Note: Descriptions are shown in the official language in which they were submitted.
CA 02780514 2012-06-21
FOOD TRAY
BACKGROUND
[0001] Typical food trays are made from a single piece of cardboard that is
folded
to form a container for storing food items. For example, a fast-food
restaurant may
package a hamburger in a food tray. A caterer catering to an office may place
a
sandwich, a bag of chips, and a cookie in a food tray.
[0002] Typical food trays are made from a single piece of cardboard that is
folded
into a configuration that provides a container with a lid. The container is
sized to
protect the food item during handling. The lid typically includes locking tabs
that
engage complementary locking means on the container when the lid is closed.
[0003] One problem with food trays is that they can tend to get soggy due
to the
humidity and heat produced by the food item. Another problem is that the lid
may
have a tendency to move into the closed position after being opened due to the
elastic nature of the cardboard.
BRIEF SUMMARY
[0004] In a first aspect, a food tray formed of a unitary sheet of material
includes
a bottom, 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.
[0005] In a second aspect, a food tray formed of a unitary sheet of
material
includes a bottom, 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 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. The front wall, rear wall, first sidewall, and second
sidewall
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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 sidewall
and are configured to be folded toward an interior of the food tray. Each of
the
first and second flaps defines a slot. A lid member extends from a top edge of
the rear wall. The lid member is configured to be folded toward the interior
of the
food tray. The lid member defines a pair of tabs on 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. A third flap extends from an edge of the
lid
member that is opposite the top edge of the rear wall. The third flap is
configured
to be folded about the edge when the lid member 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. The edge from which the third flap extends defines a slot in a
middle region that is configured to receive a slot that extends from a top
edge of
the front wall to secure the lid member to the front wall.
[0006] In a third aspect, a food tray formed of a unitary sheet of material
includes
a bottom, 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 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. The front wall, rear wall, first sidewall, and second sidewall
define an
opening through which an item is placed in the food tray. The first and second
flaps 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.
A lid
member extends from a top edge of the rear wall. The lid member is configured
to be folded toward the interior of the food tray. A third flap extends from
an edge
of the lid member that is opposite the top edge of the rear wall. The third
flap
includes a tear strip that extends along a length of the third flap that is
parallel to
the edge. The third flap is configured to be folded about the edge of the lid
member that is opposite the top edge of the rear wall when the lid member is
folded toward the interior of the food tray, and secured to an outside surface
of
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the front wall via an adhesive strip. The tear strip is configured to
facilitate
tearing of the third flap to facilitate opening of the lid member.
[0007] Other systems, methods, features and advantages of the invention
will be,
or will become, apparent to one with skill in the art upon examination of the
following
figures and detailed description. The scope of the claims should not be
limited by
the preferred embodiments set forth in the examples, but should be given the
broadest interpretation consistent with the description as a whole.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Fig. 1 illustrates a perspective view of a food tray;
[0009] Figs. 2 and 3 illustrate front and back views, respectively, of the
food tray
of Fig. 1;
[0010] Fig. 4 illustrates a side view of the food tray of Fig. 1;
[0011] Figs. 5 and 6 illustrate top and bottom views, respectively, of the
food tray
of Fig. 1;
[0012] Fig. 7. illustrates a sheet that defines the various members of the
food tray
of Fig. 1 in an unassembled configuration;
[0013] Fig. 8A illustrates a perspective view of a third embodiment of a
food tray;
[0014] Fig. 8B illustrates the food tray of Fig. 8A in an unassembled
configuration;
[0015] Fig. 9A illustrates a perspective view of a fourth embodiment of a
food
tray;
[0016] Fig. 96 illustrates the food tray of Fig. 9A in an unassembled
configuration;
[0017] Fig. 10A illustrates a perspective view of a fifth embodiment of a
food tray;
[0018] Fig. 106 illustrates the food tray of Fig. 10A in an unassembled
configuration.
[0019] Fig. 11A illustrates a perspective view of a sixth embodiment of a
food
tray;
[0020] Fig. 11B illustrates the food tray of Fig. 11A in an unassembled
configuration.
[0021] Fig. 12A illustrates a perspective view of a seventh embodiment of a
food
tray;
[0022] Fig. 12B illustrates the food tray of Fig. 12A in an unassembled
configuration.
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[0023] Fig. 13A illustrates a perspective view of an eighth embodiment of a
food
tray;
[0024] Fig. 13B illustrates the food tray of Fig. 13A in an unassembled
configuration.
[0025] Fig. 14A illustrates a perspective view of a ninth embodiment of a
food
tray;
[0026] Fig. 14B illustrates the food tray of Fig. 14A in an unassembled
configuration.
