System and method for framed lid

A package for retaining a food item includes a tray with a base connected to at least one sidewall. The sidewall extends away from the base to a rim to define an inner chamber. The tray is made of a fluid impermeable material to retain fluids in the inner chamber. The package also includes a shelf made of the fluid impermeable material that is removably supported in the inner chamber such that the shelf is spaced apart from the base of the tray to permit an absorbent pad to be positioned therebetween. The shelf is configured to support the food item in the inner chamber separated from the absorbent pad.

BACKGROUND

Product packages comprising a tray/tub with a film seal and/or a lid are known in the art. Some products require that they be kept sealed from the environment until opened by a consumer. However, current product packages with film seals are cumbersome for the consumer to use, are inefficient in design, and are limited in functionality.

Certain products require that the atmosphere in which they are stored be different than the standard environmental atmosphere and thus the product package must maintain the integrity of the modified atmosphere within the package. As a non-limiting example, some food packages require that the food product be held in a modified atmosphere. Other product packages may have different modified atmospheric requirements, such as an inert gas, nitrogen, etc. Each of these product packages must maintain their respective modified atmospheres for a reasonable period of time so that the product is sold to the consumer in the state intended by the seller.

In the case of food product packages, some tray-with-lid packages have difficulty maintaining a modified atmosphere within the package and therefore the food product is required to be sealed in a pouch which is placed within the tray. While the lid on such a package may be used more than once by the consumer, the product must still be placed in a sealed pouch prior to purchase which requires extra manufacturing steps, additional processing time, further materials, and consequently higher cost. Additionally, the consumer must perform two separate steps to open the package: a first step to remove the lid from the tray, and a second step to remove the product from the pouch.

Other food product packages which have a film sealed to the top of the tray are able to maintain the modified atmosphere inside the package until opened by the consumer. However, these tray-film-lid packages also suffer from similar drawbacks. For example, the consumer must still perform two separate steps to open the package: a first step to remove the lid, and a second step to remove the film.

Still other food packages may only have a tray—with film construction. While these packages only require one step to remove the film, these types of packages are not resealable or reusable by the consumer without resorting to the use of a different sealing material, e.g., a cling-type film, aluminum foil, etc.

Accordingly, there is a need for product packages which are easier to manufacture, easier for the consumer to open, require fewer resources to produce, and are resealable and/or reusable by the consumer.

DETAILED DESCRIPTION

The following description of the present subject matter is provided as an enabling teaching of the present subject matter and its best, currently-known embodiment. Those skilled in the art will recognize that many changes can be made to the embodiments described herein while still obtaining the beneficial results of the present subject matter. It will also be apparent that for some embodiments, some of the desired benefits of the present subject matter can be obtained by selecting some of the features of the present subject matter without utilizing other features. Accordingly, those skilled in the art will recognize that many modifications and adaptations of the present subject matter are possible and may even be desirable in certain circumstances and are part of the present subject matter. Thus, the following description is provided as illustrative of the principles of the present subject matter and not in limitation thereof and may include modification thereto and permutations thereof. While the following exemplary discussion of embodiments of the present subject matter may be directed towards or reference specific systems and/or methods for a product package, it is to be understood that the discussion is not intended to limit the scope of the present subject matter in any way and that the principles presented are equally applicable to other systems and/or methods for a product package.

Those skilled in the art will further appreciate that many modifications to the exemplary embodiments described herein are possible without departing from the spirit and scope of the present subject matter. Thus, the description is not intended and should not be construed to be limited to the examples given but should be granted the full breadth of protection afforded by the appended claims and equivalents thereto.

With reference to the figures where like elements have been given like numerical designations to facilitate an understanding of the present subject matter, various embodiments of a system and method for a novel product package are described.

With attention drawn toFIG. 1, an isometric view of an exemplary product package100is depicted showing a tray/tub110(generally referred to herein as a “tray”), a film or sealing film120, and a lid130according to an embodiment of the present subject matter. In an embodiment, the tray110may be made of a rigid or semi-rigid plastic and may be translucent. The sealing film120is typically flexible and transparent, but may be translucent, and acts to hermetically seal the interior of the product package from an external environment. The lid130may be made of a rigid or semi-rigid plastic and may be translucent. In the embodiment shown inFIG. 1, the lid130may be formed in a ring-like or frame structure with the sealing film120spanning and/or enclosing the center hole in the lid. Thus, the lid/film structure shown inFIG. 1and throughout the other figures may be a hybrid rigid/flexible construction with superior viewing and sealing properties. For embodiments where the sealing film120is transparent, a product placed in the product package100may be placed with a “good” side up to be viewed by a consumer through the sealing film120. This is a more convenient product orientation for the consumer than prior art packages which do not have transparent tops and therefore require the “good” side of the product to face downward for necessitating the consumer to pick up the package and view the product through the bottom of the package.

Further, the product package100is sealable, reusable, and leak-proof thus providing additional benefits to the consumer. In some embodiments, the product package100is also resealable in an airtight and/or watertight manner Because the sealing film120seals an interior space of the product package100from an external environment, the product carried within the interior space (e.g., a food product) need not be sealed within an inner pouch before being placed in the interior space. The elimination of the inner pouch allows for better product definition and visibility and better presentation of the product to the consumer.

Another benefit attributable to the novel design of the product package100is the reduction of materials required to make the package. Since, in particular embodiments, the lid130is a ring-like or frame structure, the material required to manufacture this type of lid is less than the material required to manufacture a whole lid (i.e., without the hole in the middle). This reduction in material may further lead to improvements in case packing, stacking, pallet, and transportation efficiencies. The reduction in material may also afford increased run rates on the production line allowing for more finished goods to be produced. Additional benefits due to the elimination of the inner pouch include: the overall package may be smaller (e.g., have a smaller height) while holding the same quantity of product; the package may be the same size as before but with an increase in the product contained therein; and/or a smaller package size leads to a reduction in the amount of materials needed, reduced packing and stacking heights, and the ability to carry more packages on a pallet.

As will be discussed in more detail below, an important benefit is the ease of accessibility of the product by the consumer since the consumer can access the product in one step rather than taking multiple steps as current packages require.

Now turning toFIG. 2, a partially-exploded isometric view is presented of the exemplary product package100ofFIG. 1during assembly with the sealing film120releasably attached to the tray110before the lid230is engaged with the tray according to an embodiment of the present subject matter.

In an embodiment for assembling the product package100including a product (not shown for clarity), the product is placed in an interior space of the product package100(e.g., the product is placed in the tray110). The tray100is then gas flushed and the sealing film120(which, in an embodiment, may be a laminated film) is releasably sealed directly to the tray110. The sealing film may be sealed to the tray in a predetermined fashion, such as, for example, the film contacting the rim of the tray (e.g., the rim of the sidewall(s) of the tray) or the film contacting a ledge formed in the sidewall(s) of the tray, as will be described in further detail below. In an embodiment, the portion of the film contacting the rim of the tray will comprise a material that will allow for an “easy peel away” function, i.e., be releasably sealed to the rim (or ledge) of the tray. Once the sealing film120is attached to the tray110, the lid230will then be applied to the tray/film assembly. The portion of the sealing film120that is in contact with the lid230will comprise a material that will allow for a relatively permanent bond between the sealing film120and the lid230thereby creating a functional leak-proof, re-sealable, re-useable product package.

As stated above, an additional benefit of the novel product package is the elimination of an inner pouch for holding a product in a modified atmosphere. Also, the hybrid rigid/flexible lid/film covering creates an enhanced leak proof, re-sealable, and reusable finished package. Furthermore, the novel product package allows for printing to appear on the film, such as a design or text, and be product specific with a variety of lid colors, and allows for a colored rim and a clear window in the lid formed by the film to showcase the product for increased product definition and visibility. Current prior art packages are typically limited to one color and require a cardstock or label to be attached to the lid or elsewhere on the package to show graphics.

FIG. 3illustrates a partially-exploded isometric view of the exemplary product package100ofFIG. 1during use by a consumer showing the lid330and the adhering sealing film320being removed from the tray110, according to an embodiment of the present subject matter. As illustrated inFIG. 3, a consumer may access a product in the product package100by simply removing the lid/film assembly in one step. As discussed above, the sealing film, as shown inFIG. 2, is initially releasably sealed to the tray110thereby hermetically sealing the interior of the package from an external environment (and allowing for a modified environment to exist within the package). The sealing film is also more permanently attached to the lid230after the lid is engaged to the tray110during manufacturing. As shown inFIG. 3, when the lid/rim is removed from the finished package by the consumer, the sealing film320will release from the tray110and stay permanently attached to the lid330. Prior art packages require more than one step for a consumer to access the product whereas a unique feature of the novel product package100is a “one-step” opening aspect where the consumer can open the package and access the product in just one step thereby increasing the utility of the product for the consumer.

