Patent Publication Number: US-2023139262-A1

Title: Integral carton and tray arrangements

Description:
BACKGROUND 
     1. Field 
     The present disclosure relates generally to a three-panel or four-panel lidding device used to seal a food container. 
     2. Description of Related Art 
     Frozen foods are easy to store, transport, and serve. Other types of foods are also sold in stores as pre-prepared and ready for immediate cooking or microwaving. The packaging of these foods typically uses a clear plastic film that covers the food product inside the food container or bowl, as well as an outer package or box in which the food container is housed. In use, the consumer must open the box, cut or remove the plastic film in order to vent the food during cooking, cook/microwave the food, then discard the box and film. There are, however, instances when the film is not properly vented or when the user does not have the proper tool (e.g., knife or scissors) to vent the film, causing undesirable mistakes in the food cooking process. Providing both a plastic film and a packaging box also creates undesirable waste. Accordingly, improvements in the packaging of pre-prepared food products are desirable. 
     The conventional techniques have been considered satisfactory for their intended purpose. However, there is an ever present need for improved systems and methods for packaging food such as pre-prepared food products. This disclosure provides a solution for this need. 
     SUMMARY 
     The systems and methods described herein can be used to seal containers, such as for frozen food products, and to provide for handling the containers when open with hot foot products therein. 
     A lidding device includes a first panel comprising a lid configured to cover and seal a food container. A second panel is foldably connected to the first panel. A third panel includes a bottom panel opposite the lid, wherein the second panel is foldably connected to the first panel and the third panel. A fourth panel is foldably connected to at least one of the first panel and the third panel, wherein the fourth panel and second panel are configured to at least partially enclose a food container between the second and fourth panels. 
     The food container can be sealed to the first panel, wherein the food container is at least partially enclosed between first panel and the third panel and between the second panel and the fourth panel. An insulation space can be defined between the food container and at least one of the first, second, third, and fourth panels. Side flaps foldably connected to at least one of the first and third panels configured for adhering the first panel to the third panel. The first panel, second panel, third panel, fourth panel, and side flaps can completely enclose the food container. It is also contemplated that two opposed panels can be foldably connected to the first, second, third, and fourth panels, wherein each of the two opposed panels includes a cutout which receives a respective edge of the food container. 
     The first panel can include a venting system including one or more lines of weakness along an edge of the first panel for venting the first panel. The first panel can include a pull tab for peeling back the first panel along one or more lines of weakness along the first panel edges. The second panel can be configured for use as a foot that allows the lidding device to stand upright on the second panel. At least one of the panels can be configured to be printable for printing product identifying material or instructions thereon. At least the first panel can comprise a thermoplastic or heat sealable coating applied to food-facing side of the panel. The thermoplastic coating can comprise a polyolefin dispersion or a polymeric-based film. 
     A method of forming a lidding device includes providing a printable or pre-printed paperboard material, forming a multi-panel blank from the paperboard material, wherein the panels are separated via lines of weakness, and applying a thermoplastic heat seal coating to at least a portion of one side of the blank. The method includes fitting the blank around a container to surround the container between at least a top panel and an opposed bottom panel and between a first side panel and an opposed second side pane and heat sealing the thermoplastic heat seal coating to the container. 
     The method can include applying one or more coatings to the paperboard material. The one or more coatings can comprise a clay coating. Applying one or more coatings can comprise applying a thermoplastic heat seal coating to at least a portion of one side of the blank. The paperboard material can be pre-printed with marketing graphics with heat resistant microwaveable inks and/or overprint. Fitting the blank around the container can include completely surrounding the container inside the blank. Fitting the blank around the container can include protruding two edges of the container through cutouts in opposed flaps of the blank. Fitting the blank around the container can include forming at least one insulation space between the container and the panels of the blank. 
     A lidding device includes a food container and a paper container sealed to the food container. The paper container surrounds the food container on at least three or four sides of the food container. There is an insulation space defined between the food container and the paper container. 
     These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein: 
         FIG.  1    shows a top perspective view of a lidding device in place on a food container. 
