectively.

[0033] In the foregoing configuration, the end flaps 163, 171 and compartment flaps 121, 123 and associated attachment tabs 137 cooperate to form a first compartment 209 with bases 179, 193 of the respective end flaps 163, 171 and compartment flaps 121, 123 forming the sides of the compartment 209 that are disposed obliquely relative to the central panel 111, and with bases 181, 195 of the respective end flaps 163, 171 forming the bottom of the compartment 209. The foregoing arrangement of the first compartment 209 may be maintained by attachment of the tabs 137, 183, 199 to the respective panels and flaps, and may be maintained at least in part with an adhesive, such as a glue.

[0034] Similarly, the end flaps 167, 175 can be folded inwardly at their respective fold lines 169, 177 to extend from the central panel 111 into engagement with the downwardly depending compartment flaps 129, 131, toward engagement with the distal portions 189, 205, and folded at their respective fold lines 191, 207 into a generally spaced apart and parallel arrangement with the central panel 111 with edges or surfaces of their distal portions 181, 195 intersecting edges or surfaces of the respective compartment flaps 129, 131. In such an arrangement, the attachment tabs 149, 153 associated with the compartment flaps 129, 131 can be folded at their respective fold lines 151, 155 into at least partial opposing contact with the end flaps 167, 175, e.g., respective portions of the distal portions 189, 205 of the respective end flaps 167, 175.

[0035] The end flaps 167, 175 and compartment flaps 129, 131 and associated attachment tabs may cooperate to form a second compartment 211, with bases 187, 203 of the compartment flaps 129, 131 forming sides of the compartment 211 disposed obliquely relative to the respective end flaps 167, 175 and central panel 111, and with bases 189, 205 of the respective end flaps 167, 175 forming the bottom of the compartment 211. The arrangement of the compartment 211 may be maintained by attachment to the respective end flaps via the arrangement of tabs 149, 153, and may be maintained at least partially with an adhesive.

[0036] The above-described configuration of the tray 105 provides multiple compartments, e.g., compartments 209, 211, such that one or more compartments 209, 211 may be utilized to, for example, separate food items for serving to one or more persons and prevent mixing thereof, serve main and side dishes, hold condiments, etc. Furthermore, due to the overlapping arrangement of the compartment flaps 121, 123 and the end flaps 163, 171, the compartment flaps 129, 131 and the end flaps 167, 175 provide a rigid structure to the compartment 209 that resists deformation, bending, breaking, etc. The compartment flaps 129, 131 and the end flaps 167, 175 provide a similar rigid structure to the second compartment 211. In this regard, the end flaps 167, 175 may be viewed as a reinforcing feature of the respective compartments 209, 211 / tray 105.

[0037] In this regard, a first internal volume V1 of the first compartment 209 can be defined between the end flaps 163, 171 and the compartment flaps 121, 123, and a second internal volume V2 of the second compartment 211 can be defined between the end flaps 167, 175 and the compartment flaps 129, 131.

[0038] Although the first compartment 209 is shown as defining an interior 213 having an interior volume V1 that is different, e.g., larger, than the interior volume V2 of the interior 215 of the second compartment 211, it will be appreciated that the compartments 209, 211 can have a different configuration or interior volume than that shown, or can have the same configuration or interior volume.

[0039] Additionally, the above-described configuration of the trays 105 allows multiple trays 105 to be nested or stacked within one another. For example, an upper tray 105 may be placed or nested within a lower tray by positioning the end flaps and compartment flaps defining the respective compartments 209, 211 at least partially within the respective interiors 213, 215 of the respective compartments 209, 211 of the lower tray 105.

[0040] In an embodiment, it can be appreciated that a liner such as liner L (FIG. 1) can be applied to at least the interiors 213, 215 of each compartment 209, 211, for example, covering the seams / intersections between the respective compartment flaps and end flaps such that the compartments 209, 211 have leak-resistant characteristics.

