Tray for Food Products

The present application claims priority to U.S. Provisional Patent Application No. 63/638,485, filed on Apr. 25, 2024.

The disclosure of U.S. Provisional Patent Application No. 63/638,485, filed on Apr. 25, 2024, is hereby incorporated by reference for all purposes as if set forth in its 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 one or more food products, the tray comprising a plurality of panels extending at least partially around an interior of the tray, the plurality of panels comprising a bottom panel, a plurality of side panels foldably connected to the bottom panel, a plurality of corner panels foldably connected to a respective side panel of the plurality of side panels and at least partially forming a plurality of gussets of the tray, at least one handle activation panel foldably connected to a respective side panel of the plurality of side panels, and at least one handle panel foldably connected to the respective side panel of the plurality of side panels and separable from the at least one handle activation panel at a cut, and handle features comprising the at least one handle panel, the at least one handle panel positionable extending outwardly from a respective panel of the plurality of panels to form at least one handle of the tray.

According to another aspect, the disclosure is generally directed to a blank for forming a tray for holding one or more food products, the blank comprising a plurality of panels for at least partially around an interior of the tray formed from the blank, the plurality of panels comprising a bottom panel, a plurality of side panels foldably connected to the bottom panel, a plurality of corner panels foldably connected to a respective side panel of the plurality of side panels and for at least partially forming a plurality of gussets of the tray formed from the blank, at least one handle activation panel foldably connected to a respective side panel of the plurality of side panels, and at least one handle panel foldably connected to the respective side panel of the plurality of side panels and separable from the at least one handle activation panel at a cut, and handle features comprising the at least one handle panel, the at least one handle panel positionable extending outwardly from a respective panel of the plurality of panels to form at least one handle 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 one or more food products, the method comprising obtaining a blank, the blank comprising a plurality of panels comprising a bottom panel, a plurality of side panels foldably connected to the bottom panel, a plurality of corner panels foldably connected to a respective side panel of the plurality of side panels, at least one handle activation panel foldably connected to a respective side panel of the plurality of side panels, at least one handle panel foldably connected to the respective side panel of the plurality of side panels and separable from the at least one handle activation panel at a cut, and handle features comprising the at least one handle panel, positioning the plurality of panels extending at least partially around an interior of the tray, positioning the plurality of corner panels at least partially forming a plurality of gussets of the tray, and forming a handle from the at least one handle panel such that the at least one handle panel is positionable extending outwardly from a respective panel of the plurality of panels.

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. In some embodiments, 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. In some embodiments, articles described herein can be food products that may be provided in discrete portions, for example, chicken nuggets, chicken strips, French fries, chips, and/or other food items that can commonly be referred to as finger foods. Such food products can also include sandwiches or the like, for example, chicken sandwiches, hamburgers, tacos, burritos, etc. In some embodiments, articles described herein can be food products that are arranged as prepared foods or prepared meals that can include one or more portions of a dish ready to be heated and served to a customer. In some 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 tray() according to an exemplary embodiment of the disclosure. In some embodiments, the blankcomprises paperboard (e.g., solid bleached sulphate folding boxboard), or other suitable material that can be recyclable and/or suitable for use in an oven (not shown).

The blankcan be formed from a single ply of material, such as but not limited to paperboard, cardboard, paper, a polymeric sheet, and/or a laminate that includes more than one layer. In some embodiments, the blankcan include a microwave interactive layer (not shown) such as is common in MicroRite® containers available from Graphic Packaging International of Atlanta, GA. The microwave interactive layer can be commonly referred to as, or can have as one of its components, a susceptor, a foil, a microwave shield, or any other term or component that refers to a layer of material suitable for shielding microwave energy and/or causing heating in a microwave oven.

As described further herein, the blankincludes handle features for forming handles(broadly, “first handle” or “second handle”) of the trayformed from the blank. In some embodiments, the handle features and handlesformed therefrom can provide an outwardly-extending structure of the trayby which a user can grasp the trayto lift, carry, move, etc., the tray. Such an upper structure of the traycan be particularly advantageous, for example, in situations in which food products are heated, e.g., in a conventional or microwave oven, or deposited into the trayin a heated condition, such that it is desirable to have one or more handles extending away from the interiorof the trayin which such heated items are positioned so as to minimize, reduce, inhibit, and/or prevent the transfer of heat from the interiorof the trayto the user's hands and/or fingers.

