Container with liner

Abstract

A container for holding a food product. The container may include a base layer, a liner at least partially attached to an inner surface of the base layer, a flange including a central panel, an opening extending through the central panel, and a sidewall including a plurality of panels. Each panel of the plurality of panels may be foldably connected to the central panel, and at least one panel may be foldably attached to the central panel along the opening. The bottom wall may include at least first and second bottom panels foldably attached to their respective panels. The second bottom panel at least partially overlaps the first bottom panel such that the second bottom panel extends along the inner surface of the base layer, and the first bottom panel extends along the inner surface of the base layer at least through a cutout in the second bottom panel.

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application is a continuation-in-part of U.S. Patent Application 17 / 867,856 filed July 19, 2022, which is a division of U.S. Patent Application 16 / 532,819 filed August 6, 2019, and claims the benefit of U.S. Provisional Patent Application 62 / 851,932 filed May 23, 2019, U.S. Provisional Patent Application 62 / 796,716 filed January 25, 2019, and U.S. Provisional Patent Application 62 / 715,520 filed August 7, 2018. This application claims the benefit of U.S. Provisional Patent Application 63 / 338,250 filed May 4, 2022, and U.S. Provisional Patent Application 63 / 336,623 filed April 29, 2022.

[0002] [Incorporated by reference] U.S. Patent Application No. 17 / 867,856 filed July 19, 2022, U.S. Provisional Application No. 63 / 338,250 filed May 4, 2022, U.S. Provisional Application No. 63 / 336,623 filed April 29, 2022, U.S. Patent Application No. 16 / 532,819 filed August 6, 2019, U.S. Patent Application No. 16 / 532,823 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. 62 / 715,520 filed July 17, 2018 The disclosures of U.S. Patent Application No. 16 / 037,425, filed on 2016-02-13, U.S. Provisional Patent Application No. 62 / 649,159, filed on March 28, 2018, U.S. Provisional Patent Application No. 62 / 643,914, filed on March 16, 2018, U.S. Patent Application No. 15 / 654,814, filed on July 20, 2017, U.S. Provisional Patent Application No. 62 / 365,635, filed on July 22, 2016, and U.S. Patent Application No. 12 / 992,131, filed on February 11, 2011, and PCT Patent Application No. PCT / GB / 09 / 50506, filed on May 13, 2009, are hereby incorporated by reference in their entireties for all purposes. [Background technology]

[0003] The present disclosure relates to blanks, containers, trays, structures, and various mechanisms and methods for forming containers from the blanks. More specifically, the present disclosure relates generally to containers having a liner, the container being suitable for heating a food product. Summary of the Invention

[0004] In general, one aspect of the disclosure relates to a container for holding food products that can include a base, a liner at least partially attached to an inner surface of the base, a flange including a central panel of the base, an opening extending into the central panel, and a sidewall including at least one panel foldably connected to the central panel along the opening.

[0005] According to another aspect, the present disclosure generally relates to a blank and a liner material for combining to form a container for holding a food product. The blank can include a central panel for at least partially forming a flange of a container formed from the blank and the liner material, an opening extending through the central panel, and a panel foldably connected to the central panel along the opening. The panel can be for at least partially forming a sidewall of the container formed from the blank and the liner material. The blank can be for forming a base layer of the container, and the liner material can be for at least partially attaching to an inner surface of the base layer when the container is formed from the blank and the liner material.

[0006] According to another aspect, the present disclosure generally relates to a method of forming a container for holding a food product. The method can include obtaining a planar structure including a central panel, an opening extending through the central panel, and a panel foldably connected to the central panel along the opening. The method can further include forming a base layer of the container by folding the panel extending at least downwardly from the central panel such that the panel at least partially forms a sidewall and the central panel at least partially forms a flange, and attaching a liner to an inner surface of the base layer.

[0007] According to another aspect, the present disclosure generally relates to a method of forming a container for holding a food product. The method can include obtaining a flat structure and applying air pressure to a heated liner material and the structure to move the liner material toward the structure. The air pressure can form a substrate having an interior in the structure. The method can further include moving the liner material into the interior of the substrate and adhering the liner material to the substrate.

[0008] According to another aspect, the present disclosure generally relates to a container for holding food products. The container can include a flange including a central panel. The opening can extend into the central panel. The container can further include a sidewall including at least a panel foldably connected to the central panel, and a de-nesting structure extending outwardly from the sidewall. The de-nesting structure can be for engaging a nested container disposed below the container in a stacked arrangement to form a de-nesting gap between the flange and the nested container.

[0009] According to another aspect, the present disclosure generally relates to a stacked arrangement of containers for holding food products. The stacked arrangement can include at least a first container and a second container, and each container in the stacked arrangement of containers can include a flange including a central panel. The opening can extend into the central panel. Each container can further include a sidewall including at least one panel foldably connected to the central panel, and a de-nesting structure extending outwardly from the sidewall. The de-nesting structure of the first container can engage with the second container to at least partially form a de-nesting gap between the second container and the flange of the first container.

[0010] According to another aspect, the present disclosure generally relates to a blank for forming a container for holding a food product. The blank can include a central panel for at least partially forming a flange of a container formed from the blank, an opening extending through the central panel, and a panel foldably connected to the central panel. The panel can be for at least partially forming a sidewall of the container formed from the blank. The blank can further include a de-nesting structure extending from the panel for extending outwardly from the sidewall when the container is formed from the blank. The de-nesting structure can be for engaging a nested container positioned below the container in a stacked arrangement and forming a de-nesting gap between the flange and the nested container when the container is formed from the blank.

[0011] According to another aspect, the present disclosure generally relates to a method of forming a container for holding a food product. The method can include obtaining a blank including a central panel, an opening extending through the central panel, a panel foldably connected to the central panel, and a de-nesting structure extending from the panel. The method can further include forming the container from at least the blank. Forming the container can include folding the panel to extend at least downwardly from the central panel, such that the central panel at least partially forms a flange of the container and the panel at least partially forms a sidewall of the container. The de-nesting structure can extend outwardly from the sidewall. The method can also include positioning the container relative to a nesting container such that the de-nesting structure engages the nesting container and forms a de-nesting gap between the nesting container and the flange of the container.

[0012] According to another aspect, the present disclosure generally relates to a container for holding food products. The container may include a base layer, a liner at least partially attached to an inner surface of the base layer, a flange including a central panel of the base layer, an opening extending through the central panel, and a sidewall including a plurality of panels. Each panel of the plurality of panels may be foldably connected to the central panel, and at least one panel of the plurality of panels may be foldably connected to the central panel along the opening. The bottom wall may include at least a first bottom panel and a second bottom panel foldably connected to each panel of the plurality of panels. The second bottom panel may include a cutout, and the second bottom panel at least partially overlaps the first bottom panel, such that the second bottom panel extends along the inner surface of the base layer, and the first bottom panel extends along the inner surface of the base layer at least through the cutout.

[0013] According to another aspect, the disclosure generally relates to a blank and a liner material for combining to form a container for holding a food product. The blank can include a central panel for at least partially forming a flange of a container formed from the blank and the liner material, an opening extending through the central panel, and a plurality of panels for forming a side wall when the container is formed from the blank and the liner material. Each panel of the plurality of panels can be foldably connected to the central panel, and at least one panel of the plurality of panels can be foldably connected to the central panel along the opening. At least a first bottom panel and a second bottom panel can be for forming a bottom wall when the container is formed from the blank and the liner material. The first bottom panel and the second bottom panel can be foldably connected to respective panels of the plurality of panels. The second bottom panel can include a cutout, and the second bottom panel is for at least partially overlapping the first bottom panel when the container is formed from the blank and the liner material. The blank can be for forming a base layer of the container and the liner material can be for at least partially attaching to an inner surface of the base layer when the container is formed from the blank and the liner material, the second bottom panel can extend along the inner surface of the base layer when the container is formed from the blank and the liner material, and the first bottom panel can be for extending along the inner surface of the base layer at least through the cutout when the container is formed from the blank and the liner material.

[0014] According to another aspect, the disclosure generally relates to a method of forming a container for holding a food product. The method can include obtaining a flat structure. The flat structure can include a central panel, an opening extending through the central panel, a plurality of panels, a first bottom panel, and a second bottom panel. Each panel of the plurality of panels can be foldably connected to the central panel, at least one panel of the plurality of panels can be foldably connected to the central panel along the opening, the first bottom panel and the second bottom panel can be foldably connected to each panel of the plurality of panels, and the second bottom panel can include a cutout. The method can further include forming a base layer of the container by folding the plurality of panels to extend at least downwardly from the central panel, such that the plurality of panels at least partially form a side wall and the central panel at least partially form a flange, and by arranging the first bottom panel and the second bottom panel to at least partially form a bottom wall. The second bottom panel can at least partially overlap the first bottom panel such that the second bottom panel extends along the inner surface of the substrate and the first bottom panel can extend along the inner surface of the substrate at least through the cutout. The method can also include attaching a liner to the inner surface of the substrate.

[0015] Those skilled in the art will appreciate the above advantages, as well as other advantages and benefits of various additional embodiments, upon reading the following detailed description of the embodiments with reference to the following drawings.

[0016] According to common practice, the various features in 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 illustrate the embodiments of the present disclosure.

[0017] Corresponding parts are designated by corresponding reference numbers throughout the drawings. [Brief description of the drawings]

[0018] [Figure 1] FIG. 2 is a plan view of a blank used to form a container according to a first exemplary embodiment of the present disclosure. [Diagram 2] FIG. 2 is a plan view of a flat structure formed from the blank of FIG. 1 according to a first exemplary embodiment of the present disclosure. [Diagram 3] FIG. 2 is a plan view of a flat structure formed from the blank of FIG. 1 according to a first exemplary embodiment of the present disclosure. [Figure 4] FIG. 4 is a perspective view of a container formed from the structure and liner of FIGS. 2 and 3 according to a first exemplary embodiment of the present disclosure. [Diagram 5] FIG. 2 is a schematic diagram of an apparatus for forming a container in an exemplary embodiment of the present disclosure. [Figure 6] FIG. 2 is a plan view of a blank used to form a container according to a second exemplary embodiment of the present disclosure. [Figure 7] FIG. 13 is a plan view of a blank used to form a container according to a third exemplary embodiment of the present disclosure. [Figure 8] FIG. 8 is a plan view of a flat structure formed from the blank of FIG. 7 according to a third exemplary embodiment of the present disclosure. [Figure 9] FIG. 8 is a plan view of a flat structure formed from the blank of FIG. 7 according to a third exemplary embodiment of the present disclosure. [Figure 10A] FIG. 10 is a top perspective view of a container formed from the structure of FIGS. 8 and 9 according to a third exemplary embodiment of the present disclosure. [Figure 10B] FIG. 10B is a schematic plan view of the bottom wall of the container of FIG. 10A. [Figure 11A] FIG. 2 is a schematic diagram of an apparatus for forming a container in an exemplary embodiment of the present disclosure. [Figure 11B] FIG. 2 is a schematic diagram of an apparatus for forming a container in an exemplary embodiment of the present disclosure. [Figure 12] FIG. 13 is a plan view of a blank used to form a container according to a fourth exemplary embodiment of the present disclosure. [Figure 13]FIG. 13 is a plan view of a flat structure formed from the blank of FIG. 12 according to a fourth exemplary embodiment of the present disclosure. [Figure 14] FIG. 14 is a perspective view of a container formed from the structure of FIG. 13 according to a fourth exemplary embodiment of the present disclosure. [Figure 15] FIG. 15 is a detailed view of a corner of the container of FIG. 14. [Figure 16] FIG. 15 is a perspective view of a stacking arrangement of the containers of FIG. 14 according to a fourth exemplary embodiment of the present disclosure. [Figure 17] FIG. 16 is a perspective view of a stacking arrangement of the containers of FIG. 15 according to a fourth exemplary embodiment of the present disclosure. [Figure 18] FIG. 13 is a plan view of a blank used to form a container according to a fifth exemplary embodiment of the present disclosure. [Figure 19] FIG. 19 is a top perspective view of a container formed from the blank of FIG. 18 according to a fifth exemplary embodiment of the present disclosure. [Figure 20] FIG. 20 is a detailed view of the container of FIG. 19. [Figure 21] FIG. 19 is a bottom perspective view of a container formed from the blank of FIG. 18 according to a fifth exemplary embodiment of the present disclosure. [Figure 22] FIG. 22 is a detailed view of the container of FIG. 21. [Figure 23A] FIG. 23 is a schematic side view of the container of FIGS. [Figure 23B] FIG. 23 is a schematic side view of the container of FIGS. [Figure 24] FIG. 13 is a plan view of a blank used to form a container according to a sixth exemplary embodiment of the present disclosure. [Diagram 25] FIG. 25 is a top perspective view of a partially formed base layer of a container formed from the blank of FIG. 24 according to a sixth exemplary embodiment of the present disclosure. [Figure 26] FIG. 25 is a top perspective view of a container formed from the blank of FIG. 24 according to a sixth exemplary embodiment of the present disclosure. [Figure 27] FIG. 27 is a detailed view of the container of FIG. 26. [Figure 28]FIG. 13 is a plan view of a blank used to form a container according to a seventh exemplary embodiment of the present disclosure. [Figure 29] FIG. 13 is a plan view of a blank used to form a container according to a seventh exemplary embodiment of the present disclosure. [Diagram 30] FIG. 29 is a detailed view of the container of FIG. 28. [Diagram 31] FIG. 13 is a plan view of a blank used to form a container according to an eighth exemplary embodiment of the present disclosure. [Diagram 32] FIG. 32 is a top perspective view of a container formed from the blank of FIG. 31 according to an eighth exemplary embodiment of the present disclosure. [Diagram 33] FIG. 32 is a bottom perspective view of a container formed from the blank of FIG. 31 according to an eighth exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] 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, implementations, 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 may be used for heating or cooking.

