Tray with partition features

Abstract

A tray for holding one or more food items comprises a plurality of panels including a central panel, at least one end panel, at least one side panel, and at least one bottom panel; a side wall extending at least partially around the interior of the tray and including at least one end panel and at least one side panel; a flange extending outward from the side wall and including the central panel; a bottom wall including at least one bottom panel; and at least one partition inside the tray, the partition having a partition feature that extends upward from the bottom wall.

Description

Technical Field

[0001] [Cross - References to Related Applications] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 452,852, filed Mar. 17, 2023.

[0002] [Incorporation by Reference] The disclosures of U.S. Patent Application No. 17 / 690,204, filed Mar. 9, 2022; U.S. Patent Application No. 16 / 532,819, filed Aug. 6, 2019; U.S. Patent Application No. 16 / 037,425, filed Jul. 17, 2018; U.S. Patent Application No. 15 / 654,814, filed Jul. 20, 2017; and U.S. Patent Application No. 12 / 992,131, filed Feb. 11, 2011; PCT Patent Application No. PCT / GB / 09 / 50506, filed May 13, 2009; and U.S. Provisional Patent Application No. 63 / 452,852, filed Mar. 17, 2023 are hereby incorporated by reference in their entirety for all purposes as if fully set forth herein.

[0003] This disclosure relates to blanks, containers, trays, assemblies, and various features and methods for forming containers from blanks. More specifically, this disclosure generally relates to trays having partition features.

Summary of the Invention

Means for Solving the Problems

[0004] In one embodiment, the disclosure generally relates to a tray for holding one or more food items, the tray comprising a plurality of panels including a central panel, at least one end panel, at least one side panel, and at least one bottom panel; a side wall extending at least partially around the interior of the tray and including at least one end panel and at least one side panel; a flange extending outward from the side wall and including a central panel; a bottom wall including at least one bottom panel; and at least one partition inside the tray, the at least one partition comprising a partition feature extending upward from the bottom wall.

[0005] In another embodiment, the disclosure generally relates to a blank for forming a tray for holding one or more food items, the blank comprising a plurality of panels including a central panel, at least one end panel, at least one side panel, and at least one bottom panel, wherein at least one end panel and at least one side panel are arranged to at least partially form a side wall that at least partially extends around the interior of a tray formed from the blank, the central panel is arranged to at least partially form a flange that extends outward from the side wall when the tray is formed from the blank, the at least one bottom panel is arranged to form the bottom wall of a tray formed from the blank, and further comprises a partition feature for forming at least one partition that extends upward from the bottom wall inside the tray when the tray is formed from the blank.

[0006] In another aspect, the disclosure relates generally to a method for forming a tray for holding one or more food items, the method comprising obtaining a blank, the blank comprising a plurality of panels including a central panel, at least one end panel, at least one side panel, and at least one bottom panel, the blank further comprising a partition feature, further comprising arranging at least one end panel and at least one side panel to form a side wall at least partially extending around the interior of the tray, arranging a central panel to form a flange extending outward from the side wall, arranging at least one bottom panel to form a bottom wall of the tray, and forming at least one partition extending upward from the bottom wall inside the tray.

[0007] Those skilled in the art will understand the above advantages and other advantages and benefits of various additional embodiments by referring to the drawings listed below and reading the following detailed description of the embodiments.

[0008] According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. The dimensions of various features and elements in the drawings may be enlarged or reduced to better illustrate embodiments of the disclosure. [Brief explanation of the drawing]

[0009] [Figure 1] This is a plan view of a blank for forming a tray according to an exemplary embodiment of the present disclosure. [Figure 2] This is a perspective view of a tray formed from the blank shown in Figure 1, according to an exemplary embodiment of the present disclosure. [Figure 3] This is another perspective view of a tray formed from the blank of Figure 1 according to an exemplary embodiment of the present disclosure. [Figure 4] This is a schematic diagram of an apparatus for processing blanks and / or trays that can be used in conjunction with exemplary embodiments of the present disclosure. [Modes for carrying out the invention]

[0010] Corresponding parts are indicated by corresponding reference numbers throughout the drawing.

[0011] This disclosure generally relates to various forms of containers, structures, trays, materials, packages, elements, and articles, as well as methods for manufacturing such containers, structures, trays, materials, packages, elements, and articles. While several different forms, practices, and embodiments are disclosed, numerous interrelationships, combinations, and modifications between the various forms, practices, and embodiments are intended herein. In one exemplary embodiment, this disclosure relates to forming a container or tray for holding food or various other articles. However, in other embodiments, the container or tray may be used to form other non-food-containing articles or for heating or cooking.

[0012] The trays described herein can be used to hold one or more articles, such as individually packaged retail foods, which may include one or more foods, such as cookies, crackers, cakes, pastries, candies, nuts, popcorn, trail mix, and gum. In some embodiments, the articles may include frozen or non-frozen foods that can be served in individual portions, such as chicken nuggets, french fries, onion rings, mozzarella sticks, chips, popcorn, and other finger foods. In embodiments, other types of articles, which may include food and / or non-food items, may be placed on the tray for service to customers. In some embodiments, such products may be placed in additional packaging before being placed on the tray. The trays may be of different shapes and arrangements and can be used to hold other products and / or articles in similar or different environments without departing from the present disclosure.

[0013] Figure 1 shows the outer surface 101 of a first blank 103 for forming a tray 105 (Figure 2) or other container according to an exemplary embodiment of the present disclosure. In one embodiment, the blank 103 includes cardboard (e.g., a collapsible boxboard of solid bleached sulfate) or other suitable material that is reusable and / or suitable for use in an oven.

