Food trays, related systems and methods

Abstract

A tray for holding one or more food items includes a plurality of panels including a central panel, at least one attachment panel in at least partial face-to-face contact with a portion of the central panel, at least one side panel foldably connected to a respective panel of the plurality of panels, at least one end panel foldably connected to a respective panel of the plurality of panels, and at least one bottom panel foldably connected to a respective panel of the plurality of panels, where the at least one side panel intersects with the at least one end panel to at least partially form a side wall of the tray extending around an interior of the tray, and the at least one bottom panel at least partially forms a bottom wall of the tray, and the tray includes a tray engagement structure for at least partially supporting another tray within the interior of the tray.

Description

[Technical field]

[0001] REFERENCE TO RELATED APPLICATIONS This application claims the benefit of each of U.S. Provisional Patent Application No. 63 / 319,872, filed March 15, 2022, and U.S. Provisional Patent Application No. 63 / 415,705, filed October 13, 2022.

[0002] Incorporation by reference U.S. Provisional Patent Application No. 63 / 319,872 filed March 15, 2022, U.S. Provisional Patent Application No. 63 / 415,705 filed September 13, 2022, U.S. Provisional Patent Application No. 63 / 159,015 filed March 10, 2021, U.S. Provisional Patent Application No. 17 / 690,204 filed March 9, 2022, U.S. Provisional Patent Application No. 16 / 532,819 filed August 6, 2019, U.S. Provisional Patent Application No. 62 / 851,932 filed May 23, 2019, U.S. Provisional Patent Application No. 62 / 796,716 filed January 25, 2019, U.S. Provisional Patent Application No. 62 / 715,520 filed August 7, 2018, U.S. Provisional Patent Application No. 17 / 2018 U.S. Patent Application No. 16 / 037,425, U.S. Provisional Patent Application No. 62 / 649,159, filed March 28, 2018, U.S. Provisional Patent Application No. 62 / 643,914, filed March 16, 2018, U.S. Patent Application No. 15 / 654,814, filed July 20, 2017, U.S. Provisional Patent Application No. 62 / 365,635, filed July 22, 2016, and U.S. Patent Application No. 12 / 992,131, filed February 11, 2011, and PCT Patent Application No. PCT / GB / 09 / 50506, filed May 13, 2009, are hereby incorporated by reference for all purposes as if set forth herein in their entireties.

[0003] Background of the disclosure FIELD OF THE DISCLOSURE The present disclosure relates to blanks, containers, trays, constructs, and various configurations and methods for forming containers from blanks. More specifically, the present disclosure is directed generally to a system of cooperating trays. Summary of the Invention

[0004] According to one aspect, the disclosure generally relates to a tray for holding one or more food products, the tray comprising a plurality of panels including a central panel, at least one mounting panel in at least partial face-to-face contact with a portion of the central panel, at least one side panel foldably connected to each of the plurality of panels, at least one end panel foldably connected to each of the plurality of panels, and at least one bottom panel foldably connected to each of the plurality of panels. The at least one side panel intersects with the at least one end panel to at least partially form a side wall of the tray extending around an interior of the tray. The at least one bottom panel at least partially forms a bottom wall of the tray. The tray comprises a tray engagement structure for at least partially supporting another tray within the interior of the tray.

[0005] According to another aspect, the disclosure generally relates to a blank for forming a tray for holding one or more food items, the blank comprising a plurality of panels including a central panel, at least one attachment panel adapted to be in at least partial face-to-face contact with a portion of the central panel when the tray is formed from the blank, at least one side panel foldably connected to each of the plurality of panels, at least one end panel foldably connected to each of the plurality of panels, and at least one bottom panel foldably connected to each of the plurality of panels. The at least one side panel intersects with the at least one end panel to at least partially form a side wall of the tray formed from the blank, the side wall extending around an interior of the tray formed from the blank. The at least one bottom panel at least partially forms a bottom wall of the tray formed from the blank. The blank comprises a tray-engaging structure for at least partially supporting another tray within the interior of the tray formed from the blank.

[0006] According to another aspect, the present disclosure generally relates to a method of forming a tray for holding one or more food items, the method including obtaining a blank having a plurality of panels, including a central panel, at least one mounting panel, at least one side panel foldably connected to a respective panel of the plurality of panels, at least one end panel foldably connected to a respective panel of the plurality of panels, and at least one bottom panel foldably connected to a respective panel of the plurality of panels, and a tray engagement feature; positioning the at least one side panel and the at least one end panel to at least partially form a sidewall extending at least partially around an interior of the tray and such that the tray engagement feature is positioned to at least partially support another tray within the interior of the tray, and positioning the at least one bottom panel to at least partially form a bottom wall of the tray.

[0007] According to another aspect, the disclosure generally relates to a system having a first tray including a plurality of panels including a central panel, at least one mounting panel in at least partial face-to-face contact with a portion of the central panel, at least one side panel foldably connected to a respective panel of the plurality of panels, at least one end panel foldably connected to a respective panel of the plurality of panels, and at least one bottom panel foldably connected to a respective panel of the plurality of panels, where the at least one side panel intersects with the at least one end panel to at least partially form a side wall of the tray extending around an interior of the tray, and the at least one bottom panel at least partially forms a bottom wall of the tray, and a tray engagement feature for at least partially supporting another tray within the tray, the system further including a second tray at least partially supported within the first tray by the tray engagement structure.

[0008] Those skilled in the art will appreciate the above advantages and other advantages and benefits of various additional embodiments upon reading the following detailed description of the embodiments with reference to the drawings listed below.

[0009] According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate embodiments of the present disclosure. [Brief description of the drawings]

[0010] [Figure 1] FIG. 2 is a plan view of a blank for forming a first tray of a system according to a first exemplary embodiment of the present disclosure. [Diagram 2] FIG. 1 is a schematic diagram of an apparatus for processing blanks and / or trays that can be used in an exemplary embodiment of the present disclosure. [Diagram 3] FIG. 2 is a plan view of a blank for forming a second tray of the system according to the first exemplary embodiment of the present disclosure. [Figure 4] FIG. 4 is an assembly diagram of a system of a first tray formed from the blank of FIG. 1 and a second tray formed from the blank of FIG. 3 according to a first exemplary embodiment of the present disclosure. [Diagram 5] FIG. 5 is a perspective view of the assembled system of FIG. [Figure 5A] FIG. 5 is a perspective view of the assembled system of FIG. 4, further comprising a lidding film and a liner applied thereto. [Figure 6] FIG. 13 is a plan view of a blank for forming a first tray of a system according to a second exemplary embodiment of the present disclosure. [Figure 7] FIG. 7 is an assembly view of a system of a first tray formed from the blank of FIG. 6 and a second tray formed from the blank of FIG. 3 according to a second exemplary embodiment of the present disclosure. [Figure 8] FIG. 8 is a perspective view of the assembled system of FIG. [Figure 9]FIG. 13 is a plan view of a blank for forming a first tray of a system according to a third exemplary embodiment of the present disclosure. [Figure 10] FIG. 13 is a plan view of a blank for forming a second tray of a system according to a third exemplary embodiment of the present disclosure. [Figure 11] 11 is an assembly view of a system of a first tray formed from the blank of FIG. 9 and a second tray formed from the blank of FIG. 10 according to a third exemplary embodiment of the present disclosure. [Figure 12] FIG. 12 is a perspective view of the assembled system of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Corresponding parts are designated by corresponding reference numbers throughout the drawings.

[0012] The present disclosure generally relates to various aspects of containers, structures, trays, materials, packages, elements, and articles, as well as methods of making such containers, structures, trays, materials, packages, elements, and articles. Although several different aspects, implementations, and embodiments are disclosed, numerous interrelationships, combinations, and modifications of the various aspects, embodiments, and embodiments are contemplated hereby. In one exemplary embodiment, the present disclosure relates to the formation of a container or tray for holding food or various other articles. However, in other embodiments, the container or tray can be used to form other non-food-containing articles, or can be used for heating or cooking.

