Blanks, Trays, and Associated Methods for Holding Food Products

The present application claims the benefit of U.S. Provisional Patent Application No. 63/656,739, filed on Jun. 6, 2024.

The disclosure of U.S. Provisional Patent Application No. 63/656,739, filed on Jun. 6, 2024, is hereby incorporated by reference for all purposes as if set forth in its entirety.

The present disclosure generally relates to laminate structures/blanks, constructs such as trays formed therefrom, and associated methods for holding one or more food products.

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 the interior of the tray, the plurality of panels comprising a central panel and a plurality of side panels in at least partial face-to-face contact with respective portions of the central panel, the plurality of panels arranged to form a tray bottom, a sidewall extending upwardly from the tray bottom, and a flange extending outwardly from the sidewall, each panel of the plurality of panels comprising a laminate structure, the laminate structure comprising a base layer and a barrier layer, the plurality of side panels positioned at least partially reinforcing the flange 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 extending at least partially around the interior of the tray formed from the blank, the plurality of panels comprising a central panel and a plurality of side panels for being positioned in at least partial face-to-face contact with respective portions of the central panel when the tray is formed from the blank, the plurality of panels for being arranged to form a tray bottom, a sidewall extending upwardly from the tray bottom, and a flange extending outwardly from the sidewall when the tray is formed from the blank, each panel of the plurality of panels comprising a laminate structure, the laminate structure comprising a base layer and a barrier layer, the plurality of side panels for being positioned at least partially reinforcing the flange 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 comprising a plurality of panels, the plurality of panels comprising a central panel and a plurality of side panels, each panel of the plurality of panels comprising a laminate structure, the laminate structure comprising a base layer and a barrier layer. The method further comprises positioning the plurality of panels extending at least partially around an interior of the tray, positioning the plurality of side panels in at least partial face-to-face contact with respective portions of the central panel, arranging the plurality of panels to form a tray bottom, a sidewall extending upwardly from the tray bottom, and a flange extending outwardly from the sidewall, and at least partially reinforcing the flange of the tray with the plurality of side 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.

Various aspects of the disclosure may be understood further by referring to the figures. For purposes of simplicity, like numerals may be used to describe like features. It will be understood that where a plurality of similar features are depicted, not all of such features necessarily are labeled on each figure. It also will be understood that the various components used to form the constructs may be interchanged. Thus, while only certain combinations are illustrated herein, numerous other combinations and configurations are contemplated hereby.

Constructs such as 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 at least partially disposed upon or within the construct embodiments.

The articles can include, but are not limited to, fresh food products such as meat products (e.g., ground meat, sliced meat, diced meat, sausage, cured meat, etc.), fish products, fast food products, take-out products, meal leftovers, and the like, or any combination thereof. Examples of such products can include pastries (e.g., filled or frosted pastries), breads, fruit bars, French toast sticks, fish, chicken (such as chicken nuggets, chicken strips, chicken fingers, etc.), popcorn, peanuts, candy, French fries (such as waffle fries, steak fries, shoestring fries, curly fries, etc.), sandwiches, pizza, calzone, turnover, burrito, or any other food product that may be provided for consumption by a consumer. In this specification, the terms “inner,” “interior,” “outer,” “exterior,” “lower,” “bottom,” “upper,” and “top” indicate orientations determined in relation to fully erected and upright constructs such as trays.

As described herein, constructs such as trays may be formed by multiple overlapping panels, end flaps, and/or other portions of blanks. Such panels, end flaps, and/or other portions of the blanks can be designated in relative terms to one another, e.g., “first”, “second”, “third”, etc., in sequential or non-sequential reference, without departing from the disclosure.

Referring to, a schematic cross-sectional view of a laminate structurefor forming a blank(),(),(),(),(),(),(),() and/or a tray(),(),(),(),(),(),(),() for holding one or more food products is illustrated according to an exemplary embodiment of the disclosure.

As shown, the laminate structurecan include a base layercomprising a composite materialand a barrier layerlaminated to the base layerand comprising a barrier material.

The composite materialcan comprise a paper or paperboard product such as kraft paper, parchment, clay-coated paperboard, solid bleached board (SBB) paperboard, solid bleached sulphate (SBS) paperboard, Kraft line paperboard, cardboard, or another suitable material that may be degradable, compostable, and/or repulpable. In some embodiments, the base layercan be comprised of composite materialin a thickness of between and including about 0.010 inches and about 0.015 inches, for example about 0.012 inches, though a different arrangement can be provided without departing from the disclosure.

The barrier materialcan comprise a polymeric material, for example, polyethylene terephthalate (PET). In some embodiments, the barrier materialcan be provided to form a barrier layerwith a thickness of between about 45 gauge and about 50 gauge, for example, about 48 gauge, though the barrier materialcan have a different configuration and/or arrangement without departing from the disclosure.

