Reclosable food tray and tray blank

• US 5,411,204 A
• Filed: 03/24/1993
• Issued: 05/02/1995
• Est. Priority Date: 09/05/1990
• Status: Expired due to Term

• Current Assignee: Rock-Tenn Shared Services, LLC (WestRock Company)
• Original Assignee: Fold-Pak Corporation (The Westervelt Company, Inc.)
• Inventors: DeMay, Karl F.
• Primary Examiner(s): Elkins, Gary E.
• Application Number:
  US08/036,510
• Time in Patent Office: 769 Days
• Field of Search: 229/40, 229/114, 229/105, 229/155, 229/156, 229/186, 229/902, 229/903, 229/906, 426/113, 426/114, 426/119, 426/120, 426/124
• US Class Current: 229/114
• 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 5/2061 of triangular shape
• CPC Class Codes: B65D 5/244 and the gussets folds connected to the outside of the container body B65D5/247, B65D5/248 take precedence
• CPC Class Codes: Y10S 229/902 Box for prepared or processed food

Abstract

A reclosable food tray is disclosed generally comprising a receptacle portion and first and second pair of opposing closure flaps. The receptacle portion has a substantially trapazoidal volume defined by a rectangular shaped bottom panel and two substantially upstanding pair of opposing side panels. The two pair of opposing side panels define four pair of adjacent panels which are hingedly connected in a liquid-sealed manner by a folded gusset secured to the exterior surface of one of the adjacent side panels by adhesive. Each side panel is disposed at an obtuse angle measured from the bottom panel to facilitate stacking of the receptacle portion of successive trays. The first pair of opposing closure flaps extend from one pair of opposing side panels and are capable of closing off a portion of the access opening. The second pair of opposing closure flaps extend from the other pair of opposing side panels and are adapted to interlock with each other, overlap a portion of the first pair of opposing closure flaps, and close off the remaining portion of the access opening. In the preferred embodiment, the food tray is erected from a paperboard material which is substantially resistant to microwave and other heat radiation. In addition, an adhesive is used which resists melting upon exposure to microwave and other heat radiation. According to another aspect of the present invention, a tray blank is provided, from which the tray can be erected according to a simple, yet efficient method utilizing a minimum of folding operations.

Claims

1. A reclosable food tray erected from a single unitary blank having an interior and exterior surface and a substantially square gross geometry, which comprises:

a fully constructed receptacle portion having an access opening permitting introduction of food into said receptacle portion having a volumetric geometry defined by a rectangular shaped bottom panel, a first substantially upstanding pair of opposing side panels, a second substantially upstanding pair of opposing side panels said pairs of opposing side panels defining four pairs of adjacent side panels, with each pair of adjacent side panels being hingedly connected by one of four folded gussets, with each of said gussets unitary with said adjacent side panels and secured to the exterior surface of one of said adjacent side panels by an adhesive applied between each said folded gusset and said exterior surface, each said side panel being disposed at a first obtuse angle measured from said bottom panel so that said volumetric geometry facilitates nesting of the receptacle portion of one reclosable food tray within the receptacle portion of another reclosable food tray;

a first pair of opposing closure flaps, each extending from one of said opposing side panels and being capable of closing off a portion of said access opening; and

a second pair of opposing closure flaps, each extending from one of the other pair of opposing side panels and being adapted to cooperatively interlock with each other and overlap a portion of said first pair of opposing closure flaps to close off said access opening.

2. The reclosable food tray of claim 1, wherein each said folded gusset is suitably dimensioned so that said receptacle portion is capable of retaining liquid or semi-solid consumables without leakage through said receptacle portion.

3. The reclosable food tray of claim 2, wherein said two substantially upstanding pair of opposing side panels comprise a first side panel disposed opposite a second side panel, a third side panel disposed opposite a fourth side panel, with said first side panel being adjacent said third and said fourth side panels and said second side panel being adjacent said third and said fourth side panels to form a volume having trapezoidal dimensions.

4. The reclosable food tray of claim 1, wherein said blank comprises paperboard material which is substantially resistant to microwave and other heat radiation and said adhesive is resistant to melting upon exposure to said microwave and other heat radiation.

5. The reclosable food tray of claim 1, wherein said first pair of opposing closure flaps are hingedly connected to said respective opposing side panels along respective top fold lines, and each folded gusset has an upper edge which extends substantially along one of said respective top fold lines.

6. The reclosable food tray of claim 5, wherein said first and second pair of opposing side panels are hingedly connected to said bottom panel along respective bottom fold lines, and each side panel has left and right side fold lines, each of which are disposed at a second obtuse angle with respect to adjacent bottom fold lines.

7. The reclosable tray of claim 6, wherein said blank comprises paperboard material which is substantially resistant to microwave and other heat radiation, and said adhesive is resistant to melting upon exposure to microwave and other heat radiation.

