Patent Publication Number: US-2021188476-A1

Title: Multi-compartment tray

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application relates and claims priority to U.S. Provisional Application 62/952,524 filed Dec. 23, 2019, the entirety of which is hereby incorporated by reference. 
    
    
     FIELD OF THE INVENTION 
     The present disclosure is directed generally to conjoined multi-compartment trays, and more particularly to such trays that are adapted to be separated into multiple, individual trays. 
     BACKGROUND 
     In packaging it is rather typical for multiple compartments in a tray to be conjoined, filled with the desired contents (i.e., food, pharmaceuticals), and then sealed for sale to an end user. The end user can then separate one compartment from the conjoined assembly to consume the contents in that compartment while leaving the other compartments in the assembly sealed (and conjoined if there are three or more compartments in the assembly). Separation of one compartment from the multi-tray assembly is typically done by tearing the tray along a two-dimensional perforated seam that extends along (and is co-planar with) the common edge between two compartments. 
     Typical materials for these types of multi-compartment trays to be composed of include polystyrene and polypropylene. Polystyrene exhibits stiff and brittle properties, while polypropylene exhibits plastic deformation early on in the deformation process, so it is generally considered a “tough” material. Toughness is defined as a material&#39;s ability to deform (plastically, not elastically) without breaking. In addition, polypropylene exhibits fatigue resistance, essentially retaining its shape after a lot of torsion, bending, and/or flexing. 
     Due to these material properties, multi-compartment containers having a perforated seam generally require the user to actually tear the compartments apart, as opposed to bending/snapping them to separate them. The tearing can be difficult for a user with limited hand strength and can also result in sharp edges being formed if the tear does not follow the perforated seam perfectly. In addition, because the perforation is in the same place as the compartments&#39; edges, the edge structure between the compartments is structurally weak/non-rigid, thereby making the package more susceptible to bending/twisting along the common edge and requiring more user support when carrying the multi-compartment tray. 
     Accordingly, there is a need in the art for a packaging solution for multi-compartment trays that permit easier separation of the compartments. 
     There is a further need in the art for a packaging solution for multi-compartment trays that enhances the rigidity of the article. 
     SUMMARY 
     The present disclosure is directed to a multi-compartment tray. 
     According to an aspect is a multi-compartment tray, comprising first and second compartments conjoined along a first longitudinal axis and each of which contains an edge that extends along the first longitudinal axis and in a first plane. The multi-compartment tray further comprises a perforation region that conjoins the first and second compartments, wherein the perforation region comprises a plurality of first and second cut-away regions formed in the edges of the first and second compartments, respectively, each of which is laterally spaced from the others along the first longitudinal axis; a first plurality of perforation tabs joining the first and second compartments and extending in series along a second longitudinal axis that is parallel to and laterally offset from the first longitudinal axis; and a second plurality of perforation tabs joining the first and second compartments and extending in series along a third longitudinal axis that is parallel to and laterally offset from the first and second longitudinal axes. 
     According to an embodiment, the first and second compartments are shaped as a polygon. 
     According to an embodiment, the first and second compartments are rectangular in shape. 
     According to an embodiment, the first and second compartments are semicircular in shape. 
     According to an embodiment, there are at least four sets of first and second cut-away regions formed in the edges of the first and second compartments. 
     According to an embodiment, there are at least five sets of first and second cut-away regions formed in the edges of the first and second compartments. 
     According to an aspect is a multi-compartment tray, comprising first and second compartments having first and second edges, respectively, that extend towards one another in a first plane; a wave-shaped perforation region having a series of undulating crests and troughs that extend in series with respective tangents that extend in second and third planes, respectively, and are parallel to and laterally offset from the first plane and from each other, wherein at least some of the undulating crests and troughs comprise a perforation tab formed thereon that connect the first and second compartments. 
     According to an aspect is a die for forming a perforation region in a multi-compartment tray, comprising an edge that extends in a wave pattern and comprising a plurality of sequentially spaced crests and troughs; and indented regions formed in at least some of the crests and troughs. 
