Food tray

• US 9,505,516 B2
• Filed: 05/03/2012
• Issued: 11/29/2016
• Est. Priority Date: 06/21/2010
• Status: Active Grant

• Current Assignee: Sabert Corporation
• Original Assignee: LBP Manufacturing LLC (Sabert Corporation)
• Inventors: Hubbard, James A. Jr., Cook, Matthew R., Fu, Thomas, Wolf, Kurt
• Primary Examiner(s): ELKINS, GARY E
• Application Number:
  US13/463,479
• Publication Number:
  US 20120261298A1
• Time in Patent Office: 1,671 Days
• Field of Search: 229/148, 229/149, 229/150, 229/128, 229/152, 229/153, 229/154, 229/157, 229/162.1, 229/162.7, 229/186
• US Class Current: 1/1
• 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 5/2057 Inter-engaging self-locking flaps B65D5/4254 takes precedence
• CPC Class Codes: B65D 5/24 with adjacent sides interconnected by gusset folds
• CPC Class Codes: B65D 5/28 with extensions of sides permanently secured to adjacent sides, with sides permanently secured together by adhesive strips, or with sides held in place solely by rigidity of material
• CPC Class Codes: B65D 5/6632 the lid-halves being held in closed position by flaps or tabs provided at their side edges only B65D5/6644, B65D5/6647 take precedence
• CPC Class Codes: B65D 5/6644 the lid-halves being held in closed position by local tabs or projections at the upper edge of opposite walls of the container body, e.g. by entering within slots provided in the lid-halves
• CPC Class Codes: B65D 5/6652 Flaps or tabs provided at the side edges of the lid only

Abstract

A food tray formed of a unitary sheet of material includes a bottom wall, a front wall, a rear wall, first sidewall, and a second sidewall that define an opening through which an item is placed in the food tray. First and second flaps extend from respective top edges of the first and second sidewalls and are configured to be folded toward an interior of the food tray. The first and second flaps each define slots. First and second lid members extend from respective top edges of the front wall and the rear wall and are configured to be folded toward the interior of the food tray. The first and second lid members define a pair of tabs on respective side edges that are configured to engage the slots defined by the first and second flaps.

Claims

1. A food tray formed of a unitary sheet of material comprising:

a front wall with a distal end and a proximal end, and a rear wall with a distal end and a proximal end;

a first sidewall that extends between the distal end of the front wall and the distal end of the rear wall, and a second sidewall that extends between the proximal end of the front wall and the proximal end of the rear wall, wherein the front wall, rear wall, first sidewall, and second sidewall extend about an opening through which an item is placed in the food tray and wherein each of said front and rear walls and said first and second sidewalls has a top edge that collectively define a top horizontal plane;

a bottom wall extending between the front wall, rear wall, first sidewall, and second sidewall;

first and second flaps that extend from the respective top edges of the first and second sidewalls, the first and second flaps configured to be folded toward an interior of the food tray along the respective top edges to extend generally along the top horizontal plane, wherein each of the first and second flaps has a slot spaced from the respective top edges of the first and second sidewalls and from respective distal edges of the first and second flaps such that the slot extends generally along the top horizontal plane; and

first and second lid members that extend from respective top edges of the front wall and the rear wall, wherein the first and second lid members are configured to be folded toward the interior of the food tray to lay on top of and in contact with said first and second flaps so as to extend over the distal edges thereof, wherein each of the first and second lid members has opposite side edges and a tab on each side edge that are each configured to engage the corresponding slots the first and second flaps with the tabs extending generally along the top horizontal plane when the first and second lid members are folded over the first and second flaps and the opening to thereby secure the first and second lid members to the first and second flaps;

wherein the side edges of the first and second lid members include proximal side edge portions that extend between the top edges of the respective front and rear walls and the tabs, and the proximal side edge portions and the tabs are configured to form hook regions therebetween for securing the tabs within the respective slots in the first and second flaps;

wherein the first and second lid members and the tabs are sized and configured such that the tabs lay over one another above the opening with the lid members in a closed configuration and the tabs inserted within the respective slots.

