Note: Descriptions are shown in the official language in which they were submitted.
~S32~6
TRAY CONTAINER WITH REINFORCED SIDET~ALLS
Background of the Invention -
This invention relates to containers and is more
particularly concerned with improvements in product containers
which are in the form of a tray and which are adapted to be
fabricated from paperboard or similar foldable sheet material
of a character which will enable the container to be used for
baking bread, or ht elike, and marketing the product in the tray
in which it has been baked.
The invention also relates to an improved cover for
the container, and in particular, to a tear-out type cover
which will serve to permit the major portion of the cover to
be torn off while leaving most or all of the marginal of the
cover or lid member in tact and secured to the top tray flange
in reinforcing relation.
Tray containers have been developed heretofore which
are particularly adapted for use in the bakery industry where
the product may be processed in an oven and subsequenlty mar-
k~ted without removing it from the container in which it has
been processed. Products such as cakesl pastry, and the like
are generally in a flowable state initially, that is, in a liquid
or semi-liquid condition, and it is a requirement that the con-
tainer be leakproof when filled to a predetermined level with
~ the product and capable of withstanding oven temperatures
i during the baking process without damage from the heat so that
the baked product may be marketed without removal from the
container. For such products, containers have been developed
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which are adapted to be formed from thin metal foil or
relatively stiff metallic sheet material which can be pressed
or shaped to the desired form and become part of the final ~
package in which the product is marketed. Such containers
are generally expensive and lacking in esthetic appeal since
they do not readily accept the inks commonly employed in
decorative printing. Efforts have been made, with some degree
of success, to provide non-metallic trays which are suitable
for this purpose. One such tray structure is disclosed in
U.S. Patent No~ 4,114,797 granted September 19, 1~78. Trays
of this type, which are formed from paperboard having a film-
like heat resistant coa~ing, have not been entirely satisfactory
for handling some bakery products, such as bread, where a
rectangular shape is desired so that the finished product will
have the conventional rectangualr shape of a loaf of bread.
The plastic film employed for trays of this type generally has
shrink characteristics which differ from paperboard with the
result that the sidewalls buckle and have an unattractive
appearance.
20~ Consequently, there appears to be a need for trays of
this type which have greater rigidity or stiffness, particular-
ly in the sidewall panels so as to more nearly retain their
shape during processing and which may be employed for pro-
cessing in a microwave oven as well as in a conventional
convection oven.
It is a general object, therefore, of the present
invention to provide an improved open top tray structure of
the type described which has greater rigidity in the sidewalls,
which is more versatile in use, and more economical so as to
compete with trays formed of metal foil, and the like.
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It is a more specific o~ject cf the invention to
provide an improved tray structure and a method of forming
the same in which the tray is fabricated from a paperboard
blank coated with a film forming heat resistant plastic
material which is cut and scored, so that it can be set-up with
sidewall panels upstanding from a rectangular bottom wall
panel and connected at the corners by pairs of integral web
members which are folded upon each other and against the out-
side faces of oppositely disposed sidewalls having narrow top
flanges for reinforcing the sidewalls and with provision for
anchoring the folded web members in position and having over-
lapping tab members forming corner connections between the top
edge flanges.
It is a further object of the invention to provide
a tray structure of the type described and a method of
:fabricating the same so as to provide integrally hinged top
flange forming strLp members on the sidewalls, with cut scoring
at~the hinge connection between the sidewalls and the top flanges
which will prevent the difference in the contraation and
expansion characteristics of the plastic film and the paper-
board from buckling the sidewalls during processing of the
tray and product in a baking oven.
A still further object of the invention is to provide
an improved lid or cover structure and method of securing the
same to the top edge flange of the tray or like container
referred to above, with the cover or lid structure be arranged
to have the major portion thereof torn out so as to expose
the contents of the tray, while leaving the remaining or
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1153~16
marginal portions of the cover in tact and secured to the top
flange of the try so as to reinforce the sidewalls of the
tray~ ~
A still further object is to provide a cover member
which is cut scored on opposite faces adjacent its outer
margins so that the marginal strip surrounding the center panel
will remain adhered to the top surface of the tray flange for
stiffening purposes when the center panel of the lid is torn
out.
The herein disclosed and claimed invention comprises
a tray structure and a method of forming the same from a cut
and scored blank of foldable paperboard which is coated with a
heat resistant plastic film, which tray comprises a bottom wall
forming panel and oppositely disposed pairs of peripheral side-
wall forming panels which are integrally hinged to and disposed
in upstanding relation with the bottom wall forming panel, with
pairs of integrally hinged triangular web members at the inter-
secting corners, which web members are folded into overlying
relation on the outside face of oppositely disposed sidewall
panels and secured in position by means of a top edge flange
formation adhesively adhered beneath an edge reinforcing strip
in the form of a flange which is integrally hinged to the top
edge of the associated sidewall forming panel on a hinge line
defined by cut-scores in which the plastic film is severed by
closely spaced small length cuts.