The laminate structurecan be formed by arranging the base layerand the barrier layerin respective overlapping relation. Such an arrangement can be provided through lamination processes that include, for example, rollers and nips, chemical deposition, the application of one or more adhesives, etc.

In some embodiments, the laminate structurecan be provided in a different arrangement. For example, in some embodiments, the laminate structurecan be provided with two barrier layers, one of each laminated on opposite sides of the base layer.

Referring additionally to, an exterior surfaceof a blankfor forming the trayis illustrated according to a first exemplary embodiment of the disclosure. The blankcan be formed from the laminate structure, though it will be understood that a different material arrangement can be provided to form the blank.

As shown, the blankcan have a longitudinal axis L, a lateral axis L, and one or more panels. In the illustrated embodiment, the blankcan include a base panel or bottom panel or main panel or central panelfoldably connected to a pair of side panels(broadly, “first side panel” and “second side panel”) at respective longitudinal fold line.

The central panel, as shown, can include a central portionand a marginal portionextending at least partially around the periphery thereof. Respective corner portionsof the central panelcan be at least partially defined proximate respective pluralities of lines of weakeningthat include respective lateral, longitudinal, and oblique lines of weakening in series adjacent and approximating the curvature of respective curved free edges of the central panel.

In the illustrated embodiment, the respective pluralities of lines of weakeningextend inwardly from a respective curved free edge of the central paneltoward the central portionthereof.

Similarly, each side panelcan include a central portionand a marginal portionextending at least partially therearound. Respective corner portionsof the side panelscan be at least partially defined proximate respective pluralities of lines of weakeningthat include respective lateral, longitudinal, and oblique lines of weakening in series adjacent and approximating the curvature of respective curved free edges of the respective side panel, with the respective lines of weakening extending inwardly thereof toward the central portion.

It will be understood that, prior to further processing, the respective side panelsof the blankcan be folded at the respective fold lineinto at least partial face-to-face contact with the central panel. In such an arrangement, the corner portionsof the side panelscan be generally aligned with the respective corner portionsof the central panel.

Turning to, a schematic representation of a forming apparatusfor reconfiguring the blankinto a trayis illustrated. As shown, the forming apparatuscan include a male forming member, e.g., an anvil or other member having one or more protruding surface features, and a female forming member, e.g., a mold/cavity of other member having one or more recessed surface features complementary to the surface features of the male forming member.

In the illustrated embodiment, the male forming memberand the female forming membercan be arranged so as to be movable relative to one another, e.g., such that one or both of the male forming memberand the female forming membercan be configured to move toward and/or away from the other of the male forming memberand the female forming member.

In this regard, the blankcan be positioned between the male forming memberand the female forming memberon one or more supporting structures. One or more of the forming members,can be drawn together/approximated toward one another such that one or more of the protruding surface features of the male forming memberurges a portion of the blankinto the corresponding recessed feature of the female forming member. Such action of the forming apparatuscan cause at least partial deformation/and or reconfiguration of the blankinto the tray.

Referring additionally to, the trayformed from the blankis illustrated according to the first exemplary embodiment of the disclosure. As shown, the traycan be formed from plurality of panels extending at least partially around an interiorthereof, with the central portionof the central panelat least partially forming a tray bottomand a sidewallextending upwardly therefrom.

The sidewallof the traycan extend to a rim or flangeextending outwardly from the sidewalland positioned in generally spaced and planar relation with the tray bottom.

The rim or flangecan be at least partially formed from the marginal portionof the central paneland the respective marginal portionsof the respective side panelsoverlapped thereupon.

In this regard, when the trayis formed from the blankin the manner described above, the respective pluralities of lines of weakening,can facilitate at least partial deformation, such as stretching, of the respective overlapped corner portions,to form cornersof the trayalong the flange.

Furthermore, the respective central portionsof the respective side panelscan be positioned overlapping respective portions of the central portionof the central panelto at least partially form respective portions of the flange, the sidewall, and the tray bottom. Such overlapping arrangement of the respective side panelscan at least partially reinforce the flange, the sidewall, and the tray bottom, e.g., so as to provide resistance to deformation such as bending, flexing, bowing, buckling, etc.

Turning to, a cross-sectional view of a portion of the trayis illustrated, showing the overlapping arrangement of a respective portion of the central paneland a respective portion of a respective side panel. Such an arrangement can include, from the interiorof the trayto an exterior environment: a base layerassociated with the central panel, a barrier layerassociated with the central panel, a barrier layerassociated with the side panel, and a base layerassociated with the side panel.

Such an overlapping arrangement of panels of the trayformed from the laminate structurecan thus provide a superior tray structure that can include increased strength due to the multi-ply arrangement thereof, as well as enhanced barrier properties at least partially due to the contacting relationship of the barrier layerassociated with the central paneland the barrier layerassociated with the respective side panel.

