Patent ID: 12252308

DETAILED DESCRIPTION OF THE DISCLOSURE

Referring now in detail to the drawing figures, wherein like reference numerals represent like parts throughout the several views, one embodiment of a tray constructed according to the present disclosure is illustrated generally at10inFIGS.1and2. The tray10is formed from a blank11that includes a first material layer12formed of a solid fiber, paperboard or corrugated material, among other suitable materials, which can have any suitable type of coating (not shown) thereon, if desired. The first material layer12includes a top surface14, and a bottom surface16. The first material layer12is optionally separated by a number of score lines or perforation lines18into a central section20, a pair of side walls22,24connected to the central section20, and a pair of end walls26,28connected to the central section20. However, the central section20, side walls22,24and end walls26,28of the first material layer12may additionally be formed from different materials as desired and subsequently joined to one another using other suitable structures and/or methods, including mechanical devices (not shown), tape and/or adhesives, among others.

Looking at the illustrated exemplary embodiment ofFIGS.1-3, each end wall26,28has a length corresponding to that of the adjacent edge of the central section20, and includes a first end wall portion30attached to the central portion20, and a second end wall portion32attached to the first end wall portion30opposite the central section20. The first end wall portion30and the second end wall portion32are joined by hinge34formed with a pair of perforation lines36disposed immediately adjacent the first end wall portion30and second end wall portion32, respectively, and spaced from one another. In the space38formed between the perforations36, a pair of slots or openings40are formed by die cuts42in the space38.

Referring now toFIGS.1-2and4, the side walls22,24are each formed with a side wall portion44that is connected to the central portion20along one perforation line18and has a length approximately equal to the length of the adjacent edge of the central portion20. Each side of the side wall portion44includes a locking tab or flap46extending outwardly therefrom. The locking flaps46extend past the dimensions of the central portion20to positions adjacent the end walls26,28, and define a gap or window48between the flaps46and the end walls26,28. The flaps46additionally include a locking tab50opposite the side wall portion44and a recess52disposed and extending inwardly from the tab50along the flaps46. The particular shape of the first material layer12including the various features thereon is created during a die cutting process of a flat preform (not shown) of the first material layer12, such that the first material layer12requires no further processing prior to use in forming the tray10.

Looking now atFIGS.1and2, the blank11additionally includes a second material layer60disposed over the top surface14of the first material layer12. The second material layer60is formed of a film of any suitable material, such as a recyclable plastic material, such as a polylactic acid (PLA) film material, or a recyclable cellulose material, and in one exemplary embodiment is formed of parchment paper. The second material layer60is applied over the central portion20, the first end wall portions30, the side wall portions44, and over at least parts of the locking flaps46and gap48, while leaving the second end wall portions32and locking tabs50uncovered. The second material layer60provides a flexible and leak-proof barrier on the top surface14of the blank11, forming a tray10that is recyclable, biodegradable, and compostable and acts as a barrier for moisture as a function of being in direct contact with a food product (not shown) positioned within the tray10. In addition, there is capability to print directly on the second material layer60, particularly when the second material layer60is formed of a clear or opaque film.

The second material layer60can be affixed to the top surface14of the first material layer12in any suitable manner, such as by printing the second material layer60directly on the first material layer12, but in the exemplary embodiment illustrated inFIG.1, the second material layer60is adhered using an adhesive62. The adhesive62is any suitable type of adhesive for use with the tray10, such as a cold adhesive application, and can be applied to the top surface14of the blank11/first material layer12using a roller coater (not shown) with subsequent application of the second material layer60to the adhesive62. The adhesive62is applied on the first material layer12registering the location of the adhesive62on the increased surface area provided by the reduced number of folded sections of the corner of the tray10, to allow for a secure web and/or leak proof corner80in the final construction of the tray10. In the illustrated exemplary embodiment ofFIG.10, the adhesive62can be applied to have a color showing where the adhesive62has been applied to the top surface14and showing through the second material layer60, particularly when the second material layer60is clear. The orientation or disposition of the adhesive62on the blank11/first material layer12by the roller coater can be selected to provide various indicia64on the central section20and/or walls22,24,26,28of the tray10, which may include cutting length or size indicia for the food item (not shown) disposed within the tray10and/or various trademarks indicating the source of the food item, among others.

In another exemplary embodiment of the disclosure, upon heating of the tray10, such as to prepare the food item therein, the adhesive62degrades, both dissipating the color in the adhesive62and enabling the second material layer60to be removed from the blank11, such that the blank11/first material layer12can be recycled separately from second material layer60.