[0041] In one embodiment, the container 105 can be formed similar to the container configurations shown and described in the applications incorporated by reference (e.g., the '425 application, the '814 application, and / or the '131 application). In an exemplary embodiment shown generally in FIG. 4, the blank 103 / container 105, or a folded configuration thereof, can be placed on a lower die 215 of the system 217, and a liner material or film sheet 219 (e.g., a polyethylene or PET web) can be fed from a feed roller 221 above the blank 103 / folded blank 103. The upper die 223 has a heater plate surface 225 having a PTFE coating, such as a Teflon coating. Alternatively, the heater plate surface 225 can have a coating of any suitable material, or the coating can be omitted. As shown generally in FIG. 4, the upper die 223 can include a plurality of holes or ducts 227 in the heater plate surface 225 for applying vacuum and / or air pressure to the sheet 219. The lower die 215 and / or upper die 223, including the ducts 227 and / or the heater plate 225, may be of other shapes, arrangements, positions, and / or configurations without departing from this disclosure. For example, the heater plate 225 may be omitted, and heat may instead be applied to the sheet 219 (e.g., using a flow of hot air).

[0042] In the illustrated embodiment, the lower die 215 can hold the blank 103 / folded blank 103 over the cavity 214 of the lower die 215 (e.g., with the central panel 111 facing up) while supporting the blank 103 / container 105 on the central panel 111 and / or the mounting panels 113, 117 (e.g., the mounting panels 113, 117). An initial vacuum can be applied to the duct 227 to draw the film sheet 219 towards the upper die 223, which can be heated to an appropriate temperature to soften the film sheet 219 and / or activate the heat seal layer. Instead of or in addition to the initial vacuum, air pressure under the film sheet 219 can be used with similar or equivalent effect. The film sheet 219 can then be pressed downward (e.g., by air pressure applied by the duct 227 and / or by vacuum applied from below the blank 103 / container 105). Air pressure can move film sheet 219 toward blank 103 / folded blank 103 and lower die 215 can support blank 103 / container 105 such that film sheet 219 is applied to one or more portions of flange 120, compartment flaps 121, 123, 129, 131 and end flaps 163, 167, 171, 175 to form liner L. In one embodiment, liner L can help hold container 105 in a tray shape after liner L is applied to container 105. In one embodiment, container 105 can be removed from lower die 215 and transported away from the forming tool, for example on a conveyor.

[0043] In one embodiment, the container 105 is formed from a blank 103 and can be applied to the liner L at a much higher rate than a system that separates and forms the container 105 from the blank 103 and then places the formed container 105 on the lower die 215. In one example, the container 105 of this embodiment can be formed from the blank 103 with the liner L at a rate of about 200 trays per minute. The container 105 can also be formed in other manners without departing from this disclosure. For example, the container 105 can be formed from the blank 103 before the liner L is applied (e.g., before engaging the lower die 215).

[0044] 5, an exterior surface 301 of a blank for forming a tray 305 (FIG. 6) according to a second exemplary embodiment of the present disclosure is generally indicated at 393. The blank 303 and tray 305 may have one or more of the following features, which are generally similar to those described above with respect to the blank 103 and tray 105, and like or similar features are indicated with like or similar reference numbers.

[0045] Blank 303 may have substantially the same construction as blank 103 described above, except that the end flaps foldably attached to side attachment panels 113, 117 are end flaps 363, 371, respectively.

[0046] As shown, the end flap 363 can be configured to have distal portions 181, 189 (broadly referred to as the “first distal portion” and the “second distal portion”) foldably connected to a base portion 379 at respective fold lines 182, 191, and an attachment tab 183 foldably connected to the distal portion 181 at fold line 185, with the base portion 379 foldably connected to the side attachment panel 113 at a lateral fold line 365 (broadly referred to as the “second fold line”).

[0047] Similarly, end flap 371 can have distal portions 195, 205 (broadly, the “first base” and “second base”) foldably connected to base 393 at respective fold lines 197, 207, and an attachment tab 199 foldably connected to distal portion 195 at fold line 201, along with base 393 foldably connected to side attachment panel 117 at a lateral fold line 373 (broadly, the “second fold line”). In this regard, distal portions 181, 189 of end flap 363 share a common base 379, and distal portions 195, 205 of end flap 371 share a common base 393.

[0048] 6 and 7, tray 305 may be formed in a manner similar to that described above for tray 105, except that bases 379, 393 of respective end flaps 363, 373 form respective sides of compartments 309, 311, such that bases 379, 393 straddle each of compartments 309, 311 and provide the same advantages as described above for tray 105. The above-described arrangement of tray 305 may be maintained, at least in part, by one or more applications of an adhesive, such as glue.