         FIG.  2    shows the device of  FIG.  1    standing on its foot panel. 
         FIG.  3    shows a top plan view one embodiment of a blank that may be used to form lidding device. 
         FIG.  4    shows a side perspective view of one embodiment of how a lidding device may be opened to vent food and to remove the lid panel. 
         FIG.  5    shows a top plan view of an alternate blank that may be used to form a lidding device. 
         FIG.  6    shows a top plan view of a further alternate blank that may be used to form a lidding device. 
         FIG.  7    shows a side perspective view of an alternate embodiment of a lidding device being vented. 
         FIG.  8    shows a top plan view of a lidding device in place on a food container, the lidding device having a perforation for its venting system. 
         FIG.  9    shows a side perspective view of an alternate venting system for a lidding device. 
         FIG.  10    shows a top plan view of one lidding device blank that has a tear strip feature. 
         FIG.  11    shows a side perspective view of a lidding device with an alternate tear strip feature being vented. 
         FIG.  12    illustrates that any number of lidding device configurations may be used, with various tabs at various locations and various perforation/score line locations. 
         FIG.  13    illustrates top plan view of a blank that has a push to vent feature. 
         FIG.  14    illustrates top plan view of a blank that has an alternate push to vent feature. 
         FIG.  15    illustrates top plan view of a blank that has a push to vent and pinch to pull and open feature. 
         FIG.  16    is a plan view of an embodiment of a blank for a lidding device constructed in accordance with the present disclosure, showing the panels and flaps. 
         FIG.  17    is a perspective view of the lidding device of  FIG.  1   , showing the flaps and panels enclosing a food container. 
         FIG.  18    is a cross-sectional side elevation view of the lidding device of  FIG.  2   , showing the insulation space between the food container and the flaps and panels. 
         FIG.  19    is a plan view of another exemplary embodiment of a blank for a lidding device, showing the panels and flaps. 
         FIG.  20    is a perspective view of the lidding device of  FIG.  4   , showing the flaps and panels at least partially enclosing a food container. 
         FIG.  21    is a cross-sectional side elevation view of the lidding device of  FIG.  5   , showing the insulation space between the food container and the flaps and panels. 
         FIG.  22    is a plan view of another exemplary embodiment of a plank for a lidding device, showing a venting system and pull tab. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an embodiment of a blank for a lidding device in accordance with the disclosure is shown in  FIG.  1    and is designated generally by reference character  10 . Other embodiments of systems in accordance with the disclosure, or aspects thereof, are provided in  FIGS.  2 - 22   , as will be described. The systems and methods described herein can be used to seal containers, such as for frozen food products, and to provide for handling the containers when open with hot foot products therein. 
     The figures illustrate various embodiments of a lidding device  10 . As shown in the Figures, the lidding device  10  comprises three panels: a first panel  14  separated from a third panel  42  by a second panel  40 . Any of the panels may include marketing materials, product identifiers and information, or graphics. The first panel  14  forms a lid that covers and seals the contents of a food container  12 . The second panel forms a foot  46  that is useful for display purposes. The third panel  42  provides a base panel. 
     A thermoplastic or heat seal coating may be applied to the food-facing side of the first panel  14 , which is the side that interacts with the container  12  to seal the contents of the container. The heat-seal coating is applied at suitable places around the panel. This coating also acts as a barrier to protect the lid from water/oils in the product(s) stored in the container. In some embodiments, the thermoplastic coating is a polyolefin dispersion, although other water or solvent-based coatings that provide a suitable seal between the device and the container may be used. For example, polymeric based films, which may be adhesively laminated to the paperboard blank or directly extrusion coated to the blank, may be used. In some embodiments, the heat sealable coating is applied to the underside of substantially the entirety of the first panel  14  so that it faces and covers/seals the contents of the container. In some cases, the coating consists of a heat sealable adhesive that is applied to the paperboard blank as part of production before the blank is cut, and in other cases is applied afterwards. The coated paperboard is configured to withstand a range of environmental conditions relating to manufacture, transportation, storage (which may include freezing), sale, and use of the product, which may include defrosting and/or heating (such as by microwave oven, conventional oven, convection oven, and/or toaster oven) of the product stored within the food container. The coated paperboard is also configured to be safe for contact with food products in compliance with 21 CFR 176.170. 
