Tray for food

Abstract

A tray for holding at least one food item, the tray having a plurality of panels extending at least partially around an interior of the tray and including a bottom panel, a front panel foldably connected to the bottom panel, a back panel foldably connected to the bottom panel, and a top panel foldably connected to one of the front and back panels, the tray further comprising a plurality of end flaps foldably connected to respective panels of the plurality of panels, the plurality of end flaps at least partially overlapping to form at least one closed end of the tray, and a flange including the top panel, the flange extending outwardly from the front panel, the back panel, and the at least one closed end of the tray.

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 339,628, filed May 9, 2022, and U.S. Provisional Patent Application No. 63 / 341,711, filed May 13, 2022.

[0002] [Incorporated by reference] U.S. Design Patent Application No. 29 / 891,539, filed May 8, 2023; U.S. Design Patent Application No. 29 / 891,540, filed May 8, 2023; U.S. Provisional Patent Application No. 63 / 110,578, filed November 6, 2020; U.S. Provisional Patent Application No. 63 / 110,582, filed November 6, 2020; U.S. Provisional Patent Application No. 63 / 110,587, filed November 6, 2020; U.S. Provisional Patent Application No. 63 / 110,590, filed December 16, 2020; No. 26,157, U.S. Provisional Patent Application No. 63 / 128,418 filed December 21, 2020, U.S. Provisional Patent Application No. 63 / 139,341 filed January 20, 2021, U.S. Provisional Patent Application No. 63 / 169,302 filed April 1, 2021, U.S. Provisional Patent Application No. 63 / 169,418 filed April 14, 2021, U.S. Provisional Patent Application No. 63 / 174,724 filed April 22, 2021 No. 63 / 178,116, U.S. Provisional Patent Application No. 63 / 191,412 filed June 1, 2021, U.S. Provisional Patent Application No. 17 / 519,080 filed November 4, 2021, U.S. Provisional Patent Application No. 17 / 519,084 filed November 4, 2021, U.S. Provisional Patent Application No. 17 / 519,092 filed November 4, 2021, U.S. Provisional Patent Application No. 17 / 519,097 filed November 4, 2022, U.S. Provisional Patent Application No. The disclosures of each of U.S. Provisional Patent Application No. 17 / 519,017, U.S. Provisional Patent Application No. 63 / 284,823, filed December 1, 2021, U.S. Provisional Patent Application No. 63 / 292,014, filed December 21, 2021, U.S. Provisional Patent Application No. 63 / 339,628, filed May 9, 2022, and U.S. Provisional Patent Application No. 63 / 341,711, filed May 13, 2022, are hereby incorporated by reference for all purposes as if set forth in their entireties in this disclosure.

[0003] FIELD OF THE DISCLOSURE The present disclosure relates generally to a tray for holding at least one food item. Summary of the Invention

[0004] According to one aspect, the present disclosure generally relates to a tray for holding at least one food item comprising a plurality of panels extending at least partially around an interior of the tray and including a bottom panel, a front panel foldably connected to the bottom panel, a back panel foldably connected to the bottom panel, and a top panel foldably connected to one of the front and back panels, a plurality of end flaps foldably connected to respective panels of the plurality of panels, the plurality of end flaps at least partially overlapping to form at least one closed end of the tray, and a flange comprising the top panel, the flange extending outwardly from the front panel, the back panel, and the at least one closed end of the tray.

[0005] In accordance with another aspect, the disclosure generally relates to a blank for forming a tray for holding at least one food item, the blank comprising a plurality of panels extending at least partially around an interior of the tray formed from the blank, the plurality of panels including a bottom panel, a front panel foldably connected to the bottom panel, a back panel foldably connected to the bottom panel, and a top panel foldably connected to one of the front and back panels, and a plurality of end flaps foldably connected to respective panels of the plurality of panels, the plurality of end flaps at least partially overlapping to form at least one closed end of the tray formed from the blank, the top panel forming a flange extending outwardly from the front panel, the back panel, and the at least one closed end of the tray formed from the blank.

[0006] According to another aspect, the disclosure generally relates to a method of forming a tray for holding at least one food item, the method including obtaining a blank comprising a plurality of panels including a bottom panel, a front panel foldably connected to the bottom panel, a back panel foldably connected to the bottom panel, and a top panel foldably connected to one of the front panel and the back panel, the blank further comprising a plurality of end flaps foldably connected to respective panels of the plurality of panels. The method further includes positioning the plurality of panels to extend at least partially around an interior of the tray, at least partially overlapping the plurality of end flaps to form at least one closed end of the tray, and positioning the top panel to form a flange extending outwardly from the at least one closed end of the tray formed from the front panel, the back panel, and the blank.

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

[0008] According to common practice, the various features of the drawings described below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate embodiments of the present disclosure. [Brief description of the drawings]

[0009] [Figure 1] FIG. 2 is a plan view of an exterior surface of a blank used to form a tray according to a first exemplary embodiment of the present disclosure. [Diagram 2] 2 is a perspective view of a tray formed from the blank of FIG. 1 according to a first exemplary embodiment of the present disclosure. FIG. [Diagram 3] FIG. 3 is another perspective view of the tray of FIG. 2. [Figure 4]FIG. 13 is a plan view of an exterior surface of a blank used to form a tray according to a second exemplary embodiment of the present disclosure. [Diagram 5] FIG. 5 is a perspective view of a tray formed from the blank of FIG. 4 according to a second exemplary embodiment of the present disclosure. [Figure 6] FIG. 6 is another perspective view of the tray of FIG. 5. [Figure 7] FIG. 13 is a plan view of an exterior surface of a blank used to form a tray according to a third exemplary embodiment of the present disclosure. [Figure 8] 8 is a perspective view of a tray formed from the blank of FIG. 7 according to a third exemplary embodiment of the present disclosure, in an open configuration. [Figure 9] 8 is a perspective view of a tray formed from the blank of FIG. 7 according to a third exemplary embodiment of the present disclosure, in a closed configuration. [Figure 10] FIG. 13 is a plan view of an exterior surface of a blank used to form a tray according to a fourth exemplary embodiment of the present disclosure. [Figure 11] 11 is a perspective view of a tray formed from the blank of FIG. 10 according to a fourth exemplary embodiment of the present disclosure, in an open configuration. [Figure 12] 11 is a perspective view of a tray formed from the blank of FIG. 10 according to a fourth exemplary embodiment of the present disclosure in a closed configuration. [Figure 13] FIG. 13 is a plan view of an exterior surface of a blank used to form a tray according to a fifth exemplary embodiment of the present disclosure. [Figure 14] FIG. 14 is a perspective view of a tray formed from the blank of FIG. 13 according to a fifth exemplary embodiment of the present disclosure. [Figure 15] FIG. 15 is another perspective view of the tray of FIG. 14. [Figure 16] FIG. 13 is a plan view of an exterior surface of a blank used to form a tray according to a sixth exemplary embodiment of the present disclosure. [Figure 17] FIG. 13 is a plan view of an exterior surface of a blank used to form a tray according to a sixth exemplary embodiment of the present disclosure, in an open configuration. [Figure 18] FIG. 17 is a perspective view of a tray formed from the blank of FIG. 16 according to a sixth exemplary embodiment of the present disclosure in a closed configuration. [Figure 19] FIG. 13 is a plan view of an exterior surface of a blank used to form a tray according to a seventh exemplary embodiment of the present disclosure. [Figure 20] FIG. 20 is a perspective view of a tray formed from the blank of FIG. 19 according to a seventh exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Corresponding parts are indicated by corresponding reference characters throughout the drawings.