[0013] 1 illustrates an exterior surface 101 of a first blank 103 for forming a first tray 105 (FIG. 2) or other container according to a first exemplary embodiment of the present disclosure. In one embodiment, the blank 103 comprises paperboard (e.g., solid bleached sulphate folding boxboard) or other suitable material that may be reusable 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, 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 can soften and fuse to the blank 103. In an alternative embodiment, the liner for attachment to the blank 103 may comprise PET or a similar material that is at least partially attached to the blank 103 by a heat seal layer (e.g., a thermoformable sealant grade transparent polyester packaging film such as Mylar® XMPOL 12 available from Teijin DuPont Films USA LLC, Hopewell, Virginia, or any suitable thermoformable sealant or adhesive, any suitable heat or pressure activated adhesive, or any other suitable material), with the PET liner being more suitable for uses requiring heating of the container in an oven.

[0015] Such a liner may be at least partially attached to the blank 103 so as to be positioned in contact with one or more food items held in the tray 105 (e.g., during heating). In one embodiment, after the food items are heated, the blank 103 and associated liner L may be separated and both the blank 103 and the liner may be recycled separately. Optionally, the blank 103 may be provided separately from the liner.

[0016] The blank 103 may be formed from a single layer of material, such as, but not limited to, paperboard, cardboard, paper, polymer sheets, and / or laminates including multiple layers, and the like. In one embodiment, the blank 103 may include a microwave interactive layer (not shown) such as is typical of MicroRite® containers available from Graphic Packaging International of Atlanta, Georgia. The microwave interactive layer may be referred to or have as one of its components a susceptor, foil, microwave shield, or any other term or component that generally refers to a layer of material suitable for shielding microwave energy and / or causing heating in a microwave oven.

[0017] 1, the blank 103 has a longitudinal direction L1 and a lateral direction L2. In the illustrated embodiment, the blank 103 and the tray 105 formed therefrom include a plurality of panels including a central panel 111, a first attachment panel 113 foldably connected to the central panel 111 at a lateral fold line 115, and a second attachment panel 117 foldably connected to the central panel 111 at a lateral fold line 119. In some embodiments, the attachment panels 113, 117 can be considered portions of the central panel 111.

[0018] As shown, a peripheral region of the central panel 111 can form a flange 120 of the blank 103 / tray 105. As shown, and as described further herein, the flange 120 can include a pair of opposing notches 122 (broadly a “first notch” and a “second notch”) along a portion of an inner edge 126 of the central panel 111. As shown, the inner edge 126 of the central panel 111 can at least partially define and / or surround an opening 137.

[0019] In one embodiment, the recesses 124 in the inner edge 126 of the central panel 111 can at least partially define respective notches 122 that can be spaced a distance DI from the lateral centerline CL of the blank 103. As described herein, one or both of the notches 122 and associated features can be second tray-engaging or compartment-forming features of the blank 103 / tray 105.

[0020] The flange 120 can at least partially define an outer edge 128 of the central panel 111. In some embodiments, the outer edge 128 can be at least partially defined by the fold lines 115, 119.

[0021] The blank 103 and the multiple panels of the tray 105 formed therefrom may also include a first end panel 121 (broadly, the “first panel”) foldably connected to the central panel 111 at a longitudinal fold line 125 (broadly, the “first fold line”) extending along the opening 137, and a second end panel 123 (broadly, the “first panel”) foldably connected to the central panel 111 at a longitudinal fold line 127 (broadly, each a “first fold line”) extending along the opening 137 to at least partially form the interior of the tray 105.

[0022] A first bottom panel 129 can be foldably connected to the first end panel 121 at a longitudinal fold line 131, and a second bottom panel 133 (broadly, the "fourth bottom panel") can be foldably connected to the second end panel 123 at a longitudinal fold line 134. The bottom panels 129, 133 can be separable at a longitudinal cut 135.

[0023] The blank 103 and the multiple panels of the tray 105 formed therefrom may also include a first side panel 141 (broadly, the “second panel”) that is foldably connected to the first mounting panel 113, e.g., via the first mounting panel 113, at a horizontal fold line 143 (broadly, the “second fold line”) that is spaced from the opening 137, and a second side panel 145 (broadly, the “second panel”) that is foldably connected to the second mounting panel 117, e.g., via the second mounting panel 117, at a horizontal fold line 147 (broadly, the “second fold line”) that is spaced from the opening 137.

[0024] Also as shown, a third bottom panel 151 (broadly referred to as the “second bottom panel”) is foldably connected to side panel 141 at horizontal fold line 153, and a fourth bottom panel 157 (broadly referred to as the “third bottom panel”) is foldably connected to second side panel 145 at horizontal fold line 159.

[0025] 4 and 5, according to one embodiment, the mounting panels 113, 117 can be folded at respective fold lines 115, 119 to make at least partial face-to-face contact with respective portions of the central panel 111. In such a configuration, the mounting panels 113, 117 can be placed under respective notches 122 along the flange 120 / central panel 111 such that the mounting panels 113, 117 are at least partially exposed along their respective notches 122 to provide a support surface along or beneath for another tray, as described further herein.

[0026] The bottom panels 129, 133, which are foldably connected to the respective end panels 121, 123, can be separated at the notches 135 and the end panels 121, 123 can be folded downwardly at the respective fold lines 125, 127, away from the central panel 111 / opening 137.

[0027] The side panels 141, 145 may be folded inwardly at respective fold lines 143, 147 to extend downwardly and away from the central panel 111 toward engagement with the downwardly extending end panels 121, 123. In this regard, an edge or surface of each of the side panels 141, 145 may intersect with an edge or surface of the respective end panels 121, 123 to form a sidewall 130 of the tray 105 that extends at least partially around the interior 107 of the tray 105.

[0028] Additionally, the bottom panels 151, 157 can be folded into a generally spaced-apart, parallel arrangement with the central panel 111 at respective fold lines 153, 159, with respective edges or surfaces of the bottom panels 151, 157 intersecting edges or surfaces of the respective end panels 121, 123. In such a configuration, the bottom panels 129, 133 can be folded into at least partial face-to-face contact with the bottom panels 151, 157 at respective fold lines 131, 134 to form a bottom wall 158 of the tray 105 and an interior / first compartment / interior 107 of the tray 105.

[0029] The aforementioned arrangement of the tray 105 may be maintained by attaching the mounting panels 113, 117 to respective portions of the central panel 111 and / or the bottom panels 129, 133 to their respective panels, which may be maintained at least in part with an adhesive such as glue.

[0030] Additionally, the overlapping arrangement of the end panels 121, 123 and side panels 141, 143 provides the tray 105 with a strong structure that resists deformation, bending, crushing, etc. In this regard, one or more of the end panels 121, 123 and side panels 141, 145 may be considered reinforcing structures for the tray 105.

[0031] It will be appreciated that in an embodiment, a liner such as liner L can be applied to at least the interior 107 of tray 105, for example, covering the seams / points of intersection between the respective panels, such that tray 105 has leak-resistant properties. Tray 105 is shown in FIG. 5A with liner L applied to one or more of its interior surfaces.

[0032] In one embodiment, the tray 105 can be formed similar to the configuration of containers as shown and described in the applications incorporated by reference (eg, the '425 application, the '814 application, and / or the '131 application).

