Tray for food products and related systems and methods

Abstract

A tray for holding one or more food items, the tray comprising a first portion having a plurality of panels including a central panel and a plurality of lower side panels foldably connected to the central panel, the tray also comprising a second portion engaging the first portion and having a plurality of panels including a flange panel and a plurality of upper side panels foldably connected to the flange panel, the plurality of upper side panels and the plurality of lower side panels being attached to one another to form a plurality of side walls 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 / 422,625, filed November 4, 2022, U.S. Provisional Patent Application No. 63 / 455,485, filed March 29, 2023, and U.S. Provisional Patent Application No. 63 / 464,781, filed May 8, 2023.

[0002] [Incorporated by reference] The disclosures of U.S. Provisional Patent Application No. 63 / 422,625, filed November 4, 2022, U.S. Provisional Patent Application No. 63 / 455,485, filed March 29, 2023, U.S. Provisional Patent Application No. 63 / 464,781, filed May 8, 2023, and U.S. Design Patent Application No. 29 / 906,128, filed October 21, 2023, are each incorporated by reference herein for all purposes as if set forth herein in their entirety. [Background technology]

[0003] FIELD OF THE DISCLOSURE The present disclosure relates to blanks, containers, trays, constructs, and various features and methods for forming containers from blanks. In some embodiments, the present disclosure relates to trays formed from multiple cooperating portions. Summary of the Invention

[0004] According to one aspect, the present disclosure generally relates to a tray for holding one or more food items, the tray comprising a first portion comprising a plurality of panels including a central panel and a plurality of lower side panels foldably connected to the central panel, the tray further comprising a second portion engaged with the first portion, the second portion comprising a plurality of panels including a flange panel and a plurality of upper side panels foldably connected to the flange panel, the plurality of upper side panels and the plurality of lower side panels attached to form a plurality of side walls of the tray.

[0005] In another aspect, the present disclosure generally relates to an assembly of blanks to form a tray for holding one or more food items, the assembly comprising: a first blank having a plurality of panels including a central panel and a plurality of lower side panels foldably connected to the central panel; a second blank adapted to be engaged with the first blank when the tray is formed from the assembly of blanks; the second blank having a plurality of panels including a flange panel and a plurality of upper side panels foldably connected to the flange panel, the plurality of upper side panels and the plurality of lower side panels adapted to be attached to form a plurality of side walls of the tray formed from the assembly of blanks.

[0006] According to another aspect, the present disclosure generally relates to a method of forming a tray for holding one or more food items, the method including: obtaining a first blank having a plurality of panels, including a central panel and a plurality of lower side panels foldably connected to the central panel; obtaining a second blank having a plurality of panels, including a flange panel and a plurality of upper side panels foldably connected to the flange panel; forming a first portion of the tray from the first blank; forming a second portion of the tray from the first blank; and attaching the plurality of upper side panels and the plurality of lower side panels to each other to form a plurality of side walls of the tray.

[0007] Those skilled in the art will appreciate the above-mentioned advantages and other advantages and benefits of various additional embodiments upon 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 explanation of the drawings]

[0009] [Figure 1] 1 is a plan view of a first blank for at least partially forming a tray for holding food items according to a first exemplary embodiment of the present disclosure; [Figure 2] FIG. 2 is a plan view of a second blank for at least partially forming a tray for holding food items according to a first exemplary embodiment of the present disclosure. [Figure 3] FIG. 1 is a schematic diagram of an apparatus for processing blanks and / or trays that can be used with exemplary embodiments of the present disclosure. [Figure 4] FIG. 3 is a perspective view of a tray formed from the blank of FIGS. 1 and 2 according to a first exemplary embodiment of the present disclosure. [Figure 5] FIG. 5 is another perspective view of the tray of FIG. 4. [Figure 6] FIG. 10 is a plan view of a first blank for at least partially forming a tray for holding food items according to a second exemplary embodiment of the present disclosure. [Figure 7] FIG. 10 is a plan view of a second blank for at least partially forming a tray for holding food items according to a second exemplary embodiment of the present disclosure. [Figure 8] FIG. 8 is a perspective view of a tray formed from the blank of FIGS. 6 and 7 according to a second exemplary embodiment of the present disclosure. [Figure 9] FIG. 10 is a plan view of a first blank for at least partially forming a tray for holding food items according to a third exemplary embodiment of the present disclosure. [Figure 10] FIG. 10 is a plan view of a second blank for at least partially forming a tray for holding food items according to a third exemplary embodiment of the present disclosure. [Figure 11]FIG. 11 is a perspective view of a tray formed from the blank of FIGS. 9 and 10 according to a third exemplary embodiment of the present disclosure. [Figure 12] FIG. 12 is another perspective view of the tray of FIG. 11 . [Figure 13] FIG. 10 is a plan view of a first blank for at least partially forming a tray for holding food items according to a fourth exemplary embodiment of the present disclosure. [Figure 14] FIG. 10 is a plan view of a second blank for at least partially forming a tray for holding food items according to a fourth exemplary embodiment of the present disclosure. [Figure 15] FIG. 15 is a perspective view of a tray formed from the blank of FIGS. 13 and 14 according to a fourth exemplary embodiment of the present disclosure. [Figure 16] FIG. 16 is another perspective view of the tray of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0010] Corresponding parts are designated by corresponding reference numerals throughout the drawings.

[0011] Various aspects of the present disclosure may be further understood by reference to the figures. For simplicity, like numerals may be used to describe like features. Where multiple like features are shown, it will be understood that not all such features are necessarily labeled on each figure. It will also be understood that the various components used to form the structures may be interchanged. Thus, although only a few combinations are shown herein, numerous other combinations and configurations are hereby contemplated.

[0012] Trays according to the present disclosure can accommodate a number of differently shaped items. For purposes of illustration and not for purposes of limiting the scope of the present disclosure, the following detailed description describes items such as food products at least partially disposed on or in embodiments of the structures.

[0013] The article can include food products such as cereal, granola, trail mix, candy, pasta, dried fruit, nuts, produce (e.g., fruits, vegetables, salads, etc.), or any other food product such as a liquid, powdered food or beverage product, etc. In other embodiments, the article can be a non-food product (e.g., detergent, cat litter, etc.) without departing from this disclosure.