[0011] A tray according to the present disclosure can accommodate articles of many different shapes. For purposes of illustration and not for purposes of limiting the scope of the present disclosure, the following detailed description describes articles such as food, e.g., fruit or vegetable items. In one embodiment, the article described herein can be a fruit, such as a tomato (e.g., cherry tomato, etc.), a berry (e.g., blueberry, raspberry, blackberry, strawberry, etc.), an apple, an orange, a tangerine, a clementine, a lemon, a lime, a cherry, etc. In another embodiment, the article described herein can be a product package, a container, a bottle, a can, etc., that is at least partially disposed within an embodiment of the tray. The article can be used, for example, to package food and beverage products. The packaged article can be made of materials of a composition suitable for packaging a particular food or beverage item, including, but not limited to, glass, aluminum and / or other metals, plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, nylon, composite materials, etc., or any combination thereof.

[0012] The articles described herein may include different types of food or beverage products, containers thereof, and / or having different shapes without departing from this disclosure. As used herein, the terms "lower", "bottom", "upper" and "top" refer to orientations that are determined in relation to a fully assembled, upright tray. As described herein, a tray may be formed from a blank by overlapping a number of panels, portions and / or end flaps. As used herein, such panels, portions and / or end flaps may be designated in consecutive or non-consecutive references relative to one another, e.g., "first", "second", "third", etc., without departing from this disclosure.

[0013] FIG. 1 is a plan view of an exterior surface 101 of a blank, generally designated 103, that is used to form a container assembly or tray 105 (FIG. 2), according to an exemplary embodiment of the present disclosure.

[0014] As described further herein, the blank 103 may include engagement features for forming engagement features of the tray 105 that provide one or more surfaces for engaging mechanical elements or other components of a system associated with forming, loading, and / or packaging the tray 105. In addition, the blank 103 / tray 105 engagement features provide one or more surfaces for receiving a cover or lidding film, such as a polymeric film or other cover, that covers the tray 105 to maintain one or more conditions of a food item held therein.

[0015] The blank 103 may also include reinforcing features to reinforce the engagement features, e.g., stiffen, stabilize, and / or otherwise minimize, inhibit, prevent, and / or resist deformation, to form reinforcing features of the tray 105. It will be understood that in some embodiments, one or more of the reinforcing features of the blank 103 / tray 105 may be considered part of the engagement features of the tray 105, or vice versa.

[0016] As shown, the blank 103 has a longitudinal axis L1 and a lateral axis L2 and includes a plurality of panels that extend at least partially around an interior 107 of the tray 105 when the tray 105 is formed from the blank 103. The panels may include a bottom panel 121, a back panel 123 foldably connected to the bottom panel 121 at a lateral fold line 125, a front panel 127 foldably connected to the bottom panel 121 at a lateral fold line 129, and a top panel 131 (broadly referred to as the “first top panel”) foldably connected to the front panel 127 at a lateral line of weakness / fold line 133.

[0017] As also shown, a first flange support panel 135 may be defined between fold line 133 and a transverse fold line 137. In some embodiments, the flange support panel 135 may be considered a part of the top panel 131 such that the top panel 131 is attached to the front panel 127 at the fold line 133. In some embodiments, the top panel 131 may be foldably connected to the support panel 135 at the fold line 137.

[0018] Additionally, the second flange support panel 139 may be foldably connected to the back panel 123 at a lateral weakening / fold line 141. In some embodiments, as described herein, one or both of the flange support panels 135, 139 may be a panel of a plurality of panels of the blank 103 / tray 105. In some embodiments, one or both of the flange support panels 135, 139 may be considered an end flap foldably connected to a respective panel of the plurality of panels of the blank 103 / tray 105.

[0019] 1 , the blank 103 and the tray 105 formed therefrom may further include a plurality of end flaps foldably connected to respective ones of the plurality of panels. The plurality of end flaps may include a first bottom end flap 143 foldably connected to the bottom panel 121 at respective longitudinal fold lines 145, a first back end flap 147 (broadly referred to as the “first end flap”) foldably connected to the back panel 123 at respective longitudinal fold lines 145, and a first front end flap 149 foldably connected to the front panel 127 at respective longitudinal fold lines 145.

[0020] As shown, the rear end flap 147 may include a base portion 151 foldably connected to the rear panel 123 at respective portions of the fold lines 145, and a distal or attachment portion 153 foldably connected to the base portion 151 at diagonal weakened lines / fold lines 152.

[0021] Additionally, a second bottom end flap 155 may be foldably connected to the bottom panel 121 at a respective longitudinal fold line 157, a second back end flap 159 (broadly referred to as the "second end flap") may be foldably connected to the back panel 123 at a respective fold line 157, and a second front end flap 161 may be foldably connected to the front panel 127 at a respective fold line 157. The back end flap 159 may include a base portion 163 foldably connected to the back panel 123 at a respective fold line 157, and a distal or attachment portion 165 foldably connected to the base portion 163 at an oblique line of weakness / fold line 167.

