PRODUCT PACKAGING

Abstract

A tray device includes plastic material. The tray device further includes divided product compartments that separate multiple products. A top reinforced ridge surrounds the tray device. A perimeter upper trim is connected to the top reinforced ridge. The perimeter upper trim includes a surface that has a return towards a base of the tray device. The upper trim flexes upon wrapping the tray device with a sealing sheet.

Description

BACKGROUND

Fresh foods packaged for shipping, distribution and sale. Packaging needs to store goods and be sealed for maintaining freshness, keeping out contaminants, etc. Many times the products are packed on top of one another and side by side. Shipping of the packaged fresh foods tends to move the packaged products causing abrasion to the sealing sheets of the packaging, which allows excess air, dust/dirt, insects, etc. to enter the product packaging.

SUMMARY

One embodiment of the invention comprises a tray device comprising plastic material. The tray device further comprises a plurality of divided product compartments that separate multiple products. A top reinforced ridge surrounds the tray device. A perimeter upper trim is connected to the top reinforced ridge. The perimeter upper trim includes a surface that has a return towards a base of the tray device. The upper trim flexes upon wrapping the tray device with a sealing sheet.

Another embodiment of the invention comprises apparatus comprising: a mold plate having a cavity for a plurality of divided product compartments for molding a tray device and a plug assist portion. A cavity for a top reinforced ridge that surrounds the tray device. A cavity for a perimeter upper trim coupled to the cavity for the top reinforced ridge. The cavity for the perimeter upper trim comprises a groove in the mold plate for molding a surface that includes a return towards a base of the tray device. The cavity for the perimeter upper trim is coupled to a first vacuum through hole within the mold plate and a second vacuum through hole within the mold plate. The first through hole and the second through hole are each coupled to a third vacuum through hole in the mold plate.

Yet another embodiment of the invention comprises an apparatus. The apparatus comprises a corn cob tray device comprising plastic material. The corn cob tray device includes a plurality of cylindrical shaped product compartments that separate multiple corn produce products from coming into contact with one another. A top reinforced ridge surrounds the corn cob tray device. A perimeter upper trim is coupled to the top reinforced ridge. The perimeter upper trim comprises a surface that includes a return towards a base of the corn cob tray device. The upper trim flexes upon wrapping the corn cob tray device with a sealing sheet for prevention of tearing the sealing sheet.

Other aspects and advantages of the present invention will become apparent from the following detailed description, which, when taken in conjunction with the drawings, illustrate by way of example the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments are illustrated by way of example, and not by way of limitation, in the Figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:

FIG. 1 illustrates a perspective view of a single row product packaging device according to one embodiment of the invention;

FIG. 2 illustrates a perspective view of a single row product packaging device shown with exemplar corn products inserted into the device, according to one embodiment of the invention;

FIG. 3 illustrates a side view of the single row product packaging device shown in FIG. 2 according to one embodiment of the invention;

FIG. 4 illustrates a side view of multiple stacked single row product packaging devices including exemplar corn products inserted into the stacked single row product packaging devices according to one embodiment;

FIG. 5 illustrates a perspective view of multiple stacked single row product packaging devices including exemplar corn products inserted into the stacked single row product packaging devices according to one embodiment;

FIG. 6 illustrates a perspective view of a double row product packaging device according to one embodiment of the invention;

FIG. 7 illustrates a perspective view of a double row product packaging device shown with exemplar corn products inserted into the device according to one embodiment of the invention;

FIG. 8 illustrates a side view of the double row product packaging device shown in FIG. 7 according to one embodiment of the invention;

FIG. 9 illustrates a side view of multiple stacked double row product packaging devices including exemplar corn products inserted into the stacked double row product packaging devices according to one embodiment;

FIG. 10 illustrates a perspective view of multiple stacked double row product packaging devices including exemplar corn products inserted into the stacked double row product packaging devices according to one embodiment;

FIG. 11 illustrates a perspective view of a mold plate according to one embodiment of the invention;