     One specific embodiment of a lidding device  10  that is useful for covering and sealing a food product container  12  is illustrated by  FIG.  1   . Appropriate food product containers  12  are typically made of plastic, but may be made of any appropriate material that can house and store food, and that also allow the food to be cooked therein. Such containers are commonly recognizable as the type of containers that are used for microwavable food products, but they may also be used in conventional ovens, toaster ovens, or convection ovens. 
     The lidding device  10  that is used to cover and protect the food contained in the container  12  is typically made of paperboard, but may be made of any printable, foldable, fiber-based substrate. In a particular embodiment, the lidding device  10  is made of a two-sided clay coated SBS (Solid Bleached Sulfate) having an appropriate coating as described above applied thereto, although it should be understood that any food-safe lidding material may be used. 
     The lidding device  10  provides a three-panel system that covers the top and bottom of the food container  12 , as well as provides a side panel that functions as a connecting panel, which also provides a display function. As shown in  FIG.  2   , a first panel  14  is provided to form the cover or lid panel of the lidding device. The first panel may have an opening feature that allows for venting during the heating process. For example, first panel may have a venting system  20 , as will be described in more detail with respect to further figures, and venting system  20  maybe provided in a number of ways. For example, the venting and/or opening feature may include lines of weakness that are configured to be broken and/or removed or displaced to provide ventilation. Optionally, a pull-tab or tear strip adjacent the opening feature may be used to move the opening feature into its vent position. 
     Specifically, as shown in  FIG.  3   , first panel  14  has one or more lines of weakness  16  provided along its edge areas  18 , which allows the first panel  14  to be removed before, during and/or after the cooking process. Lines of weakness  16  may be provided as perforations, score lines, partial cuts, reverse partial cuts, or any other feature that allows the first panel  14  to be broken, removed or displaced upon application of the appropriate amount of pressure. These lines  16  may assist with the venting, but they may also be used to remove the entire lid panel  14  from the container  12 , as shown in  FIG.  4   . 
       FIG.  3    also shows an embodiment of a venting system  20  that is created via cooperation between a pull tab  22  and a score line  24 . In use, the user grasps pull tab  22  and pulls a portion of the panel lid  14  back to the area where the score line  24  is located in order to create an opening in the panel lid  14 . The pull tab  22  is generally located near the side of the panel where the venting score line  24  is located. The pull tab  22 /score line  24  system may be provided near the right side of the panel  14  ( FIG.  3   ), along the left side of the panel  14  ( FIG.  5   ) or along the top (or bottom) of the panel  14  ( FIG.  6   ). Pull tab  22  may be any appropriate shape, such as a rectangular tab ( FIGS.  3  and  6   ) or a rounded protrusion ( FIG.  5   ). As the edge portion of the panel lid is pulled back, the lines of weakness  16  that secured the lid in place are disrupted, and they allow a peeling back of the lid portion to the score line  24 . It is also possible to create further lines of weakness  26  that extend between the tab  22  and the score line  24 , in order to further ease the peeling back of the lid, if desired or necessary. 
     In an alternate embodiment, no tab is required, but a line of weakness  28  is provided as the venting system  20 , as shown in  FIG.  8   . In use, finger pressure may be used along the venting line of weakness  28  to create the desired opening. This line of weakness  28  may be formed as a shape  28  that could be peeled back or punched out/removed completely, as shown in  FIG.  8   . Alternatively, this portion may be provided as a single perforated line  30  that is punctured to create a venting slit or hole, as shown in  FIG.  9   . 
     In a further embodiment, a pull open tear strip  36  may be provided, as shown in  FIG.  10   . The pull open tear strip  32  features a thumb tab  34  connected to a tear strip feature  36  that travels along an edge of the panel lid  14 . In an alternate embodiment as shown in  FIG.  11   , instead of a thumb tab, there is a puncturable/covered opening  35  provided in the lid where a thumb may punch out the removable portion, insert a thumb, and grasp the tear strip feature  36 . 