[0022] The plurality of end flaps may further include a first top end flap 169 (broadly the “first end flap”) foldably connected to an inner edge of the top panel 131 surrounding the opening 171 at a longitudinal line of weakness / fold line 173, and a second top end flap 175 (broadly the “second end flap”) foldably connected to the top panel 131 at an opposing edge thereof at a longitudinal line of weakness / fold line 177. In this regard, the top panel 131 may extend at least partially around the opening 171, and the top end flaps 169, 175 may be positioned to extend into the opening 171.

[0023] As shown, each top end flap 169, 175 may include a respective base portion 177, 179 foldably connected to the top panel 131 at a respective longitudinal fold line 173, 177, and a respective distal or attachment portion 181, 183 foldably connected to the respective base portion 177, 179 at a respective diagonal weakened line / fold line 185, 187.

[0024] The blank 103 and the tray 105 formed therefrom may also include locking features for at least partially maintaining the upright configuration of the tray 105. Such locking features may include one or more of locking tabs 189, 191 that project from respective front end flaps 149, 161 and correspond to respective lines of weakness 193, 195 that interrupt respective fold lines 145, 157 adjacent respective rear end flaps 147, 159. In this regard, the lines of weakness 193, 195 extend along the rear panel 123. As described further herein, the locking tabs 189, 191 are for being received at least partially through the lines of weakness 193, 195 when the tray 105 is formed from the blank 103.

[0025] As described herein, the engagement features of the blank 103 and the tray 105 formed therefrom may include the top panel 131. In some embodiments, the engagement features may include one or more of the flange support panels 135, 139.

[0026] As also described herein, the reinforcing features of the blank 103 and tray 105 may include one or more of the flange support panels 135, 139.

[0027] 2 and 3, according to an exemplary embodiment of the present disclosure, the formation of the tray 105 from the blank 103 may be performed by inverting the blank 103 such that the outer surface 101 is positioned on a support surface and the inner surface of the blank 103 may be positioned facing upward.

[0028] End flaps 143, 155 can be folded at least partially into face contact with respective portions of bottom panel 121 at respective fold lines 145, 157, end flaps 149, 161 can be folded at least partially into face contact with respective portions of front panel 127 at respective fold lines 145, 157, and end flaps 147, 159 can be folded at least partially into face contact with respective portions of back panel 123 at respective fold lines 145, 157. In the above-described arrangements, end flaps 149, 161 can be positioned in at least partial overlapping relationship.

[0029] Simultaneously or thereafter, attachment portion 153 of end flap 147 can be folded at fold line 152 and positioned to be in at least partial face contact with a respective portion of base portion 151 of end flap 147, and attachment portion 165 of end flap 159 can be folded at fold line 167 and positioned to be in at least partial face contact with a respective portion of base portion 163 of end flap 159.

[0030] The back panel 123 can be folded at fold line 125 to make at least partial face contact with the bottom panel 121, and the flange support panel 139 can be folded back at fold line 141 to make at least partial face contact with respective portions of the outer surface of the back panel 123.

[0031] Simultaneously or thereafter, the top panel 131 may be folded at fold line 137 over the flange support panel 135 and the respective portions of the end flaps 149, 161. Such folding may position the end flaps 169, 175 into at least partial face contact with the respective portions of the end flaps 149, 161.

[0032] The above-described arrangement of the panels and end flaps may be maintained, at least in part, by one or more applications of adhesive, such as glue G (FIG. 1). In particular, an inner surface of each attachment portion 153, 165 of each end flap 147, 159 may be attached / adhered to an outer surface of each end flap 143, 155, an inner surface of each attachment portion 181, 183 of each end flap 169, 175 may be attached / adhered to an outer surface of each end flap 149, 161, an inner longitudinal portion of the top panel 131 may be attached / adhered to the flange support panel 135, and an outer longitudinal portion of the top end panel 131 may be attached / adhered to the flange support panel 139.

[0033] Moreover, such an arrangement of the blank 103 / tray 105 panels and flaps may be considered a collapsed configuration of the tray 105 for an arrangement that minimizes space for shipping or storage, for example.

[0034] 2 and 3, the tray 105 can be reconfigured from a folded configuration to an upright configuration by positioning the front panel 127 and rear panel 123 in a spaced-apart, parallel arrangement, with both panels 127, 123 generally upright relative to the bottom panel 121. The top panel 131 may also be spaced-apart and parallel with the bottom panel 121.

[0035] Simultaneously or thereafter, the end flaps 149, 161 may be folded, for example, away from the interior 107 of the tray 105 at their respective portions of the fold lines 145, 157. Such movement of the end flap 149 may cause the end flap 169 attached thereto to be reconfigured such that its distal portion 181 is folded at the fold line 185 into at least partial face contact with its base portion 177. This movement of the end flap 149 may also urge the end flap 143 (and, incidentally, the end flap 147 attached thereto) to be folded, at their respective portions of the fold line 145, into a generally planar arrangement with the end flaps 149, 169. Such at least partially overlapping arrangement of the end flaps 143, 147, 149 may form the first closed end 109 of the tray 105.

[0036] Similarly, movement of end flap 161 may urge end flap 175 attached thereto to be reconfigured such that its distal portion 183 is folded at fold line 187 into at least partial face contact with its base portion 179. This movement of end flap 161 may also urge end flap 155 (and, incidentally, end flap 159 attached thereto) to be folded at respective portions of fold line 157 into a generally planar arrangement with end flaps 161, 175. Such at least partially overlapping arrangement of end flaps 155, 159, 161 may form second closed end 111 of tray 105.

[0037] When the end flaps 149, 161 are positioned as described herein, the locking tabs 189, 191 protruding from the respective end flaps 149, 161 may be at least partially received through the respective lines of weakness 193, 195 in the locking arrangement to, for example, maintain and / or strengthen the upright configuration of the tray 105. In some embodiments, one or more portions of the respective locking tabs 189, 191 may engage one or more portions of the back panel 123 and / or the respective end flaps 147, 159 adjacent the respective lines of weakness 193, 195.