[0033] In an exemplary embodiment shown diagrammatically in FIG. 2, the blank 103 / tray 105 or its folded configuration can be placed on a lower die 215 of the system 217, and a liner material or film sheet 219 (e.g., 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 may have a coating of any suitable material or the coating may be omitted. As shown diagrammatically in FIG. 2, the upper die 223 can include a number of holes or ducts 227 in the heater plate surface 225 for applying vacuum and / or air pressure to the sheet 219. The upper die 223 and / or lower die 215, including the ducts 227 and / or heater plate 225, can be of other shapes, positions, arrangements and / or configurations without departing from this disclosure. For example, the heater plate 225 can be omitted and heat can instead be applied to the sheet 219 (eg, using a stream of hot air).

[0034] 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 while supporting the blank 103 / tray 105 with the central panel 111 and / or the mounting panels 113, 117 (e.g., with the central panel 111 facing upwards). An initial vacuum can be applied to the duct 227 to draw the film sheet 19 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 below the film sheet 219 can be used with similar or equivalent effect. The film sheet 219 can then be pushed downwards (e.g., by air pressure applied by the duct 227 and / or by vacuum applied from below the blank 103 / tray 105).

[0035] The air pressure can move the film sheet 219 towards the blank 103 / folded blank 103 and the lower die 215 can support the blank 103 / tray 105 as the film sheet 219 is applied to the flange 120, end panels 121, 123, and one or more portions of the side panels 141, 143 to form the liner L. In one embodiment, the liner L can help hold the tray 105 in its tray shape after the liner L is applied to the blank 103 / folded blank 103 / tray 105. In one embodiment, the tray 105 can be ejected from the lower die 215 and transported away from the forming tool, for example, on a conveyor.

[0036] In one embodiment, the tray 105 can be formed from the blank 103 and have the liner L applied at a much higher speed than a system that separately forms the tray 105 from the blank 103 and then places the formed tray 105 into the lower die 215. In one example, the tray 105 of this embodiment can be formed from the blank 103 with the liner L at a rate of about 200 trays / min. The tray 105 can be formed in other manners without departing from this disclosure. For example, the tray 105 can be formed from the blank 103 prior to application of the liner L (e.g., prior to engaging the lower die 215).

[0037] 3, there is shown an exterior surface 301 of a blank for forming a second tray 305 (FIG. 4, broadly "container") according to a first exemplary embodiment of the present disclosure. The blank 303 and tray 305 may have one or more features substantially 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.

[0038] As shown, the blank 303 has a longitudinal axis L1 and a lateral axis L2, but is relatively more compact along the longitudinal direction than the previously described blank 103. As also shown, the panels 121, 123 and bottom panels 129, 133 of the blank 303 are laterally shorter than those previously described with respect to the blank 103, such that the bottom panels 129, 133 are spaced apart from one another along the lateral axis L2 with a generally bowtie-shaped opening 337 positioned therebetween.

[0039] Additionally, the laterally outer portions of the central panel 111 of the blank 303 form respective lateral ledges 321, 323 having free edges spaced a distance D1 from the longitudinal centerline CL2 of the blank 303. As described further herein, the lateral ledges 321, 323 project laterally beyond the portions formed by the panels 141, 145 of the tray 305 formed from the blank 303 for supporting the tray 305 on a portion of the tray 105 described above or another tray or structure.

[0040] The tray 305 may be formed from the blank 303 in a manner similar to how the tray 105, as described above, is formed from the blank 103. For example, the attachment panels 113, 117 may be folded at respective fold lines 115, 119 into at least partial face-to-face contact with respective portions of the central panel 111, the end panels 121, 123 may be folded downwardly away from the central panel 111 at respective fold lines 125, 127, and the side panels 141, 145 may be folded inwardly at respective fold lines 143, 147 to extend downwardly away from the central panel 111 toward engagement with the downwardly depending end panels 121, 123.

[0041] Additionally, the bottom panels 151, 157 can be folded at respective fold lines 153, 159 into a generally spaced parallel arrangement with the central panel 111, with respective edges or surfaces of the bottom panels 151, 157 intersecting edges or surfaces of the respective bottom panels 129, 133. In such a configuration, the bottom panels 129, 133 can be folded at respective fold lines 131, 134 into at least partial face-to-face contact with the bottom panels 151, 157 to form the second interior section / interior 307 of the tray 305. The aforementioned arrangement of the tray 105 can be maintained by attaching the mounting panels 113, 117 to respective portions of the central panel 111 and / or the bottom panels 129, 133 to the respective panels and flaps, which can be maintained at least in part with an adhesive such as glue.

[0042] It will be appreciated that a liner, such as liner L (FIG. 1), may be applied to at least the interior 307 of each tray 305, for example, covering the seams / points of intersection between each side panel and panel, such that the tray 305 may have leak-resistant characteristics. Liner L may be applied to one or more portions of the tray 305 in a manner similar to that described above with respect to the blank 103 / tray 105, for example, via system 217 shown in FIG.

[0043] 4 and 5, engagement of tray 105 with tray 305 is shown according to one exemplary embodiment of the present disclosure. As shown, tray 305 can be oriented such that ledges 321, 323 are aligned above respective notches 122 along flange 120 of tray 105 above tray 105.

[0044] The tray 305 may then be lowered into the interior 107 of the tray 105 with the ledges 321, 323 of the tray 305 bearing against respective portions of the mounting panels 113, 117 of the tray 105 and abutting edges of the central panel 111 that define the respective notches 122. In one embodiment, the edges of the central panel 111 that define the respective notches 122 may engage the ledges 321, 323 of the tray 305, e.g., via at least partial edge-to-edge contact, to positionally stabilize the tray 305 relative to the tray 105.

[0045] Further, due to the generally recessed arrangement of tray 305 along flange 120 of tray 105, for example, with ledges 321, 323 of tray 305 recessed into respective notches 122 such that ledges 321, 323 are generally flush with flange 120, flange 120 of tray 105 and ledges 321, 323 of tray 305 can generally provide an uninterrupted, smooth and flat surface along which a lid film can be applied to cover interior 107 of tray 105 as well as interior 307 of tray 305.

[0046] In one embodiment, the tray 305 can be sized and dimensioned to have a bottom that is supported above, e.g., spaced apart from, the bottom of the tray 105. In other embodiments, the bottom of the tray 305 can contact the bottom wall 158 of the tray 105.

[0047] The aforementioned arrangement of trays 105, 305 can provide multiple compartments, e.g., their respective interiors 107, 307, that allow for separation of food items, e.g., that can be served to one or more persons, that can prevent mixing of food items, that can serve main dishes and side dishes, that can utilize one or more compartments 107, 307 to hold condiments, etc. In one embodiment, the interior 107 of the tray 105 can define a first interior volume V1 that is larger than a second interior volume V2 defined by the interior 307 of the tray 305. The trays 105, 305 can be provided together as a system 110. In other embodiments, the trays 105, 305 can be considered to be provided in an at least partially nested arrangement.

[0048] 5A, in one embodiment, a lid / lidding structure such as a lidding film T may comprise a packaging film, which is a thin plastic layer used to preserve and protect food contained within the tray 105, 305, and may be removably attached, for example, to a flange 120 of each of the trays 105, 305 defined by a portion of the respective center panel 111. In the above-described system 110, such a lidding film T may cover the flange 120 of the tray 105 along with the ledges 321, 323 of the tray 305 that overlap respective portions of the flange 120 of the tray 105, and may cover the interior 107 of the tray 105 along with the interior 307 of the tray 305. In some embodiments, an airtight seal of the interior 107 of the tray 105 and / or the interior 307 of the tray 305 may be achieved by such engagement by the lidding film T.

