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.
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.
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.
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.
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 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.
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 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.
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. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the following claims.
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 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.
A bottom surface 605 (
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°.
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.
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
As shown in
As illustrated by
Bowing of the front wall 115 and the rear wall 120 provides an elastic force that causes the first and second lid members 125 and 130 to open on their own when the extensions 105b and 110b on 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 (
As illustrated in
In one embodiment, the food tray is configured by cutting the sheet along a group of cut lines 710a-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 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.
The food tray 800 includes a group of gussets 805 on respective corners of the food tray 800. In
In
The food tray 900 includes a group of gussets 905 on respective corners of the food tray 900. In
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.
In
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.
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 1015 defined by the flaps 1025 cooperate to lock the respective lid member 1005 and 1010 in a closed position.
As shown in
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 sidewalls 105 and 110. In this configuration, the flaps 1025 form a 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.
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 (
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.
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
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 a top edge of the each of the respective sidewalls 1202 and 1204 and is configured to be folded about the top edge.
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 1225 defined 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.
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
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. The slots 1305a and 1305b may be provided on any of the food tray embodiments described above.
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.
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.
As illustrated in
Referring to
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 securing the gussets 1503 to the opposing sidewalls. The food tray 1500 may be combined other elements of the food tray embodiments described above.
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.
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.
Referring to
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.
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.
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 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.
Referring to
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 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.
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.
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 1935 that 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 wall 110 and the slots 1907 formed between the lid member 1915 and the flap 1935 that extends from the lid member 1915.
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 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.
This application is a continuation-in-part application of U.S. application Ser. No. 13/165,346, filed Jun. 21, 2011, which claims priority to U.S. Provisional Application No. 61/356,847, filed Jun. 21, 2010, the contents of both of which are hereby incorporated by reference.
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Number | Date | Country | |
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20120261298 A1 | Oct 2012 | US |
Number | Date | Country | |
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61356847 | Jun 2010 | US |
Number | Date | Country | |
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Parent | 13165346 | Jun 2011 | US |
Child | 13463479 | US |