Tray For Food Products

This application is a divisional of U.S. patent application Ser. No. 18/144,312 for “Tray For Food Products” filed on May 8, 2023, which claims priority to of U.S. Provisional Patent Application No. 63/339,628, filed on May 9, 2022, and U.S. Provisional Patent Application No. 63/341,711, filed on May 13, 2022.

The disclosures of each of U.S. Design patent application Ser. No. 29/891,539, filed on May 8, 2023, U.S. Design patent application Ser. No. 29/891,540, filed on May 8, 2023, U.S. Provisional Patent Application No. 63/110,578, filed on Nov. 6, 2020, U.S. Provisional Patent Application No. 63/110,582, filed on Nov. 6, 2020, U.S. Provisional Patent Application No. 63/110,587, filed on Nov. 6, 2020, U.S. Provisional Patent Application No. 63/126, 157, filed on Dec. 16, 2020, U.S. Provisional Patent Application No. 63/128,418, filed on Dec. 21, 2020, U.S. Provisional Patent Application No. 63/139,341, filed on Jan. 20, 2021, U.S. Provisional Patent Application No. 63/169,302, filed on Apr. 1, 2021, U.S. Provisional Patent Application No. 63/169,418, filed on Apr. 1, 2021, U.S. Provisional Patent Application No. 63/174,724, filed on Apr. 14, 2021, U.S. Provisional Patent Application No. 63/178, 116, filed on Apr. 22, 2021, U.S. Provisional Patent Application No. 63/191,412, filed on Jun. 1, 2021, U.S. patent application Ser. No. 17/519,080, filed on Nov. 4, 2021, U.S. patent application Ser. No. 17/519,084, filed on Nov. 4, 2021, U.S. patent application Ser. No. 17/519,092, filed on Nov. 4, 2021, U.S. patent application Ser. No. 17/519,097, filed on Nov. 4, 2021, U.S. patent application Ser. No. 17/519,017, filed on Nov. 4, 2022, U.S. Provisional Patent Application No. 63/284,823, filed on Dec. 1, 2021, U.S. Provisional Patent Application No. 63/292,014, filed on Dec. 21, 2021, U.S. Provisional Patent Application No. 63/339,628, filed on May 9, 2022, and U.S. Provisional Patent Application No. 63/341,711, filed on May 13, 2022, are hereby incorporated by reference for all purposes as if presented herein in their entirety.

The present disclosure generally relates to trays for holding at least one food product.

According to one aspect, the disclosure is generally directed to a tray for holding at least one food product, the tray comprising a plurality of panels extending at least partially around an interior of the tray and comprising a bottom panel, a front panel foldably connected to the bottom panel, a back panel foldably connected to the bottom panel, and a top panel foldably connected to one of the front panel and the back panel, a plurality of end flaps foldably connected to a respective panel of the plurality of panels, the plurality of end flaps at least partially overlapped to form at least one closed end of the tray, and a flange comprising the top panel, the flange extending outwardly from the front panel, the back panel, and the at least one closed end of the tray.

According to another aspect, the disclosure is generally directed to a blank for forming a tray for holding at least one food product, the blank comprising a plurality of panels for extending at least partially around an interior of the tray formed from the blank and comprising a bottom panel, a front panel foldably connected to the bottom panel, a back panel foldably connected to the bottom panel, and a top panel foldably connected to one of the front panel and the back panel, a plurality of end flaps foldably connected to a respective panel of the plurality of panels, the plurality of end flaps for being at least partially overlapped to form at least one closed end of the tray formed from the blank, the top panel for forming a flange extending outwardly from the front panel, the back panel, and the at least one closed end of the tray formed from the blank.

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

Those skilled in the art will appreciate the above-stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures.

Corresponding parts are designated by corresponding reference numbers throughout the drawings.