[0014] As used herein, "inside," "internal," "outside," "external," "lower," "bottom," "upper," and "top" refer to orientations determined with respect to a fully assembled, upright tray.

[0015] As described herein, a tray may be formed by a plurality of overlapping panels, end flaps, and / or other portions of a blank. Such panels, end flaps, and / or other portions of a blank may be designated in relative terms with respect to one another, e.g., "first," "second," "third," etc., with consecutive or non-consecutive reference, without departing from this disclosure.

[0016] FIG. 1 shows an exterior surface 101 of a base or first blank 103 for forming a base or first portion 105 of a tray 110 according to a first exemplary embodiment of the present disclosure.

[0017] As shown, blank 103 has a longitudinal direction L1 and a transverse direction L2. In the illustrated embodiment, blank 103 includes a base, bottom, or central panel 111. Blank 103 may also include a plurality of lower end flaps or lower side panels 113 foldably connected to central panel 111 at transverse fold line 115A, diagonal fold line 115B, longitudinal fold line 115C, diagonal fold line 115D, transverse fold line 115E, diagonal fold line 115F, longitudinal fold line 115G, and diagonal fold line 115H, respectively.

[0018] As shown, each lower side panel 113 can include a base portion 117 and a distal portion 119 foldably connected to base portion 117 at horizontal fold line 121A, diagonal fold line 121B, longitudinal fold line 121C, diagonal fold line 121D, horizontal fold line 121E, diagonal fold line 121F, longitudinal fold line 121G, and diagonal fold line 121H, respectively.

[0019] Although the central panel 111 is shown as having a generally octagonal configuration with eight lower side panels foldably connected thereto, it will be understood that the central panel 111 can have different configurations with a correspondingly different number of lower side panels foldably connected thereto without departing from this disclosure.

[0020] Referring to FIG. 2, an exterior surface 201 of a crown or second blank 203 for forming the crown or second portion 205 of the tray 110 is shown.

[0021] As shown, the blank 203 can have a longitudinal axis L1, a transverse axis L2, and a top or flange panel 211 that generally forms the perimeter of the blank 203 to extend at least partially around a central opening 212 through which the blank 203 and the panels of the second portion 205 / tray 110 extend. As shown, the flange panel 211 can have a perimeter that is greater than the perimeter of the central panel 111.

[0022] The blank 203 may also include a plurality of upper end flaps or upper side panels 213 foldably connected to the flange panel 211 at horizontal fold line 215A, diagonal fold line 215B, longitudinal fold line 215C, diagonal fold line 215D, horizontal fold line 215E, diagonal fold line 215F, longitudinal fold line 215G and diagonal fold line 215H, respectively.

[0023] In the illustrated embodiment, each upper side panel 213 can have a generally trapezoidal configuration and can include an opening 217 at least partially formed therein and that can at least partially obstruct fold lines 215A, 215B, 215C, 215D, 215E, 215F, 215G, and 215H. In some embodiments, one or more of the openings 217 can be configured to at least partially receive one or more mechanical components during formation of the tray 110 and / or to provide visibility to components of an underlying tray behind the upper side panel 213.

[0024] As also shown, adjacent upper side panels 213 may be at least partially separable from one another at diagonal cuts 218 that extend to the flange panels 211 .

[0025] 3-5, the formation of tray 110 from cooperation of first blank 103 and second blank 203 will be described according to an exemplary embodiment.

[0026] The first blank 103 can be inverted, for example, so that its outer surface 101 is positioned on a support surface and its inner surface is positioned facing upward. The plurality of lower side panels 113 can be folded into a generally upright relationship with the central panel 111 at fold lines 115A, 115B, 115C, 115D, 115E, 115F, 115G, and 115H, respectively, to at least partially form the first portion 105 of the tray 110.

[0027] Simultaneously or thereafter, the second blank 203 can be positioned above the first blank 103 / first portion 105, and the upper side panels 213 can be folded downwardly against the flange panels 211 at fold lines 215A, 215B, 215C, 215D, 215E, 215F, 215G and 215H, respectively, to at least partially form the second portion 205 of the tray 110.

[0028] In such an arrangement, the upper side panel 213 can be positioned in at least partial face-to-face contact with a respective lower side panel 113 to form a respective side wall 219 of the tray 110 that extends at least partially around the interior 107 of the tray 110. In some embodiments, the respective lower side panel 113 and upper side panel 213 can be adhered to one another with an adhesive, such as glue. As shown, adjacent side walls of the plurality of side walls 219 can be disposed at an angle with respect to one another.

[0029] Such engagement between the first portion 105 of the tray 110 and the second portion 205 of the tray 110 can be achieved by folding the distal portion 119 of each lower side panel 113 relative to the base portion 117 of each lower side panel 113 at fold lines 121A, 121B, 121C, 121D, 121E, 121F, 121G, and 121H to bring the distal portion 119 into at least partial face-to-face contact with a respective portion of the interior surface (e.g., the surface facing the support surface) of the flange panel 211. In some embodiments, such positioning of the respective distal portions 119 can be achieved prior to engagement of the first portion 105 and the second portion 205 of the tray 110.

[0030] In this regard, the distal portion 119 of each lower side panel 113 may cooperate with the flange panel 211 to form a reinforced flange 221 of the tray 110, with multiple layers of material at least overlapping to form the flange 221 for, e.g., strength, rigidity, etc. As shown, the flange panel 211 extends outwardly away from the panels 113 and 213, e.g., away from the interior 107 of the tray 110. The flange panel 211 may be disposed in a generally spaced-apart, parallel relationship with the central panel 111.

[0031] It should be understood that the formed configuration of the tray 110 can be achieved through one or more applications of adhesive, such as glue. For example, one or more applications of adhesive may be provided between each of one or more lower side panels 113 and each of one or more upper side panels 213. As another example, one or more applications of adhesive may be provided between each of one or more distal portions 119 of the lower side panels 113 and each of one or more portions of the flange panel 211 such that the distal portions 119 of the lower side panels 113 provide additional attachment points to the flange panel 211 / second portion 205 of the tray 110, thereby securing the first portion 105 and second portion 205 of the tray 110 together and maintaining the relative positions of their side walls 219 and flanges 221.