[0049] It will be appreciated that in an embodiment, a liner such as liner L (FIG. 1) may be applied to at least the interiors 413, 415 of each compartment 409, 411 and may cover the seams / points of intersection between the respective compartment flaps and end flaps. Application of such liner L to container 305 may be accomplished, for example, in the manner described above with respect to container 105.

[0050] In one embodiment, the lid (not shown) may comprise a packaging film, which is a thin plastic layer used to preserve and protect the food contained in the tray 105, 305, and may be removably attached to the flange of the tray 105, 305 defined by a portion of the center panel 111, for example. Any plastic film, such as polyethylene, polypropylene, polyethylene terephthalate, polyvinyl chloride, polyamide, and ethylene vinyl alcohol, or other suitable material, may be used to form a lid that is sealed against the sealing surface of the flange / center panel 111. Additionally, an adhesive may be used between the lid and the sealing surface of the flange / center panel without departing from this disclosure. In one embodiment, the sealing surface of the flange is the top surface of the center panel 111, which is generally free of seams, wrinkles, fold lines, pleats, edges, and other features that may make it more difficult to seal the lid film to the flange (e.g., that may reduce the smoothness of the flange). Thus, the top surface of the center panel 111 of the tray 105, 305 in the illustrated embodiment may provide a better sealing surface than a container that has features such as pleats and seams on its upper flange surface.

[0051] Any of the features of the various embodiments of the present disclosure may be combined with, substituted for, or otherwise configured with other features of other embodiments of the present disclosure without departing from the scope of the present disclosure.

[0052] Optionally, one or more portions of the blank or other structure described or contemplated herein may be coated with varnish, clay, or other materials, either alone or in combination, and product advertising or other information or images may be printed over the coating. Additionally, the blank or other construct may be selectively coated and / or printed such that less than the entire surface area of ​​the blank, or substantially the entire surface area of ​​the blank is coated and / or printed.

[0053] Any of the blanks, trays, or other structures of the present disclosure may optionally include one or more features that alter the effect of microwave energy during heating or cooking of a food product associated with the tray or other structure. For example, a blank, tray, container, or other structure may be formed at least in part from one or more microwave energy interactive elements (hereinafter "microwave interactive elements") that facilitate heating, browning, and / or crisping of a food product, that facilitate heating, browning, and / or crisping of a particular area of ​​a food product, that prevent overcooking of the food product, that transmit microwave energy toward or away from a particular area of ​​the food product, that facilitate heating, browning, and / or crisping of a particular area of ​​the food product, that protect a particular area of ​​the food product from microwave energy, or that comprise one or more microwave energy interactive materials or segments arranged in a particular configuration to absorb microwave energy, transmit microwave energy, reflect microwave energy, or directly direct microwave energy, as needed or desired for the particular construction and food product.

[0054] In the case of a susceptor or shield, the microwave energy interactive material may include, for example, a vacuum deposited metal or metal alloy, or a conductive or semi-conductive material such as a metallic ink, an organic ink, an inorganic ink, a metallic paste, an organic paste, an inorganic paste, or the like, or any combination thereof. Examples of suitable metals and alloys include, but are not limited to, aluminum, chromium, copper, Inconel alloys (nickel-chromium-molybdenum alloys with niobium), iron, magnesium, nickel, stainless steel, tin, titanium, tungsten, and any combination or alloy thereof.

[0055] Alternatively, the microwave energy interactive material may include a metal oxide, such as oxides of aluminum, iron, and tin, optionally used in conjunction with a conductive material. Another metal oxide that may be suitable is indium tin oxide (ITO). ITO has a more uniform crystal structure and is therefore transparent at most coating thicknesses.

[0056] In a further alternative, the microwave energy interactive material may comprise a suitable conductive, semiconductive, or nonconductive artificial dielectric or ferroelectric material. The artificial dielectric material comprises a conductive subdivided material in a polymer or other suitable matrix or binder, and may include flakes of a conductive metal, for example aluminum.

[0057] In other embodiments, the microwave energy interactive material may be carbon-based, for example, as disclosed in US Pat. Nos. 4,943,456, 5,002,826, 5,118,747, and 5,410,135.

[0058] In yet another embodiment, the microwave energy interactive material can interact with the magnetic portion of the electromagnetic energy in a microwave oven. This type of material, when properly selected, can be self-limiting based on loss of interaction when the Curie temperature of the material is reached. An example of such an interactive coating is disclosed in U.S. Patent No. 4,283,427.