[0020] 1 shows a blank 3 used to form a base layer 7 (FIG. 4) of a container 5, the container 5 including a liner 9 attached to the base layer 7 (FIG. 4) according to a first embodiment of the present disclosure. In one embodiment, the base layer includes paperboard (e.g., solid bleached sulfate folding cardboard) or other suitable material that may be reusable and / or suitable for use in an oven (not shown), and the liner 9 includes a plastic layer such as polyethylene, polyethylene terephthalate (PET) material, or any other thermoplastic material, or a vegetable oil or starch based plastic, such as a bioplastic. In an exemplary embodiment, the liner 9 includes polyethylene that can soften and fuse to the base layer 7. In an alternative embodiment, the liner 9 may comprise PET or a similar material at least partially attached to the base layer 7 by 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, 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. In the illustrated embodiment, the liner 9 is at least partially attached to the base layer 7 and contacts the food held in the container 5 (e.g., during heating). In one embodiment, after the food is heated, the base layer 7 and the liner 9 may be separated and both the base layer 7 and the liner 9 may be recycled separately.

[0021] The blank 3 can be formed from a single ply of material such as, but not limited to, paperboard, cardboard, paper, a polymer sheet, and / or a laminate including multiple layers. In one embodiment, the blank 3 can include a microwave interactive layer (not shown) such as is common in MicroRite® containers available from Graphic Packaging International, Atlanta, Georgia. The microwave interactive layer can be referred to or have as one of its components a susceptor, foil, microwave shield, or any other term or component that refers to a layer of material suitable for shielding microwave energy and / or causing heating in a microwave oven.

[0022] 1, the blank 3 has a longitudinal direction L1 and a transverse direction L2. In the illustrated embodiment, the blank 3 has a central panel 11, a first end panel 13 foldably connected to the central panel 11 at a longitudinal fold line 15, a second end panel 17 foldably connected to the central panel 11 at a longitudinal fold line 19, a first side panel 21 foldably connected to the central panel 11 at a transverse fold line 23, and a second side panel 25 foldably connected to the central panel 11 at a transverse fold line 27. In the illustrated embodiment, the blank 3 further includes a first bottom panel 29 foldably connected to the first side panel 21 along a transverse fold line 31, and a second bottom panel 33 foldably connected to the second side panel 25 along a transverse fold line 35.

[0023] As shown in FIG. 1, the side panels 21, 25 include respective attachment portions 37, 39 that are at least partially defined by respective fold lines 41, 43 in the respective side panels 21, 25. In the illustrated embodiment, the end panels 13, 17 are foldably connected to the central panel 11 adjacent to and / or along a central cutout or opening 45, such that edges of the central panel 11 and the end panels 13, 17 extend along the cutout 45 in the blank 3. In one embodiment, the central panel 11 includes two edges 47 that extend in the lateral direction L2 from respective ends of the longitudinal fold line 15 to respective ends of the longitudinal fold line 19. As shown in FIG. 1, the side panels 21, 25 are foldably connected to the central panel 11 along fold lines 23, 27 spaced from the cutout 45 and the edges 47. The blank 3 may have other shapes, configurations, and / or configurations without departing from this disclosure. Additionally, any of the center panel 11, end panels 13, 17, side panels 21, 25, and / or bottom panels 29, 33 may be omitted or may be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure. For example, the blank 3 may have any suitable number of panels and any suitable shape.

[0024] 2 and 3, the blank 3 can be formed into a flat structure 51 (e.g., a folded and glued blank) that is prepared to be formed into the base 7 of the container 5, as described in more detail below. The structure 51 can be formed by applying adhesive (e.g., in the form of adhesive strips G1 as shown in phantom in FIG. 1) to the attachment portions 37, 39 of the side panels 21, 25 and / or the central panel 11, and folding the side panels 21, 25 over the central panel 11 along their respective fold lines 23, 27. The attachment portions 37, 39 can be folded into face-to-face contact with the underside 52 of the central panel 11, such that the adhesive strips G1 adhere the attachment portions 37, 39 to the central panel 11 (FIG. 2). In the illustrated embodiment, the attachment portions 37, 39 extend from their respective fold lines 23, 27 to their respective edges 47 of the central panel 11. 2 and 3, side panels 21, 25 can at least partially overlap end panels 13, 17 and cutout 45. Additionally, bottom panels 29, 33 can at least partially overlap one another in structure 51. Structure 51 may be formed in other manners without departing from this disclosure.

[0025] As shown in Figures 2 and 3, the structure 51 may be in a substantially flat state for compact storage and / or transportation while being prepared to form the container 5. In the illustrated embodiment, the container 5 may be formed from the flat structure 51 by folding the end panels 13, 17 downwardly relative to the central panel 11 along respective fold lines 15, 19, and folding the sides of the side panels 21, 25 downwardly relative to the central panel 11 and the attachment portions 37, 39 along respective fold lines 41, 43. As shown in Figure 4, the end panels 13, 17 and the sides of the side panels 21, 25 extend generally downwardly from the central panel 11 to at least partially form side walls 53 that extend around a bottom wall 55 formed from the overlapping bottom panels 29, 33. In the illustrated embodiment, the central panel 11 and the attachment portions 37, 39 may form a flange 57 of the container 5. Side wall 53, bottom wall 55, and / or flange 57 may be omitted or may be of other shapes, arrangements, positions, and / or configurations without departing from this disclosure. Also, container 5 may have one or more injection molded features that may reinforce flange 57 and / or other portions of the container without departing from this disclosure.

[0026] As shown in FIG. 4, the container 5 further includes a liner 9 attached to an inner surface of the base layer 7 formed from the blank 3. In one embodiment, the liner 9 (e.g., for a polyethylene liner) can be attached to the base layer 7 (e.g., by heating the liner and fusing it to the base layer). Alternatively, the liner 9 can be attached to the base layer 7 by a heat seal layer (e.g., for a PET liner). The liner 9 can extend over the side wall 53, the bottom wall 55, and the flange 57. In one embodiment, the liner 9 can extend beyond the flange 57, the edges of the liner 9 and the flange 57 can be aligned, and / or the liner can be spaced inwardly from the edges of the flange 57. In the illustrated embodiment, the liner 9 can be attached to at least a portion of each of the bottom panels 29, 33, the end panels 13, 17, the side panels 21, 25, and the center panel 11. In one embodiment, the liner 9 can at least partially hold the substrate 7 to the shape of the sidewall 53 and the container 5 (e.g., can help prevent the end panels 13, 17, the side panels 21, 25, and / or the bottom panels 29, 33 from separating from one another). The container 5, including the liner 9 and / or substrate 7, can be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure.

[0027] In one embodiment, the structure 51 can be considered a self-standing structure, and the heat and pressure used to apply the liner 9 to the structure can cause the flat structure 51 (FIGS. 2 and 3) to stand up into the base layer 7 of the container 5 (FIG. 4). For example, the sides of the end panels 13, 17 and side panels 21, 25 can be folded down against the central panel 11 to form side walls 53, and the bottom panels 29, 33 can be slid past each other to form a bottom wall 55. In one embodiment, the side walls 53 and bottom wall 55 can extend along the interior 59 of the base layer 7. The liner 9 can be pressed into the interior 59 to contact the end panels 13, 17, side panels 21, 25, bottom panels 29, 33, and center panel 11 (flanges 57) such that the liner 9 is at least partially adhered to the panels 13, 17, 21, 25, 29, 33, 11, and the liner 9 combines with the base layer 7 to form the container 5.

[0028] In one embodiment, the container 5 can be formed similarly to the formation of containers as shown and described in the applications incorporated by reference (e.g., the '425 application, the '814 application, and / or the '131 application), except that the forming tool can be omitted and the flat structure 51 can be transferred to the lower mold without preforming it to the substrate 7. In an exemplary embodiment shown generally in FIG. 5, the flat structure 51 can be positioned on the lower mold 140 of the system 101, and a liner material or film sheet 150 (e.g., a polyethylene or PET web) can be fed from a feed roller 151 above the structure 51. The upper mold 160 has a heater plate surface 164 having a PTFE coating, such as, for example, a Teflon® coating. Alternatively, the heater plate surface 164 can have a coating of any suitable material, or the coating can be omitted. As shown generally in FIG. 5, the upper mold 160 can include a plurality of holes or ducts 162 in the heater plate surface 164 for applying vacuum and / or air pressure to the sheet 150. The lower mold 140 and / or upper mold 160, including the ducts 162 and / or the heater plate 164, may be of other shapes, arrangements, positions, and / or configurations without departing from this disclosure. For example, the heater plate 164 may be omitted and heat may instead be applied to the sheet 150 (e.g., using a stream of hot air).

[0029] In the illustrated embodiment, the lower mold 140 can hold the structure 51 over the cavity 142 of the lower mold 140 while supporting the structure 51 on the central panel 11 and / or the mounting portions 37, 39 (e.g., with the central panel 11 facing up as shown in FIG. 4). An initial vacuum can be applied through the duct 162 to draw the film sheet 150 towards the upper mold 160, which can be heated to a suitable temperature to soften the film sheet 150 and / or activate the heat seal layer. Instead of or in addition to the initial vacuum, air pressure can be employed under the film sheet 150 to achieve the same or equivalent effect. The film sheet 150 can then be pressed downward (e.g., by air pressure applied through the duct 162 and / or by vacuum applied from below the structure 51). The air pressure can move the film sheet toward the structure, which can form the base layer 7 (e.g., end panels 13, 17 and side panels 21, 25 can be folded downward from center panel 11 to form interior 59 as shown in FIG. 4). The lower mold can support the base layer 7 as a liner is formed therein and adhered to flanges 57, side walls 53, and bottom wall 55 of the base layer 7 to form the container 5 (FIG. 4). In one embodiment, the liner 9 can help hold the container 5 in its tray shape after the liner is applied to the base layer 7. In one embodiment, the container 5 can be ejected from the lower mold 140 and transported away from the forming tool, for example on a conveyor.

[0030] In one embodiment, the container 5 can be formed from the structure 51 at a much faster rate than a system that must first form the substrate 7 from a blank and then place the formed substrate 7 into the lower mold 140. In one example, a system that first forms the substrate 7 from a blank can form containers at a rate of about 60 trays per minute, whereas the container 5 of this embodiment can be formed from the structure 51 without a prior forming step at a rate of about 200 trays per minute. The container 5 can be formed in other manners without departing from this disclosure. For example, the container 5 can be formed from the structure 51 before the liner 9 is applied (e.g., before the lower mold 140 is engaged).

[0031] In one embodiment, the lid (not shown) can include a packaging film, which is a thin plastic layer used to preserve and protect food contained in the tray, and can be removably attached to the flange 57 of the container 5. Any plastic film, such as, for example, polyethylene, polypropylene, polyethylene terephthalate, polyvinyl chloride, polyamide, and ethylene vinyl alcohol, or other suitable material, can be used to form the lid that seals against the sealing surface of the flange 57. Additionally, an adhesive can be used between the lid and the sealing surface of the flange 57 without departing from this disclosure. In one embodiment, the sealing surface of the flange 57 includes the top surface of the center panel 11, which is generally free of seams, folds, creases, folds, 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 11 in the container 5 of the exemplary embodiment can provide a better sealing surface than a container having features such as folds or seams on its upper flange surface. In one embodiment, the arrangement of end panels 13, 17 foldably connected along cutout 45 in central panel 11 and side panels 21, 25 foldably connected along the outer edges of central panel 11 and folded under the central panel allows the top surface of central panel 11 to be flat and / or smooth to form a sealing surface. In one embodiment, the smooth top surface of central panel 11 can also promote better attachment between base layer 7 and liner 9 at the top surface of the flange.

