The present disclosure relates generally to packages, and more particularly to standing packages including a tray and methods of manufacturing and using the same. The tray can include a central portion disposed between a plurality of walls and first and second legs.
The written disclosure herein describes illustrative embodiments that are non-limiting and non-exhaustive. Reference is made to certain of such illustrative embodiments that are depicted in the figures, in which:
Embodiments of the disclosure may be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood that the components of the present disclosure, as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments is not intended to limit the scope of the disclosure, but is merely representative of possible embodiments of the disclosure. In some cases, well-known structures, materials, or operations are not shown or described in detail. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.
The tray 110 can include a first wall 112 (or first lateral wall) and a second wall 116 (or second lateral wall). As shown, the first wall 112 can be disposed opposite of the second wall 114 relative to the tray 110. The tray 110 can also include a third wall 120 (or top wall) extending between a first end 113 of the first wall 112 and a first end 117 of the second wall 116. Furthermore, a fourth wall 124 (or bottom wall) can extend between a second end 114 of the first wall 112 and a second end 118 of the second wall 116. As depicted, the third wall 120 can be disposed opposite of the fourth wall 124 relative to the tray 110. Directional terms, such as “front,” “rear,” “top,” “bottom,” etc., are used herein with respect to the orientation shown, for example, in
The tray 110 can include a central portion 128 that is disposed between each of the first, second, third, and fourth walls 112, 116, 120, 124. The tray 110 can also include a first leg 132 and a second leg 136. As depicted, the tray 110 can include the first leg 132 disposed at or adjacent a junction of the first and fourth walls 112, 124 and the second leg 136 disposed at or adjacent a junction of the second and fourth walls 116, 124. In some embodiments, the first leg 132 may be disposed at or adjacent the fourth wall 124 and offset from the first wall 112. Likewise, the second leg 136 may be disposed at or adjacent the fourth wall 124 and offset from the second wall 116.
Furthermore, the first and second legs 132, 136 can protrude away from a plane formed by the central portion 128 (see, e.g., plane P1 of
With continued reference to
In some embodiments, a distance between the third wall 120 and the fourth wall 124 (i.e., the height of the package 100 not including the rim 140) may be between about 75 mm and about 150 mm, between about 85 mm and about 140 mm, between about 95 mm and about 130 mm, between about 105 mm and about 120 mm, about 115 mm, or another suitable distance. Other heights of the package 100 may also be within the scope of this disclosure. In certain embodiments, a distance between the first wall 112 and the second wall 116 (i.e., the width of the package 100 not including the rim 140) may be between about 150 mm and about 350 mm, between about 200 mm and about 300 mm, between about 225 mm and about 275 mm, about 250 mm, or another suitable distance. Other widths of the package 100 may also be within the scope of this disclosure.
In various embodiments, the width of the rim 140 (i.e., a distance between the first edges and an outside edge of the rim 140) may be between about 4 mm and about 12 mm, between about 6 mm and about 10 mm, between about 7 mm and about 9 mm, or about 8 mm. Other widths of the rim 140 may also be within the scope of this disclosure. In other embodiments, a distance (see distance D132 in
As discussed above, the package 100 or tray 110 may be configured to stand upright (i.e., in the standing or upright configuration). In other words, the package 100 or tray 110 may be capable of standing on its own. The package 100 or tray 110 may also be substantially capable of maintaining its structural conformation. In certain embodiments, a portion of the rim 140 and portions of the first and second legs 132, 136 of the package 100 or tray 110 may serve as a base on which the package 100 or tray 110 rests. In some embodiments, the first and second legs 132, 136 and/or the rim 140 can be configured such that they assist in disposing the package 100 in the standing configuration as illustrated in
The components of the tray 110 (e.g., the first, second, third, and fourth walls 112, 116, 120, 124; the first and second legs 132, 136; and the rim 140) can be formed from a unitary piece of material. For example, the first and second legs 132, 136 can be integral with the tray 110. In some other embodiments, one or more of the components of the tray 110 may be formed from discrete pieces of material. As such, the separate components of the tray 110 may be bonded or coupled to each other to form the tray 110.