ConsideringFIG. 4, an exploded elevation view is presented of an embodiment of an exemplary product package400showing the various components of the product package: a tray410, a sealing film420, and a lid430. The tray410may comprise a base portion411and at least one sidewall412having a rim413. While the product package400is depicted as being generally rectangular, any geometric shape is contemplated consistent with the teachings presented herein.

Now consideringFIG. 5, a cross-sectional view of an exemplary product package500showing the sealing film520adhering to the lid530during use of the product package by a consumer, according to an embodiment of the present subject matter. The tray510comprises a base portion511and at least one sidewall512having a rim513. Also shown in this embodiment is a ledge514formed on a sidewall512between the base511and the sidewall rim513. The sealing film520may be releasably attached to the ledge514to seal the inner space of the product package500from an external environment. Alternate embodiments allow for the sealing film520to attach to a sidewall512without the presence of a ledge, such as, for example, to the rim513which is discussed further below with respect toFIG. 8.

FIG. 6illustrates an exploded isometric view of the exemplary product package500ofFIG. 5illustrating detail of the lid530, the sealing film520, sidewall512, sidewall rim513, and the ledge514, according to an embodiment of the present subject matter. As can be seen in this embodiment, the sidewall rim513is formed in an inverted U-shape having an inner rim wall515and an outer rim wall516. The lid530includes a channel533, also formed in an inverted U-shape, for receiving the sidewall rim513when the lid is positioned on the tray510. In this embodiment, the lid530is formed as a ring and/or frame as shown inFIGS. 1-3, and the channel533is formed by an inner lid wall535and an outer lid wall536. The inner lid wall536includes a flange534to which the sealing film520may be fixedly attached. The flange534is dimensioned to mate with the ledge514with the sealing film520disposed therebetween. The ring/shaped lid530circumscribes an opening that is spanned by the sealing film520. In an embodiment, the lid530engages the sidewall rim513by an interference fit between the inner lid wall535and the inner rim wall515. In another embodiment, the lid530engages the sidewall rim513by an interference fit between the outer lid wall536and the outer rim wall516. In a further embodiment, the lid530engages the sidewall rim513by an interference fit between the inner lid wall535and the inner rim wall515and by an interference fit between the outer lid wall536and the out rim wall516.

FIG. 7depicts a cross-sectional view of an exemplary product package700during assembly with the sealing film720releasably attached to a ledge714in a sidewall of the tray710before the lid730is engaged with the tray, according to an embodiment of the present subject matter. As discussed above, the lid730will be positioned on the tray710and fixedly attached to the sealing film720. A consumer may then access the interior space of the product package700by disengaging the lid730from the tray710thereby removing the sealing film720from the ledge714.

With attention now drawn toFIG. 8a cross-sectional view of an exemplary product package800during assembly showing a tray810, a sealing film820, and a lid830, according to another embodiment of the present subject matter. In this embodiment, the sealing film820is releasably attached to the rim813of a sidewall of the tray810. The lid830is positioned on the tray810and fixedly attached to the sealing film820. The lid830may be ring-shaped, as discussed above, or may be a whole lid. In this embodiment, the lid830engages the rim813by an interference fit between an outer lid wall836and an outer rim wall816.

FIG. 9is a flow chart of steps for a method for accessing a product contained within a product package as described herein, according to an embodiment of the present subject matter. At block910, a storage device is provided where the storage device comprises a base connected to at least one sidewall which extends away from the base terminating at a rim and comprises a ledge formed between the base and the rim. At block920, a product is placed in an interior space of the storage device. At block930, a film is releasably attached to the ledge to seal the interior space of the tray from an external environment. At block940a lid is provided where the lid is dimensioned to receive the rim when the lid is positioned on the storage device. At block950, the lid is fixedly attached to the film. At block960, the product is accessed in one step by disengaging the lid from the storage device thereby removing the film from the ledge.

In another embodiment, at block925a gas flush of the interior space is performed after the product is placed in the interior space. In a further embodiment, at block970, the lid is replaced on the storage device.

FIGS. 10-14are various depictions of the exemplary product package ofFIG. 1illustrating details of the interaction of various parts during assembly and/or use of the product package according to an embodiment of the present subject matter. For the sake of simplicity, no product is shown in the package or discussed during the various stages of assembly and/or use of the package although those of skill in the art will readily understand that product would be placed in the product package at the appropriate time during assembly and in an appropriate manner.

FIG. 10is an isometric view, similar toFIG. 1, of an exemplary product package100where depicted is a tray/tub110, a film or sealing film120, and a lid130where, as described above, the sealing film120is releasably attached to a ledge on a sidewall of the tray110and fixedly attached to a flange of the lid. This is a typical configuration for the product package, according to an embodiment of the present subject matter, as it might appear on a store shelf.

FIG. 11illustrates an isometric partially-exploded view of the exemplary product package100during assembly. At this point of the assembly, the sealing film120has been releasably attached to a ledge on a sidewall of the tray110and the lid230has not yet been put in place.

FIG. 12Adepicts an isometric partially-exploded view of the product package100with the sealing film120releasably attached to the tray110as discussed above, and the lid230is then placed on the tray110as indicated by the arrow. The lid230will be prepared in a manner that when placed on the tray110the sealing film120will become fixedly attached to the lid.FIG. 12Bis a partial cross-sectional close-up view of the product package100shown inFIG. 12A. Again, the arrow inFIG. 12Bindicates the lid230being placed on the tray110as described above.

FIG. 13Aillustrates an isometric partially-exploded view of the product package100when a consumer opens the package. The consumer removes the lid330from the tray110and since the sealing film320has been fixedly attached to the lid and releasably attached to the tray, the sealing film is lifted away from the tray along with the lid, thus allowing the consumer access to the product within the package.FIG. 13Bis a partial cross-sectional close-up view of the product package100shown inFIG. 13A.

FIG. 14is a cross-sectional exploded view of the product package100showing the tray110, the lid830, and the sealing film820.FIG. 14indicates that the sealing film820is/will be fixedly attached/sealed to the lid830and is/will be releasably attached/sealed to the tray110, as described in detail above.

FIGS. 15-19are various depictions of another exemplary product package illustrating details of the interaction of various parts during assembly and/or use of the product package according to an embodiment of the present subject matter. For the sake of simplicity, no product is shown in the package or discussed during the various stages of assembly and/or use of the package although those of skill in the art will readily understand that product would be placed in the product package at the appropriate time during assembly and in an appropriate manner.

FIG. 15is an isometric view of another exemplary product package1500where depicted is a tray/tub1510, a film or sealing film1520, and a lid1530. As described above with respect toFIG. 8, the sealing film1520is releasably attached, for example, to a top ledge on a sidewall of the tray1510or to the top of the rim of the sidewall of the tray1510(the following discussion will refer to the rim of the tray for simplicity and should not be construed as limiting the scope of the disclosure in any way), and the sealing film1520is fixedly attached to an underside portion of the lid1530, an embodiment of which will be shown in further detail below. This is also a typical configuration for the product package1500, according to an embodiment of the present subject matter, as it might appear on a store shelf.

FIG. 16depicts an isometric view of the exemplary product package1500during assembly. At this point of the assembly, the sealing film1520has been releasably attached to the rim of the tray1510and a lid has not yet been placed thereon.

FIG. 17Adepicts an isometric exploded view of the product package1500with the sealing film1520dimensioned so as to fit on the rim of the tray1510, and the lid1630positioned above and configured to attach to the tray1510with the sealing film1520disposed therebetween. As discussed above, the sealing film1520will be releasably attached to the tray1510and then the lid1630will be then placed thereon, where the lid1630will have been prepared in a manner that the sealing film1520will become fixedly attached to the lid1630.FIG. 17Bis a partial cross-sectional close-up view of the product package1500shown inFIG. 17A. The downwardly-pointing arrow indicates the sealing film1520releasably attached to the rim of the tray1520and the upwardly-pointing arrow indicates the sealing film1520fixedly attached to the lid1630.

