Tray for holding a food product

• US 10,232,973 B2
• Filed: 11/05/2015
• Issued: 03/19/2019
• Est. Priority Date: 11/07/2014
• Status: Active Grant

• Current Assignee: Graphic Packaging International LLC (Graphic Packaging International Incorporated)
• Original Assignee: Graphic Packaging International LLC (Graphic Packaging International Incorporated)
• Inventors: Burke, Bradley J.
• Primary Examiner(s): Skurdal, Corey N
• Application Number:
  US14/933,324
• Publication Number:
  US 20160130028A1
• Time in Patent Office: 1,230 Days
• CPC Class Codes: B65D 5/2047 trapezoidal, e.g. to form a body with diverging side walls B65D5/2033 takes precedence
• CPC Class Codes: B65D 5/241 and the gussets folds connected to the inside of the container body B65D5/247 and B65D5/248 take precedence
• CPC Class Codes: B65D 5/244 and the gussets folds connected to the outside of the container body B65D5/247, B65D5/248 take precedence

Abstract

A tray for holding a food product. The tray includes a plurality of panels that extend at least partially around an interior of the tray. The plurality of panels includes a bottom panel, a side panel foldably connected to the bottom panel, and an end panel foldably connected to the bottom panel. The tray includes a rim structure having a rim panel foldably connected to at least one panel of the plurality of panels and a support panel foldably connected to the rim panel. The tray further includes a gusset panel foldably connected to the side panel. The gusset panel and the end panel are at least partially overlapping one another.

Claims

1. A tray for holding a food product, the tray comprising:

a plurality of panels that extend at least partially around an interior of the tray, the plurality of panels comprises a bottom panel, a side panel foldably connected to the bottom panel, and an end panel foldably connected to the bottom panel;

a rim structure comprising a rim panel foldably connected to at least one panel of the plurality of panels at a first lateral fold line, a support panel foldably connected to the rim panel at a second lateral fold line, and an attachment flap foldably connected to the support panel at a third lateral fold line and having a free edge, a first longitudinal distance is defined from the second lateral fold line to the third lateral fold line, and a second longitudinal distance is defined from the third lateral fold line to the free edge of the attachment flap, the first longitudinal distance is approximately equal to the second longitudinal distance; and

a gusset panel foldably connected to the side panel, the gusset panel and the end panel at least partially overlapping one another.

2. The tray of claim 1, wherein the rim panel extends generally parallel to the bottom panel, and the support panel extends obliquely with respect to the rim panel and the side panel.

3. The tray of claim 1, wherein the attachment flap at least partially overlaps the side panel.

4. The tray of claim 3, wherein the rim panel extends generally parallel to the bottom panel, and the support panel extends obliquely from the attachment flap to the rim panel.

5. The tray of claim 1, wherein the side panel is a first side panel, the rim structure is a first rim structure and is foldably connected to the first side panel, and the tray further comprises a second side panel foldably connected to the bottom panel and a second rim structure foldably connected to the second side panel.

6. The tray of claim 5, wherein the rim panel, the support panel, and the attachment flap of the first rim structure are a first rim panel, a second rim panel, and a first attachment flap, respectively, and the second rim structure comprises a second rim panel foldably connected to the second side panel, a second support panel foldably connected to the second rim panel, and a second attachment flap foldably connected to the second support panel.

7. The tray of claim 6, wherein the first rim panel and the second rim panel extend generally parallel to the bottom panel, and the first support panel and the second support panel extend obliquely from the respective first rim panel and second rim panel toward the respective first side panel and second side panel.

8. The tray of claim 6, wherein the first attachment flap is at least partially in face-to-face contact with the first side panel, and the second attachment flap is at least partially in face-to-face contact with the second side panel.

9. The tray of claim 6, wherein the end panel comprises a first end panel, the plurality of panels further comprises a second end panel foldably connected to the bottom panel, and the tray further comprises:

a first reinforcement flap foldably connected to the first end panel and at least partially overlapping the first end panel; and

a second reinforcement flap foldably connected to the second end panel and at least partially overlapping the second end panel.