As shown, the blankhas a longitudinal axis L1 and a lateral axis L2 and 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 first side panel(broadly, “second side panel” or “third side panel” or “fourth side panel”) foldably connected to the bottom panelat a lateral fold line, a second side panel(broadly, “first side panel” or “third side panel” or “fourth side panel”) foldably connected to the bottom panelat a lateral fold line, a third side panel(broadly, “first side panel” or “second side panel” or “fourth side panel”) foldably connected to the bottom panelat a longitudinal fold line, and a fourth side panel(broadly, “first side panel” or “second side panel” or “third side panel”) foldably connected to the bottom panelat a longitudinal fold line.

The blankcan also include a plurality of end flaps/corner panels/corner flaps foldably connected to respective panels of the plurality of panels of the blank. In the illustrated embodiment, the corner panels can include, in clockwise relation: a first corner panel(broadly, “respective first corner panel” or “respective second corner panel”) foldably connected to the side panelat an oblique fold line; a second corner panel(broadly, “respective first corner panel” or “respective second corner panel”) foldably connected the side panelat an oblique fold lineand to the third side panelat an oblique fold line; a third corner panel(broadly, “respective first corner panel” or “respective second corner panel”) foldably connected to the third side panelat an oblique fold line; a fourth corner panel(broadly, “respective first corner panel” or “respective second corner panel”) foldably connected to the third corner panelat an oblique fold lineand foldably connected to the second side panelat an oblique fold line; a fifth corner panel(broadly, “respective first corner panel” or “respective second corner panel”) foldably connected to the second side panelat an oblique fold line; a sixth corner panel(broadly, “respective first corner panel” or “respective second corner panel”) foldably connected to the fifth corner panelat an oblique fold lineand foldably connected to the fourth side panelat an oblique fold line; a seventh corner panel(broadly, “respective first corner panel” or “respective second corner panel”) foldably connected to the fourth side panelat an oblique fold line; and an eighth corner panel(broadly, “respective first corner panel” or “respective second corner panel”) foldably connected to the seventh corner panelat an oblique fold lineand foldably connected to the first side panelat an oblique fold line.

As described further herein, adjacent corner panels (e.g., foldably connected corner panels) of the plurality of corner panels of the blankand traycan together form gussets of the blankand trayformed therefrom, and relative portions of each gusset can be arranged in at least partial overlapping and/or face-to-face contact upon formation of the tray. In some embodiments, adjacent corner panels of the blank/traycan be devoid of a foldable connection.

In particular, the corner panels,can form a gussetfoldably connected to each of the side panels,at the respective fold lines,, the corner panels,can together form a gussetfoldably connected to each of the side panels,at the respective fold lines,, the corner panels,can together form a gussetfoldably connected to each of the side panels,at the respective fold lines,, and the corner panels,can together form a gussetfoldably connected to each of the side panels,at the respective fold lines,.

With continued reference to, the handle features of the blankand trayformed therefrom for forming a handleof the traycan include a first handle activation panel(broadly, “second handle activation panel”) foldably connected to the third side panelat a longitudinal fold line, and a second handle activation panel(broadly, “first handle activation panel”) foldably connected to the fourth side panelat a longitudinal fold line.

Each handle activation panel,, as shown can include and/or be associated with a respective handle panel(broadly, “first handle panel” or “second handle panel”) at least partially separable therefrom at a respective cutthat intersects the respective fold line,. Accordingly, each handle panelcan be foldably connected to the respective side panel,at a portion of the respective fold line,.

As shown, each cutcan have a generally bracket-shaped configuration, with a generally longitudinal segment that intersects a respective pair of generally oblique or generally lateral segments. The respective longitudinal segments can transition to the respective oblique or lateral segments at respective curved portion of the respective cut. It will be understood that one or both of the cutscan have a different configuration without departing from the disclosure.

Each cut/handle panelcan intersect a respective access openingformed by a respective cut in the respective handle activation panel,. While the access openingsare shown as having a generally semicircular configuration, it will be understood that one or both of the access openingscan have a different configuration without departing from the disclosure.

It will be understood that the handle features of the blankand the trayformed therefrom can include one or both of the handle panelsand associated features. In some embodiments, the handle features of the blankand trayformed therefrom can include one or both of the handle activation panels,and associated features.