Trays according to the present disclosure can accommodate articles of numerous different shapes. For the purpose of illustration and not for the purpose of limiting the scope of the disclosure, the following detailed description describes articles such as food products, e.g., fruit or vegetable items. In one embodiment, articles described herein can be fruits such as tomatoes (e.g., cherry tomatoes, etc.), berries (e.g., blueberries, raspberries, blackberries, strawberries, etc.), apples, oranges, tangerines, clementines, lemons, limes, cherries, etc. In another embodiment, articles described herein can be product packages, containers, bottles, cans, etc., that are at least partially disposed within the tray embodiments. The articles can be used for packaging food and beverage products, for example. Packaged articles can be made from materials suitable in composition for packaging the particular food or beverage item, and the materials include, but are not limited to, glass; aluminum and/or other metals; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and Nylon; composite materials; and the like, or any combination thereof.

The articles described herein can include different types of food or beverage products, containers thereof, and/or having different shapes, without departing from the disclosure. In this specification, the terms “lower,” “bottom,” “upper,” and “top” indicate orientations determined in relation to fully erected and upright trays. As described herein, trays can be formed from blanks by overlapping multiple panels, portions, and/or end flaps. Such panels, portions and/or end flaps may be designated herein in terms relative to one another, e.g., “first”, “second”, “third”, etc., in sequential or non-sequential reference, without departing from the disclosure.

is a plan view of an exterior surfaceof a blank, generally indicated at, used to form a container assembly or tray() according to an exemplary embodiment of the disclosure.

As described further herein, the blankcan include engagement features for forming engagement features of the traythat provide one or more surfaces for engaging a machine element or other component of a system associated with the formation, loading, and/or packaging of the tray. In addition, the engagement features of the blank/trayprovide one or more surfaces for receiving a covering or lidding film, e.g., a polymeric film or other cover overlying the trayto maintain one or more conditions of food products held therein.

The blankcan also include reinforcement features for forming reinforcement features of the traythat reinforce, e.g., rigidize, stabilize, and/or otherwise minimize, inhibit, prevent, and/or resist deformation of the engagement features. It will be understood that, in some embodiments, one or more of the reinforcement features of the blank/traycan be considered part of the engagement features of the tray, or vice versa.

As shown, the blankhas a longitudinal axis Land a lateral axis Land includes a plurality of panels for extending at least partially around an interiorof the traywhen the trayis formed from the blank. The panels can include a bottom panel, a back panelfoldably connected to the bottom panelat a lateral fold line, a front panelfoldably connected to the bottom panelat a lateral fold line, and a top panel(broadly, “first top panel”) foldably connected to the front panelat a lateral line of weakening/fold line.

As also shown, a first flange support panelcan be defined between the fold lineand a lateral fold line. In some embodiments, the flange support panelcan be considered a portion of the top panelsuch that the top panelis attached to the front panelat the fold line. In some embodiments, the top panelcan be foldably connected to the support panelat the fold line.

Furthermore, a second flange support panelcan be foldably connected to the back panelat a lateral line of weakening/fold line. In some embodiments, one or both of the flange support panels,can be panels of a plurality of panels of the blank/trayas described herein. In some embodiments, one or both of the flange support panels,can be considered end flaps foldably connected to a respective panel of the plurality of panels of the blank/tray.

With continued reference to, the blankand trayformed therefrom can further include a plurality of end flaps foldably connected to a respective panel of the plurality of panels. The plurality of end flaps can include a first bottom end flapfoldably connected to the bottom panelat respective portion of a longitudinal fold line, a first back end flap(broadly, “first end flap”) foldably connected to the back panelat a respective portion of the fold line, and a first front end flapfoldably connected to the front panelat a respective portion of the fold line.

As shown, the back end flapcan include a base portionfoldably connected to the back panelat the respective portion of the fold lineand a distal portion or attachment portionfoldably connected to the base portionat an oblique line of weakening/fold line.

Furthermore, a second bottom end flapcan be foldably connected to the bottom panelat a respective portion of a longitudinal fold line, a second back end flap(broadly, “second end flap”) can be foldably connected to the back panelat a respective portion of the fold line, and a second front end flapfoldably connected to the front panelat a respective portion of the fold line. The back end flapcan include a base portionfoldably connected to the back panelat the respective portion of the fold lineand a distal portion or attachment portionfoldably connected to the base portionat an oblique line of weakening/fold line.

The plurality of end flaps can further comprise a first top end flap(broadly, “first end flap”) foldably connected to an interior edge of the top panelcircumscribing an openingat a longitudinal line of weakening/fold lineand a second top end flap(broadly, “second end flap”) foldably connected to the top panelat an opposite edge thereof at a longitudinal line of weakening/fold line. In this regard, the top panelextends at least partially around the openingand the top end flaps,can be positioned extending into the opening.

Each top end flap,, as shown, can include a respective base portion,foldably connected to the top panelat the respective longitudinal fold lines,, and a respective distal portion or attachment portion,foldably connected to the respective base portion,at a respective oblique line of weakening/fold line,.

The blankand trayformed therefrom can also include locking features for at least partially maintaining an erected configuration of the tray. Such locking features can include one or more of locking tabs,protruding from the respective front end flaps,and corresponding to respective lines of weakening,interrupting the respective fold lines,adjacent the respective back end flaps,. In this regard, the lines of weakening,extend along the front panel. As described further herein, the locking tabs,are for being at least partially received through the lines of weakening,when the trayis formed from the blank.

As described herein, the engagement features of the blankand the trayformed therefrom can include the top panel. In some embodiments, the engagement features can include one or more of the flange support panels,.

As also described further herein, the reinforcement features of the blankand the traycan include one or more of the flange support panels,.

Referring to, according to an exemplary embodiment of the disclosure, formation of the trayfrom the blankcan be performed by inverting the blanksuch that the exterior surfaceis positioned on a supporting surface and such that an interior surface of the blankcan be positioned facing upwardly.

The end flaps,can be folded at respective portions of the fold lines,into at least partial face-to-face contact with respective portions of the bottom panel, the end flaps,can be folded at respective portions of the fold lineinto at least partial face-to-face contact with respective portions of the front panel, and the end flaps,can be folded at respective portions of the fold lines,into at least partial face-to-face contact with respective portions of the back panel. In the aforementioned arrangement, the end flaps,can be positioned in at least partial overlapping relation.

Simultaneously or thereafter, the attachment portionof the end flapcan be folded at the fold lineand positioned in at least partial face-to-face contact with a respective portion of the base portionof the end flap, and the attachment portionof the end flapcan be folded at the fold lineand positioned in at least partial face-to-face contact with a respective portion of the base portionof the end flap.

The back panelcan be folded at the fold lineinto at least partial face-to-face contact with the bottom panel, and the flange support panelcan be backfolded at the fold lineinto at least partial face-to-face contact with a respective portion of the exterior surface of the back panel.

Simultaneously or thereafter, the top panelcan be folded at the fold lineinto respective portions of the flange support paneland the end flaps,. Such folding can position the end flaps,into at least partial face-to-face contact with respective portions of the end flaps,.

The aforementioned arrangement of panels and end flaps can be at least partially maintained with one or more applications of adhesive such as glue G (). In particular, the interior surface of the respective attachment portions,of the respective end flaps,can be attached/adhered to the exterior surface of the respective end flaps,, the interior surface of the respective attachment portions,of the respective end flaps,can be attached/adhered to the exterior surface of the respective end flaps,, a longitudinally inner portion of the top panelcan be attached/adhered to the flange support panel, and a longitudinally outer portion of the top end panelcan be attached/adhered to the flange support panel.

Furthermore, such arrangement of the panels and flaps of the blank/traycan be considered a collapsed configuration of the tray, e.g., for a space minimizing arrangement for shipping or storage.

As shown in, the traycan be reconfigured from the collapsed configuration to an erected configuration by positioning the front paneland the back panelin spaced and parallel arrangement, both panels,generally upright relative to the bottom panel. The top panelcan also be in spaced and parallel arrangement with the bottom panel.