     In a further embodiment, there may be provided a push to vent feature in the lid. One embodiment of a simple push to vent feature is shown in  FIG.  9   , where the opening  30  is created by thumb pressure along the perforated line. More fully developed embodiments of push to vent features are shown in  FIGS.  13 - 15   . For example,  FIG.  13    shows a push to vent feature  48  which is adjacent to a pull to open feature  50 . The user may press at the push to vent  48  portion in order to create a venting area. Once the cooking/heating process has been completed, the user may then grasp the pull to open portion  50  to remove the lid from the food container. 
     An alternate embodiment of a push to vent feature is shown in  FIG.  14   . This figure illustrates back-to-back push to vent  48  and pull to open  50  areas. A further embodiment provides a pinch to open feature  52 , as shown in  FIG.  15   . In this embodiment, two push to vent features are provided as semi-circles  54  formed as perforations in the lid. After the semi-circles  54  are pressed in for venting during cooking/heating, they may be used to pinch the lid to open. The space  56  between the semi-circles creates somewhat of a handle for the user to raise the lid. 
     Although a number of alternate embodiments for venting system are shown and described, it should be understood that any configuration that provides a venting system may be used in connection with the three-panel lid disclosed herein. Regardless of the embodiment provided, upon appropriate pressure or pulling at the venting system  20 , the first panel  14  opens or separates from the container  12 , allowing air to vent into and from the food container during cooking. In some embodiments, the first panel is removed before serving and consumption. Once the food has cooked completely, the entire panel lid  14  may be removed, as shown in  FIG.  4   . The edge lines of weakness  16  may assist with this removal. 
       FIG.  12    illustrates that alternate shapes and sizes for the panels may be provided, depending upon the shape and size of the container to be lidded. In general, however, the first panel  14  is generally shaped to cover a food product container  12 , albeit slightly larger than the opening of the container so that the entire opening of the container  12  is covered. The tabs may be positioned at any appropriate location, the score lines may be interchanged for perforations and vice versa, and alternate venting systems may be provided. 
     Reference is now made back to  FIGS.  3 ,  5 ,  6 ,  8 , and  12   , which show embodiments of the lidded device blank prior to its being folded, shaped, and enclosing a container  12 . A second panel  40  is connected to the first panel  14 . As shown in  FIG.  3   , second panel  40  is positioned between and separates the first panel  14  and the third panel  42 . The connection areas are generally via either score lines  43  or small cuts or perforations  44  in the blank that allow easy removal of the second panel  40  from the first and third panels  14 ,  42  in use. Although score lines  43  are shown in some figures are perforations  44  in others, it should be understood that these features may be interchangeable and/or used collectively. 
     The second panel  40  generally forms a side or bottom panel (depending upon how the device  10  is positioned). In some embodiments, the second panel is configured to serve as a foot  46  that keeps the bowl upright, as shown in  FIG.  2   . Once the lidded device  10  is folded and positioned with respect to a food container  12 , the foot  46  can be used to allow the device  10  to stand thereon, such that the device can be easily stacked in a freezer, refrigerator, or shelf section, while still displaying the package printing and taking up less space than if the containers were stacked vertically. 
     Any or all of the panels have at least one (or both) side(s) that are configured to be printable for printing product identifying material and/or instructions thereon. For example, the non-food facing side of the first panel  14  generally contains brand and product messaging or images, while additional information, such as a list of ingredients and cooking and/or opening instructions, may be included on another panel, such as the second and/or or third panels. 