     According to an aspect is a method for separating a first compartment from a second compartment in a multi-compartment tray in which the first and second compartments have first and second edges, respectively, that extend towards one another in a first plane, and a wave-shaped perforation region having a series of undulating crests and troughs that extend in series with respective tangents that extend in second and third planes, respectively, and are parallel to and laterally offset from the first plane and from each other, wherein at least some of the undulating crests and troughs comprise a perforation tab formed thereon that connect the first and second compartments, the method comprising bending the first compartment relative to the second compartment about an axis that extends along the perforation region; and causing each perforation tab to break and the first compartment to separate from the second compartment. 
     These and other aspects of the invention will be apparent from the embodiments described below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will be more fully understood and appreciated by reading the following Detailed Description in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a perspective view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 2  is a top plan view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 3  is a side elevation view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 4  is a bottom plan view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 5  is a front elevation view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 6  is an enlarged view taken along region  6 - 6  of  FIG. 2 , in accordance with an embodiment. 
         FIG. 7  is an enlarged view showing the nesting/stacking of two trays, in accordance with an embodiment. 
         FIG. 8  is a front elevation view of one container after being split from other container, in accordance with an embodiment. 
         FIGS. 9A and 9B  are side elevation and a detailed view, respectively, illustrating the angled gap between compartments, in accordance with an embodiment. 
         FIGS. 10A and 10B  are side elevation and a detailed view, respectively, illustrating the gap edges used as leverage to facilitate separation of compartments, in accordance with an embodiment. 
         FIGS. 11A and 11B  are side elevation and a detailed view, respectively, illustrating the post-separation of compartments, in accordance with an embodiment. 
         FIGS. 12A and 12B  are a front elevation and a perspective view, respectively, illustrating the perforation tabs post-separation of compartments, in accordance with an embodiment. 
         FIG. 13  is a perspective view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 14  is a top plan view of a multi-compartment container, in accordance with an embodiment. 
         FIGS. 15A and 15B  are a cross-sectional view taken along section line  15 - 15  of  FIG. 14  and a detailed view taken along detail area AP of  FIG. 15A , respectively, in accordance with an embodiment. 
         FIGS. 16A and 16B  are a cross-sectional view taken along section line  16 - 16  of  FIG. 14  and a detailed view taken along detail area AQ of  FIG. 16A , respectively, in accordance with an embodiment. 
         FIGS. 17A and 17B  are a cross-sectional view taken along section line  17 - 17  of  FIG. 14  and a detailed view taken along detail area AR of  FIG. 17A , respectively, in accordance with an embodiment. 
         FIGS. 18A and 18B  are a cross-sectional view taken along section line  18 - 18  of  FIG. 14  and a detailed view taken along detail area AO of  FIG. 18A , respectively, in accordance with an embodiment. 
         FIG. 19  is a perspective view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 20  is a top plan view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 21  is a side elevation view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 22  is a bottom plan view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 23  is a front elevation view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 24  is an enlarged view taken along region  6 - 6  of  FIG. 2 , in accordance with an embodiment. 
         FIG. 25  is an enlarged view showing the nesting/stacking of two trays, in accordance with an embodiment. 
         FIG. 26  is a front elevation view of one container after being split from other container, in accordance with an embodiment. 
         FIG. 27  is a perspective view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 28  is a top plan view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 29  is a side elevation view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 30  is a bottom plan view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 31  is a front elevation view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 32  is an enlarged view taken along region  6 - 6  of  FIG. 2 , in accordance with an embodiment. 
         FIG. 33  is an enlarged view showing the nesting/stacking of two trays, in accordance with an embodiment. 
         FIG. 34  is a front elevation view of one container after being split from other container, in accordance with an embodiment. 
         FIG. 35  is a perspective view of a die used in the manufacture of a multi-compartment container, in accordance with an embodiment. 