The invention further comprises a cover for the tray,
which cover includes an outer margin and a central panel
design by a cut or score line, with the margins of the cover
being adhesively attached to the top flange of the tray and
with the center cover panel being thereby adapted to be torn
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1:153216
out to expose the tray contents while leaving the cover margins
adhesively secured to tlhe tray flange for reinforcing the
tray flange and sidewalls.
BRIEF DESCRIPTION OF TH~ DRAWINGS
FIG. 1 is a perspective view of a tray-type container
which embodies the principal features of the invention; the
tray beiny shown with a top covering member in place; .
FIG. 2 is an elevational view of the one side of the
tray container shown in FIG. l;
.
FIG. 3 is a plan view of the tray o FIG. 1 with the
top covering member removed;
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FIG. 4 is a cross-sectional view taken on line 4-4
of FIG. 2 to an enlarged scale;
FIG. 5 is a fragmçntary cross-sectional view taken
on the line 5-5 of FIG. 2, to a greatly enlarged scale and with
portions broken away;
:;
; FIG. 6 is a plan view, showing the inside face of a
blank which is cut and scored preparatory to the forming of the
tray shown in FIG. l;
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FIG. 7 is a perspective view of the tray with the
improved cover or lid;
FIG. 8 is a plan view with portions broken away
showing the cover in place atop the tray;
FIG. 9 is a plan view similar to that of FIG. 8,
but showing a portion of the novel cover being torn away;
FIG. 10 is a view of the tray of FIGS. 7-9, showing
the same with the cover center panel being removed and with the
outer margins of the cover remaining in place atop the upper
tray flange:
FIG. 11 is a vertical sectional vlew on an enlarged
~: scale taken along lines 11-11 of FIG. 8 and showing the outer
margins of the tray, and the lid, including the score lines
separating the cover center panel from the margins of the
cover;
FIG. 12 is a vertical sectional view of a portion of
:~ the tray of FIG. 10 with the cover center panel removed and
~ the margin remaining in place;
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FIG. 13 is a fragmentary top plan view of an alternate
form of the cover made according to the invention; and
':
: FIG. 14 is a fragmentary top plan view of the form of .
cover or lid shown in FIG. 13 and showing the lid in the process
of being removed from its associated tray.
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DESCRIPTION OF THE PREFERRED
EMBODIMENT OF THE :INV`ENTION
Referring now to the drawings in greater detail,
there is illustrated a tray-type container or carton lQ which is
adapted for use in the preparation and marketing of bakery pro-
ducts, particularly, bread; the tray structure being fabricated
from a single sheet of flexible paperboard material which is
coated with a heat resistant film and which is cut and
scored as illustrated in FIG. 6. It will be understood that
the container shown in the drawings is described and illustrated
for the purpose of setting forth the presently preferred fo~m
of the invention and that the principles of the invent~on may
be otherwise applied.
The tray 10, as illustrated in FI-GS~ 1 to 5, is
; fabricated from the cut and scored blank 12 which is shown in
FIG. 6 with the face uppermost which will become the inside
face in the set-up tray~ In the form illustrated, the blank 12
is prepared ~rom paperboard~ of relatively light weight or
~auge, which is coated or laminated with a suitable material to
render it more resistant to damage ~hen subject to high tem-
peratures, particularlv bakin~ oven temperatures. The paper-
board stock is of a gauge which will provide a predetermined
degree of stiffness, so that, the fully formed tray or carton
will retain its normal s~ape when filled with the product for
processing. The illustrated material is provided with a
coating of plastlc film material which will increase its re-
sista e to absorption of heat to the degree des~:red for
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withstanding baking oven temperatures and which will also
permit heat sealing of the coated surface to the paperboard
surface. A suitable treatment of paperboard stock to ~orm the
blank 12 is set forth in U. S. Patent No. 3,904,104 granted
September 9, 1976 to William Paul Xane.