[0038] The above-described arrangement provides a panel of the tray 105 that extends at least partially around the interior 107 of the tray 105 and a plurality of end flaps that overlap to form a first closed end 109 and a second closed end 111 of the tray 105. Because of the relative attachment of longitudinally adjacent ones of the end flaps to one another, reconfiguration of the tray 105 from a collapsed configuration to an erected configuration can be accomplished efficiently and smoothly, e.g., to minimize the number of steps or associated machinery required. For example, positioning the top panel 131 in a generally spaced parallel relationship to the bottom panel 121 can effect the above-described reconfiguration of the end flaps to form the closed ends 109, 111 of the tray 105, e.g., to eliminate the need for independent positioning of the end flaps.

[0039] In this regard, the above-described arrangement of the blank 103 and the tray 105 formed therefrom is such that the panels and flaps thereof are arranged to extend generally in a single direction, e.g., along the longitudinal axis L1, to facilitate straight line folding and gluing operations and to facilitate formation of the tray 105 on an associated forming machine. For example, upon initial folding of the end flaps 147, 143, 149, 159, 155, 161, all further folding operations will be along transverse lines of weakness spaced generally along the longitudinal axis L1.

[0040] It will be appreciated that during or following the steps described above, one or more food items may be dropped, placed, or otherwise positioned in the interior 107 of the tray 105. In one embodiment, the food item may be tomatoes, although the one or more food items may be different foods without departing from this disclosure. The tray 105 may be provided as a package with one or more food items.

[0041] As described herein, the engagement features of the tray 105 include the top panel 131 extending outwardly from the respective panel and closed end surfaces 109, 111 to form a rim or flange 190, and one or more engagement surfaces for engagement / support by mechanical elements associated with forming equipment for the tray 105, such as grippers, forks, clamps, rails, etc. In one embodiment, the outer surfaces (e.g., downward facing surfaces) of the flange support panels 135, 139 may provide the engagement surfaces for engagement / support by such mechanical elements. In other embodiments, the engagement surfaces may include any combination of one or more of the outer, inner (e.g., upward facing) and / or side facing surfaces of the top panel 131.

[0042] The positioning of the top panel 131 extending away from the panels of the tray 105 also provides multiple engagement / support surfaces for engaging / supporting a cover film or lidding film, e.g., a plastic or other polymeric film, or other covering structure. In one embodiment, the lidding film may be provided as a polymeric layer that at least partially deforms in the presence of a heat source, e.g., a heat sealable film. The lidding film may thus be positioned to extend across the opening 171 and contact one or more surfaces of the top panel 131 to cover the interior 107 of the tray 105 and maintain one or more conditions of the food product held therein, e.g., freshness, ripeness, moisture content, etc. It will be appreciated that the lidding film may minimize, inhibit, and / or prevent the passage of one or more substances, e.g., condensation or other moisture, insects or other pests, dirt, debris, etc., to the interior 107 of the tray 105. In one embodiment, the tray 105 may be provided as a package with the lidding film and one or more food products.

[0043] Additionally, the reinforcing features of the tray 105 may include at least the placement of one or both of the flange support panels 135, 139 in at least partial face contact with respective portions of the underside of the top panel 131 / flange 190, which engagement may minimize, inhibit, prevent, and / or otherwise resist bending, warping, flexing, bending, curving, warping, and / or other deformation of the flange 190. In this regard, force exerted on the flange 190 via tension applied through an overlying cover or lidding film may minimize, inhibit, and / or prevent deformation of the flange 190, for example, to avoid undesirable product aesthetics, to avoid at least partial disengagement of the lidding film from the flange 190, to maintain a generally planar configuration of the flange 190 during use, storage, transportation, etc. In some embodiments, the locking features of the tray 105 may additionally or alternatively be considered reinforcing features of the tray 105.

[0044] It will be understood that one or more of the panels, flaps, and associated features of the blank 103 / tray 105 may have different arrangements or configurations without departing from this disclosure. In one embodiment, one or more portions of the tray 105 may be separated at respective lines of weakness to facilitate access to the interior 107 of the tray 105.

[0045] 4, there is shown an exterior surface 201 of a blank 203 for forming a tray 205 according to a second exemplary embodiment of the present disclosure. The blank 203 and the tray 205 formed therefrom may include one or more components that are the same or similar to those of the blank 103 and tray 105 of the first exemplary embodiment, and like or similar features are indicated with like or similar reference numerals.

[0046] As shown, blank 203 has a longitudinal axis L1, a transverse axis L2, panels 121, 123, 127, 131, 135, 139 and associated features, and end flaps 169, 175 and associated features. However, blank 203 and tray 205 formed therefrom may have different configurations and arrangements of one or more end flaps foldably connected to each panel of the plurality of panels.

[0047] In the illustrated embodiment, the rear end flap 243 may be foldably connected to the rear panel 123 at each of the fold lines 145, the bottom end flap 247 (broadly referred to as the “first end flap”) may be foldably connected to the bottom panel 121 at each of the fold lines 145, and the front end flap 249 may be foldably connected to the front panel 127 at each of the fold lines 145.

[0048] As shown, the bottom end flap 247 may include a base portion 251 foldably connected to the bottom panel 121 at a respective portion of the fold line 145, and a distal or attachment portion 253 foldably connected to the base portion 251 at an oblique line of weakness or fold line 252. As also shown, a locking tab 289 may be positioned to extend from the base portion 251 of the end flap 247.

[0049] Similarly, the back end flap 255 may be foldably connected to the back panel 123 at the respective fold lines 157, the bottom end flap 259 (broadly the "second end flap") may be foldably connected to the bottom panel 121 at the respective fold lines 157, and the front end flap 261 may be foldably connected to the front panel 127 at the respective fold lines 157. The bottom end flap 259 may include a base portion 263 foldably connected to the bottom panel 121 at the respective fold lines 157 and a distal or attachment portion 265 foldably connected to the base portion 263 at an oblique line of weakness or fold line 267, with a locking tab 291 positioned to extend from the base portion 263 of the end flap 259.

[0050] Additionally, a line of weakness 193 may be positioned to interrupt fold line 145 adjacent end flap 249 to at least partially receive locking tab 289 when tray 205 is formed from blank 203, and a line of weakness 195 may be positioned to interrupt fold line 157 adjacent end flap 261 to at least partially receive locking tab 291 when tray 205 is formed from blank 203. In this regard, lines of weakness 193, 195 may extend at least partially along front panel 127.