[0027] Fig. 15A illustrates a perspective view of a tenth embodiment of a
food
tray;
[0028] Fig. 15B illustrates the food tray of Fig. 15A in an unassembled
configuration;
[0029] Fig. 16A illustrates a perspective view of a eleventh embodiment of
a food
tray;
[0030] Fig. 16B illustrates the food tray of Fig. 16A in an unassembled
configuration.
[0031] Fig. 17A illustrates a perspective view of a twelfth embodiment of a
food
tray;
[0032] Fig. 17B illustrates the food tray of Fig. 17A in an unassembled
configuration.
[0033] Fig. 18A illustrates a perspective view of a thirteenth embodiment
of a food
tray;
[0034] Fig. 18B illustrates the food tray of Fig. 18A in an unassembled
configuration.
[0035] Fig. 19A illustrates a perspective view of a fourteenth embodiment
of a
food tray; and
[0036] Fig. 19B illustrates the food tray of Fig. 19A in an unassembled
configuration.
DETAILED DESCRIPTION OF THE DRAWINGS
[0037] The exemplary embodiments below describe a food tray for storing
and/or
serving a food item. The food tray includes a first lid member and second lid
member that are attached to a front wall and rear wall, respectively. The
edges
between the respective lid members and walls are bowed so that tension is
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produced in the front wall and rear wall when the respective lid members are
placed
in a closed configuration. The lid members are held in place by a group of
tabs that
engage a pair of slots in first and second sidewalls of the food tray. The
slots and
tabs cooperate to prevent the lid members from opening under the tension. When
the first and second sidewalls are spread apart, the tabs are released from
the slots,
and tension in the front and rear walls causes the lid members to
automatically open.
[0038] Fig. 1 illustrates a perspective view of a food tray100. The food
tray 100
includes a first sidewall 105, a second sidewall 110, a front wall 115, a rear
wall 120,
a first lid member 125, and a second lid member 130. The first sidewall 105
extends
between the distal end 115a of the front wall 115 and the distal end 120a of
the rear
wall 120. The second sidewall 110 extends between the proximal end 115b of the
front wall 115 and the proximal end 120b of the rear wall 120.
[0039] A bottom surface 605 (Fig. 6) extends between respective bottom edges
of
the first sidewall 105, second sidewall 110, front wall 115, and rear wall 120
to define
the bottom of the food tray 100. Respective top edges of the first sidewall
105,
second sidewall 110, front wall 115, and rear wall 120 define an opening
through
which a food item may be placed in the food tray 100.
[0040] In some implementations, the first sidewall 105, second sidewall
110, front
wall 115, and rear wall 120 are tapered to enable stacking of the food tray
100. For
example, the angle between each respective wall and a line that is normal to
the
bottom surface 605 of the food tray may be greater than 0 .
[0041] In yet other implementations, the front wall 115 and/or the rear
wall 120
define openings 115d and 120d that enable venting the food tray. The openings
115d and 120d may be defined by way of perforated edges that enable a user to
push out or otherwise remove a portion of the front wall 115 and/or the rear
wall 120
to reveal the openings 115d and 120d.
[0042] The first lid member 125 extends from the top edge of the front wall
115,
and the second lid member 130 extends from the top edge of the rear wall 120,
as
shown in Fig. 1 and more clearly in Fig. 7.
[0043] As shown in Fig. 7, the first lid member 125 and the second lid member
130 each define a pair of tabs 720 that are configured to engage the slots
105a and
110a defined by the first and second sidewalls 105 and 110 when the respective
lid
members 125 and 130 are folded to cover the opening. The length of the tabs
720
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may be configured to match the length of the slots 105a and110a so that when
the
lid members 125 and 130 are folded to cover the opening, the lid members 125
and
130 are substantially prevented from moving in a lateral direction.
= [0044] As illustrated by Figs. 1-3, when the first lid member 125
is closed, the
front wall 115 is bowed so that a center region of the top edge 115c of the
front wall
115 is spaced apart from a line that extends between the distal end 115a and
the
proximal end 115b by a distance D 130. For example, the distance D 130 may
correspond to about .5 inches or a different distance. In some embodiments,
the
rear wall 120 is bowed in a similar manner when the second lid member 130 is
closed.