FIG. 18illustrates an isometric partially-exploded view of the product package1500when a consumer opens the package. The consumer removes the lid1830from the tray1510and since the sealing film1820has been fixedly attached to the lid and releasably attached to the tray, the sealing film is lifted away from the tray along with the lid, thus allowing the consumer access to the product within the package1500.

FIG. 19is a cross-sectional exploded view of the product package1500showing the tray1510, the lid1630, and the sealing film1620.FIG. 19indicates that the sealing film1620is/will be fixedly attached/sealed to the lid1630and is/will be releasably attached/sealed to the tray1510, as described in detail above.

An embodiment includes an apparatus, comprising a tray having a base connected to at least one sidewall which extends away from the base terminating at a rim and comprising a ledge formed between the base and the rim; a film releasably attached to the ledge to seal an interior space of the tray from an external environment; and a lid dimensioned to receive the rim when the lid is positioned on the tray, where the lid is fixedly attached to the film, and where the lid is configured to allow a user to access the interior space by disengaging the lid from the tray thereby removing the film from the ledge.

In another embodiment, the lid comprises a channel for receiving the rim when the lid is positioned on the tray. In yet another embodiment, the lid comprises a frame having a channel formed by an outer lid wall and an inner lid wall, where the inner lid wall comprises a flange for attaching to the film, and the frame may circumscribe an opening in the lid with the film spanning the opening.

In still another embodiment, the rim is formed in an inverted U-shape comprising an inner rim wall and an outer rim wall, and the lid comprises a channel formed by an inner lid wall and an outer lid wall for receiving the rim when the lid is positioned on the tray, and where the lid engages the rim by an interference fit between the inner lid wall and the inner rim wall. Other embodiments include a flange attached to the inner lid wall, where the flange is fixedly attached to the film. Further, the flange may mate with the ledge with the film disposed between the flange and the ledge.

In yet still another embodiment, the base is connected to four sidewalls that are arranged to approximate a rectangle.

In a further embodiment, the film comprises a design.

Yet a further embodiment includes an apparatus, comprising a tray having a base connected to at least one sidewall which extends away from the base terminating at a rim, a film releasably attached to the sidewall to seal an interior space of the tray from an external environment, and a lid dimensioned to receive the rim when the lid is positioned on the tray, where the lid is fixedly attached to the film, and where the lid is configured to allow a user to access the interior space by disengaging the lid from the tray thereby removing the film from the sidewall.

A still further embodiment includes a method for accessing a product contained within a storage device, where the method includes the steps of providing a storage device comprising a base connected to at least one sidewall which extends away from the base terminating at a rim and comprising a ledge formed between the base and the rim, placing a product in an interior space of the storage device, releasably attaching a film to the ledge to seal the interior space of the tray from an external environment, providing a lid dimensioned to receive the rim when the lid is positioned on the storage device, fixedly attaching the lid to the film, and accessing the product in one step by disengaging the lid from the storage device thereby removing the film from the ledge.

In yet still a further embodiment, the method includes the step of performing a gas flush of the interior space after the product is placed in the interior space. In an even further embodiment, the method further includes the step of replacing the lid on the storage device.

Turning now toFIGS. 20-32, another exemplary product package2000is shown. In this example, the product package2000can include a tray2010, a shelf2012and an absorbent pad2014. The package2000can be molded to include a base2018and a sidewall2016. The sidewall2016can project upwards from the base2018as shown to define a receptacle or inner chamber2022. The absorbent pad2014can be received into the inner chamber2022. The shelf2012can be positioned over the absorbent pad2014. In the assembled configuration (FIG. 20), food items such as meats can be placed on the shelf2012in the inner chamber2022. A covering film or other cover, as will be described in further detail below, can be placed over the inner chamber2022and/or around the package2000. In such a configuration, the package2000can be used to hold, transport, protect or otherwise retain food items in a convenient, durable, useful and aesthetically pleasing container.

As shown inFIG. 22, for example, the absorbent pad2014can be positioned between the shelf2012and the base2018. The shelf2012can be supported in the inner chamber2022such that the shelf2012is spaced apart from the base2018. In this position, the space between the shelf2012and the base2018forms a well into which run-off, juices or other fluids from a food item can flow away from the food item and be absorbed by the absorbent pad2014and/or be positioned away from the food item.

In one example use, the package2000can be used to hold a meat product such as uncooked chicken. Uncooked chicken can be wet and can expel juices or other drippings after packaging. Consumers often do not like the appearance of uncooked chicken when it is resting in a pool of the juices or other expelled fluids. Additionally, consumers may prefer to handle uncooked chicken that is relatively more dry than uncooked chicken that has been sitting in a pool of its own juices or other expelled fluids. The package2000can address these consumer preferences by supporting the uncooked chicken on the shelf2012away from the base2018. The package2000can include a space between the shelf2012and the base2018that can hold the juices and fluids that can drain from the uncooked chicken. The absorbent pad2014can be positioned under the shelf2012to absorb the juices or other fluids that may drain toward the base2018.

In some processing methods, food items such as uncooked chicken can be processed in a wet process in which the chicken can be submerged in a water and/or phosphate solution. Such wet processing techniques can advantageously maintain the chicken or other food item in the solution to inhibit bacteria or other contaminants from being deposited or accumulating on exposed surfaces. Such wet processing, however, can result in the chicken or other food item being entrained with fluid that can drain or otherwise flow from the chicken or other food item after processing. The packages of the present disclosure allow the fluids to drain from the chicken or other food item and be captured away from the food item(s). The packages of the present disclosure can also be used to package food items processed using other methods (e.g., air-chilled, non-enhanced, or pre-drained/aged processing methods) but are particularly well suited for food items processed using wet processing techniques.

As can be appreciated, the package2000can be used for other items or other foods other than the uncooked chicken described above. Other meats (cooked and uncooked) can be positioned in the package2000. Vegetables, prepared foods, salads, or other items can also be packaged, stored and transported in the package2000.

As shown inFIGS. 20-25, the tray2010can have a rounded rectangular shape such that the tray2010has a length that is greater than its width. The tray2010and other elements of the package2000may be described using the terms “longitudinal” and “transverse” in the present disclosure. The “longitudinal” direction means a direction aligned in or substantially parallel to a direction along the length of the tray2010(i.e., the longer side of the tray2010). The “transverse” direction means a direction substantially perpendicular to the longitudinal direction or a direction aligned in or substantially parallel to a direction along the width of the tray2010(i.e., the shorter side of the tray2010).

While the tray2010can be substantially rectangular in shape, the tray2010can have a bowl shape in that the corners2024can be radiused to show a rounded outer profile. The sidewall2016can also be angled inwardly toward a center of the tray2010. The rounded profile and the inwardly sloping sidewall2016can create the bowl shape of the tray2010. In other examples, the tray2010can have other shapes and other outer profiles. In such examples, the tray2010can have a cube shape, oval shape, round shape or other shapes as may be desired.

The base2018of the tray2010can have a platform2026. The platform2026can be raised above the base2018to define a well2028(FIG. 23). The absorbent pad2014can rest on the platform2026when the absorbent pad2014is assembled into the tray2010. As juices or other fluids flow downward toward the base2018, the fluids can be absorbed by the absorbent pad2014and/or excess fluids can fall into the well2028under the absorbent pad2014. In this manner, the fluids can be removed away from the food product that may be contained in the package2000.

The platform2026in the example shown is oval shaped. The platform can have other suitable shapes such as rectangular, square or others as may be desired. The platform2026can be used as a surface to apply, print or otherwise display product or branding information to the package2000. In some examples, a label can be applied to the bottom surface of the platform2026that is visible to a consumer. In other examples, the platform2026may be configured as one or more raised ribs, projections or other formations that can function as previously described. In still other examples, the base2018of the tray2010can be substantially planar. In such examples, the base2018may not include a platform2026.

In the example shown (FIG. 24), the tray2010may also include one or more features that support the shelf2012when the shelf2012is assembled into tray2010. In the example shown, the tray2010includes a first support2030, a second support2032, a third support2034and a fourth support2036. The second support2032and the fourth support2036can be oriented on the sidewall2016in the longitudinal direction. The first support2030and the third support2034can be oriented on the sidewall2016in the transverse direction.