The blank 12, which is particularly designed to form
a tray for processing a loaf of bread, that is, having a some-
what greater length than width, is in the form of a generally
rectangular sheet of the foldable material with a substantially
greater length than width. The blank is cut so thatithe grain
is in the direction of the width or shortest dimension of the
blank, as indicated by the arrow 13 in FIG. 6. The blank is
cut and scored or creased, so that it is symmetrical about
longitudinal and transverse center lines a-a and b-b. The
blank is divided by parallel longitudinally extending, trans-
versely spaced, hinge forming score or crease lines 14, 15
; and parallel transversely extending, longitudinally spaced,
; hlnge forming score or crease lines 16, 17 which define a
bottom wall forming center panel 18 with its edges coinaiding
with the bottom edges of sidewall forming panel portions 20
and 22, and end wall ~orming panel portions 23 and 24. The
side and end wall panel portions 20, 22 and 23, 24 are con-
~; nected at the four corners of the blank by corner connecting
web portions 25, 26, 27, and 28. The transverse score lines 16
and 17 are extended at their opposite ends on lines 30, 32
33 and 34, respectively, the latter being on a slight angle
or inclination in the direction o the opposite ends of the
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liS32~6
blank and defining the opposite ends of the sidewall panels 35and 36. The sidewall panels 35 and 36 have relatively narrow
flange forming edge reinforcing panel portions 37, 38 which
extend along the free outer margins thereof and which are
divided therefrom by combination cut and creased lines 40 and
42, the latter being parallel with and spaced outwardly of the
score lines 14 and 15, respectively. The longitudinal score
lines 14 and 15 are extended at their opposite ends on lines
43, 44 and 45, 46 which are at a slight angle or inclination
in the direction of the opposite sides of the blank and which
define the ends of end wall panels 47 and 48. The end wall
panels 47 and 48 have outboard margins with relatively narrow
edge reinforcing panel portions 50 and 52 which are divided
therefrom by combination cut and creased lines 53 and 54, the
latter being parallel with and spaced outwardly of the score :
lines 16 and 17, respectively. The corner connecting web
. panels 25, 26, 27, 28 are each divided by a center fold ~orming
score line 55, 56, 57, 58 so as to form pairs of triangular web
panels 60, 62: 63, 64: 65, 66 and 67, 68~ The pair of web
panels 60, 62 connect side and end wall panels 35 and 47 while
the panels 63, 64 connect side and end wall panels 36, 47,
; : at one end of the blank, At the other end of the blank panels
65, 66 connect side and end wall panels 35 and 48 while panels
67, 68 connect side and end wall panels 36 and 48. The out:side
edges 70, 72, 73, 74 of the corner web panels 6a, 64, 65, 68
are cut on lines which are approximatle~ normal to the score linec
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O, 32, 33, 34 and define the ends of the a=sociated sidewall
panels 35 and 36 so that each pair of these corner web panels
may be folded into overlying relation and positioned along the
outside faces of the associated sidewall panels 35, 36 with
the top edge of each triangular web panel positioned only a
small distance below the top edge of the side wall 35, 36.
The co rner web panels 62, 63 and 66, 67, which adjoin the end
wall forming panels 47 and 48, have narrow edge flange forming
panel portions 75, 76 and 77, 78 which are divided therefrom
by combination cut and scored lines 80, 82 and 83, 84. The
panel portions 75, 76, and 77, 78 will have a width somewhat
less than the width of the associated flange forming panels
37, 38 and 50, 52 which permits these panels to be engaged
beneath the opposite ends of the associated top flange forming
panels 37, 38 on the sidewall forming panels 35 and 36 when
the corner web panels are folded into overlying relation with
and along the top outside margin of the associated sidewall
panels 35 and 36. The flange forming panels 75, 76 and 77, 78
are cut at the ends adjoining panels 50 and 52 on lines 85,
86 and 87, 88 so as to leave these panels, 50 and 52, with small
tabs 90, 92 and 93, 94 extending from opposite ends thereof.
The flange forming panels 37 and 38 on the long length ~idewall
forming panels 35 and 36 are each extended at their opposite
ends to provide integral corner connecting tabs 95 and 96 on
the flange panel 37 and tabs 97 and 98 on the flange panel 38.
The tabs 95, 96 and 97, 98 extend beyond transverse hinge fold
lines 30, 32 and 33, 34 and are cut so as to overlie the end
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t s 90, 92 and 93, 94 on the end flange mem~ers 50 and 52
when the tray is set up (FIGS. 2, 3, 4).
The combination cut and scored lines 40, 42 and 53,
54 and 80, 82, 83, 84 are formed by "skip cutting" or "cut
scoring" the blank material, that is, by cutting on these
lines closely spaced cuts of relatively small length which
extend through the plastic film coating 100 (FIG. 5) but not
through the paperboard with which the film forms a laminate .
for a purpose hereinafter set forth. The intervals between the
small lengths cuts may or may not be creased, since the cuts
will define the hinge fold line for the relatively light gauge
paperboard as well as a means for relieving the tension in the
-film. The cut scoring on the lines 80, 82 and 83, 84 may be .
performed on the outside face of the blank, that is, the face
opposite the film 100 and the cuts may extend through the paper-
board 102 and the film 100.
