Carton with integrated tray

• US 7,793,821 B2
• Filed: 03/03/2009
• Issued: 09/14/2010
• Est. Priority Date: 09/12/2006
• Status: Expired due to Fees

• Current Assignee: Graphic Packaging International Incorporated
• Original Assignee: Graphic Packaging International Incorporated
• Inventors: Oliveira, Steven Manuel
• Primary Examiner(s): Elkins; Gary E
• Application Number:
  US12/396,589
• Publication Number:
  US 20090200364A1
• Time in Patent Office: 560 Days
• Field of Search: 229/104, 229/120.011, 229/235, 229/240, 229/241, 229/242, 229/243, 229/244, 229902-904, 229/906, 219/730, 219/759, 426/107, 426/109, 426/110, 426/113, 426/114, 426/122, 426/123
• US Class Current: 229/104
• CPC Class Codes: B65D 2581/346 integral to the package, e.g. the package is transformed into a stand
• CPC Class Codes: B65D 2581/3498 attached to the base surface
• CPC Class Codes: B65D 5/5475 for dividing a "cross-like" container body into separate parts
• CPC Class Codes: B65D 81/3453 Rigid containers, e.g. trays, bottles, boxes, cups
• CPC Class Codes: Y10S 229/902 Box for prepared or processed food
• CPC Class Codes: Y10S 229/903 Ovenable, i.e. disclosed to be placed in an oven
• CPC Class Codes: Y10S 229/906 Baked goods

Abstract

A carton capable of containing a plurality of food items is disclosed. The carton can be separated into two portions or trays, each of which can be converted into a tray for heating a food item in a microwave oven. One or both of the trays may be designed to elevate the food product from the turntable or floor of the microwave oven to enhance the efficiency of the heating process. One or both trays may include a microwave energy interactive to enhance browning and/or crisping of the food item.

Claims

1. A carton comprising:

a plurality of wall panels comprising two main panels, an intermediate panel positioned between and connected to the main panels, and a plurality of flap panels respectively formed by pairs of first flaps that are folded and adhered together, each of the first flaps being foldably connected to a respective one of the main panels; and

a tear strip extending around the carton, the tear strip having an alternating series of narrow and wide regions, and the tear strip being formed by a plurality of removable links connected in series, each of the removable links being disposed in a respective one of the wall panels, and at least one of the removable links of the plurality of removable links comprising a first tear-away portion formed in a flap panel of the plurality of flap panels, wherein the first-away portion is at least partially formed by a first tear-away subportion in one of the first flaps of the flap panel and a second tear-away subportion in the other of the first flaps of the flap panel, the first tear-away subportion at least partially overlapping the second tear-away subportion,

wherein the carton is convertible to a first tray and a second tray by removal of the tear strip.

2. The carton of claim 1, wherein upper and lower edges of the tear strip each include an alternating series of edges that extend parallel to a longitudinal direction of the tear strip, and that are respectively connected by an alternating series of edges that are oriented obliquely to the longitudinal direction of the tear strip.

3. The carton of claim 1, comprising:

second flaps foldably connected to opposite ends of some of the first flaps and adhered to others of the first flaps; and

secondary tear-away subportions respectively disposed in the second flaps, wherein the secondary tear-away subportions partially form one of the one or more of the removable links.

4. The carton of claim 1, wherein

one of the removable links is at least partially formed by a second tear-away portion disposed in the intermediate panel.

5. The carton of claim 4, wherein the one of the removable links comprises a pull tab partially defined by a horizontal slit in the first or second tear-away portion, and wherein the pull tab includes a free end that projects outwardly from the carton to enable the tear strip to be removed by pulling of the pull tab.

6. The carton of claim 1, wherein, upon removal of the tear strip, the first and second trays are separated into a first configuration in which each of the first and second trays comprises:

one of the main panels; and

a plurality of corner wall members respectively located at corner areas of the one of the main panels, wherein each of the corner wall members comprises a pair of walls that are perpendicular to each other and extend perpendicularly away from the one of the main panels.

7. The carton of claim 1, wherein the first and second tear-away subportions are at least partially defined by respective first lines of disruption in each of the first flaps and each of the first lines of disruption comprises a first substantially straight tear line and a pair of first crooked tear lines extending from opposite ends of the first substantially straight tear line to edges of a respective one of the first flaps.

8. The carton of claim 7, wherein each of the first substantially straight tear lines is positioned between and collinear with a pair of edge fold lines connecting a respective one of the first flaps to one of the main panels.

9. The carton of claim 7, wherein each of the first crooked tear lines includes:

a first inner segment that extends obliquely from the first substantially straight tear line;

and

a first outer segment that extends from the first inner segment, parallel to the first substantially straight tear line.