[0045] Bowing of the front wall 115 and the rear wall 120
provides an elastic force
that causes the first and second lid members125 and 130 to open on their own
when
the extensions 105b and 110bon the first and second sidewalls 105 and 110 are
pulled apart to release the tabs 720 on the first and the second lid members
125 and
130. Stated differently, when the first and second lid members 125 and 130 are
in
an open position, the first and second lid members 125 and 130 lie in the same
plane as the front wall and rear wall 115 and 120, respectively. In this
configuration,
the front wall 115 and the rear wall 120 may be generally planar and not
bowed.
When the first and second lid members 125 and 130 are moved into the closed
configuration, tension is produced in the front wall 115 and the rear wall 120
by way
of the bowing that occurs in the front wall 115 and the rear wall 120
resulting from
the arc shape crease 705a and 705j (Fig. 7) that defines the separation of the
first lid
member 125 from the front wall 115 and the second lid 130 member from the rear
wall 120. This tension causes the respective lid members 125 and 130 to
automatically open when the tabs 720 are released from the slots.
[0046] As illustrated in Fig. 7, the food tray may be formed from
a single sheet
700 of material, such as a corrugated paper material. The sheet 700 may define
a
group of creases 705a-j that further define the first sidewall 105, second
sidewall
110, front wall 115, rear wall 120, first lid member 125, and second lid
member 130.
[0047] In one embodiment, the food tray is configured by cutting
the sheet along
a group of cut lines 710 a-d to separate a group of tabs 715a-d. Next, the
sheet 700
is folded along the group of creases 705a-j to configure the food tray. The
configuration is maintained by attaching the group of tabs 715a-d to the first
sidewall
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and second sidewall. The tabs 715a-d may be attached to the first sidewall and
second sidewall via glue strips 720a-d disposed on the first and second
sidewalls, or
in a different matter.
[0048] Fig. 8A is another of a food tray 800. The food tray 800 includes a
first
sidewall 105, a second sidewall 110, a front wall 115, a rear wall 120, a
first lid
member 125, and a second lid member 130. The respective walls and lid members
may be sized and positioned relative to one another in a similar manner as the
respective walls and lid members of the food tray 100 in Fig. 1. The food tray
800
may be combined with any other elements of the food tray 100 described above.
[0049] The food tray 800 includes a group of gussets 805 on respective corners
of the food tray 800.In Fig. 8B, the gussets 805 are integrally formed with
the first
sidewall 105, second sidewall 110, front wall 115, and rear wall 120,
respectively.
The gussets 805 enable the food tray 800 to store a fluid substance without
spillage.
The gussets 805 may be folded so that they are positioned on the outside of
the food
tray 800, as shown, or on the inside of the food tray 800. The gussets 805 may
be
folded over the first sidewall 105 and second sidewall 110, as shown, over the
front
wall 115 and rear wall 120, or any combination thereof. In some
implementations,
an adhesive may be utilized to secure the gusset 805 to the respective
sidewall. The
adhesive may be pre-applied to the respective walls or the gussets 805 to
enable
quick assembly of the food tray 800 in a restaurant setting. The gussets 805
may
also be fastened differently as described below.
[0050] In Fig. 8B, a folding portion 810 may extend from the first sidewall
105 and
the second sidewall 110, respectively. In operation, the folding portion 810
is folded
towards the center of the food tray 800 along a shared edge 810 with the
respective
sidewall 105 and 110. In this configuration, the folding portion 810 forms a
shelf that
extends toward the center of the food tray 800. The shelf provides support for
the
first lid member 130 and the second lid member 125 when the respective lid
members 130 and 125 are folded to close the food tray 800.
[0051] Fig. 9A is another embodiment of a food tray 900. The food tray 900
includes a first sidewall 105, a second sidewall 110, a front wall 115, a rear
wall 120,
a first lid member 125, and a second lid member 130. The respective walls and
lid
members may be sized and positioned relative to one another in a similar
manner as
the respective walls and lid members of the food tray 100 in Fig. 1. The food
tray
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900 may be combined with any other elements of the food tray 100 of Fig. 1
and/or
the food tray 800 of Fig. 8, described above.
[0052] The food tray 900 includes a group of gussets 905 on respective corners
of the food tray 900.In Fig. 9B, the gussets 905 are integrally formed with
the first
sidewall 105, second sidewall 110, front wall 115, and rear wall 120. The
gussets
905 enable the food tray 900 to store a fluid substance without spillage. The
gussets
905 may be folded so that they are positioned on the outside of the food tray
900, as
shown. The gussets 905 may be folded over the first sidewall 105 and second
sidewall 110, as shown, over the front wall 115 and rear wall 120, or any
combination thereof.