2. The food tray according to claim 1, wherein the front wall, rear wall, first sidewall, and second sidewall are tapered to enable the insertion of a second food tray into the opening for stacking or nesting.

3. The food tray according to claim 1, further comprising a plurality of gussets formed on respective corners of the food tray.

4. The food tray according to claim 1, wherein the unitary sheet comprises a material from the group consisting of:

coated or uncoated corrugated paper, paperboard, chipboard, and plastics.

5. The food tray according to claim 1, wherein the unitary sheet of material has a generally square shape.

6. The food tray according to claim 1, wherein the unitary sheet of material has a generally rectangular shape.

7. The food tray of claim 1, wherein the proximal side edge portions of each of the first and second lid members extend inwardly toward one another from the respective top edges of the front and rear walls such that each of the first and second lid members are narrower at the hook regions than at the respective top edges of the front and rear walls.

8. The food tray according to claim 1, wherein the slots have an arcuate configuration to inhibit tearing of the tabs when the tabs are inserted or removed from the slots.

9. The food tray according to claim 1, wherein the slots are oriented to extend substantially along a length of the respective side edges.

10. The food tray according to claim 1, wherein each slot includes inner and outer edges that are spaced apart from one another to form a slot aperture in the first and second flaps for receiving the respective tabs therein.

11. The food tray according to claim 10, wherein the tabs are configured to lie over the inner edge of each slot and under the outer edge of each slot when the lid members are folded over the opening with the tabs extending through the slot apertures.

12. The food tray according to claim 1, wherein the tabs lie in substantially the same plane as the lid member from which the tabs extend when the tabs are disposed in the respective slots with the lid members in a closed configuration.

13. The food tray according to claim 1, wherein the first and second lid members are sized and configured such that a portion of one of the first and second lid members lies over the other one of the first and second lid members when the lid members are both folded over the opening to secure the lid members to the first and second flaps.

14. The food tray according to claim 1, wherein each tab on each side edge of the first and second lid members is sized and configured such that the tab does not extend beyond the adjacent sidewall when the first and second lid members are in a closed configuration with the first and second lid members laying on top of and in contact with the first and second flaps.

15. A food tray formed of a unitary sheet of material comprising:

a front wall with a distal end and a proximal end, and a rear wall with a distal end and a proximal end;

a first sidewall that extends between the distal end of the front wall and the distal end of the rear wall, and a second sidewall that extends between the proximal end of the front wall and the proximal end of the rear wall, wherein the front wall, rear wall, first sidewall, and second sidewall define an opening through which an item is placed in the food tray;

a bottom wall extending between the front wall, rear wall, first sidewall, and second sidewall;

first and second flaps that extend from respective top edges of the first and second sidewalls, the first and second flaps configured to be folded toward an interior of the food tray, wherein each of the first and second flaps defines a slot;

a lid member that extends from a top edge of the rear wall, wherein the lid member is configured to be folded toward the interior of the food tray, wherein the lid member defines a pair of tabs formed in respective side edges of the lid member that are configured to engage the slots defined by the first and second flaps when the lid is folded over the opening to thereby secure the lid member to the first and second flaps; and

a third flap that extends from an edge of the lid member that is opposite the top edge of the rear wall, wherein the third flap is configured to be folded about the edge so that when the lid member is secured to the first and second flaps, the third flap is disposed in the interior of the food tray, wherein the edge from which the third flap extends defines a slot in a middle region that is configured to receive a tab that extends from a top edge of the front wall to secure the lid member to the front wall.

16. The food tray according to claim 15, wherein the lid member defines an opening in a center region and the food tray further comprises a clear material that spans the opening to facilitate viewing of an item within the food tray.