Turning now to, formation of the trayfrom the blankaccording to an exemplary embodiment of the disclosure will be described.

The blankcan be positioned with the exterior surfacefacing downwardly, for example, on a supporting surface such as a conveyor, bedplate, table, etc., and with an interior surface of the blank(e.g., on a plane opposite the exterior surface) facing upwardly.

The side panels,,,can be at least partially folded upwardly at the respective fold lines,,,into an at least partially upright relationship with the bottom panel. In some embodiments, the panels,,,can be obliquely arranged relative to the bottom panelsuch that the traycan have a generally downwardly tapering configuration.

The aforementioned movement of the side panels,,,can cause the respective gussets,,,to activate, e.g., reconfigure. For example, the corner panels,can fold relative to one another at the fold lineinto at least partial face-to-face contact and can further fold at the respective fold lines,such that the corner panelis positioned in at least partial face-to-face contact with the side paneland such that the corner panelis exposed facing outwardly on the gusset.

Similarly, the corner panels,can fold relative to one another at the fold lineinto at least partial face-to-face contact and can further fold at the respective fold lines,such that the corner panelis positioned in at least partial face-to-face contact with the side paneland such that the corner panelis exposed facing outwardly on the gusset.

The corner panels,can fold relative to one another at the fold lineinto at least partial face-to-face contact and can further fold at the respective fold lines,such that the corner panelis positioned in at least partial face-to-face contact with the side paneland such that the corner panelis exposed facing outwardly on the gusset.

The corner panels,can fold relative to one another at the fold lineinto at least partial face-to-face contact and can further fold at the respective fold lines,such that the corner panelis positioned in at least partial face-to-face contact with the side paneland such that the corner panelis exposed facing outwardly on the gusset.

Such activation of the gussets,,,can cause adjacent side panels of the panels,,,to draw closer together into generally abutting relation. However, the arrangement of the respective gussets,,,can be such that a generally continuous surface is provided by the panels,,,,,,,,,,,,, e.g., so as to be generally devoid of seams or discontinuities. Such an arrangement can, in some embodiments, minimize, inhibit, prevent, and/or otherwise avoid inadvertent leakage or egress of material from the interiorof the tray associated with one or more food products, e.g., condensation, runoff, etc.

The handle activation panels,can be folded downwardly at the respective fold lines,into at least partial face-to-face contact with the respective side panels,. In this regard, in some embodiments, the handle activation panels,can provide reinforcement to the side panels,. For example, the overlapping relationship of the handle activation panels,and the respective side panels,can provide a two-ply relationship that can minimize, inhibit, prevent, and/or otherwise avoid bending, bowing, buckling, creasing, tearing, other deformation, etc., of the side panel,, e.g., incidental to use.

illustrates the handlesof the trayin a folded or inactivated configuration in which the handle panelsare positioned folded generally downwardly and/or in at least partial face-to-face contact with the respective side panel,.

As shown in, the handlescan be reconfigured from the inactivated configuration to an outward or activated configuration in which the handle panelscan be separated from the respective handle activation panels,at the respective cutsand folded at the respective portions of the fold lines,into an arrangement that is generally outwardly relative to the interiorof the tray. As described herein, an arrangement extending away from the interiorof the traycan be one in which the handle panelsextend away from an aligned relationship over the bottom panel. In this regard, the handle panelsare repositionable between a downwardly folded position and an outwardly extending position to provide the handlesreconfigurable between the inactivated configuration and the activated configuration.

In some embodiments, the handle panelscan separate from the respective handle activation panels,at the respective cutsincidental to the aforementioned folding of the handle activation panels,at the respective fold lines,. In some embodiments, the handle panelscan be separated by a user or machine component, for example, by engaging a free edge of the respective handle panelexposed by the respective access openingwith a finger or machine component, and urging the respective handle panelinto the aforementioned arrangement.

The handle panelsare thus arranged as handlesin a freely extending and accessible relationship by which a user can grasp the handles, for example, with his or her fingers, and lift the handlesto lift, move, reposition, etc., the remainder of the trayto which the handlesare attached. In some embodiments, the foldable connection of the handle panelsto the remainder of the trayat the respective fold lines,can allow the remainder of the trayto allow for flexion/hinging/pivoting of the handlesat the respective fold lines,, for example, to provide stability of the traywhen being carried or moved. In some embodiments, the handlescan be provided so as to give the overall appearance and function of handles that are typically provided on a metal or ceramic pot or serving tray, to enhance a serving or dining experience, entice customers, etc.