[0032] It will be understood that one or more features of tray 110 may be alternatively positioned, sized, and / or configured without departing from this disclosure.

[0033] In some embodiments, a composite and / or polymer sheet of material, such as a liner, can be applied to one or more portions of the interior 107 of the tray 110 to, for example, prevent leakage, maintain one or more sanitary conditions of one or more food items held therein, increase the shelf life of the tray 110 in the presence of fluids, etc. In such embodiments, secure engagement of the first and second portions 105, 205 of the tray 110, for example, via engagement of the distal portions 119 of each of the lower side panels 113 with respective portions of the flange panels 211, can minimize, inhibit, prevent, and / or otherwise avoid inadvertent separation of the liner from the tray 110. In some embodiments, such a liner L can at least partially maintain the engagement relationship between the first and second portions 105, 205 of the tray 110.

[0034] In this regard, the blanks 103 and 203 and / or the trays 110 formed therefrom can be provided with a liner L comprising a plastic layer such as polyethylene, polyethylene terephthalate (PET) material, or any other thermoplastic material, or a bioplastic such as a vegetable oil or starch-based plastic. In one embodiment, such a liner can comprise polyethylene that can be softened and fused to the blanks 103 and 203 / tray 110. In an alternative embodiment, the liner attached to the blanks 103 and 203 / tray 110 can comprise PET or a similar material at least partially attached to the blanks 103 and 203 / tray 110 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 Limited Partnership of Hopewell, Virginia, any suitable thermoformable sealant or adhesive, any suitable heat- or pressure-activated adhesive, or any other suitable material), with PET being more suitable for applications requiring heating of the container in an oven.

[0035] Such liners can be at least partially attached to blanks 103 and 203 / tray 110 so as to be positioned in contact with one or more food items held in tray 110 (e.g., during heating). In one embodiment, after the food items are heated, blanks 103 and 203 / tray 110 and associated liner L can be separated, allowing both blank 103 and liner to be separately recycled. If desired, blanks 103 and 203 and tray 110 formed therefrom can be provided separately from the liner.

[0036] In an exemplary embodiment shown schematically in FIG. 3, blanks 103 and 203 / tray 110, or their folded configuration, can be placed on lower die 15 of system 17, and liner material or film sheet 19 (e.g., polyethylene or PET web) can be fed from feed roller 21 above blanks 103 and 203 / tray 110. Upper die 23 has heater plate surface 25 with a PTFE coating (e.g., Teflon coating available from Chemours Company of Wilmington, Del.). Alternatively, heater plate surface 25 can have a coating of any suitable material, or the coating can be omitted. As shown schematically in FIG. 3, upper die 23 can include a plurality of holes or ducts 27 in heater plate surface 25 for applying vacuum and / or air pressure to sheet 19. The lower die 15 and / or the upper die 23, including the ducts 27 and / or heater plate surface 25, may have other shapes, arrangements, positions, and / or configurations without departing from this disclosure. For example, the heater plate surface 25 may be omitted, and heat may be applied to the sheet 19 instead (e.g., using a stream of hot air).

[0037] In the illustrated embodiment, the lower die 15 can support the blanks 103 and 203 / tray 110 while holding the blanks 103 and 203 / tray 110 over the cavity 14 of the lower die 15. An initial vacuum can be applied to the duct 27 to draw the film sheet 19 toward the upper die 23, which can be heated to an appropriate temperature to soften the film sheet 19 and / or activate the heat seal layer. Instead of, or in addition to, the initial vacuum, air pressure below the film sheet 19 can be used to achieve a similar or equivalent effect. The film sheet 19 can then be forced downward (e.g., by air pressure applied by the duct 27 and / or vacuum applied from below the blanks 103 / tray 110).

[0038] Air pressure can move film sheet 19 toward blanks 103 and 203 / tray 110, and lower die 15 can support blanks 103 and 203 / tray 110 as film sheet 19 is applied to one or more portions of blanks 103 and 203 / tray 110 to form liner L. In one embodiment, liner L can help hold tray 110 in its tray shape after liner L is applied to blanks 103 and 203. In one embodiment, tray 110 can be ejected from lower die 15 and transported away from the forming tool, for example, on a conveyor.

[0039] In one embodiment, the tray 110 can be formed from the blanks 103 and 203 and can have the liner L applied thereto at a rate much higher than a system that separately forms the tray 110 from the blanks 103 and 203 and then places the formed tray 110 into the lower die 15. In one example, the tray 110 of this embodiment can be formed from the blanks 103 and 203 along with the liner L at a rate of about 500 trays per minute. The tray 110 can be formed differently without departing from this disclosure. For example, the tray 110 can be formed from the blanks 103 and 203 before the liner L is applied (e.g., before engaging the lower die 15).

[0040] Referring to FIG. 6, there is shown an exterior surface 301 of a base or first blank 303 for forming a base or first portion 305 of a tray 310 according to a second exemplary embodiment of the present disclosure.

[0041] As shown, the blank 303 has a longitudinal direction L1 and a lateral direction L2. In the illustrated embodiment, the blank 303 includes a plurality of panels for extending at least partially around the interior 307 of the tray 310, which may include a base or bottom or center panel 311.

[0042] The central panel 311 may have an irregular, but diagonally symmetrical ten-sided arrangement as shown, but may have sides of unequal length so as to have an overall generally straight section profile. It will be understood that the central panel 311 may have a different arrangement without departing from this disclosure.

[0043] The blank 303 and the multiple panels of the first tray portion 305 / tray 310 formed therefrom can include multiple lower side panels, including pairs of side panels 313, 315, 317, 319, and 321, respectively, positioned in opposing relationship along the central panel 311.

[0044] As shown, each side panel 313 can include a base portion 323 foldably connected to the central panel 311 at a horizontal fold line 325 and a distal portion 327 foldably connected to the base portion 323 at a horizontal fold line 329.

[0045] Each side panel 315 can include a base portion 331 foldably connected to the central panel 311 at a diagonal fold line 333 and a distal portion 335 foldably connected to the base portion 331 at a horizontal fold line 337 .