[0014] In some embodiments, the blank 103 may comprise a liner F comprising a plastic layer such as polyethylene, polyethylene terephthalate (PET) material, or any other thermoplastic material, or a bioplastic such as a vegetable oil or starch-based plastic. In one embodiment, such a liner may include polyethylene that can be softened and fused to the blank 103. In an alternative embodiment, the liner attached to the blank 103 may comprise PET or a similar material that is at least partially attached to the blank 103 by a heat-seal layer (e.g., a thermoformable sealant grade transparent polyester packaging film such as Mylar® XMPOL12, available from DuPont Teijin Films US Limited Partnership in Hopewell, Virginia, or any suitable thermoformable sealant or adhesive, any suitable heat or pressure-activated adhesive, or any other suitable material), and the PET liner may be more suitable for applications requiring heating of the container in an oven.

[0015] Such a liner can be at least partially attached to the blank 103 so as to be positioned in contact with one or more food items held in the tray 105 (for example, during heating). In one embodiment, after heating the food, the blank 103 and the accompanying liner F can be separated and both the blank 103 and the liner can be disposed of separately (e.g., recycled, regenerated, reused, etc.). Optionally, the blank 103 can be provided separately from the liner or without a liner.

[0016] The blank 103 can be formed from a single ply of a material such as, but is not limited to, cardboard, thick paper, paper, polymer sheets, and / or laminates comprising multiple layers. In some embodiments, the blank 103 may include a microwave interaction layer (not shown), such as those common in MicroRite® containers available from Graphic Packaging International in Atlanta, Georgia. The microwave interaction layer may be referred to as, or may have as one of, a susceptor, foil, microwave shield, or any other term or component referring to a layer of material suitable for shielding microwave energy and / or causing heating in a microwave oven.

[0017] As shown in Figure 1, the blank 103 has a vertical direction L1 and a horizontal direction L2. In the illustrated embodiment, the blank 103 and the tray 105 formed therefrom include a plurality of panels, including a central panel 111, a first mounting panel 113 foldably connected to the central panel 111 by a horizontal fold line 115, and a second mounting panel 117 foldably connected to the central panel 111 by a horizontal fold line 119. In some embodiments, the mounting panels 113 and 117 can be considered as part of the central panel 111.

[0018] As shown, the peripheral region of the central panel 111 can form the rim or flange 121 of the blank 103 / tray 105. Also as shown, the inner edge 123 of the central panel 111 can at least partially define and / or enclose the opening 125. The flange 121 can also at least partially define the outer edge 127 of the central panel 111. In some embodiments, the outer edge 127 can be at least partially defined by fold lines 115, 119.

[0019] The blank 103 and the multiple panels of the tray 105 formed therefrom may include, at least partially, a first end panel 129 (broadly defined as "first panel") that is foldably connected to the central panel 111 by a longitudinal fold line 131 (broadly defined as "first fold line") extending along the opening 125, and a second end panel 133 (broadly defined as "first panel") that is foldably connected to the central panel 111 by longitudinal fold lines 135 (broadly defined as "first fold lines") extending along the opening 125.

[0020] The first side panel 137 (the "second panel" in a broad sense) can be foldably connected to the mounting panel 113 along a horizontal fold line 139, and the second side panel 141 (the "second panel" in a broad sense) can be foldably connected to the mounting panel 117 along a horizontal fold line 143.

[0021] The first bottom panel 145 can be foldably connected to the first end panel 129 by a vertical fold line 147, and the second bottom panel 149 (or more broadly, the "fourth bottom panel") can be foldably connected to the second end panel 133 by a vertical fold line 151.

[0022] Continuing to refer to Figure 1, the third bottom panel 153 (the "second bottom panel" in a broad sense) can be foldably connected to the first side panel 137 by a lateral fold line 155, and the fourth bottom panel 157 (the "third bottom panel" in a broad sense) can be foldably connected to the second side panel 141 by a lateral fold line 159.

[0023] The blank 103 and the tray 105 formed therefrom can include partitioning features for forming respective partitions within the interior 107 of the tray 105. In particular, the bottom panels 145, 149, 153, 157 can include partitioning features that cooperate with each other to form partitions 217 (broadly, a "first partition"), 219 (broadly, a "first partition" or a "second partition"), 221 (broadly, a "second partition" or a "third partition"), 223 (broadly, a "fourth partition") within the interior 107 of the tray 105. As also described herein, the bottom panels 145, 149, 153, 157 can include bottom wall forming features that cooperate with each other to form the bottom wall 225 of the tray 105 formed from the blank 103.

[0024] The bottom panel 145 can include a bottom wall forming portion 161 foldably connected to the end panel 129 at the fold line 147, and a partitioning forming portion 163 foldably connected to the bottom wall forming portion 161 at the longitudinal fold line 165. The partitioning forming portion 163 can include a first portion 167 (broadly, a "first partitioning forming portion") foldably connected to the bottom wall forming portion 161 at the fold line 165, and a second portion 169 (broadly, a "second partitioning forming portion") foldably connected to the first portion 167 at the longitudinal fold line 171.

[0025] Similarly, the bottom panel 149 can include a bottom wall forming portion 173 foldably connected to the end panel 133 at the fold line 151, and a partitioning forming portion 175 foldably connected to the bottom wall forming portion 173 at the longitudinal fold line 177. The partitioning forming portion 175 can include a first portion 179 (broadly, a "first partitioning forming portion") foldably connected to the bottom wall forming portion 173 at the fold line 177, and a second portion 181 (broadly, a "second partitioning forming portion") foldably connected to the first portion 179 at the longitudinal fold line 183.

[0026] The bottom panel 153 includes a bottom wall forming portion 185 that is foldably connected to the side panel 137 at a horizontal fold line 155, the bottom wall forming portion 185 having a base portion 187 adjacent to the fold line 155 and a distal portion 189 extending longitudinally away from the base portion 187.

[0027] The first partition-forming portion 191 of the bottom panel 153 can be foldably connected to the distal portion 189 of the bottom wall-forming portion 185 at a vertical fold line 193, and the second partition-forming portion 195 can be foldably connected to the distal portion 189 of the bottom wall-forming portion 185 at a vertical fold line 197.

