1. Field of the Invention
This invention relates to flat foldable paper tray having a set of fold lines inscribed therein along which the tray is bent to form a package in which to carry any one of a variety of food products, such as a baked goods, or the like. By virtue of the foregoing, a food product can be first cooked and then shipped displayed, sold and consumed within the same package to streamline the production and distribution process.
2. Background Art
Many food products intended for consumption are purchased by consumers and carried home from a place of purchase in a package. For example, it is common for baked goods to be packaged and wrapped prior to their sale. Typically, the product is first cooked in a metal base or similar cooking vessel which must be greased prior to receipt of the dough. Once the cooked product has cooled, it is removed from the cooking base and relocated to a package of the kind in which the product is sold and carried home by the consumer. The cooking base is then cleaned, dried and prepped for reuse.
The requirement for different containers in which to cook and then package the finished product for sale results in an inefficient production and distribution process. That is to say, time and labor must be devoted to transfer the product from its cooking base to a retail package and then to clean and ready the base. Time may also be wasted while waiting for the cooked product to cool before being removed from the cooking base. As a consequence of the foregoing, the cost to produce a finished baked product ready for sale is increased, which cost is usually passed on to the consumer. What is more, the bakery and/or the retail store must continuously keep on hand supplies of cooking vessels and packaging which, for large bakeries and retail chains, are known to consume valuable space. Some of the packaging may not be used until after a long delay or not at all. In this case, the packaging may ultimately be discarded to reduce space consumption.
Accordingly, it would be desirable to have a more efficient and less costly means for making, packaging and distributing cooked (e.g., baked) products from production to consumption.
Briefly, and in general, a flat, multi-purpose foldable tray is disclosed for making a package in which a food product (e.g., a baked good) can be cooked, shipped, displayed, sold and consumed. The tray is preferably manufactured from recycled corrugated paper board. The flat tray has a set of fold lines along which the tray is bent to form the package. Thus, a single package can be used from baking to consumption to streamline the production and distribution process.
According to a first preferred embodiment, the tray has a rectangular central base portion. A pair of side walls are separated from the central base portion by respective crease lines in the tray. A pair of end walls are also separated from the central base portion by respective crease lines. Each corner of the tray lying between adjacent side and end walls includes a pair of triangular fold-up panels that are formed by perforations in the tray. The fold-up panels angle outwardly from one corner of the central base portion. A locking tab is hingedly connected to one of the fold-up panels. The side and end walls of the tray are bent upwardly along their crease lines relative to the base portion to correspondingly cause each pair of triangular fold-up corner portions to be folded towards and moved face-to-face against one another. The locking tabs are bent into engagement with locking catches that project from the upstanding end walls to hold the side and end walls in end-to-end perpendicular alignment and thereby create the package for receiving the ingredients to be baked. Once folded, the corner portions will lie outside the enclosure. The locking tabs can be pulled out of their locking engagement with the locking catches to enable the previously-folded external corner portions to be unfolded and the package opened to permit the baked product to be iced or removed from the package.
Referring initially to
As will now be explained, the flat tray 1 is inscribed with a series of fold lines (e.g., creases and perforations) along which the tray is folded to create an assembled baking and shipping package 60 (of
At the center of the flat tray 1 is a (e.g., rectangular) base portion 3 which will be covered by the ingredients of the product to be baked and upon which the finished product will be seated and carried after the tray has first been folded to form the assembled baking and shipping package 60. Side walls 5 and 7 of the flat tray 1 are separated from the central base portion 3 by scored creases 8 and 10 running therebetween. End walls 12 and 14 of the flat tray 1 are separated from the central base portion 3 by scored creases 16 and 18 running therebetween.
The flat tray 1 includes four folding corners 20-1 . . . 20-4. Each folding corner angles outwardly from a corresponding one (e.g., 22) of the corners of the rectangular central base portion 3. Inasmuch as each folding corner 20-1 . . . 20-4 is identical to the others, the details of only one folding corner (e.g., 20-1) are provided herein. Identical reference numerals will be used to identify identical features of all of the folding corners 20-1 . . . 20-4 of the tray 1.
In particular, the folding corner 20-1 includes a pair of adjacent triangular fold-up panels 24 and 26 that are arranged side-by-side. The adjacent fold-up panels 24 and 26 are separated from one another by a perforated fold line 28 which forms a common side of the panels. The first triangular fold-up panel 24 includes a first side 30 which extends from the corner 22 of the central base portion 3 of tray 1 across the side wall 5. The triangular fold-up panel 24 includes a second side which corresponds to the common fold line 28. The second side (i.e., fold line 28) also extends from the corner 22 of the central base portion 3 across side wall 5. The third side 32 of the triangular fold-up panel 24 runs between the first side 30 thereof and the fold line 28. The first triangular panel 24 of the folding corner 20-1 of the flat tray 1 angles outwardly from the corner 22 of the central base portion 3 such that an acute angle 34 (e.g., of approximately 30 degrees) is formed between the first and second sides 30 and 28.