[0059] The use of other microwave energy interactive elements is also contemplated. In one example, the microwave energy interactive element may comprise a foil or high optical density evaporated material having a thickness sufficient to reflect a substantial portion of the microwave energy impinging on it. Such elements are generally in the form of solid "patches" having a thickness of about 0.000285 inches to about 0.005 inches, e.g., about 0.0003 inches to about 0.003 inches, and are usually formed from a conductive, reflective metal or metal alloy, e.g., aluminum, copper, or stainless steel. Other such elements may have a thickness of about 0.00035 inches to about 0.002 inches, e.g., 0.0016 inches.

[0060] In some cases, microwave energy reflecting (or reflective) elements may be used as shielding elements when the food product has a tendency to burn or dry out during heating. In other cases, smaller microwave energy reflecting elements may be used to diffuse or attenuate the microwave energy. One example of a material utilizing such microwave energy reflecting elements is commercially available under the tradename MicroLite® packaging material from Graphic Packaging International, Inc. (Atlanta, Georgia). In other examples, multiple microwave energy reflecting elements may be arranged to form a microwave energy distributing element to direct microwave energy to specific areas of the food product. If desired, the loop may be of a length that resonates the microwave energy, thereby enhancing the distribution effect. Microwave energy distributing elements are described in U.S. Patent Nos. 6,204,492, 6,433,322, 6,552,315, and 6,677,563, each of which is incorporated by reference in its entirety.

[0061] If desired, any of the numerous microwave energy interactive elements described or contemplated herein may be substantially continuous, i.e., without substantial breaks or interruptions, or may be discontinuous, for example, by providing one or more breaks or openings through which microwave energy is transmitted. The breaks or openings may extend through the entire structure or may extend through only one or more layers. The number, shape, size, and location of such breaks or openings may vary for a particular application depending on the type of structure being formed, the food product being heated therein or thereon, the desired degree of heating, browning, and / or crisping, whether direct exposure to microwave energy is necessary or desirable to heat the food product evenly, the need to control temperature changes in the food product due to direct heating, and whether and to what extent ventilation is required.

[0062] By way of example, a microwave energy interactive element may include one or more transparent regions to effect dielectric heating of a food item. However, where the microwave energy interactive element includes a susceptor, such openings reduce the total microwave energy interactive area and therefore the amount of microwave energy interactive material available to heat, brown, and / or crisp the surface of the food item. Thus, the relative amounts of microwave energy interactive area and microwave energy transparent area may be balanced to achieve the overall heating characteristics desired for a particular food item.

[0063] As another example, one or more portions of the susceptor may be designed to be inactive to ensure that microwave energy is efficiently focused on the areas to be heated, browned, and / or crisped, rather than on portions of the food not intended to be browned or crisped, or lost to the heating environment. Additionally or alternatively, it may be useful to create one or more discontinuities or inactive areas to prevent overheating or charring of the food and / or the structure containing the susceptor.

[0064] As yet another example, the susceptor may incorporate one or more "fuse" elements that limit the propagation of cracks in the susceptor, thereby controlling overheating in areas of the susceptor where heat transfer to the food product is poor and the susceptor may tend to become too hot. The size and shape of the fuses may vary as needed. Examples of susceptors including such fuses are described, for example, in U.S. Pat. No. 5,412,187, U.S. Pat. No. 5,530,231, U.S. Patent Application Publication No. 2008 / 0035634A1 published Feb. 14, 2008, and PCT Application Publication No. WO2007 / 127371 published Nov. 8, 2007, each of which is incorporated herein by reference in its entirety.

[0065] All dimensional information presented herein is intended to illustrate certain aspects, features, etc. of various embodiments of the present disclosure, and is not intended to limit the scope of the present disclosure. Dimensions of blanks, containers, forming tools, features, or any other dimensions may be more or less than those shown and described in the present disclosure, and may be within the recited dimensional ranges, without departing from the scope of the present disclosure. Each feature, or the range of dimensions recited for each feature, may be outside the recited dimensional ranges without departing from the scope of the present disclosure.