[0032] FIG. 6 is a plan view of a blank 203 for forming a base layer of a container (not shown) of a second embodiment of the present disclosure. The second embodiment is generally similar to the first embodiment, except for variations noted and variations that will be apparent to one skilled in the art. Accordingly, similar or identical features of the embodiments are given similar or similar reference numbers. As shown in FIG. 6, the first end panel 213 includes a lower portion 213a foldably connected to an upper portion 213b along a longitudinal intermediate fold line 261, the second end panel 217 includes a lower portion 217a foldably connected to an upper portion 217b along a longitudinal intermediate fold line 263, the first side panel 221 includes a lower portion 221a foldably connected to an upper portion 221b along a transverse intermediate fold line 265, and the second side panel 225 includes a lower portion 225a foldably connected to an upper portion 225b along a transverse intermediate fold line 267. In the illustrated embodiment, the upper portions 213b, 217b of each end panel 213, 217 are foldably connected to the central panel 11 along respective fold lines 15, 19. Similarly, the upper portions 221b, 225b of each side panel 221, 225 are foldably connected to respective attachment portions 37, 39 along respective fold lines 41, 43, which in turn are foldably connected to the central panel 11 along respective fold lines 23, 27. In one embodiment, the lower portions 213a, 217a of each end panel 213, 217 each have two downwardly beveled edges 271a, and the upper portions 213b, 217b of each end panel 213, 217 each have two upwardly beveled edges 271b. Similarly, the lower portions 221a, 225a of each side panel 221, 225 each have two downward beveled edges 273a, and the upper portions 221b, 225b of each side panel 221, 225 each have two upward beveled edges 273b. The blank 3 may be of other shapes, arrangements, and / or configurations without departing from this disclosure. Additionally, any of the central panel 11, end panels 213, 217, side panels 221, 225, and / or bottom panels 29, 33 may be omitted or may be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure.For example, the blank 203 can have any suitable number of panels and any suitable shape.

[0033] In one embodiment, when a container (not shown) is formed from the blank 203, the end panels 213, 217 and side panels 221, 225 can be assembled to form a side wall (not shown) in which a lower portion formed from lower portions 213a, 217a, 221a, 225a is foldably connected to an upper portion formed from upper portions 213b, 217b, 221b, 225b along an intermediate fold line formed by intermediate fold lines 261, 263, 265, 267. In an exemplary embodiment, in the side wall, the upper portions 213b, 217b, 221b, 225b of the panels 213, 217, 221, 225 can be angled relative to the lower portions 213a, 217a, 221a, 225a of the panels 213, 217, 221, 225, respectively. Thus, the lower portion of the sidewall can extend obliquely from the bottom wall formed by the bottom panels 29, 33 at an obtuse angle, and the upper portion of the sidewall can extend obliquely from the lower portion at an obtuse angle, allowing the liner 9 to more easily engage the sidewall and bottom wall surfaces at the corners of the container. For example, a liner 9 (e.g., a PET liner) can more easily engage an obtuse corner than a 90 degree or near corner. Thus, a container formed from the blank 203 of the second embodiment may be better suited for certain liners (e.g., a PET liner that may be more suitable for use in a conventional oven) in some exemplary embodiments.

[0034] FIG. 7 is a plan view of a blank 303 for forming a base layer 307 of a container 305 (FIG. 10A) of a third embodiment of the present disclosure. The third embodiment is similar to the previous embodiments, except for variations noted and variations that will be apparent to one skilled in the art. Thus, similar or identical features of the embodiments are given similar or similar reference numbers. As shown in FIG. 7, the blank 303 can include a first bottom panel 329 and a second bottom panel 333 foldably connected to the first side panel 21 and the second side panel 25, respectively, along respective transverse fold lines 31, 35, a third bottom panel 371 foldably connected to the first end panel 13 along a longitudinal fold line 373, and a fourth bottom panel 375 foldably connected to the second end panel 17 along a longitudinal fold line 377. As shown in FIG. 7, at the opening 45, the third bottom panel 371 and the fourth bottom panel 375 can extend from the first end panel 13 and the second end panel 17, respectively. In the illustrated embodiment, the first bottom panel 329 can include a lateral edge 379a and longitudinal edges 379b, 379c. Similarly, the second bottom panel 333 can include a lateral edge 381a, and the third bottom panel 371 and the fourth bottom panel 375 can include respective longitudinal edges 381b, 381c. In one embodiment, the bottom panels 329, 333, 371, 375 can also include beveled edges extending from the respective side panels 21, 25 and end panels 13, 17.

[0035] 7, three notches 383a, 383b, 383c can be defined in the first bottom panel 329 and can extend from the lateral edge 379a and the longitudinal edges 379b, 379c, respectively. Additionally, a tab 385a can extend from the lateral edge 381a of the second bottom panel 333, and tabs 385b, 385c can extend from the longitudinal edges 381b, 381c, respectively, of the third bottom panel 371 and the fourth bottom panel 375. In the illustrated embodiment, the tabs 385a, 385b, 385c are complementary to the notches 383a, 383b, 383c, respectively, such that the tabs 385a, 385b, 385c fit into the respective notches 383a, 383b, 383c (e.g., as shown diagrammatically in Figures 10A and 10B). For example, as shown in Figures 7, 10A, and 10B, each of the notches 383a, 383b, 383c and the tabs 385a, 385b, 385c can have three orthogonal edges connected by two beveled edges. Alternatively, the notches 383a, 383b, 383c and the tabs 385a, 385b, 385c can have any suitable shape.

[0036] 7, the attachment portions 337, 339 of each side panel 21, 25 can extend beyond the edges of the side panels 21, 25 and can have curved edges that correspond to the respective adjacent curved corner edges of the central panel 11 such that the curved edges of the attachment portions 337, 339 extend along or adjacent to the respective adjacent curved corner edges of the central panel 11 when the structure 351 is formed (FIGS. 8 and 9). The blank 303 can be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure.

[0037] 8 and 9, the blank 303 may be formed into a flat structure 351 (e.g., a folded and glued blank) that is prepared to be formed into the base 307 of the container 305, as described in more detail below. The structure 351 may be formed by applying adhesive (e.g., in the form of glue strips) to the attachment portions 337, 339 of the side panels 21, 25 and / or portions of the central panel 11 adjacent the attachment portions 337, 339, and folding the side panels 21, 25 over the central panel 11 along respective fold lines 323, 327. The attachment portions 337, 339 may be folded into face-to-face contact with the underside 52 of the central panel 11, such that the glue strips adhere the attachment portions 337, 339 to the central panel 11 (FIG. 9). 8 and 9, the side panels 21, 25, end panels 13, 17, and bottom panels 329, 333, 371, 375 can at least partially overlap one another adjacent the cutout 45. The structure 351 can have other shapes without departing from this disclosure.

[0038] 8 and 9, the structure 351 may be substantially flat for compact storage and / or transportation while preparing to form the container 305. In the illustrated embodiment, the container 305 may be formed from the flat structure 351 by folding the end panels 13, 17 downwardly relative to the central panel 11 along respective fold lines 315, 319, and folding the sides of the side panels 21, 25 downwardly relative to the central panel 11 and attachment portions 337, 339 along respective fold lines 341, 343. As shown in FIG. 10A, the end panels 13, 17 and the sides of the side panels 21, 25 extend generally downwardly from the central panel 11 to at least partially form side walls 353 that extend around a bottom wall 355 formed from the bottom panels 329, 333, 371, 375. 10A and 10B, the bottom wall 355 can be formed by folding the bottom panels 329, 333, 371, 375 relative to the respective side panels 21, 25 and end panels 13, 17 along respective fold lines 31, 35, 373, 377 such that the bottom panels 333, 371, 375 are disposed adjacent to the first bottom panel 329. In the illustrated embodiment, the tabs 385a, 385b, 385c can be received in respective cutouts 383a, 383b, 383c in the first bottom panel 329 (e.g., an edge of each tab is adjacent, proximate, or abuts an edge of a respective cutout). In one embodiment, the bottom panels 329, 333, 371, 375 can be coplanar.

[0039] In the illustrated embodiment, the central panel 11 and the attachment portions 337, 339 can form a flange 357 of the container 305. In the illustrated embodiment, the top surface of the central panel 11 forms the top surface of the flange 357, such that the top surface of the flange 357 is devoid of seams, creases, fold lines, folds, edges, and / or other features that may reduce the smoothness of the flange. This can help the flange 357 provide a better surface for attaching the liner 309 to the base 307 (FIG. 10A) and / or attaching a lidding film (not shown) to the flange 357. The liner 309 can be similar or identical to the liner 9 of the first embodiment. In one embodiment, a lidding film or other cover for enclosing the interior 359 of the container 305 can form a tighter seal with the flange 357 than if the flange included seams, creases, fold lines, folds, edges, and / or other features that may interfere with the formation of a seal between the cover and the flange. The side walls 353, bottom wall 355, and / or flange 357 may be omitted or may be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure. Additionally, the flange 357 may comprise one piece of board (e.g., center panel 11) having an upper surface that extends around the perimeter of the container. Attachment portions 337, 339 adhered to center panel 11 reinforce the flange 357 and strengthen and increase the rigidity of the container 305. In alternative embodiments, the attachment portions 337, 339 may be omitted without departing from this disclosure.

[0040] 11A and 11B, the container 305 can be formed by placing a structure 351 in a lower mold 140' of a molding tool or system 101' (FIG. 11A) in an upright orientation (e.g., as shown in FIG. 8) such that the mounting portions 337, 339 of the center panel 11 and side panels 21 rest on the upper surface of the lower mold 140' and the end panels 13, 17, sides of the side panels 21, 25, and bottom panel 329, 333, 371, 375 extend above the cavity 142 of the lower mold. A plunger 160' of the forming tool 101' can be moved downwardly onto the structure 351 and can press downwardly against the end panels 13, 17, sides of the side panels 21, 25, and bottom panels 329, 333, 371, 375 as it moves through the opening 45 in the structure 351. As the plunger continues to move downward into the lower mold cavity, it can press the sides of end panels 13, 17 and side panels 21, 25 against the side walls of the cavity and can press bottom panels 329, 333, 371, 375 against the bottom wall of the cavity, thereby forming side walls 353 and bottom wall 355 of base 307 (e.g., Figures 10A and 10B).

[0041] In one embodiment, vacuum pressure may be applied to one or more of the bottom panels 329, 333, 371, 375, end panels 13, 17, and side panels 21, 25 to help fold the panels in place and / or hold the panels in place in the cavity of the lower mold. For example, vacuum pressure may be applied to the bottom panels at vacuum location 387 shown diagrammatically in FIG. 10B via vacuum duct 162' extending through the lower mold 140'. In one embodiment, vacuum pressure at vacuum location 387 may help hold the bottom panels 329, 333, 371, 375 against the bottom wall of the lower mold with tabs 385a, 385b, 385c engaged with respective notches 383a, 383b, 383c until the liner 309 is applied to the base 307, as described in more detail below. Once the sidewall 353 and bottom wall 355 are formed and vacuum pressure is applied to the bottom wall 355 (eg, at vacuum location 387) and / or the sidewall 353, the plunger can be retracted from the lower mold.

[0042] Subsequently, as shown in FIG. 11B, a liner sheet 309′ (e.g., a liner material for forming the liner 309) can be moved over the lower mold and prepared for attachment to the base 307 (e.g., laminated, glued, heat sealed, and / or otherwise attached to the base). In one embodiment, the liner sheet 309′ can be formed and sized to be applied to the base with zero or near zero wasted material. The liner sheet 309′ can be heated (e.g., by heating the plunger 160′ or another suitable device and / or by directing hot air through the duct 162 in the plunger 160′) to the sheet). In an exemplary embodiment, heating the liner sheet 309′ can facilitate heat sealing and / or formation of the liner sheet and / or activation of a heat-activated adhesive or heat-seal layer of the liner sheet 309′. In one embodiment, the heated liner sheet 309' can be pressed onto the flange 357 and into the cavity 142 on the sidewalls 353 and bottom wall 355 (e.g., by air pressure applied above the liner sheet 309' via duct 162 as shown in FIG. 11B and / or by vacuum pressure applied below the liner sheet 309' and base layer 307 via vacuum duct 162'). Alternatively, an upper mold, such as plunger 160', that formed base 307, can be moved downward to press the liner sheet 309' against the flange 357 and into the cavity 142 against the sidewalls 353 and bottom wall 355. In one embodiment, the plunger 160' can heat the liner sheet 309' as it presses the liner sheet against the base layer 307.

