paper tray

Abstract

To create a paper tray capable of storing food, by devising a folding and molding method, it is possible to form intersecting partition sections from a single sheet of cardboard without defects such as folding failures or paper tearing. [Solution] The paper tray 10 comprises a tray body 11 made from a single sheet of cardboard, a bottom section 14 arranged in parallel in the front, back, left, and right directions on the tray body 11 and on which food 20 can be placed, and vertical partitions 15 and horizontal partitions 16 that divide the space between the bottom sections 14. The space divided by the bottom section 14 and the vertical partitions 15 and horizontal partitions 16 becomes the storage area for food 20. An opening 17 is formed where the vertical partitions 15 and horizontal partitions 16, which extend in intersecting directions, would like to meet, and the vertical partitions 15 and horizontal partitions 16 are separated. During molding, the vertical partitions 15 and horizontal partitions 16 are folded separately and independently, so they do not restrain or interfere with each other, preventing folding defects and tearing due to excessive folding.

Description

Technical Field

[0001] The present invention relates to a paper tray, a sheet for a paper tray that becomes a paper tray when assembled, and a food packaging body formed by storing and packaging food in the paper tray.

Background Art

[0002] Trays mainly for storing foods such as frozen foods are known. In this type of tray, storage portions recessed in a pocket shape for storing items such as foods are formed in parallel vertically and horizontally. The stored items are provided to consumers in the state of a package formed by being stored and packaged in the tray.

[0003] As in Patent Document 1, the most common type in the past was a tray formed by press-molding a plastic sheet (so-called plastic tray). If it is a plastic material with a high degree of molding freedom, it was relatively easy to mold a plurality of storage portions with a large pocket depth according to the shape, thickness or height of items such as foods in the tray. By forming a storage portion with a sufficient depth and size according to the stored item, displacement movement of the stored item and the like were sufficiently prevented.

[0004] However, in consideration of the environment, with the growing movement towards plastic reduction, there is a search for using a paper tray that causes less environmental load, that is, is easy to recycle or dispose of, instead of plastic.

[0005] Actually, as in Patent Document 2, a paper tray provided with a storage portion recessed in a pocket shape formed by press-molding cardboard base paper has also been put on the market. However, the paper material has a disadvantage that its molding freedom is lower than that of the plastic material, and it is difficult to mold a plurality of storage portions with a large pocket depth from a single cardboard base paper by deep drawing molding by pressing because paper breakage and the like occur.

[0006] In this regard, instead of press molding, a paper container has also been devised in which multiple storage compartments are formed by folding paper, as shown in Patent Document 3. Thus, by folding and forming, it is relatively easy to create parallel partitions that are aligned in the same direction by folding the paper at predetermined intervals (folding it into an inverted V-shape), and to create deep storage compartments between the partitions. [Prior art documents] [Patent Documents]

[0007] [Patent Document 1] Patent No. 7437829 [Patent Document 2] Japanese Patent Publication No. 2001-055220 [Patent Document 3] Utility Model Registration No. 3121055 (Publication) [Overview of the project] [Problems that the invention aims to solve]

[0008] However, forming cross-shaped intersecting partitions by folding is difficult because the intersecting partitions are constrained or interfere with each other during folding, leading to problems such as folding defects and paper tearing similar to that caused by press molding. If, in effect, only parallel partitions can be formed, the layout of the storage area will be severely restricted. Furthermore, to improve this, it is possible to insert a separate partition member so as to intersect the parallel partition section formed by bending and molding in a cross shape, but this is time-consuming and costly.

[0009] Therefore, the problem to be solved by the present invention is to enable the formation of intersecting partitions in a paper tray capable of storing food and other items from a single sheet of cardboard base paper, without defects such as folding defects or paper tearing, by devising a method of folding and molding. [Means for solving the problem]

[0010] To solve the above-mentioned problems, the paper tray according to the invention is formed by folding a single sheet of cardboard, and comprises a tray body, a bottom portion on which items can be placed, which is parallel to at least a first direction and a second direction different from the first direction of the tray body, a folded first partition portion extending in a direction substantially perpendicular to the first direction between bottom portions of the tray body adjacent to the first direction, and a folded second partition portion extending in a direction substantially perpendicular to the second direction between bottom portions of the tray body adjacent to the second direction, and the space partitioned by the bottom portion and the first and second partition portions surrounding it constitutes the storage area for the items to be stored. In addition, the tray body is further provided with an opening at the point where the first partition and the second partition meet, so that the first partition and the second partition are separated by the opening.

[0011] In this configuration, although the first and second partitions extend in intersecting directions, they are separated by the presence of an opening and do not merge, allowing them to be folded independently. Therefore, when the partitions are folded during paper tray molding, the stress generated from the vertical (Z direction) and horizontal (XY direction) directions due to the partitions connecting to each other can be relieved. In this way, since the partitions are not constrained or interfere with each other, folding defects during molding and the occurrence of tears due to excessive folding are prevented. Furthermore, by simply forming the openings by punching or other means, the effort of later attaching separate partition members is eliminated, making it possible to easily manufacture paper trays with intersecting partitions. In the storage compartment, items placed at the bottom are held in place by the first and second partitions arranged to surround them, thus preventing them from shifting or falling out of the storage compartment. Because the tray is made entirely of paper, it is easy to recycle and dispose of, resulting in a low environmental impact.