[0066] Blanks according to the present invention may be formed, for example, from coated paperboard and similar materials. For example, the blanks may be coated on the inside and / or outside with a clay coating. The clay coating may then be printed with product, advertising, price codes, and other information and images. The blanks may then be coated with a varnish to protect the information printed on the blank. For example, the blanks may also be coated with a moisture barrier on one or both sides of the blank.

[0067] According to an exemplary embodiment, the blank can be constructed of caliper paperboard so that it is heavier and stiffer than ordinary paper. The blank can also be constructed of other materials such as cardboard, rigid paper, or other materials having suitable properties to enable the carton packaging to function at least generally as described above. The foregoing description illustrates and describes various embodiments of the present disclosure. Since various changes can be made in the above configurations without departing from the scope of the present disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present invention includes various modifications, combinations, alterations, etc. of the above embodiments. Moreover, the present disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are contemplated and are within the scope of the inventive concepts expressed herein, commensurate with the above teachings, and / or within the skill or knowledge of those skilled in the relevant art. Moreover, the specific features and characteristics of each embodiment can be selectively interchanged and applied to other illustrated and unillustrated embodiments without departing from the scope of the present disclosure.

[0068] Various implementations of the present invention have been shown and described. Various modifications can be made in the above configurations without departing from the scope of the present disclosure. All matters contained in the disclosure or shown in the accompanying drawings are for illustrative purposes only and should not be construed in a limiting sense. Furthermore, the scope of the present disclosure includes various modifications, combinations, and substitutions of the above implementations. In addition, the disclosure describes only selected embodiments, and various other combinations, modifications, and contexts may be incorporated within the scope of the inventive concept as presented herein, within the scope of the art and knowledge, consistent with the above teachings, and / or within the scope of the art or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively substituted and applied to others shown and not shown without departing from the scope of the present disclosure.

Claims

1. A tray for holding a plurality of food items, said tray comprising: a plurality of panels including a central panel; a plurality of compartment flaps including a first compartment flap, a second compartment flap, a third compartment flap, and a fourth compartment flap, each of the plurality of compartment flaps foldably connected to the central panel; a plurality of end flaps foldably connected to each of the plurality of panels; A tray, wherein the plurality of compartment flaps and the plurality of end flaps overlap to form a plurality of compartments of the tray.

2. 2. The tray of claim 1, wherein the plurality of end flaps includes a first end flap extending from the central panel and engaging respective portions of the first and second compartment flaps to at least partially form a first compartment of the plurality of compartments of the tray.

3. 3. The tray of claim 2, wherein the central panel defines a flange for at least partially receiving a liner; Further, in combination with the liner, the liner is disposed on a portion of the flange, at least one compartment flap of the plurality of compartment flaps, and at least one end flap of the plurality of end flaps.

4. 3. The tray of claim 2, wherein one of the first compartment flap and the second compartment flap is foldably connected to the central panel at a fold line that intersects with a notch adjacent the first compartment flap and the second compartment flap, and the first end flap is foldably connected to a respective panel of the plurality of panels at a second fold line, the second fold line being spaced from the notch.

5. 3. The tray of claim 2, wherein the first end flap comprises a base portion extending from the central panel and a distal portion foldably connected to the base portion.

6. 6. The tray of claim 5, wherein the distal portion is disposed at an angle relative to the base portion, and the distal portion is disposed generally parallel to the central panel.

7. 7. The tray of claim 6, wherein an attachment tab is foldably connected to one of the first and second compartment flaps and positioned to at least partially face and contact a distal portion of the first end flap, and the attachment tab is foldably connected to the distal portion of the first end flap and positioned to at least partially face the other of the first and second compartment flaps.

8. 7. The tray of claim 6, wherein the plurality of end flaps further comprises a second end flap extending away from the central panel and engaging a portion of each of the first and second compartment flaps to at least partially form the first compartment; A tray wherein a first interior volume of the first compartment is defined between the first compartment flap, the second compartment flap, the first end flap, and a second end flap.

9. 9. The tray of claim 8, wherein the plurality of panels further comprises a first attachment panel foldably connected to the central panel and a second attachment panel foldably connected to the central panel, the first end flap being foldably connected to the first attachment panel and the second end flap being foldably connected to the second attachment panel; The tray, wherein each of the first mounting panel and the second mounting panel is in at least partial opposing contact with the central panel.

