Patent Application
20250197048
The present invention relates to thermoformed, molded fiber containers useful in food service and related industries and, more specifically, mass-produced plates or trays having multiple, divided compartments with features to allow for the stacking and separation (i.e., “denesting”) of individual plates/trays without unwanted coupling or adhesion of multiple units within the stack.
Molded paper and pulp products are widely used in food services and other areas where mass-produced, commodity-type implements are needed. These products tend to be made from a thermoformed web of fiber, with presses and molded designed to create hundreds or thousands of units per day. In order to pack and store the resulting products efficient, considerable efforts have been made to develop plates, bowls, trays, and other articles that can seated one-on-top-of-another in a vertical stack. Vertical stacks are preferred insofar as gravity alone provide sufficient force to seat and retain the members within the stack, without the need for compressive force, wraps, or other implements.
U.S. Pat. No. 8,534,460 describes and depicts pressed paperboard bowls specifically designed to be arranged in vertical stacks. In particular, each bowl has pleated sidewalls and a circular shape with a radial flange extending outward at its top end. Denesting features are provided along a majority of the surface area on the top facing of the flange, with the denesting feature taking the form of a thickened peripheral portion at the inner circumference of the flange.
U.S. Pat. No. 11,186,411 considers thermoformed plastic containers, again with a design purporting to enable efficient vertical stacking. Here, the containers have a polygonal shape, thereby requiring attention to proper orientation of the containers relative to one another in order to form a stack (and in contrast to circular articles, where no such indexing or registry of individual items is needed). Multiple denesting features are required on and adjacent to the inner and outer periphery of a radial sealing flange formed at the top of the container. The inner denesting feature constitutes a pair of spaced “knobs” positioned at each corner. Additionally, the flange itself has a two-step cross-sectional profile so that an angled or “undercut” wall leads to an outer peripheral and horizontal surface defining a secondary recess. Separate and additional denesting features (which appear to take the form of cuboid projections on the top facing of the secondary recess) are projected up from the outermost periphery in this secondary recess. Notably, the denesting features are spaced apart at regular intervals.
European patent publication EP4105135A1 describes a circular bowl with undulations provided around its top peripheral flange. Other approaches to denesting involve formation of flutes or features in the sidewalls of the bowl itself, as exemplified by U.S. Pat. No. 9,392,891.
U.S. Pat. No. 10,906,709 identifies another salient design feature—the provision of locking lugs on the flange and stiffening ribs in the sidewalls of thermoformed containers. While these features impart additional, desirable functionality to containers, they appear to be at cross-purposes when compared to the foregoing denesting features.
Finally, U.S. Pat. Nos. 11,286,104; 11,051,485; 9,555,916; and 8,777,010 all provide further examples of articles designed specifically for the unique exigencies that arise in the context of particularized industries (e.g., paperboard products, cheesemaking, etc.). As such, these provide still further examples of the challenges and difficulties in creating and executing designs for stackable articles.
All of the aforementioned patent documents are incorporated by reference for background purposes.
A new design for a multi-compartment tray that is capable of easily stacking and denesting would be welcomed. Specifically, a design that eliminated or minimized the appearance of unsightly protrusions on the exterior rim of the lid (which may also impede attachment, and/or require specialized use, of covering lids) is needed. Finally, to the extent protrusions and/or thickened portions of sidewalls and flanges require additional material for manufacturing, a design that minimized material usage while still delivering denesting functionality is desired.
A stackable tray having a non-circular shape, and a volumetrically compact system and method for stacking such trays, is contemplated. The tray has a polygonal shape when viewed from the top, with at least two distinct compartments extending below a horizontally-oriented peripheral flange that defines the upper most plane/surface of the tray. The compartments have angled (relative to a vertical axis) sidewalls, each terminating in a floor.
A single denesting formation is formed in at least two corners of each compartment. The formation has a dimple-like appearance that is flush with the peripheral flange and extends downward along a portion of the sidewall(s) defining that corner. The dimple includes a small area of increased thickness, but it is disposed at an angle (relative to the vertical axis) that is larger than the angled sidewalls. Notably, the sidewalls defining the ends of the tray are also formed at an angle that differs from the angle of the sidewalls that define the divider provided along an interior section of the tray. It is believed this combination of features imparts and enables the desired denesting functionality, all while: a) minimizing the need for multiple, discrete denesting formations clustered together and/or covering a significant portion of the flange, b) retaining a flat horizontal surface along the top planar facing of the tray, and c) effectively concealing the denesting formations on an interior surface.