The tray 110 may be semirigid. In other words, the tray 110 may be formed from a material that is semirigid (e.g., the material may be stiff and/or stable but the material may also be flexible). In some embodiments, the tray 110 may be rigid. In some other embodiments, the tray 110 may be flexible.
In some embodiments, the tray 110 may be formed from a polymer web including a multi-layer film. The multi-layer film may include at least a first layer and a second layer. The first layer may be coupled (e.g., laminated to or coextruded with) the second layer. The first layer may include polyester, polypropylene, polystyrene (such as high-impact polystyrene (HIPS)), or combinations thereof. Other suitable materials are also within the scope of this disclosure. Additionally, a thickness of the first layer may be between about 10 mils and about 40 mils, between about 12 mils and about 25 mils, between about 14 mils and about 30 mils, between about 16 mils and about 24 mils, or another suitable thickness. The second layer may include ethylene vinyl alcohol (EVOH), polyamide (nylon), polyethylene, polyolefin, amorphous polyester (APET), ionomer, or combinations thereof. The EVOH may be a barrier layer. Other suitable materials are also within the scope of this disclosure. Additionally, a thickness of the second layer may be between about 1 mil and about 5 mils, between about 1.5 mils and about 4 mils, between about 2 mils and about 3 mils, or another suitable thickness. In certain embodiments, the tray 110 may be formed from a single-layer film. The single-layer film may include APET, polystyrene (e.g., HIPS), polypropylene, or polyester. The first and/or the second layers of the tray 110 may be multi-layer films or structures including any of the above-identified components.
The lid 105 may be flexible. In other words, the lid may be formed from a material that is flexible. In some embodiments, the lid 105 may be semirigid or rigid. For example, the lid may be a snap-on lid. In other embodiments, the package 100 may include a first lid (e.g., a first flexible lid coupled to the tray) and a second lid (e.g., a second semirigid or rigid lid that is a snap-on lid). The second lid may be couplable to the tray over or around the first lid such that the first lid is disposed between the tray and the second lid when the first and second lids are coupled to the tray. The lid 105 may be releasably coupled to the tray 110 along at least a portion of the rim 140 (e.g., via a peelable seal). In some embodiments, the lid 105 may be a single-use lid. In some other embodiments, the lid 105 may be a multiple-use lid. For example, the lid 105 may be resealable to the tray. In other words, the package 100 may be configured such that a user can remove at least a portion of the lid 105 from the tray 110 (e.g., to access the contents of the package 100) and then the user may recouple or reseal the lid 105 to the tray 110 (e.g., such that the remaining contents of the package 100 may be kept fresh). A seal may be disposed between the lid 105 and the tray 110. The seal may or may not be airtight, liquid-tight, and/or hermetic.
In certain embodiments, the lid 105 may be formed from a polymer web including a multi-layer film. In certain other embodiments, the lid 105 may be formed from a single-layer film. The multi-layer film may include at least a first layer and a second layer. The first layer may be coupled (e.g., laminated to or coextruded with) the second layer. The first layer may include polyester, polypropylene (e.g., oriented polypropylene), polyamide (nylon (e.g., biaxially-oriented nylon)), or combinations thereof. Other suitable materials are also within the scope of this disclosure. A thickness of the first layer may be between about between about 20 gauge and about 200 gauge, between about 32 gauge and about 175 gauge, between about 36 gauge and about 150 gauge, between about 40 gauge and about 120 gauge, between about 40 gauge and about 48 gauge, or another suitable thickness. The second layer may include EVOH (e.g., a barrier layer), polyamide, an adhesive layer, ionomer, APET, polyolefin, polyethylene, or combinations thereof. Other suitable materials are also within the scope of this disclosure. A thickness of the second layer may be between about 1 mil and about 5 mils, between about 1.5 mils and about 4.5 mils, between about 2 mils and about 4 mils, between about 2 mils and about 3 mils, or another suitable thickness. The first and/or the second layers of the lid 105 may be multi-layer films or structures including any of the above-identified components.