It will be understood that the aforementioned arrangement of the traycan be at least partially maintained with one or more applications of an adhesive such as glue.

With additional reference to, it will be understood that one or more articles such as one or more food products P can be positioned in the interiorof the trayat one or more points during the formation thereof. In some embodiments, one or more food products P can be positioned in the interiorof the trayprior to heating, for example, in a conventional or microwave oven.

Accordingly, the trayis provided with handle features for forming at least one handleconfigured and arranged not only to allow a user to grasp the trayin a convenient manner, but also to avoid discomfort or injury associated with close contact with one or more food products P in the interiorof the traythat can be heated, e.g., so as to minimize, reduce, inhibit, and/or prevent the transfer of heat from the interiorof the trayto the user's hands and/or fingers.

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

The blanks according to the present disclosure can be, for example, formed from coated paperboard and similar materials. For example, the interior and/or exterior sides of the blanks can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blank. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. In accordance with the above-described embodiments, the blank may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the trays, to function at least generally as described above. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.

In accordance with the above-described embodiments of the present disclosure, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features.

As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the spaced apart slits to be replaced with a continuous slit, a continuous score, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure. Also, a tear line can be a series of cut scores passing completely, or partially, through the material, that are separated by nicks.

The term “glue” is intended to encompass all manner of adhesives commonly used to secure tray panels in place.

Any of the blanks, trays, or other constructs of this disclosure may optionally include one or more features that alter the effect of microwave energy during the heating or cooking of a food item that is associated with the tray or other construct. For example, the blank, tray, container, or other construct may be formed at least partially from one or more microwave energy interactive elements (hereinafter sometimes referred to as “microwave interactive elements”) that promote heating, browning and/or crisping of a particular area of the food item, shield a particular area of the food item from microwave energy to prevent overcooking thereof, or transmit microwave energy towards or away from a particular area of the food item. Each microwave interactive element comprises one or more microwave energy interactive materials or segments arranged in a particular configuration to absorb microwave energy, transmit microwave energy, reflect microwave energy, or direct microwave energy, as needed or desired for a particular construct and food item.

In the case of a susceptor or shield, the microwave energy interactive material may comprise an electroconductive or semiconductive material, for example, a vacuum deposited metal or metal alloy, or a metallic ink, an organic ink, an inorganic ink, a metallic paste, an organic paste, an inorganic paste, or any combination thereof. Examples of metals and metal alloys that may be suitable include, but are not limited to, aluminum, chromium, copper, inconel alloys (nickel-chromium-molybdenum alloy with niobium), iron, magnesium, nickel, stainless steel, tin, titanium, tungsten, and any combination or alloy thereof.

Alternatively, the microwave energy interactive material may comprise a metal oxide, for example, oxides of aluminum, iron, and tin, optionally used in conjunction with an electrically conductive material. Another metal oxide that may be suitable is indium tin oxide (ITO). ITO has a more uniform crystal structure and, therefore, is clear at most coating thicknesses.

Alternatively still, the microwave energy interactive material may comprise a suitable electroconductive, semiconductive, or non-conductive artificial dielectric or ferroelectric. Artificial dielectrics comprise conductive, subdivided material in a polymeric or other suitable matrix or binder, and may include flakes of an electroconductive metal, for example, aluminum.

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

In still other embodiments, the microwave energy interactive material may interact with the magnetic portion of the electromagnetic energy in the microwave oven. Correctly chosen materials of this type can self-limit based on the loss of interaction when the Curie temperature of the material is reached. An example of such an interactive coating is described in U.S. Pat. No. 4,283,427.

The use of other microwave energy interactive elements is also contemplated. In one example, the microwave energy interactive element may comprise a foil or high optical density evaporated material having a thickness sufficient to reflect a substantial portion of impinging microwave energy. Such elements typically are formed from a conductive, reflective metal or metal alloy, for example, aluminum, copper, or stainless steel, in the form of a solid “patch” generally having a thickness of from about 0.000285 inches to about 0.005 inches, for example, from about 0.0003 inches to about 0.003 inches. Other such elements may have a thickness of from about 0.00035 inches to about 0.002 inches, for example, 0.0016 inches.