CARRYING TRAY FOR HOLDING, TRANSPORTING, AND/OR DELIVERING FOOD AND BEVERAGE CONTAINERS AND METHOD THEREFOR

Abstract

A carrying tray having a top wall and a plurality of receptacle cavities in the top wall with each cavity being configured to accept a container such as a beverage cup therein and having retaining features for holding the cup upright with a substantial portion of the cup sidewall being retained below the top wall of the tray within the cavity. The retaining features include a plurality of collar tabs that limit tipping of the cups within the cavity particularly during transportation. The carrying tray can be assembled from a flat die-cut blank without the aid of adhesives and fasteners by utilizing a combination of locking tabs and cooperative openings in the sidewalls. The carrying tray along with the cups can be placed in a tamper evident delivery bag for convenient transportation of the beverage cups in a secure tamper resistant manner to a consumer.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. Provisional Patent Application No. 63/111,945, filed on Nov. 10, 2020, in the United States Patent and Trademark Office. The disclosure of which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

This invention relates to a carrying tray for securely holding, transporting, and delivering food and beverage containers. More specifically, the present invention relates to a carrier device that is formed from a pre-cut blank and assembled into a carrying tray for conveniently holding, transporting, and delivering a plurality of food and/or beverage containers in a safe and secure manner and method therefor.

BACKGROUND OF THE INVENTION

Beverages such as tea, coffee, soft drinks, carbonated drinks are often sold or served in a disposable plastic or paper cup that a customer can either consume on-site or takeaway with them for consumption at another location. Therefore, a carrying device is often required when beverage cups are to be carried or transported to another location, particularly when a person must carry more than one cup or even a single cup with other food items.

Cup carriers and trays for holding and carrying beverage cups or similar containers are well-known and are frequently used in restaurants, coffee shops, cafeterias, airports, stadiums, and the like. A popular style of tray for holding beverage cups is typically constructed from a molded fiber and includes a plurality of pocket cavities for receiving cup bottoms.

While a number of molded fiber tray designs and pocket structures for holding cups therein have been proposed, the molded fiber trays tend to have many shortcomings including the tendency of the cup carriers to collapse along a line between adjacent cup pockets, that make them less than ideal for transporting and delivering. Furthermore, beverage cups that are particularly tall have a greater tendency for spillage and tipping during transport due their relatively large height/diameter ratio. Additionally, these trays despite being nestable are not compact and require a restaurant or foodservice operator to commit a large area of backroom space to storage of packaging instead of storage of food or beverage items.

Other cup carrier devices include a paperboard tray that often is provided to operators in a folded state. Typically, this tray has a floor and cut outs in the floor for creating a pop-up containment area. These devices only capture a small portion of the cup bottom making the contained cups prone to tipping.

What is needed, therefore, is a carrying tray that provides a reliable and stable solution for holding, carrying, transporting and delivering beverage cups and containers and overcome the general shortcomings of molded fiber trays discussed above. These and other needs that have so far remain unfilled, are addressed by the carrying tray of the present invention.

SUMMARY OF THE INVENTION

One of the needs that has so far remained relatively unfilled is safe delivery of drinking beverages and fluid foods such as soup in a convenient manner without tipping and spilling. It has been realized that due to manufacturing reasons and other constraints, a basic limitation of molded fiber trays is that the pocket cavities, or “sockets” as they are sometimes referred to, are configured to capture only a relatively narrow bottom section of the cup-sidewall making the tray top-heavy, leading to increased propensity for tipping and spillage of the beverage from the cups. Additionally, the molded fiber trays and similar carrier devices are not particularly suitable for being placed in a delivery bag as the tension of the bag sidewalls due to weight of the contents and flexing of the tray, may knock-off or displace the cups from the molded fiber tray sockets when the delivery bag is being carried or transported.

Accordingly, the present invention overcomes the shortcomings of molded fiber carrying trays and provides a carrying tray that can securely hold beverage and food containers.

The present invention provides a carrying tray that can be placed in a delivery bag for convenient transportation of beverage and food containers without disturbing the sidewalls of the containers or adversely affecting the holding functionality of the carrying tray.

The present invention provides a carrying tray that can be assembled on-demand from a flat die-cut blank.

The present invention provides a carrying tray with a top planar surface comprising receptacle cavities configured for receiving and retaining beverage cups or food containers therein, wherein the drink cups being inserted into the receptacle cavities with at least 25% of their overall height below the top planar surface and preferably more than 50% of their overall height below the top planar surface.

The present invention provides a carrying device that can provide thermal insulation for hot foods so that beverages or foods can be delivered without the consumer having to rewarm the food or beverage.

According to an exemplary embodiment of the invention, the carrying tray is assembled from a die-cut tray blank by an operator. The die-cut blank is sometimes referred as a carrying tray precursor blank. The carrying tray has an approximately square planar top comprising four receptacle cavities for receiving and holding generally frusto-conical containers such as coffee cups, drinking cups, deli containers, to-go bowls and/or other similar containers.

According to an embodiment of the invention, a carrying tray for holding at least a container therein, said tray comprising: a top wall, a first set of opposing sidewalls, and a second set of opposing sidewalls; said top wall comprising at least one receptacle cavity, said receptacle cavity being configured for receiving a first portion of the container therethrough, wherein the first portion of the container is held below the top wall in the carrying tray and a second portion of the container is held above said top wall; said at least one receptacle cavity in the top wall comprising a retaining feature, wherein the retaining feature is configured to contact said first portion of the container and restrain movement of the container relative to said receptacle cavity; and wherein, said carrying tray is configured for facilitating transportation of said container held in said receptacle cavity without tipping.

The carrying tray is assembled from a planar blank, the first set of opposing walls are configured to be secured with the second set of opposing sidewalls during assembly of said carrying tray. The retaining feature of carrying tray includes a plurality of slits extending radially inwardly from a periphery of the receptacle cavity. The retaining feature may include a plurality of collar tabs extending radially inwardly from a periphery of said receptacle cavity. The tray height or height of the first set of opposing sidewalls is greater than the diameter of said receptacle cavity. The first set of opposing sidewalls comprise a first set of flaps and a second set of flaps. The second set of opposing sidewalls include a first set of locking features and a second set of locking features, and wherein the first set of locking features are configured for engaging with the first set of flaps, and the second set of locking features are configured for engaging with said second set of flaps.

The invention further provides a method for transporting one or more containers within the carrying tray to limit tipping or overturning of the container(s) wherein the carrying tray is carried either directly or in a bag. The invention also teaches a tamper evident delivery system for cups and containers that can be transported and delivered in a secure manner in a tamper-evident bag in an upright orientation while being retained within the carrying tray receptacles to limit tipping or overturning of the containers.

According to an embodiment of the invention there is provided a method for delivering a container in a generally upright orientation, said method comprising: providing a tray having a top wall, a first set of opposing sidewalls and a second set of opposing sidewalls, said top wall comprising at least one cavity, said cavity being configured for receiving a first portion of the container therein; providing at least one retaining feature within said cavity, said retaining feature being configured for engaging with said first portion of the container; loading said container into said at least one cavity with said first portion of the container disposed below said top wall and said retaining feature in engagement with said first portion of the container; loading said tray into a delivery bag; and restricting movement of the container within said tray during transportation of said delivery bag and holding said first and second set of opposing sidewalls in the generally upright orientation within said delivery bag.

According to an embodiment of the invention there is provided a tamper evident delivery system for delivering a container in a generally upright orientation, said system comprising: a tray comprising a top wall, a first set of opposing sidewalls and a second set of opposing sidewalls, said top wall comprising at least one cavity, said cavity including a retaining feature and being configured for receiving a first portion of the container therein, said retaining feature being configured for engaging with said first portion of the container; a delivery bag comprising a front panel, a rear panel, a mouth end and a closed bottom end; the delivery bag includes a closure system for sealing off the mouth end of the delivery bag and a frangible line configured for tearing the delivery bag for accessing the contents sealed therein; said tray being configured for loading into the delivery bag with said first portion of the container included in said cavity and engaged with said retaining feature, wherein said carrying tray is configured for maintaining said first and second set of opposing sidewalls and said container in the generally upright orientation in said delivery bag.

While frusto-conical containers are contemplated, the invention envisages other container configurations to be accepted within the top planar openings. The trays may be provided with instructions for assembly and/or use, and may include indicia printed on the tray in the manner of text, images, graphics, colors, or other descriptions to benefit an operator or user. An embodiment of the tray provides for customization of the tray based on an operator's needs such as including branding, logos, coloring, text, or other modifications including specialized cut-outs for a distinctive appearance.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, which are not necessarily to scale, wherein:

FIG. 1 is a bottom view of a die-cut precursor blank according to an embodiment of the invention;

FIG. 2 is a bottom view of a blank for a carrying tray showing assembly instructions;

FIG. 3 is a perspective bottom view of the carrying tray assembled from the blank shown in FIG. 1;

FIG. 4 is a perspective top view of the assembled carrying tray of FIG. 3 showing the top wall and receptacle cavities;

FIG. 5 is a side view of the assembled carrying tray with cups installed in the receptacle cavities;

FIG. 6 is a side view of the carrying tray inside a delivery bag with the cups installed in the receptacle cavities;

FIG. 7 is a side view of the carrying tray with the cups inside a tamper evident delivery bag including a sealed off mouth region;

FIG. 8 is a bottom view of a carrying tray precursor blank according to another embodiment of the invention showing handles in a set of opposing sidewalls;

FIG. 9 is a perspective view of the carrying tray assembled from the blank shown in FIG. 8.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the embodiments of the present invention is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. The following description is provided herein solely by way of example for purposes of providing an enabling disclosure of the invention, but does not limit the scope or substance of the invention.

The present invention relates to a carrying device or tray for securely holding, transporting and/or delivering food and beverage containers. The carrying tray according to the invention could be constructed from a variety of sheet-like materials of appropriate thickness and rigidity including paperboard, plastic, or combinations thereof. The terms “carrying device” or “carrying tray” are not intended to be utility limiting. Accordingly, the device of the present invention can be utilized for transporting and delivering objects that are not necessarily beverage or food containers but have similar structural characteristics. As an example, the carrying tray could be utilized for holding and transporting items of glass, china, pottery, metal, or wood.

The present invention is described herein with reference to only a few of the exemplary embodiments of the invention detailing carrier tray construction, method of assembly the carrier tray from a blank die-cut, and delivery system and method for delivering beverage and food containers, nonetheless, it should be understood that the description herein is illustrative of the invention and is not to be considered as limiting the invention to the specific embodiments or features that are shown or described. The invention is capable of various modifications and variations that can be conceived by one of skill in the art without undue experimentation, and all such modifications and variations are deemed to be included within the scope of the invention.

It would be realized by those skilled in the art that the carrying tray and tray precursor blank of the present invention may be physically configured to an appropriate size, shape, and thickness for holding the desired type of containers, in accordance with the physical characteristics of the container items to be held and transported therein. In the exemplary embodiment detailed herein, the carrying tray is shown with four receiving cavities or receptacles or receptacle cavities for holding up to four cups or containers, it would be apparent to those of ordinary skill that the holding capacity of the carrying tray can be modified by adjusting the size of the carrying tray for achieving a desired number of available receptacles for commercial purposes.

FIG. 1 shows a bottom view of a carrying tray precursor blank 100 constructed as a flat substrate according to an exemplary embodiment of the invention. Blank 100 is configured for assembly into a carrying tray 200 shown in various views in FIGS. 3 through 5, wherein like numerals represent like parts. It will be realized that while the top and bottom views of blank 100 are substantially similar, FIG. 1 shows a bottom view of blank 100 to illustrate the various indented or scored edges that tend to be more readily visible in the bottom view of blank 100. In a preferred embodiment of the invention, blank 100 is made from a paper based substrate of suitable grammage (weight per unit area) for providing sufficient stability for holding and supporting beverage and food containers when assembled to yield carrying tray 200.

Blank 100 comprises a square shaped center panel or wall 10, with the bottom surface of the wall 10, denoted by 10b, visible in the bottom view shown in FIG. 1. Wall 10 is defined by two pairs of opposing fold edges, namely, opposing fold edges 20 and 20′ and opposing fold edges 30 and 30′. Fold edges 20, 20′, 30, 30′ can be created by indenting or scoring the paperboard material so that the flat substrate material could be readily bent along the indented region or fold edges to facilitate conversion and assembly of blank 100 to carrying tray 200. It will be apparent to those skilled in the art that the folding indentations can be imparted by a variety of methods known in the art including scoring, creasing, mechanical indenting, perforating, or by creating fault lines or lines of weakness in the substrate material of blank 100 by other methods. Wall 10 includes four receiving cavities or receptacles 12 configured for receiving and holding beverage cups or containers therein once blank 100 has been assembled into carrying tray 200. The structure of receptacles 12 is detailed further in connection with description of carrying tray 200 hereinafter in conjunction with FIGS. 3-5.

A first set of opposing sidewalls 22 and 22′ extend from fold edges 20 and 20′, respectively and can be folded along the respective fold edges for providing a sidewall structure for the carrying tray 200.

A second set of opposing sidewalls 32 and 32′ extend from fold edges 30 and 30′ respectively and can be folded along the respective fold edges for providing a sidewall structure for the carrying tray 200. Sidewall 32 features flaps 34 and 36 positioned at each longitudinal end of the sidewall 32. Similarly, sidewall 32′ features flaps 34′ and 36′ at each longitudinal end of sidewall 32′. Flaps 34 and 36 are foldable along fold edges 38 and 40, respectively. Similarly, flaps 34′ and 36′ are foldable along fold edges 38′ and 40′, respectively. Flaps 34, 36, 34′, 36′ of blank 100 can feature a tapered edge so that the flaps will not interfere with the proximate sidewall while it is being folded during the assembly process, thereby allowing struggle-free assembly. The tapered edges of flap 34 and 36 are denoted by 34t and 36t for illustration.

Flaps 34 and 34′ include openings 42 and 42′, respectively, for engaging and interlocking with locking tabs provided in sidewall 22. Similarly, flaps 36 and 36′ include openings 44 and 44′, respectively, for engaging and interlocking with locking tabs provided in sidewall 22′ as further described below.

Sidewall 22 includes arcuate slit 24a defining an arcuate locking tab 26a that can be flexed or bent around indent 28a. Locking tab 26a is configured for interlocking with opening 42 in flap 34 once the sidewall 22 and flap 34 are in proximate alignment for assembly. Sidewall 22 also includes another arcuate slit 24b defining arcuate locking tab 26b that can flex around indent 28b. Locking tab 26b is configured for interlocking with opening 42′ in flap 34′ once the sidewall 22 and flap 34′ are in proximate alignment for assembly.

Similarly, sidewall 22′ includes arcuate slits 24c and 24d defining corresponding arcuate locking tabs 26c and 26d that flex around indents 28c and 28d, respectively. Locking tab 26c is configured for interlocking with opening 44 in flap 36 once the sidewall 22′ and flap 36 are in proximate alignment post folding for assembly. Similarly locking tab 26d is configured for interlocking with opening 44′ in flap 36′ once the sidewall 22′ and flap 36′ are in proximate alignment post folding for assembly. Distal edge corners of sidewalls 22 and 22′ may generally also feature chamfer 29 so that the sidewalls will not snag against bag walls when the carrying tray is being inserted into the delivery bag.

A convenient sequence for assembling and converting blank 100 into carrying tray 200 (shown in FIGS. 3 and 4) is to begin from the starting position shown in FIG. 1, with blank 100 resting on a generally horizontal table or working surface with the bottom surface 10b of central wall 10 facing up towards the operator or user. The operator starts by folding flaps appended to sidewalls 32 and 32′. Specifically, flaps 34 and 36 are folded upwardly at approximately 90 degrees by folding along fold edges 38 and 40, respectively; and, flaps 34′ and 36′ are folded upwardly at about 90 degrees by folding along fold edges 38′ and 40′. The sequence of folding of the 4 flaps can be determined by the operator. Once all the flaps have been folded at about 90 degrees, sidewalls 32 and 32′ can be folded upwardly to about 90 degrees by folding along fold edges 30 and 30′. Once folded, opposing sidewalls 32 and 32′ are nearly vertical and perpendicular relative to the horizontal central wall 10 with the appended flaps being aligned along fold edges 20 and 20′. Alternately, the operator may begin from the starting position shown in FIG. 1 by folding the sidewalls 30 and 30′ upwardly for creating the opposing sidewalls first and then proceeds with folding the flaps inwardly to bring them in alignment with edges 20 and 20′.

After the sidewalls 32 and 32′ and all the appended flaps (34, 36, 34′, 36′) have been folded, the operator can then fold sidewall 22 upwardly so that it is nearly perpendicular to central wall 10; and, locking tabs 26a and 26b are in proximate alignment with flap openings 42 and 42′, respectively. Thereafter, the operator continues by folding sidewall 22′ upwardly and ensuring that locking tabs 26c and 26d are in proximate alignment with flap openings 44 and 44′, respectively. To secure the folded assembly and fasten all the sidewalls together the operator pushes all the locking tabs inwardly (towards the center of wall 10) through the corresponding flap openings; specifically locking tabs 26a and 26b are pushed through the flap openings 42 and 42′, respectively, and locking tabs 26c and 26d are pushed through the flap openings 44 and 44′, respectively. The locking tab attachment shown herein provides stability between flaps and the sidewalls limiting lateral and axial movement therebetween, and since the flaps are attached to the sidewalls the locking tab arrangement serves to stabilize all the sidewalls of the carrying tray 20 so that it will be functionally usable when cups or containers are loaded therein as further described below.

It will be realized that the locking tabs in the sidewall and the corresponding openings in the sidewall flaps may be configured in a variety of shapes, sizes, designs and may be provided at multiple locations in the same flap. In alternate constructions, the relative locations of the locking tabs and openings can be interchanged, with locking tabs being provided in the flaps and corresponding interlocking openings can be provided in the sidewalls.

It will also be appreciated by those skilled in the art that in the exemplary embodiment shown in FIG. 1, blank 100 can be assembled into carrying tray 200 without utilizing adhesives or separate fastening materials. Nonetheless, it will be realized that in alternate constructions the sidewalls of the carrying tray 200 can be fastened by utilizing adhesive strips or glue if so desired.

Blank 100 may also include printed instructions and guidance for assembly on the underside surface. FIG. 2 shows blank 101, having the same construction as blank 100 of FIG. 1, except that blank 101 includes an example of simple instructions that can be printed on the blank for a user to assemble blank 101 into a carrying tray 200 shown in FIGS. 3 and 4. It will be of course realized that the instructions for assembly can include additional details and can be enhanced with illustrations and may include a link to an online video or a QR code. It will also be realized that blank 100 or blank 101 can be assembled into a carrying tray by utilizing a slightly different folding sequence than the printed instructions on blank 101 shown in FIG. 2 while still preserving the relational arrangement between the sidewalls and appended locking tabs and flap openings.

FIG. 3 shows a bottom perspective view of carrying tray 200 that has been assembled using blank 100 of FIG. 1, according to the general instructions above. As indicated above, the preferred sequence for assembling and converting blank 100 into carrying tray 200 is to begin from the starting position shown in FIG. 1, which shows a bottom view. In the view shown in FIG. 3, while sidewall 22 is behind flaps 34 and 34′, locking tab 26a is shown in pushed-through the opening in flap 34 while locking tab 26b in shown pushed-through the opening in flap 34′. Similarly, locking tabs 26c and 26d in sidewall 22′ are engaged with openings in flaps 36 and 36′, respectively thus creating a stable sidewall assembly. It will be realized that the carrying tray 200 shown in FIG. 3 is assembled with the bottom surface 10b in plain view and needs to be inverted or turned over after assembly is completed so that the carrying tray can be utilized for loading cups or containers therein.

FIG. 4 shows a top perspective view of carrying tray 200 shown in FIG. 3, wherein like parts bear like reference numerals. In the top perspective view of FIG. 4, the top surface of wall 10, denoted by 10t, is visible. Wall 10 is generally planar and includes four receiving cavities or receptacle cavities (“receptacles”) generally denoted by reference numeral 12. Wall 10 is supported by four sidewalls 22, 22′, 32, and 32′ that are generally perpendicular to wall 10. Only two of the sidewalls (22′ and 32′) are viewable in the perspective view of FIG. 4. Each receiving cavity or receptacle 12 is configured for receiving and holding a frusto-conical cup or container (not shown), which can be a coffee cup, a drinking cup, a souvenir cup, a deli container, a soup bowl, or another item having a similar construction. Receptacle cavities 12 may further comprise retaining features for supporting the cup or container sidewall within the receptacle as described below.

Each receptacle 12 includes a central opening 14 and a periphery 19. A plurality of radial slits 16 extending radially inwardly from periphery 19 to central opening 14 are provided in each receptacle 12. The plurality of slits 16 divide up the receptacle 12 into a plurality of sections or collar tabs 18 that extend radially inwardly from the periphery 19 with their proximal ends connected to periphery 19 and the distal ends of collar tabs 18 forming the central opening 14. As a container or cup is inserted through the receptacle cavity 12, collar tabs 18 are deflected by the cup or container being inserted therethrough, causing the distal ends of the collar tabs 18 to swivel downwardly from the (typically horizontal) plane of wall 10 and away from the central axis of receptacle cavity 12 to accommodate the sidewall of the cup or container and collectively form a supportive collar around the cup to corral and support the cup therein. The collar tabs 18 are configured to hinge or swivel from their proximal connection at periphery 19 under a relatively minor force as a cup or container is inserted through the receptacle cavity 12.

In FIG. 4, a couple of the receptacle cavities 12 are shown with collar tabs 18 being coplanar with wall 10, while other receptacle cavities are shown with collar tabs 18 bent downwardly from the top plane of wall 10 showing various size configurations for the opening 14. As a cup or container is inserted through one of the receptacles 12, the collar tabs 18 are pushed down and spread apart thereby expanding the opening 14 for accommodating the cup or container into receptacle 12.

In embodiments, periphery 19 of each receptacle cavity 12 can be indented, scored, or intermittently perforated, to facilitate swivel of collar tabs 18 as a cup is inserted into the receptacle cavity 12. Periphery 19 of receptacle cavity 12 is appropriately sized to allow penetration of at least 30 percent of the cup or container overall height into the carrying tray below the plane of wall 10. It will be appreciated by those skilled in the art that receptacle periphery 19 and the height of the carrying tray (or its sidewalls) should be configured so that the cup sidewall would be retained by the receptacle cavity 12 in a snug fashion with the collar tabs 18 providing circumferential support. For instance, if the carrying tray is too short or if the periphery 19 is too wide, then the cup or container may not be appropriately supported within the receptacle cavity 12. According to a preferred embodiment of the invention, the height of the carrying tray 200 (or the sidewall height) and the diameter of periphery 19 are cooperatively configured such that at least 50 percent of the cup or container height is retained within the carrying tray below planar surface of wall 10. In other embodiments, the carrying tray 200 is configured to retain at least 60 percent of the cup height below planar wall 10. In still other embodiments, the carrying tray 200 is configured to retain at least 70 percent of the cup height below planar wall 10.

According to an embodiment of the invention the carrying tray 200 has a height greater than about 3.5 inches. According to an embodiment of the invention the carrying tray has a height of about 4 inches. According to an embodiment of the invention the carrying tray has height of less than about 5 inches. According to another embodiment of the invention each receptacle cavity 12 has a diameter of more than 3 inches. According to another embodiment of the invention each receptacle cavity has a diameter of less than 4 inches. According to another embodiment of the invention each receptacle cavity has a diameter of about 3.5″. According to another embodiment of the invention the height of the carrying tray 200 is greater than the diameter of the receptacle cavity 12.

FIG. 5 shows a side view of carrying tray 200 showing frontal view of tray sidewall 22′ along with cups 60 installed in the receptacle cavities of carrying tray 200. Locking tabs 26d and 26c engaged with the respective flaps 36′ and 36 disposed behind tray sidewall 22′. Each cup 60 includes a lid 62, cup sidewall 64 and cup bottom 66. As shown in FIG. 5 a substantial portion of cup sidewall 64 is retained below the top planar wall 10 of carrying tray 200 and the plurality of collar tabs 18 encircle the cup sidewall 64 to stabilize cup 60 and preserve it in an upright orientation.

The carrying tray of the invention may be used in many ways by an operator in a food service setting, such as by a restaurant server placing beverage orders within the carrying tray to serve patrons spaced across unstable or precarious distances from the kitchen/preparation area. Placing the drink cups in a carrying tray allows a server to transport drinks and beverages to a guest table in a sanitary manner without touching the outer surfaces of the cups and the carrying tray can be left at the guest table wherefrom they can be retrieved by the guests. As seen in recent pandemic times, many food service establishments have created or expanded outdoor seating for patrons, thus increasing the complexity for a server having to navigate through foyers, lobbies, breezeways, multiple doors, up and down steps, over sidewalks and curbs, and across grassy and uneven areas. The carrying tray of the present invention provides additional stability to the containers held therein avoiding unfortunate spills. Additionally, the tray may be placed on a table or generally flat surface to hold and provide stability to containers in the presence of children or persons with an unsteady bearing.

FIG. 6 shows an embodiment of the invention, wherein the carrying tray 200 along with the cups 60 installed in the receiving cavities or receptacles thereof (as shown in FIG. 5) is placed inside a delivery bag 70 for transporting or delivering a plurality of beverages or food items that a consumer or a delivery person can handle conveniently. Bag 70 comprises a front panel 72 and a rear panel 72′ (not shown) and is equipped with carrying handle openings 74 to conveniently lift bag 70. Bag 70 may also include a bottom gusset 76 to comfortably accommodate the carrying tray 200 such that top wall 10 of carrying tray 200 remains substantially in a horizontal plane when bag 70 is lifted. One advantage of the carrying tray according to the present invention is that the cups 60 held within the carrying tray 200 and supported by the encircling collar tabs 18 are not influenced or knocked over by the pressure or tension of the walls of the bag 70 as the bag is lifted or carried for delivery. During bag loading, the carrying tray 200 can be placed first inside the delivery bag by itself, without any of the cups or containers therein, and the cups can then be placed in the receptacle cavities of the bagged tray. Alternately, the cups or containers can be preloaded in the carrying tray 200 prior to installing the loaded tray in the delivery bag 70. A preferred method for preparing a delivering bag is to install an empty carrying tray into the bag first without the beverage or food containers as it has been found to be less cumbersome, whereafter the drink cups or other containers can be conveniently positioned in the receptacle cavities of the tray in an upright orientation. It will be realized that a carrying tray may be configured to fit into a variety of bag types and bag sizes to allow for a desired number of containers to be stabilized within a transportable bag across a wide spectrum of needs in the marketplace.

FIG. 7 shows another embodiment of the invention, illustrating a tamper evident delivery system for beverage cups and containers for convenient carrying and tamper evident delivery thereof. Specifically, carrying tray 200 is loaded into a tamper-evident bag 80 that has a front panel 82 and a rear panel 82′ (not shown) and is equipped with carrying handle openings 84 located close to the mouth region of the bag. Bag 80 includes a bottom gusset 86 at the closed bottom end of the bag to comfortably accommodate the carrying tray 200 and to avoid excessive tilting the top wall 10 of the tray when bag 80 is lifted. During loading, ideally bag 80 is placed on a flat, stable surface such as a counter or table or is held securely within a dispenser allowing an operator to load carrying tray into the bag allowing the carrying tray walls to sit evenly in an upright orientation and wall 10 being close to horizontal. The relatively wide and stable footprint of carrying tray 80 within bag 80 maintains said carrying tray in an upright position while the bag is being transported in usual fashion by lifting at the handle openings. It will be realized that the beverage cups and food containers can be either preloaded in the carrying tray 200 prior to its placement in the bag 80, or the cups/containers may be installed subsequent to loading the carrying tray in the bag.

Bag 80 includes a closure system 88, which is shown in a sealed configuration in FIG. 7. Closure system 88 is configured to seal the front and rear panels of the bag and seal off the carrying tray 200 and its contents so that they can be securely delivered to an intended user. Closure system 88 can be implemented by using an adhesive strip and adhesively bonding the front and rear panels of the bag 80. Adhesive closure system 88 is configured to provide a sufficiently strong bond between the front and rear wall sections of bag 80 for preventing failure of the adhesive layer at the junction interface and assuring tamper detection, such that the adhesive junction between the wall sections of bag 80 is not easily compromised even when tamper is attempted, while persistent efforts to open bag 80 resulting in readily apparent substrate stress, stretch marks, tearing or other discernible signs of tamper. The adhesive layer and the wall sections of bag 80 are strong enough to withstand carrying stress exerted by the weight of carrying tray contents as bag 80 is physically lifted and carried by a user during the delivery trip to the delivery destination.

Furthermore, the adhesive bond of the closure system 88 is not compromised due to incidental steam or moisture build-up at the interior surfaces of bag 80 when the adhesive closure system 88 is deployed right after hot beverage cups or food containers are loaded in the carrying tray within the bag. Accordingly, bag 80 includes a sidewall venting system comprising a plurality of vents generally denoted by numeral 92 that are configured for expelling steam or hot air from the bag. The individual vents 92 are distributed across the bag surface to facilitate localized venting of steam emanating from hot beverages and wherein the individual vents are sufficiently small to inhibit tamper or to at least provide conspicuous indication of tamper through the vents. In FIG. 7, vents 92 are shown as narrow arcuate slits, however, it will be realized that vents 92 may be configured to be straight, or curvilinear, or any other shape. A distributed venting system with a plurality of relatively small vents allows placement of individual vents in close proximity to the beverage containers or food items thereby preventing excessive condensation within the bag; and smaller vents further deter tamper and facilitate tamper detection.

Once the sealed and closed bag is delivered to the consumer or user, the user can access the contents inside the sealed bag by tearing along a frangible line 90 provided below the closure system 88. To tear along frangible line 90, the user can insert their finger (or a slender article such as a pen) through the frangible line 90 and slide their finger (or the slender article) across it to create a breech in the tamper-evident bag for retrieving the contents.

FIGS. 8 and 9 shows another embodiment of the invention, wherein FIG. 8 shows a precursor blank 120 for assembling carrying tray 220. Blank 120 has a similar construction as blank 100, except that blank 120 includes provisions for handles 50 and 50′ in opposing sidewalls 32 and 32′, respectively. Specifically, handle 50 includes a handle slit 52, a handle tab 54 that can be flexed or bent around a handle indent 56. Similarly, handle 50′ includes a handle slit 52′, a handle tab 54′, and a handle indent 56′. A user can swivel handle tabs 54 and 54′ to insert their fingers through the resultant opening. FIG. 9 shows a perspective view of carrying tray 220 which shows the top wall surface 10t and sidewalls 22′ and 32′. In FIG. 9, only one the handles 50′ in wall 32′ is visible and is shown with handle tab 54′ deflected inwardly. A user can insert their finger through the handles 50 and 50′ to conveniently transport carrying tray 220. Handle flaps 54 and 54′ can be deflected by user's fingers and provide a convenient sturdy surface when lifting carrying tray 220 particularly when it is loaded with filled beverage cups or food containers.

In some embodiments of the invention the carrying tray may be configured to have straight cut-through handle openings without the handle flaps. The cut-out handles may be positioned in any location on the carrying tray sidewalls, such as in the middle of the sidewalls of the carrying tray, proximate to the top wall, or away from the top wall. The size of the handle openings can be configured for a user to insert one or more fingers therethrough.

The precursor blank for the carrying tray according to the invention may be manufactured from a variety of materials including but not limited to paperboard, cardboard, chipboard, fiberboard, boxboard, or kraft board. Furthermore, blank materials can be fabricated in a variety of thicknesses for meeting the desired use-application criteria, such as, strength, rigidity, tray height, number of desired receiving cavities, weight of the contents, etc. The blank may be made of virgin material or may include any ratio of recycled content from 0-100 percent. The blank may be made from materials that are renewable, or biodegradable, or compostable, or any combination thereof. An advantage of the assembled carrying tray is that after use it may easily be disassembled for recycling or storage for reuse by disengaging the locking tabs and reverting the tray into its flat configuration. Accordingly, the tray precursor blank of the invention may be assembled, disassembled, and reassembled multiple times.

As will be apparent from the foregoing description, the present invention teaches a carrying tray constructed from a precursor blank for retaining one or more cups or containers of generally frusto-conical shape. The invention also teaches a method of assembling the carrying tray from a flat blank substrate which may be constructed from paperboard or other paper-based substrate. A plurality of blanks may be easily stacked together to provide substantial space savings over molded trays. Based on calculations by the inventors, the carrying tray blanks according to the present invention occupy less than one-fifth or 20% of the space relative to molded fiber trays resulting in storage and footprint advantage for the store operator. The carrying trays can be assembled on demand based on carryout and delivery needs over a given period or shift. Alternately, a food establishment may convert a certain number of blanks into carrying trays for use during the day, thereby avoiding the need to assemble the trays during rush-hour.

The invention further provides a method for transporting one or more containers within the carrying tray to limit tipping or overturning of the container(s) wherein the carrying tray is carried either directly or in a bag. The invention also teaches a tamper evident delivery system for cups and containers that can be transported and delivered in a secure manner in a tamper-evident bag in an upright orientation while being retained within the carrying tray receptacles to limit tipping or overturning of the containers.

The carrying tray precursor blanks according to the invention may be provided with instructions for assembly and use, and may include indicia in the manner of text, images, graphics, colors, or other information printed on the tray. In embodiments, the carrying tray may be customized based on an operator's needs for transporting a specific size of container and may include marketing information such as branding, logos, coloring, text, or other modifications including specialized cut-outs for a distinctive appearance.

Embodiments of the invention allow for various configuration of receptacle cavities provided in the carrying tray along with various retaining features including variants of the collar tabs shown in FIGS. 3-5. For example, the number of collar tabs 18 shown in FIG. 4 in each receptacle cavity can be increased or decreased by including additional slits 16. Furthermore, the collar tabs can be made shorter or longer relative to those shown in FIG. 4, or a short collar tab may be included between two adjacent long collar tabs. The collar tabs for retaining cups and containers within the receptacle cavities may be provided in a variety of configurations, shapes and sizes depending on the type of containers or cups intended to be placed in the carrying tray. In an embodiment of the invention, the slits that define the collar tabs are not parallel to the radial lines of the receptacle cavity but are inclined to the radial lines thus resulting in collar tabs that partially wrap around a section of the cup sidewall. In other embodiments, the slits that define the collar tabs are arcuate thus resulting in collar tabs with curved sides. Therefore, it will be realized that the retaining features may be combined in any manner desired to achieve the desired level of retention for an inserted container.

In embodiments, the locking tabs of the invention may be provided in any size, shape, or quantity as desired to increase stability of the assembled carton. It is envisaged that the openings provided in the extended flaps can be accordingly configured to engage with the size, shape, or quantity of the locking tabs.

In an embodiment, the blank may be assembled by using adhesives or fasteners as desired to provide a carrying tray assembly that is irreversible. In addition, adhesives, fasteners, tape, or labels may be used to supplement the locking tabs for imparting additional stability to the carrying tray.

The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description and not for limiting the scope of the invention. Each and every page of this submission, and all content herein, however characterized, identified, or numbered, is considered a substantive part of this application for all purposes, irrespective of form or placement within the application.

This specification is not intended to be exhaustive. Although the present application is shown in a limited number of forms, the scope of the invention is not limited to just these forms but is amenable to various changes and modifications without departing from the spirit thereof. It will be apparent to those skilled in the art from the foregoing description that many modifications and variations to the embodiments shown herein are possible in light of this disclosure. Accordingly, the claimed subject matter includes any combination of the above-described elements in all possible variations thereof, unless otherwise indicated herein or otherwise clearly contradicted by context. In particular, the limitations presented in dependent claims below can be combined with their corresponding independent claims in any number and in any order without departing from the scope of this disclosure, unless the dependent claims are logically incompatible with each other.

It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements.

Claims

1. A carrying tray for holding at least a container therein, said tray comprising:

a top wall, a first set of opposing sidewalls, and a second set of opposing sidewalls;

said top wall comprising at least one receptacle cavity, said receptacle cavity being configured for receiving a first portion of the container therethrough, wherein the first portion of the container is held below the top wall in the carrying tray and a second portion of the container is held above said top wall;

said at least one receptacle cavity in the top wall comprising a retaining feature, wherein the retaining feature is configured to contact said first portion of the container and restrain movement of the container relative to said receptacle cavity;

and wherein, said carrying tray is configured for facilitating transportation of said container held in said receptacle cavity without tipping.

2. The carrying tray of claim 1, wherein said carrying tray is assembled from a planar blank.

3. The carrying tray of claim 1, wherein said first set of opposing walls are configured to be secured with said second set of opposing of sidewalls during assembly of said carrying tray.

4. The carrying tray of claim 1, wherein said retaining feature includes a plurality of slits extending radially inwardly from a periphery of said receptacle cavity.

5. The carrying tray of claim 1, wherein said retaining feature includes a plurality of collar tabs extending radially inwardly from a periphery of said receptacle cavity.

6. The carrying tray of claim 1, wherein said retaining feature extends radially inwardly from a periphery of said receptacle cavity to a central opening within said receptacle cavity.

7. The carrying tray of claim 1, wherein the height of said first set of opposing sidewalls is greater than a diameter of said receptacle cavity.

8. The carrying tray of claim 1, wherein the first set of opposing sidewalls comprise a first set of flaps and a second set of flaps.

9. The carrying tray of claim 1, wherein the second set of opposing sidewalls include a first set of locking features and a second set of locking features, and wherein said first set of locking features are configured for engaging with said first set of flaps, and the second set of locking features are configured for engaging with said second set of flaps.

10. The carrying tray of claim 9, wherein said first set of flaps include a first set of openings, and said second set of flaps include a second set of openings; and wherein the first and second set of openings are configured for engaging with a first and a second set of locking tabs provided in said second set of opposing sidewalls.

11. The carrying tray of claim 1, wherein said carrying tray is configured for placement in a delivery bag.

12. The carrying tray of claim 1, wherein said carrying tray is configured for delivery in a tamper-evident bag wherein a mouth region of the tamper-evident bag being sealed for assuring security of the bag contents.

13. The carrying tray of claim 1, wherein said tray is constructed from one of paperboard, chipboard, and boxboard.

14. The carrying tray of claim 1, wherein said tray is constructed from one of cardboard, fiberboard, and kraft board.

15. The carrying tray of claim 1, wherein said container is a cup.

16. The carrying tray of claim 1, wherein said container has a frusto-conical shape.

17. A method for delivering a container in a generally upright orientation, said method comprising:

providing a tray having a top wall, a first set of opposing sidewalls and a second set of opposing sidewalls, said top wall comprising at least one cavity, said cavity being configured for receiving a first portion of the container therein;

providing at least one retaining feature within said cavity, said retaining feature being configured for engaging with said first portion of the container;

loading said container into said at least one cavity with said first portion of the container disposed below said top wall and said retaining feature in engagement with said first portion of the container;

loading said tray into a delivery bag; and

restricting movement of the container within said tray during transportation of said delivery bag and holding said first and second set of opposing sidewalls in the generally upright orientation within said delivery bag.

18. The method according to claim 17, wherein said delivery bag is gusseted.

19. The method according to claim 17, wherein said delivery bag is constructed from polyethylene.

20. The method according to claim 17, wherein said delivery bag includes a tamper-evident feature.

21. The method according to claim 17, wherein said delivery bag includes an adhesive closure configured for sealing a mouth region of the delivery bag and restricting access into the delivery bag during transportation.

22. The method according to claim 17, wherein said retaining feature comprises a plurality of collar tabs configured for stabilizing the first portion of the container within said cavity.

23. The method according to claim 17, wherein said delivery bag includes a tamper-evident closure and a tear line below said tamper-evident closure, said tear line being configured for opening the delivery bag after said tamper-evident closure is deployed.

24. The method according to claim 17, wherein said delivery bag includes at least one vent for expelling air or steam from the delivery bag.

25. The method according to claim 17, wherein said tray is constructed from one of paperboard, chipboard, and boxboard.

26. The method according to claim 17, wherein said tray is constructed from one of cardboard, fiberboard, and kraft board.

27. A tamper evident delivery system for delivering a container in a generally upright orientation, said system comprising:

a tray comprising a top wall, a first set of opposing sidewalls and a second set of opposing sidewalls, said top wall comprising at least one cavity, said cavity including a retaining feature and being configured for receiving a first portion of the container therein, said retaining feature being configured for engaging with said first portion of the container;

a delivery bag comprising a front panel, a rear panel, a mouth end and a closed bottom end; the delivery bag includes a closure system for sealing off the mouth end of the delivery bag and a frangible line configured for tearing the delivery bag for accessing the contents sealed therein;

said tray being configured for loading into the delivery bag with said first portion of the container included in said cavity and engaged with said retaining feature, wherein said carrying tray is configured for maintaining said first and second set of opposing sidewalls and said container in the generally upright orientation in said delivery bag.

28. The tamper evident delivery system of claim 27, wherein said tray is assembled from a planar blank.

29. The tamper evident delivery system of claim 27, wherein said first set of opposing walls are configured to be secured with said second set of opposing of sidewalls during assembly of said tray.

30. The tamper evident delivery system of claim 27, wherein said retaining feature includes a plurality of slits extending radially inwardly from a periphery of said cavity.

31. The tamper evident delivery system of claim 27, wherein said retaining feature includes a plurality of collar tabs extending radially inwardly from a periphery of said receptacle cavity.

32. The tamper evident delivery system of claim 27, wherein said retaining feature extends radially inwardly from a periphery of said receptacle cavity to a central opening within said receptacle cavity.

33. The tamper evident delivery system of claim 27, wherein the height of said first set of opposing sidewalls is greater than a diameter of said receptacle cavity.

34. The tamper evident delivery system of claim 27, wherein the first set of opposing sidewalls comprise a first set of flaps and a second set of flaps.

35. The tamper evident delivery system of claim 34, wherein the second set of opposing sidewalls include a first set of locking features and a second set of locking features, and wherein said first set of locking features are configured for engaging with said first set of flaps, and the second set of locking features are configured for engaging with said second set of flaps.

36. The tamper evident delivery system of claim 34, wherein said first set of flaps include a first set of openings, and said second set of flaps include a second set of openings; and wherein the first and second set of openings are configured for engaging with a first and a second set of locking tabs provided in said second set of opposing sidewalls.

37. The tamper evident delivery system of claim 27, wherein said tray is constructed from one of paperboard, chipboard, cardboard, fiberboard, kraft board, and boxboard.

38. The tamper evident delivery system of claim 27, wherein said tray is constructed from a coated paper substrate.

39. The tamper evident delivery system of claim 27, wherein said delivery bag includes at least one vent for expelling air from said delivery bag.

40. The tamper evident delivery system of claim 27, wherein said wherein said container is a cup.

41. The tamper evident delivery system of claim 27, wherein said delivery bag is constructed from polyethylene.

42. The tamper evident delivery system of claim 27, wherein said delivery bag is constructed from a paper substrate.

43. The tamper evident delivery system of claim 27, wherein said delivery bag is constructed from a coated paper substrate.