10. The tray of claim 9, wherein the first side panel, the second side panel, the first end panel and the second end panel are sloped so that one or more trays may be stacked together in an at least partially nested relationship.

11. The tray of claim 1, further comprising a reinforcement flap foldably connected to the end panel, the reinforcement flap at least partially overlapping the end panel.

12. The tray of claim 11, wherein the reinforcement flap is at least partially in face-to-face contact with an exterior surface of the end panel.

13. The tray of claim 11, wherein the side panel is a first side panel, the gusset panel is a first gusset panel, the plurality of panels further comprises a second side panel foldably connected to the bottom panel, the tray further comprises a second gusset panel foldably connected to the second side panel, the first gusset panel and the second gusset panel are at least partially in face-to-face contact with the end panel, and the reinforcement flap is at least partially in face-to-face contact with the first gusset panel and the second gusset panel.

14. The tray of claim 11, wherein the reinforcement flap is foldably connected to the end panel along a longitudinal fold line, and the end panel comprises an edge extending from an end of the longitudinal fold line toward the bottom panel.

15. The tray of claim 14, wherein the edge of the end panel is oblique with respect to the longitudinal fold line.

16. The tray of claim 14, wherein the edge of the end panel is a first edge, the end panel comprises a second edge extending from the first edge to the bottom panel.

17. The tray of claim 1, wherein the rim panel extends obliquely upwardly from the first lateral fold line.

18. A blank for forming a tray for holding a food product, the blank comprising:

a plurality of panels comprising a bottom panel, a side panel foldably connected to the bottom panel, and an end panel foldably connected to the bottom panel;

a gusset panel foldably connected to the side panel; and

rim features for forming a rim structure when the blank is formed into the tray, the rim features comprise a rim panel foldably connected to at least one panel of the plurality of panels at a first lateral fold line, a support panel foldably connected to the rim panel at a second lateral fold line, and an attachment flap foldably connected to the support panel at a third lateral fold line and having a free edge, a first longitudinal distance is defined from the second lateral fold line to the third lateral fold line, and a second longitudinal distance is defined from the third lateral fold line to the free edge of the attachment flap, the first longitudinal distance is approximately equal to the second longitudinal distance.

19. The blank of claim 18, wherein the rim panel is configured to extend generally parallel to the bottom panel, and the support panel is configured to extend obliquely with respect to the rim panel and the side panel when the blank is formed into the tray.

20. The blank of claim 18, wherein the attachment flap is configured to at least partially overlap the side panel when the blank is formed into the tray.

21. The blank of claim 20, wherein the rim panel is configured to extend generally parallel to the bottom panel, and the support panel is configured to extend obliquely from the attachment flap to the rim panel when the blank is formed into the tray.

22. The blank of claim 18, wherein the side panel is a first side panel, the rim features are first rim features and are foldably connected to the first side panel, and the blank further comprises a second side panel foldably connected to the bottom panel and second rim features foldably connected to the second side panel.

23. The blank of claim 22, wherein the rim panel, the support panel, and the attachment flap of the first rim features are a first rim panel, a first support panel, and a first attachment flap, respectively, and the second rim features comprise a second rim panel foldably connected to the second side panel, a second support panel foldably connected to the second rim panel, and a second attachment flap foldably connected to the second support panel.

24. The blank of claim 23, wherein the first rim panel and the second rim panel are configured to extend generally parallel to the bottom panel when the tray is formed from the blank, and the first support panel and the second support panel are configured to extend obliquely from the respective first rim panel and second rim panel toward the respective first side panel and second side panel when the tray is formed from the blank.

25. The blank of claim 23, wherein the first attachment flap is positionable to be at least partially in face-to-face contact with the first side panel when the blank is formed into the tray, and the second attachment flap is positionable to be at least partially in face-to-face contact with the second side panel when the blank is formed into the tray.

26. The blank of claim 23, wherein the end panel comprises a first end panel, the plurality of panels further comprises a second end panel foldably connected to the bottom panel, and the blank further comprises:

a first reinforcement flap foldably connected to the first end panel and configured to at least partially overlap the first end panel when the blank is formed into the tray; and

a second reinforcement flap foldably connected to the second end panel and configured to at least partially overlap the second end panel when the blank is formed into the tray.