[0043] In the illustrated embodiment, the liner sheet 309' can be contacted with the base 307 (e.g., the liner sheet can be pressed against the base) such that an adhesive layer, a heat seal layer, and / or any other suitable attachment means can attach the liner sheet 309' to the base layer 307 to form the liner 309 (FIG. 10A). Alternatively or additionally, the liner sheet 309' can be heated to soften and / or melt the liner sheet such that it at least partially fuses to the base layer 307 as they are pressed together. With the base 307 and liner 309 attached, the vacuum pressure and / or any other air pressure can be stopped and / or the top mold can be removed from the bottom mold and the container 305 can be ejected from the molding tool. Another structure 351 can then be moved onto the bottom mold and the process repeated. The container 305 can have other shapes without departing from this disclosure. For example, adhesive can be applied to the liner sheet 309' and the plunger 160' can press the liner sheet 309' against the substrate 307 to form the liner 309 without heating the liner sheet 309'.

[0044] In one embodiment, a liner 309 can be attached to the top surface of the flange 357 (e.g., the top surface of the central panel 11), to each of the end panels 13, 17 and side panels 21, 25 of the side wall 353, and to each of the bottom panels 329, 333, 371, 375 of the bottom wall 355. In one embodiment, the liner 309 can at least partially retain the base 307 in the shape of the side wall 353 and the bottom wall 355. For example, the liner 309 can help maintain the bottom panels 329, 333, 371, 375 in a flush relationship with tabs 385a, 385b, 385c engaging respective notches 383a, 383b, 383c (e.g., notches that receive tabs). In one embodiment, the engagement of the tabs and notches can help to strengthen the bottom wall 355 and the container 305 as a whole. The container 305, including the liner 309 and / or base layer 307, may be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure. The container 305, having a flange 357, a bottom wall 355, and side walls 353, is formed from a blank 303 that is a single board. In some embodiments, the container 305 may be a generally four-sided container, having four side walls 353 that extend downwardly from the flange 357 to the bottom wall 355. The container 305 may be of shapes other than four-sided without departing from this disclosure.

[0045] FIG. 12 is a plan view of a blank 403 for forming a base layer 407 of a container 405 (FIGS. 14-17) of a fourth embodiment of the present disclosure. The fourth embodiment is similar to the previous embodiments, except for variations noted and variations that will be apparent to one of ordinary skill in the art. Accordingly, similar or identical features of the embodiments are given similar or similar reference numbers. As shown in FIG. 12, the first end panel 13 and the second end panel 17 are foldably connected to the central panel 11 along respective fold lines 415, 419, and the blank 403 can include a first side panel 421 and a second side panel 425 foldably connected to the central panel 11 along respective fold lines 423, 427. In the illustrated embodiment, the first bottom panel 429 and the second bottom panel 433 are foldably connected to the respective first side panel 421 and second side panel 425 along respective transverse fold lines 31, 35, the third bottom panel 471 is foldably connected to the first end panel 13 along a longitudinal fold line 473, and the fourth bottom panel 475 is foldably connected to the second end panel 17 along a longitudinal fold line 477. As shown in FIG. 12 , the third bottom panel 471 and the fourth bottom panel 475 can extend from the respective first end panel 13 and second end panel 17 at the opening 45 and can have beveled edges that converge to respective points on the bottom panels 471, 475 that can abut one another at the opening 45. Alternatively, the bottom panels 471, 475 may be other shaped and / or spaced apart from one another. In the illustrated embodiment, the first bottom panel 429 and the second bottom panel 433 may have beveled edges that extend to the ends of their respective lateral edges. As shown in FIG. 12, the side panels 421, 425 include respective attachment portions 437, 439 that are at least partially defined by respective fold lines 441, 443 and respective fold lines 423, 427.

[0046] 12, the blank 403 may include a de-nesting structure including a spacer or shoulder 490 extending from an end of the side panels 421, 425 adjacent the respective attachment portions 437, 439. In the illustrated embodiment, each shoulder 490 may include a lateral edge 491 extending from the respective side panel 421, 425 and a longitudinal edge 493 extending from the lateral edge 491 to the central panel 11. As shown in FIG. 12, each of the shoulders 490 extends from a lateral edge 494 of a lateral portion of the respective side panel 421, 425. In one embodiment, each lateral edge 491 can form a flange-engaging edge having a length D1 (FIGS. 12 and 15), which can correspond to the distance each of the lateral edges 491 extends outwardly from the sidewall 453 (FIGS. 14, 15, and 17) of the container 405 to engage a flange 457 of another container 405 (e.g., a nested container) when the containers are arranged in a stack (FIGS. 16 and 17). As shown in FIG. 12, each of the longitudinal edges 493 can extend a distance D2 from the lateral edge 491 to a respective fold line 441, 443, which can correspond to the spacing between the lateral edge 491 and the flange 457 of the container 405 (FIGS. 14, 15, and 17). The de-nesting structure, including the shoulder 490, can be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure.

[0047] 13 and 14, the blank 403 may be formed into a flat structure 451 (e.g., a folded and glued blank) that is prepared to be formed into the base 407 of the container 405. The structure 451 may be formed by applying adhesive (e.g., in the form of glue strips) to the attachment portions 437, 439 of the side panels 421, 425 and / or portions of the central panel 11 adjacent the attachment portions 437, 439, and folding the side panels 421, 425 over the central panel 11 along respective fold lines 423, 427. The attachment portions 437, 439 may be folded into face-to-face contact with the underside 52 of the central panel 11 such that the glue strips adhere the attachment portions 437, 439 to the central panel 11. 13 and 14, the side panels 421, 425, end panels 13, 17, and bottom panels 429, 433, 471, 475 can at least partially overlap one another adjacent the cutout 45. The structure 451 can have other shapes without departing from this disclosure.

[0048] 13 and 14, the structure 351 can be flattened (e.g., nearly or substantially flat) for compact storage and / or transport while being prepared to form the container 405. In the illustrated embodiment, the container 405 can be formed from the flat structure 451 by folding the end panels 13, 17 downwardly relative to the central panel 11 along respective fold lines 415, 419 and folding the sides of the side panels 421, 425 downwardly relative to the central panel 11 and attachment portions 437, 439 along respective fold lines 441, 443. As shown in FIGS. 14 and 15, the end panels 13, 17 and the side panels 421, 425 extend generally downwardly from the central panel 11 to at least partially form side walls 453 that extend around a bottom wall 455 (FIG. 16) formed from at least partially overlapping bottom panels 429, 433, 471, 475. In one embodiment, the end panels 13 , 17 and side panels 421 , 425 may extend diagonally (eg, upwardly and outwardly) from the bottom wall 455 .

[0049] As shown in FIGS. 14-17, the center panel 11 and the attachment portions 437, 439 can form a flange 457 of the container 405. In the illustrated embodiment, the top surface of the center panel 11 forms the top surface of the flange 457, such that the top surface of the flange 457 is devoid of seams, creases, fold lines, folds, edges, and / or other features that may reduce the smoothness of the flange. This can help the flange 457 provide a better surface for attaching the liner 409 (FIG. 16) to the base 407 and / or for attaching a lidding film (not shown) to the flange 457. In one embodiment, a lidding film or other cover for enclosing the interior 459 of the container 405 can form a tighter seal with the flange 457 than if the flange included seams, creases, fold lines, folds, edges, and / or other features that may interfere with the formation of a seal between the cover and the flange. The side walls 453, bottom wall 455, and / or flange 457 may be omitted or may be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure. Additionally, the flange 457 may comprise one piece of board (e.g., center panel 11) having a top surface that extends around the perimeter of the container. The attachment portions 437, 439 bonded to the center panel 11 reinforce the flange 457 and strengthen and increase the rigidity of the container 405. In one embodiment, the base 407 may be formed and a liner may be applied to the base 407 to form the container 405 in a manner similar or identical to any of the containers 5, 305 of the previous embodiments. The container 405 may be alternatively formed without departing from this disclosure.

[0050] As shown in Figures 16 and 17, the containers 405 can be arranged with other containers 405 in a nested or stacked arrangement 495, with the sidewall 453 and bottom wall 455 of each container 405 positioned at least partially within the interior 459 of the nested container 405 below. As shown in Figures 14, 15, and 17, a shoulder 490 can extend downwardly from the flange 457 of each container 405 (e.g., from the respective fold lines 441, 443) to form a de-nested structure. In the illustrated embodiment, the shoulder 490 extends outwardly a distance D1 from each corner of the sidewall 453 of the container 405 and extends downwardly a distance D2 from the flange 457 of the container 405. Thus, when the end panels 13, 17 of the upper container 405 are positioned adjacent the inner surfaces of the respective end panels 13, 17 of the lower nested container 405, the lateral edge 491 of the shoulder 490 extends outwardly from the side wall 453 of the upper container 405 and beyond the flange 457 of the lower container 405. In the illustrated embodiment, the shoulder 490 may support the upper container 405 at the lateral edge 491 relative to the lower container 405 (e.g., the lateral edge 491 of the upper container may engage a top surface of the central panel 11 of the lower container) and may prevent the upper container 405 from moving further into the interior 459 of the lower nested container 405. As shown in FIGS. 16 and 17 , the shoulder 490 may form a de-nesting gap 497 between the flanges 457 of adjacent containers 405 in the stacked arrangement 495. In one embodiment, the height of each gap 497 can be equal (e.g., approximately or substantially equal) to the distance D2 between the lateral edge 491 of each shoulder 490 and the respective fold line 441, 443. Any of the stacking arrangement 495 and / or shoulders 490 can be other shapes, arrangements, positioning, and / or configurations without departing from this disclosure.

[0051] In one embodiment, the de-nesting gap 497 formed by the shoulder 490 in the stacked arrangement can facilitate separation of the containers 405 from the stacked arrangement 495 (e.g., de-nesting of the containers 405). For example, if the shoulder 490 were omitted, the containers 405 could move further into the interior 459 of the respective lower container 405, which could result in the flanges 457 of adjacent containers 405 being positioned adjacent to one another (e.g., the adjacent flanges 457 could be spaced apart by a small distance or in contact or engagement with one another). Without the de-nesting gap 497 formed by the shoulder 490, it could be more difficult to grasp the flanges 457 of the stacked arrangement containers 405 and pull the containers apart and / or it could be more difficult for a de-nesting device (not shown) to move between the two flanges 457 to separate the containers 405. In the illustrated embodiment, the de-nesting structure 497 may allow a user to more easily grasp the flange 457 of one of the containers 405 (e.g., the top container) and pull the container 405 away from the stacked arrangement 495 by its flange 457. Alternatively or additionally, the de-nesting gap 497 may provide space for a de-nesting device (not shown) to move between the flanges 457 of two adjacent containers 405 in the stacked arrangement 495, such that the de-nesting device can push the containers 405 apart at their flanges 457.

[0052] 18-25 show various structures, blanks, and containers of the fifth embodiment of the present disclosure. The fifth embodiment is similar to the previous embodiments, except for the variations noted and those that will be apparent to one skilled in the art. Thus, similar or identical features of the embodiments are given similar or similar reference numbers. FIG. 18 is a plan view of a blank 503 for forming a base layer 507 of a container 505 (FIGS. 19-23B) of the fifth embodiment of the present disclosure. As shown in FIG. 18, the blank 503 has a longitudinal direction L1 and a transverse direction L2, and can include a first bottom panel 529 and a second bottom panel 533 foldably connected to the first side panel 21 and the second side panel 25, respectively, along respective transverse fold lines 31, 35, a third bottom panel 571 foldably connected to the first end panel 13 along a longitudinal fold line 573, and a fourth bottom panel 575 foldably connected to the second end panel 17 along a longitudinal fold line 577. As shown in Figure 18, the third bottom panel 571 and the fourth bottom panel 575 can extend from the first end panel 13 and the second end panel 17, respectively, at the opening 45. As shown in Figure 18, the attachment portions 537, 539 of the respective side panels 21, 25 can extend beyond the edges of the side panels 21, 25 and can have edges that correspond to the respective adjacent corner edges of the central panel 11, such that when the container 505 is formed, the edges of the attachment portions 537, 539 extend along or adjacent the respective adjacent corner edges of the central panel 11. The blank 503 can be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure.