[0049] Any plastic film, such as polyethylene, polypropylene, polyethylene terephthalate, polyvinyl chloride, polyamide, and ethylene vinyl alcohol, or other suitable material, can be used to form the lidding film that is sealed against the sealing surface of the flange / center panel 111. Additionally, an adhesive can be used between the lidding film and the sealing surface of the flange / center panel without departing from this disclosure. In one embodiment, the sealing surface of the flange includes the top surface of the center panel 111, which is generally free of seams, creases, folds, creases, edges, and other structures that may make it more difficult to seal the lidding film to the flange (e.g., structures that may reduce the smoothness of the flange). Thus, the top surface of the center panel 111 in the tray 105, 305 of the illustrated embodiment can provide a better sealing surface than a container that has structures such as pleats or seams on its upper flange surface.

[0050] 6, an exterior surface 401 of a blank for forming a tray according to a second exemplary embodiment of the present disclosure is generally indicated at 403. The blank 403 and the tray formed therefrom may have one or more features substantially similar to the features described above with respect to the blank 103 and the tray 105, with like or similar features being indicated with like or similar reference numerals.

[0051] As shown, the blank 403 has a longitudinal axis L1 and a lateral axis L2, a central panel 111, mounting panels 113, 117, end panels 121, 123, side panels 141, 145, and bottom panels 129, 133, 151, 157.

[0052] However, as illustrated, notches 122 formed along the flange 120 / center panel 111 of the blank 403 / tray formed therefrom are laterally offset from their respective locations described above with respect to the blank 103 / tray 105. In this regard, the tray 405 formed from the blank 403 may be configured to support the ledges 321, 323 of the tray 305 along the flange 120 of the tray formed from the blank 403 at locations that are laterally offset from the locations described and illustrated above with respect to the tray 105.

[0053] It will be appreciated that a liner, such as liner L (FIG. 1), can be applied to at least the interior 407 of the tray 405 formed from the blank 403, for example, covering the seams / points of intersection between the respective side panels and panels, such that the tray 405 formed from the blank 403 has leak-resistant characteristics. Liner L can be applied to one or more portions of the tray 405 formed from the blank 403 in a manner similar to that described above with respect to the blank 103 / tray 105, for example, via system 217 shown in FIG.

[0054] 7 and 8, tray 405 and tray 305 may be formed and assembled into system 410 in a manner similar to that described above with respect to system 110 formed from tray 105 and tray 305. However, as shown, ledges 321, 323 of tray 305 may be at least partially received within respective notches 122 of tray 405 at positions offset from their positions in tray 105.

[0055] 9, there is shown an exterior surface 501 of a blank 503 for forming a first tray 505 (FIG. 11) according to a third exemplary embodiment. The blank 503 and the tray 505 formed therefrom may include one or more features that are the same or similar to those described above with respect to the blanks 103, 403 and trays 105, 405, and the like or similar features are indicated with like or similar reference numbers.

[0056] As shown, the blank 503 can have a longitudinal axis L1 and a lateral axis L2. The blank 503 and the tray 505 formed therefrom can include a central panel 111, a first mounting panel 113, a second mounting panel 117, a first end panel 121, a second end panel 123, a first side panel 141, a second side panel 145, bottom panels 129, 133, 151, 157, and associated features.

[0057] Additionally, the panels of the blank 503 and tray 505 may lack the respective notches 122 and recessed edges 124 therethrough. Instead, the blank 503 and tray 505 may further comprise first and second side reinforcement panels 537, 539 foldably connected to the central panel 111 at respective lateral fold lines 538, 540. In this regard, the inner edges 126 of the central panel 111 of the blank 503 and the tray 505 formed therefrom may be at least partially defined by the fold lines 125, 127, 538, 540.

[0058] The blank 503 and tray 505 formed therefrom may also include respective notches 561, 563 (broadly referred to as a "first notch" and a "second notch") defined in respective side reinforcement panels 537, 539. As shown, the notch 561 may have a generally trapezoidal configuration including an upper edge 565, a lower edge 567, and side edges 569, 571 that extend diagonally downward from an end of the upper edge 565 to respective ends of the lower edge 567. The upper edge 565 may be positioned to interrupt the fold line 538 as shown.

[0059] Similarly, notch 563 can also have a generally trapezoidal configuration including an upper edge 573, a lower edge 575, and side edges 577, 579 that extend diagonally downward from an end of upper edge 573 to respective ends of lower edge 575. Upper edge 573 can be positioned to interrupt fold line 540 as shown. It will be understood that one or both of notches 561, 563 can have different configurations without departing from this disclosure.

[0060] As described herein, one or both of the notches 561, 563 and associated edges may be second tray-engaging or compartment-forming features of the blank 503 / tray 505.

[0061] Additionally, the blank 503 and the tray 505 formed therefrom can include a pair of corner flaps 581, 583 foldably connected to opposing free edges of the side panel 141 at respective diagonal fold lines 585, 587, and a pair of corner flaps 589, 591 foldably connected to opposing free edges of the side panel 145 at respective diagonal fold lines 593, 595.

[0062] Referring to FIG. 10, there is shown an exterior surface 601 of a blank 603 for forming a second tray 605 according to a second exemplary embodiment of the present disclosure.

[0063] As shown, the blank 603 can have a longitudinal axis L1 and a lateral axis L2. In the illustrated embodiment, the blank 603 and the tray 605 formed therefrom can include a central or bottom panel 621, a first side panel 623 foldably connected to the bottom panel 621 at a lateral fold line 625, a second side panel 627 foldably connected to the bottom panel 621 at a lateral fold line 629, a first end panel 631 foldably connected to the bottom panel 621 at a longitudinal fold line 633, and a second end panel 635 foldably connected to the bottom panel 621 at a longitudinal fold line 637.

[0064] The blank 603 and the tray 605 formed therefrom can have different configurations without departing from this disclosure.

[0065] With further reference to Figures 11 and 12, the tray 505 can be formed from the blank 503 in a manner generally similar to that described above with respect to the formation of the tray 105 from the blank 103 and the tray 405 from the blank 403, such that the end panels 121, 123 and the side panels 141, 145 at least partially form the side walls of the tray 505 extending around its interior 507, and the bottom panels 129, 133, 151, 157 at least partially form the bottom wall 158 of the tray 505.

[0066] In the illustrated embodiment, the side reinforcement panels 537, 539 are folded downward at respective fold lines 538, 540 toward the interior 507 of the tray 505 and positioned such that the side reinforcement panels 537, 539 are in at least partial face-to-face contact with their respective side panels 141, providing a two-layer structure therealong that can reinforce the tray 505 and provide the tray 505 with a robust structure that resists deformation, bending, crushing, and the like.

[0067] In addition, corner flaps 581, 589 may be folded at their respective diagonal fold lines 585, 593 into at least partial face-to-face contact with their respective portions of end panel 121, and corner flaps 583, 591 may be folded at their respective fold lines 587, 595 into at least partial face-to-face contact with their respective portions of end panel 123.

[0068] It will be appreciated that in an embodiment, a liner such as liner L (FIG. 1) can be applied to at least the interior 507 of the tray 505, for example, covering each of the side panels, the reinforcing panels, and the seams / points of intersection between the panels, such that the tray 505 has leak-resistant characteristics.

[0069] A second tray 605 (broadly a "container") can be formed from the blank 603 by folding the panels 623, 627, 631, 635 relative to the bottom panel 621 at respective fold lines 625, 629, 633, 637 so that the panels 623, 627, 631, 635 extend generally diagonally upwardly from the bottom panel 621 and so that the panels 621, 623, 627, 631, 635 extend at least partially around the perimeter of the interior / second compartment / interior 607 of the tray 605. In some embodiments, each adjacent panel 623, 627, 631, 635 can be attached to one another with an adhesive, such as glue, for example, via one or more direct applications of adhesive or via application of adhesive to attachment flaps associated with the respective panels.