[0012] Furthermore, the tray may or may not have peripheral walls (side walls and end walls if the tray body is rectangular), and if it does have peripheral walls, they may be formed integrally with the tray body or they may be formed separately, for example, attached to the container in which the tray is placed. Furthermore, the partition may consist only of the first partition and the second partition, or it may include other partitions, such as a third partition extending in a direction substantially perpendicular to a third direction that is different from both the first and second directions.

[0013] In the paper tray according to the invention, it is preferable that the first partition and the second partition are formed by folding the cardboard base paper into an inverted V shape.

[0014] With this configuration, the first and second partition sections can be easily formed by a simple folding operation known as a mountain fold. It should be noted that the term "inverted V-shape" here also includes cases where the folding angle is large, causing the two sides of the V-shape to be very close together and approximate an I-shape.

[0015] In the paper tray according to the invention, the bottom portion is arranged in parallel to the front, back, left, and right of the tray body, the first direction is the left-right direction of the tray body, the first partition portion is a vertical partition portion extending in the front-rear direction between adjacent bottom portions in the left-right direction of the tray body, the second direction is the front-rear direction of the tray body, the second partition portion is a horizontal partition portion extending in the left-right direction between adjacent bottom portions in the front-rear direction of the tray body, and the opening is preferably formed at the point where the vertical partition portion and the horizontal partition portion extending in orthogonal directions meet.

[0016] This configuration makes it possible to create a paper tray suitable for storing general food items and other similar goods.

[0017] In the paper tray according to the invention, a configuration can be adopted in which a cylindrical portion is further provided at the edge of the opening and intervenes between the vertical partition portion and the horizontal partition portion.

[0018] With such a configuration, even when a force is applied to the opening in the front-rear, left-right direction (direction toward the opening) from any of the respective partition portions by the cylindrical portion, the opening is difficult to deform. Also, even when a force is applied to the opening itself from above, the opening is difficult to deform, so that deformation of the partition portion in the vertical direction can also be suppressed. As a result, the strength of the entire paper tray is improved, and breakage or the like during use is prevented. Further, since the vertical partition portion and the horizontal partition portion are supported by the cylindrical portion, the bending state is stable, and it is suppressed that the vertical partition portion and the horizontal partition portion return (collapse) to the state before bending due to the restoring elasticity of the paper material or the like. Note that the cylindrical portion may be either separated from or connected to the vertical partition portion and the horizontal partition portion.

[0019] In the paper tray according to the invention, a configuration can be adopted in which the opening is rectangular, the cylindrical portion is connected to the vertical partition portion and the horizontal partition portion, and is bent into a rectangular tubular shape in conjunction with the bending of the vertical partition portion and the horizontal partition portion.

[0020] With such a configuration, since the opening is rectangular, it is easy to form, and since the cylindrical portion is rectangular tubular, it is also high in strength and can be formed simultaneously with the bending of the partition portion, so that manufacturing is also easy. That is, it is possible to achieve both ease of forming the opening when bending and forming the paper tray and difficulty of deformation of the opening when using the paper tray or the like.

[0021] In the paper tray according to the invention, a configuration can be adopted in which the tray body is rectangular, and further includes end walls that are bent and erected and extend in the front-rear direction along the left and right edges of the tray body, and side walls that are bent and erected and extend in the left-right direction along the front and rear edges of the tray body.

[0022] This configuration further enhances the overall strength of the paper tray through the end walls and side walls, preventing damage during use. Furthermore, in the storage area, the outer surfaces and outer edges that do not have vertical or horizontal partitions are surrounded by end walls and side walls, which further suppresses the shifting movement of stored items placed at the bottom and prevents them from spilling out of the storage area.

[0023] In the paper tray according to the invention, it is preferable to adopt a configuration in which the heights of the vertical partition, the horizontal partition, the end wall, and the side wall are set to be the same.

[0024] With this configuration, since the height of each component is the same, when packaging the paper trays into packaging bags, it prevents situations where parts of the trays get caught in the packaging bags, which can occur when the heights vary. Furthermore, if a cylindrical section is attached to the opening, it is preferable to set the height of that cylindrical section to the same level.

[0025] In the paper tray according to the invention, it is preferable to further provide a recess that is recessed from the outer edge of the tray body, formed at either the point where the end wall and the vertical partition are to meet, or the point where the side wall and the horizontal partition are to meet, and that the end wall and the vertical partition, and the side wall and the horizontal partition are separated by this recess.

[0026] With this configuration, similar to the openings in the vertical and horizontal partitions, the recesses separate the end walls from the vertical partitions and the side walls from the horizontal partitions, allowing them to be folded independently. Therefore, they do not restrain or interfere with each other, preventing folding defects during molding and tearing caused by excessive bending. Furthermore, it is preferable that the recesses are formed at both the point where the end wall and the vertical partition meet, and the point where the side wall and the horizontal partition meet.

[0027] In the paper tray according to the invention, it is preferable to adopt a configuration in which the edge of the recess is further provided with a vertical groove interposed between the end wall and the vertical partition or between the side wall and the horizontal partition.

[0028] With this configuration, the vertical grooves, similar to those in the cylindrical section, improve the overall strength of the paper tray, preventing damage during use. In particular, the strength of the side walls or end walls can be improved, especially at the points where the partitions intersect with the side walls or end walls. Furthermore, because the end walls and side walls are supported by the vertical grooves, the folded state is stable, and the restorative elasticity of the paper material prevents the end walls and side walls from returning to their original state (falling over). Preferably, the vertical grooves are angular, with the corners facing inward towards the paper tray.