FIG. 12A illustrates a top view of the mold plate shown in FIG. 11 according to one embodiment of the invention;

FIG. 12B illustrates a cross-sectional view of the mold plate shown in FIG. 12A along section A-A according to one embodiment of the invention

FIG. 12C illustrates a detailed view of B shown in FIG. 12B according to one embodiment of the invention;

FIG. 13 illustrates a close-up view of the mold plate shown in FIG. 11 according to one embodiment of the invention;

FIG. 14 illustrates a cross-section view of a plug assist for the mold plate shown in FIG. 11 according to one embodiment of the invention; and

FIG. 15 illustrates a close-up view of the cross-section view shown in FIG. 14 according to one embodiment of the invention.

DETAILED DESCRIPTION

The following description is made for the purpose of illustrating the general principles of the invention and is not meant to limit the inventive concepts claimed herein. Further, particular features described herein can be used in combination with other described features in each of the various possible combinations and permutations. Unless otherwise specifically defined herein, all terms are to be given their broadest possible interpretation including meanings implied from the specification as well as meanings understood by those skilled in the art and/or as defined in dictionaries, treatises, etc.

The description may disclose several preferred embodiments of product packaging, as well as operation and/or component parts thereof. While the following description will be described in terms of corn cob product packaging for clarity and to place the invention in context, it should be kept in mind that the teachings herein may have broad application to all types of systems, devices and applications.

The embodiments relate to product packaging, and in particular to molds and product packaging for corn products having specialized features for preventing tearing of sealing sheets. One embodiment of the invention provides a tray device comprising plastic material. The tray device further comprises a plurality of divided product compartments that separate multiple products. A top reinforced ridge surrounds the tray device. A perimeter upper trim is connected to the top reinforced ridge. The perimeter upper trim includes a surface that has a return towards a base of the tray device. The upper trim flexes upon wrapping the tray device with a sealing sheet.

FIG. 1 illustrates a perspective view of a single row product packaging device (or tray device) 100 according to one embodiment of the invention. In one example, the product packaging device 100 may be manufactured by a thermoforming, injection molding, or any equivalent forming processes. In one example the raw material may comprise a flat extruded sheet of recycled and recyclable polyethylene terephthalate (RPET) plastic resin, polypropylene (PP), PVC, polyethylene (PE), polystyrene (PS), etc. (e.g., recycled water bottles, soda bottles, etc.). In one embodiment of the invention, the product packaging device 100 includes multiple (e.g., 4, 6, 8, etc.) curved or semi-cylindrical (e.g., partial cylindrical) shaped product dividing compartments 120. In one example, the dividing compartments 120 separate corn cob produce products from contacting one another while packaged within the product packaging device 100.

In one embodiment, the product packaging device 100 includes a top reinforced ridge 140 surrounding the product packaging device 100. The top reinforced ridge 140 includes strengthening ribs 130 that prevent deflection of the top reinforced ridge 140 upon wrapping the product packaging device 100 with the sealing sheet (e.g., plastic sheeting, wrapping film, plastic wrap, perforated plastic wrap, shrink wrap, high density polyethylene, etc.). In one embodiment, a perimeter upper trim is formed with the top reinforced ridge 140. The perimeter upper trim includes a surface 145 (FIG. 2) that has a return towards a base 150 (or bottom) of the product packaging device 100. In one example, the return is thermoformed and has a thickness that is less than a thickness for all other tray device components of the product packaging device 100. In one example, the lesser thickness of the return provides a feature that a sealing sheet avoids tearing from abrasion by having a greater flexibility than other portions of the product packaging device 100.

An exterior surface of the base 150 is flat. The upper trim has a thickness that provides for flexing upon the product packaging device 100 being wrapped with a plastic sealing sheet. In one embodiment, the product packaging device 100 includes flat exterior side walls 110.