[0028] The bottom panel 157 may include a bottom wall forming portion 199 that is foldably connected to the side panel 141 at a transverse fold line 159, the bottom wall forming portion 199 having a base portion 201 adjacent to the fold line 159 and a pair of transversely spaced distal portions 203, 205 (broadly speaking, the "first bottom wall forming portion" and the "second bottom wall forming portion," respectively) that extend longitudinally away from the base portion 201.

[0029] The first partition-forming portion 207 of the bottom panel 157 can be foldably connected to the distal portion 203 of the bottom wall-forming portion 199 at a vertical fold line 209, and the second partition-forming portion 211 can be foldably connected to the distal portion 205 of the bottom wall-forming portion 199 at a vertical fold line 213.

[0030] In addition, referring to Figures 2 and 3, according to one embodiment, the mounting panels 113 and 117 can be folded so that they are located below each portion of the central panel 111 at their respective fold lines 115 and 119, and at least partially face and contact with each of those portions.

[0031] The end panels 129, 133 can be folded downward away from the central panel 111 / opening 125 at their respective fold lines 131, 135, and the side panels 137, 141 can be folded toward engagement with the downward-hanging end panels 129, 133 at their respective fold lines 139, 143.

[0032] In this regard, the edges or surfaces of the side panels 137 and 141 can intersect with the edges or surfaces of the end panels 129 and 133 to form a side wall 215 of the tray 105 that extends at least partially around the interior 107 of the tray 105.

[0033] Furthermore, the bottom panels 145, 149 are arranged such that their respective bottom wall forming portions 161, 173 are positioned parallel to the central panel 111 with a general gap between them, and they can be folded along their respective fold lines 147, 151 such that the respective edges or surfaces of the respective bottom wall forming portions 161, 173 intersect with the edges or surfaces of the respective side panels 137, 141.

[0034] Similarly, the bottom panels 153, 157 can be folded along their respective fold lines 155, 159 such that their respective bottom wall forming portions 185, 199 are arranged parallel to and generally spaced apart from the central panel 111, and each edge or surface of each bottom wall forming portion 185, 199 intersects with the edges or surfaces of the respective side panels 137, 141.

[0035] The partition-forming portion 163 of the bottom panel 145 can be configured such that a first portion 167 is at least partially folded upward at the fold line 165 and positioned substantially obliquely to the bottom wall-forming portion 161, and a second portion 169 is at least partially folded downward at the fold line 171 and positioned substantially obliquely to the first portion 167, thereby forming a partition 217 inside the tray 105. In some embodiments, the edge or surface of the second portion 169 of the bottom panel 145 may be in contact with the edge or surface of the bottom panels 153, 157.

[0036] The partition-forming portion 207 of the bottom panel 157 can be folded upward at least partially along the fold line 209 to be positioned substantially obliquely to the bottom wall-forming portion 199 of the bottom panel 157. The partition-forming portion 191 of the bottom panel 153 can be folded upward at least partially along the fold line 193 to be positioned substantially obliquely to both the bottom wall-forming portion 185 of the bottom panel 153 and the partition-forming portion 207 of the bottom panel 157, thereby forming a partition 219 inside the tray 105 109. In some embodiments, the edge or surface of the partition-forming portion 191 of the bottom panel 153 can be in contact with the edge or surface of the partition-forming portion 207 of the bottom panel 157.

[0037] Similarly, the partition-forming portion 195 of the bottom panel 153 can be folded at least partially upward along the fold line 197 to be positioned substantially obliquely to the bottom wall-forming portion 185 of the bottom panel 153. The partition-forming portion 211 of the bottom panel 157 can be folded at least partially upward along the fold line 213 to be positioned substantially obliquely to both the bottom wall-forming portion 199 of the bottom panel 157 and the partition-forming portion 195 of the bottom panel 153, thereby forming a partition 221 inside the tray 105 109. In some embodiments, the edge or surface of the partition-forming portion 211 of the bottom panel 157 can be in contact with the edge or surface of the partition-forming portion 195 of the bottom panel 153.

[0038] The partition-forming portion 175 of the bottom panel 149 can be arranged such that the first portion 179 is at least partially folded upward at the fold line 177 and positioned substantially obliquely to the bottom wall-forming portion 173, and the second portion 181 is at least partially folded downward at the fold line 183 and positioned substantially obliquely to the first portion 179, thereby forming a partition 223 inside the tray 105 107. In some embodiments, the edge or surface of the second portion 181 of the bottom panel 149 can be in contact with the edge or surface of the bottom panels 153, 157.

[0039] The aforementioned arrangement of the panels and feature portions can be maintained at least partially by one or more applications of an adhesive such as glue. In some embodiments, as will be further described below, the forming system may include features that facilitate the arrangement of panels, end flaps, and feature portions of the blank 103 for forming the tray 105.

[0040] The upright configuration of tray 105 provides a bottom wall 225 formed by the overlapping arrangement of bottom panels 145, 149, 153, and 157, from which partitions 217, 219, 221, and 223 extend at least partially to provide compartments or partitions within the interior 107 of tray 105.

[0041] In some embodiments, the respective bottom wall forming portions 161, 173, 189, 203, 205 of each bottom panel 145, 149, 153, 157 can form the bottom wall 225 of the tray 105, and the partitions 217, 219, 221, 223 can be positioned extending upward from the bottom wall 225 of the tray 105. In other embodiments, one or more partitions 217, 219, 221, 223 can form part of the bottom wall 225 of the tray 105.

[0042] In some embodiments, one or more spaces or gaps between each of the partitions 217, 219, 221, 223 and the rest of the tray 105 can provide one or more outlet routes for, for example, ventilation and fluid discharge.

[0043] In some embodiments, a compartment can be defined at least partially between partition 217 and a portion of the side wall 215 of the tray 105; a compartment can be formed between partition 217 and partition 219; a compartment can be formed between partition 219 and partition 221; a compartment can be formed between partition 221 and partition 223; and a compartment can be formed between partition 223 and a portion of the side wall 215. It will be understood that different compartment arrangements can be formed inside 107 of the tray 105 without departing from the present disclosure.

