Abstract:
There is provided a backer card for use with a tray comprising rows of compartments, wherein adjacent compartments are separated by a corresponding recess, the backer card comprising: a central portion, at least one side portion and at least one locking tab extending from the central portion to the at least one side portion. The at least one locking tab is configured to be insertable into the recess.

Description:
[0001]    The present invention relates generally to containers and in particular, to a backer card for providing support to a container so that it may be stacked in an upright position. 
       BACKGROUND OF THE INVENTION 
       [0002]    Food products can come packaged in trays within containers. One conventional type of container includes a thermoformed tray. Several conventional lidding materials are available for covering conventional trays. Lidding materials may be metal foil, flexible plastic wrap or rigid plastic. 
         [0003]    One such container disclosed in U.S. Patent Application Publication No. 2010/0230411 is a container for food product and includes a film affixed to a food tray. The film forms a top of the container and has an access opening. The sealing label, adhesively sealed to the top around the opening, is re-sealable when a tab of the sealing label is pulled back. The sealing label is re-sealable against the top layer to seal the opening when the label is moved back against the top. In one form, the sealing label extends along the top of the container and seals along a portion of the film which is affixed to one or more top end surfaces of walls forming the tray. 
         [0004]    Another such container disclosed in U.S. Pat. No. 6,918,532 is a container for a food product and includes a wrapper which surrounds a frame. The container can be any polygonal shape which is defined by the shape of the frame. The wrapper forms a top of the container which has an access opening. A sealing layer is adhesively sealed to the top around the opening. The sealing layer is re-sealable when a tab of the sealing layer is pulled back. The sealing layer is re-sealable against the top layer to seal the opening when the sealing layer is moved back to a flat position on the top. Various tamper-evident structures are provided to indicate when the container has been initially opened or tampered with. 
         [0005]    Such containers are effective when the container is positioned horizontally, or “lying down”. However, when it is desired or required to position the container vertically, or “standing up”, the containers are less effective and it may be difficult to prevent the container from falling over. Accordingly, there exists a need for improvements to trays and containers such the container is better suited to be maintained in an upright position. 
       SUMMARY OF THE INVENTION 
       [0006]    In accordance with an aspect of the present invention there is provided a backer card for use with a tray comprising rows of compartments, wherein adjacent compartments are separated by a corresponding recess, the backer card comprising: a central portion; at least one side portion; and at least one locking tab extending from the central portion to the at least one side portion, wherein the at least one locking tab is configured to be insertable into the recess. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which: 
           [0008]      FIG. 1  is a front view of a backer card; 
           [0009]      FIG. 2  is an isometric view of the backer card of  FIG. 1 ; 
           [0010]      FIG. 3  is an isometric view of a sample tray (prior art); 
           [0011]      FIG. 4  is an isometric view of the backer card of  FIG. 1  in use with the tray of  FIG. 3 ; 
           [0012]      FIG. 5  is an isometric view of a container comprising the backer card and tray of  FIG. 4 ; 
           [0013]      FIG. 6  is an isometric view of the container of  FIG. 5  in a partially open configuration; 
           [0014]      FIG. 7  is a front view of another embodiment of a backer card; 
           [0015]      FIG. 8  is an isometric view of the backer card of  FIG. 7 ; and 
           [0016]      FIG. 9  is a front side view of another embodiment of the backer card. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0017]    For convenience, like numerals in the description refer to like structures in the drawings. Referring to  FIG. 1 , a front view of a backer card is illustrated generally as reference numeral  100 . As can be seen, backer card  100  comprises a central portion  102 , a first side portion  104 , a second side portion  106  and a plurality of locking tabs  108 . The first side portion  104  is bendable relative to the central portion  102  about a first line of flex  110 . The second side portion  106  is bendable relative to the central portion  102  about a second line of flex  112 . 
         [0018]    In this embodiment, six locking tabs  108  are provided. Three locking tabs  108  are provided along each of the first line of flex  110  and the second line of flex  112  providing a top locking tab  108   a,  a middle locking tab  108   b  and a bottom locking tab  108   c.    