         FIG. 36  is a perspective view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 37  is a top plan view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 38  is a side elevation view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 39  is a perspective view of one container when separated from a multi-compartment container, in accordance with an embodiment. 
         FIG. 40  is a front elevation view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 41  is an enlarged view taken along region  41 - 41  of  FIG. 37 , in accordance with an embodiment. 
         FIG. 42  is cross-sectional view taken along section line  42 - 42  of  FIG. 27 , in accordance with an embodiment. 
         FIG. 43  is cross-sectional view taken along section line  43 - 43  of  FIG. 27 , in accordance with an embodiment. 
         FIG. 44  is a perspective view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 45  is a top plan view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 46  is a side elevation view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 47  is a front elevation view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 48  is a perspective view of one container when separated from a multi-compartment container, in accordance with an embodiment. 
         FIG. 49  is a cross-sectional view taken along section line  49 - 49  of  FIG. 45 , in accordance with an embodiment. 
         FIG. 50  is cross-sectional view taken along section line  50 - 50  of  FIG. 45 , in accordance with an embodiment. 
         FIG. 51  is cross-sectional view taken along section line  51 - 51  of  FIG. 45 , in accordance with an embodiment. 
         FIG. 52  is an enlarged view taken along region  52 - 52  of  FIG. 49 , in accordance with an embodiment. 
         FIG. 53  is an enlarged view taken along region  53 - 53  of  FIG. 50 , in accordance with an embodiment. 
         FIG. 54  is a perspective view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 55  is a top plan view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 56  is a side elevation view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 57  is a front elevation view of a multi-compartment container, in accordance with an embodiment. 
         FIG. 58  is a perspective view of a multi-compartment container with one container separated therefrom, in accordance with an embodiment. 
         FIG. 59  is a cross-sectional view taken along section line  59 - 59  of  FIG. 55 , in accordance with an embodiment. 
         FIG. 60  is cross-sectional view taken along section line  60 - 60  of  FIG. 55 , in accordance with an embodiment. 
         FIG. 61  is an enlarged view taken along region  61 - 61  of  FIG. 55 , in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     The present disclosure describes a multi-compartment tray  10 . Tray  10  comprises multiple compartments, two compartments  12  and  14  being used for purposes of illustration although more than two could be formed (e.g., four, six, etc.), that are connected at the time of sale and then able to be split into separate, detached compartments by a user, as will be described hereinafter. Tray  10  is preferably composed of polypropylene, polystyrene, polyethylene, PET, PVC, or any combination of these, with or without barrier materials such as EVOH, minerals, thermoplastic starch, and other well understood barrier materials. 
     Referring to  FIG. 1 , in one embodiment, is a multi-compartment tray, designated generally by reference numeral  10 , comprising first and second compartments  12  and  14 , respectively, adapted to hold contents, such as food, liquids, solids, nutraceuticals, and pharmaceuticals, therein. First and second compartments  12  and  14  include upwardly facing flanges  16  and  18 , respectively, which extend in a common plane F. Each flange  16  and  18  includes a terminal edge  20  and  22 , respectively, that are positioned adjacent to one another but are slightly separated by a small angled and/or notched gap  23  (e.g., V-shaped as shown most clearly in  FIGS. 9A and 9B ) from one another on either side of an elongated axis X-X. A perforation region, designated generally by reference numeral  24 , generally extending along axis X-X joins compartments  12  and  14  together. In use, a user may snap (by bending) tray  10  about axis X-X to separate one compartment from the other. 
     Perforation region  24  comprises a series of perforation waves, each designated generally by reference number  26 . Notably, the “wave” can be of a typical sinusoidal shape as shown, but could take other shapes, such as saw tooth or truncated saw tooth as well. Each wave  26  comprises a trough  28  and a crest  30 . A tangent to each trough  28  of each wave  26  extends along an axis A-A and in a plane T that is parallel to and offset from axis X-X and plane F. Likewise, a tangent to each crest  30  of each wave  26  extends along an axis B-B and in a plane C that is parallel to and offset from axes A-A and X-X and planes T and F. 