8. The reclosable food tray of claim 1, which further comprises a folded partition for insertion into said receptacle portion to divide said receptacle portion into two or more separate food storage compartments.

9. A reclosable food tray constructed from a single unitary blank having an interior and exterior surface, which comprises:

a receptacle portion having an access opening permitting introduction of food into said receptacle portion having a volume defined by a rectangular shaped bottom panel, a first substantially upstanding pair of opposing side panels, a second substantially upstanding pair of opposing side panels said pairs of opposing side panels defining four pairs of adjacent side panels, with each pair of adjacent side panels being hingedly connected by one of four folded gussets, with each of said gussets unitary with said adjacent side panels and secured to the exterior surface of one of said adjacent side panels by an adhesive applied between each said folded gusset and said exterior surface, each said side panel being disposed at a first obtuse angle measured from said bottom panel;

a first pair of opposing closure flaps, each extending from one of said opposing side panels and being capable of closing off a portion of said access opening; and

a second pair of opposing closure flaps, each extending from one of the other pair of opposing side panels, said second pair of opposing closure flaps comprise a releasable tab and slot adapted to interlock with each other and overlap a portion of said first pair of opposing closure flaps to close off said access opening.

10. A blank adapted to be folded into a reclosable food tray having a fully constructed receptacle portion with a volumetric geometry which facilitates nesting of the receptacle portion of one food tray within the receptacle portion of another said food tray, said blank having a planar unitary construction, an interior and an exterior surface and a substantially square gross geometry, which comprises:

a bottom panel of rectangular shape having a surface area defined by a first and second pair of opposing bottom fold lines;

a first and second pair of opposing side panels hingedly connected to said bottom panel along said first and second pair of opposing bottom fold lines, said opposing panels defining four pair of adjacent side panels;

four foldable gussets, each said foldable gusset being hingedly connected to each pair of adjacent side panels so that when said first and second opposing side panels are folded substantially upright with respect to said bottom panel, a receptacle portion with an access opening is formed, each said foldable gusset is folded and can be secured to said exterior surface of one of said side panels, and each said side panel is disposed substantially upright at a first predetermined obtuse angle with respect to said bottom panel;

a first pair of opposing closure panels, each hingedly connected to one of said first pair of opposing side panels and being dimensioned to close off a portion of said access opening when folded over said access opening and disposed substantially parallel to said bottom panel;

a second pair of opposing closure panels, each hingedly connected to one of said second pair of opposing side panels and being dimensioned to close off said access opening when folded over said access opening and said first pair of opposing closure panels.

11. The blank of claim 10, wherein said second pair of opposing closure flaps comprises a releasable fastening means to selectively open and close said second pair of closure flaps when folded down over said first pair of closure flaps and said access opening.

12. The blank of claim 10, wherein said first pair of opposing bottom fold lines comprises a first bottom fold line opposing a second bottom fold line, said second pair of opposing bottom fold lines comprises a third bottom fold line opposing a fourth bottom fold line;

said first pair of opposing side panels comprises a first side panel contiguous with said first bottom fold line, and having a surface area defined by a first top fold line, a first left side fold line, a first right side fold line and said first bottom fold line, said first top and bottom fold lines being substantially parallel and said first left and right side fold lines diverging from said first bottom fold line at a said predetermined obtuse angle; and

a second side panel disposed opposite of said first side panel, being contiguous with said second bottom fold line, and having a surface area defined by a second top fold line, a second left side fold line, a second right side fold line and said second bottom edge fold line, said second top and bottom fold lines being substantially parallel and said second left and right side fold lines diverging from said second bottom fold lines at said second predetermined obtuse angle; and

said second pair of opposing side panels comprises a third side panel contiguous with said third bottom fold line, and having a surface area defined by a third top fold line, a third left side fold line, a third right side fold line and said third bottom fold line, said third top and bottom fold lines being substantially parallel and said third left and right side fold lines diverging from said third bottom fold line at said second predetermined obtuse angle; and

a fourth side panel disposed opposite of said second side panel, being contiguous with said fourth bottom fold line, and having a surface area defined by a fourth top fold line, a fourth left side fold line, a fourth right fold and said fourth bottom fold line, said fourth top and bottom fold line being substantially parallel and said fourth left and right side fold lines diverging from said fourth bottom fold line at said second predetermined obtuse angle.

13. The blank of claim 10, wherein said foldable gussets comprise:

a first foldable gusset being contiguous with said first and third side panels, and having a first corner fold line and a first corner edge;

a second foldable gusset being contiguous with said first and fourth side panels, and having a second corner fold line and a second corner edge;

a third foldable gusset being contiguous with said fourth and second side panels, and having a third corner fold line and a third corner edge; and

a fourth foldable gusset being contiguous with said second and third side panels, and having a fourth corner fold line and a fourth corner edge.