[0046] Similarly, each side panel 317 can include a base portion 339 foldably connected to the central panel 311 at a diagonal fold line 341 and a distal portion 343 foldably connected to the base portion 339 at a diagonal fold line 345.

[0047] As shown, each side panel 319 can include a base portion 347 foldably connected to the central panel 311 at a longitudinal fold line 349 and a distal portion 351 foldably connected to the base portion 347 at a longitudinal fold line 353.

[0048] Each side panel 321 can include a base portion 355 foldably connected to the central panel 311 at a diagonal fold line 357 and a distal portion 359 foldably connected to the base portion 355 at a diagonal fold line 361 .

[0049] The blank 303, and the tray portion 305 / tray 310 formed therefrom, may also include a plurality of end flaps foldably connected to each panel / side panel of the plurality of panels / side panels.

[0050] In the illustrated embodiment, the plurality of end flaps may include corner end flaps 363 foldably connected to the base portion 331 of each of the side panels 315 at diagonal fold lines 365 .

[0051] A corner end flap 367 can be foldably connected to the base portion 339 of each side panel 317 at a diagonal fold line 369, and another corner end flap 371 can be foldably connected to the opposite edge of the base portion 339 of each side panel 317 at a diagonal fold line 373.

[0052] Similarly, a corner end flap 375 can be foldably connected to the base portion 355 of each side panel 321 at a diagonal fold line 377, and another corner end flap 379 can be foldably connected to the opposite edge of the base portion 355 of each side panel 321 at a diagonal fold line 381.

[0053] Referring to FIG. 7, the outer surface 401 of a crown or second blank 403 for forming the crown or second portion 405 of the tray 310 is shown.

[0054] As shown, the blank 403 can have a longitudinal axis L1, a transverse axis L2, and a top or flange panel 411 that generally forms the periphery of the blank 403 to extend at least partially around a central opening 412 through which multiple panels of the blank 403 and the second portion 405 / tray 310 extend.

[0055] In the illustrated embodiment, the flange panel 411 can have a configuration that is generally complementary to that of the central panel 311 described above, although it will be understood that the flange panel 411 can have a different configuration without departing from this disclosure. As shown, the flange panel 411 can have a perimeter that is greater than the perimeter of the central panel 311.

[0056] The blank 403, and the tray portion 405 / tray 310 formed therefrom, can include a plurality of side panels extending within the central opening 412, including respective pairs of side panels 413, 415, 417, 419 and 421 positioned in opposing relationship along the flange panel 411.

[0057] Each side panel 413 can be foldably connected to flange panel 411 at a horizontal fold line 423, each side panel 415 can be foldably connected to flange panel 411 at a diagonal fold line 425, each side panel 417 can be foldably connected to flange panel 411 at a diagonal fold line 427, each side panel 419 can be foldably connected to flange panel 411 at a longitudinal fold line 429, and each side panel 421 can be foldably connected to flange panel 411 at a diagonal fold line 431.

[0058] Side panels 413, 415, 417, 419, and 421 have a configuration generally complementary to the configuration of side panels 313, 315, 317, 319, and 321, respectively, although it will be understood that one or more of side panels 413, 415, 417, 419, and 421 can have a different configuration without departing from this disclosure.

[0059] With further reference to FIG. 8, the cooperation of first blank 303 and second blank 403 to form tray 310 will be described according to an exemplary embodiment.

[0060] First blank 303 can be inverted, for example, so that its outer surface 301 is positioned on a support surface and its inner surface faces up. Lower side panels 313, 315, 317, 319, and 321 can be folded at fold lines 325, 333, 341, 349, and 357, respectively, into a generally upright relationship with central panel 311.

[0061] The second blank 403 can then be positioned above the first blank 303 / first portion 305, and the upper side panels 413, 415, 417, 419 and 421 can be folded downwardly against the flange panel 411 at fold lines 423, 425, 427, 429 and 431, respectively, to at least partially form the second portion 405 of the tray 310.

[0062] In such an arrangement, the lower side panels 313, 315, 317, 319, and 321 can be positioned in at least partial face-to-face contact with the upper side panels 419, 417, 415, 413, and 421, respectively, to form side walls 433 / 435, 437 / 439, 441 / 443, 445 / 447, and 449 / 451 of the tray 310 that extend at least partially around the interior 307 of the tray 310. In some embodiments, the side panels 313, 315, 317, 319, 321, 419, 417, 415, 413, and 421, respectively, can be adhered to one another with an adhesive, such as glue. As shown, adjacent side walls of the plurality of side walls 433, 435, 437, 439, 441, 443, 445, 447, 449, and 451 can be disposed at an angle with respect to one another.

[0063] Such engagement of the first portion 305 of the tray 310 with the second portion 405 of the tray 310 can at least partially form the first portion 305 of the tray 310 by folding the distal portion 327 of the side panel 313 outward at fold line 329, e.g., in a generally spaced-apart and parallel relationship above the central panel 311, folding the distal portion 335 of the side panel 315 outward at fold line 337, folding the distal portion 343 of the side panel 317 outward at fold line 345, folding the distal portion 351 of the side panel 319 outward at fold line 353, and folding the distal portion 359 of the side panel 321 outward at fold line 361.

[0064] In this regard, distal portions 327, 335, 343, 351, and 359 of lower side panels 313, 315, 317, 319, and 321, respectively, can cooperate with flange panel 411 of second portion 405 to form a reinforced flange 463 of tray 310, with multiple layers of material at least overlapping to form flange 463 for, e.g., strength, rigidity, etc. As shown, flange panel 411 extends outwardly away from panels 313, 315, 317, 319, 321, 419, 417, 415, 413, and 421, e.g., away from interior 307 of tray 310. Flange panel 411 can be positioned in a generally spaced-apart, parallel relationship with central panel 311.

[0065] Additionally, the inner surface of each corner end flap 363 may be positioned in at least partial face-to-face contact with a portion of the base portion 323 of the adjacent side panel 313. It will be appreciated that such positioning of one or both corner end flaps 363 may include at least partially folding them relative to the base portion 331 of the side panel 315 at fold line 365.