     Also disclosed is a method of forming a lidding device. In one embodiment, the device may be formed using standard paperboard forming machinery to form a die-cut blank, having various lines of weakness, such as score lines and/or perforations, positioned thereon. A clay coating is then applied to the blank. Next, the suitable thermoplastic heat sealcoating is applied to one side of the blank, which will generally be the food-facing side of at least the first panel  14 . Alternatively, the thermoplastic heat seal coating may be applied during manufacture of the paperboard out of which the blank is cut. The paperboard may be printed with heat resistant microwaveable inks and/or overprint. Moreover, the blank used to form the lidding device may be die cut to a customer&#39;s specifications, depending upon the shape of the food container to be covered and sealed. 
     In use, the container  12  is filled with food (or other product) and the lidding device  10  is folded and formed from the blank and wrapped around the container  12 . Heat sealing equipment may then be used to activate the heat sealable coating to bind the paperboard to the container. In other embodiments, ultrasonic or radio frequency sealing technology may be used to activate the heat sealable coating. This may be done using any suitable machinery or method. 
     The blank  100  for a lidding device  102  (shown in  FIG.  17    erected from the blank  100  of  FIG.  16   ) includes a first panel  104  comprising a lid  106  configured to cover and seal a food container  108 . A second panel  110  is foldably connected to the first panel  104 . A third panel  112  includes a bottom panel opposite the lid  106  when the blank is erected as shown in  FIG.  17   . The second panel  110  is foldably connected between the first panel  104  and the third panel  112 . A fourth panel  114  is foldably connected the third panel  112 , and a fifth panel  116  is foldably connected to the first panel  104 . When the blank  100  is erected as shown in  FIG.  17   , the fourth and fifth panels  114  and  116  are adhered together to form a single panel that is opposite the second panel  110  for at least partially enclosing the food container  108  between the second and fourth panels  110 ,  114 . 
     With continued reference to  FIGS.  16  and  17   , the food container  108  is sealed to the first panel  104  around a sealing perimeter  118  around the lid  106 . The food container  108  enclosed between first panel  104  and the third panel  112 , as well as between the second panel  110  and the fourth panel  114 . An insulation space  120  (identified in  FIGS.  16  and  18   ) is defined between the food container  108  and each of the first, second, third, and fourth panels  104 ,  110 ,  112 ,  114 . Side flaps  122 ,  124  are foldably connected to at least one of the first and third panels  104 ,  112  configured for adhering the first panel  104  to the third panel  112  (e.g. by adhering the flaps  122 ,  124  to the respective sections  126 ,  128  of the third panel  112 . The corner sub-panels  130  of the first, second, third, fourth, and fifth panels  104 ,  110 ,  112 ,  114 ,  116  are used to form the recessed corners  132  when the blank  100  is erected as shown in  FIG.  17   . The first panel  104 , second panel  110 , third panel  112 , fourth panel  114 , and side flaps  122  completely enclose the food container  108 . The blank  100  thus forms a paper container in a lidding device that includes the food container  108 . The paper container surrounds the food container  108  on at least four sides of the food container, and there is an insulation space  120  is defined between the food container  108  and the paper container. 
     With reference now to  FIGS.  19 - 21   , another embodiment of a blank  200  and lidding device  202  is shown. A first panel  204  defining a lid  206  is foldably connected to a second panel  210 , which is foldably connected to a bottom or fourth third panel  212 . A fourth panel  214  is foldably connected to the first panel  204  and can be connected to the third panel  212  adhering the adhesive flap  215  (that is foldably connected to the fourth panel  214 ) to the third panel  212  to erect the blank  200  into the lidding device  202  of  FIG.  20   . The reinforcement flap  213  is foldably connected to the third panel  212  to form a foot  236  that can be used to stand the lidding device  202  upright relative to the position shown in  FIG.  20   . Two opposed panels  222 ,  224  are each foldably connected to the first, second, third, and fourth panels  204 ,  210 ,  212 ,  214  (i.e. the panels  222 ,  224  are foldably connected directly to the first panel  104 . Each of the two opposed panels  222 ,  224  includes a respective cutout  238 , which receives a respective protruding corner or edge  240  of the food container  208  extending therethrough. The insulation space  220  is provided in the corners of the lidding device. The insulation spaces  120 ,  220  allow for handling the lidding devices  102 ,  202  when hot, e.g., after microwaving the food contents, a user can handle the lidding devices  102 ,  202  by grabbing the lidding device  102 ,  202  proximate the insulation space  120 ,  220 . 
     With reference now to  FIG.  22   , another blank  300  is shown, including first, second, third, and fourth panels  304 ,  310 ,  312 ,  314  similar to those described above with respect to blank  200 . The lid  306  can be adhered to a food container (such as food containers  108 ,  208 ) and the blank  300  can be erected around the food container, adhering the adhesive flap  315  to the third panel  312  much as described above with reference to  FIGS.  19 - 21   . Flaps  322  can be overlapped and adhered together to partially enclose opposed ends of the food container (e.g. food container  108  and  208 ). Corner regions  323  are left open, not fully enclosing the food container, and corners  352  provide the insulation space  320  much as described above with respect to blanks  100 ,  200 . The first panel  304  includes a venting system including one or more lines of weakness  342  along an edge of the first panel  304  for venting the food container, e.g. during cooking. The first panel  304  includes a pull tab  346  for a user to use in peeling back the lid  306  of the first panel  304  along one or more lines of weakness along the first panel edges. Blanks  100 ,  200  described above can have similar venting systems and pull tabs. 
     In any of the blanks  100 ,  200 ,  300 , at least one of the panels can be configured to be printable for printing product identifying material or instructions thereon. At least the first panel of the blanks  100 ,  200 ,  300  can comprise a thermoplastic or heat sealable coating applied to food-facing side of the panel, and the thermoplastic coating can comprise a polyolefin dispersion or a polymeric-based film. 
     A method of forming a lidding device (e.g. lidding device  102 ,  202 ,  302 ) includes providing a printable or pre-printed paperboard material, forming a multi-panel blank (e.g. blanks  100 ,  200 ,  300 ) from the paperboard material, wherein the panels (e.g. panels  104 ,  110 ,  112 ,  114 ) are separated via lines of weakness (e.g. fold lines  150  shown in  FIG.  16   ), and applying a thermoplastic heat seal coating to at least a portion of one side of the blank. The method includes fitting the blank around a container (e.g. food container  108 ,  208 ) to surround the container between at least a top panel and an opposed bottom panel and between a first side panel and an opposed second side pane and heat sealing the thermoplastic heat seal coating to the container. Three-sided embodiments, e.g., as in  FIG.  1   , are wrapped around the respective tray, and the four-sided embodiments, e.g.  FIG.  16   , can have the tray inserted in a form/fill/seal operation. 
     The method can include applying one or more coatings to the paperboard material. The one or more coatings can comprise a clay coating. The applying the one or more coatings can comprise applying a thermoplastic heat seal coating to at least a portion of one side of the blank. The paperboard material can be pre-printed with marketing graphics with heat resistant microwaveable inks and/or overprint. Fitting the blank around the container can include completely surrounding the container inside the blank (e.g. as shown in  FIG.  17   ). Fitting the blank around the container can include protruding two edges of the container through cutouts in opposed flaps of the blank (e.g. as shown in  FIG.  20   ). Fitting the blank around the container can include forming at least one insulation space (e.g. insulation spaces  120 ,  220 ,  320 ) between the container and the panels of the blank. 
     Systems and methods disclosed herein provide consumer features such as the following. The plastic tray does not have to be removed from the carton for cooking. The carton can provide a convenient means of handling the food tray for placement in the oven and removal of the hot tray after cooking, by virtue of the insulation spaces which serve as carrying handles. The integrated food tray and carton, especially in the case of the four-sided embodimens can potentially create a more aesthetically pleasing food vessel. The option of a hinged lid can allow for convenient venting but can also serve as a splatter guard inside the oven. A lid can also provide a means of protecting food and keeping it warm as it is transported from oven to table or desk. The lid can also be used to cover food discreetly when others are near. Also, paperboard and plastic components can be separated for recycling. 
     The methods and systems of the present disclosure, as described above and shown in the drawings, provide for lidding and containing products such as frozen foods, while providing for ease of handling the products when hot. While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.