[0053] Each gusset 905 includes a lock tab 910 positioned on a tip of the
gusset
905. The lock tab 910 is configured to enter through an aperture defined by a
complementary lock tab 910 that extends in a substantially perpendicular
direction
away from an outside surface of a sidewall 105 and 110 of the food tray 900.
[0054] In Fig. 9B, the lock tabs 915 may be integrally formed with the
first sidewall
105 and the second sidewall 110, respectively. In particular, the respective
lock tabs
910 may extend from a first folding portion 920a and a second folding portion
920b
of the first sidewall and the second sidewall, respectively.
[0055] In operation, the second folding portion 920b is folded towards the
center
of the food tray 900 along a shared edge 925 with the respective sidewall 105
and
110. Next, the first folding portion 920a is folded about a shared edge 926
with the
second folding portion 920b, so that the lock tabs 915 extend over the first
sidewall
105 and the second sidewall 110, respectively to engage the lock tabs 910 of
the
respective gussets 905. The first folding portion 920a and the second folding
portion
290b form a shelf that extends toward the center of the food tray 900. The
shelf
provides support for the first lid member 125 and the second lid member 130
when
the respective lids 125 and 130 are folded to close the food tray 900.
[0056] Fig. 10A is another embodiment of a food tray 1000. The food tray
1000
includes a first sidewall 105, a second sidewall 110, a front wall 115, a rear
wall 120,
a first lid member 1005, a second lid member 1010, and a pair of flaps 1025
extending from the first sidewall 105 and the second sidewall 110,
respectively. The
respective walls members may be sized and positioned relative to one another
in a
similar manner as the respective walls members of the food tray 100 in Fig. 1.
The
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=
food tray 1000 also includes a group of gussets 805 on corners of the food
tray 1000
that may be configured similar to the gussets 805 of the food tray 800 of Fig.
8A.
The food tray 1000 may be combined with any other elements of the food tray
100 of
Fig. 1, the food tray 800 of Fig. 8A, and/or the food tray 900 of Fig. 9A.
[0057] The first lid member 1005 and the second lid member 1010 are configured
to be folded to cover a food item placed within the food tray 1000. The first
lid
member 1005 of the food tray 1000 defines a pair of lock tabs 1020 configured
to
engage a complementary pair of lock tabs 1015 defined by the flaps 1025
extending
from the first sidewall 105 and the second sidewall 110, respectively. The
lock tabs
1020 defined by the first lid member 1005 and the lock tabs 1 01 5 defined by
the
flaps 1025 cooperate to lock the respective lid member 1005 and 1010 in a
closed
position.
[0058] As shown in Fig. 10B, the lock tabs 1015 may be integrally formed
with the
flaps 1025.
[0059] In operation, in the assembled configuration, the flaps1025 are
folded
towards the center of the food tray 1000 along a shared edge 1030 with the
respective sidewalls 105 and 110. In this configuration, the flaps1025 forma
shelf
that extends toward the center of the food tray 1000. The shelf provides
support for
the first lid member 1005 and the second lid member 1010 when the respective
lid
members 1005 and 1010 are folded to close the food tray 1000.
[0060] Fig. 11A is,yet another embodiment of a food tray 1100. The food
tray
1100 includes a first sidewall 105, a second sidewall 110, a front wall 115, a
rear wall
120, a first lid member 1005, a second lid member 1105, and a pair of flaps
1025.
The respective wall members may be sized and positioned relative to one
another in
=
a similar manner as the respective wall members of the food tray 1000 in Figs.
10A
and 10B. The food tray 1000 may be combined with any other elements of the
food
trays described above.
[0061] The first lid member 1005 and the second lid member 1105 are configured
to be folded to cover a food item placed within the food tray 1100. The first
lid
member 1005 of the food tray 1000 defines a pair of lock tabs 1020 configured
to
pass through a respective pair of openings 1110 (FIG. 11B) defined by the
second
lid member 1105 to engage a complementary pair of lock tabs 1015 defined by
the
flaps 1025. The lock tabs 1020 defined by the first lid member 1005 and the
lock
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tabs 1015 defined by the flaps 1025 cooperate to lock the respective lid
member
1005 and 1010 in a closed position.
[0062] In operation, in the assembled configuration, the flaps 1025 are
folded
towards the center of the food tray 1000 along a shared edge 1030 with the
respective sidewall 105 and 110. Next the second lid member 1105 is folded
about
a shared edge with the front wall 115. In this configuration, the lock tabs
1015 on the
flaps 1025 are positioned below the openings 1110. Next, the first lid member
1005
is folded over the second lid member 1105. The lock tabs 1020 defined by the
first
lid member 1005 are then inserted through the openings 1110 defined by the
second
lid member 1105 so as to engage the lock tabs 1015 defined by the flaps 1025.
