Food Tray with Informational Insert

A food tray has upper and lower tray shaped members and an informational insert sandwiched between them for viewing of an informational display of the insert through a transparent or translucent window portion of at least one of the tray-shaped members. Two interlocking mechanisms are operable to reliably secure the tray members to one another when engaged together by sliding of the lower tray member into place along an underside of the upper tray member. The insert includes a rear wall portion disposed between upstanding rear walls of the tray members, and a height of the upper tray member is reduced at a front edge thereof to provide optimal viewing of the opposing rear wall portion of the insert. A seal positively positioned in a groove of the lower tray member provides a water tight seal between the tray members to protect the informational insert.

DETAILED DESCRIPTION

FIG. 1shows an exploded view of a first embodiment food tray device10of the present invention, which is assembled from a lower or bottom tray-shaped member12, a transparent cover in the form of an upper or top tray-shaped member14, a printed informational insert16, a pair of threaded fasteners18(only one of which is visible), a gasket (not shown), and a fluid control membrane20. When the device is assembled, the membrane20is mounted over an opening in the lower tray12, and the insert16is sandwiched between the upper and lower trays12,14so that printed information on the insert is readable through the transparent upper tray14.

The upper tray12features a rectangular base panel24whose four-sided perimeter defines a front edge24a, a rear edge24bparallel to and opposite the front edge24a, and two side edges24c,24dthat lie parallel and opposite to one another to join the front and rear edges at both ends thereof. A rear wall26stands upward from the base panel24along the rear edge24bthereof at a slight incline sloping outward from over the base panel.

A pair of side walls28,30stand upward from the base panel24along the opposing side edges thereof each extend from the rear wall26to the front edge of the base panel. The side walls28,30are shorter than the rear wall. The rear wall is substantially uniform in height over its full length. The side walls are shorter than the rear wall over the full length of each side wall, and also incline slightly outward from the respective edges of the base panel. A side flange32projects laterally outward from each side wall28,30over part of its length from the rear wall26, but stopping well short of the front edge of the base panel. Each side wall is uniform in height over the length of the respective side flange, and then reduces in height through a linear downward slope toward the front edge24aof the base panel24.

As best shown inFIG. 3, two partial-length front wall34,36are each upstanding from the base panel24at the front edge24athereof from the respective side wall28,30over a partial length of this front edge24a. Each partial-length front wall34is equal in height with the reduced-height front end of the respective side wall. At a central portion of the front edge24aof the base panel, there is either a reduced height front wall section that is substantially shorter than the equal-height partial-length front walls34,36on opposite sides thereof, or no front wall at all, i.e. with the flat topside of base panel defining the maximum height of the upper tray14at this central portion of the front edge24aof the base panel24. As seen inFIG. 3, this central portion38at the front of the upper tray14maximizes the visibility of the rear wall26of the upper tray14from the front side thereof, for reasons set out herein further below.

Referring toFIG. 5, a front lip40depends integrally downward from the front edge of the of the base panel24of the upper tray14to wrap slightly under the otherwise-planar base panel toward the opposing rear edge thereof, thus presenting a rear face42that lies parallel to the front edge of the base panel and faces toward the rear edge of the base panel24at position beneath the same. A series of slots44are recessed into the rear face42of the lip40at positions spaced apart therealong.

As best shown inFIG. 4, the side flange32of each side wall28,30of the top tray14also features a downturned lip46or thickened border region along its outer side edge and front edge of the flange32. On each side flange32, at a rear end of the side lip46athat runs along the outer side edge of the flange, a rear notch48recesses laterally into this lip46aat the inner side thereof that faces toward the respective side wall of the tray14, and forwardly into this lip46aat the rear end thereof. Also on each side flange32, at the corner formed between the side lip46aand the front lip46bthat runs laterally inward from the side lip46ato the respective side wall along the front edge of the side wall flange, a second front notch50recesses forwardly into the rear-facing side the front lip46bof the flange32.