10. 9. The tray of claim 8, wherein the plurality of end flaps further comprises a third end flap extending away from the central panel and engaging a portion of each of the third and fourth compartment flaps to form a second of the plurality of compartments of the tray; The third end flap has a base portion extending away from the central panel and a distal portion foldably connected to the base portion of the third end flap.

11. 11. The tray of claim 10, wherein the plurality of end flaps further comprises a fourth end flap extending away from the central panel and engaging a portion of each of the third and fourth compartment flaps to at least partially form the second compartment of the plurality of compartments of the tray; A tray wherein a second interior volume of the second compartment is defined between the third compartment flap, the fourth compartment flap, the third end flap and the fourth end flap, the second interior volume being different from the first interior volume.

12. 6. The tray of claim 5, wherein the distal portion of the first end flap is a first distal portion foldably connected to the base, the first end flap further comprising a second distal portion foldably connected to the base, the second distal portion of the first end flap engaging a portion of each of the third compartment flap and the fourth compartment flap to at least partially form a second compartment of the plurality of compartments of the tray; A tray in which a portion of the second end flap engages with a portion of each of the third compartment flap and the fourth compartment flap to at least partially form the second compartment of the plurality of compartments of the tray.

13. 1. A blank for forming a tray for holding a plurality of food items, the blank comprising: a plurality of panels including a central panel; a plurality of compartment flaps including a first compartment flap, a second compartment flap, a third compartment flap, and a fourth compartment flap, each of the plurality of compartment flaps foldably connected to the central panel; a plurality of end flaps foldably connected to each of the plurality of panels, the plurality of compartment flaps and the plurality of end flaps overlapping to form a plurality of compartments of the tray formed from the blank.

14. 14. The blank of claim 13, wherein the plurality of end flaps include a first end flap positioned to extend from the central panel and engage respective portions of the first and second compartment flaps to at least partially form a first compartment of the plurality of compartments of the tray from the blank.

15. 15. The blank of claim 14, wherein the central panel defines a flange for at least partially receiving a liner, and further wherein, in combination with the liner, the liner is disposed over a portion of the flange, at least one compartment flap of the plurality of compartment flaps, and at least one end flap of the plurality of end flaps.

16. 15. The blank of claim 14, wherein one of the first and second compartment flaps is foldably connected to the central panel at a fold line that intersects a notch adjacent the first and second compartment flaps, and the first end flap is foldably connected to a respective one of the plurality of panels at a second fold line, the second fold line being spaced from the notch.

17. 15. The blank of claim 14, wherein the first end flap comprises a base portion extending from the central panel and a distal portion foldably connected to the base portion, the distal portion being disposed at an angle relative to the base portion and the distal portion being disposed substantially parallel to the central panel.

18. 18. The blank of claim 17, wherein an attachment tab is foldably connected to one of the first and second compartment flaps and positioned to contact at least partially opposite a distal portion of the first end flap when the tray is formed from the blank, and the attachment tab is foldably connected to the distal portion of the first end flap and positioned to contact at least partially opposite the other of the first and second compartment flaps when the tray is formed from the blank.

19. 18. The blank of claim 17, wherein the plurality of end flaps further comprises a second end flap positioned to extend away from the central panel and engages with a portion of each of the first and second compartment flaps to at least partially form the first compartment when the tray is formed from the blank.

20. 20. The blank of claim 19, wherein the plurality of panels further comprises a first attachment panel foldably connected to the central panel and a second attachment panel foldably connected to the central panel, the first end flap being foldably connected to the first attachment panel and the second end flap being foldably connected to the second attachment panel, each of the first attachment panel and the second attachment panel being positioned to at least partially face and contact the central panel when the tray is formed from the blank.

21. 20. The blank of claim 19, wherein the plurality of end flaps further comprises a third end flap positioned to extend away from the central panel and engaging a portion of each of the third and fourth compartment flaps to form a second of the plurality of compartments of the tray formed from the blank; the third end flap includes a base portion and a distal portion foldably connected to the base portion of the third end flap; The blank further comprises a fourth end flap positioned to extend away from the central panel and engaging with a portion of each of the third and fourth compartment flaps to at least partially form the second compartment of the multiple compartments of the tray formed from the blank.