In setting up the tray 10 from the blank 12, the end
wall panels 47 and 48 may be folded on the hinge lines 16 and
17 simultaneously with the folding of the sidewall panels 35
and 36 about the hinge lines 14 and 15. The corner connecting
web structures 25, 26, and 27, 28 will fold with the end and
sidewall panels with which they are integrally connected and the
two halves of each such corner structure will fold upon them-
selves and about the hinge lines 30, 33 and 32, 34 with the
folded panels being directed into overlying relation on the
outside faces of the sidewall panels 35 and 36, leaving the
small flange forming panels 75, 77 and 76, 78 with the coated or
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o film side or face exposed for heat sealing to the outside
faces of the end portions of the flange forming panels 37, 38 -
on the sidewalls 35, 36. The end wall flange portions 50 and
52 will be folded into outwardly directed flange position
followed by folding of the flange portions 37, 38 so as to bring
the flange end tabs 95, 96, 97, 98 and 90, 92, 93, 94 into
overlying sealed relation.
In FIG. 5, the purpose in forming the cut scoring of
the material on the lines 40, 42, and 53, 54 is illustrated.
The plastic film material 100 and the paperboard material have
sufficiently different shrinking and stretching characteristics
when heated and cooled so that the sidewalls otherwise may be
buckled due to this difference. This is undesirable. The cut
scoring relieves or counteracts this to a substantial degree,
so that the corner connecting web arrangement and the sidewall
top flange formation is effective to prevent any substantial
~; ~)wing in the associated sidewalls.
One form of separate cover member or lid is shown
at 105 in FIG. 1. This cover 105 may be provided which may be
applied with its margins adhesively secured to the flanges 37,
38, and 50, 52 so as to seal the contents in the tray. To
facilitate removal of the lid by the consumer r a corner flange
tab, for example, 96, may be cut or weakened, on the line 106,
to enable the associated corner of the lid to be more firmly
grasped and more easily torn loose so as to start the separation
of the lid margins from the sidewall flanges.
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Referring now to FIGS . 7-14, an improved form of lid
or cover which is particularly adapted for use with the tray
10 is shown. FIG. 7 shows the novel cover to be generally
designated 110 and to include among its principal elements,
a center cover panel 112, an outer margin 114 separat~d from
the cover panel 112 by an exterior or upwardly extending score
line 116 and an inner or downwardly directed score line 118.
As is shown in F:IG. 11, the tray 10 includes the plastic film
material 100 adhesively secured to and overlying the paperboard
102. The composite material is formed into tray elements which
include a sidewall panel 36 and a flange forming portion 38.
According to the invention, the outer margin 114 is also com-
posed of a paperboard portion 120 and a plastic film portion
122. Furthermore, the slit 116 which separates the center panel
112 of the cover 110 from the margins 114 extends only through
the paperboard and terminates above a part of the flange 38.
The other means serving to separate the outer margin 114 from
the cover panel 112 is~the inner cut or score 118, which extends
only through the plastic film 122 and terminates adjacent the
junction of the sidewall 36 and the flange 38. Consequently,
the line of weakness separating the center panel 112 from the
margins 114 includes a pair of cut lines which are offset
slightly from each other.
In use, when it is desired to open the container by
separating the top 110 from the tray lOA, a finger tab 124
(FIG. 8) which is designed in part by cut lines 126, 128 is
grasped and pull upwardly. As shown in FIG. 9, the center
panel 112 may be pulled upwardly, with separation taking place
along the score lines 116-118, permitting the cover to be
removed. As shown in FIG. 10, when the cover is removed by
13l~i~2~6
outer margin 114 of the cover remains atop the tray flange 38 -
serving to reinforce the same, while a margin 130 of plastic
film 122 remains adhered to its counterpart 100 (FIG. 12).
By providing the offset or space between score lines 116 and 118,
an air tight package may be provided, while desirable separation
of the cover center panel from the remainder of the panel 110
may be achieved.
FIG. 13 and 14 show a modified from of cover generally
designated 130 which includes a center panel 132, an outer
margin 134, and outer and inner score lines 136, 138. The only
difference in these constructions is that, in the embodiments
of FIGS. 13 and 14, a tear tab assembly 140 is provided which
includes parallel, spaced apart outer and inner score lines
142, 144. The tear tab 140 is spaced just inwardly of the
corner of the cover 132.
In use, the tab 140 is pulled or pried upwardly
where it readily separates along line 142. The cut line 144
on the inner surface permits separation of the tab from the
remainder of the cover panel when a force i9 applied and the
cover may be peeled back as shown in FIG. 14. This con-
struction insures that an entire, uninterrupted outer margin
may be provided and sealed.
It will thus be seen that the improved cover assembly
utilizing the offset or spaced apart parallel score lines pro-
vides a good seal, easy separation characteristics and insures
that a substantial margin of a composite, paperboard and plastic
film margin will remain affixed to the tray flange to add
stiffening support thereto.
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