[0044] In some embodiments, the dividers 217, 219, 221, 223 provide such partitions in the interior 107 of the tray 105, allowing one or more food items, such as cookies or other pastries, crackers, chips, snacks, candies, or other foods, to be separated at least partially from the interior 107 of the tray 105.

[0045] Furthermore, the overlapping arrangement of the end panels 129, 133 and the side panels 137, 141 provides the tray 105 with a robust structure that resists deformation, bending, and crushing. In this regard, one or more of the end panels 129, 133 and the side panels 137, 141 can be considered as reinforcing features of the tray 105.

[0046] As shown in Figure 2, in some embodiments, the lid / lid structure, such as a lid film T, may include a packaging film that is a thin plastic layer used to preserve and protect the food contained in the tray 105 and can be removably attached to the flange 121 of the tray 105, for example, defined by a portion of the central panel 111. Such a lid film T can cover the flange 121 of the tray 105 so as to cover the interior 107 of the tray 105. In some embodiments, such engagement by the lid film T can achieve an airtight seal of the interior 107 of the tray 105.

[0047] For example, any plastic film such as polyethylene, polypropylene, polyethylene terephthalate, polyvinyl chloride, polyamide, and ethylene vinyl alcohol, or other suitable materials, can be used to form a lid film that seals to the sealing surface of the flange / central panel 111. Furthermore, an adhesive can be used between the lid film and the sealing surface of the flange / central panel without departing from the present disclosure.

[0048] Continuing to refer to Figure 3, it is understood that in the embodiment, a liner such as liner F can be applied to at least the interior 107 of the tray 105 and can be superimposed on the seams / intersections between the respective panels, for example, so that the tray 105 has leak-proof properties. The tray 105 is shown in Figure 7 with liner F applied to one or more inner surfaces of the tray 105. Liner F can be detachably connected to one or more surfaces of the tray 105 along the interior 107 of the tray 105 so that, for example, liner F and the tray 105 can be disposed of separately after use. In this regard, the detachable arrangement of the tray 105 and liner F makes it easier to reuse, recycle, etc., the cardboard material forming the tray 105 and the polymer material forming the liner F separately without mixing them.

[0049] In one embodiment, the tray 105 can be formed in a manner similar to the formation of a container as shown and described in the incorporated applications (e.g., applications 425, 814 and / or 131).

[0050] In the exemplary embodiment schematically shown in Figure 4, a blank 103 / tray 105 or its folded configuration can be placed on the lower die 315 of the system 317, and liner material or film sheet 319 (e.g., polyethylene or PET web) can be supplied from a feed roller 321 on the blank 103 / folded blank 103. The upper die 323 has a heater plate surface 325 having a PTFE coating, for example, a Teflon® coating. Alternatively, the heater plate surface 325 may have a coating of any suitable material, or the coating may be omitted.

[0051] As schematically shown in Figure 4, the upper die 323 may include a plurality of holes or ducts 327 in the heater plate surface 325 to apply vacuum and / or pneumatic pressure to the sheet 319. The lower die 315 and / or upper die 323, including the ducts 327 and / or heater plate 325, may be in other forms, arrangements, configurations, and / or configurations without departing from the present disclosure. For example, the heater plate 325 may be omitted, and heat may be applied to the sheet 319 by an alternative means (e.g., a flow of hot air).

[0052] In the illustrated embodiment, the lower die 315 can hold the blank 103 / folded blank 103 on the cavity 314 of the lower die 315, while supporting the blank 103 / tray 105 with the central panel 111 and / or mounting panels 113, 117 (for example, so that the central panel 111 faces upward). Vacuum can be initially applied to the duct 327 to pull the film sheet 319 toward the upper die 323, and the upper die 323 can be heated to a suitable temperature to soften the film sheet 319 and / or activate the heat seal layer. Instead of, or in addition to, the initial vacuum, air pressure beneath the film sheet 319 can be used with a similar or equivalent effect. The film sheet 319 can then be pushed downward (for example, by air pressure applied by the duct 327 and / or vacuum applied from beneath the blank 103 / tray 105).

[0053] The air pressure can move the film sheet 319 toward the blank 103 / tray 105, and the lower die 315 can support the blank 103 / tray 105 when the film sheet 319 is applied to one or more parts of the flange 121, end panels 129, 133, and side panels 137, 141 to form the liner F.

[0054] As shown in the figures, in some embodiments, the lower die 315 (broadly speaking, the "molding die") may be provided with a plurality of projections 316 extending upward within the cavity 314 to facilitate the formation of one or more partitions 217, 219, 221, 223. For example, the protrusions 316 can each provide a raised surface thereon, the first portion 167 and the second portion 169 of the partition-forming portion 163 of the bottom panel 145 can be folded along the respective fold lines 165 and 171 to form a partition 217, the partition-forming portion 207 of the bottom panel 157 and the partition-forming portion 191 of the bottom panel 153 can be folded along the respective fold lines 209 and 193 to form a partition 219, the partition-forming portion 195 of the bottom panel 153 and the partition-forming portion 211 of the bottom panel 157 can be folded along the respective fold lines 197 and 213 to form a partition 221, and the first portion 179 and the second portion 181 of the partition-forming portion 175 of the bottom panel 149 can be folded along the respective fold lines 177 and 183 to form a partition 223. In this regard, each projection 316 may be wedge-shaped overall as shown in the figure, or it may have a different configuration, such as a column or rib, to facilitate the formation of such partitions 217, 219, 221, and 223.

[0055] In some embodiments, the liner F can help hold the tray 105 in its tray shape after the liner F has been applied to the blank 103 / folded blank 103 / tray 105. For example, in some embodiments, the attachment of the liner F to the tray 105 can at least partially maintain the diagonal arrangement of the partition-forming portions 191,207 and 195,211.

[0056] In some embodiments, the tray 105 may be discharged from the lower die 315 and transported away from the forming tool, for example, on a conveyor.