Further reference should be made to the appended or incorporated information embraced by this disclosure, including any and all claims, drawings, and description. While specific embodiments may be identified, it will be understood that elements from one described aspect may be combined with those from a separately identified aspect. In the same manner, a person of ordinary skill will have the requisite understanding of common processes, components, and methods, and this description is intended to encompass and disclose such common aspects even if they are not expressly identified herein.
Operation of the invention may be better understood by reference to the detailed description taken in connection with the following illustrations. These appended drawings form part of this specification, and each figure is individually drawn to scale. Any information on/in the drawings is both literally encompassed (i.e., the actual stated values) and relatively encompassed (e.g., ratios for respective dimensions of parts). In the same manner, the relative positioning and relationship of the components as shown in these drawings, as well as their function, shape, dimensions, and appearance, may all further inform certain aspects of the invention as if fully rewritten herein. Unless otherwise stated, all dimensions in the drawings are unit-less so as to allow for ratios and comparative metrics to be created for any combination of the disclosed values (excepting arc lengths, which are measured/disclosed in degrees). Any and all printed information on/in the drawings form part of this written disclosure.
In the drawings and attachments, all of which are incorporated as part of this disclosure:
The following description and any reference to the drawings and claims are merely exemplary, and nothing should limit alternatives and modifications that may be possible while adhering to the spirit and scope of the invention. Also, the drawings form part of this specification, and any written information in the drawings should be treated as part of this disclosure. In the same manner, the relative positioning and relationship of the components as shown in these drawings, as well as their function, shape, dimensions, and appearance, may all further inform certain aspects of the invention as if fully rewritten herein.
As used herein, the words “example” and “exemplary” mean an instance or illustration of broader concept; however, use of these words do not necessarily indicate a required, key, or preferred aspect or embodiment. Similarly, the word “or” is intended to be inclusive rather an exclusive, unless context suggests otherwise. As an example, the phrase “A employs B or C,” includes any inclusive permutation (e.g., A employs B; A employs C; or A employs both B and C). As another matter, the articles “a” and “an” are generally intended to mean “one or more” unless context suggest otherwise. Approximating language such “about” or “substantially” may be used (or, when consistent with context and reasonable expectations, implied) so as to modify quantitative representations, in which cases the stated value(s)/range(s) may be modified within the reasonable expectations of this art field and not necessarily limited to the precise value specified (unless specifically indicated herein as being precise or critical).
The descriptions and drawings in this disclosure, and any written matter within the drawings should be deemed to be reproduced as part of this specification. In the drawings, the depicted objects have a height 101 (as seen in side and perspective views), as well as length 102 and width 103 (as seen in top and perspective views). References to vertical or vertical axis mean a straight line running from the top to bottom of the image(s) on a page, where as horizontal and horizontal axis run from side/ege to side/edge so as to be at a right angle in comparison to the vertical. In all instances, a person of skill in this field will interpret this description in a manner that is consistent with the state of the art at the time of this invention.
With reference to
At least two compartments 130, 130a positioned on either side of divider 120. Compartments 130, 130a may be identical, although side compartment 130a preferably has a smaller width in comparison to main compartment 130. The bottom of each compartment 130, 130a presents as a flat surface, preferably aligned in a plane that is parallel to that defined by the flange 110. In total, the axial/vertical height of the tray 10 is defined by line I. Further, in some aspects, the flange 120 may include a terminal stepped section 111 in which an angled wall 112 slopes downward to connect with a radial projection 113. The axial/vertical height from the flat planar surface of flange 110 to projection 113 is defined by line J.