[0029] In the paper tray according to the invention, a configuration can be adopted in which the angle of rise of the vertical partition and the horizontal partition relative to the bottom is 30° or more and 70° or less.

[0030] By setting the rising angle to 30° or more, the height of the vertical and horizontal partitions becomes sufficient, ensuring that the storage area has the necessary volume to accommodate the intended items. Furthermore, by keeping the rising angle to 70° or less, damage caused by bending the vertical and horizontal partitions during formation is prevented.

[0031] In the paper tray according to the invention, a configuration can be adopted in which easy-cutting lines are provided along the edges of the vertical and horizontal partitions, allowing adjacent storage sections to be separated from each other.

[0032] This configuration is convenient because, for example, if you want to use the stored items individually, such as frozen foods that you want to microwave and eat separately, you can easily detach each storage compartment. Furthermore, the presence of easy-cutting lines such as perforations, half-cuts, and score lines along the edges makes it easier to fold the vertical and horizontal partitions, and also prevents them from returning to their original shape due to restorative elasticity after being folded.

[0033] In the paper tray according to the invention, it is preferable to adopt a configuration in which the multiple slits formed on the bottom are further folded to form multiple upright portions that rise vertically.

[0034] With this configuration, the items stored in the storage compartment are supported from below by multiple upright sections, further suppressing any shifting or movement of the contents. Furthermore, because a space is formed between the bottom of the storage compartment and the stored items, even when the stored items are food and are heated in a microwave oven, steam can escape smoothly without accumulating and causing the food to become soggy.

[0035] In the paper tray according to the invention, it is preferable that the slit is U-shaped and the top of the upright portion is flat.

[0036] With this configuration, the top of the upright section is flat, which means that the stored items are supported from below by that flat top, resulting in a stable support and preventing the stored items from tilting. Furthermore, the space formed between the bottom of the storage compartment and the stored items is also stably formed, allowing steam to escape more smoothly.

[0037] In the paper tray according to the invention, the upright portions are formed in a pair parallel to each other with a predetermined gap between them so as to be able to support the stored items placed on the bottom from below, and the predetermined gap can be configured such that when the stored items placed horizontally on the bottom are turned vertically, they can be sandwiched between the pair of upright portions.

[0038] This configuration allows for minimal cutouts and areas, while providing stable support for stored items from below with a minimum number of upright sections. Furthermore, since items can be placed vertically between the upright sections, the variety of placement options increases, improving convenience. For example, if the stored items are frozen foods such as frozen grilled rice balls, heating them in an upright position rather than lying on their side in the microwave is more efficient and helps prevent the bottom of the food from becoming soggy due to the steam generated during heating. In such cases, the frozen food can be held upright by sandwiching it between the upright sections.

[0039] In the paper tray according to the invention, it is preferable to adopt a configuration in which the shape of the storage section in plan view is substantially rectangular.

[0040] By making the storage compartment roughly rectangular in plan view, multiple storage compartments can be efficiently arranged in the front, back, left, and right directions, maximizing the usable storage area (size) of the paper tray relative to the overall size (size) of the paper tray.

[0041] Furthermore, in order to solve the above-mentioned problems, the paper tray according to the invention is formed by folding a single sheet of cardboard, and comprises a tray body, a bottom portion on which items can be placed, which is parallel to at least a first direction and a second direction different from the first direction of the tray body, a folded first partition portion extending in a direction substantially perpendicular to the first direction between bottom portions of the tray body adjacent to the first direction, and a folded second partition portion extending in a direction substantially perpendicular to the second direction between bottom portions of the tray body adjacent to the second direction, and the space partitioned by the bottom portion and the first and second partition portions surrounding it constitutes the storage area for the items to be stored. In addition, the structure further includes an opening formed at the point where the virtual extension line of the vertex portion of the first partition and the virtual extension line of the vertex portion of the second partition intersect, so that the first partition and the second partition are arranged so that their vertices do not intersect.

[0042] Furthermore, in order to solve the above-mentioned problems, the food packaging according to the invention is composed of a paper tray according to the invention, food that maintains a solid state as stored in the storage section, and a packaging bag that packages the paper tray containing the food.

[0043] Furthermore, in order to solve the above-mentioned problems, the paper tray sheet according to the invention, which can be folded to form a paper tray, is configured to include: bottom portions that are parallel to each other on the front, back, left, and right sides of the sheet and are not folded, on which stored items are placed; vertical partition forming portions that extend in the front-to-back direction between adjacent bottom portions of the sheet in the left-to-right direction and can be folded to form vertical partition portions; horizontal partition forming portions that extend in the left-to-right direction between adjacent bottom portions of the sheet in the front-to-back direction and can be folded to form horizontal partition portions; and an opening provided at the point where the intersecting vertical partition forming portions and the horizontal partition forming portions are about to meet, wherein the vertical partition forming portions and the horizontal partition forming portions are separated by the opening. [Effects of the Invention]

[0044] With the present invention configured as described above, it is possible to form intersecting partitions in a paper tray from a single sheet of cardboard without causing defects such as folding problems or paper tearing. [Brief explanation of the drawing]