[0066] 6-8 , the inner surface of each corner end flap 367 can be positioned in at least partial face-to-face contact with a portion of the base portion 331 of the adjacent side panel 315. Similarly, the inner surface of each corner end flap 371 can be positioned in at least partial face-to-face contact with a portion of the base portion 347 of the adjacent side panel 319. It will be appreciated that such positioning of one or more of the corner end flaps 367 and 371 can include at least partial folding of the base portion 339 of the side panel 317 at fold lines 369 and 373.

[0067] Similarly, the inner surface of each corner end flap 375 can be positioned in at least partial face-to-face contact with a portion of the base portion 347 of the adjacent side panel 319. The inner surface of each corner end flap 379 can be positioned in at least partial face-to-face contact with a portion of the base portion 323 of the adjacent side panel 313. It will be appreciated that such positioning of one or more of the corner end flaps 375 and 379 can include at least partial folding of the base portion 355 of the side panel 321 at fold lines 377 and 381.

[0068] The above-described positioning of corner end flaps 363, 367, 371, 375, and 379 can generally abut or at least partially overlap gaps, e.g., seams, between otherwise adjacent side panels 313, 315, 317, 319, and 321, and can provide at least partial resistance to leakage of food-related fluids (e.g., dressings, concentrates, fluids, etc.) within interior 307 of tray 310.

[0069] Additionally, the positioning of corner end flaps 363, 367, 371, 375 and 379 overlapping side panels 313, 315, 317, 319 and 321, respectively, can provide reinforcement to side walls 433, 435, 437, 439, 441, 443, 445, 447, 449 and 451, with a double layer construction being provided at such overlapping portions to avoid, for example, buckling, bowing or other undesirable deformation.

[0070] In some embodiments, a composite and / or polymer sheet of material, such as liner L, may be applied to one or more portions of the interior 307 of the tray 310 to, for example, prevent leakage of one or more food items held therein, maintain one or more sanitary conditions, extend the shelf life of the tray 310 in the presence of fluids, etc. In some embodiments, secure engagement between the first portion 305 and the second portion 405 of the tray 310 can minimize, inhibit, prevent, and / or otherwise avoid inadvertent separation of the liner from the tray 310. In some embodiments, such liner L can at least partially maintain the engagement between the first portion 305 and the second portion 405 of the tray 310. It will be appreciated that a liner can be applied to the blanks 303 and 403 and / or the tray 310 formed therefrom in the manner described above with respect to the blanks 103 and 203 and / or the tray 110 formed therefrom, as shown generally in FIG. 3 .

[0071] It will be appreciated that in some embodiments, the shaped configuration of the tray 310 may be achieved through one or more applications of an adhesive, such as glue.

[0072] It will be understood that one or more features of tray 310 may be alternatively positioned, sized, and / or configured without departing from this disclosure.

[0073] For example, according to an alternative exemplary embodiment of the present disclosure, the blank, and the tray formed therefrom, may lack side panels 331 and 417 and associated features, and the central panel 311 may be configured accordingly such that the tray has the general shape of a tray having four sides with four beveled corners.

[0074] Referring to FIG. 9, there is shown an exterior surface 501 of a base or first blank 503 for forming a base or first portion 505 of a tray 510 according to a third exemplary embodiment of the present disclosure.

[0075] As shown, the blank 503 has a longitudinal direction L1 and a lateral direction L2. In the illustrated embodiment, the blank 503 includes a plurality of panels for extending at least partially around the interior 507 of the tray 510, which may include a base or bottom or center panel 511.

[0076] The central panel 511 may have a generally circular configuration as shown, although the central panel 511 may have a different configuration without departing from this disclosure.

[0077] The blank 503, and the plurality of panels of the first portion 505 / tray 510 formed therefrom, can include a plurality of upper side panels, each including a pair of side panels 513 and 517 positioned in opposing relationship along a central panel 511. Each of the side panels 513 can be foldably connected to the central panel 511 at a diagonal fold line 515, and each of the side panels 517 can be foldably connected to the central panel 511 at a diagonal fold line 519.

[0078] Each side panel 513 and 517 may include a diagonal line of weakness 521 extending at least partially therealong to facilitate formation of the first portion 505 of the tray 510, as shown and as further described herein.

[0079] Referring to FIG. 10, an outer surface 601 of a crown or second blank 603 for forming the crown or second portion 605 of the tray 510 is shown.

[0080] As shown, the blank 603 can have a longitudinal axis L1, a transverse axis L2, and a top panel or flange panel 611 that generally forms the periphery of the blank 603 to extend at least partially around a central opening 612 through which the blank 603 and multiple panels of the second portion 605 / tray 510 extend.

[0081] In the illustrated embodiment, the flange panel 611 can have a configuration that is generally complementary to that of the central panel 511 described above, although it will be understood that the flange panel 611 can have a different configuration without departing from this disclosure. As shown, the flange panel 611 can have a perimeter that is greater than the perimeter of the central panel 511.

[0082] The blank 603, and the second portion 605 / tray 510 formed therefrom, can include a plurality of side panels extending into the central opening 612, including a plurality of circumferentially arranged side panels 613 positioned to extend into the central opening 612.

[0083] As shown, each side panel 613 may be foldably connected to the flange panel 611 at lines of weakness 615A, 615B, 615C, 615D, 615E, 615F, 615G, 615H, 615I, 615J, 615K, 615L, 615M, 615N, 615P, and 615Q. Additionally, each side panel 613 may be at least partially separable from an adjacent side panel 613 at a respective diagonal cut.

[0084] 11 and 12, the cooperation of first blank 503 and second blank 603 to form tray 510 will be described according to an exemplary embodiment.

[0085] The first blank 503 can be inverted, for example, so that its outer surface 501 is positioned on a support surface and its inner surface faces upward. The lower side panels 513 and 517 can be folded at fold lines 515 and 519, respectively, into a generally upright relationship with the central panel 511.

[0086] In such an arrangement, each of the side panels 513 and 517 can be at least partially bent, curved, etc. at the line of weakness 521, and the side panel 517, for example, overlaps and at least partially contacts the side edge portion of the adjacent side panel 513.