In
this configuration, the flaps 1025, first lid member 1005 and second lid
member 1105
cooperate to provide a top surface capable of supporting additional food trays
1100.
For example, the second lid member 1105 is substantially prevented from being
pushed into the cavity of the food tray because the respective locking tabs
1015 and
1020 engage one another by passing through the openings 1110. This, in turn
enables the food tray 1100 to support the weight of additional food trays with
food
items stored therein as is the case when food trays are stacked.
[0063] Fig. 12A is yet another embodiment of a food tray 1200. The food tray
1200 includes a first sidewall 1202, a second sidewall 1204, a front wall 115,
a rear
wall 120, a first lid member 1205, and a second lid member 1210. The
respective
walls members may be sized and positioned relative to one another in a similar
manner as the respective walls members of the food tray 100 in Fig. 1. The
food
tray 1200 may be combined with any other elements of the various food trays
described above.
[0064] The first lid member 1205 and the second lid member 1210 are configured
to be folded to cover a food item placed within the food tray 1200. Referring
to Fig.
12B, the first lid member 1205 defines a pair of slots 1230. Each slot 1230
includes
a tab 1235 that extends from one edge of the slot 1230 into a center region of
the
slot 1230. The second lid member 1220 includes a pair slots 1220 that are
configured to overlap the slots 1230 defined by the first lid member 1205 when
the
first lid member 1205 is folded over the second lid member 1220.
[0065] The first sidewall 1202 and the second sidewall 1204 each define an
extension section 1224 that defines a slot 1225. A flap 1215 extends from atop
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edge of the each of the respective sidewalls 1202 and 1204 and is configured
to be
folded about the top edge.
[0066] The extension section 1224 is sized to pass through the slots 1230
and
1220 defined by the first lid member 1205 and the second lid member 1220 when
the
food tray 1200 is in an assembled configuration, and the respective lid
members
1205 and 1210 are folded over one another. The slot 1225 defined by the
extension
section 1224 is sized to receive the tabs 1235 of the slots 1230 defined by
the first lid
member 1205, such that when the first lid member 1205 and the second lid
member
1210 are folded and the extension section 1224 passes through the respective
slots
1230 and 1220 on the respective lid members 1205 and 1210, the tab 1235
extends
through the slot 1225 defined by the extension section 1202. In other words,
the tab
1235 engages the slot 1225defined by the extension section 1224 to secure the
respective lid members 1205 and 1210 in a closed configuration. Moreover,
because the extension section 1224 passes through the slots 1230 and 1220 of
both
lid members 1205 and 1210, both lid members 1205 and 1210 are prevented from
being pushed in when in a closed configuration. This, in turn enables the food
tray
1200 to support the weight of additional food trays with food items stored
therein as
is the case when food trays are stacked.
[0067] While various embodiments of the invention have been described, it
will be
apparent to those of ordinary skill in the art that many more embodiments and
implementations are possible that are within the scope of the invention. For
example, referring to Figs. 13a and 13b, in some embodiments slots 1305a and
1305b are formed in the first lid member 125 and the second lid member 130.
The
slots are configured to mesh with one another (Fig. 13A) to facilitate locking
of the
respective lid members 125 and 130. Locking of the lid members 125 and 130
facilitates a tighter fit between the lid members 125 and 130, thus preventing
any
slight opening from forming between the respective lid members 125 and 130,
due,
for example, to board warp. The tighter fit also provides a more visual
appealing
appearance.
[0068] The slots 1305a and 1305b may have a triangular shape or a different
shape that facilities locking of the lid members 125 and 130. The slots 1305a
and
1305b may be positioned along the edge of the respective lid members 125 and
130.
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=
The slots 1305a and 1305b may be provided on any of the food tray embodiments
described above.
[0069] Figs. 14A and14B illustrate yet another embodiment of a food tray
1400.
The food tray 1400 includes a first sidewall 105, a second sidewall 110, a
front wall
115, a rear wall 120, a first lid member 125, and a second lid member 130. As
described above, the first sidewall 105 extends between the respective distal
ends of
the front wall 115 and the rear wall 120. The second sidewall 110 extends
between
respective proximal ends the front wall and the rear wall 120.
[0070] In some implementations, the first sidewall 105, second sidewall
110, front
wall 115, and rear wall 120 may be tapered as described above to enable
stacking of
the food tray 1400. Other features described with respect to the embodiments
described above may be provided.
[0071] The first lid member 125 extends from the top edge of the front wall
115,
and the second lid member 130 extends from the top edge of the rear wall 120.