[0051] 5 and 6, according to one embodiment of the present disclosure, formation of tray 205 from blank 203 may be performed in a manner similar to that described above with respect to formation of tray 105 from blank 103, for example, by positioning front panel 127 and back panel 123 in a spaced apart parallel arrangement with both panels 127, 123 generally upright relative to bottom panel 121. Top panel 131 may also be in a spaced apart parallel arrangement with bottom panel 121.

[0052] However, after inverting the blank 203 such that the outer surface 201 is positioned on a support surface and the inner surface of the blank 203 is positioned facing up, forming the closed ends 209, 211 of the tray 205 involves folding end flaps 243 at respective portions of fold lines 145 into at least partial surface contact with respective portions of the back panel 123, folding end flaps 247 at respective portions of fold lines 145 into at least partial surface contact with respective portions of the bottom panel 121, and folding end flaps 247 at respective portions of fold lines 145 into at least partial surface contact with respective portions of the front panel 127. 127, folding end flaps 249 at respective portions of fold lines 145 so as to be in at least partial surface contact with respective portions of back panel 123, folding end flaps 255 at respective portions of fold lines 157 so as to be in at least partial surface contact with respective portions of bottom panel 121, and folding end flaps 261 at respective portions of fold lines 157 so as to be in at least partial surface contact with respective portions of front panel 127.

[0053] Further, forming the closed ends 209, 211 of the tray 205 may include folding the attachment portion 253 of the end flap 247 at fold line 252 so as to be in at least partial face contact with its base portion 251, and folding the attachment portion 265 of the end flap 259 at fold line 267 so as to be in at least partial face contact with its base portion 263.

[0054] The above-described arrangement of the panels and end flaps may be maintained, at least in part, by one or more applications of adhesive, such as glue G. In particular, an inner surface of a respective distal portion 253, 265 of each end flap 247, 259 may be attached / adhered to a respective end flap 243, 255, an inner surface of a respective distal portion 181, 183 of each end flap 169, 175 may be attached / adhered to a respective inner surface of an end flap 249, 261, an inner longitudinal portion of the top panel 131 may be attached / adhered to a flange support panel 135, and an outer longitudinal portion of the top end panel 131 may be attached / adhered to a flange support panel 139.

[0055] When the tray 205 is formed from the blank 203, the end flaps 169, 175 may be folded downward at their respective fold lines 173, 177 into the interior 207 of the tray 205. Such movement of the end flaps 169, 175 may cause the respective end flaps 249, 261 attached thereto to fold away from the interior 207 of the tray 205 at their respective fold lines 145, 157. This movement may also cause the end flaps 247, 259 to fold upward at their respective fold lines 145, 157 to cause the respective end flaps 243, 255 attached thereto to fold away from the interior 207 of the tray 205 at their respective fold lines 145, 157.

[0056] In this regard, the end flaps 243, 247, 249, 169 may be positioned in a generally planar and at least partially overlapping arrangement to form a first closed end 209 of the tray 205, and the end flaps 255, 259, 261, 175 may be positioned in a generally planar and at least partially overlapping arrangement to form a second closed end 211 of the tray 205.

[0057] When the end flaps 247, 259 are positioned as described herein, the locking tabs 289, 291 projecting therefrom may be at least partially received through the respective lines of weakness 193, 195 in a locking arrangement to, for example, maintain and / or strengthen the upright configuration of the tray 205. In some embodiments, one or more portions of the respective locking tabs 289, 291 may engage one or more portions of the front panel 127 and / or the respective end flaps 249, 261 adjacent the respective lines of weakness 193, 195.

[0058] The upright configuration of tray 205 may provide advantages similar to those described above with respect to tray 105. Additionally, tray 205 may be provided with one or more food items and / or lidding films in the manner described above with respect to tray 105.

[0059] 7, there is shown an exterior surface 301 of a blank 303 for forming a tray 305 according to a third exemplary embodiment of the present disclosure. The blank 303 and the tray 305 formed therefrom may include one or more components that are the same or similar to those of the blanks 103, 203 and trays 105, 205 described above, and like or similar features are indicated with like or similar reference numerals.

[0060] As shown, the blank 303 may be generally similar to the blank 203 of the second exemplary embodiment, but may further include a top panel 331 (broadly, a "second top panel") foldably connected to the flange support panel 139 at a transverse fold line 333. In this regard, the top panel 131 may be the first top panel of the blank 303 / tray 305, and the top panel 331 may be the second top panel of the blank 303 / tray 305.

[0061] The top panel 331 may include a number of product viewing features, such as openings 336, 338, 340, 342, 344, as will be further described herein.

[0062] 8 and 9 , the tray 305 may be formed from the blank 303 in a manner similar to that described above with respect to forming the tray 205 from the blank 203. However, as a final step, the second top panel 331 may be folded downwardly at fold line 333 such that the second top panel 331 is in at least partial face contact with the top panel 131. In this regard, the second top panel 331 may be positioned to extend over the opening 171 in the top panel 131.

[0063] Because of the product visibility features of top panel 331, the arrangement of top panels 131, 331 provides product visibility, such that, for example, one or more food items in the interior 307 of tray 305 can be viewed through openings 336, 338, 340, 342, 344. Additionally, the portions of top panel 331 surrounding openings 336, 338, 340, 342, 344 may provide at least a partial barrier to ingress into openings 171, for example, minimizing, inhibiting, and / or preventing debris or other undesirable material from entering interior 307 of tray 305.

[0064] The closed configuration of the tray 305 / top panel 331 may be provided when the top panel 331 is in a closed position at least partially covering the top panel 131 to at least partially restrict access to the interior 307 of the tray 105. In some embodiments, the top panel 331 may be positioned in at least partial face contact with the top panel 131 in its closed position to form the closed configuration of the tray 305. When it is desired to access one or more food items in the interior 307 of the tray 305, the top panel 331 may be folded upwardly at fold line 333 and lifted away from the top panel 131 to an open position to provide the open configuration of the tray 305 / top panel 331.

[0065] In some embodiments, the need for a lid film over top panel 131 may be avoided by the presence of top panel 331. In some embodiments, as explained above, a lid film may be affixed to top panel 131, and top panel 331 may cover the lid film and top panel 131. In some embodiments, a lid film may be affixed to top panel 331.

[0066] In this regard, the tray 305 may provide advantages similar to those described above with respect to the trays 105, 205.