[0087] Each of the upper side panels 613 of the second blank 603 can then be folded downwardly at fold lines 615A-615Q relative to the flange panel 615 to at least partially form the second portion 605 of the tray 510. In this regard, each of the upper side panels 613 can be positioned in at least partial face-to-face contact with upper edge portions of the lower side panels 513 and 517.

[0088] In such an arrangement, each of the upper side panels 613 can be positioned in at least partial face-to-face contact with the lower side panels 513 and 517 to form side walls 665, 667, 669, and 671 of the tray 510 that extend at least partially around the interior 507 of the tray 510. In some embodiments, each of the side panels 513, 517, and 613 can be adhered to one another with an adhesive, such as glue. As shown, adjacent side walls of the plurality of side walls 665, 667, 669, and 671 can be arranged to generally extend along a common curved line relative to one another.

[0089] In this regard, the upper side panel 613 can extend downwardly from the flange panel 611 of the second portion 605, which flange panel 611 forms the flange or reinforced flange 663 of the tray 510. As shown, the flange panel 611 extends outwardly away from the panels 513, 517, and 613, e.g., away from the interior 607 of the tray 610. The flange panel 611 can be disposed in a generally spaced-apart, parallel relationship with the central panel 511.

[0090] The above-described positioning of each lower side panel 513 and 517 can generally abut or at least partially overlap a gap, e.g., a seam, between otherwise adjacent adjacent side panels 513 and 517, and can provide at least partial resistance to leakage of food-related fluids (e.g., dressings, concentrates, fluids, etc.) within the interior 507 of the tray 510.

[0091] The positioning of each of the side panels 513 and 517 can also provide reinforcement to the side walls 665, 667, 669 and 671, providing a double layer construction at such overlapping areas to avoid, for example, buckling, bowing or other undesirable deformation.

[0092] In some embodiments, a composite and / or polymer sheet of material, such as liner L, can be applied to one or more portions of the interior 507 of the tray 510 to, for example, prevent leakage of one or more food items held therein, maintain one or more sanitary conditions, extend the shelf life of the tray 510 in the presence of fluids, etc. In some embodiments, the secure engagement of the first portion 505 and the second portion 605 of the tray 510 can minimize, inhibit, prevent, and / or otherwise avoid inadvertent separation of the liner from the tray 510. In some embodiments, such liner L can at least partially maintain the engaged relationship between the first portion 505 and the second portion 605 of the tray 510. It will be appreciated that liners can be applied to the blanks 503 and 603 and / or the trays 510 formed therefrom in the manner described above with respect to the blanks 103, 203, 303, and 403 and / or the trays 110 and 310 formed therefrom, as shown generally in FIG. 3 .

[0093] It will be appreciated that in some embodiments, the shaped configuration of the tray 510 may be achieved through one or more applications of an adhesive, such as glue.

[0094] It will be understood that one or more features of tray 510 may be alternatively positioned, sized, and / or configured without departing from this disclosure.

[0095] Referring to FIG. 13, there is shown an outer surface 701 of a base or first blank 703 for forming a base or first portion 705 of a tray 710 according to a fourth exemplary embodiment of the present disclosure.

[0096] As shown, the blank 703 has a longitudinal direction L1 and a lateral direction L2. In the illustrated embodiment, the blank 703 includes a plurality of panels for extending at least partially around the interior 707 of the tray 710, which may include a base or bottom or center panel 711.

[0097] The central panel 711 may have a generally square or rectangular configuration having four sides as shown, although it will be understood that the central panel 711 may have a different configuration without departing from this disclosure.

[0098] The blank 703 and the multiple panels of the first portion 705 / tray 710 formed therefrom can include multiple lower side panels, each including a pair of side panels 713 and 717 positioned in opposing relationship along the central panel 711, with each side panel 713 being foldably connected to the central panel 711 at a diagonal fold line 715 and each side panel 717 being foldably connected to the central panel 711 at a diagonal fold line 719.

[0099] Each side panel 713 and 717, as shown, can include a diagonal line of weakness 721 extending at least partially therealong to facilitate formation of the first portion 705 of the tray 710, as described further herein. In some embodiments, one or more of the side panels 713 and 717 can include multiple additional lines of weakness along a top edge portion thereof.

[0100] The blank 703, and the first portion 705 / tray 710 formed therefrom, may also include a plurality of end flaps foldably connected to each panel / side panel of the plurality of panels / side panels.

[0101] In the illustrated embodiment, the multiple end flaps may include corner end flaps 723 and 727 that are at least partially foldably connected to the side panel 713 at diagonal fold lines 725 and 729, and corner end flaps 731 and 735 that are at least partially foldably connected to the side panel 713 at diagonal fold lines 733 and 737.

[0102] Referring to FIG. 14, the outer surface 801 of a crown or second blank 803 for forming the crown or second portion 805 of the tray 710 is shown.

[0103] As shown, the blank 803 can have a longitudinal axis L1, a transverse axis L2, and a top panel or flange panel 811 that generally forms the periphery of the blank 803 to extend at least partially around a central opening 812 through which the blank 803 and multiple panels of the second portion 805 / tray 710 extend.

[0104] In the illustrated embodiment, the flange panel 811 can have a generally circular configuration with one or more diametrically opposed flat edges, although the flange panel 811 can have different configurations without departing from this disclosure. As shown, the flange panel 811 can have a perimeter that is greater than the perimeter of the central panel 711.

[0105] The blank 803, and the second portion 805 / tray 710 formed therefrom, can include a plurality of side panels extending into the central opening 812, including a plurality of circumferentially arranged side panels 813 positioned to extend into the central opening 812.

[0106] As shown, each side panel 813 may be foldably connected to flange panel 811 at lines of weakness 815A, 815B, 815C, 815D, 815E, 815F, 815G, 815H, 815I, 815J, 815K, 815L, 815M, 815N, 815P, and 815Q. Additionally, each side panel 813 may be at least partially separable from an adjacent side panel 813 at a respective diagonal cut.

[0107] 15 and 16, the cooperation of first blank 703 and second blank 803 to form tray 710 will be described according to an exemplary embodiment.

[0108] The first blank 703 can be inverted, for example, so that its outer surface 701 is positioned on a support surface and its inner surface faces upward. The lower side panels 713 and 717 can be folded at fold lines 715 and 719, respectively, into a generally upright relationship with the central panel 711.