The
first lid member 125 and second lid member 130 each include a horizontal
portion
1407a and 1407b and a flap portion 1405a and 1405b. Each flap portion 1405a
and
1405b includes first and second tabs 1410a and 1410b. The first sidewall 105
and
second sidewall 110 include an extension member 1415a and 1415b that define
and
opening configured to respectively engage the first and second tabs 1410a and
1410b to lock first lid member 125 and second lid member 130 in a closed
configuration. In the closed configuration, the horizontal portions 1407a and
1407b
are configured to substantially close the top of the food tray 1400. Surfaces
of the
flap portions 1405a and 1405b are held in contact with one another via the
elastic
force described above that occurs as a result of the bowing of the front wall
115 and
the rear wall 120 to thereby form a vertical rib that extends perpendicular to
top of
the food tray 1400. The elastic force helps to maintain the surfaces of the
flaps
1405a and 1405b against one another to thereby improve sealing of the food
tray
1400.
[0072] As illustrated in Fig. 14B, the food tray 1400 may be formed from a
single
sheet 1450 of material, such as a corrugated paper material. The sheet 1450
may
define a group of creases as described above and shown in dashed lines that
further
define the first sidewall 105, second sidewall 110, front wall 115, rear wall
120, first
lid member 125, second lid member 130, and respective flaps 1405a and 1405b
that
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define the vertical rib described above. The sheet 1450 may define a group of
gussets 1455 for sealing respective corners of the food tray.
[0073] Fig. 15A illustrates yet another food tray embodiment 1500 in an
assembled configuration. Fig. 15B illustrates a blank 1501 from which the food
tray
1500 is formed. The dashed lines in the blank 1501 correspond to fold lines
that
define the respective members of the food tray 1500. The blank 1501 may be
formed of a fluted or non-fluted material, such as corrugated paper,
paperboard,
chipboard, or any other material suitably rigid to hold the shape of a food
tray. The
material may be biodegradable or non-biodegradable.
[0074] Referring to Figs. 15A and 15B, the food tray 1500 includes a first
sidewall
105, a second sidewall 110, a front wall 115, a rear wall 120, a pair of lid
member
1515, a pair of flaps 1505, and a bottom panel 1502. The bottom panel 1502 is
generally rectangular. The sidewalls (105, 110), front wall 115, and rear wall
120
extend from the bottom panel 1502. The flaps 1505 extend from the first
sidewall
105 and the second sidewall 110, respectively. The lid members 1515 extend
from
the front wall 115 and the rear wall 120, respectively. The respective walls
members
may be sized and positioned relative to one another in a similar manner as in
any of
the embodiments described above.
[0075] The food tray 1500 includes a group of gussets 1503 on corners of the
food tray 1500 that may be configured similar to the gussets described above.
The
gussets 1503 may be folded outwardly to be visible from outside of the food
tray
1500, as illustrated, or inwardly so that they are not visible when the food
tray 1500
is closed. Glue strips (1530a, 1530b) or some other form of adhesive may be
provided on the gussets and the sidewalls (105, 110) to secure the gussets to
the
sidewalls. Alternatively, glue strips or the other form of adhesive may be
provided on
the front and rear walls (115, 120) to secure the gussets to the front and
rear walls
(115, 120). In some implementations, a polyethylene coating applied to the
food tray
1500 as a moisture barrier may be utilized as the adhesive for securing the
gussets
to the sidewalls rather than or in addition to glue strips. For example, heat
may be
applied to the gussets 1503 and/or the opposing sidewall to which the gussets
are to
be secured to cause the polyethylene to bond. The gussets are then brought in
contact with the opposing sidewalls and the polyethylene is allowed to cool,
thus
13
CA 02780514 2012-06-21
securing the gussets 1 503 to the opposing sidewalls. The food tray 1500 may
be
combined other elements of the food tray embodiments described above.
[0076] The flaps 1505 are configured to be folded towards an interior of
the food
tray 1500. In this configuration, the flaps 1505 form a shelf that extends
toward the
center of the food tray 1500. The shelf provides support for the lid members
1505,
which are configured to be folded over the flaps 1505 and each other. Each
flap
1505 defines a slot 1510 in a middle region. The slots 1510 may define the
shape of
an arc. Each lid member 1515 includes a pair tabs 1520 that are configured to
engage the slots 1510 of the flaps 1505 to secure the lid members 1515 to the
flaps
1505 and thereby seal the top of the food tray 1500.The outside edges of the
tabs
1520 are curved and cooperate with the arc shaped slots 1510 to facilitate
smoother
insertion of the tabs 1520 into the slots 1510, and to minimize tearing of the
tabs
1520 that might otherwise occur during opening and closing the food tray 1500.