FIG. 2 illustrates a perspective view of a single row product packaging device 100 shown with exemplar corn cob produce products 210 inserted into the product packaging device 100, according to one embodiment of the invention. As shown, corn cob produce products are each inserted to their own dividing compartment 120, which holds the respective corn cob produce product 210 in place. The corn cob produce products 210 are packed closely together in the product packaging device 100, but do not come in contact with one another due to the width of the upper ridge 125 between each dividing compartment 120.

FIG. 3 illustrates a side view of the single row product packaging device 100 shown in FIG. 2 according to one embodiment of the invention. FIG. 4 illustrates a side view example 400 of multiple stacked single row product packaging devices 100 including exemplar corn cob produce products 210 inserted into the stacked single row product packaging devices according to one embodiment. In one example, due to the combination of the base 150 being flat, the reinforcing ribs 130, and the placement of the corn cob products 210 in the dividing compartments 120 for tightly packing corn cob products 210, multiple corn cob packed product packaging devices 100 are stackable with stability, and without damaging the corn cob product products 210. FIG. 5 illustrates a perspective view of multiple stacked single row product packaging devices 100 including exemplar corn cob produce products 210 inserted into the stacked single row product packaging devices 100, according to one embodiment.

FIG. 6 illustrates a perspective view of a double row product packaging device 600 according to one embodiment of the invention. In one example, the product packaging device 600 may be manufactured by a thermoforming, injection molding, or any equivalent forming processes. In one example the raw material may comprise the same or similar materials as with product packaging device 100 (FIG. 1). In one embodiment of the invention, the product packaging device 100 includes multiple (e.g., 8, etc.) curved or semi-cylindrical (e.g., partial cylindrical) shaped product dividing compartments 620. In one example, the dividing compartments 620 separate corn cob produce products from contacting one another while packaged within the product packaging device 100 based on the width of the upper ridge 625 between each dividing compartment 620 and the gap or groove 626 between the two columns of dividing compartments 620.

In one embodiment, the product packaging device 600 includes a top reinforced ridge 640 surrounding the product packaging device 600. The top reinforced ridge 640 includes strengthening ribs 630 that prevent deflection of the top reinforced ridge 640 upon wrapping the product packaging device 600 with the sealing sheet (e.g., plastic sheeting, wrapping film, plastic wrap, perforated plastic wrap, shrink wrap, high density polyethylene, etc.). In one embodiment, a perimeter upper trim is formed with the top reinforced ridge 640. The perimeter upper trim includes a surface 645 (FIG. 7) that has a return towards a base 650 (or bottom) (FIG. 8) of the product packaging device 600. In one example, the return is thermoformed and has a thickness that is less than a thickness for all other tray device components of the product packaging device 600.

An exterior surface of the base 650 is flat. The upper trim has a thickness that provides for flexing upon the product packaging device 600 being wrapped with a plastic sealing sheet. In one embodiment, the product packaging device 600 includes flat exterior side walls 610.

FIG. 7 illustrates a perspective view of a double row product packaging device 600 shown with exemplar corn cob produce products 710 inserted into the product packaging device 600, according to one embodiment of the invention. As shown, corn cob produce products 710 are each inserted to their own dividing compartment 620, which holds the respective corn cob produce product 710 in place. The corn cob produce products 710 are packed closely together in the product packaging device 600, but do not come in contact with one another due to the width of the upper ridge 625 between each dividing compartment 620 and the gap or groove 626.

FIG. 8 illustrates a side view of the double row product packaging device 600 shown in FIG. 7 according to one embodiment of the invention. FIG. 9 illustrates a side view example 900 of multiple stacked single row product packaging devices 600 including exemplar corn cob produce products 710 inserted into the stacked double row product packaging devices according to one embodiment. In one example, due to the combination of the base 650 being flat, the reinforcing ribs 630, and the placement of the corn cob products 710 in the dividing compartments 620 for tightly packing corn cob products 710, multiple corn cob packed product packaging devices 600 are stackable with stability, and without damaging the corn cob product products 710. FIG. 10 illustrates a perspective view of multiple stacked double row product packaging devices 600 including exemplar corn cob produce products 710 inserted into the stacked single row product packaging devices 600, according to one embodiment.