[0109] In such an arrangement, each of the side panels 713 and 717 can bend, curve, etc., at least partially at the line of weakness 721, such that the inner surface of each of the side panels 717 overlaps, e.g., at least partially in face-to-face contact, with the outer surfaces of the corner end flaps 723, 727, 731, and 735 extending from the side panel 713. Such movement of each of the corner end flaps 723, 727, 731, and 735 can include at least partial folding at the fold lines 725, 729, 733, and 737.

[0110] Each of the upper side panels 813 of the second blank 803 can then be folded downwardly at fold lines 815A-815Q relative to the flange panel 811 to at least partially form the second portion 805 of the tray 710. In this regard, each of the upper side panels 813 can be positioned in at least partial face-to-face contact with upper edge portions of the lower side panels 713 and 717.

[0111] In such an arrangement, the upper side panel 813 can be positioned in at least partial face-to-face contact with the lower side panels 713 and 717, respectively, to form side walls 865, 867, 869, and 871 of the tray 710 that extend at least partially around the interior 707 of the tray 710. In some embodiments, the side panels 713, 717, and 813 can be adhered to one another with an adhesive, such as glue. As shown, adjacent side walls of the plurality of side walls 865, 867, 869, and 871 can be disposed diagonally or perpendicularly relative to one another.

[0112] Such a configuration of tray 710 provides a generally square or rectangular bottom profile that transitions along side walls 865, 867, 869 and 871 to a generally circular top profile.

[0113] In this regard, the upper side panels 813 can each extend downwardly from a flange panel 811 of the second portion 805, which flange panels 811 form a flange or reinforced flange 863 of the tray 710. As shown, the flange panels 811 extend outwardly away from the panels 713, 717, and 813, e.g., away from the interior 707 of the tray 710. The flange panels 811 can be disposed in a generally spaced-apart, parallel relationship with the central panel 711.

[0114] The above-described positioning of the lower side panels 713 and 717 and corner end flaps 723, 727, 731 and 735 can generally abut or at least partially overlap gaps, e.g., seams, between otherwise adjacent side panels 713 and 717, and can provide at least partial resistance to leakage of food-related fluids (e.g., dressings, concentrates, fluids, etc.) within the interior 707 of the tray 710.

[0115] The positioning of each of the side panels 713 and 717 can also provide reinforcement to the side walls 865, 867, 869 and 871, e.g., where such overlapping portions are provided with a double layer construction to avoid buckling, bowing or other undesirable deformation.

[0116] In some embodiments, a composite and / or polymer sheet of material, such as liner L, can be applied to one or more portions of the interior 707 of the tray 710 to, for example, prevent leakage of one or more food items held therein, maintain one or more sanitary conditions, extend the shelf life of the tray 710 in the presence of fluids, etc. In some embodiments, secure engagement between the first portion 705 and the second portion 805 of the tray 710 can minimize, inhibit, prevent, and / or otherwise avoid inadvertent separation of the liner from the tray 710. In some embodiments, such liner L can at least partially maintain the engagement between the first portion 705 and the second portion 805 of the tray 710. It will be appreciated that liners can be applied to blanks 703 and 803 and / or trays 710 formed therefrom in the manner described above with respect to blanks 103, 203, 303, 404, 503, and 603 and / or trays 110, 310, and 510 formed therefrom, as shown generally in FIG. 3 .

[0117] It will be appreciated that in some embodiments, the shaped configuration of the tray 710 may be achieved through one or more applications of an adhesive, such as glue.

[0118] It will be understood that one or more features of tray 710 may be alternatively positioned, sized, and / or configured without departing from this disclosure.

[0119] Any feature of the various embodiments of the present disclosure may be combined with, substituted by, or otherwise configured with other features of other embodiments of the present disclosure without departing from the scope of the present disclosure. Also, it should be noted that the blank and carton nesting arrangements and / or features of the various embodiments may be incorporated into cartons or blanks having any carton style or panel configuration. The carton styles and panel configurations described above are included as examples.

[0120] Blanks according to any of the embodiments of the present disclosure can be formed from, for example, coated paperboard and similar materials. For example, the blank can be coated on the inside and / or outside with a clay coating. Product, advertising, price codes, and other information or images can then be printed on top of 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 on one or both sides of the blank with, for example, a moisture barrier. In accordance with the above-described embodiments, the blank can be constructed from paperboard of a thickness such that it is heavier and more rigid than regular paper. The blank can also be constructed from other materials, such as cardboard, rigid paper, or any other material having suitable properties to enable the carton to function at least generally as described herein. The blank can also be laminated or coated with one or more sheet-like materials in selected panels or panel sections.

[0121] In accordance with the above-described embodiments of the present disclosure, the fold lines are not necessarily straight, but can be any substantially straight form of weakness that facilitates folding therealong. More specifically, without intending 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 that extend partially into the material along the desired line of weakness, and / or a series of cuts that extend partially into and / or through the material along the desired line of weakness, and various combinations of these features.

[0122] As an example, a tear line can include a slit extending partially into the material along the desired line of weakness, and / or a series of spaced slits extending partially into the material along the desired line of weakness and / or extending entirely 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 extending completely through the material, with adjacent slits spaced slightly apart so that a notch (e.g., a small, somewhat bridge-like piece of material) is defined between the adjacent slits to typically temporarily connect the material across the tear line. The notch is broken during tearing along the tear line. The notch is typically a relatively small percentage of the tear line; alternatively, the notch can be omitted from or torn at the tear line so that the tear line is a continuous discontinuity. That is, it is within the scope of this disclosure to replace each tear line with a continuous slit, etc. For example, the cut may be a continuous slit or may be wider than a slit without departing from this disclosure.

[0123] The above embodiments may be described as having one or more panels adhered together by an adhesive during assembly of the carton embodiment, the term "adhesive" being intended to encompass any type of adhesive commonly used to secure carton panels in place.

