Patent Publication Number: US-11649103-B2

Title: Tray with removable insert

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to a self-draining tray for food products which release extrudate, such as fresh meats. 
     BACKGROUND 
     Existing trays for fresh meat products typically utilize an absorbent pad positioned directly beneath the meat product. The absorbent pad is designed to capture or collect and retain extrudate that drains out of the meat, such as water, blood etc. The absorbent pad poses a problem for recycling centers, however, because consumers often fail to remove the pad from the tray before depositing it into the recycling stream. The tray cannot be recycled in this format. Through hard work and ingenuity, the inventors have developed a tray for meat products which drains the extrudate from the meat product, securely separates the extrudate from the meat product during shelf storage, and is fully recyclable. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING(S) 
       Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein: 
         FIG.  1    illustrates a perspective view of a tray and removable insert of the present invention. 
         FIG.  2    illustrates a perspective view of a tray and removable insert of the present invention, wherein the insert is removed from the tray. 
         FIG.  3    illustrates a side view of a tray and removable insert of the present invention, wherein the insert is positioned near the top of the tray. 
         FIG.  4    illustrates an exploded view of the interior bottom surface of the tray in an embodiment of the invention. 
         FIG.  5    illustrates an exploded cross-sectional view of the interior of the tray and insert in an embodiment of the invention. 
         FIG.  6    illustrates a top view of the insert in an embodiment of the invention. 
         FIG.  7    illustrates a side view of the insert in an embodiment of the invention. 
         FIG.  8    illustrates an exploded cross-sectional view of the insert in an embodiment of the invention. 
         FIG.  9 A  illustrates a perspective view of the insert in an embodiment of the invention. 
         FIG.  9 B  illustrates an exploded perspective view of the insert in an embodiment of the invention. 
         FIG.  10 A  illustrates a top view of the tray and insert in an embodiment of the invention. 
         FIG.  10 B  illustrates an exploded cross-sectional view of the insert peripheral flange through line B-B in  FIG.  10 A . 
         FIG.  10 C  illustrates an exploded cross-sectional view of the insert peripheral flange through line A-A in  FIG.  10 A . 
     
    
    
     SUMMARY 
     In an embodiment, the inventors have developed a fully recyclable tray package for meats, vegetables, or other products that produce extrudate. The inventive tray utilizes a polymeric insert, optionally made from polyethylene terephthalate, to allow the extrudate (juices, liquids, blood, and/or water) to drain away from the meat. The tray itself may also comprise a polymeric material that is recyclable in the same stream as the insert, such as polyethylene terephthalate. Any polymeric material known in the art may be utilized for the tray and/or the insert, however. In an embodiment, the tray and the insert are thermoformed. In some embodiments, the polymeric tray and/or insert may be transparent, translucent, or opaque. 
     The inventive design minimizes the contact of the extrudate with the meat. In one embodiment, the polymeric insert may be placed into the tray to form a false bottom during the tray manufacturing process. Similarly, the insert can be placed into the tray at a food processor&#39;s filling line, prior to the placement of the meat product. While the specification may largely refer to meat products, the invention should not be so limited. The tray and insert of the invention could be utilized in connection with seafood, produce, fruit, or any other food product which extrudates liquids, such as sliced tomatoes. 
     In an embodiment, the insert has one or more edges which engage locking detents on the inside walls of the tray to retain it in place. The insert may additionally be tapered downward on one or more sides to facilitate drainage. In an embodiment, grooves are disposed in the insert to direct the extrudate to the side edges of the insert. The extrudate may then drain down the sidewalls of the tray and may be captured in the bottom or base of the tray. In an embodiment, there may be strategically placed, elevated elements in the tray base which prevent or minimize the extrudate from moving upwardly to during transportation or consumer handling. In an embodiment, the base of the tray may be designed with grooves to create an arduous path for the extrudate. The grooves may additionally aid in creating more surface tension in the extrudate, which may further maintain the liquid in the base of the tray. The base of the tray may be designed in such a manner to also support the insert when the meat product is introduced to the package. In some embodiments, the tray base and/or the insert may be opaque to minimize the visual observation of the extrudate. 
     In an aspect, the invention is directed to a container comprising a tray, an insert, and a locking mechanism. In an embodiment, the tray comprises a bottom wall having a perimeter, at least one raised area, and at least one lower surface; at least one sidewall extending upwardly from the perimeter of the bottom wall and terminating at a rim, the at least one sidewall having an inner, product facing surface; and a plurality of vertically oriented concave flutes disposed on the inner surface of the at least one sidewall, the flutes extending from an upper portion of the tray at least one sidewall to the tray bottom wall. In an embodiment, the insert comprises a bowed surface terminating in a peripheral edge; a plurality of elevated portions extending upwardly from the bowed surface; and a locking mechanism which removably affixes the insert to the tray. When affixed to the tray, the bowed surface of the insert may be removably disposed on the at least one raised area of the bottom wall of the tray. A reservoir may be defined between the insert and the at least one lower surface of the tray bottom wall and the elevated portions of the insert, the flutes, and the at least one raised area of the tray bottom may define a plurality of channels which direct extrudate to the reservoir. 
     In an embodiment, the locking mechanism comprises a plurality of inwardly-directed locking detents located along a lower portion of the tray at least one sidewall, above the bottom wall, and a flange extending horizontally outward from the peripheral edge of the insert, wherein the insert is secured within the tray by positioning the insert flange under the locking detents. In an embodiment, the plurality of dams project upwardly from the bottom wall, each dam positioned between a flute and the interior of the tray, wherein the dams have a width that is at least as wide as a width of the flutes. In an embodiment, the plurality of dams comprise isosceles trapezoids comprising a longer base wall, a shorter base wall, and two leg walls and wherein the shorter base wall faces the flute. 
     DETAILED DESCRIPTION 
     The present invention now will be described more fully hereinafter with reference to the accompanying drawings in which some but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. 
       FIGS.  1  through  3    illustrate a container  10  for holding a food product. The container  10  comprises a tray  12  and an insert  14  that fits within the tray  12 , near the tray bottom wall  18 . In an embodiment, when the insert  14  is disposed within the tray  12 , a reservoir  16  is created between the insert  14  and the tray bottom wall  18 . While the preferred embodiment of the invention avoids the need for an absorbent pad, an absorbent bad could be utilized in the reservoir  16  between the insert  14  and the tray bottom wall  18 , if desired. In another embodiment, a surface desiccant could be utilized between the insert  14  and the tray bottom wall  18 . In an embodiment, the desiccant could be sprayed onto the tray bottom wall  18  or the underside of the insert  14 . The desiccant may comprise any composition which absorbs moisture or holds moisture through surface adhesion forces. Preferably any such desiccant would not inhibit the recyclability of the container  10 . 
     In addition to the bottom wall  18 , the tray  12  comprises at least one sidewall. In an embodiment, the tray  12  comprises four sidewalls. In a particular embodiment, the tray  12  comprises two short sidewalls  20  and two long sidewalls  22 , each extending upwardly from the perimeter of the bottom wall  18 . The sidewalls  20 ,  22  may terminate in a rim  24 . The rim  24  may be square, circular, or rectangular, in an embodiment. It will be understood that the rim may take any shape, based upon the configuration of the sidewalls. A flange  26  may extend horizontally outwardly or inwardly from the rim  24  and may be configured to receive a lid (not shown) or support a flexible film cover. Horizontally oriented stacking grooves  28  may be disposed along the corners of the rim  24  of the tray  12 , in an embodiment, and may facilitate stacking of multiple trays  12 , one upon another. 
     In an embodiment, the sidewalls  20 ,  22  may comprise a plurality of integrally formed, vertically oriented, outwardly extending ribs  30 . The ribs  30 , being convex when viewed from the tray exterior, may define vertically oriented concave flutes  32  on the inner surfaces of the sidewalls  20 ,  22 . Alternatively, the vertically oriented concave flutes  32  may be formed in an otherwise flat sidewall. In any case, the flutes  32  may extend horizontally into, through, or from the sidewalls  20 ,  22  any depth. Likewise, the flutes  32  may extend vertically through the sidewalls  20 ,  22  any distance, but preferably extend at least from a position that is above the insert  14  (when the insert  14  is snapped into the tray  12 ) downwardly to the bottom wall  18 . In an embodiment, the flutes  32  may extend from a position at or near the rim  24  of the tray  12  to the tray bottom wall  18 . In an embodiment, the flutes  32  serve as channels through which extrudate may drain into the reservoir  16  below the insert  14 . 