[0045] [Figure 1] (a) is an overall perspective view of the food packaging, and (b) is a magnified plan view of the main part of (a). [Figure 2] (a) is a plan view of the paper tray, and (b) is an enlarged perspective view of the main part of (a). [Figure 3](a) is a plan view of the paper tray, (b) is a side view of the paper tray, and (c) is a cross-sectional view of the paper tray. [Figure 4] (a) is an enlarged plan view of the main part of the paper tray, and (b) is an enlarged cross-sectional view of the main part of the paper tray. [Figure 5] Plan view of the paper tray sheet [Figure 6] Enlarged plan view of key parts of another example paper tray [Figure 7] (a) is a plan view of another example of a paper tray, (b) is a side view of another example of a paper tray, and (c) is a cross-sectional view of another example of a paper tray. [Figure 8] Plan view of a sheet for another paper tray [Figure 9] Enlarged plan view of key parts of another example paper tray [Modes for carrying out the invention]

[0046] Embodiments of the present invention will be described below with reference to the drawings. The food packaging of the embodiment shown in Figure 1 consists of a paper tray 10 as shown in the embodiments in Figures 2 to 4, frozen grilled rice balls as food items 20 as shown in Figures 1, 2(a), and 4, which are stored in the paper tray 10, and a packaging bag 30 that packages the paper tray 10 containing the food items 20.

[0047] Furthermore, the paper tray 10 of the embodiment shown in Figures 2 to 4 is manufactured by folding and molding a paper tray sheet 10' of the embodiment, which is made from a single sheet of cardboard as shown in Figure 5. Since the paper tray 10 and the sheet for the paper tray 10' are made entirely of cardboard, they are easy to recycle and dispose of, resulting in a low environmental impact. Furthermore, it is preferable that conventionally known resins (PP, PE, PET, etc.) are laminated on both sides or one side of the paper tray 10 and the paper tray sheet 10' by extrusion lamination or the like, and in that case, it is more preferable that the resin is laminated on at least the side on which the food 20 is placed. This method prevents moisture and oil from the food 20 from penetrating the paper tray 10.

[0048] As shown in Figures 2 to 4, the paper tray 10 is used to store multiple food items 20. The paper tray 10 is rectangular in plan view and comprises a flat tray body 11 and peripheral walls that rise from the periphery of the tray body 11. The peripheral wall consists of side walls 12 rising from the left and right edges of the tray body 11, and end walls 13 rising from the front and rear edges of the tray body 11. The side walls 12 extend in the front-to-back direction of the tray body 11, and the end walls 13 extend in the left-to-right direction of the tray body 11. The side wall 12 and the end wall 13 are connected via a corner portion 12a that is bent into an L-shape in a plan view. The side walls 12 and end walls 13 prevent the food 20 stored in the paper tray 10 from spilling out.

[0049] Here, the side walls 12 and end walls 13 are formed by folding the paper tray sheet 10' of the embodiment, which is made of cardboard base paper, so that its vertical cross-section forms a V-shape with the tray body 11. The angle of rise of the side walls 12 and end walls 13 relative to the tray body 11 is not particularly limited, but it is preferable that the angle θ in Figure 4(b) is between 30° and 70°. By setting the rising angle to 30° or more, the height of the side walls 12 and end walls 13 becomes sufficient, further preventing food 20 from overflowing, and by setting the rising angle to 70° or less, the situation in which the cardboard is excessively bent and damaged during the folding and forming of the side walls 12 and end walls 13 is prevented.

[0050] As shown in Figures 2 to 4, the tray body 11 is divided into bottom sections 14 that are arranged in parallel in the front-to-back and left-to-right directions. The base 14 is roughly square in plan view, and in the illustration, it is formed in a row of 3 in the front-to-back direction and 2 in the left-to-right direction, for a total of 6 bases. Food items 20 will be placed on each base 14.

[0051] As shown in Figures 2 to 4, adjacent bottoms 14 are separated by a partition. The partition consists of a vertical partition 15 that separates adjacent bottoms 14 in the left-right direction, and a horizontal partition 16 that separates adjacent bottoms 14 in the front-back direction. The vertical partition 15 extends in the front-to-back direction of the tray body 11, and the horizontal partition 16 extends in the left-to-right direction of the tray body 11. The vertical partition 15 and the horizontal partition 16 run in directions that are almost perpendicular to the vertical and horizontal directions. In the diagram, the vertical partitions 15 are arranged in a single row in the left-right direction of the tray body 11, and the horizontal partitions 16 are arranged in two rows in the front-to-back direction of the tray body 11.

[0052] The vertical partition 15 and the horizontal partition 16 are formed by folding the paper tray sheet 10' of the embodiment, which is made of cardboard base paper, so that its cross-section forms an inverted V shape (a mountain fold). The vertical partition 15 has left and right surfaces, each of which faces the side wall 12 with the bottom 14 in between. The left and right surfaces of the vertical partition 15 and the opposing side wall 12 are identical in shape and are inclined in opposite directions. Each of the parallel horizontal partition sections 16 has front and rear surfaces, with each surface facing the end wall 13 and one side of the other horizontal partition section 16, with the bottom 14 in between. The front and rear surfaces of the horizontal partition section 16 and the opposing end wall 13 are identical in shape and inclined in opposite directions.

[0053] The angles of rise of the left and right sides of the vertical partition 15 and the front and rear sides of the horizontal partition 16 relative to the bottom 14 are not particularly limited, but for the same reasons as the angles of rise of the side walls 12 and end walls 13 (angle θ in Figure 4(b)), it is preferable that they be between 30° and 70°. Furthermore, perforations 15a and 16a are formed along the edges of the vertical partition 15 and the horizontal partition 16, serving as lines for easy breakage.

[0054] As shown in Figures 2 to 4, the space partitioned by the bottom 14 and the vertical partition 15, horizontal partition 16, side wall 12, and end wall 13 surrounding the bottom 14 serves as a storage area for the food 20 placed on the bottom 14. These vertical partitions 15, horizontal partitions 16, side walls 12, and end walls 13 hold the food items 20 within the storage compartment, preventing them from shifting or spilling out.