[0124] The foregoing description of the present disclosure illustrates and describes various exemplary embodiments. Various additions, modifications, and alterations may be made to the exemplary embodiments without departing from the spirit and scope of the present disclosure. It is intended that all matter contained in the above description or shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. In addition, while the present disclosure shows and describes only selected embodiments of the present disclosure, the present disclosure can be used in various other combinations, modifications, and environments, and changes or modifications can be made in accordance with the above teachings and / or within the skill or knowledge of the relevant art, within the scope of the inventive concept as expressed herein. Furthermore, some features and characteristics of each embodiment can be selectively interchanged and applied to other shown and unshown embodiments of the present disclosure.

Claims

1. A tray for holding one or more food items, a first portion comprising a plurality of panels including a central panel and a plurality of lower side panels foldably connected to the central panel; a second portion engaging the first portion, the second portion comprising a plurality of panels including a flange panel and a plurality of upper side panels foldably connected to the flange panel; Equipped with The tray, wherein the plurality of upper side panels and the plurality of lower side panels are attached to one another to form a plurality of side walls of the tray.

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

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

4. 4. The tray of claim 3, wherein the flange panels have a perimeter that is longer than the perimeter of the central panel.

5. 4. The tray of claim 3, wherein adjacent ones of the plurality of side walls are disposed at an angle relative to one another.

6. 4. The tray of claim 3, wherein each of said plurality of lower side panels is at least partially curved.

7. 7. The tray of claim 6, wherein the center panel has a square configuration.

8. 4. The tray of claim 3, wherein each of said plurality of upper side panels is adhesively attached to each of said plurality of lower side panels.

9. 4. The tray of claim 3, wherein the flange panels extend away from the plurality of upper side panels and the plurality of lower side panels to form reinforced flanges of the tray.

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

11. 11. The tray of claim 10, wherein the distal portion of each of the plurality of lower side panels is positioned in at least partial face-to-face contact with the flange panel to at least partially form the reinforced flange of the tray.

12. 10. The tray of claim 9, wherein the first portion of the tray further comprises a plurality of corner end flaps foldably connected to each of the plurality of lower side panels.

13. 13. The tray of claim 12, wherein each of the plurality of corner end flaps is positioned in at least partial face-to-face contact with a portion of each of the plurality of lower side panels to form each of the plurality of side walls of the tray.

14. 1. An assembly of blanks to form a tray for holding one or more food items, comprising: a first blank comprising a plurality of panels including a central panel and a plurality of lower side panels foldably connected to the central panel; a second blank that engages with the first blank when the tray is formed from the combination of the blanks, the second blank comprising a plurality of panels including a flange panel and a plurality of upper side panels foldably connected to the flange panel; Equipped with A combination of blanks, wherein the plurality of upper side panels and the plurality of lower side panels are intended to be attached to one another to form a plurality of side walls of the tray formed from the combination of blanks.

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

16. 16. The combination of claim 15, wherein said flange panels have a perimeter that is greater than the perimeter of said central panel.

17. 16. The combination of claim 15, wherein the plurality of upper side panels and the plurality of lower side panels are intended to be attached to one another to form the plurality of side walls of the tray formed from the combination of the blanks such that adjacent side walls of the plurality of side walls are disposed at an angle relative to one another.

18. 16. The combination of claim 15, wherein each of said plurality of lower side panels is at least partially curved when said tray is formed from said combination of blanks.

19. 20. The combination of claim 18, wherein the central panel has a square configuration.

20. 16. The combination of claim 15, wherein the flange panel extends away from the plurality of upper side panels to form a reinforced flange of the tray formed from the combination of the blanks.

21. 21. The combination of claim 20, wherein each of the plurality of lower side panels comprises a base portion foldably connected to the central panel and a distal portion foldably connected to the base portion.

22. 22. The combination of claim 21, wherein the distal portion of each of the plurality of lower side panels is positioned in at least partial face-to-face contact with the flange panel to at least partially form the reinforced flange of the tray formed from the combination of the blanks.

23. 21. The combination of claim 20, wherein said first blank further comprises a plurality of corner end flaps foldably connected to each of said plurality of lower side panels.

24. 24. The combination of claim 23, wherein each of the plurality of corner end flaps is positioned in at least partial face-to-face contact with a portion of each of the plurality of lower side panels to form each of the plurality of side walls of the tray formed from the combination of the blanks.

25. 1. A method of forming a tray for holding one or more food items, comprising: obtaining a first blank comprising a plurality of panels including a central panel and a plurality of lower side panels foldably connected to the central panel; obtaining a second blank comprising a plurality of panels including a flange panel and a plurality of upper side panels foldably connected to the flange panel; forming a first portion of the tray from the first blank; forming a second portion of the tray from the second blank; attaching the plurality of upper side panels and the plurality of lower side panels to one another to form a plurality of side walls of the tray; A method comprising:

26. 26. The method of claim 25, wherein the first portion of the tray is a base portion of the tray and the second portion of the tray is a crown portion of the tray positioned above the base portion of the tray.

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

28. 28. The method of claim 27, wherein the flange panels have a perimeter that is greater than the perimeter of the central panel.

29. 28. The method of claim 27, wherein adjacent sidewalls of the plurality of sidewalls are disposed at an angle relative to one another.

30. 30. The method of claim 27, further comprising at least partially curving each of the plurality of lower side panels.

31. 31. The method of claim 30, wherein the central panel has a square configuration.

32. 30. The method of claim 27, further comprising adhering each of the plurality of upper side panels to each of the plurality of lower side panels.

33. 28. The method of claim 27, further comprising positioning the flange panel to extend away from the plurality of upper side panels and the plurality of lower side panels to form a reinforced flange of the tray.

34. 34. The method of claim 33, wherein each of the plurality of lower side panels comprises a base portion foldably connected to the central panel and a distal portion foldably connected to the base portion.

35. 35. The method of claim 34, further comprising positioning the distal portion of each of the plurality of lower side panels in at least partial face-to-face contact with the flange panel to at least partially form the reinforced flange of the tray.

36. 34. The method of claim 33, wherein the first blank further comprises a plurality of corner end flaps foldably connected to each of the plurality of lower side panels.

37. 37. The method of claim 36, further comprising positioning each of the plurality of corner end flaps in at least partial face-to-face contact with a portion of each of the plurality of lower side panels to form each of the plurality of side walls of the tray.

Images