[0057] In one embodiment, the tray 105 can be formed from a blank 103, allowing the liner F to be applied at a much faster rate than a system in which the tray 105 is formed separately from the blank 103 and the formed tray 105 is placed on the lower die 315. In one example, the tray 105 of this embodiment can be formed from the blank 103 together with the liner F at a rate of about 200 trays per minute. The tray 105 can be formed in other ways without departing from the present disclosure. For example, the tray 105 can be formed from the blank 103 before the liner F is applied (for example, before engaging with the lower die 315).

[0058] Any of the features of the various embodiments of this disclosure may be combined with, replaced by, or otherwise configured with other features of other embodiments of this disclosure without departing from the scope of this disclosure.

[0059] If necessary, one or more portions of the blanks or other components described or intended herein may be coated with varnish, clay, or other materials, either alone or in combination. The coatings may then be printed together with product advertisements or other information or images. The blanks or other components may also be selectively coated and / or printed such that less than or substantially the entire surface area of ​​the blank is coated and / or printed.

[0060] Any of the blanks, trays, or other components of this disclosure may, as necessary, include one or more features that modify the effects of microwave energy during heating or cooking of food associated with the tray or other component. For example, a blank, tray, container, or other component may be at least partially formed from one or more microwave energy interacting elements (hereinafter sometimes referred to as "microwave interacting elements") that facilitate heating, browning, and / or crisping of specific areas of food, shield specific areas of food from microwave energy to prevent overheating, or transfer microwave energy toward or away from specific areas of food. Each microwave interacting element includes one or more microwave energy interacting materials or segments arranged in a particular configuration to absorb, transfer, reflect, or guide microwave energy, as required or desired for the particular component and food.

[0061] In the case of a susceptor or shield, the microwave energy interacting material may include conductive or semiconductor materials, such as vacuum-deposited metals or metal alloys, or metal inks, organic inks, inorganic inks, metal pastes, organic pastes, inorganic pastes, or any combination thereof. Examples of suitable metals and metal alloys include, but are not limited to, aluminum, chromium, copper, Inconel alloy (nickel-chromium-molybdenum alloy with niobium), iron, magnesium, nickel, stainless steel, tin, titanium, tungsten, and any combination or alloy thereof.

[0062] Alternatively, microwave energy interacting materials include metal oxides, such as aluminum, iron, and tin oxides, and can optionally be used in combination with conductive materials. Another metal oxide that may be suitable is indium tin oxide (ITO). ITO has a more uniform crystalline structure and is therefore transparent at most coating thicknesses.

[0063] Furthermore, by alternative means, the microwave energy interacting material may include an appropriate conductive, semiconductive, or nonconductive artificial dielectric or ferroelectric. The artificial dielectric may include a fractionated conductive material in a polymer or other suitable matrix or binder, and may include flakes of a conductive metal, such as aluminum.

[0064] In other embodiments, the microwave energy interacting material may be carbon-based, for example, as disclosed in U.S. Patents 4,943,456, 5,002,826, 5,118,747, and 5,410,135.

[0065] In yet another embodiment, a microwave energy interacting material can interact with the magnetic portion of the electromagnetic energy in a microwave oven. A well-selected material of this type can self-limit based on the loss of interaction when the material reaches its Curie temperature. An example of such an interacting coating is described in U.S. Patent No. 4,283,427.

[0066] The use of other microwave energy interacting elements is also intended. In one example, a microwave energy interacting element may include a foil or high optical density deposited material having sufficient thickness to reflect a substantial portion of the incoming microwave energy. Such elements are typically formed from conductive, reflective metals or metal alloys, such as aluminum, copper, or stainless steel, in the form of solid "patches" generally having a thickness of about 0.000285 inches to about 0.005 inches, for example, about 0.0003 inches to about 0.003 inches. Other such elements may have a thickness of about 0.00035 inches to about 0.002 inches, for example, 0.0016 inches.

[0067] In some cases, microwave energy reflecting (or reflective) elements can be used as shielding elements when food is prone to burning or drying out during heating. In other cases, smaller microwave energy reflecting elements can be used to diffuse or reduce the intensity of microwave energy. An example of a material utilizing such microwave energy reflecting elements is commercially available from Graphic Packaging International, Inc. (Atlanta, Georgia) under the trade name MicroRite® packaging material. In other examples, multiple microwave energy reflecting elements can be arranged to form a microwave energy distribution element, directing microwave energy to specific areas of food. If desired, the loop can be of a length that resonates the microwave energy, thereby enhancing the distribution effect. Microwave energy distribution elements are described in U.S. Patents 6,204,492, 6,433,322, 6,552,315, and 6,677,563, respectively, which are incorporated by reference in their entirety.

[0068] Where necessary, any of the numerous microwave energy interacting elements described or intended herein may be substantially continuous, i.e., without substantial cracks or breaks, or may be discontinuous, for example, by including one or more cracks or openings that transmit microwave energy. Cracks or openings may extend through the entire structure or through only one or more layers. The number, shape, size, and location of such cracks or openings may vary for a particular application depending on the type of structure to be formed, the food to be heated in or on therein, the desired degree of heating, browning, and / or crisping, whether direct exposure to microwave energy is necessary or desired to achieve uniform heating of the food, whether there is a need to regulate temperature changes in the food by direct heating, and whether there is a need for ventilation, and to what extent.

[0069] For example, a microwave energy interaction element may include one or more transparent regions for dielectric heating of food. However, if the microwave energy interaction element includes a susceptor, such an opening reduces the overall microwave energy interaction region and therefore reduces the amount of microwave energy interaction material available for heating, browning, and / or crisping the surface of the food. Thus, the relative amounts of the microwave energy interaction region and the microwave energy transparent region may be balanced to achieve the desired overall heating characteristics of a particular food.

[0070] As another example, one or more portions of a susceptor may be designed to be microwave energy inert to ensure that microwave energy is efficiently concentrated in the areas to be heated, browned, and / or crisped, rather than being lost to portions or heating environments not intended for browning and / or crisping of the food. Additionally or alternatively, it may be beneficial to form one or more discontinuities or inert regions to prevent overheating or carbonization of the food and / or the components including the susceptor.

[0071] As yet another example, a susceptor may incorporate one or more “fuse” elements to limit the propagation of cracks within the susceptor and thereby control overheating in areas of the susceptor where heat transfer to food is low and the susceptor tends to overheat. The size and shape of the fuse can be modified as needed. Examples of susceptors incorporating such fuses are provided, for example, in U.S. Patent No. 5,412,187, U.S. Patent No. 5,530,231, U.S. Patent Application Publication 2008 / 0035634A1, published on 14 February 2008, and PCT Application Publication WO2007 / 127371, published on 8 November 2007, each incorporated herein by reference in its entirety.

[0072] All dimensional information presented herein is intended to illustrate specific aspects, features, etc., of various embodiments of the Disclosure and is not intended to limit the scope of the Disclosure. Dimensions of blanks, containers, forming tools, features, or any other dimensions may be greater than or less than those shown and described herein, and may be within or outside the range of dimensions described for each feature, without departing from the scope of the Disclosure.

[0073] The blank according to the present invention can be formed from, for example, coated cardboard and similar materials. For example, the inside and / or outside of the blank can be coated with a clay coating. The clay coating can then be printed with product information, advertisements, price codes, and other information or images. The blank can then be coated with varnish to protect the information printed on the blank. The blank can also be coated on one or both sides with, for example, a moisture barrier layer.

[0074] According to an exemplary embodiment, the blank may be made of cardboard of a thickness that is heavier and more rigid than ordinary paper. The blank may also be made of corrugated cardboard, rigid paper, or any other material having properties suitable for enabling the carton package to function at least generally as described above.

[0075] The foregoing description illustrates and illustrates various embodiments of the present disclosure. Since various modifications can be made to the above configurations without departing from the scope of the disclosure, all matters included in the foregoing description or shown in the accompanying drawings are intended to be construed as illustrative and not limiting. Furthermore, the scope of the present disclosure includes various modifications, combinations, and changes to the above embodiments. Furthermore, while the present disclosure shows and describes only selected embodiments, various other combinations, modifications, and settings are intended and within the scope of the concept of the invention presented herein, corresponding to the foregoing teachings and / or within the scope of the art or knowledge of the related art. Furthermore, specific features and characteristics of each embodiment can be selectively substituted and applied to other illustrated and unillustrated embodiments without departing from the scope of the present disclosure.

Claims

1. A tray for holding one or more food items, A plurality of panels including a central panel, at least one end panel, at least one side panel, and at least one bottom panel, Extending at least partially around the interior of the tray, the side wall includes at least one end panel and at least one side panel, A flange extending outward from the side wall and including the central panel, A bottom wall including at least one bottom panel, The tray includes at least one partition inside, the at least one partition having a partition feature portion that extends upward from the bottom wall, A tray equipped with a tray.

2. The tray according to claim 1, wherein the at least one bottom panel includes a bottom wall forming portion that forms at least a portion of the bottom wall and at least one partition forming portion that forms at least a portion of the at least one partition.

3. The tray according to claim 2, wherein the at least one partition-forming portion extends diagonally upward from the bottom wall-forming portion inside the tray.

4. The tray according to claim 3, wherein the at least one bottom panel includes a bottom wall forming portion, a first partition forming portion foldably connected to the bottom wall forming portion, and a second partition forming portion foldably connected to the first partition forming portion, the first partition forming portion and the second partition forming portion being arranged diagonally to form the at least one partition.

5. The tray according to claim 3, wherein the at least one partition is a first partition extending upward from the bottom wall, the partition feature further includes a second partition extending upward from the bottom wall, the at least one partition forming portion is a first partition forming portion that is foldably connected to the bottom wall forming portion of the at least one bottom panel and forms at least partially the first partition, and the at least one bottom panel further includes a second partition forming portion that is foldably connected to the bottom wall forming portion and extends diagonally upward from the bottom wall forming portion inside the tray and forms at least partially the second partition.

6. The tray according to claim 3, wherein the at least one partition is a first partition extending upward from the bottom wall, the partition feature further includes a second partition extending upward from the bottom wall, the bottom wall forming portion is a first bottom wall forming portion, the at least one bottom panel further includes a second bottom wall forming portion spaced apart from the first bottom wall forming portion, the at least one partition forming portion is a first partition forming portion foldably connected to the first bottom wall forming portion and forming at least a portion of the first partition, and the at least one bottom panel further includes a second partition forming portion foldably connected to the second bottom wall forming portion and extending diagonally upward from the second bottom wall forming portion inside the tray and forming at least a portion of the second partition.

7. The tray according to claim 3, wherein the at least one bottom panel is a first bottom panel, and the plurality of panels further include a second bottom panel that at least partially forms the bottom wall, the second bottom panel includes a bottom forming portion and at least one partition forming portion that is foldably connected to the bottom forming portion of the second bottom panel, and the at least one partition forming portion of the first bottom panel and the at least one partition forming portion of the second bottom panel are arranged diagonally to form the at least one partition.

8. The at least one bottom panel is a first bottom panel, and the plurality of panels further include a second bottom panel, a third bottom panel, and a fourth bottom panel, each of the first bottom panel, the second bottom panel, the third bottom panel, and the fourth bottom panel includes a bottom forming portion and each at least one partition forming portion that is foldably connected to the respective bottom forming portion, the at least one partition being a first partition, and the partition feature portion includes a second partition, a third partition, and extending upward from the bottom wall inside the tray. The tray according to claim 3, further comprising a fourth partition, wherein at least one partition-forming portion of the first bottom panel is arranged to at least partially form the first partition, at least one partition-forming portion of the second bottom panel is arranged to at least partially form the second partition, at least one partition-forming portion of the third bottom panel is arranged to at least partially form the third partition, and at least one partition-forming portion of the fourth bottom panel is arranged to at least partially form the fourth partition.