22. 20. The blank of claim 19, wherein the distal portion of the first end flap is a first distal portion foldably connected to the base, the first end flap further comprising a second distal portion foldably connected to the base, the second distal portion of the first end flap positioned to engage a portion of each of the third compartment flap and the fourth compartment flap to at least partially form a second of the plurality of compartments of the tray formed from the blank; A blank wherein a portion of the second end flap is positioned to engage with a portion of each of the third compartment flap and the fourth compartment flap, at least partially forming the second compartment of the plurality of compartments of the tray formed from the blank.

23. 1. A method of forming a tray for holding a plurality of food items, the method comprising: A method comprising obtaining a blank comprising a plurality of panels including a central panel, a plurality of compartment flaps including a first compartment flap, a second compartment flap, a third compartment flap and a fourth compartment flap, each of the plurality of compartment flaps being foldably connected to the central panel, and a plurality of end flaps being foldably connected to each of the plurality of panels, and overlapping the plurality of compartment flaps and the plurality of end flaps to form a plurality of compartments of the tray.

24. 24. The method of claim 23, wherein the plurality of end flaps comprises a first end flap, the method comprising positioning a first end flap extending from the central panel and engaging respective portions of the first and second compartment flaps to at least partially form a first compartment of the plurality of compartments of the tray.

25. 25. The method of claim 24, wherein the central panel defines a flange for at least partially receiving a liner.

26. 26. The method of claim 25, further comprising disposing a liner over a portion of the flange, at least one compartment flap of the plurality of compartment flaps, and at least one end flap of the plurality of end flaps.

27. 25. The method of claim 24, wherein one of the first compartment flap and the second compartment flap is foldably connected to the central panel at a fold line that intersects a notch adjacent the first compartment flap and the second compartment flap, and the first end flap is foldably connected to a respective panel of a plurality of panels at a second fold line, the second fold line being spaced from the notch.

28. 25. The method of claim 24, wherein the first end flap comprises a base portion extending from the central panel and a distal portion foldably connected to the base portion.

29. 30. The method of claim 28, further comprising: positioning the distal portion at an angle relative to the base portion and generally parallel to the central panel.

30. 30. The method of claim 29, wherein an attachment tab is foldably connected to one of the first compartment flap and the second compartment flap, the method comprising positioning the attachment tab in at least partial opposing contact with a distal portion of the first end flap; The attachment tab is foldably connected to the distal portion of the first end flap, the method comprising positioning the attachment tab at least partially opposite the other of the first compartment flap and the second compartment flap.

31. 30. The method of claim 29, wherein the plurality of end flaps further comprises a second end flap, the second end flap engaging a portion of each of the first compartment flap and the second compartment flap to extend away from the central panel to at least partially form the first compartment.

32. 32. The method of claim 31, wherein a first interior volume of the first compartment is defined between the first compartment flap, the second compartment flap, the first end flap, and a second end flap.

33. 33. The method of claim 32, wherein the plurality of panels further comprises a first attachment panel foldably connected to the central panel and a second attachment panel foldably connected to the central panel, the first end flap being foldably connected to the first attachment panel and the second end flap being foldably connected to the second attachment panel; positioning each of the first and second mounting panels in at least partial opposing contact with the central panel.

34. 34. The method of claim 33, wherein the plurality of end flaps further comprises a third end flap, the method comprising positioning the third end flap to extend away from the central panel and engage a portion of each of the third and fourth compartment flaps to form a second one of the plurality of compartments of the tray; the third end flap includes a base portion extending away from the central panel and a distal portion foldably connected to the base portion of the third end flap; the plurality of end flaps further comprising a fourth end flap extending away from the central panel and positioned to engage a portion of each of the third and fourth compartment flaps to at least partially form the second compartment of the plurality of compartments of the tray; A second interior volume of the second compartment is defined between the third compartment flap, the fourth compartment flap, the third end flap and the fourth end flap, and the second interior volume is different from the first interior volume.

35. 34. The method of claim 33, wherein the distal portion of the first end flap is a first distal portion foldably connected to the base, the first end flap further comprising a second distal portion foldably connected to the base, the method comprising positioning the second distal portion of the first end flap into engagement with a portion of each of the third compartment flap and the fourth compartment flap to at least partially form a second compartment of the plurality of compartments of the tray; and engaging a portion of the second end flap with a portion of each of the third compartment flap and the fourth compartment flap to at least partially form the second compartment of the plurality of compartments of the tray.

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