The supports2030,2032,2034,2036can project inwardly away from the sidewall2016. The supports2030,2032,2034,2036can define a support surface or support plane P1(FIG. 25) on which the shelf2012can be positioned during assembly. Because the supports2030,2032,2034,2036project inwardly, the shelf2012can be restricted from moving toward the base2018. As will be further described, the support plane P1can be positioned at any suitable vertical distance from the base2018in order to provide a desired position of the shelf and/or to provide spacing for the absorbent pad2014.

In the example shown, the supports2030,2032,2034,2036are discrete projections that are positioned around the sidewall2016as previously described. As shown, the second and fourth supports,2032,2036are longer than the first and third supports,2030,2034. The second and fourth supports,2032,2036can be approximately twice as long as the first and third supports,2030,2034. The supports can have other relative sizes as well and also can be configured as a single continuous support that is positioned around the side wall2016. In still other examples, the support plane P1can be defined by a series of projections, darts or other features that can be used to support the shelf2012. The tray2010may also only include supports positioned longitudinally (e.g., only supports2032,2036) or may only include transverse supports (e.g., only supports2030,2034).

The tray2010can also include one or more features that can retain the shelf2012in a desired position once it is seated in the tray2010. In the example shown, the tray2010includes a first retention grip2038, a second retention grip2040, a third retention grip2042and a fourth retention grip2044. The retention grips2038,2040,2042,2044can each be positioned at a corner2024of the tray2010. The retention grips2038,2040,2042,2044can be positioned at a vertical location above the base2018and vertically above the support plane P1such that the shelf2012can be positioned between the supports2030,2032,2034,2036and the retention grips2038,2040,2042,2044. In this manner, the shelf2012can be retained in position on or at the support plane P1.

Each of the retention grips2038,2040,2042,2044can be similar to one another with one of each of the retention grips positioned at a corner2024of the tray2010. For the sake of brevity, the first retention grip2038is described further below. It should be understood, however, that each of the other retention grips, namely, the second retention grip2040, the third retention grip2042and the fourth retention grip2044can be similarly configured.

As shown, the first retention grip2038can project inwardly from the side wall2016. The first retention grip2038can include an outer edge2046that follows the profile of the sidewall2016at the corner2024. The outer edge2046can have an arcuate shape that is shaped similarly to the rounded bowl shape of the tray2010. The first retention grip2038can also include an inner edge2048. The inner edge2048, in this example, has a linear profile that can essentially be a chord of the arc of the outer edge2046. The inner edge2048is positioned inward of the sidewall2016and is closer to a center of the tray2010. In this configuration, the first retention grip can overlap a portion of the shelf2012to retain the shelf in position in the tray2012.

Referring now toFIG. 29, a cross section of the first retention grip2038at the corner2024is shown. The first retention grip2038can also include a top surface2050and a gripping surface2052. The top surface2050can be angled downwardly toward the base2018and include a smooth radius at the inner edge2048. The gripping surface2052can be located on a lower portion of the first retention grip2038and can be rounded and/or angled downwardly toward the sidewall2016. The smooth surfaces of the first retention grip2038allow the gripping surface to contact the shelf2012to retain it in position but also allow fluids to easily flow toward the base2018. In addition, the smooth surface prevent stress concentrations from occurring in the region of the first retention grip2038so that the tray2010resists cracking, breaking or other failures.

In other examples, the retention grips2038,2040,2042,2044can be configured differently. For example, the retention grips can have different shapes or profiles or be of other sizes from that shown in the figures. In one alternate example, the tray2010can only include two retention grips positioned at diagonally opposite corners of the tray2010. In another alternate example, the retention grips can be configured as one or more projections or darts located at one or more of the corners of the tray2010. Still further, alternatively configured trays with retention grips positioned at or near the supports is shown, for example, inFIGS. 38-44.

In other examples, the shelf2012can be retained to the tray using other methods of attachment. In such other examples, the shelf2012can be retained to the tray2010while still permitting the tray to be moved, opened or otherwise removed so that a consumer can access the absorbent pad2014for removal. In such alternate examples, the shelf2012can be movably attached to the tray using a staking process, a living hinge, a male-female mating connector, a releasable adhesive or other suitable feature.

As shown inFIGS. 27 and 28, the shelf2012can have a generally rounded rectangular shape. The shelf2012can also include one or more drain holes2060that can be dispersed along a support surface2058of the shelf2012. The drain holes2060can have any suitable pattern along the shelf2012to allow juices or other fluids to flow from an item that is positioned on the shelf toward the base2018of the tray2010.

The configuration of the tray2010and the shelf2012can also be shaped such that the drain holes2060may not be necessary to allow the fluid from a food item to flow toward the base2018. The smooth shape of the tray2010and the angled sidewall2016can allow the fluid to flow down the sidewall2016toward the base2018. In addition, the shelf2012can be sized such that one or more edges of the shelf2012is spaced apart from the adjacent portion of the sidewall2016when the shelf2012is seated in the tray2010. The edge of the shelf2012and an adjacent portion of the sidewall2016can define a gap through which fluid from a food item can flow toward the base2018. Such gaps, for example, can be located around the entire periphery of the shelf2012or around different regions of the shelf2012, such as the corners, the longitudinal edges and/or the transverse edges. In still other examples, the shelf2012can include one or more notches, slits, scallops, channels or other openings along the edges of the shelf2012to facilitate the drainage of fluids toward the base2018.

The shelf2012may also include one or more elements along the surface of the support surface2058that can limit the food item that is placed in the package2000from moving or sliding along the support surface2058. In the example shown, the shelf2012includes a series of ridges2062that project upwards from the support surface2058. The ridges2062can have a rounded profile and an arcuate shape as shown. In other examples, the ridges2062can have a rectangular profile or other shapes or profiles. The ridges2062can also be shaped as dimples, projections or have other designs, or shaped to include a logo or other design element or word.

When an item, such as a piece of uncooked chicken, is placed in the package2000, the item is supported on the shelf2012and is in contact with the ridges2062. If the package is tipped or angled during shipment or during use by the customer, the ridges2062“grip” the item in the package2000to prevent the item from sliding along the shelf2012and being clumped together in a corner of the package2000. In addition, the ridges2062can stiffen the shelf2012and allow the shelf2012to support a larger weight than it otherwise would be able to support without the ridges2062.

In other examples, such as the example shown inFIG. 32, the package2000can include a shelf2100that is configured differently from the shelf2012previously described. The package2000can be substantially similar to the package2000previously described and can include the tray2010and the absorbent pad2014. The shelf2100can include, for example, ridges2102that project downward or toward the base2018. The general outer profile of the shelf2100can be similar to that previously described such that the shelf2100can be positioned at a vertical location at or near the support plane P1and spaced apart from the base2018. The ridges2102, in this example, can project from the support plane P1toward the base2018to define a cavity in which the absorbent pad2014can be positioned to absorb and retain fluids that may exude from item that is positioned on the shelf2100.

The shelf2100may include one or more drain holes2060that can permit fluids to flow toward the base2018and toward the absorbent pad2014. In this example, the ridges2102may also include one or more apertures2104. The apertures2104can permit fluid that may otherwise be trapped inside the ridges2102to drain toward the base2018and toward the absorbent pad2014. The apertures2104, in the example shown, can be rounded openings but in other examples, the apertures2104can have other shapes or configurations such as rectangular or oval slots. The size of such apertures2104can be of a sufficient size to permit the fluids that may flow from a food item (such as a piece of uncooked chicken) to flow through the apertures2104and not be retained in the ridges2102and/or above the shelf2100due to particulates that may become suspended in the fluid or due to the surface tension of the fluid.

As shown inFIGS. 30-31, the absorbent pad2014can have a truncated rectangular shape. The absorbent pad2014can have a rectangular profile that is then trimmed at each corner to result in the octagonal shape as shown. In other examples, the absorbent pad2014can have other shapes such as rectangular, oval or other shapes. In general, the absorbent pad2014can have any suitable shape such that it can fit inside the tray2010and sit at or near the base2018.

The absorbent pad2014can have one or more layers of material commonly used in the food packing industry. In the example shown, the absorbent pad2014can include an outer layer2078, a middle layer2066and an inner layer2070. The outer layer2078can be a water-resistant layer of material such as a polyethylene film or other suitable material. The middle layer2066can be made of a non-woven fabric that is formed from a water impermeable material such as a polymer film, polyethylene fiber, a polypropylene fiber, a polyester fiber, or the like. The inner layer2068can be made of an absorbent medium or superabsorbent medium such as pulp, cellulosic material or the like. The absorbent or superabsorbent medium can have the property of being able to absorb and retain a significant amount of the fluid material.