[0067] Additionally, the placement of the top panel 331 over the top panel 131 can reinforce the flange 190 when the top panel 331 is in a closed configuration. For example, the at least partial surface contact of the top panels 331, 131 can provide an additional layer of material to minimize, inhibit, prevent, and / or otherwise resist bending, warping, flexing, buckling, curving, warping, and / or other deformation of the flange 190.

[0068] 10, there is shown an exterior surface 401 of a blank 403 for forming a tray 405 according to a fourth exemplary embodiment of the present disclosure. The blank 403 and the tray 405 formed therefrom may include one or more components that are the same or similar to those of the blanks 103, 203, 303 and trays 105, 205, 305 described above, and similar or like features are indicated with similar or like reference numerals.

[0069] As shown, the blank 403 may be generally similar to the blank 103 of the first exemplary embodiment, but may further include the top panel 331 of the second exemplary embodiment foldably connected to the flange support panel 139 at a transverse fold line 333.

[0070] Additionally, with reference to Figures 11 and 12, the tray 405 can be formed from the blank 403 in a manner similar to that described above with respect to forming the tray 105 from the blank 103, with the added step of folding the second top panel 331 downwardly at fold line 333 to provide the closed configuration of the tray 405 / closed position of the top panel 331 as described above.

[0071] In this regard, the tray 405 may provide advantages similar to those described above with respect to the above-described trays 105, 205, 305. Additionally, the tray 405 may be provided with one or more food items and / or lidding films in the manner described above with respect to the above-described trays 105, 205, 305.

[0072] 13, there is shown an exterior surface 501 of a blank 503 for forming a tray 505 according to a fifth exemplary embodiment of the present disclosure. The blank 503 and the tray 505 formed therefrom may include one or more components that are the same or similar to those of the blanks 103, 203, 303, 403 and trays 105, 205, 305, 405 described above, and like or similar features are indicated with like or similar reference numerals.

[0073] As shown, the blank 503 may be generally similar to the blank 103 of the first exemplary embodiment, except that the locking features of the blank 503 / tray 505 may include locking tabs 591 foldably connected to respective end flaps 149, 161 at respective longitudinal lines of weakness 592 and positioned to be received in respective locking openings formed by respective cuts 593 in the back panel 123. As shown, the cuts 593 may have one or more of straight, curved, and / or angled portions.

[0074] As also shown, the top panel 131 of the blank 503 / tray 505 may include an engagement tab 532 that projects inwardly into the opening 171. As explained above, the flange 190 of the tray 505 may be configured to engage / support a cover or lidding film, and the engagement tab 532 may provide additional surface area / support structure for engaging and supporting such a cover or film. In this regard, in some embodiments, the top panel 131 may be provided with an increased or optimized surface area / width, etc. to facilitate engaging / supporting the cover or lidding film. Such increased size of the top panel 131 / flange 190 may also facilitate enhanced engagement with mechanical elements or other components of a system associated with forming, loading, and / or packaging the tray 505.

[0075] 13, the bottom panel 121 may include a plurality of chamfered / angled / rounded corner edges 522 that intersect respective portions of the fold lines 125, 129, 152, 167, the back panel 123 may include a respective pair of chamfered / angled / rounded corner edges 524 that intersect an endpoint of the fold line 125, and the front panel 127 may include a respective pair of chamfered / angled / rounded corner edges 526 that intersect an endpoint of the fold line 129. Additionally, the end flaps 147, 149, 159, 161 may include respective chamfered / angled / rounded corner edges 528 that intersect respective edges 522 of the bottom panel 121.

[0076] 14 and 15, the tray 505 may be formed from the blank 503 in a manner similar to that described above with respect to forming the tray 105 from the blank 103, with the added step of at least partially inserting each of the locking tabs 591 through a respective locking opening formed by a respective cut 593 in the back panel 123. Such insertion of the tabs 591 through the respective openings formed by the cuts 593 may include at least partially folding one or both of the tabs 591 against the respective flaps 149, 161 at the respective lines of weakness 592. Such engagement of the tabs 591 with the openings formed by the respective cuts 593 may facilitate forming and maintaining the tray 505 in an erected configuration.

[0077] Additionally, the arrangement of edges 522, 524, 526, 528 of each panel and flap of tray 505 is such that upon formation of tray 505, each bottom corner opening 530, 532, 534, 536 is provided in tray 505 that extends away from bottom panel 121 for, e.g., drainage, ventilation, material reduction, additional product visibility, etc. In some embodiments, one or more of corner openings 530, 532, 534, 536 may be positioned and arranged to at least partially receive / engage one or more components of a machine or other system associated with forming, loading, and / or packaging tray 505.

[0078] In this regard, the tray 505 may provide similar advantages as those described above with respect to the above-described trays 105, 205, 305, 405. Additionally, the tray 505 may be provided with one or more food items and / or lidding films in the manner described above with respect to the trays 105, 205, 305, 405.

[0079] 16, there is illustrated an exterior surface 601 of a blank 603 for forming a tray 605 according to a sixth exemplary embodiment of the present disclosure. The blank 603 and the tray 605 formed therefrom may include one or more components that are the same or similar to those of the blanks 103, 203, 303, 403, 503 and trays 105, 205, 305, 405, 505 described above, and similar or like features are indicated with similar or like reference numerals.

[0080] As shown, the blank 603 may be generally similar to the blank 503 of the fifth exemplary embodiment, but may additionally include a second top panel 331 foldably attached to the flange support panel 139 at fold line 333. As also shown, the top panel 131 may lack an engagement tab 532, although the engagement tab 532 may be included without departing from this disclosure.

[0081] Additionally, with reference to Figures 17 and 18, the tray 605 can be formed from the blank 603 in a manner similar to that described above with respect to forming the tray 505 from the blank 503, with the added step of at least partially folding the second top panel 331 downwardly onto the first top panel 131 at the fold line 333 to form the tray 605 in its closed position / configuration, as described above.

[0082] In this regard, the tray 605 may provide advantages similar to those described above with respect to the above-described trays 105, 205, 305, 405, 505. Additionally, the tray 605 may be provided with one or more food items and / or lidding films in the manner described above with respect to the trays 105, 205, 305, 405, 505.