As best shown inFIG. 2, a series of rectangular protrusions52project rearwardly from the rear wall26of the upper tray14at spaced positions therealong at a short height below a rearwardly projecting overhang54at the top edge of the rear wall26. A respective internally-threaded boss56projects rearwardly from the corner formed between the rear wall26and each side wall28,30of the upper tray14.

Referring now toFIGS. 1 and 6to7, the lower tray shaped member12has a similar overall shape to the upper tray member, thus featuring a base panel124with a front edge124a, an opposing parallel rear edge124b, a pair of opposing parallel side edges124c,124dthat interconnect the front and rear edges at opposite ends thereof, and a rear wall126and side walls128,130each upstanding from a respective edge of the base panel at a slight outward incline. Each side wall128,130features a respective side flange132projecting laterally outward from the top end of the side wall. Like in the upper tray, the side flanges lie parallel to the plane of the base panel. The lower tray's base panel slightly exceeds the upper tray base panel in length, as measured between the side edges of each base panel. The lower tray walls are slightly shorter in height than the upper tray walls, and the lower tray flanges are slightly shorter in width than the upper tray walls.

Referring toFIG. 1, a series of rectangular tabs144project forwardly from the front edge124aof the base panel124of the lower tray12at spaced apart locations therealong, with the number of tabs144and the relative positions of same matching the slots44in the rear facing side42of the front edge lip40of the upper tray14. Turning toFIG. 6, on each side flange132of the lower tray12, a rear nub148projects laterally outward from the otherwise linear outer edge of the side flange132at the rear end thereof. On each side flange132of the lower tray, a front nub150projects forwardly from the corner formed between the outer edge of the side flange132and front edge thereof.

Referring toFIG. 8, a series of rectangular recesses152extend into the front side of the rear wall126of the lower tray12at spaced positions along the top edge of the wall at a short height therebelow. The number and relative positions of the recesses152match those of the rectangular protrusions52on the front side of the upper tray's rear wall26. A respective through bore156projects rearwardly through the corner formed between the rear wall126and each side wall128,130of the lower tray12, and has a counter-bored configuration at both ends. A hole120opens through the base panel124of the lower tray member120, and has a stepped or counter-bored configuration where the hole diameter is greater at the top of the tray than at the underside. A Gore-Tex™ membrane sits in the larger diameter top end of the hole to reside over the reduced-diameter opening that passes through the underside of the base panel.

Turning back toFIG. 1, the informational insert16has a similar overall shape to the two tray members12,14, featuring a rectangular base panel portion224, a rear wall portion226upstanding at an oblique angle from a rear edge224bof the base panel portion224, two side wall portions228,230upstanding at oblique angles from respective side edges224c,224dof the base panel portion224, and two side flange portions232each projecting laterally outward from the top edges of the side wall portions in a plane parallel to that of the base panel portion224. Advertising or other printed information (not shown) is displayed on one or more portions of the insert.

The first embodiment tray is assembled as follows. The informational insert16seated atop the lower tray12so that the base panel portion224of the insert overlies the topside of the base panel124of the lower tray12and the membrane recessed therein. The side walls portion228,230of the insert16overlie the inner faces of the side walls128,130of the lower tray12, the side flange portions232of the insert16overlie the side flanges132of the lower tray and the rear wall portion226of the insert16overlies the front face of the rear wall126of the lower tray12. The dimensions of the insert are such that the insert stops short of the boundaries of the lower tray around the full perimeter thereof.

The top tray14is slid onto the bottom tray from the front side thereof, or the stacked bottom tray12and insert are slid under the top tray from the rear side thereof with all thee of these components having their widths in general alignment with one another, whereby the tray members slide relative to one another along the parallel planes of their base panels in a direction drawing the front edges of the two trays toward one another and the rear edges of the trays toward one another. The side flanges of the two trays likewise slide along one another through this process.