[0070] The tray 505 is formed such that a portion of each side panel 141, 145 is exposed along each notch 561, 563 and each edge associated with each notch 561, 563 projects from each side panel 141, 145 into the interior 507 of the tray 505. In this regard, each lower edge 567, 575 of each notch 561, 563 may be arranged as a shelf-like feature to support one or more portions of the tray 505.

[0071] Thus, for example, tray 505 and tray 605 can be assembled such that the edge of tray 605 between bottom panel 621 and end panel 631 adjacent fold line 633 can be supported on lower edge 567 of notch 561, and the edge of tray 605 between bottom panel 621 and end panel 635 adjacent fold line 637 can be supported on lower edge 575 of notch 563, or vice versa.

[0072] In such a configuration, the end panels 631, 635 of the tray 605 may be at least partially circumscribed by the edges of their respective cutouts 561, 563 (or vice versa) so that the end panels 631, 635 of the tray 605 may be at least partially recessed within the walls of the tray 505, e.g., the end panels 631, 635 may be positioned approximately flush with their respective reinforcing panels 537, 539 and at least partially in face-to-face contact with their respective side panels 141, 145.

[0073] The above-described arrangement of trays 505, 605 can provide multiple compartments, e.g., their respective interiors 507, 607, that allow for separation of food products having the advantages described above with respect to tray 105 and trays 305, 405. In one embodiment, the interior 507 of tray 505 can define a first interior volume V3 that is larger than a second interior volume V4 defined by the interior 607 of tray 605. The trays 605, 605 can be provided together as a system 510. In other embodiments, the trays 505, 605 can be considered to be provided in an at least partially nested arrangement.

[0074] In one embodiment, a lid / lidding structure, such as the lidding film T described above, can be removably attached to a flange 520 of the tray 505, for example, defined by a portion of the respective central panel 111. Due to the generally recessed arrangement of the tray 605 in the interior 507 of the tray 505, the flange 520 of the tray 505 is generally uninterrupted to provide a smooth, flat surface along which the lidding film can be applied to cover the interior 507 of the tray 505 as well as the interior 607 of the tray 605. In some embodiments, a hermetic sealing of the interior 507 of the tray 507 and / or the interior 607 of the tray 605 can be achieved by such engagement by the lidding film T.

[0075] Any plastic film, such as polyethylene, polypropylene, polyethylene terephthalate, polyvinyl chloride, polyamide, and ethylene vinyl alcohol, or other suitable material, can be used to form the lidding film that is sealed to the sealing surface of the flange 520 / center panel 111. Additionally, an adhesive can be used between the lidding film and the sealing surface of the flange / center panel without departing from this disclosure. In one embodiment, the sealing surface of the flange 520 includes the upper surface of the center panel 111, which is generally free of seams, creases, folds, creases, edges, and other features that may make it more difficult to seal the lidding film to the flange (e.g., that may reduce the smoothness of the flange). Thus, the upper surface of the center panel 111 in the tray 105, 305, 505 of the illustrated embodiment can provide a better sealing surface than the sealing surface of a container that has features such as pleats or seams on its upper flange surface.

[0076] 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.

[0077] Optionally, one or more portions of the blank, or other constructs described or contemplated herein, can be coated with varnish, clay, or other materials, alone or in combination. The coatings may then be printed with product advertising or other information or images. Blanks or other structures may also 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 may be coated and / or printed.

[0078] Any of the blanks, trays, or other structures of the present disclosure may optionally include one or more features that modify 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 sometimes referred to as "microwave interactive elements") that facilitate heating, browning, and / or crisping of a particular area of ​​a food product, shield a particular area of ​​a food product from microwave energy and prevent overcooking thereof, or transmit microwave energy toward or away from a particular area of ​​a food product. Each microwave interactive element comprises one or more microwave energy interactive materials or segments arranged in a particular configuration to absorb microwave energy, transmit microwave energy, reflect microwave energy, or direct microwave energy as needed or desired for the particular composition and food product.

[0079] In the case of a susceptor or shield, the microwave energy interactive material may include a conductive or semiconductive material, such as a vacuum deposited metal or metal alloy, or a metallic ink, an organic ink, an inorganic ink, a metallic paste, an organic paste, an inorganic paste, or any combination thereof. Examples of metals and metal alloys that may be suitable include, but are not limited to, aluminum, chromium, copper, Inconel alloy (nickel-chromium-molybdenum alloy with niobium), iron, magnesium, nickel, stainless steel, tin, titanium, tungsten, and any combination or alloy thereof.

[0080] Alternatively, the microwave energy interactive material may include a metal oxide, such as an oxide of aluminum, an oxide of iron, and an oxide of 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.

[0081] Further alternatively, the microwave energy interactive material may comprise a suitable conductive, semiconductive, or nonconductive artificial dielectric or ferroelectric. The artificial dielectric may comprise a conductive fractionated material in a polymer or other suitable matrix or binder, and may include flakes of a conductive metal, for example aluminum.

[0082] In other embodiments, the microwave energy interactive material may be carbon-based, for example, as disclosed in US Pat. No. 4,943,456, US Pat. No. 5,002,826, US Pat. No. 5,118,747, and US Pat. No. 5,410,135.

[0083] In yet another embodiment, the microwave energy interactive material may interact with the magnetic portion of the electromagnetic energy in a microwave oven. Properly selected materials of this type 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 described in U.S. Patent 4,283,427.

[0084] 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 thereon. Such elements are typically formed from a conductive, reflective metal or metal alloy, such as aluminum, copper, or stainless steel, in the form of a solid "patch" generally having a thickness of about 0.000285 inches to about 0.005 inches, e.g., about 0.0003 inches to about 0.003 inches. Other such elements may have a thickness of about 0.00035 inches to about 0.002 inches, e.g., 0.0016 inches.

[0085] In some cases, microwave energy reflecting elements may be used as shielding elements when the food product tends to burn or dry out during heating. In other cases, smaller microwave energy reflecting elements may be used to diffuse or reduce the intensity of the microwave energy. One example of a material utilizing such microwave energy reflecting elements is commercially available under the trade name MicroRite® 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 distribution 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 distribution elements are described in U.S. Pat. No. 6,204,492, U.S. Pat. No. 6,433,322, U.S. Pat. No. 6,552,315, and U.S. Pat. No. 6,677,563, each of which is incorporated by reference in its entirety.

[0086] 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 including one or more breaks or openings that are transparent to microwave energy. 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 construct being formed, the food product to be heated therein or thereon, the degree of heating, browning, and / or crisping desired, whether direct exposure to microwave energy is required or desired to achieve uniform heating of the food product, the need to regulate temperature changes in the food product through direct heating, and the need to regulate the presence and degree of ventilation required.

[0087] 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, when 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 for heating, browning, and / or crisping the surface of the food item. Thus, the relative amounts of microwave energy interactive and microwave energy transparent regions may be balanced to achieve the desired overall heating characteristics of a particular food item.

[0088] As another example, one or more portions of the susceptor can be designed to be inactive to microwave energy to ensure that the microwave energy is efficiently focused on the areas to be heated, browned, and / or crisped, rather than being lost to portions of the food item not intended to be browned and / or crisped, or to the heating environment. Additionally or alternatively, it may be beneficial to form one or more discontinuities or inactive areas to prevent overheating or charring of the food item and / or the construct including the susceptor.

[0089] 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 low and the susceptor tends to overheat. The size and shape of the fuse may be varied as needed. Examples of susceptors including such fuses are provided, for example, in U.S. Pat. No. 5,412,187, U.S. Pat. No. 5,530,231, U.S. Patent Application Publication US2008 / 0035634A1 published Feb. 14, 2008, and PCT Application Publication WO2007 / 127371 published Nov. 8, 2007, each of which is incorporated herein by reference in its entirety.