Referring back toFIG. 22, the absorbent pad2018can be positioned in the tray2010between the base2018and the shelf2012. As such, a thickness of the absorbent pad2018can be less than the space between the base2018(and/or the platform2026) and the bottom surface of the shelf2012. As shown, the height of this space (denoted as H1inFIG. 22) allows the absorbent pad2018to be in a position to collect the juices or other fluid that may flow downward toward the base2010from a food item packaged in the package2000. The height H1can be configured to allow the absorbent pad2014to expand when it collects fluid. The “dry” height of the absorbent pad2014(denoted as H2inFIG. 22) can be compared with the height H1of the space between the base2018and the shelf2012. In one example, the ratio of the height H1:H2can be 2:1. In another example, the ratio H1:H2can be 3:1. In still other examples, the ratio H1:H2can be 4:1, 5:1, 6:1, 7:1 or 8:1. In another example, the ratio H1:H2is between 2:1 to 5:1. In yet another example, the ratio H1:H2is between 3:1 to 8:1. In other examples, the heights H1and H2can have other relative sizes.

In absorbent pads such as the example pad2014previously described, the outer layers of polymer material can restrict the absorbent middle layer's ability to expand and absorb fluid. Some absorbent materials are able to expand to10xto30xtheir original thicknesses when absorbing fluids. When restricted by polymer outer layers, the inner absorbent layer can be restricted and only increase to 2× or 3× its original thickness. The package2000of the present disclosure can be used with absorbent pads different from the absorbent pad2014previously described.

It can be desirable to use an absorbent pad with outer polymer layers in traditional packages because the pad can contact the food item that is located in the package. In the package2000, however, the food item is supported above the absorbent pad2014by the shelf2012. Since the absorbent pad does not contact the food item, one or more of the polymer layers (i.e. the outer layer2078or the middle layer2068) can be removed from the absorbent pad2014. Such elimination of layers can result in cost saving because of the reduced material and/or reduced processing. Furthermore, the “dry” thickness of the absorbent pad can be reduced in pads without one or more polymer layers because the absorbent material of the middle layer2068can be unrestricted from absorbing fluids to its full absorbency capacity. Such reduction in the “dry” thickness of the absorbent pad can also reduce the cost of the pad and/or reduce the cost and/or size of the package2000.

The packages of the present disclosure can also reduce cost by eliminating the need to affix the absorbent pad2014to the tray2010. In traditional packages, the absorbent pad is often affixed to the tray using a hot melt adhesive or other staking, adhesive, or securing method. Since the absorbent pad2014of the package2000is contained in the chamber2022between the shelf2012and the base2018of the tray2010, the absorbent pad2014does not need to be affixed to the tray2010as would be the case in traditional packages. The packages of the present disclosure can be less costly since the step of affixing the absorbent pad can be eliminated. In addition, the material costs associated with the hot melt adhesive can be eliminated as well. As will be described below, the package2000also allows for simple disposal of the adhesive pad2014(without touching of the adhesive pad2014) to allow the tray2010and the shelf2012to be recycled

The configuration of the package2000as previously described further allows the absorbent pad2014to fully expand to its absorbent capacity. In traditional packaging, the food items can be placed directly on top of the absorbent pad. In these circumstances, the food items can be tightly packed in a manner that does not allow the fluids that may flow from the food items to reach the absorbent pad. Instead, the fluids can pool on top of or between the food items. Testing of traditional packaging has confirmed that as much as 25% to 50% of traditional packages have absorbent pads that remain in a dry or unabsorbed state after packaging.

In addition to sealing fluids from flowing to the absorbent pad, traditional packaging also prevents the absorbent pads from utilizing their absorbent capacities. Since the food items are placed directly on top of absorbent pads in traditional packaging, the weight of the food item(s) can prevent and/or limit the absorbent pad from swelling and utilizing its complete absorbent capacity.

The packages of the present disclosure can address these undesirable aspects of traditional packaging. The packages of the present disclosure separate the food item(s) from the absorbent pad. In the example described above, the food item(s) can be placed on the shelf2012that is spaced apart from the base2018of the tray2010and from the absorbent pad2014. In this configuration, the weight of the food item(s) is supported by the shelf2012and not by the absorbent pad2014or the base2018. This can allow the absorbent pad2014to fully utilize its absorbent capacity. In addition, the shaped of the tray2010, the fit between the shelf2012and the tray2010, and the drain holes in the shelf2012allow fluids to drain from the food item(s) toward the base2018and toward the absorbent pad2014.

Turning now toFIG. 33, the package2000is shown covered in a film wrap2074(shown in dashed lines). The film wrap2074can be any suitable wrap for food products such as a polymer film wrap. The package2000including the tray2010, the absorbent pad2014, the shelf2012and a food item (not shown) can be wrapped in the film wrap2074. After the package2000is wrapped, the package2000can be stored, transported and displayed for retail sale to a consumer. The film wrap2074can be any suitable polymer film wrap and can be a permeable or non-permeable material depending on the type of food item that is placed in the package2000. The type of film wrap2074may also be dependent on whether the food item is packaged in an ambient atmosphere or in a modified atmosphere environment. As can be appreciated, the film wrap can be a barrier or non-barrier material depending on the desired atmosphere of the packaged food item.

As shown inFIG. 26A, the tray2010can include a rim2020around the upper portion of the sidewall2016. The rim2020can include a rim radius2082, a rim wall2084and a rim lip2086. The sidewall2016can curve outward in a rounded shape to define the rim radius2082. The rim radius2082can have any suitable shape but is preferably a smooth rounded shape to permit the film wrap2074to contact the rim at the apex of the rim radius2082to result in a first seal to prevent the leakage of fluids from the package2000.

The rim2020also includes the rim wall2084that can project downward or away from the rim radius2082on a side of the sidewall2016outside of the inner chamber2022. The rim lip2086can be connected to a lower portion of the rim wall2084. The rim lip2086can project outwards away from the rim wall2084. In the example shown, the rim lip2086is oriented substantially parallel to the base2018. The film wrap2074can contact the rim lip2086after the film wrap2074wraps over the rim radius2082and downward toward the base2018. The film wrap2074can create a second seal to prevent the leakage of fluids from the package2000.

As shown inFIG. 26B, an alternatively configured rim2090is shown. In this example, the rim2090can have many of the same features previously described with respect toFIG. 26A. In this example, however, the rim2090can include a groove2092positioned between the rim wall2094and the rim lip2096. The groove2092can have a rounded shape defined by the rim wall2094and an outer rim wall2098as shown. The film wrap2074can be sealed into the groove2092to provide another seal that can prevent the leakage of fluids from the package2000.

In other examples, the package2000can be inserted into a bag or pouch (not shown). In such examples, the bag or pouch serves to seal the contents of the package2000from leaking and from contact with the ambient environment. The bag or pouch can serve a similar function as the film wrap2074previously described. The bag or pouch can be shaped to securely fit around the package2000. In other examples, the bag or pouch can be shrink wrapped around the package2000to engage the rim2020and to form around the other contours of the package2000.

Referring now toFIGS. 34 and 35, a product package3000is shown. The product package3000can incorporate many of the features and/or elements of the product package2000. For example, the package3000can include the basic structure of the tray2010, the shelf2012and the absorbent pad2014. Instead of being covered in the film wrap2074, however, the package3000can incorporate the lid and the sealing film as previously described with respect to packages100,500,700,800and1500. As shown, the package3000can include a lid3002, a tray3004, a shelf3006, a sealing film3008and an absorbent pad (not shown). For the sake of brevity, the various details of the lid, sealing film and the mating structures of the tray are not repeated. It should be appreciated, however, that any of the variations on the lid, sealing film and the tray can be used in conjunction with the package3000.

As shown inFIG. 34, the sealing film3008can be clear or transparent and/or can be substantially free from markings or other graphics. In other examples (FIG. 35), the sealing film3008can include graphic3022that is printed or registered on the sealing film3008. The graphic3022can have any shape or size and can include any type of graphic elements, branding materials or other product information. In still other examples, the sealing film3008can include multiple graphics3022, labels, branding information or other product information. Such graphics, labels, branding information or other product information can also be positioned on the lid3002or be positioned across both the lid3002and the sealing film2008. As can be appreciated, the film wrap2074and/or sealing films120,320,420,520can also be substantially clear or may include one or more graphics, labels, branding materials or other product information.