[0083] 19, there is shown an exterior surface 701 of a blank 703 for forming a tray 705 according to a seventh exemplary embodiment of the present disclosure. The blank 703 and the tray 705 formed therefrom may include one or more components that are the same or similar to those of the blanks 103, 203, 303, 403, 503, 603 and trays 105, 205, 305, 405, 505, 605 described above, and similar or like features are indicated with similar or like reference numerals.

[0084] 20, the tray 705 may be formed from the blank 703 in a manner similar to that described above with respect to forming the tray 505 from the blank 503, except that the respective corner openings 530, 532, 534, 536 are not formed. It will be understood that the tray 705 may include one or more of the corner openings 530, 532, 534, 536 without departing from this disclosure.

[0085] In this regard, the tray 705 may provide advantages similar to those described above with respect to the above-described trays 105, 205, 305, 405, 505, 605. Additionally, the tray 705 may be provided with one or more food items and / or lidding films in the manner described above with respect to the tray 105.

[0086] Blanks according to the present disclosure can be formed, for example, from coated cardboard and similar materials. For example, the interior and / or exterior surfaces of the blank can be coated with a clay coating. Product, advertising, price codes, and other information or images can then be printed on the clay coating. 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. In accordance with the above-described embodiments, the blank can be constructed of cardboard having a thickness such that it is heavier and harder than regular paper. The blank can also be constructed of other materials, such as cardboard, stiffened paper, or any other material having suitable properties to enable the tray to function at least generally as described above. The blank can also be laminated or coated with one or more sheet-like materials on selected panels or panel sections.

[0087] In accordance with the above embodiments of the present disclosure, the fold lines can be any substantially linear, though not necessarily straight, form of weakening that facilitates folding therealong. More specifically, and not to narrow the scope of the present disclosure, fold lines include score lines, such as lines formed with a blunt scoring knife or the like that create a crushed portion in the material along the desired line of weakness, cuts partially into the material along the desired line of weakness, and / or a series of cuts that partially and / or completely through the material along the desired line of weakness, and various combinations of these features.

[0088] As an example, the tear line can include a slit partially into the material along the desired line of weakness, and / or a series of spaced slits that are partially into the material along the desired line of weakness and / or completely through the material, or various combinations of these features. As a more specific example, one type of tear line is in the form of a series of spaced slits that are completely through the material, with adjacent slits spaced slightly apart such that a nick (e.g., a small piece of material somewhat like a bridge) is defined between them to connect the material across the tear line, usually temporarily. The nicks are broken along the tear line during tearing. Nicks usually make up a relatively small percentage of the tear line, and alternatively, they can be omitted from the tear line or broken on the tear line, such that the tear line is a continuous cut line. That is, it is within the scope of this disclosure for each of the spaced slits to be replaced with a continuous slit, a continuous score, etc. For example, the score line can be a continuous slit or can be wider than a slit without departing from this disclosure, and the tear line can be a series of score lines that pass completely or partially through the material and are separated by nicks.

[0089] The term "glue" is intended to encompass all manner of adhesives commonly used to secure tray panels in place.

[0090] The above description of the present disclosure illustrates and describes various exemplary embodiments. Various additions, modifications, alterations, etc. may be made to the exemplary embodiments without departing from the spirit and scope of the present disclosure. It is intended that all matters contained in the above description or shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Furthermore, the present disclosure illustrates and describes only selected embodiments of the present disclosure, but the present disclosure can be used in various other combinations, modifications, and environments, and can make modifications or alterations within the scope of the inventive concepts as described herein, modifications or alterations equivalent to the above teachings, and / or modifications within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment can be selectively interchanged and applied to other described and undescribed embodiments of the present disclosure.

Claims

1. 1. A tray for holding at least one food item, the tray comprising: a plurality of panels extending at least partially around an interior of the tray, the plurality of panels including a bottom panel, a front panel foldably connected to the bottom panel, a back panel foldably connected to the bottom panel, and a top panel foldably connected to one of the front panel and the back panel; a plurality of end flaps foldably connected to respective ones of the plurality of panels, the plurality of end flaps at least partially overlapping to form at least one closed end of the tray; a flange including the top panel, the flange extending outwardly from the front panel, the rear panel, and the at least one closed end of the tray; A tray comprising:

2. 2. The tray of claim 1, wherein at least one end flap of the plurality of end flaps comprises a base portion foldably connected to a respective panel of the plurality of panels and an attachment portion foldably connected to the base portion.

3. The tray of claim 2 , wherein the attachment portion is positioned in at least partial surface contact with adjacent ones of the plurality of end flaps.

4. The tray of claim 3 , wherein the at least one end flap of the plurality of end flaps is foldably connected to one of the front panel and the rear panel.

5. The tray of claim 3 , wherein the at least one end flap of the plurality of end flaps is foldably connected to the bottom panel.

6. The tray of claim 3 , wherein the at least one end flap of the plurality of end flaps is foldably connected to the top panel.

7. 4. The tray of claim 3, wherein the at least one closed end of the tray is a first closed end of the tray and the plurality of end flaps are at least partially overlapped to form a second closed end of the tray.

8. 8. The tray of claim 7, wherein the at least one end flap of the plurality of end flaps is a first end flap that at least partially forms the first closed end of the tray, and the plurality of end flaps includes a second end flap that at least partially forms the second closed end of the tray, the second end flap having a base portion foldably connected to a respective panel of the plurality of panels and an attachment portion foldably connected to the base portion of the second end flap.

9. 4. The tray of claim 3, wherein the top panel is a first top panel, and the plurality of panels further includes a second top panel foldably connected to one of the front panel and the rear panel.

10. 10. The tray of claim 9, wherein the second top panel is reconfigurable between a closed position in which the second top panel is positioned to cover the interior of the tray and an open position in which the second top panel is lifted away from the interior of the tray.

11. The tray of claim 10 , wherein the second top panel is positioned in at least partial surface contact with the first top panel in the closed position.

12. The tray of claim 3 , wherein the top panel extends at least partially around an opening and includes an engagement tab that extends into the opening.

13. 4. The tray of claim 3, further comprising a locking feature comprising a locking tab extending from each end flap of the plurality of end flaps and at least partially received through a line of weakness extending at least partially along each panel of the plurality of panels.

14. The tray of claim 13 , wherein the locking tab is foldably connected to each end flap of the plurality of end flaps.

15. The tray of claim 3 , wherein the plurality of panels further includes at least one flange support panel foldably connected to each panel of the plurality of panels.