[0090] All dimensional information presented herein is intended to be illustrative of certain aspects, features, etc. of various embodiments of the present disclosure, and is not intended to limit the scope of the present disclosure. The dimensions of the blanks, containers, forming tools, and features, or any other dimensions, may be larger or smaller than those shown and described in this disclosure without departing from the scope of the present disclosure, and may be within the range of dimensions recited for each feature, or may be outside the range of dimensions recited for each feature without departing from the scope of the present disclosure.

[0091] Blanks according to the invention can be formed, for example, from coated paperboard and similar materials. For example, the interior and / or exterior surfaces of the blank can be coated with a clay coating. The clay coating can then be printed with product, advertising, price coding, and other information or images. The blank can then be coated with a varnish to protect any information printed on the blank. The blank can also be coated, for example, with a moisture barrier layer on one or both sides of the blank.

[0092] According to an exemplary embodiment, the blanks may be constructed of caliper paperboard so that they are heavier and more rigid than regular paper. The blanks may also be constructed from other materials, such as cardboard, hard paper, or any other material having suitable properties to enable the carton package to function at least generally as described above.

[0093] The foregoing description illustrates and describes various embodiments of the present disclosure. It is intended that all matters contained in the above description or shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense, since various changes can be made to the above configurations without departing from the scope of the present disclosure. Furthermore, the scope of the present disclosure encompasses various modifications, combinations, and alterations of the above-described embodiments. In addition, the present disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are contemplated and within the scope of the inventive concept expressed herein that are commensurate with the above teachings and / or are within the skill or knowledge of the relevant art. Furthermore, the specific features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments without departing from the scope of the present disclosure.

Claims

1. 1. A tray for holding one or more food items, comprising: a plurality of panels including a central panel, at least one mounting panel in at least partial face-to-face contact with a portion of the central panel, at least one side panel foldably connected to a respective panel of the plurality of panels, at least one end panel foldably connected to a respective panel of the plurality of panels, and at least one bottom panel foldably connected to a respective panel of the plurality of panels, wherein the at least one side panel intersects with the at least one end panel to at least partially form a side wall of the tray extending around an interior of the tray, and the at least one bottom panel at least partially forms a bottom wall of the tray; and a tray engagement structure for at least partially supporting another tray within the tray.

2. The tray of claim 1 , wherein the tray engagement structure includes at least one notch defined along the central panel.

3. The tray of claim 2 , wherein the at least one notch is defined at least partially along an inner edge of the central panel.

4. The tray of claim 2 , wherein the at least one mounting panel is exposed along the at least one notch for at least partially supporting another tray.

5. 5. The tray of claim 4, wherein the at least one notch is a first notch and the tray engagement structure further comprises a second notch defined at least partially along an inner edge of the central panel opposite the first notch.

6. 5. The tray of claim 4, wherein the central panel extends at least partially around an opening, the at least one end panel is foldably connected to the central panel at a first fold line extending along the opening, the at least one mounting panel is foldably connected to the central panel, and the at least one side panel is foldably connected to the at least one mounting panel at the second fold line with a second fold line spaced away from the opening.

7. 5. The tray of claim 4, wherein the at least one mounting panel is foldably connected to the central panel, the at least one side panel is foldably connected to the at least one mounting panel, the at least one bottom panel is a first bottom panel foldably connected to the at least one end panel, and the plurality of panels further comprises a second bottom panel foldably connected to the at least one side panel, the first bottom panel and the second bottom panel being in at least partial face-to-face contact to at least partially form a bottom wall of the tray.

8. 8. The tray of claim 7, wherein the at least one mounting panel is a first mounting panel, the plurality of panels further includes a second mounting panel in at least partial face-to-face contact with the central panel, the at least one side panel is a first side panel foldably connected to the first mounting panel, the plurality of panels further includes a second side panel foldably connected to the second mounting panel, the at least one end panel is a first end panel foldably connected to the central panel, the plurality of panels comprises a second end panel foldably connected to the central panel, a third bottom panel foldably connected to the second side panel, and a fourth bottom panel foldably connected to the second end panel, wherein the first side panel, the second side panel, the first end panel, and the second end panel at least partially form side walls of the tray, and the first bottom panel, the second bottom panel, the third bottom panel, and the fourth bottom panel at least partially form a bottom wall of the tray.

9. 2. The tray of claim 1, wherein the plurality of panels further includes at least one side reinforcement panel foldably connected to the central panel, and the tray engagement structure includes at least one cutout in the at least one side reinforcement panel.

10. 10. The tray of claim 9, wherein the at least one cutout includes a top edge, a bottom edge, and a pair of side edges extending diagonally from the top edge to the bottom edge.

11. 10. The tray of claim 9, wherein the at least one side reinforcement panel is in at least partial face-to-face contact with the at least one side panel such that a portion of the at least one side panel is exposed along at least one cutout to at least partially support another tray.

12. 12. The tray of claim 11, wherein the at least one side reinforcement panel is a first side reinforcement panel, the plurality of panels further comprising a second side reinforcement panel foldably connected to the central panel, the at least one cutout is a first cutout, and the tray engagement structure further comprises a second cutout in the second side reinforcement panel.

13. 10. The tray of claim 9, wherein the central panel extends at least partially around an opening, the at least one end panel is foldably connected to the central panel at a first fold line extending along the opening, the at least one mounting panel is foldably connected to the central panel, and the at least one side panel is foldably connected to the at least one mounting panel at the second fold line with a second fold line away from the opening.

14. 14. The tray of claim 13, further comprising a liner at least partially covering an interior of the tray.

15. 10. The tray of claim 9, wherein the at least one mounting panel is foldably connected to the central panel, the at least one side panel is foldably connected to the at least one mounting panel, the at least one bottom panel is a first bottom panel foldably connected to the at least one end panel, and the plurality of panels further comprises a second bottom panel foldably connected to the at least one side panel, the first bottom panel and the second bottom panel being in at least partial face-to-face contact to at least partially form a bottom wall of the tray.

16. 16. The tray of claim 15, wherein the at least one mounting panel is a first mounting panel, the plurality of panels further includes a second mounting panel in at least partial face-to-face contact with the central panel, the at least one side panel is a first side panel foldably connected to the first mounting panel, the plurality of panels further includes a second side panel foldably connected to the second mounting panel, the at least one end panel is a first end panel foldably connected to the central panel, the plurality of panels further includes a second end panel foldably connected to the central panel, a third bottom panel foldably connected to the second side panel, and a fourth bottom panel foldably connected to the second end panel, wherein the first side panel, the second side panel, the first end panel, and the second end panel at least partially form side walls of the tray, and the first bottom panel, the second bottom panel, the third bottom panel, and the fourth bottom panel at least partially form a bottom wall of the tray.

17. 1. A blank for forming a tray for holding one or more food items, comprising: a plurality of panels including a central panel, at least one attachment panel adapted to be in at least partial face-to-face contact with a portion of the central panel when the tray is formed from the blank, at least one side panel foldably connected to a respective panel of the plurality of panels, at least one end panel foldably connected to a respective panel of the plurality of panels, and at least one bottom panel foldably connected to a respective panel of the plurality of panels, wherein the at least one side panel intersects with the at least one end panel to at least partially form a side wall of the tray extending around an interior of the tray formed from the blank, and the at least one bottom panel is adapted to at least partially form a bottom wall of the tray formed from the blank; and a tray engagement structure for at least partially supporting another tray within the tray formed from the blank.

18. The blank of claim 17 , wherein the tray-engagement structure includes at least one notch defined along the central panel.

19. 20. The blank of claim 18, wherein the at least one notch is defined at least partially along an inner edge of the central panel.

20. 20. The blank of claim 18, wherein the at least one mounting panel is adapted to be exposed along the at least one notch for at least partially supporting another tray when the tray is formed from the blank.

