CARTON WITH INTEGRATED TRAY

• US 20090200364A1
• Filed: 03/03/2009
• Published: 08/13/2009
• Est. Priority Date: 09/12/2006
• Status: Active Grant

• Current Assignee: Graphic Packaging International Incorporated
• Original Assignee: Graphic Packaging International Incorporated
• Inventors: Oliveira, Steven Manuel
• Granted Patent: US 7,793,821 B2
• Time in Patent Office: Days
• US Class Current: 229/235
• 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 blank comprising:

a first panel;

a second panel;

a third panel disposed between the first panel and the second panel, the first panel and the second panel being foldably connected to opposite sides of the third panel;

a plurality of first flaps, each of the first flaps being connected to the first panel or the second panel; and

a plurality of first tear-away subportions respectively disposed in the first flaps and being at least partially defined by respective first lines of disruption in each of the first flaps, wherein

the first flaps are configured to be folded such that the first tear-away subportion in one of the plurality of first flaps combines with the first tear-away subportion in another of the plurality of first flaps to at least partially define a plurality of first tear-away portions.

2. The carton blank of claim 1, wherein 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.

3. The carton blank of claim 2, 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 the first panel or the second panel.

4. The carton blank of claim 2, 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.

5. The carton blank of claim 4, comprising:

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

a plurality of second 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 second tear-away subportions.

6. The carton blank of claim 5, wherein:

the third panel comprises a second tear-away portion; 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.

7. The carton blank of claim 6, 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 links of a tear strip.

8. The carton blank of claim 6, 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.

9. The carton blank of claim 8, comprising:

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

a plurality of third tear-away subportions 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.

10. The carton blank of claim 9, wherein one of the third flaps includes a horizontal slit that extends between the second lines of disruption, thereby defining a pull tab that is configured to be exposed upon folding the blank into a carton, wherein the slit is offset from a fold line connecting the one of the third flaps to the third panel.

11. The carton blank of claim 9, wherein the first tear-away portion, the second tear-away subportions, the second tear-away portion and the third tear-away subportions are configured to form a continuous tear strip upon folding of the blank into a carton.

12. The carton blank of claim 2, comprising corner fold lines extending obliquely across corners of the first panel and the second panel.

13. The carton blank of claim 12, wherein each of the corner fold lines extends from an end of one of the substantially straight tear lines to an end of another one of the substantially straight tear lines.

14. The carton blank of claim 12, comprising first tabs and second tabs extending from opposite sides of each of the corner fold lines, wherein each of the first tabs and second tabs are defined by tear lines centered along and extending transverse to a respective one of the center fold lines.

15. The carton blank of claim 14, wherein each of the first tabs and second tabs are defined by tear lines centered along and extending transverse to a respective one of the center fold lines.

16. The carton blank of claim 14, wherein the first tabs and second tabs are of different sizes.

17. The carton blank of claim 1, comprising at least one microwave energy interactive element disposed on the first panel or the second panel.

18. A carton blank comprising:

a first panel;

a second panel;

a third panel disposed between the first panel and the second panel, the first panel and the second panel being foldably connected to opposite sides of the third panel; and

a tear-away portion disposed in the third panel, wherein the tear-away portion is at least partially defined by a pair of spaced-apart lines of disruption, each of the lines of disruption comprising a substantially straight tear line and a pair of crooked tear lines respectively extending from opposite ends of the substantially straight tear line.

19. The carton blank of claim 18, wherein the substantially straight tear line of a first of the pair of spaced-apart lines of disruption is positioned between and collinear with two edge fold lines connecting the third panel to the first panel, and wherein the substantially straight tear line of a second of the pair of spaced-apart lines of disruption is positioned between and collinear with a pair of edge fold lines connecting the third panel to the second panel.

20. The carton blank of claim 18, comprising a pair of flaps connected to ends of the third panel, wherein the each of the crooked tear lines extends into a respective one of the flaps to partially form tear-away subportions connected to the tear-away portion.

21. The carton blank of claim 20, wherein one of the flaps includes a horizontal slit that extends between the lines of disruption, thereby defining a pull tab that is configured to be exposed upon folding the blank into a carton, wherein the slit is offset from a fold line connecting the one of the flaps to the third panel.

22. The carton blank of claim 18, comprising at least one microwave energy interactive element disposed on the first panel or the second panel.

23. A carton blank comprising:

a first panel;

a second panel;

a third panel disposed between the first panel and the second panel, the first panel and the second panel being foldably connected to opposite sides of the third panel; and

a plurality of first flaps, each of the first flaps being connected to the first panel or the second panel; and

a plurality of first tear-away subportions respectively disposed in the first flaps, each of the first tear-away subportions being at least partially defined by a first line of disruption, the first line of disruption comprising 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; and

a plurality of second flaps respectively connected to the first flaps, wherein at least one of the crooked tear lines extends into a corresponding one of the second flaps to form a second tear-away subportion connected to one of the first tear-away subportions.

26. The carton blank of claim 23, comprising at least one microwave energy interactive element disposed on the first panel or the second panel.

24. (canceled)

25. (canceled)

27. A carton comprising:

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

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

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

28. The carton of claim 27, 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.

29. The carton of claim 27, wherein the tear strip is 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.

30. The carton of claim 29, wherein:

the wall panels comprise;

(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; and

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.

31. The carton of claim 30, comprising:

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

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

33. The carton of claim 30, wherein

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

35. The carton of claim 30, wherein the one of the removable links comprises a pull tab partially defined by a horizontal slit in the 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.

37. The carton of claim 30, 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.

38. The carton of claim 37, comprising 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.

39. The carton of claim 38, 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.

32. (canceled)

34. (canceled)

36. (canceled)

40. (canceled)

41. 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.

42. The method of claim 41, 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.

43. The method of claim 41, 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.

44. The method of claim 41, wherein the carton comprises at least one microwave energy interactive element disposed on at least one wall panel of the carton.

45. The method of claim 41, 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 extend perpendicularly away from the platform.

46. The method of claim 45, wherein each of the first and second trays comprises 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.

47. A paperboard tray construct comprising at least one tray, wherein, when in a first configuration, the at least one tray comprises:

a platform;

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

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

48. The paperboard tray construct of claim 47, wherein the at least one tray 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 platform in an elevated position.

49. The paperboard tray construct of claim 48, 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 platform and interlocked so as to lock the corner areas underneath the platform.

50. The paperboard tray construct of claim 47, wherein the platform comprises a microwave energy interactive element disposed on a surface thereof.

51. A method for reconfiguring a paperboard tray, comprising:

providing a paperboard tray, wherein, when in a first configuration, the tray comprises

(a) a platform,

(b) a plurality of corner wall members respectively located at corner areas of the platform, each of the corner wall members comprising a pair of walls that are perpendicular to each other and extend perpendicularly away from the platform, and

(c) a plurality of oblique corner fold lines respectively located at the corner areas of the platform; and

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 the each of the corner areas lies underneath the platform and can support the platform in an elevated position.

52. The method of claim 51, wherein the tray comprises first and second tabs located on opposite sides of each of the corner fold lines, the method further comprising partially tearing the tabs away from the platform and interlocking the first and second tabs so as to lock the corner areas underneath the platform.

53. The method of claim 51, wherein the platform comprises a microwave energy interactive element disposed on a surface thereof.