14. The blank of claim 12, wherein said first pair of opposing closure panels comprises:

a first closure panel being contiguous with said first side panel; and

a second closure panel being contiguous with said second side panel; and

said second pair of opposing closure panels comprises a third closure panel being contiguous with said third side panel; and

a fourth closure panel being contiguous with said fourth side panel.

15. The blank of claim 12, wherein an interlocking means is formed in one of said opposing first and second closure panels or said opposing third and fourth closure panels for selectively opening and closing said opposing closure panels.

16. The blank of claim 11, wherein said first foldable gusset has a surface area generally defined by said first left side fold line, said third right side fold line and said first corner edge;

said second foldable gusset has a surface area generally defined by said first right side fold line, said fourth left side fold line and said second corner edge;

said third foldable gusset has a surface area defined by said fourth right side fold line, said second left side fold line and said third corner edge; and

said fourth foldable gusset has a surface area generally defined by said second right side fold line, said third left side fold line and said fourth corner edge.

17. The blank according to claim 14, wherein said first closure panel has a first left closure panel edge, a first right closure panel edge, and a surface area generally defined by said first top fold line, said left closure panel edge and said first right closure panel edge;

said second closure panel has a second left closure panel edge, a second right closure panel edge, and a surface area generally defined by said second top fold line, said second left closure panel edge and said second right closure panel edge;

said third closure panel has a third left closure panel edge, a third right closure panel edge, and a surface area generally defined by said third top fold line, said third left closure panel edge and said third right closure panel edge; and

said fourth closure panel has a fourth left closure panel edge, a fourth right closure panel edge, and a surface area generally defined by said fourth top fold line, said fourth left closure panel edge and said fourth right closure panel edge.

18. The blank according to claim 17, wherein said first left closure panel edge has a portion adjacent said first top fold line which is substantially parallel to said third bottom fold line;

said first right closure panel edge has a portion adjacent said first top fold line which is substantially parallel to said fourth bottom fold line;

said second left closure panel edge has a portion adjacent to said second top fold line which is substantially parallel to said fourth bottom fold line; and

said second right closure panel edge has a portion adjacent to said second top fold line which is substantially parallel to said third bottom fold line.

19. The blank according to claim 16, wherein said third left closure edge has a portion adjacent to said third top fold line which is substantially parallel to said second bottom fold line;

said third right closure panel edge has a portion adjacent to said third top fold line which is substantially parallel to said first bottom fold line;

said fourth left closure panel edge having a portion adjacent to said fourth top fold line which is substantially parallel to said first bottom fold line; and

said fourth right closure panel edge has a portion adjacent to said fourth top fold line which is substantially parallel to said second bottom edge fold line.

20. A blank adapted to be folded into a reclosable food tray having a receptacle portion with a volumetric geometry which facilitates nesting of the receptacle portion of one food tray within the receptacle portion of another said food tray, said blank having planar unitary construction and a substantially square gross geometry, which comprises:

a bottom panel of rectangular shape having a surface area defined by first, second, third and fourth bottom fold lines;

a first side panel contiguous with said first bottom fold line having a surface area defined by a first top fold line, a first left side fold line, a first right side fold line and said first bottom fold line, said first top fold line and said first bottom fold line being substantially parallel and said first left and right side fold lines diverging from said first bottom fold at a predetermined angle;

a second side panel disposed opposite said first side panel and contiguous with said second bottom fold line, having a surface area defined by a second top fold line, a second left side fold line, a second right side fold line and said second bottom fold, said second top and bottom fold lines being substantially parallel and said second left and right side fold lines diverging from said second bottom fold line at said predetermined angle;

a third side panel contiguous with said third bottom fold line having a surface area defined by a third top fold line, a third left side fold line, a third right side fold line and said third bottom fold, said third top and bottom fold lines being substantially parallel and said third left and right side fold lines diverging from said third bottom fold line at said predetermined angle;

a fourth side panel disposed opposite said second side panel and contiguous with said fourth bottom fold line, having a surface area defined by a fourth top fold line, a fourth left side fold line, a fourth right side fold line and said fourth bottom fold line, said fourth top and bottom fold lines being substantially parallel and said fourth left and right side fold lines diverging from said fourth bottom fold line at said predetermined angle;

a first foldable gusset being contiguous with said first and third side panels, and having a first corner fold line and a first corner edge;

a second foldable gusset being contiguous with said first and fourth side panels, and having a second corner fold line and a second corner edge;

a third foldable gusset being contiguous with said fourth and second side panels, and having a third corner fold line and a third corner edge;

a fourth foldable gusset being contiguous with said second and third side panels, and having a fourth corner fold line and a fourth corner edge;

a first closure panel being contiguous with said first side panel;

a second closure panel being contiguous with said second side panel;

a third closure panel being contiguous with said third side panel;

a fourth closure panel being contiguous with said fourth side panel; and

fastening means formed in at least one of said closure panels for selectively opening and closing said closure panels.