Under sufficient relative sliding of the trays in this manner, the tabs144at the front end of the of the lower tray are brought into mating engagement within the matching slots144are the rear face42of the top tray's front lip40, which coincides with mating insertion of the rectangular protrusions52on the back of rear wall26of the upper tray14into the rectangular recesses at the front of the rear wall126of the lower tray12, and the mating insertion of the front and rear nubs148,150of each side flange132of the lower tray12into the front and rear notches48,50of the upper tray14. This sliding of the trays into this engaged state also inserts the bosses56at the rear corners of the top tray14into the front ends of the through-bores156at the rear corners of the lower tray, abutting each boss against the front face of a reduced diameter central portion of the respective through-bore.

With the upper and lower trays mated in this manner, rear walls and side walls of the two trays lies closely adjacent one another, with respective portions of the informational insert sandwiched between the trays at these walls and at the base panels and side flanges of the trays12,14. The male/female engagement of the tabs and slots, nubs and notches, and protrusions and recesses at the front, rear and sides of the trays provides a first interlocking action between the trays in order to effectively hang the lower tray from the upper tray in close adjacency thereto in order to securely retain the informational insert in a sandwiched condition between the two trays.

A second interlocking action is provided by threading a respective headless set screw or headed threaded fastener18into the matingly threaded bore of each of the internally threaded bosses56of the top tray14through the respective through-bore156in the rear of the lower tray. This threaded engagement prevents sliding of the trays relative to one another along the parallel planes of their base panels, thereby preventing disengagement of the first interlocking action. The male-female engagement of the trays along the parallel axes of the male-female pairings of slots and tabs, protrusions and recesses, and nubs and notches prevents vertical separation of the trays. The abutment of the front edge of the lower tray against the rear face of the front lip of the upper tray prevents separation of the trays in one horizontal direction, and the threaded fasteners prevent separation of the trays in the other horizontal direction. Use of slide-together male female features on all sides of the tray provides significant stability in the closely-abutted sandwiched configuration of the trays and insert around the full perimeter thereof with only a minimal number of threaded fasteners, thereby easing the assembly and disassembly process. It will be appreciated that the second interlocking action may be provided by means other than threaded fasteners, for example using snap-fit fasteners or quarter-turn fasteners, and that the fasteners may be engaged between the two trays at locations other than at the rear walls thereof. Where threaded fasteners are used, internally threaded metal inserts may be used within the trays to increase the strength and integrity of the threaded connection compared to embodiments where the plastic of the trays forms the threads to which the fasteners engage.

The informational insert may have printed advertising or other information or indicia on any one of more of its different portions. In the illustrated embodiments, the top tray is transparent or sufficiently translucent over its full expanse to maximize the possible advertising space of the assembled tray by allowing viewing of the insert over the full area of the trays. Other embodiments may employ one or more translucent or transparent viewing windows spanning only partial portions of the overall upper tray, with other portions of the upper tray being opaque or otherwise obscured. With the reduced height of the tray assembly at the front edge thereof, as provided by the reduced height of top tray at all or part of the front edge thereof, a user is intended to use this front edge of the tray assembly as the access area from which they reach food or beverage items occupying the base panel of the top tray member. Such orientation of the assembled tray relative to the user places the large, upright rear wall of the top tray, and thus the rear wall portion of the insert, at a position and orientation readily viewable to the tray user with minimal obscuring of the same from the front of the tray, thereby increasing the advertising or informational effectiveness compared to prior art trays that employ only base-panel insert placement or have wall-placed advertisement features that are obscured by other equal-height walls around the perimeter of the tray.

A groove160runs around the perimeter of the lower tray14, along the front edge124aof the lower tray base panel124, up the front edge of the side wall and along the top edge thereof to the respective side flange132, where it runs around the top side of the respective side flange, first outwardly along the front edge of the side flange, rearwardly along the outer side edge of the side flange, and then back inwardly along the rear edge of the side flange, from where it then runs across the rear wall126of the lower panel at the top edge thereof. A gasket (not shown) is placed in the groove160prior to assembly of the trays to form a seal between the trays around the full perimeter thereof outside of the area spanned by the informational insert sandwiched between the trays.

At the top edge of the rear wall of the lower tray, the gasket seals against the overhang54at the top edge of the rear wall of the upper tray. The gasket also seals between the topside of the lower tray side flanges and underside of the upper tray side flanges, the rear ends of which are continuous integral extensions of the rear wall overhang54.

