Nested Pan and Folded Pan Cover

The present invention relates to the art of packaging foil pans and similar items, and more particularly, the present invention is directed to a packaging one or more foil pans with folded pan covers to form a packaged assembly.

Foil pans are well known in the industry. In addition, the packaged consumer products further include lids. In some instances the lids are folded such that pans can be stacked and lids nested in-between the pans. This has lead to numerous consumer products. In all of these products the lids are paper based with one side coated in aluminum or made of an aluminum material that is glued or secure to the paper side. The aluminum side is provided to allow the retention of heat and provide a moisture barrier between the contents of the pan and the paper side of the lid. However, one major issue with this lid is that the lid is not recyclable because a large percentage of the lid is aluminum. To be recyclable the aluminum must be stripped from the lid. Since the consumer does not have the means to remove the aluminum the lid must be trashed. As such, there is a great need to have a lid that has recyclable properties but still provides similar characteristics of an aluminum side.

In accordance with the present invention there is provided a packaged pan and lid that includes:

(a) at least two nested pans, each pan having a well with a bottom surface and a single continuous wall surface extending upwardly from the bottom surface, a rim extending outwardly from an upper edge of the wall surface and a lip extending upwardly from a terminus of the rim, and wherein one of the nested pans is positioned in the other nested pan such that the wells of the nested pans substantially abut each other;

(b) at least two lids corresponding to the at least two nested pans, each lid having at least one bi-lateral fold line across the lid, such that the lid is configurable into a folded configuration, the lids being configured into the folded configuration and being removable secured within the well of one of the pans positioned below another pan, such that the at least two lids are secured between the at least two nested pans, and wherein the at least two lids are removable from the well when the at least two nested pans are separated, and each of the lids being adapted to unfold to a substantially flat configuration, and wherein the lip is configured to bend over the edge of the lid when the lid is unfolded to a substantially flat configuration and positioned such that the perimeter of the lid is positioned on the rim; and

(c) wherein each one of the lids is configured out of a cardboard material and includes a first surface being coated with a repulpable barrier substrate defined to provide a water, oil, and grease barrier, and wherein a second surface which is opposed to the first surface maintains a cardboard finish that is configured with an area of indicia printable on the second surface.

The pan and lid includes a repulpable barrier substrate that represents 10% or less of the total mass of the lid or alternatively represents 5% or less of the total mass of the lid.

The pan and lid may have an elliptical shaped configuration or have a polygonal configuration.

Numerous other advantages and features of the invention will become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims, and from the accompanying drawings.

While the invention is susceptible to embodiments in many different forms, there are shown in the drawings and will be described herein, in detail, the preferred embodiments of the present invention. It should be understood, however, that the present disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the spirit or scope of the invention and/or claims of the embodiments illustrated.

With reference to, a first preferred embodiment of a packaged assemblywhich includes at least three nested pans(,,) and pan lids(,,) are shown. Each pan includes a well bottomwith a single continuous wall surfaceextending upwardly from the bottom. The wall surfaceterminates at an edgewith a rimextending radially outwardly therefrom. Extending upwardly from the rimis a lipconfigured to be folded over when the lidis placed thereon, thereby securing the edge of the lidto the rimof the pan.

While the pans are shown in the first embodiment as being elliptical and more particular circular, a quick reference is made towhich shows a polygonal pan or rectangular. Other pan shapes would be included within the scope of this invention. In addition, the number of pans while shown as three can change to include simply a single pan or more than one pan.

Continuing to refer to, the pansinclude lids. The lidsmay be separately secured to the well bottomof a corresponding pan. Alternatively, the multiple lids may be packaged together and inserted between a two adjacent pans to prevent the lid attached to the topmost well bottomfrom being lost or damaged.

Referring now to, there is shown the panwith a lid. One important aspect of the present invention is that the lidis folded to permit the lid to fit easily within the well. Since the lidin this configuration is circular cross folding linesand() are provided to allow the lid to fold into a quarter configuration().