Simultaneously or thereafter, end flaps,can be folded at respective portions of the fold lines,, e.g., away from the interiorof the tray. Such movement of the end flapcan cause the end flapattached thereto to reconfigure such that the distal portionthereof folds at the fold lineand into at least partial face-to-face contact with the base portionthereof. This movement of the end flapcan also urge the end flap(and, incidentally, the end flapattached thereto) to fold at respective portions of the fold lineinto a generally planar arrangement with the end flaps,. Such at least partially overlapping arrangement of the end flaps,,can form a first closed endof the tray.

Similarly, movement of the end flapcan cause the end flapattached thereto to reconfigure such that the distal portionthereof folds at the fold lineand into at least partial face-to-face contact with the base portionthereof. This movement of the end flapcan also urge the end flap(and, incidentally, the end flapattached thereto) to fold at respective portions of the fold lineinto a generally planar arrangement with the end flaps,. Such at least partially overlapping arrangement of the end flaps,,can form a second closed endof the tray.

Upon positioning the end flaps,as described herein, the locking tabs,protruding from the respective end flaps,can be at least partially received through the respective lines of weakening,in a locking arrangement, e.g., to maintain and/or enhance the erected configuration of the tray. In some embodiments, one or more portions of the respective locking tabs,can engage one or more portions of the back paneland/or respective end flaps,adjacent the respective lines of weakening,.

The aforementioned arrangement provides the panels of the trayextending at least partially around the interiorof the trayand the plurality of end flaps overlapped to form a first closed endand a second closed endof the tray. Due to the relative attachment of longitudinally adjacent end flaps of the plurality of end flaps to one another, reconfiguration of the trayfrom a collapsed configuration to an erected configuration can be accomplished efficiently and smoothly, for example, so as to minimize a required number of steps or associated machinery. For example, positioning the top panelin generally spaced and parallel relation with respect to the bottom panelcan cause the aforementioned reconfiguration of end flaps to form the closed ends,of the tray, e.g., so as to obviate the need to independently position the end flaps.

In this regard, the above-described arrangement of the blankand trayformed therefrom is such that the panels and flaps thereof are generally arranged extending in a single direction, e.g., along the longitudinal axis LI, to facilitate folding and gluing operations along a straight line to facilitate formation of the trayon related forming machinery. For example, upon initial folding of the end flaps,,,,,, further folding operations are all along generally lateral lines of weakening spaced apart along the longitudinal axis LI.

It will be understood that one or more food products can be dropped, placed, or otherwise positioned in the interiorof the trayduring or subsequent to the aforementioned steps. In one embodiment, the food products can be tomatoes, though one or more of the food products can be a different food product without departing from the disclosure. The traycan be provided with one or more food products as a package.

As described herein, engagement features of the trayincludes the top panel, which extends outwardly from the respective panels and closed ends,to form a rim or flangeand one or more engagement surfaces for being engaged/supported by an element associated with a forming apparatus for the tray, for example a machine element such as a grasper, fork, pincer, rail, etc. In one embodiment, the exterior (e.g., downward facing) surface of the flange supporting panels,can present engagement surfaces for being engaged/supported by such a machine component. In other embodiments, engagement surfaces can include any combination of one or more of the exterior, interior (e.g., upward facing), and/or side-facing surfaces of the top panel.

The positioning of the top panelextending away from the panels of the tray, also presents a plurality of engagement/support surfaces for engaging/supporting a covering or lidding film, e.g., a plastic or other polymeric film, or other covering structure. In one embodiment, the lidding film can be provided as a polymeric layer that at least partially deforms in the presence of a heat source, e.g., a heat sealable film. The lidding film can thus be positioned extending across the openingand in contact with one or more surfaces of the top panelto cover the interiorof the trayand maintain one or more conditions of the food products held therein, e.g., freshness, ripeness, moisture content, etc. It will be understood that the lidding film can minimize, inhibit, and/or prevent the passage of one or more materials into the interiorof the tray, for example, condensation or other moisture, insects or other pests, dirt, debris, etc. In one embodiment, the traycan be provided together with the lidding film and one or more food products as a package.