         [0019]    Each of the locking tabs  108  is configured to extend from the central portion  102  to a corresponding one of the first side portion  104  or the second side portion  106 . Each locking tab  108  is generally rectangular in shape and formed by creating a top slit  114  along a top length of the locking tab  108  and a bottom slit  116  along a bottom length of the locking tab  108 . 
         [0020]    Referring to  FIG. 2 , an isometric view of the backer card  100  with the first side portion  104  and the second side portion  106  folded is illustrated generally as reference numeral  200 . The first side portion  104  is folded at angle θ 1  with respect to the central portion  102 . The second side portion  106  is folded at angle θ 2  (not shown) with respect to the central portion  102 . Further, the locking tabs  108  are shown in a lock position. In the lock position, each locking tab  108  comprises a first member  202  extending from the central portion  102  and a second member  204  extending from the first side portion  104  toward the second side portion  106 . The second member  204  extends from the first side portion  104  at an angle φ 1  with the first member  202  that is equal to the angle θ 1  formed by the first side portion  104  and the central portion  102 . Although only the locking tabs  108  for the first side portion  104  are visible in  FIG. 2 , the locking tabs  108  for the second side portion  106  are similarly configured. 
         [0021]    Referring to  FIG. 3  an example of a typical tray is illustrated generally as reference numeral  300 . The tray has a length  301 , a width  303  and a height  305 . The tray  300  comprises a plurality of distinct compartments  302  defined, at least in part, by dividers  308 . The dividers  308  between adjacent compartments  302  are spaced apart creating recesses  304  between the compartments  302 . The compartments  302  are dimensioned to fit food. Thus, although the compartments  302  are illustrated having a squared-off bottom portion  302   a,  the bottom portion  302   a  may take other contours, depending on the food. For example, for the tray  300  used for storing Oreo® cookies, the bottom portion  302   a  is rounded. 
         [0022]    The backer card  100  is to be positioned behind the tray  300  to provide support thereto. Thus, thus it will be appreciated that the configuration of the backer card  100  is closely related to the tray  300  for which it will provide the support. That is, the dimensions of the backer card  100  rely, at least in part, on the dimensions of the tray  300 . For example, the central portion  102  is configured to be at least as wide as the width  303  of the tray  300 . Depending on the implementation, the length of the backer card  100  may not need to be the same as the length  301  of the tray  300 . Only a fraction of the length  301  of the tray  300  may be sufficient to provide the necessary support. 
         [0023]    Similarly, the size, position and number of locking tabs  108  may depend on the recesses  304  in the tray  300 . For example, the locking tabs  108  are sized and positioned so that they fit within the recesses  304 . In one implementation, two locking tabs  108  may be provided for each recess  304 , one on each side of the central portion  102 . In another implementation, each recess  304  may only need one locking tab  108 . In this implementation, the locking tabs  108  may be placed on the same side of the central portion  102  for each recess  304  or may alternate sides of the central portion  102  between adjacent recesses  304 . In yet another implementation, the locking tabs  108  may only be provided for the top and bottom recesses  304 . Accordingly, it will be appreciated that various configurations of the locking tabs  108  can be implemented. 
         [0024]    Further, the width of the first side portion  104  and the second side portion  106  may vary depending on the implementation. For example, in one implementation, the width of each side portion  104  and  106  is the same as the height  305  of the tray  300 . In another implementation, the width of each side portion  104  and  106  is a fraction the height  305  of the tray  300 . In yet another implementation, the width of one of the side portions  104  and  106  is the same as the height  305  of the tray  300  and the width of the other of the side portions  106  and  104  is a fraction the height  305  of the tray  300 . 
         [0025]    Referring to  FIG. 4 , an assembly of the backer card  200  and the tray  300  is illustrated generally by numeral  400 . The backer card  200  is positioned around the tray  300  such that the locking tabs  108  are inserted into the recesses  304  between the compartments  302 . In this configuration two locking tabs  108  are provided in each of the recesses  304 . That is, for each recess  304 , one locking tab  108  is provided proximate the first side portion  104  and one locking tab is provided proximate the second side portion  106 . The six locking tabs  108  are arranged amongst the three recesses  304  in this manner. As will be appreciated, the locking tabs  108  facilitate maintaining the backer card  100  in position in the assembly  400 , thus assisting packaging thereof. 