17. The food tray according to claim 15, wherein the front wall, rear wall, first sidewall, and second sidewall are tapered to enable the insertion of a second food tray into the opening.

18. The food tray according to claim 15, further comprising a plurality of gussets formed on respective corners of the food tray.

19. The food tray according to claim 15, wherein the unitary sheet comprises a material from the group consisting of:

coated or uncoated corrugated paper, paperboard, chipboard, and plastics.

20. The food tray according to claim 15, wherein the unitary sheet of material has a generally square shape.

21. The food tray according to claim 15, wherein the unitary sheet of material has a generally rectangular shape.

22. The food tray according to claim 15, wherein the lid member includes opposite pairs of spaced-apart slits in the respective side edges thereof that form opposite sides of the tabs.

23. The food tray according to claim 15, wherein the tabs each have an outward edge recessed from the corresponding side edge of the lid member.

24. A food tray formed of a unitary sheet of material comprising:

a front wall with a distal end and a proximal end, and a rear wall with a distal end and a proximal end;

a first sidewall that extends between the distal end of the front wall and the distal end of the rear wall, and a second sidewall that extends between the proximal end of the front wall and the proximal end of the rear wall, wherein the front wall, rear wall, first sidewall, and second sidewall extend about an opening through which an item is placed in the food tray and wherein each of said front and rear walls and said first and second sidewalls has a top edge that collectively define a top horizontal plane;

a bottom wall extending between the front wall, rear wall, first sidewall, and second sidewall;

first and second flaps that extend from the respective top edges of the first and second sidewalls, the first and second flaps configured to be folded toward an interior of the food tray along the respective top edges to extend generally along the top horizontal plane, wherein each of the first and second flaps has a slot spaced from the respective top edges of the first and second sidewalls and from respective distal edges of the first and second flaps such that the slot extends generally along the top horizontal plane; and

first and second lid members that extend from respective top edges of the front wall and the rear wall, wherein the first and second lid members are configured to be folded toward the interior of the food tray to lay on top of and in contact with said first and second flaps so as to extend over the distal edges thereof, wherein each of the first and second lid members has opposite side edges and a tab on each side edge that are each configured to engage the corresponding slots the first and second flaps with the tabs extending generally along the top horizontal plane when the first and second lid members are folded over the first and second flaps and the opening to thereby secure the first and second lid members to the first and second flaps;

wherein the side edges of the first and second lid members include proximal side edge portions that extend between the top edges of the respective front and rear walls and the tabs, and the proximal side edge portions and the tabs are configured to form hook regions therebetween for securing the tabs within the respective slots in the first and second flaps;

wherein each tab has a convex configuration and the slots curve away from the respective side edges such that each tab extends further into the respective slot near a middle portion of the slot then at either end of the slot.

25. A food tray formed of a unitary sheet of material comprising:

a front wall with a distal end and a proximal end, and a rear wall with a distal end and a proximal end;

a first sidewall that extends between the distal end of the front wall and the distal end of the rear wall, and a second sidewall that extends between the proximal end of the front wall and the proximal end of the rear wall, wherein the front wall, rear wall, first sidewall, and second sidewall extend about an opening through which an item is placed in the food tray and wherein each of said front and rear walls and said first and second sidewalls has a top edge that collectively define a top horizontal plane;

a bottom wall extending between the front wall, rear wall, first sidewall, and second sidewall;

first and second flaps that extend from the respective top edges of the first and second sidewalls, the first and second flaps configured to be folded toward an interior of the food tray along the respective top edges to extend generally along the top horizontal plane, wherein each of the first and second flaps has a slot spaced from the respective top edges of the first and second sidewalls and from respective distal edges of the first and second flaps such that the slot extends generally along the top horizontal plane; and