[0055] Furthermore, by breaking the perforations 15a and 16a on the edges of the vertical partition 15 and horizontal partition 16 described above, the vertical partition 15 is divided into left and right sides, and the horizontal partition 16 is divided into front and rear sides, allowing the storage compartments containing the food 20 to be separated individually. This means that, for example, if food item 20 is a frozen food such as a frozen rice ball, it can be heated individually in a microwave oven, increasing convenience. In addition, perforations 15a and 16a can be replaced with other easily breakable wires, such as half-cuts.

[0056] As shown in Figures 2 to 4, multiple slits 14a are provided in the center of the bottom portion 14. The slits 14a are elongated U-shaped and are provided in pairs in parallel at a predetermined distance apart in the front-to-back direction of the paper tray 10. The upright portion 14b is formed by folding the rectangular area, which is demarcated by a U-shaped slit 14a and an imaginary line connecting both ends of the U-shape in a straight line, along the imaginary line. By cutting and raising the upright portion 14b, a hole 14c identical in shape to the upright portion 14b is created in the center of the tray body 11 at the bottom portion 14. As shown in the figure, the upright portion 14b rises almost perpendicular to the plate surface of the tray body 11.

[0057] As shown in Figure 4, the top of the upright portion 14b is in contact with the underside of the food 20 which is placed on its side on the bottom portion 14. The pair of upright portions 14b, each with a flat top, ensure that the food 20 is stably supported from below without tilting. Therefore, the shifting movement of the food items 20 within the storage compartment and their protrusion from the storage compartment are further suppressed.

[0058] Furthermore, as the food 20 is supported by the upright portion 14b, a space is formed between the lower surface of the food 20 and the bottom portion 14, as shown in Figure 4. As a result, even if steam is generated from the food 20, such as when heating the food 20 in a microwave oven, the steam will not linger but will be released from the space. Therefore, the accumulation of moisture at the bottom 14 due to steam, and the subsequent adhesion of that moisture to the underside of the food 20, which would impair the taste, are prevented.

[0059] Here, the distance d between the pair of upright portions 14b in Figure 4(a) is approximately equal to the thickness of the food 20 (its height when laid on its side). As a result, as shown in Figure 4, the food items 20 that were stored horizontally in the storage compartment can be raised vertically and sandwiched between the upright sections 14b, thereby maintaining the food items 20 in an upright position. When heating food 20 in a microwave oven, heating it upright rather than lying on its side can sometimes improve heating efficiency. Therefore, using the upright portion 14b as an auxiliary tool to hold the food 20 upright improves convenience.

[0060] As shown in Figures 2 to 4, an opening 17 is formed where the vertical partition 15 and the horizontal partition 16, which extend in intersecting directions, meet. In other words, an opening 17 is formed where the virtual extensions of the edges corresponding to the vertices of the vertical partition 15 and the horizontal partition 16 intersect. The opening 17 is square in plan view. Of the four sides of this square, the two sides facing each other in the front and back are parallel to the perforations 16a of the horizontal partition 16, and the two sides facing each other on the left and right are parallel to the perforations 15a of the vertical partition 15. This opening 17 separates the vertical partition 15 from the horizontal partition 16. Furthermore, the ridges corresponding to the vertices of the vertical partition 15 and the horizontal partition 16 do not intersect. Therefore, when folding and molding the vertical partition 15 and the horizontal partition 16, they can be folded independently. Therefore, this prevents folding defects at the junction of the vertical partition 15 and the horizontal partition 16, as well as tearing caused by excessive folding.

[0061] As shown in Figures 2 to 4, a rectangular cylindrical portion 17a is provided at the edge of the opening 17. The cylindrical portion 17a is interposed between the vertical partition portion 15 and the horizontal partition portion 16, with the front and rear surfaces connected to the vertical partition portion 15 and the left and right surfaces connected to the horizontal partition portion 16. The presence of this cylindrical portion 17a makes it difficult for the opening 17 to deform even when force is applied to the opening 17 from any of the partition portions 15 and 16 in the front-back, left-right, or right-side directions (towards the opening). Furthermore, it also makes it difficult for the opening 17 to deform even when force is applied to the opening 17 itself from above, thus suppressing vertical deformation of the partition portions 15 and 16. As a result, the overall strength of the paper tray 10 is improved. Furthermore, since the vertical partition 15 and horizontal partition 16 are supported by the cylindrical portion 17a, the folded state is stable, and the restorative elasticity of the cardboard base prevents the vertical partition 15 and horizontal partition 16 from returning to their pre-folded state.

[0062] The cylindrical section 17a consists of four cylindrical pieces that are bent into an L-shape in a plan view, with the ends of the L-shapes butted together. In each cylindrical piece, one end of the L-shape intersects with the ridge of the vertical partition section 15, and the other end of the L-shape intersects with the ridge of the horizontal partition section 16. As a result, when the vertical partition portion 15 and the horizontal partition portion 16 are folded and formed, the cylindrical portion 17a is automatically folded and formed in conjunction with them.