[0053] In the illustrated embodiment, the first bottom panel 529 can include embossed areas 579a, 579b, 579c. In one embodiment, the second bottom panel 533 can include a bottom opening 581 spaced apart from an outer edge 533a of the second bottom panel 533. In the illustrated embodiment, the third bottom panel 571 and the fourth bottom panel 575 have respective free edges 582, 584 that each form two protrusions 586 on either side of a notch 588. In an embodiment, the bottom opening 581 and the notch 588 and / or other suitable features can generally be considered cutouts.

[0054] 19-23B, when the container 505 is formed from the blank 503, the end panels 13, 17 and side panels 21, 25 extend generally downwardly from the central panel 11 to at least partially form side walls 553 that extend around a bottom wall 555 formed from the bottom panels 529, 533, 571, 575. The bottom wall 555 can be formed by folding the bottom panels 529, 533, 571, 575 relative to the respective side panels 21, 25 and end panels 13, 17 along respective fold lines 31, 35, 573, 577 such that the second bottom panel 533 is first folded inwardly adjacent the third and fourth bottom panels 571, 575 (FIGS. 19 and 20). The first bottom panel 529 is then folded inward to overlap the second bottom panel 533, the third bottom panel 571, and the fourth bottom panel 575 (FIGS. 21 and 22). As shown in FIGS. 21 and 22, the first bottom panel 529 forms an exterior or bottom layer of the bottom wall 555 of the container 505, with the bottom panels 533, 571, 575 overlapping the first bottom panel 529 along the interior of the container 505.

[0055] 19 and 20, when the bottom wall 555 is formed, the first embossed portion 579a is adjacent the notch 588 of the fourth bottom panel 575, the second embossed portion 579b fits into the opening 581 of the second bottom panel 533, and the third embossed portion 579c is adjacent the notch 588 of the third bottom panel 571. As shown in FIGS. 19 and 20, the protrusions 586 of the bottom panels 571, 575 can connect, contact, and / or abut or be adjacent to the outer edge 533a of the second bottom panel 533, and the notch 588 cooperates with the outer edge 533a to form a bottom opening in addition to the bottom opening 581 of the second bottom panel 529. Thus, the second embossed portion 579b is at least partially received in the opening 581 of the second bottom panel 533, and the embossed portions 579a, 579c are received in the respective notches 588 of the respective bottom panels 575, 571 (e.g., received between the free edges 582, 584 of the bottom panels 571, 575 extending along the respective notches 588 and respective portions of the outer edge 533a of the second bottom panel 533).

[0056] In embodiments, the embossed portions 579b, 579c, 579a can at least partially correspond to the shape of the respective bottom opening 581 and notch 588 (e.g., respective notches 581, 588). For example, the embossed portion 579b can be rectangular with lateral and longitudinal edges and can be slightly smaller than the rectangular bottom opening 581 such that the embossed portion 579b fits within the bottom opening 581 (FIGS. 19 and 20). As shown in FIG. 18, the embossed portions 579c, 579a can be trapezoidal with two hypotenuses and an outer short longitudinal side that fits along the corresponding diagonal portions and longitudinal portions of the respective free edges 582, 584 of the respective bottom panels 571, 575 (FIGS. 19 and 20). Additionally, each of the embossed portions 579c, 579a can have longer longitudinal sides that extend between the apexes of the protrusions of the respective bottom panels 571, 575 and along respective longitudinal portions of the outer edge 533a of the second bottom panel 533 (FIGS. 19 and 20). Thus, as shown in FIG. 19 and FIG. 20, the trapezoidal embossed portions 579c, 579a can extend into respective notches 588 between the second bottom panel 533 and the longitudinal edges of the respective bottom panels 571, 575, and can extend between the hypotenuses of the protrusions 586 of the respective bottom panels 571, 575.

[0057] In the interior 559 of the container 505, portions of all bottom panels 529, 533, 571, 575 are exposed to the interior 559 and can be attached to the liner 9 to increase the rigidity of the container 505 (FIGS. 19 and 20). The first bottom panel 529 is sized to substantially overlap the entire bottom wall 505 (FIGS. 21 and 22), and through the features of the embossed portion 579b of the opening 581 and the embossed portions 579a, 579c of the respective cutouts 588, the portions of the first bottom panel 529 are substantially flush with the other bottom panels 533, 571, 575 to form the bottom wall 555. In another embodiment, the embossed portions 579a, 579b, 579c can be omitted without departing from the present disclosure. In an embodiment, regardless of whether the embossed portions 579a, 579b, 579c are contained and received in the notches 581, 588 or the embossed portions are omitted and the flat portions of the first bottom panel 529 are exposed to the interior through the notches 581, 588, the first bottom panel 529 can extend along the inner surface of the base layer 507 through the notches 581, 588. Thus, the liner 9 can be secured to the first bottom panel 529 through at least the notches 581, 588 along with the second bottom panel 533, the third bottom panel 571, and the fourth bottom panel 575.

[0058] In the illustrated embodiment, the central panel 11 and the attachment portions 537, 539 can form a flange 557 of the container 505, with the central panel 11 overlapping the attachment portions 537, 539 (FIGS. 23A and 23B). In the illustrated embodiment, the top surface of the central panel 11 forms the top surface of the flange 557, such that the top surface of the flange 557 is devoid of seams, creases, fold lines, folds, edges, and / or other features that may reduce the smoothness of the flange. This can help the flange 557 provide a better surface for attaching the liner 9 to the base layer 507 and / or attaching the lidding film to the flange 557. The liner can be similar or identical to the liner 9 of the first embodiment. In one embodiment, a lidding film or other cover for enclosing the interior 559 of the container 505 may form a tighter seal with the flange 557 than if the flange included pleats, joints, fold lines, creases, edges, and / or other features that may prevent the formation of a seal between the cover and the flange. The side walls 553, bottom wall 555, and / or flange 557 may be omitted or may be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure. Additionally, the flange 557 may include one piece of board (e.g., the center panel 11) having a top surface that extends around the perimeter of the container. The attachment portions 537, 539 bonded to the center panel 11 reinforce the flange 557 and strengthen and increase the rigidity of the container 505. In alternative embodiments, the attachment portions 537, 539 may be omitted without departing from this disclosure.

[0059] The vessel 505 can be made by a method, process, system, machine, etc. similar to any of the vessels disclosed herein.

[0060] 24-27 show various structures, blanks, and containers of the sixth embodiment of the present disclosure. The sixth embodiment is generally similar to the previous embodiments, except for variations noted and variations that will be apparent to one skilled in the art. Thus, similar or identical features of the embodiments are given similar or similar reference numbers. FIG. 24 is a plan view of a blank 603 for forming a base layer 607 of a container 605 (FIGS. 25-27) of the sixth embodiment of the present disclosure. As shown in FIG. 24, the blank 603 can include a first bottom panel 629 and a second bottom panel 633 having a longitudinal direction L1 and a lateral direction L2 and foldably connected to the respective first side panel 21 and second side panel 25 along respective lateral fold lines 31, 35. In the illustrated embodiment, the third bottom panel 671 can be foldably connected to the first end panel 13 along a longitudinal fold line 673, and the fourth bottom panel 675 can be foldably connected to the second end panel 17 along a longitudinal fold line 677. As shown in FIG. 24, the third bottom panel 671 and the fourth bottom panel 675 can extend from the first end panel 13 and the second end panel 17, respectively, of the opening 45. As shown in FIG. 24, the attachment portions 637, 639 of the respective side panels 21, 25 can extend beyond the edges of the side panels 21, 25 and can have edges that correspond to the respective adjacent corner edges of the central panel 11, such that when the container 605 is formed, the edges of the attachment portions 637, 639 extend along or adjacent the respective adjacent corner edges of the central panel 11. The blank 603 may have other shapes, arrangements, positioning, and / or configurations without departing from this disclosure.

[0061] In the illustrated embodiment, the first bottom panel 629 can optionally include embossed areas 679a, 679b, 679c. In one embodiment, the second bottom panel 633 can include an opening 681, with the rectangular embossed area 679b sized and shaped to fit into the rectangular bottom opening 681 (FIGS. 25-27). In other embodiments, the embossed area 679b and / or the bottom opening 681 can be any suitable shape. In the illustrated embodiment, the third bottom panel 671 and the fourth bottom panel 675 have respective free edges 682, 684 that each form two protrusions 686 on either side of a notch 688. Similarly, the second bottom panel 633 has respective longitudinal free edges 634, 636 that each have a respective notch 638. In an embodiment, the free longitudinal edges 634, 636 of the second bottom panel 633 can be portions of the outer edge 633a of the second bottom panel 633. As shown in FIG. 24, the free edges 634, 636 of the second bottom panel 633 can each have two angled and longitudinal portions that cooperate with two angled and longitudinal portions of the respective free edges 684, 682 of the respective bottom panels 675, 671 to form respective hexagonal bottom openings when the bottom wall 655 (FIGS. 26 and 27) is formed. The hexagonal embossed areas 679a, 679c can be sized and shaped to fit into respective bottom openings formed by the notches 638, 688 when the bottom wall 655 is formed (FIGS. 26 and 27).

[0062] 24, the first bottom panel 629 has corner flaps 691a, 691b foldably connected to the first bottom panel 629 along respective diagonal fold lines 691c, 691d adjacent the first side panel 21, and the second bottom panel 633 has corner flaps 693a, 693b foldably connected to the second bottom panel 633 along respective diagonal fold lines 693c, 693d adjacent the second side panel 25. In the illustrated embodiment, the third bottom panel 671 has corner flaps 694, 695 foldably connected to the third bottom panel 671 along respective diagonal fold lines 694a, 695a, and the fourth bottom panel 675 has corner flaps 696, 697 foldably connected to the fourth bottom panel 675 along respective diagonal fold lines 696a, 697a. Any of the corner flaps 691a, 691b, 693a, 693b, 694, 695, 696, 697 and / or diagonal fold lines 691c, 691d, 693c, 693d, 694a, 695a, 696a, 697a may be omitted or may be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure.

[0063] 25-27, when the container 605 is formed from the blank 603, the end panels 13, 17 and side panels 21, 25 extend generally downwardly from the central panel 11 to at least partially form side walls 653 that extend around a bottom wall 655 formed from the bottom panels 629, 633, 671, 675. The bottom wall 655 may be formed by folding the bottom panels 629, 633, 671, 675 relative to the respective side panels 21, 25 and end panels 13, 17 along respective fold lines 31, 35, 673, 677 such that the second bottom panel 633 is first folded inwardly adjacent the third and fourth bottom panels 671, 675. The first bottom panel 629 is then folded inward to overlap the second bottom panel 633 and the adjacent third bottom panel 671 and fourth bottom panel 675. The first bottom panel 629 forms an exterior or bottom layer of the bottom wall 655 of the container 605. In one embodiment, when the bottom wall 655 is formed, the first embossed portion 679a is adjacent one of the notches 688 of the fourth bottom panel 675 and the notches 638 of the second bottom panel 633, the second embossed portion 679b fits into the opening 681 of the second bottom panel 633, and the third embossed portion 679c is adjacent the notches 688 of the third bottom panel 671 and one of the notches 638 of the second bottom panel 633. In an embodiment, the embossed areas 679a, 679c can extend between the respective notches 638 of the second bottom panel 633 and the respective notches 688 of the respective bottom panels 675, 671 such that the embossed areas 679a, 679c are received in respective bottom openings defined between the respective notches.

[0064] In the illustrated embodiment, the corner flap 691a of the first bottom panel 629 cooperates with the corner flap 695 of the third bottom panel 671 to form the corner 608 of the container 605, and the angled fold lines 691c, 695a are at least partially aligned (e.g., collinear) at the corner 608. The corner flap 691b of the first bottom panel 629 cooperates with the corner flap 697 of the fourth bottom panel 675 to form the corner 610 of the container 605, and the angled fold lines 691d, 697a are at least partially aligned (e.g., collinear) at the corner 610. Corner flap 693a of the second bottom panel 633 cooperates with corner flap 694 of the third bottom panel 671 to form a corner 612 of the container 605, with diagonal fold lines 693c, 694a at least partially aligned (e.g., collinear) at corner 612. Corner flap 693b of the second bottom panel 633 cooperates with corner flap 696 of the fourth bottom panel 675 to form a corner 614 of the container 605, with diagonal fold lines 693d, 696a at least partially aligned (e.g., collinear) at corner 614. As shown in the partially formed base layer 607 of Figure 25 and the lined tray 605 of Figures 26 and 27, the corner flaps 691a, 695, 691b, 697, 693a, 694, 693b, 696 can extend alongside one another at respective corners 608, 610, 612, 614. In an embodiment, the corner flaps can be folded upward against the bottom wall 655 of the partially formed base layer 607 of Figure 25. In embodiments, the corner flaps can be folded upward at the corners 608, 610, 612, 614 such that the corner flaps 691a, 691b, 693a, 693b, 694, 695, 696, 697 can extend diagonally from the bottom wall 655 to the central panel 11 of the flange 657 and can extend diagonally between the respective side panels 21, 25 and the end panels 13, 17. For example, the corner flaps 691a, 691b, 693a, 693b, 694, 695, 696, 697 can extend along the corners of the side wall 653.As shown in FIG. 26 , corner flaps 691 a, 691 b can extend along respective ends of the first side panel 21, corner flaps 693 a, 693 b can extend along respective ends of the second side panel 25, corner flaps 694, 695 can extend along respective ends of the first end panel 13, and corner flaps 696, 697 can extend along respective ends of the second end panel 17.