         [0026]    Optionally, an adhesive may be used to further facilitate maintaining the backer card  100  in position in the assembly  400 . The adhesive could be applied to one or more of the central portion  102 , the first side portion  104  or the second side portion  106 . Placement of the adhesive may vary depending on the implementation. For example, if the adhesive is applied to the central portion  102  it may be placed on an entire surface area of the central portion  102  that will be in contact with the tray  300 . Alternatively, the adhesive may only be applied at strategic points of the central portion  102  that will be in contact with the tray  300 . Similarly, the adhesive may be applied to an entire surface area of the first side portion  104  that will be in contact with the tray  300  or only at strategic points thereof. Also, the adhesive may be applied to an entire surface area of the second side portion  106  that will be in contact with the tray  300  or only at strategic points thereof. 
         [0027]    The type of adhesive may vary depending on a number of factors including cost, effectiveness, the type of materials used for the backer card  100  and the tray  300 , and the like. Examples of types of adhesive that could be used include glue, double-sided tape and the like. 
         [0028]    Referring now to  FIGS. 5 and 6 , an example of a container is illustrated generally as reference numeral  500 . The container  500  contains the backer card  100  and tray  300 . The container  500  comprises a top  512 , bottom  513 , opposing sides  514   a  and  514   b,  opposing ends  515   a  and  515   b,  a corner  524  and a re-sealable panel  516  with a tab  522 . The top  512  has an opening  518  from which the contents of the compartments  302  are accessible.  FIG. 5  shows the container  500  in a closed configuration while  FIG. 6  shows the container  500  in a partially open configuration. 
         [0029]    The panel  516 , when pulled back from the container  500 , forms an opening  518  from which the contents of the compartments  302  are accessible. A sealing layer  520  is affixed to the panel  516  using an appropriate adhesive. The sealing layer  520  covers a substantial portion of the top  512  extending from the proximity of the end  515   b  to the proximity of the end  515   a.  The re-sealable panel  516  is also described in U.S. Pat. No. 6,918,532. 
         [0030]    The tab  522  extends past the corner  524  and can be grasped and is easily accessible to pull the panel  516  open. Adhesive  526  is applied to the surface of the sealing layer  520  which is in contact with the top  512 . The adhesive  526  provides a re-sealable seal between the sealing layer  520  and the top  512 . 
         [0031]    A person of skill in the art will appreciate that while one particular type of container  500  has been described, different types of containers or packaging can be used. 
         [0032]    If it is desired to display the container  500  in an upright, or vertical, position, the container would be placed on one of the opposing ends  515   a  or  515   b.  Accordingly, as will be appreciated, the general u-shape of the backer card  200  in the assembly  400  provides support for maintaining the container  500  in this position. Further, the locking tabs  108  provide some additional support to maintain separation of the compartments  302  in this position. 
         [0033]    Furthermore, as described above, while the backer card  100  with six locking tabs  108  has been described, more or less supports may be used. For instance, in another embodiment, four locking tabs  108  are formed into the backer card  100  as shown in  FIGS. 7 and 8 . 
         [0034]    In addition, although two slits  114  and  116  have been described to form the locking tabs  108  other methods may be employed. For example, in another embodiment, the locking tabs  108  are formed by cutting or punching apertures  902  in the backer card  100  along the top length of the locking tab  108  and bottom length of the locking tab  108  as shown in  FIG. 9 . 
         [0035]    In the embodiments described above, the backer card  108  is cardboard. However, as a person of skill in the art will appreciate, other materials may be used depending on the tray material, the container materials and the product stored within the tray  300 . 
         [0036]    While a particular configuration of locking tabs  108  has been described, a person of skill in the art will appreciate that the number, spacing and location of the locking tabs  108  may vary depending on the application. Furthermore, the locking tabs  108  may not be symmetrical about the first line of flex  110  and/or the second line of flex  112 . 
         [0037]    Yet further, although the backer card  100  and the tray  300  are described as separate pieces, it may be possible to create combination tray and backer card in which the backer card  100  is integral to the tray to form the assembly  400 . 
         [0038]    Although embodiments have been described above with reference to the figures, those of skill in the art will appreciate that variations and modifications may be made without departing from the scope thereof as defined by the appended claims.