     In an embodiment, a dam  23  is provided near the base of each flute  32 . In an embodiment, a plurality of dams  23  are provided. In an embodiment, the number of dams coincides with the number of flutes  32 . Each dam  23  may force the draining extrudate to flow from each flute, around each dam  23 , and toward the center of the tray  12 . In addition, the dams  23  may prevent or reduce the likelihood that the extrudate, once in the reservoir  16 , will move upwardly or splash upwardly into the flutes  32 , as the dams  23  may block the extrudate from the flutes  32  once the extrudate is in the reservoir  16 . Each dam  23  may be an elongated element that is at least at wide as a flute  32 . In an embodiment, the dam  23  may be wider than the width of an adjacent flute  32 . In an embodiment, the dams  23  may be positioned at the base of the flute  32 . In an embodiment, the dams  23  are formed integrally with surface  45  of the tray  12 . In an embodiment, the dams  23  may be elevated above the surface  45  of the tray. In an embodiment, the dams  23 , viewed in top view, may be rectangular, ovular, trapezoidal, or any other shape known in the art. In an embodiment, the dams  23 , viewed in top view, may comprise isosceles trapezoids have two base walls and two leg walls. In an embodiment, the shorter base wall of the isosceles trapezoid dam  23  faces the flute  32 . In this embodiment, the extrudate is more likely to flow easily into the reservoir  16  but will have a more arduous path flowing around the longer base wall of the dam  23  to exit the reservoir and enter a flute  32 . 
     In an embodiment, the tray bottom wall  18  may be contoured and may include one or more lower surfaces  33  and one or more raised areas  34 . The lower surfaces  33  and raised areas  34  may be configured in many configurations and should not be limited to those set forth in the figures. In an embodiment, one raised area  34  may be centrally located and may be circular, ovular, rectangular, square, or any other shape known in the art. In an embodiment, the central raised area  34  may be partially or fully surrounded by a lower surface  33 . The lower surface  33  that surrounds the central raised area  34  may be in the form of a trough or moat. The lower surface  33  that surrounds the central raised area  34  may completely or partially surround the central raised area  34 . In an embodiment, the lower surface  33  that surrounds the central raised area  34  may be connected to one or more lower surfaces  33  which extend therefrom. For example, four additional lower surfaces  33  may extend outwardly from the central portion, toward the sidewalls  20 ,  22 . One or more raised areas  34  may additionally positioned about the bottom wall  18 . For example, a peripheral raised area  40  may be disposed near each corner of the bottom wall  18 . In an embodiment, the peripheral raised areas  40  are radially oriented about the central raised area  34 . In an embodiment, the raised areas  34 ,  40  extend upwardly, into the container receptacle, and above the lower surface  33 . 
     In a particular embodiment, one or more of the peripheral raised areas  40  may be angled such that the innermost height H of the peripheral raised area  40  (i.e. nearest the central raised area  34 ) is greater than the outermost height H 1  of the peripheral raised area  40  (i.e. nearest the sidewalls  20 ,  22 ) (see  FIG.  4   ). In an embodiment, the angle between the inner edge  35  of the peripheral raised area  40  and the outer edge  37  of the peripheral raised area  40  may be between about 1 degree and about 5 degrees. In another embodiment, the angle between the inner edge  35  of the peripheral raised area  40  and the outer edge  37  of the peripheral raised area  40  may be between about 1 degree and about 3 degrees. In yet another embodiment, the angle between the inner edge  35  of the peripheral raised area  40  and the outer edge  37  of the peripheral raised area  40  may be about 2 degrees. Such a configuration may aid in draining of extrudate from the middle region of the tray  12  and/or insert  14  toward the sidewalls  20 ,  22 . The peripheral raised areas  40  may comprise any shape known in the art. In an embodiment, the peripheral raised areas  40  may be elongated, square, rectangular, circular, ovular, or irregularly shaped. 
     In an embodiment, the height H 2  of the central raised area  34  may be the same as or nearly the same as the height of the inner edge  35  of the peripheral raised area  40 . In an embodiment, the height H 2  of the central raised area  34  is consistent across its length and width and is not angled. 
     In an embodiment, the lower surface  33  comprises one or more channels. For example, the lower surface  33 , in relation to the raised areas  34 ,  40 , may form one or more first channels  25  about the central raised area  34 , one or more second channels  27  between the peripheral raised areas  40 , and one or more third channels  29  surrounding the entirety of the raised areas  34 ,  40 . In an embodiment, the channels  25 ,  27 ,  29  may be connected to one another such that extrudate may flow from one channel to another. In other embodiments, the channels  25 ,  27 ,  29  may be separated from one another and may each retain extrudate from time to time. 