[0077] The tabs 1520 define hook regions 1521 that are configured to hook
within
the slots 1510 after insertion. Hooking of the tabs 1520 to the slots 1510
helps
prevent unintended opening of the lid member. Once hooked, the tabs 1520 may
be
removed from the slots 1510 by, for example, applying pressure against the
front
and rear walls (115, 120) to unhook the tabs 1520 from the slots and then by
pinching the lid members 1515 so as to pull the tabs 1520 out of the slots
1510.
[0078] Figs. 16 and 17 illustrate alternative food trays 1600 and 1700 that
generally include the features of the food tray 1500 illustrated in Fig. 15.
However,
the size and general shape of the respective food trays may be different. For
example, the food tray blank 1501 of Fig. 15B may have a generally square
geometry. And when folded the food tray 1500 may have a generally rectangular
shape as evinced by the generally rectangular bottom panel 1502. The food tray
blank 1601 illustrated in Fig. 16B may have a generally square geometry. And
when
folded, the food tray 1600 may have a generally square shape as evinced by the
generally square bottom the bottom panel 1602. The food tray 1700 illustrated
in
Fig. 17B is a smaller version of the food tray 1600 illustrated in Fig. 16B.
The food
tray blank 1701 illustrated in Fig. 17B may have a generally square geometry.
And
when folded, the food tray 1700 may have a generally square shape as evinced
by
the generally square bottom the bottom panel 1702. Although, in other
implementations, the food tray blank may have a multifaceted geometry.
14
CA 02780514 2012-06-21
[0079] Fig. 18A illustrates yet another food tray embodiment 1800 in an
assembled configuration. Fig. 18B illustrates a blank 1801 from which the food
tray
1800 is formed. The fold lines in the blank 1801 correspond to fold lines that
define
the respective members of the food tray 1800.
[0080] Referring to Figs. 18A and 18B, the food tray 1800 includes a first
sidewall
105, a second sidewall 110, a front wall 115, a rear wall 120, a lid member
1815, a
pair of flaps 1805, and a bottom panel 1802. The bottom panel 1802 is
generally
rectangular. The sidewalls (105, 110), front wall 115, and rear wall 120
extend from
the bottom panel 1802. The respective walls members may be sized and
positioned
relative to one another in a similar manner as the respective walls members
described in the embodiments above. The food tray 1800 also includes a group
of
gussets 1803 on corners of the food tray 1800 that may be configured similar
to the
gussets described in any of the other embodiments disclosed herein. The
gussets
1803 may be secured to opposing sidewalls via glue strips (1830a, 1830b) as
described above.
[0081] The lid member 1815 extends from a top edge of the rear wall 120. The
lid member 1815 may include a window 1825 formed of a clear material that
facilitates viewing of contents stored within the food tray 1800. The lid
member 1815
includes a flap 1835 that extends from an edge of the lid member 1815 that is
opposite the top edge of the rear wall 120. A slot 1840 is formed in a central
region
of the edge from which the flap 1835 extends. The slot 1840 is sized to
received a
tab 1845 that extends from a top edge of the front wall 115. The lid member
1815
also includes a pair tabs 1820 on side edges that are recessed somewhat
relative to
the side edges.
[0082] Flaps 1805 extend from the first sidewall 105 and the second
sidewall 110,
respectively. The flaps 1805 are configured to be folded towards an interior
of the
food tray 1800. In this configuration, the flaps 1805 form a shelf that
extends toward
the center of the food tray 1800. The shelf provides support for the lid
member 1805
when the lid member 1805 is folded over the flaps 1805. Each flap 1805 defines
a
slot 1810 or cutout in a middle region. The slots 1810 are sized to receive
the tabs
1820 of the lid member 1815.
[0083] In operation, when closing the food tray 1800, the flaps 1805 that
extend
from the sidewalls (105, 110) are folded inwardly towards the center of the
food tray
CA 02780514 2012-06-21
1800. The lid member 1815 is then folded to close the food tray 1800. The flap
1835 of the lid member is folded so that it is behind the front wall 115 when
the lid
member 1815 is closed. The lid member 1815 may then be warped slightly to
facilitate insertion of the tabs 1820 into the slots 1810. Once released, the
slots
1810 and tabs 1820 cooperate to secure the lid member 1815 to the flaps 1805
and
thereby seal the top of the food tray 1800. The tab 1845 that extends from the
front
wall 115 is then inserted into the slot 1840 of the lid member 1815 to further
secure
the lid member to the front wall 115. Thus, the lid member 1815 is secured
along all
four walls of the food tray 1800.