[0065] Within the container 605, portions of all bottom panels 629, 633, 671, 675 are exposed and may be attached to the liner 9 to increase the rigidity of the container 605. The first bottom panel 629 is sized to overlap substantially the entire bottom wall 605, and through the features of the embossed portion 679b of the opening 681 and the embossed portions 679a, 679c of the respective cutouts 688, 638, portions of the first bottom panel 629 are substantially flush with the other bottom panels 633, 671, 675 to form the bottom wall 655 (e.g., forming a flat or at least partially flat surface for holding food products). In another embodiment, the embossed portions 679a, 679b, 679c may be omitted or may be of alternative shapes, arrangements, and / or configurations without departing from the present disclosure. Additionally, corner flaps 691a, 691b, 693a, 693b, 694, 695, 696, 697 may be omitted or may be of alternative shapes, arrangements, and / or configurations without departing from this disclosure.

[0066] In the illustrated embodiment, the central panel 11 and the attachment portions 637, 639 can form a flange 657 of the container 605. In the illustrated embodiment, the top surface of the central panel 11 forms the top surface of the flange 657, such that the top surface of the flange 657 is devoid of seams, creases, fold lines, folds, edges, and / or other features that may reduce the smoothness of the flange. This may help the flange 657 provide a better surface for attaching the liner 9 to the base and / or attaching the lidding film to the flange 657. The liner can be similar or identical to the liner 9 of the first embodiment. In one embodiment, a lidding film or other cover for enclosing the interior 659 of the container 605 can form a tighter seal with the flange 657 than if the flange included seams, creases, fold lines, folds, edges, and / or other features that may interfere with the formation of a seal between the cover and the flange. The side walls 653, bottom wall 655, and / or flange 657 may be omitted or may be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure. Additionally, the flange 657 may include one piece of board (e.g., center panel 11) having an upper surface that extends around the perimeter of the container. The attachment portions 637, 639 adhered to the center panel 11 reinforce the flange 657 and strengthen and increase the rigidity of the container 605. In alternative embodiments, the attachment portions 637, 639 may be omitted without departing from this disclosure.

[0067] The vessel 605 can be made by a method, process, system, machine, etc. similar to any of the vessels disclosed herein.

[0068] 28-30 show various structures, blanks, and containers of the seventh embodiment of the present disclosure. The seventh embodiment is generally similar to the previous embodiment, except for variations noted and variations that will be apparent to one of ordinary skill in the art. Thus, similar or identical features of the embodiments are given similar or similar reference numbers. FIG. 28 is a plan view of a blank 703 for forming a base layer 707 of a container 705 (FIGS. 29 and 30) of the seventh embodiment of the present disclosure. As shown in FIG. 28, the blank 703 has a longitudinal direction L1 and a transverse direction L2, and can include a first bottom panel 729 and a second bottom panel 733 foldably connected to the first side panel 21 and the second side panel 25, respectively, along respective transverse fold lines 31, 35, a third bottom panel 771 foldably connected to the first end panel 13 along a longitudinal fold line 773, and a fourth bottom panel 775 foldably connected to the second end panel 17 along a longitudinal fold line 777. As shown in Figure 28, the third bottom panel 771 and the fourth bottom panel 775 can extend from the first end panel 13 and the second end panel 17, respectively, of the opening 45. As shown in Figure 28, the attachment portions 737, 739 of the respective side panels 21, 25 can extend beyond the edges of the side panels 21, 25 and can have edges that correspond to the respective adjacent corner edges of the central panel 11, such that when the container 705 is formed, the edges of the attachment portions 737, 739 extend along or adjacent to the respective adjacent corner edges of the central panel 11. The blank 703 can be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure.

[0069] In the illustrated embodiment, the third bottom panel 771 and the fourth bottom panel 775 are shaped similarly to the third bottom panel 671 and the fourth bottom panel 675 of the sixth embodiment, with each of the bottom panels 771, 775 having respective free edges 782, 784 each forming two protrusions 786 on either side of a notch 788. As shown in FIG. 28, the second bottom panel 733 can be smaller in the longitudinal direction L1 than the second bottom panel in the conventional embodiment. Instead of a bottom opening as included in the second bottom panel in the previous embodiment, the second bottom panel 733 can have a notch 781 formed in the outer edge 733a of the second bottom panel 733. In the illustrated embodiment, the first bottom panel 729 has corner flaps 791a, 791b adjacent the first side panel 21, the second bottom panel 733 has corner flaps 793a, 793b adjacent the second side panel 25, the third bottom panel 771 has corner flaps 794, 795, and the fourth bottom panel 775 has corner flaps 796, 797. In an embodiment, the corner flaps 791a, 791b, 793a, 793b, 794, 795, 796, 797 can be similar or identical to the corner flaps 691a, 691b, 693a, 693b, 694, 695, 696, 697 of the embodiment of Figures 24-27, for example.

[0070] 29 and 30, when the container 705 is formed from the blank 703, the end panels 13, 17 and side panels 21, 25 extend generally downwardly from the central panel 11 to at least partially form side walls 753 that extend around a bottom wall 755 formed from the bottom panels 729, 733, 771, 775. The bottom wall 755 may be formed by folding the bottom panels 729, 733, 771, 775 relative to the respective side panels 21, 25 and end panels 13, 17 along respective fold lines 31, 35, 773, 777 such that the second bottom panel 733 is first folded inwardly adjacent the third bottom panel 771 and the fourth bottom panel 775. The first bottom panel 729 is then folded inward to overlap the second bottom panel 733 and the adjacent third bottom panel 771 and fourth bottom panels 775. The first bottom panel 729 forms an outer or bottom layer of the bottom wall 755 of the container 705. In the seventh embodiment, the container 705 is formed from a blank 703 that uses less paperboard to reduce the size of the second bottom panel 733, but increases the rigidity of the container 705 as more surface area of ​​the first bottom panel 729 is exposed for adhesion to the liner 9.

[0071] In the illustrated embodiment, the corner flap 791a of the first bottom panel 729 cooperates with the corner flap 795 of the third bottom panel 771 to form the corner 708 of the container 705. The corner flap 791b of the first bottom panel 729 cooperates with the corner flap 797 of the fourth bottom panel 775 to form the corner 710 of the container 705. The corner flap 793a of the second bottom panel 733 cooperates with the corner flap 794 of the third bottom panel 771 to form the corner 712 of the container 705. The corner flap 793b of the second bottom panel 733 cooperates with the corner flap 796 of the fourth bottom panel 775 to form the corner 714 of the container 705. Inside the container 705, portions of all bottom panels 729, 733, 771, 775 are exposed and can be attached to the liner 9 to increase the rigidity of the container 705, and the size of the second bottom panel 733 is reduced resulting in a larger surface area of ​​the first bottom panel 729 being exposed.

[0072] In the illustrated embodiment, the central panel 11 and the attachment portions 737, 739 can form a flange 757 of the container 705. In the illustrated embodiment, the top surface of the central panel 11 forms the top surface of the flange 757, such that the top surface of the flange 757 is devoid of seams, creases, fold lines, folds, edges, and / or other features that may reduce the smoothness of the flange. This may help the flange 757 provide a better surface for attaching the liner 9 to the base and / or attaching the lidding film to the flange 757. The liner may be similar or identical to the liner 9 of the first embodiment. In one embodiment, a lidding film or other cover for enclosing the interior 759 of the container 705 can form a tighter seal with the flange 757 than if the flange included seams, creases, fold lines, folds, edges, and / or other features that may interfere with the formation of a seal between the cover and the flange. The side walls 753, bottom wall 755, and / or flanges 757 may be omitted or may be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure. Additionally, the flanges 757 may include one piece of board (e.g., center panel 11) having an upper surface that extends around the perimeter of the container. Attachment portions 737, 739 adhered to the center panel 11 reinforce the flanges 757 and strengthen and increase the rigidity of the container 705. In alternative embodiments, the attachment portions 737, 739 may be omitted without departing from this disclosure.

[0073] The vessel 705 can be made by a method, process, system, machine, etc. similar to any of the vessels disclosed herein.

[0074] 31-33 show various structures, blanks, and containers of the eighth embodiment of the present disclosure. The eighth embodiment is generally similar to the previous embodiments, except for variations noted and variations that will be apparent to one of ordinary skill in the art. Thus, similar or identical features of the embodiments are given similar or similar reference numbers. FIG. 31 is a plan view of a blank 803 for forming a base layer 807 of a container 805 (FIGS. 31 and 32) of the eighth embodiment of the present disclosure. As shown in FIG. 31, the blank 803 has a longitudinal direction L1 and a transverse direction L2, and can include a first bottom panel 829 and a second bottom panel 833 foldably connected to the first side panel 21 and the second side panel 25, respectively, along respective transverse fold lines 31, 35, a third bottom panel 871 foldably connected to the first end panel 13 along a longitudinal fold line 873, and a fourth bottom panel 875 foldably connected to the second end panel 17 along a longitudinal fold line 877. 31, the third bottom panel 871 and the fourth bottom panel 875 can extend from the respective first end panel 13 and second end panel 17 at the central opening 45. Additionally, in embodiments, the blank 803 can include side reinforcement flaps 894, 895 foldably connected to either side of the central panel 11 along respective transverse fold lines 894a, 895a and extending to the central opening 45 of the central panel 11. In the illustrated embodiment, respective edges of the bottom panels 871, 875 and the side reinforcement flaps 894, 895 can extend along the central opening 45 of the blank 803. In exemplary embodiments, ends of the side reinforcement flaps 894, 895 can abut the respective bottom panels 871, 875 and / or end panels 13, 17 (e.g., along respective cuts or slits or other suitable features).In an embodiment, the side reinforcement flaps 894, 895 may be partially connected to their respective bottom panels 871, 875 and / or end panels 13, 17 by nicks or other suitable mechanisms, which may help keep the blank 803 flat during formation of the base layer 807 of the container 805 from the blank 803 until the nicks are broken to separate the side reinforcement flaps 894, 895 from their respective bottom panels 871, 875 and / or end panels 13, 17.

[0075] 31, the attachment portions 837, 839 of each side panel 21, 25 can include extensions 891a, 891b, 893a, 893b that extend away from the central panel (e.g., in the longitudinal direction L1) and beyond the edges of the side panels 21, 25. In an exemplary embodiment, each of the extensions 891a, 891b, 893a, 893b can have a length that is approximately half the distance between the transverse fold lines 23, 27 such that the distal free edges of the extensions 891a, 893a and 891b, 893b are brought together (e.g., proximate or abutting) under the central panel 11 when the container 805 is formed, as described in more detail below. 31, each of the extensions 891a, 891b, 893a, 893b can include a respective end reinforcement flap 896a, 896b, 897a, 897b foldably connected to the respective extension along a respective longitudinal fold line 891c, 891d, 893c, 893d to reinforce the end panels 13, 17 when the container 805 is formed from the blank 803. In an exemplary embodiment, the end reinforcement flap 896a, 896b, 897a, 897b can be separable from the respective bottom panel 829, 833 and / or side panel 21, 25 along a respective cut or slit or other suitable feature. In an embodiment, each of the end reinforcement flaps 896a, 896b, 897a, 897b may be at least partially connected to their respective bottom panels 829, 833 and / or side panels 21, 25 by one or more notches or other suitable mechanisms, which may help keep the blank 803 flat during formation of the base layer 807 of the container 805 from the blank 803 until the notches are broken to separate the end reinforcement flaps 896a, 896b, 897a, 897b from their respective bottom panels 829, 833 and / or side panels 21, 25.As shown in Figure 31, each of the extensions 891a, 891b, 893a, 893b can include a respective opening or slot aligned with a respective fold line 891c, 891d, 893c, 893d which can help prevent bunching of material when the end reinforcement flaps are folded over their respective extensions when the extensions and end reinforcement flaps are placed in face-to-face contact with the central panel 11 and respective end panels 13, 17 (e.g., Figure 33). Blank 803 can be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure.