As previously described, the sealing film3008can be releasably attached and/or sealed to the tray3004and fixedly attached and/or sealed to a frame3010of the lid3002. The lid3002can create a mechanical seal to the tray3004and can also be heat sealed to the tray3004or sealed with an adhesive to the tray3004. In this configuration, a consumer can open the package3000by lifting and separating the lid3002from the tray3004. As such action occurs, the sealing film3008can release from the tray3004in order to access a food item that may be contained in the package3000. The consumer can then reseal the package3000by replacing and lowering the lid3002onto the tray3004. As can be seen, the frame3010of the lid3002can define and/or circumscribe an opening. The sealing film3008can be positioned across the opening to seal the contents of the package3000when the lid3002is positioned on the tray3004. The package3000can also be configured such that a consumer may reseal the package3000by covering the opening of the tray3004with a common cling wrap or plastic film often found in consumer's kitchens.

The tray3004can include a first release tab3012and the lid3002can include a second release tab3014. When the lid3002is positioned on the tray3004, the first release tab3012and the second release tab3014are located at a common corner of the package3000. The first release tab3012and the second release tab3014can be skewed from one another and/or have mismatched shapes such that the outer edges of the first release tab3012and the second release tab3014are not aligned with one another. In this configuration, a consumer can grasp each of the first release tab3012and the second release3014to easily separate the lid3002(and the sealing film3008) from the tray3004.

The package3000may also include a tamper evident sticker3016. The tamper evident sticker3016can be any suitable material that can be attached across a portion of the first release tab3012and a portion of the second release tab3014. When a consumer opens the package3000, the sticker3016clearly displays to the consumer that the package3000has been opened. When the sticker3016is intact or otherwise in its original state, the consumer can have confidence that the package3000has not been opened since it was originally packaged and/or sealed. In the example shown, the sticker3016is a rectangular piece of adhesive material. In other examples, the sticker3016can have other shapes (e.g., circular, square-shaped, star-shaped, polygonal) and can be attached using other fastening methods (e.g., hot melt, shrink-wrapped, etc.).

In other examples, the package3000can include other types of tamper-evident or tamper-resistant features. Such tamper-evident or tamper-resistant features can be included on the tray3004and/or the lid3002. Other types of tamper-evident or tamper-resistant features may include a heat sealed joint between the tray3004and/or the lid3002, a perforated tear tab at a joint between the tray3004and the lid3002, and/or a male/female plug fit on the tray3004and the lid3002.

As shown inFIG. 36, the package2000, in one example, can be sized and configured to permit one or more food items2076that may be positioned inside the package2000to extend above the rim2020of the tray2010. The film wrap2074, in the example shown, can be wrapped over the food items2076and can contact the rim2020such that any fluids that may drain from the food items2076flow into the tray2010. As previously described, the fluids can also be absorbed by the absorbent pad2014positioned under the food items2076in the tray2010.

Depending on the size of the food items2076, the distance that the food items2076may extend above the rim2020can vary. As shown, the food items2076can extend above the rim2020by a vertical distance μl. In some examples, the food items2076may extend above the rim2020by a distance μl that is equal to or greater than 1 inch. In other examples, the food items2076may extend above the rim2020by a distance μl that is greater than or equal to 2 inches. In still other examples, the food items may extend above the rim2020by a distance μl that is greater than or equal to 3 inches. As can be appreciated, food items such as ground meat or de-boned chicken may extend above the rim2020by a distance less than a larger food item such as bone-in chicken pieces, a whole chicken or a pork or beef roast, for example.

The ability of the package2000to accommodate different size food items and to capture fluids that may drain from such food items is advantageous. This functionality and versatility of the packages of the present disclosure allow food producers and/or packagers to reduce the amount of different size packages that are needed to package the various different food items that they may supply to the marketplace. In addition, the ability of the packages of the present disclosure to allow food items to extend above the rim of the package allows producers/packagers to more densely pack multiple packages together and/or to reduce or minimize “empty” space inside the packages. Such advantages can reduce costs for the producer/packagers. Such savings can also extend to retailers that can more densely pack the packages into coolers or other retail spaces.

As shown inFIG. 37, the package2000can include a shelf3020that has a different outer profile from that previously described and shown. In another example of the package2000, the shelf3020can have a rounded cross-shape as shown. In this example, the corners of the shelf3020have a concave rounded profile that are rounded inward toward a center of the shelf3020. With this configuration, the shelf3020can be spaced away from each of the corners2024of the tray2010. The shelf3020can be otherwise similarly configured to that of the shelf2012. While not shown, the shelf3020and/or the tray2010can include one or more retention grips that can retain the shelf3020to the tray2010. In one example, the retention grips can be positioned along the longitudinal or transverse portions of the sidewall to interact with the portions of the shelf3020that may be located adjacent the sidewall.

The shelf3020has a shape with less surface area than that of shelf2012. Subsequently, the shelf3020can be made with less material than that of shelf2012. In one example, the shelf3020has a shape and/or surface area that permits the shelf3020to be nested with one or more of the components of the package2000. In one example, the shelf3020is shaped to permit the shelf3020to be nested with the tray2010during the forming process to reduce the amount of waste material.

Another example package2200is shown inFIGS. 38-40. The package2200can have many of the same features and be configured similarly to the other packages in the present disclosure. The package2200can be similarly configured, for example, to package2000previously described. For the sake of brevity, some of the differences between package2200and package2000are described below.

Package2200can include a tray2210, a shelf2212and an absorbent pad (not shown). The tray2210can be similarly configured as previously described with respect to tray2010. In this example, however, the tray2210can include retention grips2238,2240positioned on the sidewall of the tray at or near the supports2230,2232. Instead of being positioned at or near the corners of the tray2210, the retention grips2238,2240can be positioned at or near approximate mid-points of the sides of the tray2210. While not visible inFIGS. 38 and 39, the tray can have retention grips and supports positioned on opposite sides of the tray2210from retention grips2238,2240and supports2238,2240. The tray2210can include any suitable number of retention grips to retain the shelf2212in a position separated from the base2218of the tray2210. In this manner, the shelf2212can support food items at a position above the base2218of the tray2210to allow fluids to flow into the base2218and/or toward the absorbent pad. In the example shown, the tray2210includes four retention grips2238,2240each positioned on a side of the tray2210. In other examples, the tray2210may include two retention grips. In such examples, the pair of retention grips can be positioned on opposing sides of the tray2210to retain the shelf2212in position.

The tray2210can also include one or more gussets2256. The gussets2256can positioned along the rim2220of the tray210to prevent or minimize leak points that may be induced into the package after the wrapping process. Such leak points can be created if the rim2220of the tray2210buckles during or after the wrapping process. When the tray2210is wrapped, a force is applied to the film wrap2074to smoothly, sealingly and securely wrap the package2200. When such force is used during the wrapping process, the film wrap2074can cause the rim2220of the tray2210to buckle. If buckling occurs in a manner in which the rim2220folds on itself, a sharp point can be created at the point of buckling. This sharp point can pierce, cause abrasion, tear or otherwise compromise the film wrap2074and allow fluids to escape at this leak point. Such leak points are undesirable. The gussets2256assist in minimizing the likelihood that, should buckling occur, that the rim2220will buckle outward and create a sharp point to pierce or otherwise compromise the film wrap2074. Such pre-designed detents, such as gussets2256, can act as a shock absorber to redirect deformation of the tray2210.

In the example shown, the gussets2256can have a rounded concave shape that projects inwardly from the rim2220a center of the tray2210. In other examples, the gussets2256can have other shapes and can be positioned at other locations on the rim2220. In the example shown, the tray2210includes two gussets along each longitudinal side and one gusset on each transverse side. In other examples, the tray2210can include more or less gussets. In still other examples, the tray2210can also or alternatively include ribs, darts or other stiffening features to assist in preventing the rim2220from buckling.

The shelf2212can be similarly shaped as the shelf3020previously described. In the example shown, the shelf2212can include ridges2262that project upwards and away from the base2218of the tray2210. The shelf2212can also include a series of drain holes2264positioned between the ridges2262. The drain holes2264can allow fluids to flow from the food items that may be positioned on the shelf2212to the base2218and/or toward the absorbent pad positioned below the shelf2212. The ridges2262can have any suitable shape, profile or layout and can stiffen the shelf2212and/or assist in limiting movement of the food items in the package2200as previously described.