21. 21. The blank of claim 20, wherein the at least one notch is a first notch, and the tray engagement structure further comprises a second notch defined at least partially along an inner edge of the central panel opposite the first notch.

22. 21. The blank of claim 20, wherein the central panel extends at least partially around an opening, the at least one end panel is foldably connected to the central panel at a first fold line extending along the opening, the at least one attachment panel is foldably connected to the central panel, and the at least one side panel is foldably connected to the at least one attachment panel at the second fold line such that a second fold line is spaced away from the opening.

23. 21. The blank of claim 20, wherein the at least one mounting panel is foldably connected to the central panel, the at least one side panel is foldably connected to the at least one mounting panel, the at least one bottom panel is a first bottom panel foldably connected to the at least one end panel, and the plurality of panels further comprises a second bottom panel foldably connected to the at least one side panel, the first bottom panel and the second bottom panel being adapted to at least partially come into face-to-face contact to at least partially form a bottom wall of the tray formed from the blank.

24. the at least one mounting panel is a first mounting panel, the plurality of panels further includes a second mounting panel, the at least one side panel is a first side panel foldably connected to the first mounting panel, the plurality of panels further includes a second side panel foldably connected to the second mounting panel, the at least one end panel is a first end panel foldably connected to the central panel, the plurality of panels further includes a second end panel foldably connected to the central panel, a third bottom panel foldably connected to the second side panel, and a fourth bottom panel foldably connected to the second end panel; 24. The blank of claim 23, wherein the first side panel, the second side panel, the first end panel, and the second end panel are for at least partially forming side walls of the tray formed from the blank, and the first bottom panel, the second bottom panel, the third bottom panel, and the fourth bottom panel are for at least partially forming a bottom wall of the tray formed from the blank.

25. 20. The blank of claim 17, wherein the plurality of panels further includes at least one side reinforcement panel foldably connected to the central panel, and the tray engagement structure includes at least one cutout in the at least one side reinforcement panel.

26. 26. The blank of claim 25, wherein the at least one cutout includes a top edge, a bottom edge, and a pair of side edges extending diagonally from the top edge to the bottom edge.

27. 26. The blank of claim 25, wherein the at least one side reinforcement panel is for at least partial face-to-face contact with the at least one side panel when the tray is formed from the blank, such that a portion of the at least one side panel is exposed along the at least one cutout for at least partially supporting another tray.

28. 28. The blank of claim 27, wherein the at least one side reinforcement panel is a first side reinforcement panel, the plurality of panels further comprising a second side reinforcement panel foldably connected to the central panel, the at least one cutout is a first cutout, and the tray engagement structure further comprises a second cutout in the second side reinforcement panel.

29. 26. The blank of claim 25, wherein the central panel extends at least partially around an opening, the at least one end panel is foldably connected to the central panel at a first fold line extending along the opening, the at least one attachment panel is foldably connected to the central panel, and the at least one side panel is foldably connected to the at least one attachment panel at the second fold line such that a second fold line is spaced away from the opening.

30. 30. The blank of claim 29 in combination with a liner for at least partially covering an interior of the tray formed from the blank.

31. 26. The blank of claim 25, wherein the at least one mounting panel is foldably connected to the central panel, the at least one side panel is foldably connected to the at least one mounting panel, the at least one bottom panel is a first bottom panel foldably connected to the at least one end panel, and the plurality of panels further comprises a second bottom panel foldably connected to the at least one side panel, the first bottom panel and the second bottom panel being for at least partially face-to-face contact to at least partially form a bottom wall of the tray formed from the blank.

32. the at least one mounting panel is a first mounting panel, the plurality of panels further includes a second mounting panel, the at least one side panel is a first side panel foldably connected to the first mounting panel, the plurality of panels further includes a second side panel foldably connected to the second mounting panel, the at least one end panel is a first end panel foldably connected to the central panel, the plurality of panels further includes a second end panel foldably connected to the central panel, a third bottom panel foldably connected to the second side panel, and a fourth bottom panel foldably connected to the second end panel; 32. The blank of claim 31 , wherein the first side panel, the second side panel, the first end panel, and the second end panel are for at least partially forming side walls of the tray formed from the blank, and the first bottom panel, the second bottom panel, the third bottom panel, and the fourth bottom panel are for at least partially forming a bottom wall of the tray formed from the blank.

33. 1. A method of forming a tray for holding one or more food items, comprising: obtaining a blank comprising a plurality of panels, the plurality of panels comprising a central panel, at least one mounting panel, at least one side panel foldably connected to each panel of the plurality of panels, at least one end panel foldably connected to each panel of the plurality of panels, and at least one bottom panel foldably connected to each panel of the plurality of panels; and a tray engagement structure; positioning the at least one side panel and the at least one end panel to at least partially form a sidewall extending at least partially around an interior of the tray, such that the tray engagement structure is positioned to at least partially support another tray within the tray; and positioning the at least one bottom panel to at least partially form a bottom wall of the tray.

34. 34. The method of claim 33, wherein the tray engagement structure includes at least one notch defined along the central panel.

35. 35. The method of claim 34, wherein the at least one notch is defined at least partially along an inner edge of the central panel.

36. 35. The method of claim 34, further comprising positioning the at least one mounting panel into at least partial face-to-face contact with the central panel such that the at least one mounting panel is exposed along the at least one notch to at least partially support another tray.

37. 37. The method of claim 36, wherein the at least one notch is a first notch, and the tray engagement structure further comprises a second notch defined at least partially along an inner edge of the central panel opposite the first notch.

38. 37. The method of claim 36, wherein the central panel extends at least partially around an opening, the at least one end panel is foldably connected to the central panel at a first fold line extending along the opening, the at least one mounting panel is foldably connected to the central panel, and the at least one side panel is foldably connected to the at least one mounting panel at the second fold line such that a second fold line is spaced away from the opening.

39. 37. The method of claim 36, wherein the at least one mounting panel is foldably connected to the central panel, the at least one side panel is foldably connected to the at least one mounting panel, the at least one bottom panel is a first bottom panel foldably connected to the at least one end panel, the plurality of panels further comprising a second bottom panel foldably connected to the at least one side panel, the method further comprising positioning the first bottom panel and the second bottom panel in at least partial face-to-face contact to at least partially form a bottom wall of the tray.

40. the at least one mounting panel is a first mounting panel, the plurality of panels further includes a second mounting panel, the at least one side panel is a first side panel foldably connected to the first mounting panel, the plurality of panels further includes a second side panel foldably connected to the second mounting panel, the at least one end panel is a first end panel foldably connected to the central panel, the plurality of panels further includes a second end panel foldably connected to the central panel, a third bottom panel foldably connected to the second side panel, and a fourth bottom panel foldably connected to the second end panel; 40. The method of claim 39, further comprising positioning the first side panel, the second side panel, the first end panel, and the second end panel to at least partially form side walls of the tray, and positioning the first bottom panel, the second bottom panel, the third bottom panel, and the fourth bottom panel to at least partially form a bottom wall of the tray.

41. 34. The method of claim 33, wherein the plurality of panels further comprises at least one side reinforcement panel foldably connected to the central panel, and the tray engagement structure comprises at least one cutout in the at least one side reinforcement panel.

42. 42. The method of claim 41, wherein the at least one cutout includes a top edge, a bottom edge, and a pair of side edges extending diagonally from the top edge to the bottom edge.

43. 42. The method of claim 41, further comprising positioning the at least one side reinforcement panel in at least partial face-to-face contact with the at least one side panel such that a portion of the at least one side panel is exposed along the at least one cutout to at least partially support another tray.

44. 44. The method of claim 43, wherein the at least one side reinforcement panel is a first side reinforcement panel, the plurality of panels further comprising a second side reinforcement panel foldably connected to the central panel, the at least one cutout is a first cutout, and the tray engagement structure further comprises a second cutout in the second side reinforcement panel.