first and second lid members that extend from respective top edges of the front wall and the rear wall, wherein the first and second lid members are configured to be folded toward the interior of the food tray to lay on top of and in contact with said first and second flaps so as to extend over the distal edges thereof, wherein each of the first and second lid members has opposite side edges and a tab on each side edge that are each configured to engage the corresponding slots the first and second flaps with the tabs extending generally along the top horizontal plane when the first and second lid members are folded over the first and second flaps and the opening to thereby secure the first and second lid members to the first and second flaps;

wherein the side edges of the first and second lid members include proximal side edge portions that extend between the top edges of the respective front and rear walls and the tabs, and the proximal side edge portions and the tabs are configured to form hook regions therebetween for securing the tabs within the respective slots in the first and second flaps;

wherein each of the tabs has an edge portion that meets the corresponding proximal side edge portion at an acute angle to minimize unintended opening of the lid members with the tabs received in the slots.

26. A food tray formed of a unitary sheet of material comprising:

a front wall with a top edge;

a rear wall with a top edge;

a first sidewall with a top edge;

a second sidewall with a top edge;

wherein the top edges of each said walls and sidewalls collectively define a top plane;

said first sidewall extending between the front wall and the rear wall, said second sidewall opposing the first sidewall and extending between the front wall and the rear wall, wherein the front wall, rear wall, first sidewall, and second sidewall define an opening for receiving a food item;

a bottom wall extending between the front wall, rear wall, first sidewall, and second sidewall;

first and second flaps that extend from the respective top edges of the first and second sidewalls configured to be folded therealong toward an interior of the food tray to extend generally along said top plane, wherein each of the first and second flaps defines a respective slot that extends generally along said top plane when the respective flap is folded toward said interior;

first and second lid members having side edges that extend from the respective top edges of the front and rear walls, wherein the first and second lid members are configured to be folded toward the interior of the food tray to extend generally along said top plane and contact said flaps; and

first and second tabs extending from the respective side edges of each of the first and second lid members, wherein the first and second tabs of the first lid member are configured to be superimposed with the corresponding first and second tabs of the second lid member when the lid members are in a closed configuration, such that in the closed configuration both of the superimposed first tabs are received within the slot of the first flap that is folded under and in contact with each of said lid members and both of the superimposed second tabs are received within the slot of the second flap that is folded under and in contact with each of said lid members, wherein said tabs extend into said slots generally along the top plane to thereby secure the first and second lid members to the first and second flaps;

wherein at least a majority of each of the first and second tabs of one of the first and second lid members lay over the first and second tabs of the other of the first and second lid members when the first tabs and second tabs are superimposed with one another with the lid members in the closed configuration and the superimposed tabs received within the slots.

27. The food tray according to claim 26, wherein the entirety of each of the first and second tabs of one of the first and second lid members lay over the first and second tabs of the other of the first and second lid members when the first tabs and second tabs are superimposed with one another with the lid members in the closed configuration and the superimposed tabs received within the slots.

28. The food tray according to claim 26, wherein hook regions are located at a junction of the first and second tab members and the respective side edges from which the tab members extend for securing the tabs within the respective slots in the first and second flaps.

29. The food tray according to claim 26, wherein the slots and tabs each have an arcuate configuration for facilitating insertion and hooking of the tabs within the slots and inhibiting tearing of the tabs when removed from the slots.

30. The food tray according to claim 26, wherein the slots are spaced from the respective top edges of the first and second sidewalls and from respective distal edges of the first and second flaps.

31. The food tray according to claim 26, wherein the first and second lid members are sized and configured to lay over one another above the opening when the lid members are in a closed configuration.

32. The food tray according to claim 26, wherein the first and second tabs lie in substantially the same plane as the respective lid member from which the tabs extend when the tabs are disposed in the respective slots with the lid members in a closed configuration.

33. The food tray according to claim 26, wherein each of the first and second tabs of the first and second lid members is sized and configured such that the tab does not extend beyond the adjacent sidewall when the first and second lid members are in the closed configuration.