In another example package2300(FIGS. 41-43), a shelf2312can be configured to have ridges2362that project downwards or toward the base2318of the tray2310. The package2300can be similarly configured as the package2200previously described. As shown, the package2300can include a tray2310, a shelf2312and an absorbent pad (not shown). In such examples, the shelf2312may include one or more apertures2364positioned in the ridges2362to permit fluids to flow toward the base2318and/or the absorbent pad. The shelf2312may be solid between the ridges2362and not include drain holes between the ridges2362. In other examples, drain holes can be positioned between the ridges2362. The tray2310can also include one or more gussets2356along the rim of the tray2310. The gussets2356can be similar to the gussets2256previously described.

As further shown in the packages2200,2300, the shelf2212,2312can include one or more relief features at a location toward the periphery of the shelf2212,2312. In the examples shown, the shelf2212,2312can include a first relief2270,2370, a second relief2272,2372, a third relief2274,2374and a fourth relief2276,2376. The first relief2270,2370can be positioned at or near the first retention grip2238,2338. The second relief2272,2372can be positioned at or near the second retention grip2240,2340. The third relief2274,2374and the fourth relief2276,2376can be positioned at or near the third retention grip and the fourth retention grip, respectively.

In this manner, the shelf2212,2312can include a relief at or near each respective retention grip. The relief can allow the shelf2212,2312to deform at or near the retention grip when the shelf2212,2312is installed into the supported position on the supports at the support plane P1(FIG. 43). When the shelf2212,2312is installed into the supported position, the longitudinal length and/or the transverse width of the shelf2212,2312can be greater than the longitudinal gap and/or the transverse gap between the oppositely positioned retention grips. The reliefs can allow the edges of the shelf2212,2312at the retention grips to deform inwardly toward a center of the tray2210,2310to allow the shelf2212,2312to move past the retention grips. After the edges of the shelf2212,2312have passed the retention grip, the edges of the shelf2212,2312can flex back toward their original positions and be seated under the retention grip to retain the shelf2212,2312in a retained position at the support plane P1.

Turning now toFIGS. 43 and 44, the shelf2312is shown in a supported position in the tray2310. As shown, the retention grip2342can be a formation that projects inwardly from the sidewall of the tray2310toward a center of the tray2310. The retention grip2342can then slope back outwardly at a position above the support2334. In this manner, the retention grip2342and the support2334define a retention groove in which the shelf2312can be retained in position. As shown inFIG. 44, the edge2378of the shelf2312positioned outward of the relief2374can contact the tray2310between the retention grip2342and the support2334.

The relief2374can have an elongated rectangular shape with rounded ends to define an elongated slot. In other examples, the relief2374or the other reliefs positioned at the various edges of the shelf2212,2312can have other shapes or other configurations to permit the edges of the shelf2212,2312to flex during installation or removal. In other examples, the reliefs can be slits in the material, slots that define one or more fingers at the edges of the shelf, living hinges, or the like. While the retention grip2342and the support2334are shown inFIGS. 43 and 44, it should be appreciated that each of the retention grips and supports can be similarly configured on the packages2200,2300.

The tray2010, the shelf2012and/or the shelf3020(or other trays and shelves as described herein) can be formed using any suitable process. Example processes include thermoforming, vacuum forming, injection molding, blow molding or the like. In one example, the tray2010, the shelf2012and/or the shelf3020can be formed from polyethylene terephthalate (PET) using a vacuum forming process. In such a process, a suitable blank of material is placed into a vacuum forming mold that includes the shape of the component to be formed. After the blank of material is heated, the heated blank is pressed into the mold and air is evacuated between the blank and the mold. This action causes the heated blank to come into contact with the mold and the blank to take the shape of the mold. When the formed blank is cooled, the formed component can be removed from the mold. As can be appreciated, a draft angle is often maintained on the part of at least 3 degrees relative to direction substantially perpendicular to a direction of insertion of the blank into the mold. In this manner, the formed component can be easily removed from the mold after cooling.

As shown inFIG. 29, the shape of the retention grip2038can generally violate this general guideline. As shown, the formation of the retention grip2038and particularly the shape of the gripping surface2052, the inner edge2048and/or the top surface2050can cause the tray2010to bind within a traditional vacuum forming mold. To remedy this potential problem, the mold used in forming the tray2010can include a movable insert that forms one or more features of the retention grip2038. The mold can also include other movable inserts for the formation of the retention grips2040,2042,2044. The movable inserts can travel in a direction substantially parallel to the direction of insertion/removal of the blank/formed component in the mold. As the movable inserts move away from the mold, the movable inserts and/or the formed component (e.g., the formed tray2010) can flex in a direction substantially perpendicular to the insertion/removal direction to allow the formed component to “release” from the formation of the movable insert. In such a manner, the vacuum forming process and/or the mold is simplified, is less costly and allows for the formation of the retention grip2038(and the other retention grips of the packages2000,2200,2300).

As shown inFIG. 45, in one example process, the tray2010can be formed from a tray blank3030. As can be seen, the tray blank3023is sized to permit four individual trays2010to be formed at the same time. Given the requirements for the forming process such as a required border and a required spacing between adjacent elements, the material in between and around the trays2010is waste material that is unused and discarded after the forming process. Similarly, the shelf2012, in one example process, if formed from a shelf blank3032(FIG. 46). As shown, four individual shelves2012can be formed at the same time. The material in between and around the shelves2012is waste material that is unused and discarded after the forming process.

In another example process as shown inFIG. 47, the shelf3020can have the alternate shape as described above. Since the shelf3020has a smaller footprint than shelf2012, the shelf3020can be nested between trays2010in the forming process. In this example, four shelves3020can be nested with four trays2010in a combined blank3034. The material between and around the trays2010and the shelves3020in the combined blank3034is waste material that is unused and discarded after the forming process. The total waste material that results from the combined blank3034is less than the total waste material that results from the combination of the waste material from the tray blank3030and from the shelf blank3032. As a result, the use of the shelf3020can result in a cost savings from the reduction of material. In one example, the material reduction can be approximately 8%. In another example, the material reduction can be greater than or equal to 8%. In yet another example, the material reduction can be at least 5%.

In one example forming process, a combined blank3034can be cut having a predetermined size. Such predetermined size can be a size that can accommodate at least four trays2010and four shelves3020. The combined blank3034can then be inserted into a forming mold, such as a mold in a vacuum forming process, and formed into four trays2010. The skeletal waste from the tray forming process can then be inserted into a second forming mold, such as a mold in a vacuum forming process, and formed into four shelves3020. The rounded corners of the shelves3020can have profiles that align with and/or have similar shapes as the outer profile of the trays2010such that the shelves3020can be nested adjacent to the trays2010in the combined blank3034to reduce the waste material from the process in the manner previously described. In other examples, other process can be used such as using a single mold that includes four trays2010and four shelves3020in the single mold.

Turning now toFIG. 48, another example tray3040is shown. In this example the tray3040includes many of the same features and shape as tray2010and such common features are not repeated for the sake of brevity. The tray3040can include one or more additional features that can stiffen and/or resist the risk of the tray3040being deformed during the packaging process. When the tray is wrapped with the film wrap2074(not shown inFIG. 48, but seeFIG. 33for example), the film wrap2074can be secured tightly around the tray to prevent the leakage of fluids out of the tray. The tightly secured film wrap2074can exert forces on the outer perimeter of the tray and cause the tray to deform, crease or buckle. It is undesirable to have such deformation in a finished wrapped package because the deformation is visually unappealing and the deformation can cause points of leakage or lead to holes, tears or other failures in the film wrap2074.

As shown, the tray3040can include one or more longitudinal ribs3042and/or one or more transverse ribs3044. The longitudinal ribs3042can extend from the sidewall2016on one side of the tray3040across the base2018and to the sidewall2016on the opposite side of the tray3040. Similarly, the transverse ribs3044can extend from the sidewall2016on one transverse side of the tray3040across the base2018and to the sidewall2016on the opposite transverse side of the tray3040. The longitudinal ribs3042and the transverse ribs3044can project into the inner chamber of the tray3040and have a rounded profile. In other examples, the tray3040can more or less longitudinal or transverse ribs than that shown in the example. In addition, the longitudinal or transverse ribs can also be of different lengths to add the desired stiffness to the tray3040.