45. 42. The method of claim 41, wherein the central panel extends at least partially around an opening, the at least one end panel is foldably connected to the central panel at a first fold line extending along the opening, the at least one mounting panel is foldably connected to the central panel, and the at least one side panel is foldably connected to the at least one mounting panel at the second fold line such that a second fold line is spaced away from the opening.

46. 46. ​​The method of claim 45, further comprising obtaining a liner and positioning the liner to at least partially cover an interior of the tray.

47. 42. The method of claim 41 , wherein the at least one mounting panel is foldably connected to the central panel, the at least one side panel is foldably connected to the at least one mounting panel, the at least one bottom panel is a first bottom panel foldably connected to the at least one end panel, the plurality of panels further comprising a second bottom panel foldably connected to the at least one side panel, the method further comprising positioning the first bottom panel and the second bottom panel in at least partial face-to-face contact to at least partially form a bottom wall of the tray.

48. the at least one mounting panel is a first mounting panel, the plurality of panels further includes a second mounting panel, the at least one side panel is a first side panel foldably connected to the first mounting panel, the plurality of panels further includes a second side panel foldably connected to the second mounting panel, the at least one end panel is a first end panel foldably connected to the central panel, the plurality of panels further includes a second end panel foldably connected to the central panel, a third bottom panel foldably connected to the second side panel, and a fourth bottom panel foldably connected to the second end panel; 48. The method of claim 47, further comprising positioning the first side panel, the second side panel, the first end panel, and the second end panel to at least partially form side walls of the tray, and positioning the first bottom panel, the second bottom panel, the third bottom panel, and the fourth bottom panel to at least partially form a bottom wall of the tray.

49. 34. The method of claim 33, wherein the tray formed from the blank is a first tray, the method further including obtaining a second tray, the method further including at least partially receiving a portion of the second tray in the tray engagement structure of the first tray to at least partially support the second tray within the first tray.

50. a plurality of panels comprising: a central panel; at least one mounting panel in at least partial face-to-face contact with a portion of the central panel; at least one side panel foldably connected to a respective panel of the plurality of panels; at least one end panel foldably connected to a respective panel of the plurality of panels; and at least one bottom panel foldably connected to a respective panel of the plurality of panels, wherein the at least one side panel intersects with the at least one end panel to at least partially form a side wall of the tray extending around an interior of the tray, and the at least one bottom panel at least partially forms a bottom wall of the tray; a first tray having a tray engagement structure for at least partially supporting another tray within said tray; a second tray at least partially supported within the first tray by the tray engagement structure.

51. 51. The system of claim 50, wherein the tray engagement structure includes at least one notch defined along the central panel.

52. 52. The system of claim 51, wherein the at least one notch is defined at least partially along an inner edge of the central panel.

53. 52. The system of claim 51, wherein the at least one mounting panel is exposed along the at least one notch and at least partially supports the second tray.

54. 54. The system of claim 53, wherein the at least one notch is a first notch, and the tray engagement structure further comprises a second notch defined at least partially along an inner edge of the central panel opposite the first notch.

55. 54. The system of claim 53, wherein the central panel extends at least partially around an opening, the at least one end panel is foldably connected to the central panel at a first fold line extending along the opening, the at least one mounting panel is foldably connected to the central panel, and the at least one side panel is foldably connected to the at least one mounting panel at the second fold line such that a second fold line is spaced away from the opening.

56. 54. The system of claim 53, wherein the at least one mounting panel is foldably connected to the central panel, the at least one side panel is foldably connected to the at least one mounting panel, the at least one bottom panel is a first bottom panel foldably connected to the at least one end panel, the plurality of panels further comprising a second bottom panel foldably connected to the at least one side panel, the first bottom panel and the second bottom panel being at least partially in face-to-face contact to at least partially form a bottom wall of the first tray.

57. The at least one mounting panel is a first mounting panel, the plurality of panels further includes a second mounting panel in at least partial face-to-face contact with the central panel, the at least one side panel is a first side panel foldably connected to the first mounting panel, the plurality of panels further includes a second side panel foldably connected to the second mounting panel, the at least one end panel is a first end panel foldably connected to the central panel, and the plurality of panels further includes a second side panel foldably connected to the second mounting panel, the at least one end panel is a first end panel foldably connected to the central panel, and the plurality of panels fold to the central panel.

57. The system of claim 56, comprising a second end panel bendably connected, a third bottom panel bendably connected to the second side panel, and a fourth bottom panel bendably connected to the second end panel, wherein the first side panel, the second side panel, the first end panel, and the second end panel at least partially form side walls of the first tray, and the first bottom panel, the second bottom panel, the third bottom panel, and the fourth bottom panel at least partially form a bottom wall of the first tray.

58. 51. The system of claim 50, wherein the plurality of panels further includes at least one side reinforcement panel foldably connected to the central panel, and the tray engagement structure includes at least one cutout in the at least one side reinforcement panel.

59. 60. The system of claim 58, wherein the at least one cutout includes a top edge, a bottom edge, and a pair of side edges extending diagonally from the top edge to the bottom edge.

60. 60. The system of claim 58, wherein the at least one side reinforcement panel is in at least partial face-to-face contact with the at least one side panel such that a portion of the at least one side panel is exposed along the at least one cutout and at least partially supports the second tray.

61. 61. The system of claim 60, wherein the at least one side reinforcement panel is a first side reinforcement panel, the plurality of panels further comprising a second side reinforcement panel foldably connected to the central panel, the at least one cutout is a first cutout, and the tray engagement structure further comprises a second cutout in the second side reinforcement panel.

62. 59. The system of claim 58, wherein the central panel extends at least partially around an opening, the at least one end panel is foldably connected to the central panel at a first fold line extending along the opening, the at least one mounting panel is foldably connected to the central panel, and the at least one side panel is foldably connected to the at least one mounting panel at the second fold line such that a second fold line is spaced away from the opening.

63. 63. The system of claim 62, further comprising a liner at least partially covering an interior of the first tray.

64. 59. The system of claim 58, wherein the at least one mounting panel is foldably connected to the central panel, the at least one side panel is foldably connected to the at least one mounting panel, the at least one bottom panel is a first bottom panel foldably connected to the at least one end panel, and the plurality of panels further comprises a second bottom panel foldably connected to the at least one side panel, the first bottom panel and the second bottom panel being at least partially in face-to-face contact to at least partially form a bottom wall of the first tray.

65. The at least one mounting panel is a first mounting panel, the plurality of panels further includes a second mounting panel in at least partial face-to-face contact with the central panel, the at least one side panel is a first side panel foldably connected to the first mounting panel, the plurality of panels further includes a second side panel foldably connected to the second mounting panel, the at least one end panel is a first end panel foldably connected to the central panel, and the plurality of panels further includes a second side panel foldably connected to the second mounting panel, the at least one end panel is a first end panel foldably connected to the central panel, and the plurality of panels fold to the central panel.

65. The system of claim 64, comprising a second end panel bendably connected, a third bottom panel bendably connected to the second side panel, and a fourth bottom panel bendably connected to the second end panel, wherein the first side panel, the second side panel, the first end panel, and the second end panel at least partially form side walls of the first tray, and the first bottom panel, the second bottom panel, the third bottom panel, and the fourth bottom panel at least partially form a bottom wall of the first tray.

66. 60. The system of claim 58, wherein the second tray comprises a flange at least partially received in the at least one notch of the first tray.

67. 60. The system of claim 58, wherein the first tray is spaced above a bottom of a second tray.

68. 60. The system of claim 58, wherein the first tray defines an interior volume that is larger than an interior volume defined by the second tray.

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