FIG. 11 illustrates a perspective view of a mold plate system 1100 according to one embodiment of the invention. In one embodiment, the mold plate system 1100 includes a metal (e.g., aluminum) mold plate 1110, a first corn cob tray cavity 1120 for either single row (not shown) or double row corn cob dividing compartments, a second corn cob tray cavity 1125, a plug assist 1130 and a plug assist mounting holes 1131.

FIG. 12A illustrates a top view of the mold plate system 1100 shown in FIG. 11 according to one embodiment of the invention. In one example, the line A-A is shown across the middle/center of the mold plate 1110. FIG. 12B illustrates a cross-sectional view of the mold plate system 1100 shown in FIG. 12A along section A-A according to one embodiment of the invention. As shown, the internal view of the mold plate 1230 includes the view of the plug assist 1210 and the view of the corn tray 1220. The circle referenced as “B” is enlarged in FIG. 12C. As shown in FIG. 12C, a detailed view of the circle “B” shown in FIG. 12B includes the view of the plug assist 1210, the view of the corn tray 1220, the mold plate 1230, a large drilled vacuum hole 1231, a vacuum groove 1232, small vacuum holes 1233, and air gap 1234 between the bottom of the mold plate 1110 and the plug assist 1130.

FIG. 13 illustrates a close-up view of the mold plate 1110 of the mold plate system 1100 shown in FIG. 11, according to one embodiment of the invention. The details of the mold plate 1110 including the plug assist 1130, the plug assist mounting holes 1131 and the first corn cob tray cavity 1120 for corn cob dividing compartments are shown in the close-up view.

FIG. 14 illustrates a cross-section view of a plug assist 1130 for the mold plate 1110 of the mold plate system 1100 shown in FIG. 11, according to one embodiment of the invention. In one embodiment, the mold plate 1110 includes a mold portion for a return 1420 that extends towards a base of the tray portion and has an extension that is perpendicular to the top ridge 1510 (FIG. 15). In one example, the return 1420 prevents plastic wrap film from being cut due to abrasion. In on embodiment, the return 1420. In one embodiment, the space 1410 provides for a vacuum to be created for the mold plate system 1100.

FIG. 15 illustrates a close-up view of the cross-section view shown in FIG. 14 according to one embodiment of the invention. In one embodiment, the mold plate 1110 includes a top ridge 1510 opposite the return 1420. In one example, the return 1420 is formed by milling an extra groove in the mold plate 1110. In one embodiment, grooves 1520 are milled into wall 1521 of the mold plate 1110 for forming strengthening ribs 130 (FIG. 1).

In the description above, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. For example, well-known equivalent components and elements may be substituted in place of those described herein, and similarly, well-known equivalent techniques may be substituted in place of the particular techniques disclosed. In other instances, well-known structures and techniques have not been shown in detail to avoid obscuring the understanding of this description.

Reference in the specification to “an embodiment,” “one embodiment,” “some embodiments,” or “other embodiments” means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments. The various appearances of “an embodiment,” “one embodiment,” or “some embodiments” are not necessarily all referring to the same embodiments. If the specification states a component, feature, structure, or characteristic “may”, “might”, or “could” be included, that particular component, feature, structure, or characteristic is not required to be included. If the specification or claim refers to “a” or “an” element, that does not mean there is only one of the element. If the specification or claims refer to “an additional” element, that does not preclude there being more than one of the additional element.

While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those ordinarily skilled in the art.

Claims

1. A tray device for product packaging comprising:

a tray device comprising plastic material, the tray device including: a plurality of divided product compartments that separate multiple products; a top reinforced ridge surrounding the tray device; and a perimeter upper trim coupled to the top reinforced ridge, the perimeter upper trim comprises a surface that includes a return towards a base of the tray device, the upper trim flexes upon wrapping the tray device with a sealing sheet.