[0063] As shown in Figures 2 to 4, recesses 18 are formed in the left and right edges of the tray body 11 where the side wall 12 and the horizontal partition 16 meet, and recesses 18 are formed in the front and rear edges of the tray body 11 where the end wall 13 and the vertical partition 15 meet. The recessed portion 18 is U-shaped in plan view (the shape differs when it is in the form of a paper tray sheet, as will be explained later). This recess 18 separates the side wall 12 from the horizontal partition 16, and the end wall 13 from the vertical partition 15. Therefore, when the side wall 12 and end wall 13 are folded and formed, they can be folded separately and independently from the horizontal partition 16 and vertical partition 15. Therefore, this prevents bending defects at the junction of the side wall 12 and the horizontal partition 16, and at the junction of the end wall 13 and the vertical partition 15, as well as the occurrence of tears due to excessive bending.

[0064] As shown in Figures 2 to 4, the edge of the recess 18 is provided with a vertical groove 18a in the shape of a halved rectangular tube. The vertical groove 18a is interposed between the side wall 12 and the horizontal partition 16, and between the end wall 13 and the vertical partition 15. The presence of this vertical groove 18a improves the overall strength of the paper tray 10. Furthermore, since the side walls 12 and end walls 13 are supported by the vertical grooves 18a, the folded state is stable, and the side walls 12 and end walls 13 are prevented from returning to their pre-folded state (flattening) due to the restorative elasticity of the cardboard base.

[0065] The vertical groove 18a consists of two L-shaped cylindrical pieces that are joined together with one end of each L-shape facing the other. In the case of the vertical grooves 18a on the left and right edges of the tray body 11, one end of the L-shape of each cylindrical piece intersects the side wall 12 and the other end intersects the ridge of the horizontal partition 16. In the case of the vertical grooves 18a on the front and rear edges of the tray body 11, one end of the L-shape of each piece intersects the end wall 13 and the other end intersects the ridge of the vertical partition 15. As a result, when the side wall 12 and end wall 13 are folded and formed, the vertical groove portion 18a can be folded and formed in conjunction with them.

[0066] Here, as shown in Figures 3(b) and (c), the heights of the side wall 12, end wall 13, vertical partition 15, horizontal partition 16, cylindrical portion 17a, and vertical groove 18a are approximately the same. Therefore, since the heights of the paper trays 10 are uniform and there are no irregularities in the height direction, it is prevented that any part of the tray may get caught when it is placed in the packaging bag 30.

[0067] The paper tray sheet 10' for the embodiment, which is used to manufacture the paper tray 10 of the embodiment by folding and molding, is formed by punching out cardboard or the like. Furthermore, the paper tray sheet 10' may have folding lines, such as creases, perforations, or half-cuts, formed at the points where folding is planned to facilitate bending. In this embodiment, creases and perforations are used as folding lines, as shown in Figure 5. As shown in Figure 5, the paper tray sheet 10' is made from a single flat piece of cardboard, and side wall forming sections 12 and end wall forming sections 13 are attached in a manner that surround the front, back, left, and right edges of the tray body 11, and these sections become side walls 12 and end walls 13 when folded. Furthermore, the space between the parallel bottoms 14 on the tray body 11 is divided into a grid of vertical and horizontal partition sections 15 and 16, which can be folded into an inverted V shape to form vertical and horizontal partition sections 16. The vertical and horizontal partition sections 15 and 16 are rectangular, and perforations 15a and 16a are formed along the center of their shorter sides. Each bottom portion 14 has a U-shaped slit 14a that can be cut and bent to form an upright portion 14b.

[0068] An opening 17 is provided at the point where the vertical partition forming section 15 and the horizontal partition forming section 16, which extend in intersecting directions, are about to meet. This opening 17 separates the vertical partition forming section 15 and the horizontal partition forming section 16. The opening 17 is square, and each of its vertices intersects with the perforations 15a and 16a, which form the centerlines of the vertical partition forming section 15 and the horizontal partition forming section 16. Each side of the square opening 17 is inclined at an angle of approximately 45 degrees with respect to the direction in which the perforations 15a and 16a extend.

[0069] Each of the four sides of the opening 17 is attached to a triangular tube-forming piece 17a, which can be folded and assembled to form a rectangular tube-shaped section 17a. The other two sides of the triangular tube-forming piece 17a are connected to a vertical partition-forming section 15 and a horizontal partition-forming section 16, respectively. The cylindrical piece 17a can be bent into an L-shape at the boundary between the half connected to the vertical partition forming section 15 and the half connected to the horizontal partition forming section 16. As the cylindrical forming piece 17a is folded into an L-shape, the four sides of the square opening 17 are also folded into an L-shape. As a result, as shown in Figures 1 to 4, the orientation of the square in the opening 17 after the paper tray 10 has been folded and formed is rotated by approximately 45 degrees from the orientation of the square in the opening 17 of the paper tray sheet 10'.

[0070] At the point where the side wall forming section 12, the end wall forming section 13 and the vertical partition forming section 15 or the horizontal partition forming section 16 are to meet, a recess 18 is provided that extends inward from the outer edge of the paper tray sheet 10'. This recess 18 separates the side wall forming section 12, the end wall forming section 13 from the vertical partition forming section 15 or the horizontal partition forming section 16. The recess 18 is V-shaped in plan view, and the space inside it is triangular in shape, as if the opening 17 had been cut in half diagonally. Two sides of the triangular recess 18 are attached to triangular groove-forming pieces 18a, which can be folded and assembled to form a semi-split rectangular tube-shaped vertical groove 18a. The other two sides of the triangular groove-forming pieces 18a are connected to the vertical partition forming section 15 and the end wall forming section 13, or to the horizontal partition forming section 16 and the side wall forming section 12, respectively. The groove-forming piece 18a is bendable into an L-shape at the boundary between the half connected to the vertical partition forming section 15 or the horizontal partition forming section 16 and the half connected to the end wall forming section 12 or the side wall forming section 13. As a result of this bending, the shape of the recess 18 changes from a V-shape as shown in Figure 5 to a U-shape as shown in Figures 1 through 4, as both sides of the V-shape bend into an L-shape.