In addition, the surfaces of the lid may be different to help keep packaged food warmer while maintaining the ability to fold the lid. For example, the lid is made of a paper or cardboard to ensure it will hold its shape when unfolded. However, one side 48 of the surface of the lid is coated with a barrier substrate that is repulpable. The repulpable barrier substrate also provides a water, oil, and grease barrier while representing 10% or less of the total mass of the lid, and preferable less than 5% of the total mass of the lid. This is in stark contrast to existing lids that have one side completely coated with aluminum and which makes up almost about 50% of the mass of the lid, making existing lids non-recyclable.

The other side may be made of a thin cardboard(). The cardboard permits the lid to be folded for packaging and unfolded for use, while the aluminum side provides for the ability to keep moisture out and/or help maintain the heat within the pan when closed and re-heating.

The lidsmay also include corner edgessecured to the perimeterof the lid. The corner sectionsare attached to the perimeterby a perforated edgeto allow the corner sectionsto tear away easily. The corner sectionsprovide a surface that can be gluedto each other to keep the lid in a folded position. In addition, a corner section can be glued to the pan without interfering with one of the surfaces of the lid. As such if glue gets stuck to the corner section it simply will be removed when the corner sectionsare removed.

Referring back to, when packaged the pans may be secured together by a bandmade out of a heat-shrinkable plastic is placed around the outwardly-extending rimand lipportions of the nested foil pans. Upon the application of heat, the plastic shrinks so as to fit snugly about the top and bottom rims, thereby holding the foil panstogether.

Referring now to, there is shown in a second embodiment a rectangular pan. As disclosed above, the panincludes a wellwith a bottom surface. Extending from the edge of the bottom surface is a continuous wall surfaceterminating at a rim. Extending upwardly from the rimis a lip, which is configured to be folded over the edge of a lid when placed and rested on the rim. The panis shown nested in a group of three pans (,,). Lids(,,) are provided and are secured within the well to its corresponding pan. In addition, a labelmay be placed over each lidto help secure the lid in place, preventing accidental removal of the lid by a consumer or during shipping and handling. Lastly, the pansmay be secured together by a bandmade out of a heat-shrinkable plastic is placed around the outwardly-extending rimand lipportions of the nested foil pans. Upon the application of heat, the plastic shrinks so as to fit snugly about the top and bottom rims, thereby holding the foil panstogether.

Referring now to, the lidsmay be designed with two lateral folding linessuch that the folded lidcan easily rest within the wellof the pan. The lidmay also include a removable tabthat can be used to help keep the lid in a folded position. Glue or another type of adhesive may be used to secure the tab to a portion of the lid to keep the lid in a folded position for packaging and shipping. As noted above, the surfaces of the lid may be different to help keep packaged food warmer while maintaining the ability to fold the lid.

For example, the lid is made of a paper or cardboard to ensure it will hold its shape when unfolded. However, one sideof the surface of the lid is coated with a barrier substrate that is repulpable. The repulpable barrier substrate also provides a water, oil, and grease barrier while representing 10% or less of the total mass of the lid, and preferable less than 5% of the total mass of the lid. This is in stark contrast to existing lids that have one side completely coated with aluminum and which makes up almost about 50% of the mass of the lid, making existing lids non-recyclable. The other side may be made of a thin cardboard. The cardboard permits the lid to be folded for packaging and unfolded for use, while the aluminum side provides for the ability to keep moisture out and/or help maintain the heat within the pan when closed and re-heating. In addition, the cardboard sidemay configured to allow for indiciathat allows the consumer to write directly on the lid.

It should be known that the number of fold lines is not important. The aspect of the invention is that the folded lid is sized such that it easily fits within the well of the pan and then is unfolded to a substantially flat configuration, such that the edges of the lid fits onto the rim of the pan. Referring now to, there is shown the pan (and) and lid (and) as the lid is unfolded, resting on the rim, and having the lip (and) folded over to secure the lid on to the pan.

Referring now to, there are shown additional embodiments that define pans() packaged together with the lids() positioned between at least two of the pans. In this embodiment, the lids() are secured between two adjacent pans() and the likelihood that a lid is prematurely removed or lost is reduced. Pans are then secured with tape or a shrink wrap material around the edge of the pans.

From the foregoing and as mentioned above, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the novel concept of the invention. It is to be understood that no limitation with respect to the specific methods and apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims.