Tray For Food Products

A method of forming a tray for holding at least one food product includes obtaining a blank having a plurality of panels including a bottom panel, a front panel, a back panel, and at least one side panel, a plurality of end flaps foldably connected to a respective panel of the plurality of panels, and reinforcement features. The method further includes folding the plurality of panels at least partially around an interior of the tray, folding the plurality of top end flaps to form a rim extending from the plurality of panels when the tray is formed from the blank, and activating the reinforcement features to maintaining an integrity of the rim such that at least one end flap of the plurality of end flaps is biased downward to maintain an outward arrangement from a respective panel of the plurality of panels.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of each of U.S. Provisional Patent Application No. 63/110,578, filed on Nov. 6, 2020, U.S. Provisional Patent Application No. 63/110,582, filed on Nov. 6, 2020, U.S. Provisional Patent Application No. 63/110,587, filed on Nov. 6, 2020, U.S. Provisional Patent Application No. 63/126,157, filed on Dec. 16, 2020, U.S. Provisional Patent Application No. 63/128,418, filed on Dec. 21, 2020, U.S. Provisional Patent Application No. 63/139,341, filed on Jan. 20, 2021, U.S. Provisional Patent Application No. 63/169,302, filed on Apr. 1, 2021, U.S. Provisional Patent Application No. 63/169,418, filed on Apr. 1, 2021, U.S. Provisional Patent Application No. 63/174,724, filed on Apr. 14, 2021, U.S. Provisional Patent Application No. 63/178,116, filed on Apr. 22, 2021, and U.S. Provisional Patent Application No. 63/191,412, filed on Jun. 1, 2021.

INCORPORATION BY REFERENCE

The disclosures of each of U.S. Provisional Patent Application No. 63/110,578, filed on Nov. 6, 2020, U.S. Provisional Patent Application No. 63/110,582, filed on Nov. 6, 2020, U.S. Provisional Patent Application No. 63/110,587, filed on Nov. 6, 2020, U.S. Provisional Patent Application No. 63/126,157, filed on Dec. 16, 2020, U.S. Provisional Patent Application No. 63/128,418, filed on Dec. 21, 2020, U.S. Provisional Patent Application No. 63/139,341, filed on Jan. 20, 2021, U.S. Provisional Patent Application No. 63/169,302, filed on Apr. 1, 2021, U.S. Provisional Patent Application No. 63/169,418, filed on Apr. 1, 2021, U.S. Provisional Patent Application No. 63/174,724, filed on Apr. 14, 2021, U.S. Provisional Patent Application No. 63/178,116, filed on Apr. 22, 2021, and U.S. Provisional Patent Application No. 63/191,412, filed on Jun. 1, 2021, are hereby incorporated by reference for all purposes as if presented herein in their entirety.

BACKGROUND OF THE DISCLOSURE

The present disclosure generally relates to trays for holding at least one food product.

SUMMARY OF THE DISCLOSURE

According to one aspect, the disclosure is generally directed to a method of forming a tray for holding at least one food product, the method comprising obtaining a blank comprising a plurality of panels comprising a bottom panel, a front panel, a back panel, and at least one side panel, a plurality of end flaps foldably connected to a respective panel of the plurality of panels, and reinforcement features. The method further comprises folding the plurality of panels at least partially around an interior of the tray, folding the plurality of top end flaps to form a rim extending from the plurality of panels when the tray is formed from the blank, and activating the reinforcement features to maintaining an integrity of the rim such that at least one end flap of the plurality of end flaps is biased downward to maintain an outward arrangement from a respective panel of the plurality of panels.

According to another aspect, the disclosure is generally directed to a tray for holding at least one food product, the tray comprising a plurality of panels at least partially extending around an interior of the tray and comprising a bottom panel, a front panel, a back panel, and at least one side panel, a plurality of end flaps comprising a plurality of top end flaps cooperating to form a rim extending from the plurality of panels, and reinforcement features for maintaining an integrity of the rim, the reinforcement features comprising an arrangement of the plurality of top end flaps such that at least one end flap of the plurality of end flaps is biased downward to maintain an outward arrangement from a respective panel of the plurality of panels.

According to another aspect, the disclosure is generally directed to a blank for forming a tray for holding at least one food product, the blank comprising a plurality of panels comprising a bottom panel, a front panel, a back panel, and at least one side panel, a plurality of end flaps comprising a plurality of top end flaps for cooperating to form a rim extending from the plurality of panels when the tray is formed from the blank, and reinforcement features for maintaining an integrity of the rim, the reinforcement features comprising an arrangement of the plurality of top end flaps such that at least one end flap of the plurality of end flaps is biased downward to maintain an outward arrangement from a respective panel of the plurality of panels.

Those skilled in the art will appreciate the above-stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.

FIG. 1 is a plan view of an exterior surface of a blank used to form a tray according to an exemplary embodiment of the disclosure.

FIG. 2 is a perspective view of a tray formed from the blank of FIG. 1 according to an exemplary embodiment of the disclosure.

FIG. 3 is another perspective view of the tray of FIG. 2.

FIG. 4 is a perspective view of the tray of FIG. 2 holding a plurality of food products and covered with a lidding film.

Corresponding parts are designated by corresponding reference numbers throughout the drawings.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

Trays according to the present disclosure can accommodate articles of numerous different shapes. For the purpose of illustration and not for the purpose of limiting the scope of the disclosure, the following detailed description describes articles such as food products, e.g., fruit or vegetable items. In one embodiment, articles described herein can be fruits such as tomatoes (e.g., cherry tomatoes, etc.), berries (e.g., blueberries, raspberries, blackberries, strawberries, etc.), apples, oranges, tangerines, clementines, lemons, limes, cherries, etc. In another embodiment, articles described herein can be product packages, containers, bottles, cans, etc., that are at least partially disposed within the tray embodiments. The articles can be used for packaging food and beverage products, for example. Packaged articles can be made from materials suitable in composition for packaging the particular food or beverage item, and the materials include, but are not limited to, glass; aluminum and/or other metals; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and Nylon; composite materials; and the like, or any combination thereof.

The articles described herein can include different types of food or beverage products, containers thereof, and/or having different shapes, without departing from the disclosure. In this specification, the terms “lower,” “bottom,” “upper,” and “top” indicate orientations determined in relation to fully erected and upright trays. As described herein, trays can be formed from blanks by overlapping multiple panels, portions, and/or end flaps. Such panels, portions and/or end flaps may be designated herein in terms relative to one another, e.g., “first”, “second”, “third”, etc., in sequential or non-sequential reference, without departing from the disclosure.

FIG. 1 is a plan view of an exterior surface 101 of a blank, generally indicated at 103, used to form a container assembly or tray 105 (FIG. 2) according to an exemplary embodiment of the disclosure. In embodiments, the trays 105 described herein can have a generally square/rectangular tapered configuration with a flanged rim. It will be understood that the trays described herein can have a different configuration without departing from the disclosure, such as a carton or other construct.

As described further herein, the blank 103 can include engagement features for forming engagement features of the tray 105 that provide one or more surfaces for engaging a machine element or other component of a system associated with the formation, loading, and/or packaging of the tray 105. In addition, the engagement features of the blank 103/tray 105 provide one or more surfaces for receiving a covering or lidding film, e.g., a polymeric film or other cover overlying the tray 105 to maintain one or more conditions of food products held therein.

The blank 103 can also include reinforcement features for forming reinforcement features of the tray 105 that reinforce, e.g., rigidize, stabilize, and/or otherwise minimize, inhibit, prevent, and/or resist deformation of the engagement features. It will be understood that, in some embodiments, one or more of the reinforcement features of the blank 103/tray 105 can be considered part of the engagement features of the tray 105, or vice versa.

As shown, the blank 103 has a longitudinal axis L1 and a lateral axis L2 and includes a plurality of panels for extending at least partially around an interior 107 of the tray 105 when the tray 105 is formed from the blank 103. The panels can include a bottom panel 121, a front panel 123 foldably connected to the bottom panel 121 at a lateral fold line 125, a back panel 127 foldably connected to the bottom panel 121 at a lateral fold line 129, a first side panel 131 foldably connected to the bottom panel 121 at a longitudinal fold line 133, and a second side panel 135 foldably connected to the bottom panel 121 at a longitudinal fold line 137.

The plurality of panels of the blank 103 can also include a plurality of corner panels for forming corner portions/corners/gussets of the tray 105. As shown, the corner panels can include a first corner panel 139 foldably connected to the front panel 123 at an oblique fold line 141, a second corner panel 143 foldably connected to the corner panel 139 at an oblique fold line 144, and the corner panel 143 further foldably connected to the first side panel 131 at an oblique fold line 145. The corner panels can further include a first corner panel 147 foldably connected to the first side panel 131 at an oblique fold line 149, a second corner panel 151 foldably connected to the corner panel 147 at an oblique fold line 152, and the corner panel 151 further foldably connected to the back panel 127 at an oblique fold line 153.

The corner panels can further include a first corner panel 155 foldably connected to the back panel 127 at an oblique fold line 157, a second corner panel 159 foldably connected to the corner panel 155 at an oblique fold line 160, and the corner panel 159 further foldably connected to the second side panel 135 at an oblique fold line 161. The corner panels can further include a first corner panel 163 foldably connected to the second side panel 135 at an oblique fold line 165, a second corner panel 167 foldably connected to the corner panel 163 at an oblique fold line 168, and the corner panel 167 further foldably connected to the front panel 123 at an oblique fold line 169.

With continued reference to FIG. 1, the blank 103/tray 105 can include a plurality of end flaps foldably connected to respective panels of the plurality of panels. As shown, the end flaps can include a front top end flap 171 foldably connected to the front panel 123 at a lateral fold line 173, and, similarly, a back top end flap 177 can be foldably connected to the back panel 127 at a lateral fold line 179.

A first side top end flap 181 can be foldably connected to the first side panel 131 at a longitudinal fold line 183, and a second side top end flap 185 can be foldably connected to the second side panel 135 at a longitudinal fold line 187.

As shown, the top end flap 171 can have outer marginal portions 172, 174 that extend past respective free edges of the front panel 123 and which curve at least partially downwardly, e.g., toward the bottom panel 121. Similarly, the top end flap 177 can have outer marginal portions 178, 180 that extend past respective free edges of the back panel 127.

The side top end flap 181 can have outer marginal portions 184, 186 that extend past respective free edges of the first side panel 131 and which have longitudinal free edges that intersect curved edges of the top end flap 181 to define at least partially pointed outer edges of the top end flap 181.

Similarly, the top end flap 185 can have outer marginal portions 188, 190 that extend past respective free edges of the second side panel 135 and which have longitudinal free edges that intersect curved edges of the top end flap 185 to define at least partially pointed outer edges of the top end flap 185.

The blank 103 can also include product visibility features for forming product visibility features of the tray 105. In the illustrated embodiment, generally circular cuts 191 can be provided in the front panel 123 and the back panel 127. Furthermore, generally circular cuts 192 can be provided at least partially along corners of the bottom panel 121, and extend into respective portions of the front panel 123, the back panel 127, and the respective corner panels 139, 143, 147, 151, 155, 159, 163, 167. The product visibility features can provide a customer with line-of-sight passages into the interior 107 of the tray 105, for example, to inspect food products held therein. In addition, one or more of the product visibility features can provide a path of egress for moisture, e.g., condensation, runoff, etc., to exit the interior 107 of the tray 105.

Referring to FIGS. 2 and 3, according to one embodiment of the disclosure, formation of the tray 105 from the blank 103 can be performed by inverting the blank 103 such that the exterior surface 101 is positioned on a supporting surface and such that the interior surface of the blank 103 can be positioned facing upwardly.

The front panel 123, the back panel 127, the first side panel 131, and the second side panel 135 can be folded upwardly relative to the bottom panel 121 at the respective fold lines 125, 129, 133, 137.

The corner panel 143 can be folded at the fold line 145 into at least partial face-to-face contact with the side panel 131, and the corner panel 139 can be folded at the fold line 144 into at least partial face-to-face contact with the corner panel 143. Similarly, the corner panel 147 can be folded at the fold line 149 into at least partial face-to-face contact with the side panel 131, and the corner panel 151 can be folded at the fold line 152 into at least partial face-to-face contact with the corner panel 147.

Still referring to FIGS. 2 and 3, the corner panel 159 can be folded at the fold line 161 into at least partial face-to-face contact with the side panel 135, and the corner panel 155 can be folded at the fold line 160 into at least partial face-to-face contact with the corner panel 159. Similarly, the corner panel 163 can be folded at the fold line 165 into at least partial face-to-face contact with the side panel 135, and the corner panel 167 can be folded at the fold line 168 into at least partial face-to-face contact with the corner panel 163.

The aforementioned folding of the corner panels can have the effect of drawing edges of the front panel 123 and respective adjacent edges of the side panels 131, 135 into proximity, and/or drawing edges of the back panel 127 can respective adjacent edges of the side panels 131, 135 into proximity. Furthermore, the arrangement of the corner panels 139, 143 can form a first gusset 140 of the tray 105, the arrangement of the corner panels 147, 151 can form a second gusset 148 of the tray 105, the arrangement of the corner panels 155, 159 can form a third gusset 156 of the tray 105, and the arrangement of the corner panels 163, 167 can form a fourth gusset 164 of the tray 105.

The front top end flap 171 can be folded downwardly at the fold line 173 to extend outwardly from the front panel 123, e.g., in a generally horizontal orientation parallel to the bottom panel 121. Similarly, the back top end flap 177 can be folded downwardly at the fold line 179 to extend outwardly from the back panel 127, the first side top end flap 181 can be folded downwardly at the fold line 183 to extend outwardly from the first side panel 131, and the second side top end flap 185 can be folded downwardly at the fold line 187 to extend outwardly from the second side panel 135.

In such an arrangement the top end flaps 171, 177 can be positioned overlapping, e.g., in at least partial face-to-face contact with, respective portions of the top end flaps 181, 185 to form an upper rim/flange 189 of the tray 105. In the illustrated embodiment, the outer marginal portion 172 of the top end flap 171 can be positioned in at least partial face-to-face contact with the outer marginal portion 184 of the top end flap 181, the outer marginal portion 178 of the top end flap 177 can be positioned in at least partial face-to-face contact with the outer marginal portion 186 of the top end flap 181, the outer marginal portion 180 of the top end flap 177 can be positioned in at least partial face-to-face contact with the outer marginal portion 190 of the top end flap 185, and the outer marginal portion 174 of the top end flap 171 can be positioned in at least partial face-to-face contact with the outer marginal portion 188 of the top end flap 185.

In one embodiment, the biasing/pressure of respective portions of the top end flaps 171, 177 on respective portions of the top end flaps 181, 185 as described above can maintain a generally planar and outward arrangement of the top end flaps 171, 177, 181, 185 that form the rim/flange 189, e.g., such that the rim/flange 189 is positioned in generally spaced and parallel relation with the bottom panel 121. In one embodiment, one or both of the top end flaps 171, 177 can be arranged, e.g., through a configuration of the respective fold lines 173, 179, so as to be biased downward and/or toward a planar and outward arrangement to maintain the above-identified configuration. For example, in one embodiment, one or more of more of the top end flaps 171, 177, 181, 185 can be overfolded, e.g., folded downwardly at the respective fold lines 173, 179, 183, 187 past their respective positions that form that rim/flange 189 such that the respective fold lines 173, 179, 183, 187 are crushed/deformed to have a memory or otherwise maintain/bias the top end flaps 171, 177, 181, 185 toward a planar and outward arrangement to maintain the above-identified configuration of the rim/flange 189

The engagement of the top end flaps 171, 177, 181, 185 described above can provide stability, rigidity, reinforcement, etc. to the rim/flange 189 and tray 105. In one embodiment, one or more of the contacting portions of the top end flaps 171, 177, 181, 185 can be maintained with an adhesive such as glue. In one embodiment, one or more of the end flaps 171, 177, 181, 185 can be configured with edge or surface features that engage one or more complementary features or other positions of the respective other one or more of the end flaps 171, 177, 181, 185.

In the illustrated embodiment of the tray 105, the panels 123, 127, 131, 135 can extend generally upwardly and obliquely outwardly from the bottom panel 121 such that the tray 105 has a generally tapered configuration, e.g., such that a top opening defined by the upper edges of the panels 123, 127, 131, 135 is larger than the bottom panel 121.

In this regard, the tray 105 can be provided with a configuration suitable for nesting with vertically adjacent trays 105, for example, to optimize space savings during transport and/or storage.

Turning to FIG. 4, it will be understood that one or more food products P can be dropped, placed, or otherwise positioned in the interior 107 of the tray 105 during or subsequent to the aforementioned steps. In one embodiment, the food products P can be tomatoes, though one or more of the food products can be a different food product without departing from the disclosure. The tray 105 can be provided with one or more food products as a package.

As described herein, engagement features of the tray 105 include the arrangement of the top end flaps 171, 177, 181, 185, together or in subcombinations. As shown, the folded arrangement of the top end flaps 171, 177, 181, 185 extending outwardly from the respective panels forms the rim 189 and one or more engagement surfaces for being engaged/supported by an element associated with a forming apparatus for the tray 105, for example a machine element such as a grasper, fork, pincer, rail, etc. In one embodiment, the exterior (e.g., downward facing) surface of the top end flaps can present engagement surfaces for being engaged/supported by such a machine component. In other embodiments, engagement surfaces can include any combination of one or more of the exterior, interior (e.g., upward facing), and/or side-facing surfaces of one or more of the top end flaps 171, 177, 181, 185.

The positioning of the top end flaps 171, 177, 181, 185 extending away from the panels of the tray 105, also presents a plurality of engagement/support surfaces for engaging/supporting a covering or lidding film F, e.g., a plastic or other polymeric film, or other covering structure. In one embodiment, the lidding film F can be provided as a polymeric layer that at least partially deforms in the presence of a heat source, e.g., a heat sealable film. The lidding film f can thus be positioned extending across a top opening of the tray 105 in contact with one or more surfaces of one or more of the top end flaps 171, 177, 181, 185 to cover the interior 107 of the tray 105 and maintain one or more conditions of the food products held therein, e.g., freshness, ripeness, moisture content, etc. It will be understood that the lidding film can minimize, inhibit, and/or prevent the passage of one or more materials into the interior 107 of the tray 105, for example, condensation or other moisture, insects or other pests, dirt, debris, etc. In one embodiment, the tray 105 can be provided together with the lidding film and one or more food products as a package.

Furthermore, the reinforcement features of the tray 105 can include at least the arrangement of the top end flaps 171, 177, 181, 185 and/or the marginal portions 172, 174, 178, 180, 184, 186, 188, 190 thereof, the engagement of which can minimize, inhibit, prevent, and/or otherwise resist bending, bowing, flexing, buckling, curling, deflection, and/or other deformation of the rim/flange 189. In this regard, forces exerted on the rim/flange 189 via tension applied through a covering or lidding film disposed thereon can minimize, inhibit, and/or prevent deformation of the rim/flange 189, e.g., to avoid undesirable product aesthetics, to avoid at least partial disengagement of the lidding film with the rim/flange 189, to maintain a generally planar configuration of the rim/flange 189 for stacking, storage, transport, etc.

It will be understood that one or more of the panels, flaps, and associated features of the blank 103/tray 105 can have a different arrangement or configuration without departing from the disclosure.

The blanks according to the present disclosure can be, for example, formed from coated paperboard and similar materials. For example, the interior and/or exterior sides of the blanks can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blank. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. In accordance with the above-described embodiments, the blank may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the trays, to function at least generally as described above. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.

In accordance with the above-described embodiments of the present disclosure, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features.

As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the spaced apart slits to be replaced with a continuous slit, a continuous score, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure. Also, a tear line can be a series of cut scores passing completely, or partially, through the material, that are separated by nicks.

The term “glue” is intended to encompass all manner of adhesives commonly used to secure tray panels in place.

The foregoing description of the disclosure illustrates and describes various exemplary embodiments. Various additions, modifications, changes, etc., could be made to the exemplary embodiments without departing from the spirit and scope of the disclosure. 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. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.

Claims

1. A method of forming a tray for holding at least one food product, the method comprising:

obtaining a blank comprising a plurality of panels comprising a bottom panel, a front panel, a back panel, and at least one side panel, a plurality of end flaps foldably connected to a respective panel of the plurality of panels, and reinforcement features;
folding the plurality of panels at least partially around an interior of the tray;
folding the plurality of top end flaps to form a rim extending from the plurality of panels when the tray is formed from the blank; and
activating the reinforcement features to maintaining an integrity of the rim such that at least one end flap of the plurality of end flaps is biased downward to maintain an outward arrangement from a respective panel of the plurality of panels.

2. The method of claim 1, wherein the folding the plurality of top end flaps comprises folding the at least one top end flap of the plurality of end flaps generally parallel to the bottom panel.

3. The method of claim 1, wherein activating the reinforcement features comprises biasing each top end flap of the plurality of end flaps downwardly to maintain an outward arrangement from a respective panel of the plurality of panels.

4. The method of claim 1, wherein the folding the plurality of top end flaps comprises overlapping at least a portion of the at least one top end flap on a respective portion of an adjacent end flap of the plurality of top end flaps.

5. The method of claim 4, wherein the at least a portion of the at least one top end flap is a marginal portion of the at least one top end flap.

6. The method of claim 5, wherein the marginal portion extends perpendicularly away from a central portion of the at least one top end flap.

7. The method of claim 6, wherein the marginal portion is a first marginal portion extending perpendicularly away from the central portion of the at least one top end flap, and the at least one top end flap further comprises a second marginal portion extending perpendicularly away from the central portion and overlapping a respective portion of an adjacent end flap of the plurality of end flaps.

8. The method of claim 1, wherein the plurality of panels further comprises at least one corner panel foldably connected to a respective panel of the plurality of panels.

9. The method of claim 8, wherein the at least one corner panel is a first corner panel foldably connected to one of the front panel and the back panel, and the plurality of panels further comprises a second corner panel foldably connected to the first corner panel and the at least one side panel and the method further comprises positioning the first corner panel in at least partial face-to-face contact with the second corner panel to form a gusset of the tray.

10. A tray for holding at least one food product, the tray comprising:

a plurality of panels at least partially extending around an interior of the tray and comprising a bottom panel, a front panel, a back panel, and at least one side panel;
a plurality of end flaps comprising a plurality of top end flaps cooperating to form a rim extending from the plurality of panels; and
reinforcement features for maintaining an integrity of the rim, the reinforcement features comprising an arrangement of the plurality of top end flaps such that at least one end flap of the plurality of end flaps is biased downward to maintain an outward arrangement from a respective panel of the plurality of panels.

11. The tray of claim 10, wherein the at least one top end flap of the plurality of end flaps is generally parallel to the bottom panel.

12. The tray of claim 10, wherein each top end flap of the plurality of end flaps is biased downwardly to maintain an outward arrangement from a respective panel of the plurality of panels.

13. The tray of claim 10, wherein a portion of the at least one top end flap is overlapped on a respective portion of an adjacent end flap of the plurality of top end flaps.

14. The tray of claim 13, wherein the at least a portion of the at least one top end flap is a marginal portion of the at least one top end flap.

15. The tray of claim 14, wherein the marginal portion extends perpendicularly away from a central portion of the at least one top end flap.

16. The tray of claim 15, wherein the marginal portion is a first marginal portion extending perpendicularly away from the central portion of the at least one top end flap, and the at least one top end flap further comprises a second marginal portion extending perpendicularly away from the central portion and overlapping a respective portion of an adjacent end flap of the plurality of end flaps.

17. The tray of claim 10, wherein the plurality of panels further comprises at least one corner panel foldably connected to a respective panel of the plurality of panels.

18. The tray of claim 17, wherein the at least one corner panel is a first corner panel foldably connected to one of the front panel and the back panel, and the plurality of panels further comprises a second corner panel foldably connected to the first corner panel and the at least one side panel and the first corner panel is positioned in at least partial face-to-face contact with the second corner panel to form a gusset of the tray.

19. A blank for forming a tray for holding at least one food product, the blank comprising:

a plurality of panels comprising a bottom panel, a front panel, a back panel, and at least one side panel;
a plurality of end flaps comprising a plurality of top end flaps for cooperating to form a rim extending from the plurality of panels when the tray is formed from the blank; and
reinforcement features for maintaining an integrity of the rim, the reinforcement features comprising an arrangement of the plurality of top end flaps such that at least one end flap of the plurality of end flaps is biased downward to maintain an outward arrangement from a respective panel of the plurality of panels.

20. The blank of claim 19, wherein at least a portion of the at least one top end flap is for being overlapped on a respective portion of an adjacent end flap of the plurality of top end flaps when the tray is formed from the blank.

21. The blank of claim 20, wherein the at least a portion of the at least one top end flap is a marginal portion of the at least one top end flap.

22. The blank of claim 21, wherein the marginal portion extends perpendicularly away from a central portion of the at least one top end flap.

23. The blank of claim 22, wherein the marginal portion is a first marginal portion extending perpendicularly away from the central portion of the at least one top end flap, and the at least one top end flap further comprises a second marginal portion extending perpendicularly away from the central portion and for being overlapping a respective portion of an adjacent end flap of the plurality of end flaps when the tray is formed from the blank.

24. The blank of claim 19, wherein the plurality of panels further comprises at least one corner panel foldably connected to a respective panel of the plurality of panels.

25. The blank of claim 24, wherein the at least one corner panel is a first corner panel foldably connected to one of the front panel and the back panel, and the plurality of panels further comprises a second corner panel foldably connected to the first corner panel and the at least one side panel, the first corner panel for being positioned in at least partial face-to-face contact with the second corner panel to form a gusset of the tray formed from the blank.

Patent History
Publication number: 20220144477
Type: Application
Filed: Nov 4, 2021
Publication Date: May 12, 2022
Inventor: Thomas Brink (Grand Rapids, MI)
Application Number: 17/519,107
Classifications
International Classification: B65D 5/24 (20060101);