On each side of the top tray, a respective out-turned connection lip62integrally connects the downturned lip40at the front edge of the top tray with the downturned lip46bat the front edge of the respective side flange32, first running up the front edge of the respective side wall and then rearward along the top edge thereof, as best shown inFIG. 5. The gasket seals against the underside of the top tray's base panel24along the front edge124aof the bottom tray's base panel124, and along each connection lip62out to the respective pair of matching side flanges. The gasket thus forms a continuous seal between the two tray members around the full perimeter of the assembly, thereby protecting the information insert against penetration of liquid into the space between the trays. Thus, the same insert can be used repeatedly, and the tray assembly can even be washed by hand or machine without requiring replacement or removal and reinsertion of the insert.

The Gore-Tex™ membrane20recessed into the top face of the lower tray base panel to enable flush seating of the information insert over the base panel, acts to help protect the information insert16and trays from moisture-related complications. Gore-Tex™ fabric is known to allow air, and water vapour molecules in the air, to pass through it in one direction, while preventing passage of liquid water through the fabric in the opposing direction. Accordingly, the membrane is oriented in a position allowing water vapour to escape from the space between the trays while preventing liquids from accessing this space through the membrane-covered opening in the bottom tray. Through cooperation of the gasket and membrane, the assembly thus remains significantly water-tight to protect the informational insert, while still allowing escape of water vapour that may have become trapped inside the assembly. The membrane thus acts as a valve to control entry and exit of fluids to and from the insert-containing space of the assembly by preventing liquid access while allowing vapour discharge. An example of another membrane material which may be employed is Tyvek™.

The top and bottom trays are preferably formed of sufficiently rigid molded plastic, although other materials or constructions capable of providing a full or partial area viewing window in the top tray and sufficient rigidity in the overall tray assembly to support the weight of food and beverage items may be employed. The bottom tray may be opaque, transparent or translucent. In embodiments where the bottom try is transparent over at least a portion of its surface area, the insert may be printed on both sides to enable viewing of information on the insert through both the top tray and bottom tray. The trays therefore may be configured to not only display information as viewed from the front and top of the assembly, but also from one or more of the sides, rear and underside of the assembly. The insert may be made of paper or cardstock, or other relatively thin materials or structures capable of displaying advertising or other information printed or otherwise displayed on the insert.

While the first embodiment features rectangular trays with side and rear walls, it will be appreciated that other tray shapes and wall configurations that still allow engagement of the trays together through relative sliding between the base panels may alternatively be employed. For example, even circular trays with curved side edges, or polygonal trays with non-parallel linear segments at its side edges, may still slide together in the back-front direction if there are no side walls that would block sliding in this direction.

FIG. 10illustrates a second embodiment tray assembly10′ that again features upper and lower trays14′,12′ that slide together to form a first level of engagement, and then are further secured in this engaged state by use of threaded fasteners engaging the two trays together at their rear walls. One notable difference in the second embodiment is the lack of side walls and side flanges on the lower tray12′, which instead features only the rectangular base panel124′ and rear wall126′. As a result of this, the arrangement of male/female features involved in the first interlocking action between the trays is somewhat different than in the first embodiment.

More particularly, while the second embodiment tray assembly10′ uses the same tab and slot engagement of the upper and lower trays14′ at the front edge of the lower tray and the front edge lip40′ of the upper tray, the lack of side walls and side flanges in the lower tray prevents use of the flange-mounted nubs and notches of the first embodiment. Instead, referring toFIG. 11, the upper tray14′ features not only the front edge lip40′ with spaced apart slots44′ therein, but also features matching downturned side edge lips at the opposite side edges of the base panel24′. Each such side edge lip forms a track or rail200that runs along the respective side of the base panel24′ along the underside of the base panel24′ from the rear edge thereof to the front edge lip40′. Each track defines a respective channel202that opens horizontally toward the other track at the opposing side edge of the base panel24′, and extends from an open rear end202aof this channel beneath the rear edge of the base panel24′ to a closed front end of this channel202badjacent the front edge of the base panel24′, where this end202bof the channel is closed off by the downturned front edge lip40′.