In terms of three dimensional shape, the compartments 130, 130a present as truncated rectangular pyramids extending down from a peripheral flange 110 (and, along one edge, from divider 120). These pyramids are defined by lengthwise end walls 132, 132a and widthwise side walls 134, 134a, with all of the end walls—as well as the corner wall sections 133—having specifically selected angles (relative to the vertical axis) to facilitate stacking and de-nesting, as will be discussed below (note divider walls 122, 122a are similarly angled for these purposes). From the top view (i.e., within the same planar surface defined by the top flat facing of flange 110), these walls 122, 132, 134, etc. may join at right angles in each intersecting corner or, more preferably, an angled corner wall section 133 is interposed at one or all such intersecting corners. Each of the wall sections 122, 132, 133, 134 may include transitional panels 132b, 133b, 134b connects to the features above (e.g., the flange 110) and below (e.g., the planar bottom of the compartments 130, 130a) by way of a curved or angled section that differs from that imparted upon the major facing of that respective section. In this context, angles M, N, and O are measured along that major facing (and not the transitional panels). Similar transitional sections 132c, 133c, 134c can be provided to connect the lateral (e.g., within the horizontal plane of
Disposed in at least two corners of each compartment 130, 130a—and more preferably at each and every corner of each compartment—a single denesting formation 140 is disposed below the planar horizontal surface defined by the flange 110. Formation 140 has a small dimple shape that extends laterally along the surface the angled corner wall 133 or its transitional panel 133b, when present (i.e., the portion exposed to/defining a side portion of the compartment 130 or 130a). In one implementation, the formation 140 is formed integrally within a specific portion of the wall connecting the specific sidewall(s) to the ledge.
With reference to
While this trapezoidal shape of the denesting formation 140 is most pronounced in the cross-sectional view of
In a preferred aspect, as shown in
More importantly, and irrespective of the comparative dimensions of the compartments, the comparatively small number and positioning of features 140 coupled with the differing angles of selected sidewalls (where angle M>N>O) and the inclination of the dimpled portion along angle P (where P<M and, more preferably, P<O and/or P is equal to about one half of M) help allow for stacking and denesting of individual trays 100 in a vertical orientation so that the force of gravity, and any adhesion forces between adjoining surfaces, are what retain the trays 100 within the stack 10.
As used herein, denesting means the ability to grasp the top or bottom tray and apply force sufficient (and no more than 10%, no more than 20%, or no more than 25% more force—and preferably as little as 0.25% to 5%—otherwise normally required to lift a single tray) in order to separate that single tray from the rest of the stack in its vertical orientation (i.e., resting on a flat horizontal surface). More ideally, separation and denesting occurs with little to no appreciable difference experienced by the user.
Other significant relationships can be gleaned from a comparison of the various values provided in
To that end, it is believed the comparative and differential sizes of angles M, N, O, and P are relevant to denesting. Specifically, the angle M of the corner wall 133 is largest in comparison to vertical, whereas angle P is the smallest (and, preferably, about one half of angle M). Depending on whether the feature 140 is on the divider wall 122 or the end wall 132, Angle M will be between 15% to 40% larger than the angle N and/or angle O. Each of angle M, N, O, and P are measured relative to vertical axis of the container/stack.
These and other relationships help to create conditions for denesting of individual trays from the stack. Similarly, their positioning (i.e., at corners only; oriented along an axial/height-wise surface; etc.) and physical shape (i.e., presenting smooth, flat horizontal surfaces for stacking; comparatively small dimensions/volumes allowing for sufficient separation and acceptable stabilization of vertically adjacent trays; etc.) minimizes the number and obtrusiveness of these features in comparison to previous designs discussed in the background above. Specifically, eight or less (and possibly as few as four total) denesting features 140 can be positioned at selected junctions of the lengthwise and widthwise walls defining each of the two compartments 130, 130a. The features 140 will be disposed beneath the top horizontal planar surface defined by the flange 110, and preferably on an interior facing of each compartment 130, 130a, so as to minimize or eliminate their visibility while also maintaining a smooth top facing in the event a lid was to be attached.
A stack of containers each having the same construction is also contemplated. Advantageously, this stack provides for compact and efficient storage of a large number of containers in a minimal amount of space. In particular, using the features noted above and shown in the drawings, at least four, five, or even six entire containers can be received within the total height of a single container within the stack (i.e., with reference to Table 1, container received=I/L), so that the bottom of at least. Further, owing to the configuration of the various denesting features (e.g., specific and differentiated wall angles, denesting features, positioning of denesting features, etc.), an individual tray can be removed from the top or bottom of this stack without
Still other aspects of the invention are possible. Further reference to the foregoing description and the appended claims, in combination with the background information provided herein, help to elucidate these aspects. Unless otherwise noted, all reported values are in common units accepted in this field, with observations made at ambient conditions (e.g., room temperature and pressure, etc.).
Although the present embodiments have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the invention is not to be limited to just the embodiments disclosed, and numerous rearrangements, modifications and substitutions are also contemplated. The exemplary embodiment has been described with reference to the preferred embodiments, but further modifications and alterations encompass the preceding detailed description. These modifications and alterations also fall within the scope of the appended claims or the equivalents thereof.