27. The blank of claim 18, further comprising a reinforcement flap foldably connected to the end panel, the reinforcement flap is configured to at least partially overlap the end panel when the blank is formed into the tray.

28. The blank of claim 27, wherein the reinforcement flap is configured to be at least partially in face-to-face contact with an exterior surface of the end panel when the blank is formed into the tray.

29. The blank of claim 27, wherein the side panel is a first side panel, the gusset panel is a first gusset panel, the plurality of panels further comprises a second side panel foldably connected to the bottom panel, the blank further comprises a second gusset panel foldably connected to the second side panel, the first gusset panel and the second gusset panel are configured to be at least partially in face-to-face contact with the end panel when the tray is formed from the blank, and the reinforcement flap is configured to be at least partially in face-to-face contact with the first gusset panel and the second gusset panel when the tray is formed from the blank.

30. The blank of claim 27, wherein the reinforcement flap is foldably connected to the end panel along a longitudinal fold line, and the end panel comprises an edge extending from an end of the longitudinal fold line away from the reinforcement flap.

31. The blank of claim 30, wherein the edge of the end panel is oblique with respect to the longitudinal fold line.

32. The blank of claim 30, wherein the edge of the end panel is a first edge, the end panel comprises a second edge extending from the first edge to the bottom panel.

33. The tray of claim 18, wherein the rim panel is for extending obliquely upwardly from the first lateral fold line in the tray formed from the blank.

34. A method of forming a tray for holding a food product, the method comprising:

obtaining a blank comprising a plurality of panels comprising a bottom panel, a side panel foldably connected to the bottom panel, and an end panel foldably connected to the bottom panel, a gusset panel foldably connected to the side panel, and rim features comprising a rim panel foldably connected to at least one panel of the plurality of panels at a first lateral fold line, a support panel foldably connected to the rim panel at a second lateral fold line, and an attachment flap foldably connected to the support panel at a third lateral fold line and having a free edge, a first longitudinal distance is defined from the second lateral fold line to the third lateral fold line, and a second longitudinal distance is defined from the third lateral fold line to the free edge of the attachment flap, the first longitudinal distance is approximately equal to the second longitudinal distance;

forming an interior of the tray at least partially defined by the plurality of panels, the forming of the interior of the tray comprising positioning the gusset panel and the end panel to at least partially overlap one another; and

forming a rim structure by folding the rim panel and the support panel with respect to the side panel.

35. The method of claim 34, wherein the forming the rim structure further comprises positioning the rim panel to extend generally parallel to the bottom panel and positioning the support panel to extend obliquely with respect to the rim panel and the side panel.

36. The method of claim 34, wherein the forming the rim structure further comprises at least partially overlapping the attachment flap and the side panel.

37. The method of claim 36, wherein the forming the rim structure further comprises positioning the rim panel to extend generally parallel to the bottom panel and positioning the support panel to extend obliquely from the attachment flap to the rim panel.

38. The method of claim 34, wherein the blank further comprises a reinforcement flap foldably connected to the end panel, and the method further comprises at least partially overlapping the reinforcement flap and the end panel.

39. The method of claim 38, wherein the at least partially overlapping the reinforcement flap and the end panel further comprises positioning the reinforcement flap to be at least partially in face-to-face contact with an exterior surface of the end panel.

40. The method of claim 38, wherein the side panel is a first side panel, the gusset panel is a first gusset panel, the plurality of panels further comprises a second side panel foldably connected to the bottom panel, the blank further comprises a second gusset panel foldably connected to the second side panel, the forming the interior of the tray further comprises positioning the first gusset panel and the second gusset panel in face-to-face contact with the end panel, and the at least partially overlapping the reinforcement flap and the end panel further comprises positioning the reinforcement flap to be at least partially in face-to-face contact with the first gusset panel and the second gusset panel.

41. The tray of claim 34, wherein the forming the rim structure comprises positioning the rim panel to extend obliquely upwardly from the first lateral fold line.