[0076] As shown in FIG. 31, each of the free edges 882, 884 of the bottom panels 871, 875 can have two sloping portions extending from a respective longitudinal portion, which gives the bottom panels 871, 875 a trapezoidal shape. In an embodiment, the second bottom panel 833 can include two notches 838 formed in the respective free edges 834, 836, which can be shaped to receive the bottom panels 871, 875 when the bottom wall 855 is formed (FIG. 32). As shown in FIG. 31, the second bottom panel 833 can include a plurality of notches or bottom openings 881a, 881b, which can include a rectangular bottom opening 881a extending in the longitudinal direction L1 and a bottom opening 881b located at an end of the second bottom panel 833 and generally following the contours of the free edges 836, 834. In the illustrated embodiment, each of the bottom panels 871, 875 can include a notch or bottom opening 881c, which can be trapezoidal as shown or any suitable shape. Any of the bottom panels 833, 871, 875 and / or bottom openings can be omitted or can be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure. For example, each of the bottom panels 833, 871, 875 can have any suitable number of bottom openings having any suitable shape and / or orientation. Further, in an embodiment, the first bottom panel 829 can include one or more embossed areas corresponding to one or more of the openings 881a, 881b, 881c such that when the bottom wall 855 is formed, the embossed areas will be at least partially received in the openings 881a, 881b, 881c.

[0077] 32 and 33, when the container 805 is formed from the blank 803, the end panels 13, 17 and side panels 21, 25 extend generally downwardly from the central panel 11 to at least partially form side walls 853 that extend around the periphery of a bottom wall 855 formed from the bottom panels 829, 833, 871, 875. The bottom wall 855 may be formed by folding the bottom panels 829, 833, 871, 875 relative to the respective side panels 21, 25 and end panels 13, 17 along respective fold lines 31, 35, 873, 877 such that the second bottom panel 833 is first folded inwardly adjacent the third bottom panel 871 and the fourth bottom panel 875 (FIG. 32). The first bottom panel 829 is then folded inwardly to overlap the second bottom panel 833 and the adjacent third and fourth bottom panels 871 and 875. The first bottom panel 829 forms an outer or bottom layer of the bottom wall 855 of the container 805 (FIG. 33). As shown in FIG. 32, the second bottom panel 833, the third bottom panel 871, and the fourth bottom panel 875 extend along the interior of the container 805 with the bottom panels 871, 875 received in the notches 838 of the second bottom panel 833 and the liner 9 attached to the upper surfaces of the bottom panels 833, 871, 875. In the illustrated embodiment, the top surface of the first bottom panel 829 also extends along the interior of the container 805 through bottom openings 881a, 881b, 881c in the bottom panels 833, 871, 875, such that the liner 9 is attached to the top surface of the first bottom panel 829 through openings 881a, 881b, 881c. The bottom wall 855 may be formed in other manners without departing from this disclosure.

[0078] 33, when the side panels 21, 25 are positioned to form the side wall 853, the attachment portions 837, 839 along with their extensions 891a, 891b, 893a, 893b can be folded under the central panel 11. In the illustrated embodiment, the attachment portions 837, 839 and extensions 891a, 891b, 893a, 893b can be adhered to the underside of the central panel 11 such that the central panel 11 and the attachment portions 837, 839 cooperate to form the flange 857 of the container 705. In an embodiment, the extensions 891a, 893a can be mated together adjacent to the first end panel 13 (e.g., can be adjacent to each other and / or can abut / contact each other) and the extensions 891b, 893b can be mated together adjacent to the second end panel 17 (e.g., can be adjacent to each other and / or can abut / contact each other). In the illustrated embodiment, the attachment portions 837, 839 and extensions 891a, 891b, 893a, 893b can reinforce the central panel 11 along with the side panels 21, 23 and end panels 13, 17. As shown in FIG. 32, the top surface of the central panel 11 forms the top surface of the flange 857, which is thereby devoid of joints, pleats, fold lines, folds, edges, and / or other features that may reduce the smoothness of the flange. This may facilitate the flange 857 providing a better surface for attaching the liner 9 to the base and / or attaching the lidding film to the flange 857. The liner may be similar or identical to the liner 9 of the first embodiment. In one embodiment, a lidding film or other cover for enclosing the interior 859 of the container 805 may form a tighter seal with the flange 857 than if the flange included pleats, joints, fold lines, folds, edges, and / or other features that may interfere with the formation of a seal between the cover and the flange.

[0079] As shown in Figure 33, the end reinforcement flaps 896a, 897a of extensions 891a, 893a can be placed in face-to-face contact with an outer surface of the first end panel 13, and the end reinforcement flaps 896b, 897b of extensions 891b, 893b can be placed in face-to-face contact with an outer surface of the second end panel 17. In embodiments, the end reinforcement flaps 896a, 897a, 896b, 897b can be glued or otherwise attached to the outer surface of the respective end panel 13, 17 to reinforce the respective end panel 13, 17. As shown in Figure 32, the side reinforcement flaps 894, 895 can be folded downwardly relative to the central panel 11 along respective fold lines 894a, 895a such that the side reinforcement flaps 894, 895 are in face-to-face contact with the inner surface of the respective side panel 21, 23. In an embodiment, to reinforce the side panels 21, 23, the side reinforcement flaps 894, 895 may be adhered or otherwise attached to the inner surface of the respective side panels 21, 23. Thus, the side wall 853 of the container 805 may be reinforced by the side reinforcement flaps 894, 895 and the end reinforcement flaps 896a, 897a, 896b, 897b extending along the respective side panels 21, 23 and respective end panels 13, 17, strengthening and stiffening the container 805.

[0080] The side walls 853, bottom wall 855, and / or flanges 857 may be omitted or may be of other shapes, arrangements, positioning, and / or configurations without departing from this disclosure. Additionally, the flanges 857 may include one piece of board (e.g., center panel 11) having an upper surface that extends around the perimeter of the container. The attachment portions 837, 839 and their extensions 891a, 891b, 893a, 893b adhered to the center panel 11 strengthen the flanges 857 and increase the strength and stiffness of the container 805. In alternative embodiments, the attachment portions 837, 839 may be omitted without departing from this disclosure.

[0081] The container 805 can be made by a method, process, system, machine, etc. similar to any of the containers disclosed herein.

[0082] Any of the features of the various embodiments of the present disclosure may be combined, substituted, or otherwise configured with other features of other embodiments of the present disclosure without departing from the scope of the present disclosure.

[0083] Optionally, one or more portions of the blank, or other structures described or contemplated herein, may be coated with varnish, clay, or other materials, either alone or in combination. The coating may then be printed with product advertising or other information or images. Also, the blank or other structures 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 may be coated and / or printed.

[0084] Any of the blanks, containers, or other structures of the present disclosure may optionally include one or more mechanisms that modify the effect of microwave energy during heating or cooking of a food item 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 particular areas of a food item, shield particular areas of a food item from microwave energy to prevent overheating, or transmit microwave energy toward or away from particular areas of a food item. Each microwave interactive element includes 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 structure and food item.

[0085] In the case of a susceptor or shield, the microwave energy interactive element may comprise a conductive or semiconductive element, 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 suitable metals and metal alloys 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.

[0086] Alternatively, the microwave energy interactive element may include a metal oxide, such as an oxide of aluminum, iron, and tin, optionally used in conjunction with a conductive material. Another suitable metal oxide is indium tin oxide (ITO). ITO has a more uniform crystal structure and is therefore transparent at most film thicknesses.

[0087] Alternatively or additionally, the microwave energy interactive element may comprise a suitable conductive, semiconductive, or nonconductive artificial dielectric or ferroelectric material. The artificial dielectric material consists of conductive finely divided elements in a polymer or other suitable matrix or binder, and may include flakes of a conductive metal, for example aluminum.

[0088] In other embodiments, the microwave energy interactive element 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.

[0089] In yet another embodiment, the microwave energy interactive element can interact with the magnetic portion of the electromagnetic energy of a microwave oven. Properly selected elements of this type can be self-limiting based on loss of interaction when the Curie temperature of the element is reached. An example of such an interactive coating is described in U.S. Patent 4,283,427.

[0090] The use of other microwave energy interactive elements is also contemplated. In one example, the microwave energy interactive element may include a foil or high optical density evaporation element having a thickness sufficient to reflect a substantial portion of the microwave energy impinging on it. 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.

[0091] In some cases, microwave energy reflecting (or reflective) elements may be used as shielding elements when the food product is prone to burning or drying 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. Patents 6,204,492, 6,433,322, 6,552,315, and 6,677,563, each of which is incorporated herein by reference in its entirety.

[0092] Optionally, any of the numerous microwave energy interactive elements described or contemplated herein may be substantially continuous, i.e., substantially free of breaks or interruptions, or may be discontinuous, for example, by including one or more breaks or openings that transmit 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 structure being formed, the food product being 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 due to direct heating, and the presence and degree of need for ventilation.

[0093] By way of example, a microwave energy interactive element may include one or more transparent areas 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 thus the amount of microwave energy interactive element available for heating, browning, and / or crisping the surface of the food item. Thus, the relative amounts of microwave energy interactive area and microwave energy transparent areas may be balanced to achieve the desired overall heating characteristics of a particular food item.

[0094] As another example, one or more portions of the susceptor may be designed to be microwave energy inert, thereby ensuring that microwave energy is efficiently focused on the areas to be heated, browned, and / or crisped, rather than being lost to portions of the food not intended to be browned and / or crisped, or to the heating environment. Additionally, or alternatively, it may be beneficial to create one or more discontinuities or inactive areas to prevent overheating or charring of the food and / or the structure containing the susceptor.

[0095] As yet another example, the susceptor may incorporate one or more "fuse" elements that limit the propagation of cracks in the susceptor in areas of the susceptor where heat transfer to the food product is low and the susceptor tends to overheat, thereby controlling overheating. The size and shape of the fuses 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 (February 14, 2008), and PCT Application Publication WO2007 / 127371 (November 8, 2007), each of which is incorporated herein by reference in its entirety.

[0096] 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. Dimensions of blanks, containers, forming tools, features, or any other dimensions may be larger or smaller than those shown and described in the present disclosure without departing from the scope of the present disclosure, and may be within or outside the dimensional ranges described for each feature without departing from the scope of the present disclosure.

[0097] Blanks according to the invention can be formed, for example, from coated paperboard and similar materials. For example, the inside and / or outside of the blank can be coated with a clay coating. The clay coating can then be printed with product, advertising, price codes, 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.

[0098] According to an exemplary embodiment, the blanks may be constructed of paperboard, which is heavier and stiffer than regular paper, or the blanks may be constructed of cardboard, rigid paper, or any other material having suitable properties to enable the carton package to function at least generally as described above.

[0099] The foregoing description illustrates and describes various embodiments 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, since various changes may be made to the above configurations without departing from the scope of the present disclosure. 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 presented herein, commensurate with the above teachings, and / or within the skill or knowledge of the relevant art. Moreover, 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 container for holding food, comprising: a substrate and a liner at least partially attached to an inner surface of the substrate; a flange comprising a central panel of the substrate; an opening extending through the central panel; a sidewall comprising a plurality of panels, each panel of the plurality of panels being foldably connected to the central panel, at least one panel of the plurality of panels being foldably connected to the central panel along the opening; a bottom wall comprising at least a first bottom panel and a second bottom panel foldably connected to each panel of the plurality of panels, the second bottom panel comprising a cutout; the second bottom panel at least partially overlaps the first bottom panel such that the second bottom panel extends along the inner surface of the substrate; The first bottom panel extends along the inner surface of the base layer at least through the cutout.

2. 10. The container of claim 1, wherein the liner is at least partially attached to the first bottom panel through the cutout in the second bottom panel.

3. 2. The container of claim 1, wherein the plurality of panels comprises a first panel foldably connected to the central panel along a first fold line spaced from the central opening, and the first bottom panel foldably connected to the first panel.

4. 4. The container of claim 3, wherein the plurality of panels further comprises a second panel foldably connected to the central panel along a second fold line spaced from the central opening, the second panel being opposite the first panel, and the second bottom panel foldably connected to the second panel.

5. 5. The container of claim 4, wherein the cutout extends through the second bottom panel and comprises a bottom opening spaced from an outer edge of the second bottom panel.

6. 6. The container of claim 5, wherein the first bottom panel includes an embossed area that is at least partially received in the bottom opening of the second bottom panel.

7. 6. The container of claim 5, wherein the cutout comprises a first cutout and the second bottom panel comprises a second cutout in the form of a notch formed in the outer edge of the second bottom panel.