2. The tray device of claim 1, wherein the plastic material comprises one of:

recycled polyethylene terephthalate (RPET), polypropylene (PP), polyethylene (PE) or polystyrene (PS).

3. The tray device of claim 2, wherein the tray device further comprises flat exterior side walls.

4. The tray device of claim 2, wherein an exterior surface of the base is flat.

5. The tray device of claim 4, wherein each of the divided product compartments has a curved shape and prevents adjacent products from contacting one another.

6. The tray device of claim 4, wherein each of the divided product compartments has a semi-cylindrical shape.

7. The tray device of claim 6, wherein the top reinforced ridge comprises strengthening ribs that prevent deflection of the top reinforced ridge upon wrapping the tray device with the sealing sheet.

8. The tray device of claim 4, wherein the tray device is stackable with other tray devices.

9. The tray device of claim 8, wherein the return is thermoformed and has a thickness that is less than a thickness for all other components of the tray device.

10. The tray device of claim 1, wherein the tray device formed by thermoforming or injection molding, the plastic material comprises recycled or recyclable material, and the plurality of divided product compartments comprise one of a single row of divided corn produce product compartments or double rows of divided corn produce product compartments.

11. An apparatus comprising:

a mold plate having a cavity for a plurality of divided product compartments for molding a tray device, and a plug assist portion;

a cavity for a top reinforced ridge that surrounds the tray device;

a cavity for a perimeter upper trim coupled to the cavity for the top reinforced ridge, the cavity for the perimeter upper trim comprises a groove in the mold plate for molding a surface that includes a return towards a base of the tray device,

wherein the cavity for the perimeter upper trim is coupled to a first vacuum through hole within the mold plate and a second vacuum through hole within the mold plate, the first through hole and the second through hole are each coupled to a third vacuum through hole in the mold plate.

12. The apparatus of claim 11, wherein the third through hole has a larger volume in the mold plate than each of the first through hole and the second through hole.

13. The apparatus of claim 12, wherein the groove in the mold plate is configured for forming a flexible surface coupled to the top reinforced ridge of the tray device.

14. The apparatus of claim 13, wherein the mold plate receives molding material comprising one of: recycled polyethylene terephthalate (RPET), polypropylene (PP), polyethylene (PE) or polystyrene (PS).

15. The apparatus of claim 14, wherein the mold plate includes a cavity for forming flat exterior side walls for the tray device, each divided product compartment has a curved shape and is configured for preventing adjacent produce products from contact with one another, and each of the divided product compartments has a semi-cylindrical shape.

16. The apparatus of claim 15, wherein the flexible surface is thermoformed for having a thickness that is less than a thickness for all other components of the tray device.

17. The apparatus of claim 11, wherein the plurality of divided product compartments comprise one of a single row of divided corn produce product compartments or double rows of divided corn produce product compartments.

18. An apparatus comprising:

a corn cob tray device comprising plastic material, the corn cob tray device including: a plurality of semi-cylindrical shaped product compartments that separate multiple corn produce products from coming into contact with one another; a top reinforced ridge surrounding the corn cob tray device; and a perimeter upper trim coupled to the top reinforced ridge, the perimeter upper trim comprises a surface that includes a return towards a base of the corn cob tray device, the upper trim flexes upon wrapping the corn cob tray device with a sealing sheet for prevention of tearing the sealing sheet.

19. The apparatus of claim 18, wherein:

the plastic material comprises one of: recycled polyethylene terephthalate (RPET), polypropylene (PP), polyethylene (PE) or polystyrene (PS);

the top reinforced ridge comprises strengthening ribs that prevent deflection of the top reinforced ridge upon wrapping the corn cob tray device with the sealing sheet;

the return is thermoformed and has a thickness that is less than a thickness for all other components of the corn cob tray device; and

the corn cob tray device formed by thermoforming or injection molding.

20. The apparatus of claim 19, wherein the corn cob tray device further comprises flat exterior side walls,

wherein an exterior surface of the base is flat.