Other example trays are shown inFIGS. 49-53. These example trays can have profiles and shapes that are similar to the tray2010previously described. For the sake of brevity, only those features that may differ from the tray2010are described in further detail below.

As shown inFIG. 49, the example tray4080can include a base4002with one or more support braces4004. The support braces4004can be formed integrally into the base4002and project upward into the inner chamber4006. The tray4080can also include a flexible sheet4008that is positioned on and/or adhered to a perimeter4010of the base4002. The flexible sheet4008can be a polymer film that stretches over the base4002. An absorbent pad (not shown) can be positioned in a well4012between the base4002and the sheet4008. The flexible sheet4008can include perforations, holes, slots or other openings through which juices and/or other fluids can flow from the inner chamber4006and into the well4012. Once in the well4012, the absorbent pad can absorb the fluids.

In this example, the sheet4008can function similarly to the shelf2012previously described but can be co-molded and or printed as part of an integrally formed tray4080. Since the sheet4008can be a thin layer of material, it may not be able to support the weight of a food item that is positioned on the sheet4008. For this reason, the base4002includes the support braces4004previously described. The braces4004can support a food item on the sheet4008and maintain a spacing in the well4012for the absorbent pad. As shown, the braces4004are oriented transversely across the base4002. In other examples, the braces4004can have other shapes or orientations.

As shown inFIG. 50, an example tray4100can include a flexible sheet4102. The flexible sheet4102can include a film portion4104and an absorbent portion4106. The flexible sheet4102can integrate the sheet4008and the absorbent pad (previously described with respect to tray4000) into a unitary component. The film portion4104can be a thin polymer film that is positioned and/or bonded to a perimeter4108of the tray4100. The absorbent portion4106is positioned on a lower surface of the film portion4104such that it can be located between the film portion4104and the base4110in the well4112. The film portion4104can include perforations, holes, slots or other openings that allow juices or fluids to flow from the inner chamber4114of the tray4100onto the absorbent portion4106. In this manner, the juices or fluids can be collected in a position remote from the food item that may be stored in the tray4100. The tray4100can include the support braces4116as previously described.

Another variation of the tray4100is shown inFIG. 51. In this example, the flexible sheet4102has a different shape from that previously described. In this example, the absorbent portion4106of the flexible sheet4102has a shape that is a complimentary shape as that of the braces4116. As can be seen, rather than having a continuous thickness in the longitudinal direction as shown inFIG. 50, the absorbent portion4106in this example fits between each of the support braces4116. In this example, the absorbent portion4106can be positioned in the well4112such that the force exerted by the food item that may be placed in the inner chamber4114of the tray4100does not compress the absorbent portion4106of the flexible sheet4102. The absorbent portion4106can include transversely oriented strips of absorbent material in a pattern consistent with the support braces4116. In examples in which the support braces4116have a different pattern and/or orientation, the absorbent portion4106can also have such different patterns and/or orientations.

Referring now toFIG. 52, another example package4300is shown. The example package4300can include a tray4302, an absorbent pad4304and a film wrap4306. As can be seen, the tray4302can be similarly shaped to the trays previously described. The tray4302, in this example however, can include a platform4310that is formed into the base4306. The platform4310can include a support surface4308on which a food item can be positioned. The platform4310can be vertically offset from a lower surface4320of the base4306. In this manner, the platform4304defines a recess4312into which the absorbent pad4304can be located. The film wrap4306can be wrapped around the tray4302. The film wrap4306can cover and/or enclose an inner chamber4314of the tray4302as well as cover and/or enclose the recess4312. Thus, the film wrap4306can retain the contents of the inner chamber4314in a desired location as well as retain the absorbent pad4304and any fluids that may flow into the recess4312in a desired location.

As further shown, the support surface4308may include one or more drain holes4316. The drain holes4316can permit juices and/or other fluids to flow through the platform4310and toward the absorbent pad4304. The drain holes4316can be positioned in any suitable pattern to enable such drainage or flow of fluids. The tray4302can also include one or more side channels4318. The side channels4318can be positioned on a riser wall4322that connects between the base4320and the support surface4308. Since the support surface4308of the platform4310has a smaller horizontal footprint than the base4320, the tray4302defines a groove4324around support surface4308. Juices and/or fluids collect in and/or flow into the groove4324. The side channels4318permit the juices and/or fluids to flow from the groove4324toward the absorbent pad4304. As shown, the side channels4318can be vertically oriented slots positioned around the support surface4308. In other examples, other perforations, drain openings or channels with different orientations and shapes can also be used.

Another example package4400is shown inFIG. 53. The package4400can include a tray4402and a flexible sheet4404. The tray4402can be substantially similar to the tray4302previously described. As shown, the tray4402can include a platform4408that defines a groove4410and a recess4412as previously described with respect to the tray4302. Instead of using the film wrap4306to cover the recess4412, however, the package4400can include the flexible sheet4404that extends across the recess4412. The flexible sheet can include a film portion4406and an absorbent portion4414. The film portion4406can be a thin layer of polymer material. The film portion4406can extend across the recess4412and prevent juices and/or fluids from leaking out of the tray4402. The absorbent portion4414can be made of absorbent material and can collect the fluids that flow into the recess4412.

In still other examples contemplated by the present disclosure, the package may include a shelf supported in other manners from that described above. In such other examples, a shelf can be placed in a tray and be supported above the base using other support structures. For example, the shelf and/or the base may include legs or support columns that extend downward from the shelf or extend upward from the base. In such examples, the legs or support columns can support the shelf in a position vertically spaced apart from the base of the tray. Such a configuration can result in a chamber in which the absorbent pad can be positioned to absorb fluids than can flow from a food item placed on the shelf in the package. In still other examples, other support structures can be used.

As shown inFIG. 54, one or more packages of the present disclosure can be stacked for transport or processing. The package2000can be nested into a stack4500of two or more packages2000.FIG. 54shows three packages,2000a,2000band2000cstacked together. Since the respective rims2020a,2020b,2020cof the packages2000a,2000b,2000c, are vertically spaced apart from one another in the stack4500, the packages can be easily de-nested from each other. Since the base2018a,2018b,2018cis disposed on the shelf2012a,2012b,2012cof the adjacent package, the packages2000do not nest so closely that separation of the packages2000is difficult.

The packages of the present disclosure and the various components thereof can be disposable, recyclable, compostable and/or reusable. In addition, the package2000can be configured in order to permit a consumer to easily dispose of the absorbent pad2014. It can be desirable to allow a consumer to dispose of the absorbent pad2014without the need for the consumer to touch the absorbent pad2014. The consumer may prefer not to touch the absorbent pad2014due to the fact that the absorbent pad2014has been exposed to juices and/or fluids from uncooked meat. To prevent exposure to such juices and/or fluids or for personal preference, the absorbent pad2014can be easily removed from the package2000.

To accomplish the disposal and/or removal of the absorbent pad2014, a consumer can grip the package2000and turn the package upside down such that the shelf2012that is positioned in the inner chamber2022faces downward over a trash container. The consumer can twist the tray2010such that the opposite transverse ends of the tray2010are rotated in opposite rotational directions. As such twist is induced in the tray2010, the shelf2012can disengage from the retention grips2038,2040,2042,2044. When such disengagement occurs, the shelf2012and the absorbent pad2014can freely fall in a downward direction into the trash container. The consumer has thusly disposed of the absorbent pad2014while only gripping and twisting the tray2010. The other packages of the present disclosure, for example packages2200and2300, can also be utilized by consumer in a similar manner to easily disengage the shelf2212,2312from the tray2210,2310to access and/or dispose of the absorbent pad. This easily access and disposal of the absorbent pad can make the packages of the present disclosure suitable for recycling, washing and/or re-use by the consumer.

The trays, shelves and other elements described in the foregoing disclosure can be made of any suitable rigid or semi-rigid materials including rigid or semi-rigid plastics. In addition, other examples include use of stamped metals, bio-polymers, pulp, paper, paperboard or other suitable materials.

As previously described, the implementation of the packages, elements thereof and related methods can have many benefits and advantages. Among such advantages are increased customer satisfaction, reduction of materials, reduction in packaging costs, increased run rates, increased packing density, and others.

Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results, so long as the result is consistent with the description provided above.