     In an embodiment, the tray  12  and insert  14  comprise a locking mechanism which secures the insert within the tray. In an embodiment, the locking mechanism is a removable lock—in that the insert may be secured within the tray but may be removable. In one embodiment, the locking mechanism may comprise locking detents on the tray  12  and a flange on the insert  14 . More particularly, in an embodiment, the tray  12  further includes one or more inwardly directed locking detents  38  located along a lower portion of the tray sidewalls  20  and/or  22  just above the bottom wall  18 , as shown in  FIG.  5   . In an embodiment, the detents  38  are horizontally oriented. The detents  38  may be disposed along only each short sidewall  20 , only each long sidewall  22 , or another both the long and short sidewalls  20 ,  22 . In an embodiment, the detents  38  may be substantially wedged shaped and comprise a curved, sloped, or angled upper surface  41  and a sloped lower surface  39 . In an embodiment, the upper surface  41  and the lower surface  39  may meet at an apex or convex curve. In other embodiments, the upper surface  41  and the lower surface  39  may each be adjacent and connect to flattened inner surface  42 . In other embodiments, the detents  38  may be substantially triangular, rounded, squared, or any other shape or configuration known in the art to retain the insert  14 . 
     In an embodiment, the locking detents  38  are designed to capture the insert  14  and hold it in place. Thus, the angle and configuration of the upper surface  41 , lower surface  39 , and inner surface  42  may be such that the insert  14  can slide over the upper surface  41  and inner surface  42  upon insertion and be locked in place beneath the lower surface  39  of the detents  38 . The plurality of detents  38  could be replaced by one elongated detent  38  in an embodiment. 
     In another embodiment, the locking mechanism may comprise one or more concave indents located along a lower portion of the tray sidewalls  20  and/or  22  just above the bottom wall  18 . The indents may take any shape or configuration known in the art, in an embodiment. In this embodiment, the perimeter of the insert may comprise tabs or extension elements which can be snap-fit into the indents to secure the tray in place. In an embodiment, the tabs may be compressible such that their shape compresses to fit into the indents and then expands once in the indents. In an embodiment, the number of indents and tabs may vary, but should correlate in number and positioning. Any other locking mechanism known in the art which secures the insert  14  within the tray  12  may also or alternatively be utilized in the invention. 
     In an embodiment, the insert  14  may be sized and configured to fit within the tray  12 . In an embodiment, the insert  14  may be square or rectangular. In an embodiment, the insert  14  may be sized and configured to be snap-fit into the tray  12 . The insert  14  may be semi-rigid so that it can be deformed to pass over the upper surface  41  and inner surface  42  and fit below the detents  38  when inserted into the tray  12  and still support the weight of a food product on top of the insert  14 . The insert  14  may comprise a bowed surface  45 , in an embodiment. In an embodiment, the bowed surface  45  is convex. In this embodiment, the term bowed surface means that the midsection  61  of the insert  14  may be disposed further from a horizontal plane  60  than the end portions  62  of the insert (see  FIGS.  7  and  8   ). In an embodiment, the angle between the horizontal plane  60  and the center of the bowed surface  45  may be between about 1 degree and about 5 degrees. In another embodiment, the angle between the horizontal plane  60  and the center of the bowed surface  45  may be between about 1 degree and about 3 degrees. In yet another embodiment, the angle between the horizontal plane  60  and the center of the bowed surface  45  may be about 2 degrees. This configuration may allow drainage from the central portion of the insert  14  and toward the edges of the insert  14 . 
     In an embodiment, the insert  14  may comprise a plurality of elevated portions, in various shapes and configurations. The invention should not be limited to the configurations shown, as any configuration of elevated portions may be utilized. 
     In an embodiment, the elevated portions comprise an elevated central portion  43 . The central portion  43  may comprise any shape known in the art, such as a circle, oval, ellipse, square, rectangle, or an irregular shape. In addition, one or more peripheral elevated portions  47  may be disposed at or near the four corners of the insert  14 . In an embodiment, the central elevated portion  43  and/or the peripheral elevated portions  47  may connect to the surface  45  via a convex curved portion  49 . One or more central portion channels  51  may be formed within the convex curved portion  49  of the central elevated portion  43 . These central portion channels  51  may encourage extrudate to flow through one or more paths P toward the outer periphery of the insert  14 . In addition, channels  55  may be formed between adjacent peripheral elevated portions  47  (see  FIG.  9 B ). The peripheral elevated portions channels  55  may be formed as each peripheral elevated portion  47  meets the surface  45  via a concave curved portion or angled portion  57 . In an embodiment, an obtuse angle may be formed between angled portion  57  and surface  45 . 
     In an embodiment, the elevated portions additionally comprise a plurality of half-cylindrical elements  44  which extend upwardly away from the bowed surface  45 . In an embodiment, the half-cylindrical elements  44  are disposed in a radially extending pattern, moving radially outward from the central portion  43  and toward the peripheral portions  47 . In an embodiment, some or all of the half-cylindrical elements  44  may have a lateral curvature, particularly if the central portion  43  has a curvature (i.e. is a circle or an oval). That is, the half-cylindrical elements  44  may curve laterally about the curvature of the central portion  43 . 