In another exemplary embodiment, for prior blanks11/first material layers12that include a coating (not shown), in the prior art the corrugated is applied to the blank11or to one or more of the layers of materials (not shown) forming the corrugated blank11prior to the blank11being processed by and/or manufactured on a corrugator (not shown) that uses heat in the manufacturing process to form the blank11into the desired configuration and shape for use in forming a container. The temperatures reached by the corrugator can degrade and/or render the coating material applied to one or more portions of the blank11inoperable. But, with the application of the second material layer60in the present disclosure, e.g., the paper or film layer, over the top of an already corrugated and formed blank11in place of a separate coating on the blank11, the present disclosure provides two very distinct advantages:1) applying the second material layer60, e.g., release film or paper, to an already manufactured/die cut blank11eliminates the difficulties of corrugating coated materials as the blank11can be formed without any coating thereon that could be degraded by the manufacturing process for the blank11; and2) applying the second material layer60to an already die cut blank11including the coated material provides the opportunity to manipulate certain folds with only the paper or film. When coated materials are produced on the corrugator the entire blank contains the coated material.

In another exemplary embodiment of the disclosure, the central section20can be formed with a number of apertures100therein, as shown inFIGS.12-15. The apertures100can have any configuration and number desired, and extend completely through the central section20of the blank11/first material layer12and are covered by the second material layer60in the final construction of the tray10. The apertures100enable heat to more readily contact the food item positioned within the tray10, counteracting the insulating properties of the solid fiber, paperboard or corrugated material forming the blank11/first material layer12and thereby enabling more even and faster heating of the food item in the tray10.

Looking now atFIGS.5-9, an exemplary method of assembling the tray10from the blank11including the first material layer12and the second material layer60is illustrated. Initially, as shown inFIG.5, the end walls26and28are folded upwardly with regard to the central section20, which partially folds the area of the second material layer60disposed between the end walls26,28and the adjacent side walls22,24. Next, as shown inFIG.6the side walls22,24are folded upwardly relative to the central section20and the locking flaps46are folded inwardly towards the associated end walls26,28. This movement of the side walls22,24and the flaps46creates a bellows corner in the second material layer60between the end wall26,28and the side wall22,24, as shown inFIG.6. Then, as shown inFIG.7, the flap46is secured against the exposed surface of first end wall portion30of the end wall26,28, to compress and form the leak-proof bellows corner with the second material layer60and to form the corner of the tray10.

While the flap46can be secured to the adjacent or associated end wall26,28in any suitable manner, in one particular embodiment an adhesive, such as adhesive62, is placed on the flap46to adhere the flap46to the adjacent end wall26,28and thus form the leak-proof corner80, as described previously. In one exemplary embodiment, the adhesive62is applied to the flap46at a forty-five degrees (45°) relative to the corner, such as by an aligned gluing plate (not shown) in order to precisely place the adhesive62on the flap46in this orientation. The adhesive62positioned in this manner allows for the flap46to positioned and secured to the end wall26,28in the correct location to form the leak-proof corner80with the second material layer60.

Once the flap46is attached, as shown inFIG.8, the second end wall portion32can be folded inwardly over the central section20relative to the first end wall portion30. In this position the second end wall portion32extends over the associated lengths of the adjacent side walls22,24and forms a stacking tab70on which additional trays10can be positioned for shipment, as best shown inFIG.11.

With the use of the second material layer60, the amount or thickness of the material forming the tray10at the corners80is greatly reduced, e.g., only two thicknesses of the material forming the first material layer12as opposed to three thicknesses in prior art trays, resulting in greatly reduced material usage and associated cost. Further, a more vertical position of the side walls22,24extending between the corners can be maintained using the perforations in the first material layer12, such as at an angle of approximately seven (7°) from perpendicular to the central portion20as opposed to between fifteen (15°) and twenty (20°) degrees from perpendicular to the central portion20in prior art trays, greatly reducing the variation in the width of the tray10as opposed to prior art trays. Also, the use of the second material layer60to form the leak-proof bellows corners80can be maintained to retain the food items therein, even during preparation of the food items, such as by heating or baking the food items directly in the tray10. Further, in another exemplary embodiment, the folded or “web” corner of second material layer60is glued on a forty-five (45°) degree angle which creates the leak proof corner. Additionally, the ability to form the perforation lines18in the first material layer12more effectively takes the memory out of the material thrilling the first material layer12along with allowing gasses to escape the ray10through the first material layer12.

Looking now atFIG.9, when it is desired to open the tray10to access a prepared food item held therein, the locking flaps46can be disengaged from the first side wall portion30on one side wall26,28to enable the end wall26,28to be pivoted away from the central section20, forming and access channel into the interior of the tray10. If and when it is desired to close the tray10to retain the unused portion of the food item therein. The first end wall portion30can be pivoted hack to the shipment position and the locking flaps46can be repositioned against the first end wall portion30, The second end wall portion32can then be folded over the flaps46, such that the locking tabs48on the flaps46become engaged within the openings40formed in the space38between the first end wall portion30and the second end wall portion32.

Changes can be made in the above constructions and method steps without departing from the scope of the invention, such as by firming a tray10and or blank11having a polygonal shape other than square or rectangular, and potentially including exclusively foldable sections including locking flaps on one end that are engageable with slots formed in the opposite end of each foldable section, and it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Various other embodiments of the present invention are contemplated as being within the scope of the filed claims particularly pointing out and distinctly claiming the subject matter regarded as the invention.