In this regard, the traycan receive one or more food products in the interiorthereof, and can have a relatively increased resistance to failure due to the multi-ply arrangement of the tray. Furthermore, fluids incidental to one or more food products in the interiorof the tray, for example, runoff, blood, juices, moisture due to condensation, seasonings, food additives or treatments, etc., can have an increased resistance to egress from the interiorof the trayto an exterior environment due to the contacting relationship of the barrier layerassociated with the central paneland the barrier layerassociated with the respective side panel, which can minimize, inhibit, prevent, and/or otherwise avoid the passage of fluids thereby.

It will be understood that, in some embodiments, an upper surface of the flangeof the traycan present 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 a top opening of the trayin contact with one or more surfaces of the flangeto 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 some embodiments, the traycan be provided together with the lidding film and one or more food products as a package.

In this regard, the reinforcement of the flangeprovided by the at least partial overlapping arrangement of the respective side panelscan at least partially maintain a generally flat and outward arrangement of the flange, for example, under tensile and/or compresses stresses generated by the engagement of the lidding film with the flange. Furthermore, in high-moisture content environments, the reinforcement of the flangeby the side panelscan at least partially maintain an integrity of the flangein the presence of moisture.

With additional reference to, the exterior surfaceof a blankfor forming a tray() according to a second exemplary embodiment of the disclosure is illustrated. The blankcan be formed of the laminate structureand can have an arrangement generally similar to the blankdescribed above, though one or more portions thereof can have a different arrangement and/or orientation.

For example, and as shown, the central paneland side panelscan be reoriented to generally extend along the longitudinal axis L, e.g., such that the side panelsare foldably connected to the central panelat respective lateral fold lines.

In this regard, and with additional reference to, the traycan be formed from the blankin a manner generally similar to that described above with respect to the formation of the trayfrom the blank, with similar advantages and functionality.

Turning to, the exterior surfaceof a blankfor forming a tray() according to a third exemplary embodiment of the disclosure is illustrated. The blankcan be formed of the laminate structureand can have an arrangement generally similar to the blanks,described above so as to include the central paneland associated features.

The blankand trayformed therefrom can include additional side panels foldably connected thereto, such that a side panel is foldably connected to each side of the central panel. In the illustrated embodiment, a pair of side panels(broadly, “first side panel” and “second side panel”) can be foldably connected to the central panelat respective lateral fold lines.

Each side panelcan include a central portionand a marginal portionextending at least partially therearound. Respective corner portionsof the side panelscan be at least partially defined proximate respective pluralities of lines of weakeningthat include respective lateral, longitudinal, and oblique lines of weakening in series adjacent and approximating the curvature of respective curved free edge portions of the corner portionsof the respective side panel, with the respective lines of weakening extending inwardly thereof toward the central portion.

In the illustrated embodiment, the side panelscan have an at least partially triangular configuration at portions extending away from the corner portionsthereof, e.g., so as to have a generally tapered configuration.

With continued reference to, a pair of side panels(broadly, “third side panel” and “fourth side panel”) can be foldably connected to the central panelat respective longitudinal fold lines. Each side panelcan include a central portionand a marginal portionextending at least partially therearound. Respective corner portionsof the side panelscan be at least partially defined proximate respective pluralities of lines of weakeningapproximating the curvature of respective curved free edge portions of the corner portions of the respective side panel, with the respective lines of weakening extending inwardly thereof toward the central portion.

In the illustrated embodiment, the side panelscan have an at least partially triangular configuration at portions extending from the corner portionsthereof, e.g., so as to have a generally tapered configuration. As shown, the side panelscan taper to a respective blunted or flat free edge.

With additional reference to, the traycan be formed in a manner generally similar to that described above with respect to the formation of the trays,from the blanks,, with similar advantages and functionality.

For example, the respective side panelsof the blankcan be folded at the respective fold linesinto at least partial face-to-face contact with the central panel. In such an arrangement, the corner portionsof the side panelscan be generally aligned with the respective corner portionsof the central panel. Further, the respective side panelscan be folded at the respective fold linesinto at least partial face-to-face contact with the central panelsuch that the respective corner portionsthereof are generally aligned with the respective corner portionsof the central panel. In such an arrangement, the free edges of the side panels,can be in general alignment such that the side panels,substantially overlie, e.g., in at least partial face-to-face contact with, the exterior surfaceof the central panel.

The blankcan be positioned between the male forming memberand the female forming memberof the forming apparatus() or another forming apparatus and further formed into the traythereby in a manner generally similar to that described above with respect to the action of the forming apparatuson the blank/tray.

In this regard, the traycan be formed from plurality of panels extending at least partially around an interiorthereof, with the central portionof the central panelat least partially forming a tray bottomand a sidewallextending upwardly therefrom.