     During manufacturing, one perforation tab  32 ,  34  is formed on each trough  28  and crest  30 , respectively, and the containers  12  and  14  are joined by attachment/bonding of corresponding tabs  32 ,  34 . Thus, the sole attachment between compartments  12  and  14  is achieved through connection/bonding of tabs  32  and  34  on correspondingly positioned troughs  28  and waves  30 . Therefore, as shown in  FIGS. 9-12 , by holding and bending/snapping compartments  12  and  14  about axis X-X, the corresponding tabs  32  and  34  will break apart, thereby separating compartments  12  and  14 . Because the connection is done at the series of tabs  32 / 34 , as opposed to being a bond along the entire edges of the compartments, the amount of force required to break the attachment between tabs is relatively minor and certainly significantly less than would be required with a continuous attachment/bond. Moreover, the perforations created by the tabs  32 / 34  lie in two planes thus creating a 3-dimensional perforation structure which elongates and stretches the leverage points further facilitating the clean and relative low force break between compartments. Accordingly, a user can apply leverage across the offset planes to break the tabs resulting in a “snapping” a part of the two compartments. Further this 3-dimensional perforation structure provides increased rigidity when the two compartments remain connected, as compared to a liner (or 2-dimensional) perforation. 
     With reference to  FIGS. 15-18 , the connectivity structure between corresponding tabs  32  and  34  can be seen most clearly. Further, the slight gap  23  that exists between compartments  12  and  14  in areas where tabs  32  and  34  are absent is shown in  FIGS. 17A, 17B, 18A and 18B . 
     The number of waves  26  can vary depending on the size of containers  12 / 14 . For example, there are 4 waves shown in the embodiment of  FIGS. 1-14 , five waves in the embodiments of  FIGS. 19-25 and 36-43 , one wave in the embodiment of  FIGS. 44-53 , and seven waves in the embodiment of  FIGS. 54-61 . Likewise, the shape of containers  12 / 14  can be formed as desired; for example rectangular ( FIGS. 1-25 ), semicircular ( FIGS. 28-33 ), or most any other shape (e.g., triangular, trapezoidal, circular, etc.), as long as the shape provides an elongated edge in which the wave perforations can be formed. Further, the angle at which the wave perforation regions  24  extend relative to the containers  12 / 14  can be transverse/perpendicular (for example, as in the embodiments of 1-33 and 44-58) or at any other non-orthogonal angle (for example, as in the embodiment of  FIGS. 36-43 ). Finally, the number of containers  12 / 14  that can be a part of the multi-compartment tray  10  can be any number from two on, and can be of the same or different sizes/volumes. For example, the embodiment of  FIGS. 54-61  comprises six compartments  202 ,  204 ,  206 ,  208 ,  210 ,  212  (the reference numerals differing from  12 ,  14  simply due to the exemplary nature of providing an embodiment that includes more than two compartments). In this embodiment, there are two lines of wave perforation regions  24  separating each compartment from its two neighboring compartments; and each of the two wave perforation areas associated with each container is perpendicularly oriented relative to the other (of course, other structural arrangements of compartments are possible with the angles between perforation regions varying depending on the geometric shape selected for the multi-compartment tray  10 .) 
     In manufacturing container  12 , a die  100  is used to produce perforation region  24 . The die  100 , shown in  FIG. 35 , is mechanically pushed down onto the material composing container  12 / 14  in the area to become perforation region  24 . Die  100  comprises a wave-shaped edge  102  that corresponds with the wave shape of perforation region  24  and forms the troughs  28  and waves  30  with edge portion. In addition, indented areas  104 / 106  are formed in edge  102  to form the perforation tabs  32 ,  34 , respectively. 
     While various embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, embodiments may be practiced otherwise than as specifically described and claimed. Embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the scope of the present disclosure.