     In an embodiment, the depth of each half-cylindrical element  44  increases, moving from the innermost half-cylindrical element  44  (nearest the central portion  43 ) to the outermost half-cylindrical elements  44 . This feature can be seen in cross-section in  FIG.  8   . The depth D 1  of the half-cylindrical element  44  shown on the inner (shown on left) side of the insert  14  is less than the depth D 2  of the half-cylindrical element  44  shown in a position which is outer of it. The depth D 3  of the next outwardly positioned half-cylindrical element  44  is greater, and the depth D 4  of the outermost half-cylindrical element  44  is greater than each of the other half-cylindrical elements  44 . In an embodiment, the length and/or width of one or more of the half-cylindrical elements  44  may increase moving from the innermost half-cylindrical element  44  (nearest the central portion  43 ) to the outermost half-cylindrical elements  44 . 
     In an embodiment, because the surface  45  of the insert  14  may be convex, the increasing depth of the half-cylindrical elements  44 , as one moves from the innermost half-cylindrical element  44  (nearest the central portion  43 ) to the outermost half-cylindrical elements  44 , creates a horizontal surface  63  to support a food product. That is, the depth of the half-cylindrical elements  44  may be configured to correspond to the curvature of the surface  45  of the insert  14  to provide a food surface  63  which is horizontal or substantially horizontal (see  FIGS.  7  and  8   ). This prevents food products from sliding or rolling toward the outward edges of the tray  12 . 
     In an embodiment, each half-cylindrical element  44  may create a path P between it and the adjacent half-cylindrical element  44  (see  FIG.  9 B ). For example, each half-cylindrical element  44  may have a longitudinal wall  53 . The longitudinal wall  53  may be curved, angled, or flat with respect to the surface  45 . In an embodiment, an obtuse angle may be formed between the longitudinal wall  53  and the surface  45 . The disposition of the longitudinal wall  53  may encourage extrudate to flow through the path P created between the longitudinal wall  53  and the adjacent longitudinal wall  53 . 
     In an embodiment shown in  FIGS.  10 A- 10 C , the surface  45  of the insert  14  terminates in a peripheral flange  56 . The peripheral flange  56  may be fully circumferential (i.e. disposed along all sides of the insert  14 ), may be present on two sides of the insert  14 , or may comprise a plurality of flanges  56  positioned along the periphery of two or more sides of the insert  14 . In an embodiment, the flange  56  may be substantially rectangular or square and may have rounded edges. The flange  56  may extend horizontally outward from the surface  45  in an embodiment. 
       FIG.  10 B  illustrates a cross-section through a peripheral elevated portion  47  of the insert (line B-B in  FIG.  10 A ). In this embodiment, the peripheral elevated portion  47  terminates near the flange in a convex curved portion  49 . Thus, in this embodiment, the flange  56  extends peripherally and horizontally from the convex curved portion  49 . In  FIG.  10 C , the cross-section is shown between two peripheral elevated portions  47  (line A-A in  FIG.  10 A ). The  FIG.  10 C  cross-section illustrates the surface  45 . The surface  45  connects to the flange  56  though a substantially vertical connecting member  59 . 
     The produce container  10  may be assembled as follows. The insert  14  may be placed within the tray and locked into place. To secure the insert  14  within the tray  12 , the insert flange  56  may be snapped into place under the tray detents  38  so that the flange  56  is held down by the detents  38  as best shown in  FIG.  10 B . This arrangement locks the insert  14  in place and prevents it from falling out of the tray  12  or becoming dislodged when the container  10  is tilted. 
     When the insert  14  is locked into place, the insert  14  and tray  12  define a reservoir  16  between the insert  14  and the tray bottom wall  18 . The insert  14  rests on the tray bottom wall  18  or, more particularly, on the raised areas  34 ,  40  of the tray bottom wall  18 . As shown in  FIG.  10 A , the path P of the extrudate may, in an exemplary manner, flow from the food product resting upon the central portion  43  of the insert  14 , between respective longitudinal walls  53  of adjacent half-cylindrical elements  44 , over the flange  56 , and through a flute  32 . Referring now to  FIG.  4   , the extrudate may then follow a path P which is forced around a dam  23 , through a second channel  27  between peripheral raised areas  40 , and toward the first channel  25  which circumvents the central raised area  34  of the tray  12 . The skilled artisan will understand that many extrudate paths are possible. 
     The accompanying figures are provided for explanatory purposes and may not show all components described herein with respect to embodiments of the system. In addition, those components that are illustrated are not necessarily drawn to scale. 
     Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.