Turning toFIG. 12, each side edge of the base panel124′ of the lower tray12′ is reduced in thickness compared to the main span of the tray's base panel between the side edges, as best shown at204, where this reduction of edge thickness from the underside of the base panel124′ can be seen to create an overhanging extent of the topside of the base panel124′. This overhang204resides over an apparent cutaway206or open space beneath it. Turning back toFIG. 11, the height of the channel204in each rail202of the upper tray14′ slightly exceeds the thickness of the overhanging edge204of the lower tray12′ at the respective side thereof, whereby the male feature defined by the overhanging side edge204projecting from the full thickness remainder of the tray fits slidingly into the female feature defined by the channel202of the upper tray14′ from the open rear end202aof the channel. So inserted, sliding of the overhanging side edge204of the lower tray member along the channel202continues until the two tray members are fully engaged by receipt of the front edge tabs of the lower tray in the front lip slots44′ of the upper tray14′.

The engagement of the lower tray side edge204with the side edge rail channels202of the upper tray thus forms a male-female engagement of features at the sides or outermost lateral extents of the lower tray in order to engage the trays together, much like the mating of the nubs and notches at the side flanges of in the wider side-flanged lower tray of the first embodiment. It will be appreciated that forward and lateral jutting nubs at the front and rear ends of the side edge of the lower tray may alternatively cooperate with notches in the downturned side lip200and front lip40′ instead of using a slide-rail engagement over the substantially full length of the tray side edges. However, the slide-rail fit may provide improved self-alignment when mating the two trays together. Each bottom corner of the rear wall126′ of the lower tray12′ may jut laterally outward past the reach of the overhanging side edge204of the lower tray12′, as best shown at208inFIG. 12, in order to cap off the rear end of the track or rail200of the upper tray member, as shown inFIG. 10.

Another difference in the second embodiment compared to the first is the presence of through-holes210in the lower tray12′ at locations within, and spaced apart along, a groove that extends fully around the perimeter of the lower tray at the top face of the base panel and front face of the rear wall (like groove160of the first embodiment). The groove is again intended for seating therein of a seal212therein that is suitably sized and made of suitable water tight resilient material, for example silicone, to form a water tight sealed condition between the two tray's when engaged and fastened together. As shown inFIG. 13, the seal212features integral or attached resilient enlargements214at spaced apart locations along the seal212. The enlargements jut downwardly from the seal at the side and front portions thereof that run along the side edges and front edge of the lower tray member, while the enlargements at the rear portion of the seal that runs along the top edge of the lower tray's rear wall project rearward from the seal. The enlargements are sized to engage snugly within the holes210that communicate through the lower tray12′ into the bottom of the seal-receiving groove therein, whereby under insertion of the enlargements into the holes210while pressing the seal into the groove, the enlargements frictionally hold the seal in place in order to positively position the seal in the groove and maintain this proper position of the seal around the perimeter of the lower tray during the sliding together of the two trays to ensure the proper seal in the resulting tray assembly. It may be possible to achieve the same effect using recesses in the bottom of the groove instead of through-holes210passing fully through the tray12′.

Although not shown the drawings, o-ring seals may be disposed around each of the threaded fasteners to better maintain a liquid tight condition between the tray members.

Another feature unique to the second embodiment tray assembly is the presence of one or more sets of adjacent parallel ridges216lying perpendicular to the side edges of the base panel124′ of the lower tray12′ on the underside thereof, for example near the four corners of the base panel124′ as shown inFIG. 10. The ridges protrude from the otherwise substantially flat underside of the base panel to provide frictional gripping areas to aid in sliding apart of the two trays from one another, for example when switching out one informational insert for another. The second embodiment also differs in an increased number of threaded bosses56′ on the rear wall of the upper tray and matching fastener holes or bores156′ in the rear wall of the lower tray, providing a series of each spaced apart along the top side fof the respective rear wall, and a further pair of each near opposite ends of the rear walls where they join to the respective base panels.