[0084] Fig. 19A illustrates yet another food tray embodiment 1900 in an
assembled configuration. Fig. 19B illustrates a blank 1901 from which the food
tray
1900 is formed. The fold lines in the blank 1901 correspond to fold lines that
define
the respective members of the food tray 1900.
[0085] Referring to Figs. 19A and 19B, the food tray 1900 includes a first
sidewall
105, a second sidewall 110, a front wall 115, a rear wall 120, a lid member
1915, a
pair of flaps 1905, and a bottom panel 1902. The bottom panel 1902 is
generally
rectangular. The sidewalls (105, 110), front wall 115, and rear wall 120
extend from
the bottom panel 1902. The respective walls members may be sized and
positioned
relative to one another in a similar manner as the respective walls members of
any of
the food tray embodiments described above. The food tray 1900 also includes a
group of gussets 1903 on corners of the food tray 1900 that may be configured
similar to the gussets of any of the food tray embodiments described above and
secured via glue strips (1930a, 1930b).
[0086] The lid member 1915 extends from a top edge of the rear wall 120. The
lid member 1915 may include a window 1925 formed of a clear material that
facilitates viewing of contents stored within the food tray 1900. A flap 1935
extends
from an edge of the lid member 1915 that is opposite the top edge of the rear
wall
120. The flap 1935 defines a tear strip 1940 that extends substantially the
entire
length of the flap 1935 in a direction that is parallel to the edge. The tear
strip 1940
is a perforated portion of the flap that facilitates easy and controlled
separation of the
flap 1935 from the lid member 1915. A glue strip 1910 is positioned adjacent
to the
tear strip 1940 on a side of the tear strip 1940 that is opposite the edge
that
separates the flap 1935 from the lid member 1915. The glue strip 1910 may
extend
16
CA 02780514 2012-06-21
for the length of the flap or a lesser length. While illustrated on the flap
1935, in
alternative embodiments, the glue strip 1910 may be arranged instead on the
front
wall 115 or both the front wall 115 and the flap 1935.
[0087] _ Flaps 1585 extend from the first sidewall 105 and the second sidewall
110,
respectively. The flaps 1905 are configured to be folded towards an interior
of the
food tray 1900. In this configuration, the flaps 1905 form a shelf that
extends toward
the center of the food tray 1900. The shelf provides support for lid member
1915
when the lid member 1915 is folded over the flaps 1905. Each flap 1905 defines
a
notched portion 1907 configured to enter within a respective slot 1907 formed
in the
outside ends of the edge between the lid member 1915 and the flap 1935, when
the
lid member 1915 is closed.
[0088] In operation, when closing the food tray 1900, the flaps 1905 that
extend
from the sidewalls (105, 110) are folded inward towards the center of the food
tray
1900. The lid member 1915 is then folded to close the food tray 1900. The flap
1935that extends from the lid member is folded so that it is in front of the
front wall
115 when the lid member 1915 is closed. That is, the flap 1935 is disposed on
the
outside of the food tray 1900. The flap 1935 is pressed against the outside
surface
of the front wall 115 to secure the lid member 1915 to the front wall 115 via
the glue
strip 1910. The tear strip 1940 is configured to provide a user friendly and
tamper
evident method of separating the portion of the flap 1935 that is secured to
the front
wall 115 from the portion that is attached to the lid member 1915 to
facilitate opening
of the lid member 1915. After opening, the lid member 1915 may be re-secured
to
the front wall 115 via interlocking of the notched portion 1908 of the flaps
1905 that
extend from the first sidewall 105 and the second side wal1110 and the slots
1907
formed between the lid member 1915 and the flap 1935 that extends from the lid
member 1915.
[0089] Many other modifications may be provided to one or more of the food
tray
embodiments described above. For example, gusseted sides may or may not be
provided. When provided, the gussets may be configured to be positioned inside
the
food tray or outside the food tray. The respective sheets from which the
respective
food trays are formed may be made from paperboard, micro-fluted paperboard
coated with a water and/or grease barrier coating or lamination, or an
uncoated
paperboard or microfluted paperboard, or a type of plastic. The food trays may
be
17
CA 02780514 2012-06-21
formed of corrugated paper, chipboard or other suitably rigid material. The
features
of the various food trays may be combined in various ways to provide any of
the
advantages described above in any of the food tray embodiments. Other
modifications may be made without departing from the scope of the claims.
18