10. The carton of claim 9, comprising:

a plurality of second flaps respectively connected to ends of some of the first flaps; and

a plurality of secondary tear-away subportions respectively defined on the second flaps, wherein

the first outer segment of at least one of the first lines of disruption extends into one of the second flaps to at least partially define one of the secondary tear-away subportions.

11. The carton of claim 10, wherein:

one of the removable links of the plurality of removable links comprises a second tear-away portion formed in the intermediate panel; and

the second tear-away portion is at least partially defined by a pair of spaced-apart second lines of disruption, each of the second lines of disruption being formed by a second substantially straight tear lines and a pair of second crooked tear lines extending from opposite ends of the second substantially straight tear line.

12. The carton of claim 11, wherein the second tear-away portion is configured to join the first tear-away portions such that the first tear-away portions and the second tear-away portion at least partially form the plurality of removable links of the tear strip.

13. The carton of claim 11, wherein each of the second crooked tear lines includes:

a second inner segment that extends obliquely from the second substantially straight tear line; and

a second outer segment that extends from the second inner segment, parallel to the second substantially straight tear line.

14. The carton of claim 13, comprising:

a pair of third flaps respectively connected to ends of the intermediate panel; and

a plurality of third tear-away portions respectively defined on the third flaps, wherein

each of the second outer segments extends into one of the third flaps to partially define the third tear-away subportions.

15. The carton of claim 14, wherein the first tear-away portion, the secondary tear-away subportions, the second tear-away portion and the third tear-away portions are configured to form the tear strip.

16. A carton comprising:

a plurality of wall panels arranged so that the carton is substantially rectangular, the plurality of wall panels comprises;

(a) two main panels,

(b) an intermediate panel positioned between and connected to the main panels, and

(c) a plurality of flap panels respectively formed by pairs of first flaps that are folded and adhered together, each of the first flaps being foldably connected to one of the main panels;

a tear strip extending around the carton, the tear strip having an alternating series of narrow and wide regions, and the tear strip being formed by a plurality of removable links connected in series, each of the removable links being disposed in a respective one of the wall panels, wherein one or more of the removable links is at least partially formed by a pair of first tear-away subportions respectively disposed in one of the pairs of the first flaps;

wherein the carton is convertible to a first tray and a second tray by removal of the tear strip and upon removal of the tear strip, the first and second trays are separated into a first configuration in which each of the first and second trays comprises;

one of the main panels, and

a plurality of corner wall members respectively located at corner areas of the one of the main panels, wherein each of the corner wall members comprises a pair of walls that are perpendicular to each other and extend perpendicularly away from the one of the main panels; and

wherein the carton further comprises a plurality of oblique corner fold lines respectively located at the corner areas of the one of the main panels, whereby the first and second trays can be placed in a second configuration in which each of the corner areas is folded through about 180°

about a respective one of the corner fold lines, with respect to the first configuration, such that the each of the corner areas lies underneath the one of the main panels and can support the one of the main panels in an elevated position.

17. The carton of claim 16, comprising first and second tabs located on opposite sides of each of the corner fold lines, wherein the first and second tabs can be partially torn away from the one of the main panels and interlocked so as to lock the corner areas underneath the one of the main panels.

18. A method of converting a carton into at least one other construct, comprising:

providing a carton comprising a tear strip extending around the carton, the tear strip having an alternating series of narrow and wide regions; and

removing the tear strip such that the carton is converted into at least a first tray and a second tray, wherein removing the tear strip separates the at least first and second trays such that the at least first and second trays are each configured in a first configuration in which the at least first and second trays each comprise;

a platform, and

a plurality of corner wall members respectively located at corner areas of the platform, wherein each of the corner wall members comprises a pair of walls that are perpendicular to each other and extended perpendicularly away from the platform, and

a plurality of oblique corner fold lines respectively located at the corner areas of the platform;

the method further comprising placing at least one of the at least first and second trays in a second configuration by folding each of the corner areas through about 180°

about a respective one of the corner fold lines with respect to the first configuration such that each of the corner areas lies underneath the platform and can support the platform in an elevated position.

19. The method of claim 18, wherein upper and lower edges of the tear strip each include an alternating series of edges that extend parallel to a longitudinal direction of the tear strip, and that are respectively connected by an alternating series of edges that are oriented obliquely to the longitudinal direction of the tear strip.

20. The method of claim 18, wherein the tear strip is formed by a plurality of removable links connected in series, each of the removable links being disposed on a respective wall panel of the carton.

21. The method of claim 18, wherein the carton comprises at least one microwave energy interactive element disposed on at least one wall panel of the carton.