9. The tray according to claim 8, wherein at least one partition-forming portion of the second bottom panel is a first partition-forming portion that at least partially forms the second partition, and the second bottom panel further comprises a second partition-forming portion that at least partially forms the third partition.

10. The tray according to claim 9, wherein at least one partition-forming portion of the third bottom panel is a first partition-forming portion that at least partially forms the second partition, and the third bottom panel further comprises a second partition-forming portion that at least partially forms the third partition.

11. The tray according to claim 10, wherein the first partition-forming portion of the second bottom panel is positioned diagonally with the first partition-forming portion of the third bottom panel to form the second partition.

12. The tray according to claim 11, wherein the second partition-forming portion of the second bottom panel is positioned diagonally with the second partition-forming portion of the third bottom panel to form the third partition.

13. The tray according to claim 3, wherein the at least one end panel and the at least one side panel extend downward from the central panel.

14. The tray according to claim 13, wherein at least one end panel is foldably connected to the central panel, and at least one side panel is foldably connected to a mounting panel that overlaps the central panel.

15. The tray according to claim 14, wherein the central panel at least partially defines an outer edge and an inner edge surrounding an opening, and at least one end panel is foldably connected to the inner edge of the central panel.

16. The tray according to claim 3, further comprising a liner detachably attached to at least a portion of each of the plurality of panels.

17. A blank for forming a tray for holding one or more food items, It comprises a plurality of panels, including a central panel, at least one end panel, at least one side panel, and at least one bottom panel. The at least one end panel and the at least one side panel are arranged to at least partially form a side wall that extends at least partially around the interior of the tray formed from the blank, The central panel is positioned to at least partially form a flange extending outward from the side wall when the tray is formed from the blank, The at least one bottom panel is positioned to form the bottom wall of the tray formed from the blank, and further, A blank comprising a partition feature portion for forming at least one partition extending upward from the bottom wall within the tray formed therefrom.

18. The blank according to claim 17, wherein the at least one bottom panel comprises a bottom wall forming portion for at least partially forming the bottom wall and at least one partition forming portion for at least partially forming the at least one partition when the tray is formed from the blank.

19. The blank according to claim 18, wherein the at least one bottom panel includes a bottom wall forming portion, a first partition forming portion foldably connected to the bottom wall forming portion, and a second partition forming portion foldably connected to the first partition forming portion, the first partition forming portion and the second partition forming portion being positioned diagonally to form the at least one partition when the tray is formed from the blank.

20. The blank according to claim 18, wherein the at least one partition is a first partition formed by a partition feature extending upward from the bottom wall when the tray is formed from the blank, the at least one partition forming portion is a first partition forming portion that is foldably connected to the bottom wall forming portion of the at least one bottom panel in order to at least partially form the first partition when the tray is formed from the blank, and the at least one bottom panel further comprises a second partition forming portion that is foldably connected to the bottom wall forming portion in order to extend diagonally upward from the bottom wall forming portion inside the tray in order to at least partially form a second partition when the tray is formed from the blank.

21. The blank according to claim 18, wherein the at least one partition is a first partition formed by a partition feature extending upward from the bottom wall when the tray is formed from the blank, the bottom wall forming portion is a first bottom wall forming portion, and the at least one bottom panel further includes a second bottom wall forming portion spaced apart from the first bottom wall forming portion, the at least one partition forming portion is a first partition forming portion foldably connected to the first bottom wall forming portion to at least partially form the first partition when the tray is formed from the blank, and the at least one bottom panel further includes a second partition forming portion foldably connected to the second bottom wall forming portion to extend obliquely upward from the second bottom wall forming portion inside the tray to at least partially form the second partition when the tray is formed from the blank.

22. The blank according to claim 18, wherein the at least one bottom panel is a first bottom panel, and the plurality of panels further include a second bottom panel for at least partially forming the bottom wall when the tray is formed from the blank, the second bottom panel including a bottom forming portion and at least one partition forming portion foldably connected to the bottom forming portion of the second bottom panel, and the at least one partition forming portion of the first bottom panel and the at least one partition forming portion of the second bottom panel are positioned diagonally to form the at least one partition when the tray is formed from the blank.

23. The at least one bottom panel is a first bottom panel, and the plurality of panels further include a second bottom panel, a third bottom panel, and a fourth bottom panel, each of the first bottom panel, the second bottom panel, the third bottom panel, and the fourth bottom panel includes a bottom forming portion and each at least one partition forming portion foldably connected to the respective bottom forming portion, the partition feature portion being for forming at least one partition which is a first partition when the tray is formed from the blank, and the partition feature portion being for further forming a second partition, a third partition, and a fourth partition inside the tray which extend upward from the bottom wall when the tray is formed from the blank. The blank according to claim 18, wherein at least one partition-forming portion of the first bottom panel is arranged to at least partially form the first partition when the tray is formed from the blank, at least one partition-forming portion of the second bottom panel is arranged to at least partially form the second partition when the tray is formed from the blank, at least one partition-forming portion of the third bottom panel is arranged to at least partially form the third partition when the tray is formed from the blank, and at least one partition-forming portion of the fourth bottom panel is arranged to at least partially form the fourth partition when the tray is formed from the blank.

24. The blank according to claim 23, wherein at least one partition-forming portion of the second bottom panel is a first partition-forming portion for at least partially forming the second partition when the tray is formed from the blank, and the second bottom panel further includes a second partition-forming portion for at least partially forming the third partition when the tray is formed from the blank.

25. The blank according to claim 24, wherein at least one partition-forming portion of the third bottom panel is a first partition-forming portion for at least partially forming the second partition when the tray is formed from the blank, and the third bottom panel further includes a second partition-forming portion for at least partially forming the third partition when the tray is formed from the blank.

26. The blank according to claim 18, wherein at least one end panel is foldably connected to the central panel, and at least one side panel is foldably connected to a mounting panel that overlaps the central panel when the tray is formed from the blank.