The second triangular fold-up panel 26 of the folding corner 20-1 of the flat tray 1 includes a first side 36 which extends from the corner 22 of the central base portion 3 of tray 1 across the end wall 12. The triangular fold-up panel 26 includes a second side which corresponds to the fold line 28 and is common to the second side of the first triangular fold-up panel 24. The third side 38 of the triangular fold-up panel 26 runs between the first side 36 thereof and the fold line 28. The second triangular panel 26 of the folding corner 20-1 angles outwardly from the corner 22 of the central base portion 3 such that an acute angle 40 (e.g., of approximately 30 degrees) is formed between the first and second sides 36 and 28.
Each of the fold lines from the first sides 30 and 36 of the first and second triangular fold-up panels 24 and 26 of folding corner 20-1 is preferably perforated through the tray 1 to facilitate folding therealong for an advantage that will soon be explained. The angle (including the sum of the angles 34 and 40) of the folding corner 20-1 which originates at the corner 22 of base portion 3 and extends between the perforated fold lines 30 and 36 is approximately 60 degrees.
A locking tab 44 is hingedly attached to the second triangular fold-up panel 26 of each of the folding corners 20-1 . . . 20-4 of the flat tray 1. In particular, the locking tabs 44 are joined to respective ones of the second fold-up panels 26 along the third side 38 of each panel 26. That is, the side 38 is common to each one of a fold-up panel 26 and an adjacent locking tab 44. The third side 38 is preferably a scored crease that is formed in the tray 1 and functions as a living hinge. An attachment slot 46 is cut or punched through each of the locking tabs 44.
A pair of locking catches 50 having hook ends projects outwardly from each of the end walls 12 and 14 of the flat tray 1. The pairs of locking catches 50 are located along the end walls 12 and 14 so that one locking catch lies adjacent one of the locking tabs 44 in order for the locking catch 50 and locking tab 44 to be connected together during the folding of tray 1 and the assembly of the package in which a baked product is cooked, transported and sold.
Referring concurrently in this regard to
All of the folding corners 20-1 . . . 20-4 are closed in the same manner. For purposes of convenience, details are provided only with respect to the closure of the folding corner 20-2 shown in
The fold-up panel 24 continues to rotate around its perforated side (i.e., fold line) 28 until panel 24 is moved face-to-face against panel 26 (best shown in
In order to preserve the perpendicular alignment of the side and end walls 7 and 12 so as to hold the folding corner 20-2 closed and thereby prevent leakage throughout the baking process, the locking tab 44 is bent or folded downwardly (in the direction of the reference arrow 54 of
Once all four folding corners 20-1 . . . 20-4 (of
Once the ingredients within package 60 have been cooked, it may be necessary to open the package such as in those cases where the backed product will be covered with icing or removed from the package. Because the fold-up panels 24 and 26 of each of the closed corners 20-1 . . . 20-4 are held together and located outside the confines of the package 60, the corners may be easily opened to gain access to the baked product. To accomplish the foregoing, the locking tabs 44 are simply pulled upwardly and out of their locking engagement with the locking catches 50. The fold-up panels 24 and 26 of each corner may now be rotated apart and away from their face-to-face alignment. The corners 20-1 . . . 20-4 of the package 60 can be partially or completely opened on an as-needed basis. Once access to the baked product is completed, the corners 20-1 . . . 20-4 may once again be closed in the manner previously described so that the product surrounded by the package 60 may continue to move through the production process.
Turning now to
As in the case of the tray 1 of
A pair of locking catches 82 have hook ends project outwardly from each of the end walls 12 and 14 of the flat tray 70. The pairs of locking catches 82 are located along the end walls 12 and 14 so that one locking catch lies adjacent one of the locking tabs 72 in order for the locking catch 82 and the locking tab 72 to be connected together during the folding of tray 70 and the assembly of the package 88. A pair of locking reinforcements 84 extend outwardly from each of the side walls 5 and 7 of the flat tray 70. The pairs of locking reinforcements 84 are located along the side walls 5 and 7 so that one locking reinforcement 84 lies adjacent one of the folding corners (e.g., 20-1) of tray 70 in order for the locking reinforcement and one of the locking tabs 72 to be connected together during folding of the tray as will now be described.