16. The tray of claim 15 , wherein the at least one flange support panel is positioned in at least partial face contact with the flange.

17. 1. A blank for forming a tray for holding at least one food item, the blank comprising: a plurality of panels extending at least partially around an interior of the tray formed from the blank, the plurality of panels including a bottom panel, a front panel foldably connected to the bottom panel, a back panel foldably connected to the bottom panel, and a top panel foldably connected to one of the front panel and the back panel; a plurality of end flaps foldably connected to respective ones of the plurality of panels, the plurality of end flaps at least partially overlapping to form at least one closed end of the tray formed from the blank; Equipped with The blank, wherein the top panel forms a flange extending outwardly from the front panel, the rear panel, and the at least one closed end of the tray formed from the blank.

18. 20. The blank of claim 17, wherein at least one end flap of the plurality of end flaps comprises a base portion foldably connected to a respective panel of the plurality of panels and an attachment portion foldably connected to the base portion.

19. The blank of claim 18 , wherein the attachment portions are positioned in at least partial face contact with adjacent ones of the plurality of end flaps when the tray is formed from the blank.

20. 20. The blank of claim 19, wherein the at least one end flap of the plurality of end flaps is foldably connected to one of the front panel and the back panel.

21. 20. The blank of claim 19, wherein the at least one end flap of the plurality of end flaps is foldably connected to the bottom panel.

22. 20. The blank of claim 19, wherein the at least one end flap of the plurality of end flaps is foldably connected to the top panel.

23. 20. The blank of claim 19, wherein the at least one closed end of the tray formed from the blank is a first closed end of the tray formed from the blank, and the plurality of end flaps are at least partially overlapped to form a second closed end of the tray formed from the blank.

24. 24. The blank of claim 23, wherein the at least one end flap of the plurality of end flaps is a first end flap that at least partially forms the first closed end of the tray formed from the blank, and the plurality of end flaps includes a second end flap that at least partially forms the second closed end of the tray formed from the blank, the second end flap having a base portion foldably connected to a respective panel of the plurality of panels and an attachment portion foldably connected to the base portion of the second end flap.

25. 20. The blank of claim 19, wherein the top panel is a first top panel, and the plurality of panels further includes a second top panel foldably connected to one of the front panel and the back panel.

26. 20. The blank of claim 19, wherein the top panel extends at least partially around an opening and includes an engagement tab that extends into the opening.

27. 20. The blank of claim 19, wherein the tray further comprises a locking feature comprising a locking tab extending from each end flap of the plurality of end flaps for being at least partially received through a line of weakness extending at least partially along each panel of the plurality of panels when the tray is formed from the blank.

28. 28. The blank of claim 27, wherein the locking tab is foldably connected to each end flap of the plurality of end flaps.

29. 20. The blank of claim 19, wherein the plurality of panels further comprises at least one flange support panel foldably connected to each panel of the plurality of panels.

30. 1. A method of forming a tray for holding at least one food item, the method comprising: obtaining a blank comprising a plurality of panels including a bottom panel, a front panel foldably connected to the bottom panel, a back panel foldably connected to the bottom panel, and a top panel foldably connected to one of the front panel and the back panel, the blank further comprising a plurality of end flaps foldably connected to respective panels of the plurality of panels; positioning the plurality of panels to extend at least partially around an interior of the tray; at least partially overlapping the plurality of end flaps to form at least one closed end of the tray; positioning the top panel and forming a flange extending outwardly from the at least one closed end of the tray formed from the front panel, the rear panel, and the blank; A method comprising:

31. 31. The method of claim 30, wherein at least one end flap of the plurality of end flaps comprises a base portion foldably connected to a respective panel of the plurality of panels and an attachment portion foldably connected to the base portion.

32. 32. The method of claim 31, wherein at least partially overlapping the plurality of end flaps comprises positioning the attachment portion in at least partial face contact with adjacent end flaps of the plurality of end flaps.

33. 33. The method of claim 32, wherein the at least one end flap of the plurality of end flaps is foldably connected to one of the front panel and the rear panel.

34. 33. The method of claim 32, wherein the at least one end flap of the plurality of end flaps is foldably connected to the bottom panel.

35. 33. The method of claim 32, wherein the at least one end flap of the plurality of end flaps is foldably connected to the top panel.

36. 33. The method of claim 32, wherein the at least one closed end of the tray is a first closed end of the tray, and at least partially overlapping the plurality of end flaps includes forming a second closed end of the tray.

37. 37. The method of claim 36, wherein the at least one end flap of the plurality of end flaps is a first end flap at least partially forming the first closed end of the tray, and the plurality of end flaps includes a second end flap at least partially forming the second closed end of the tray, the second end flap comprising a base portion foldably connected to a respective panel of the plurality of panels and an attachment portion foldably connected to the base portion of the second end flap.

38. 33. The method of claim 32, wherein the top panel is a first top panel, and the plurality of panels further includes a second top panel foldably connected to one of the front panel and the back panel.

39. 40. The method of claim 38, wherein the second top panel is reconfigurable between a closed position in which the second top panel is positioned to cover the interior of the tray and an open position in which the second top panel is lifted away from the interior of the tray.

40. 40. The method of claim 39, wherein positioning the plurality of panels includes positioning the second top panel to be lifted away from the interior of the tray to provide the open position.

41. 40. The method of claim 39, wherein positioning the plurality of panels includes positioning the second top panel into at least partial surface contact with the first top panel to provide the closed position.

42. 33. The method of claim 32, wherein the top panel includes an engagement tab extending at least partially around and into an opening.

43. 33. The method of claim 32, wherein the blank further comprises a locking feature including a locking tab extending from each end flap of the plurality of end flaps, and wherein at least partially overlapping the plurality of end flaps includes positioning the locking tab to be at least partially received through a line of weakness extending at least partially along each panel of the plurality of panels.

44. 44. The method of claim 43, wherein the locking tab is foldably connected to each end flap of the plurality of end flaps.

45. 33. The method of claim 32, wherein the plurality of panels further comprises at least one flange support panel foldably connected to each panel of the plurality of panels.

46. 46. ​​The method of claim 45, wherein positioning the plurality of panels includes positioning the at least one flange support panel in at least partial face contact with the flange.

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