27. The blank according to claim 26, wherein the central panel at least partially defines an outer edge and an inner edge surrounding an opening, and at least one end panel is foldably connected to the inner edge of the central panel.

28. The blank according to claim 18, which is combined with a liner that is detachably attached to at least a portion of each of the plurality of panels.

29. A method for forming a tray for holding one or more food items, Obtaining a blank, wherein the blank comprises a plurality of panels including a central panel, at least one end panel, at least one side panel, and at least one bottom panel, and the blank further comprises a partition feature. The at least one end panel and the at least one side panel are arranged to form a side wall that extends at least partially around the inside of the tray, The central panel is positioned to form a flange extending outward from the side wall, The at least one bottom panel is positioned to form the bottom wall of the tray, To form at least one partition extending upward from the bottom wall inside the tray, A method that includes this.

30. The method according to claim 29, wherein the at least one bottom panel includes a bottom wall forming portion, arranging the at least one bottom panel includes arranging the bottom wall forming portion to form at least a portion of the bottom wall, and forming the at least one partition includes arranging the at least one partition forming portion to form at least a portion of the at least one partition.

31. The method according to claim 30, wherein forming the at least one partition includes positioning the at least one partition-forming portion extending diagonally upward from the bottom wall-forming portion within the tray.

32. The method according to claim 31, wherein forming the at least one partition includes positioning the at least one partition-forming portion on a projection extending upward from a molding die.

33. The method according to claim 31, wherein the at least one bottom panel includes a bottom wall forming portion, a first partition forming portion foldably connected to the bottom wall forming portion, and a second partition forming portion foldably connected to the first partition forming portion, and forming the at least one partition includes arranging the first partition forming portion and the second partition forming portion diagonally.

34. The method according to claim 33, wherein forming the at least one partition includes arranging the first partition-forming portion and the second partition-forming portion obliquely on a projection extending upward from the molding die.

35. The method according to claim 31, wherein the at least one partition is a first partition extending upward from the bottom wall, and the method further comprises forming a second partition extending upward from the bottom wall, wherein the at least one partition forming portion is a first partition forming portion that is foldably connected to the bottom wall forming portion of the at least one bottom panel and forms at least partially the first partition, and the at least one bottom panel further comprises a second partition forming portion that is foldably connected to the bottom wall forming portion, and forming the second partition comprises positioning the second partition forming portion that extends diagonally upward from the bottom wall forming portion inside the tray to form at least partially the second partition.

36. The method according to claim 31, wherein the at least one partition is a first partition extending upward from the bottom wall, and the method further comprises forming a second partition extending upward from the bottom wall, the bottom wall forming portion being a first bottom wall forming portion, and the at least one bottom panel further comprises a second bottom wall forming portion spaced apart from the first bottom wall forming portion, the at least one partition forming portion being a first partition forming portion foldably connected to the first bottom wall forming portion and forming at least a portion of the first partition, and the at least one bottom panel further comprises a second partition forming portion foldably connected to the second bottom wall forming portion, and the method further comprises positioning the second partition forming portion extending diagonally upward from the second bottom wall forming portion inside the tray.

37. The method according to claim 31, wherein the at least one bottom panel is a first bottom panel, and the plurality of panels further include a second bottom panel, the second bottom panel including a bottom forming portion and at least one partition forming portion foldably connected to the bottom forming portion of the second bottom panel, forming the bottom wall includes positioning the second bottom panel, and forming the at least one partition includes arranging the at least one partition forming portion of the first bottom panel and the at least one partition forming portion of the second bottom panel at an angle.

38. The method according to claim 37, wherein forming the at least one partition includes arranging at least one partition-forming portion of the first bottom panel and at least one partition-forming portion of the second bottom panel obliquely on a projection extending upward from the molding die.

39. The at least one bottom panel is a first bottom panel, and the plurality of panels further include a second bottom panel, a third bottom panel, and a fourth bottom panel, each of the first bottom panel, the second bottom panel, the third bottom panel, and the fourth bottom panel includes a bottom forming portion and each at least one partition forming portion foldably connected to the bottom forming portion, the at least one partition being a first partition, and the method includes a second partition, a third partition, and a third partition extending upward from the bottom wall inside the tray. The method according to claim 31, further comprising forming a first partition, a second partition, and a fourth partition, wherein forming the first partition includes arranging at least one partition-forming portion of the first bottom panel, forming the second partition includes arranging at least one partition-forming portion of the second bottom panel, forming the third partition includes arranging at least one partition of the third bottom panel, and forming the fourth partition includes arranging at least one partition of the fourth bottom panel.

40. The method according to claim 39, wherein at least one partition-forming portion of the second bottom panel is a first partition-forming portion that forms at least a portion of the second partition, and the second bottom panel further includes a second partition-forming portion, and forming the third partition includes positioning the second partition-forming portion of the second bottom panel.

41. The method according to claim 40, wherein at least one partition-forming portion of the third bottom panel is a first partition-forming portion that at least partially forms the second partition, and the third bottom panel further includes a second partition-forming portion, and forming the third partition includes positioning the second partition-forming portion of the third bottom panel.

42. The method according to claim 41, wherein forming the second partition includes arranging the first partition-forming portion of the second bottom panel diagonally with the first partition-forming portion of the third bottom panel.

43. The method according to claim 42, wherein forming the third partition includes arranging the second partition-forming portion of the second bottom panel diagonally with the second partition-forming portion of the third bottom panel.

44. The method according to claim 31, wherein forming the side wall includes positioning the at least one end panel and the at least one side panel to extend downward from the central panel.

45. The method according to claim 44, wherein at least one end panel is foldably connected to the central panel, and at least one side panel is foldably connected to a mounting panel, the method comprising overlapping the mounting panel and the central panel.

46. The method according to claim 45, wherein the central panel at least partially defines an outer edge and an inner edge surrounding an opening, and the at least one end panel is foldably connected to the inner edge of the central panel.

47. The method according to claim 31, further comprising attaching a liner detachably to at least a portion of each of the plurality of panels.

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