Furthermore, the reinforcement features of the traycan include at least the arrangement of one or both of the flange supporting panels,in at least partial face-to-face contact with respective portions of the underside of the top panel/flange, the engagement of which can minimize, inhibit, prevent, and/or otherwise resist bending, bowing, flexing, buckling, curling, deflection, and/or other deformation of the flange. In this regard, forces exerted on the flangevia tension applied through a covering or lidding film disposed thereon can minimize, inhibit, and/or prevent deformation of the flange, e.g., to avoid undesirable product aesthetics, to avoid at least partial disengagement of the lidding film with the flange, to maintain a generally planar configuration of the flangeduring use, storage, transport, etc. In some embodiments, the locking features of the traycan additionally or alternatively be considered reinforcement features of the tray.

It will be understood that one or more of the panels, flaps, and associated features of the blank/traycan have a different arrangement or configuration without departing from the disclosure. In one embodiment, one or more portions of the traycan be separated at respective lines of weakening to facilitate access to the interiorof the tray.

Turning to, the exterior surfaceof a blankfor forming a trayaccording to a second exemplary embodiment of the disclosure is illustrated. The blankand trayformed therefrom can include one or more components that are the same or similar to those of the blankand trayof the first exemplary embodiment, and like or similar features are designated with like or similar reference numerals.

As shown, the blankhas the longitudinal axis LI, the lateral axis L, the panels,,,,,and associated features, and the end flaps,and associated features. However, the blankand the trayformed therefrom can have a different configuration and arrangement of one or more end flaps foldably connected to a respective panel of the plurality of panels.

In the illustrated embodiment, a back end flapcan be foldably connected to the back panelat a respective portion of the fold line, a bottom end flap(broadly, “first end flap”) can be foldably connected to the bottom panelat a respective portion of the fold line, and a front end flapcan be foldably connected to the front panelat a respective portion of the fold line.

The bottom end flap, as shown, can include a base portionfoldably connected to the bottom panelat the respective portion of the fold line, and a distal portion or attachment portionfoldably connected to the base portionat an oblique line of weakening or fold line. As also shown, a locking tabcan be positioned extending from the attachment portionof the end flap.

Similarly, a back end flapcan be foldably connected to the back panelat a respective portion of the fold line, a bottom end flap(broadly, “second end flap”) can be foldably connected to the bottom panelat a respective portion of the fold line, and a front end flapcan be foldably connected to the front panelat a respective portion of the fold line. The bottom end flapcan include a base portionfoldably connected to the bottom panelat the respective portion of the fold line, and a distal portion or attachment portionfoldably connected to the base portionat an oblique line of weakening or fold line, with a locking tabpositioned extending from the distal portionof the end flap.

In addition, the line of weakeningcan be positioned interrupting the fold lineadjacent the end flapfor at least partially receiving the locking tabwhen the trayis formed from the blank, and the line of weakeningcan be positioned interrupting the fold lineadjacent the end flapfor at least partially receiving the locking tabwhen the trayis formed from the blank. In this regard, the lines of weakening,can at least partially extend along the back panel.

Referring to, according to one embodiment of the disclosure, formation of the trayfrom the blankcan be performed in a manner similar to that described above with regard to the formation of the trayfrom the blank, e.g., by positioning the front paneland the back panelin spaced and parallel arrangement, both panels,generally upright relative to the bottom panel. The top panelcan also be in spaced and parallel arrangement with the bottom panel

However, after inverting the blanksuch that the exterior surfaceis positioned on a supporting surface and such that the interior surface of the blankis positioned facing upwardly, formation of closed ends,of the traycan include folding the end flapat the respective portion of the fold lineinto at least partial face-to-face contact with a respective portion of the back panel, folding the end flapat the respective portion of the fold lineinto at least partial face-to-face contact with a respective portion of the bottom panel, folding the end flapat the respective portion of the fold lineinto at least partial face- to-face contact with a respective portion of the front panel, folding the end flapat the respective portion of the fold lineinto at least partial face-to-face contact with a respective portion of the back panel, folding the end flapat the respective portion of the fold lineinto at least partial face-to-face contact with a respective portion of the bottom panel, and folding the end flapat the respective portion of the fold lineinto at least partial face-to-face contact with a respective portion of the front panel.