[0071] The embodiments disclosed herein are illustrative in all respects and not restrictive. The scope of this invention is defined by the claims, and all modifications within the meaning and scope equivalent to the claims are included.

[0072] In this embodiment, the bottom 14 of the food tray 10 is arranged in parallel to the front, back, left, and right of the tray body 11, and the partitions consist of a vertical partition 15 extending in the front-to-back direction of the tray body 11 and a horizontal partition 16 extending in the left-to-right direction. However, the direction of the parallel arrangement of the bottom 14 and the configuration of the partitions are not limited to this. The parallel directions of the bottom portion 14 only need to be at least two directions: a first direction and a second direction that is different from the first direction (not necessarily perpendicular to the first direction). The partitions also only need to consist of a first partition perpendicular to the first direction and a second partition perpendicular to the second direction.

[0073] For example, as shown in Figure 6, the bottom portions 14 may be arranged in parallel in a Y-shape, or in a third direction different from both the first and second directions (for example, a diagonal direction relative to the front-to-back and left-to-right directions). Correspondingly, in addition to the first partition portion 15 and the second partition portion 16, a third partition portion 19 (for example, a diagonal partition portion relative to the vertical and horizontal partition portions) may be provided that extends in a direction perpendicular to the third direction. In that case as well, an opening 17 can be provided at the point where the third partition 19 meets the first partition 15 or the second partition 16. Note that in Figure 6, the cylindrical portion 17a is not attached to the opening 17, but it can be attached. Also, in Figure 6, the bottom portion 14 does not have a slit 14a, an upright portion 14b, or a hole 14c, but these can be provided.

[0074] In this embodiment, the vertical partition 15 and the horizontal partition 16 are shown as being in an inverted V shape (including an I shape), but the shape of the partition is not limited to this, as long as it can be formed by folding the cardboard base paper, and for example it can be M-shaped or inverted U-shaped.

[0075] In this embodiment, a cylindrical portion 17a is attached to the opening 17 of the paper tray 10, but it is also possible to have a configuration with only an opening 17 without the cylindrical portion 17a. Furthermore, although the shape of the opening 17 is square in this embodiment, it is not limited to this and can be circular, polygonal, or the like. The shape of the cylindrical portion 17a is also not limited to the rectangular cylindrical shape of this embodiment. The cylindrical portion 17a and the vertical partition portion 15 and the horizontal partition portion 16 can be left unconnected.

[0076] Similarly, in the embodiment, a recess 18 of the paper tray 10 is shown as having a vertical groove 18a attached to it, but it is also possible to have a configuration with only a recess 18 without a vertical groove 18a. Furthermore, although the shape of the recess 18 is rectangular in this embodiment, it is not limited to this and can be circular, polygonal, or the like. The shape of the vertical groove 18a is also not limited to the half-square cylindrical shape of this embodiment. The vertical groove 18a and the side wall 12 or end wall 13 can be left unconnected.

[0077] In this embodiment, the paper tray 10 is exemplified as having three rows of storage compartments in the front-to-back direction and two rows in the left-to-right direction, for a total of six compartments. However, the number of compartments and the number of compartments are not limited to this. For example, as shown in Figures 7 and 8, the storage compartments can be arranged in two rows front to back and two rows left to right, for a total of four compartments.

[0078] Furthermore, although the embodiment illustrates a base 14 that is square, the shape of the base 14 is not limited to this, and can be rectangular, for example, as shown in Figure 9. Also, as partially shown in Figure 6, it may be a polygon other than a rectangle. The shape of the tray body 11 is not limited to the rectangular shape in plan view of the embodiment, but can also be a square, a circle, an oval, or a polygon in plan view.

[0079] In this embodiment, a paper tray 10 having side walls 12 and end walls 13 is provided as an example, but the invention is not limited to this, and a tray without side walls 12 and end walls 13 can also be provided. Furthermore, such a paper tray 10 can also be used in combination with a separate container having a bottom wall and peripheral walls rising from the bottom wall (by placing it inside the separate container). In this case, the peripheral walls of the separate container serve the role of the peripheral walls in the paper tray 10 of the embodiment. Even when side walls 12 and end walls 13 are provided, the recess 18 can be omitted.

[0080] The food packaging in this embodiment is packaged in a packaging bag 30, but is not limited to this, and may be replaced with other packaging such as a packaging box. In this embodiment, food 20 was given as an example of what can be stored in the paper tray 10, but the contents are not limited to this. Furthermore, even in the case of food 20, it is not limited to frozen foods such as frozen grilled rice balls, but any food can be used as long as it is in a generally solid state, that is, as long as it is not a food that will easily lose its shape when placed on the paper tray 10. [Explanation of Symbols]

[0081] 10 paper trays 10' Paper tray sheet 11 Tray body 12 Side wall (side wall forming part) 12a Corner section 13 End wall (end wall forming portion) 14 Bottom 14a Slit 14b Standing part 14c hole 15. Vertical partition section (Vertical partition forming section, first partition section) 15a Perforation 16. Horizontal partition section (second partition section of the horizontal partition forming section) 16a Perforation 17 Aperture 17a Cylinder part (tube forming piece) 18 recesses 18a Vertical groove part (groove forming piece) 19 Third partition 20 Food 30 packaging bags d distance θ Tilt angle

Claims

1. A paper tray formed by folding a single sheet of cardboard base paper, The tray body and The tray body has a bottom portion on which items can be placed, which is parallel to at least a first direction and a second direction different from the first direction, A bent first partition portion extends in a direction substantially perpendicular to the first direction between adjacent bottom portions of the tray body in the first direction, The tray body comprises a bent second partition portion extending in a direction substantially perpendicular to the second direction between adjacent bottom portions in the second direction, The space partitioned by the bottom and the first and second partitions surrounding it constitutes the storage area for the stored items. The tray body further comprises an opening formed at the point where the first partition and the second partition meet, A paper tray in which the first partition and the second partition are separated by the aforementioned opening.

2. The paper tray according to claim 1, wherein the first partition and the second partition are formed by folding the cardboard base paper into an inverted V shape.

3. The bottom portion is arranged in parallel on the front, back, left, and right sides of the tray body. The first direction is the left-right direction of the tray body, and the first partition is a vertical partition that extends in the front-rear direction between adjacent bottom portions in the left-right direction of the tray body. The second direction is the front-to-back direction of the tray body, and the second partition is a lateral partition extending in the left-to-right direction between adjacent bottom portions in the front-to-back direction of the tray body. The paper tray according to claim 1 or claim 2, wherein the opening is formed at the point where the vertical partition and the horizontal partition, which extend in perpendicular directions, are about to meet.

4. The paper tray according to claim 3, further comprising a cylindrical portion interposed between the vertical partition portion and the horizontal partition portion at the edge of the opening.

5. The paper tray according to claim 4, wherein the opening is rectangular, the cylindrical portion is connected to the vertical partition portion and the horizontal partition portion, and is folded into a rectangular cylindrical shape in conjunction with the folding of the vertical partition portion and the horizontal partition portion.

6. The tray body is rectangular, The end walls that extend in the front-to-back direction along the left and right edges of the tray body and that are bent and stand upright The paper tray according to claim 3, further comprising side walls that extend in the left-right direction along the front and rear edges of the tray body and are folded to stand upright.

7. The paper tray according to claim 6, wherein the heights of the vertical partition, the horizontal partition, the end wall, and the side wall are set to be the same.

8. The tray body is further provided with recesses that are recessed from the outer edge, formed at the point where the end wall and the vertical partition meet, and at the point where the side wall and the horizontal partition meet. The paper tray according to claim 3, wherein the recess separates the end wall from the vertical partition and the side wall from the horizontal partition.

9. The paper tray according to claim 8, further comprising a vertical groove interposed between the end wall and the vertical partition or between the side wall and the horizontal partition at the edge of the recess.

10. The paper tray according to claim 3, wherein the angle of rise of the vertical partition and the horizontal partition relative to the bottom is 30° or more and 70° or less.

11. The paper tray according to claim 3, wherein easy-cutting lines are provided along the ridges of the vertical and horizontal partitions, allowing adjacent storage sections to be separated from each other.

12. The paper tray according to claim 3, further comprising a plurality of upright portions formed by folding a plurality of slits formed on the bottom so as to rise vertically.

13. The paper tray according to claim 12, wherein the slit is U-shaped and the top of the upright portion is flat.

14. The upright portions are formed in pairs parallel to each other at a predetermined interval so as to be able to support the stored items placed on the bottom from below. The paper tray according to claim 13, wherein the predetermined interval is such that when an item placed horizontally on the bottom is turned vertically, it can be sandwiched between a pair of upright parts.

15. The paper tray according to claim 1 or claim 2, wherein the storage compartment has a substantially rectangular shape when viewed from above.

16. A paper tray formed by folding a single sheet of cardboard base paper, The tray body and The tray body has a bottom portion on which items can be placed, which is parallel to at least a first direction and a second direction different from the first direction, A bent first partition portion extends in a direction substantially perpendicular to the first direction between adjacent bottom portions of the tray body in the first direction, The tray body comprises a bent second partition portion extending in a direction substantially perpendicular to the second direction between adjacent bottom portions in the second direction, The space partitioned by the bottom and the first and second partitions surrounding it constitutes the storage area for the stored items. The present invention further comprises an opening formed at the point where the virtual extension line of the vertex portion of the first partition and the virtual extension line of the vertex portion of the second partition intersect, A paper tray in which the first partition and the second partition are arranged such that their vertices do not intersect due to the aforementioned opening.

17. A paper tray according to claim 1 or claim 2, Food items stored in the aforementioned storage compartment, A packaging bag for packaging the paper tray containing the aforementioned food, A food packaging material consisting of the following.

18. A sheet for paper trays, consisting of a single sheet of cardboard, which can be folded to form a paper tray, The aforementioned sheet has a bottom forming section that is arranged in parallel on the front, back, left, and right sides, on which stored items are placed without being folded, A vertical partition forming portion extends in the front-to-back direction between adjacent bottom portions of the sheet in the left-to-right direction, and can be folded to form a vertical partition portion, A horizontal partition forming portion extends horizontally between adjacent bottom portions in the front-to-back direction of the sheet, and can be folded to form a horizontal partition portion, The intersecting vertical partition forming section and the horizontal partition forming section are provided with an opening at the point where they meet, A sheet for a paper tray, wherein the vertical partition forming portion and the horizontal partition forming portion are separated by the aforementioned opening.

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