Referring concurrently in this regard to
All of the folding corners 20-1 . . . 20-4 are closed and locked in the same manner. For purposes of convenience, details are provided only with respect to the closure and locking of the folding corner 20-1 shown in
The fold-up panel 26 continues to rotate towards fold-up panel 24, and panel 24 rotates around its first side (i.e., fold line) 30 until both panels 26 and 24 are moved (in the direction of reference arrow 86) into face-to-face alignment against side wall 5 (best shown in
In order to preserve the perpendicular alignment of the side and end walls 5 and 12 so as to hold the folding corner 20-1 closed and thereby prevent leakage throughout the baking process, the locking tab 72 is bent and folded downwardly towards the locking catch 82 around the side 38 or hinge of the fold-up panel 26 which joins the locking tab 72 and the panel 26. The locking tab 72 is pulled over top the side wall 5 and against the end wall 12 until the locking catch 82 which now stands upwardly from the upturned end wall 12 is received through the locking receptacle 80 formed through the locking tab 72 (best shown in
The receipt of the locking catch 82 through the locking receptacle 80 rotates the push-out locking flap 78 upwardly and out of the locking receptacle. Because of its hook end, the locking catch 82 is disposed in locking engagement with the locking tab 72 at the locking receptacle 80. The push-out locking flap 78 lies alongside and supports the locking catch 82 so as to prevent an unintended disconnection of locking catch 82 from locking tab 78 via locking receptacle 80. The locking catch 82 holds the locking tab 72 down over the intersection of the perpendicularly-aligned side and end walls 5 and 12 so as to avoid a separation (i.e., unfolding) thereof and prevent the closed folding corner 20-1 from opening.
As the locking catch 82 engages the locking tab 72, the locking reinforcement 84 which extends from the now upstanding side wall 5 is received through the locking cavity 76 formed in locking tab 72 (also best shown in
Once all four folding corners 20-1 . . . 20-4 (of
Referring to
Locking flaps 92 and 94 are hingedly attached to respective ones of the end walls 12 and 14 of tray 90 along fold lines 96 and 98. Each of the locking flaps 92 and 94 has an upturned ear 100 and 102 located at each of the opposite ends thereof. A locking slot 106 is formed through each of the upturned ears 100 and 102 of the locking flaps 92 and 94. A locking projection 108 extends outwardly from each end of each of the side walls 5 and 7 of tray 90 adjacent the folding corners 20-1 . . . 20-4. The locking projections 108 are sized and shaped to match the size and shape of the locking projections 74 which extend from the triangular fold-up panels 26 of folding corners 20-1 . . . 20-4.
Referring concurrently to
All of the folding corners 20-1 . . . 20-4 are closed and locked in the same manner. For purposes of convenience, details are provided only with respect to the closure and locking of the folding corner 20-1. As the wall 5 of tray 90 is folded upwardly relative to the base portion 3 around the crease 8 and the end wall 12 is folded upwardly around the crease 16, the folding corner 20-1 folds up upon itself. That is, the triangular fold-up panel 26 is bent towards the adjacent triangular fold-up panel 24 (best shown in
The fold-up panel 26 continues to rotate towards the fold-up panel 24, and panel 24 rotates around its first side (i.e., fold line) 30 until both panels 26 and 24 are moved (in the direction of reference arrow 110) into face-to-face alignment against the side wall 5 (best shown in
In order to preserve the perpendicular alignment of the side and end walls 5 and 12 so as to hold the folding corner 20-1 closed and thereby prevent leakage throughout the baking process, the locking flap 92 is bent around the fold line 96 and folded downwardly towards the face-to-face aligned locking projections 74 and 108 (in the direction of reference arrow 112 of
The pair of locking projections 74 and 108 create a sufficient thickness and locking force within the locking slot 106 to prevent an unintended separation of the locking flap 92 from the locking projections. That is, the receipt of the locking projections 74 and 108 within the locking slot 106 holds the locking flap 92 down over the intersection of the perpendicularly-aligned side and end walls 5 and 12 so as to avoid a separation (i.e., unfolding) thereof and prevent the closed folding corner 20-1 from opening.
Once all four folding corners 20-1 . . . 20-4 (of
Number | Name | Date | Kind |
---|---|---|---|
3008626 | Lawrence | Nov 1961 | A |
3368734 | Wainberg | Feb 1968 | A |
4114797 | Manizza | Sep 1978 | A |
4308985 | Manizza et al. | Jan 1982 | A |
4998669 | Karolyi | Mar 1991 | A |
5086971 | Detzel et al. | Feb 1992 | A |
Number | Date | Country | |
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20110315594 A1 | Dec 2011 | US |