8. 5. The container of claim 4, wherein the plurality of panels further comprises a third panel foldably connected to the central panel along the opening, the bottom wall further comprises a third bottom panel foldably connected to the third panel and at least partially overlapping the first bottom panel, the cutout being a first cutout and the third bottom panel comprising a second cutout.

9. 9. The container of claim 8, wherein the second cutout is a notch formed in a free edge of the third bottom panel, and the first bottom panel has a first embossed area at least partially received in the first cutout and a second embossed area at least partially received in the second cutout between the free edge of the third bottom panel and an outer edge of the second bottom panel.

10. 9. The container of claim 8, wherein the first cutout is in the form of a first notch formed in an outer edge of the second bottom panel and the second cutout is in the form of a second notch formed in a free edge of the third bottom panel, the first bottom panel including an embossed area at least partially received in the first notch and the second notch extending between the outer edge of the second bottom panel and the free edge of the third bottom panel.

11. 5. The container of claim 4, wherein the cutout is in the form of a notch formed in an outer edge of the second bottom panel.

12. 4. The container of claim 3, wherein the plurality of panels further comprises a second panel foldably connected to the central panel along a second fold line extending along the opening, the second bottom panel being foldably connected to the second panel.

13. 13. The container of claim 12, wherein the cutout is in the form of a notch in a free edge of the second bottom panel.

14. 14. The container of claim 13, wherein the bottom wall further comprises a third bottom panel at least partially overlapping the first bottom panel, the first bottom panel extending along the inner surface of the base layer at least through the notch between the free edge of the second bottom panel and an outer edge of the third bottom panel.

15. 14. The container of claim 13, wherein the bottom wall further comprises a third bottom panel at least partially overlapping the first bottom panel, the first bottom panel comprising an embossed area at least partially received in the notch between the free edge of the second bottom panel and an outer edge of the third bottom panel.

16. 14. The container of claim 13, wherein the bottom wall further comprises a third bottom panel at least partially overlapping the first bottom panel, the second bottom panel comprising two protrusions formed on the free edge, the notch extending between the two protrusions, and the two protrusions contacting an outer edge of the third bottom panel.

17. 2. The container of claim 1, further comprising a first corner flap foldably connected to the first bottom panel and a second corner flap foldably connected to the second bottom panel, the first corner flap and the second corner flap cooperating to form a corner of the container.

18. 20. The container of claim 17, wherein the corner flap is aligned with the corner of the container and extends diagonally relative to the panel of the plurality of panels.

19. 18. The container of claim 17, wherein the plurality of panels comprises a first panel foldably connected to the central panel along a first fold line spaced from the central opening and a second panel foldably connected to the central panel along a second fold line extending along the opening, the first bottom panel being foldably connected to the first panel and the second bottom panel being foldably connected to the second panel, and the first and second corner flaps extending along the respective first and second panels at the corners of the container.

20. 18. The container of claim 17, wherein the first corner flap and the second corner flap extend from the bottom wall to the center panel along at least a portion of the side wall.

21. 18. The container of claim 17, wherein the corner is a first corner, the bottom wall further comprises a third bottom panel at least partially overlapping the first bottom panel, and the container further comprises a third corner flap foldably connected to the third bottom panel and a fourth corner flap foldably connected to the second bottom panel, the third corner flap and the fourth corner flap cooperating to form a second corner of the container.

22. 18. The container of claim 17, wherein the corner is a first corner, the bottom wall further comprises a third bottom panel at least partially overlapping the first bottom panel, and the container further comprises a third corner flap foldably connected to the third bottom panel and a fourth corner flap foldably connected to the first bottom panel, the third corner flap and the fourth corner flap cooperating to form a second corner of the container.

23. 10. The container of claim 1, further comprising a side reinforcement flap foldably connected to the central panel along a transverse fold line and in at least partial face-to-face contact with one of the plurality of panels.

24. 2. The container of claim 1, wherein the plurality of panels comprises side panels foldably connected to the central panel along a first fold line spaced from the central opening and end panels foldably connected to the central panel along a second fold line extending along the opening, the side panels having attachment portions in face-to-face contact with an underside of the central panel, and end reinforcement flaps foldably connected to extensions of the attachment portions, the end reinforcement flaps in at least partial face-to-face contact with the end panels.

25. 25. The container of claim 24, further comprising a side reinforcement flap foldably connected to the central panel along a third fold line extending along the opening, the side reinforcement flap being in at least partial face-to-face contact with the side panel.

26. 2. The container of claim 1, further comprising a plurality of bottom openings extending through the second bottom panel, the first bottom panel extending along the inner surface of the base layer through each bottom opening of the plurality of bottom openings.

27. 27. The container of claim 26, wherein the bottom wall further comprises a third bottom panel at least partially overlapping the first bottom panel, a bottom opening extending into the third bottom panel, and the first bottom panel extending along the inner surface of the base layer through the bottom opening of the third bottom panel.

28. 1. A combination of a blank and a liner material to form a container for holding a food product, said blank comprising: a central panel at least partially forming a flange of the container formed from the blank and the liner material; an opening extending through the central panel; a plurality of panels for forming side walls when the container is formed from the blank and the liner material, each panel of the plurality of panels being foldably connected to the central panel, and at least one panel of the plurality of panels being foldably connected to the central panel along the opening; at least a first bottom panel and a second bottom panel for forming a bottom wall when the container is formed from the blank and the liner material, the first bottom panel and the second bottom panel being foldably connected to respective panels of the plurality of panels, the second bottom panel including a cutout; when the container is formed from the blank and the liner material, the second bottom panel at least partially overlaps the first bottom panel; the blank is for forming a base layer of the container, the liner material being for being at least partially attached to an inner surface of the base layer when the container is formed from the blank and the liner material; a combination wherein when the container is formed from the blank and the liner material, the second bottom panel extends along an inner surface of the base layer, and when the container is formed from the blank and the liner material, the first bottom panel extends along the inner surface of the base layer through at least the cutout.

29. 30. The combination of claim 28, wherein the liner is for being at least partially attached to the first bottom panel through the cutout in the second bottom panel when the container is formed from the blank and the liner material.

30. 30. The combination of claim 28, wherein the plurality of panels comprises a first panel foldably connected to the central panel along a first fold line spaced from the central opening, and the first bottom panel foldably connected to the first panel.

31. 31. The combination of claim 30, wherein the plurality of panels further comprises a second panel foldably connected to the central panel along a second fold line spaced from the central opening, the second panel being opposite the first panel, and the second bottom panel foldably connected to the second panel.

32. 32. The combination of claim 31, wherein the cutout comprises a bottom opening extending through the second bottom panel and spaced from an outer edge of the second bottom panel.

33. 33. The combination of claim 32, wherein the first bottom panel includes an embossed area for being at least partially received in the bottom opening of the second bottom panel when the container is formed from the blank and the liner material.

34. 33. The combination of claim 32, wherein the cutout comprises a first cutout and the second bottom panel comprises a second cutout in the form of a notch formed in the outer edge of the second bottom panel.

35. 32. The combination of claim 31 , wherein the plurality of panels further comprises a third panel foldably connected to the central panel along the opening, the blank further comprises a third bottom panel foldably connected to the third panel, the cutout being a first cutout and the third bottom panel comprising a second cutout.

36. 36. The combination of claim 35, wherein the second cutout is a notch formed in a free edge of the third bottom panel, and the first bottom panel has a first embossed area at least partially received in the first cutout and a second embossed area at least partially received in the second cutout between the free edge of the third bottom panel and an outer edge of the second bottom panel.

37. 36. The combination of claim 35, wherein the first cutout is in the form of a first notch formed in an outer edge of the second bottom panel and the second cutout is in the form of a second notch formed in a free edge of the third bottom panel, the first bottom panel including an embossed area at least partially received in the first notch and the second notch extending between the outer edge of the second bottom panel and the free edge of the third bottom panel when the container is formed from the blank and the liner material.

38. 32. The combination of claim 31, wherein the cutout is in the form of a notch formed in an outer edge of the second bottom panel.

39. 31. The combination of claim 30, wherein the plurality of panels further comprises a second panel foldably connected to the central panel along a second fold line extending along the opening, the second bottom panel foldably connected to the second panel.

40. 40. The combination of claim 39, wherein the cutout is in the form of a notch in a free edge of the second bottom panel.

41. 41. The combination of claim 40, wherein the bottom wall further comprises a third bottom panel for at least partially overlapping the first bottom panel when the container is formed from the blank and the liner material, the first bottom panel for extending along the inner surface of the base layer through the notch between at least the free edge of the second bottom panel and an outer edge of the third bottom panel when the container is formed from the blank and the liner material.

42. 41. The combination of claim 40, wherein the bottom wall further comprises a third bottom panel for at least partially overlapping the first bottom panel when the container is formed from the blank and the liner material, the first bottom panel comprising an embossed area for at least partially being received in the notch between the free edge of the second bottom panel and an outer edge of the third bottom panel.

43. 41. The combination of claim 40, wherein the bottom wall further comprises a third bottom panel for at least partially overlapping the first bottom panel when the container is formed from the blank and the liner material, the second bottom panel having two protrusions formed on the free edge, the notch extending between the two protrusions, and the two protrusions for contacting an outer edge of the third bottom panel when the container is formed from the blank and the liner material.

44. 30. The combination of claim 28, further comprising a first corner flap foldably connected to the first bottom panel and a second corner flap foldably connected to the second bottom panel, the first corner flap and the second corner flap being for cooperating to form a corner of the container formed from the blank and the liner material.

45. 45. The combination of claim 44, wherein the plurality of panels comprises a first panel foldably connected to the central panel along a first fold line spaced from the central opening and a second panel foldably connected to the central panel along a second fold line extending along the opening, wherein the first bottom panel is foldably connected to the first panel and the second bottom panel is foldably connected to the second panel, and the first corner flap and the second corner flap are for extending along the respective first and second panels at the corners of the container formed from the blank and the liner material.

46. 30. The combination of claim 28, further comprising a side reinforcement flap foldably connected to said central panel along a transverse fold line, said side reinforcement flap for at least partial face-to-face contact with one of said plurality of panels when said container is formed from said blank and said liner material.

47. 29. The combination of claim 28, wherein the plurality of panels comprises side panels foldably connected to the central panel along a first fold line spaced from the central opening and end panels foldably connected to the central panel along a second fold line extending along the opening, the side panels having attachment portions for face-to-face contact with at least a portion of the central panel when the container is formed from the blank and the liner material, and end reinforcement flaps foldably connected to extensions of the attachment portions, the end reinforcement flaps for at least partial face-to-face contact with the end panels when the container is formed from the blank and the liner material.

48. 48. The combination of claim 47, further comprising a side reinforcement flap foldably connected to said central panel along a third fold line extending along said opening, said side reinforcement flap for at least partial face-to-face contact with said side panel when said container is formed from said blank and said liner material.

49. 30. The combination of claim 28, wherein the bottom wall further comprises a third bottom panel for at least partially overlapping the first bottom panel when the container is formed from the blank and the liner material, the blank further comprising a plurality of bottom openings extending through the second bottom panel and the third bottom panel.

50. 1. A method of forming a container for holding a food product, comprising the steps of: obtaining a flat structure comprising a central panel, an opening extending through the central panel, a plurality of panels, a first bottom panel, and a second bottom panel, each panel of the plurality of panels being foldably connected to the central panel, at least one panel of the plurality of panels being foldably connected to the central panel along the opening, the first bottom panel and the second bottom panel being foldably connected to each panel of the plurality of panels, the second bottom panel comprising a cutout; forming a base for the container by folding the panels to extend at least downwardly from the central panel, whereby the panels at least partially form side walls, the central panel at least partially form a flange, and positioning the first and second bottom panels to at least partially form a bottom wall, wherein the second bottom panel at least partially overlaps the first bottom panel, whereby the second bottom panel extends along an inner surface of the base, and the first bottom panel extends along the inner surface of the base at least through the cutout; and attaching a liner to the inner surface of the substrate.

51. 51. The method of claim 50, wherein attaching the liner to the inner surface of the base layer comprises at least partially attaching the liner to the first bottom panel through the cutout in the second bottom panel.

52. 51. The method of claim 50, wherein the first bottom panel comprises an embossed area, and the positioning the first bottom panel and the second bottom panel comprises positioning the embossed area to be at least partially received in the cutout of the second bottom panel.

53. 51. The method of claim 50, wherein the blank further comprises a first corner flap foldably connected to the first bottom panel and a second corner flap foldably connected to the second bottom panel, and forming the base layer further comprises forming a corner of the container by folding the first corner flap and the second corner flap to extend along the corner of the container.

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