In an exemplary embodiment, the multi-layer film forming the lid 105 may include a polyethylene terephthalate (PET) layer, a tie layer, an EVOH layer, a tie layer, a polyethylene (PE) layer, a hot melt adhesive layer, and a sealant layer (e.g., a second PE layer). To form a seal, an outer PE layer of the multi-layer film forming the lid 105 may be bonded or coupled to a PE layer disposed on an outer surface of the multi-layer film forming the tray 110. A hot melt adhesive layer of the multi-layer film forming the lid 105 may allow or permit the lid 105 to be resealed to the tray 110. Multi-layer films including more or fewer layers may also be used to form the lid 105 or the tray 110. In another exemplary embodiment, the polymer web forming the lid 105 may have a thickness of between about 1 mil and about 7 mils, between about 2 mils and about 5 mils, between about 3 mils and about 4 mils, or about 3.75 mils. Other suitable materials, layers, or thicknesses may also be used.
In some embodiments, at least a portion of the tray 110 and/or the lid 105 may be clear. In some other embodiments, at least a portion of the tray 110 and/or the lid 105 may be tinted (e.g., the tray 110 may be tinted black). Furthermore, at least a portion of the tray 110 and/or the lid 105 may include a matte finish or a shiny/glossy finish. One or more labels or indicia may be disposed on at least a portion of the tray 110 and/or the lid 105.
The first leg 132 can be disposed at or adjacent a first corner 152 formed by the plurality of walls (i.e., by the first and fourth walls 112, 124). The second leg 136 can be disposed at or adjacent a second corner 154 formed by the plurality of walls (i.e., by the second and fourth walls 116, 124). The first and second legs 132, 136 can extend away from the central portion 128 of the cavity 144 relative to the plane formed by the rim 140.
As depicted, the cavity 144 (and/or the tray 110) can be substantially rectangular. In some embodiments, the shape of the cavity 144 (and/or the tray 110) can be substantially oval, substantially circular, substantially square, or substantially triangular. Any other suitable shape can also be used. For example, the shape of the cavity 144 (and/or the tray 110) can be irregular (i.e., not a traditionally defined shape). A zone 156 may be disposed or present between each of the first and second legs 132, 136 along at least a portion of the fourth wall 124. As illustrated, the zone 156 can have a length such that at least a portion of the central portion 128 of the cavity 144 can be disposed between each of the first leg 132 and the second leg 136. The distance between the plane formed by the inside surface of the central portion 128 and the plane formed by the rim 140 at a position at or adjacent the third wall 120 may be substantially equal to the distance between the plane formed by the inside surface of the central portion 128 and the plane formed by the rim 140 at a position at or adjacent the fourth wall 124 (e.g., at a position in the zone 156 between the first and second legs 132, 136). Stated another way, the cavity 144 can have a constant or substantially constant depth from the third wall 120 to the fourth wall 124 of the tray 110.
In some embodiments, the thickness of the multi-layer film forming the tray 110 may depend on the depth of the cavity 144 and/or the depth of the first and second legs 132, 136. For example, the greater the depth of the cavity 144, the greater the thickness of the multi-layer film forming the tray 110. The thickness of the multi-layer film forming the tray 110 may be between about 5 mils and about 50 mils, between about 10 mils and about 40 mils, between about 12 mils and about 30 mils, between about 15 mils and about 25 mils, about 24 mils, or another suitable thickness.
As shown, a distance between an inside surface of the first leg 132 and the plane P2 formed by the rim 140 can be greater than the distance D1 between the plane P1 formed by an inside surface of the central portion 128 and the plane P2 formed by the rim 140. Likewise, a distance between an inside surface of the second leg 136 and the plane P2 formed by the rim 140 can be greater than the distance D1 between the plane P1 formed by an inside surface of the central portion 128 and the plane P2 formed by the rim 140.
With reference to
Likewise, the second leg 136 can extend between a position along the fourth wall 124 and a position 148b distal of a median M116 of the second wall 116 relative to the fourth wall 124. Additionally, the second leg 136 can extend distally away from the plane P1 formed by an inside surface of the central portion 128 relative to the plane P2 formed by the rim 140 at a second angle such that a distance of a portion of an inside surface of the second leg 136 at or adjacent the fourth wall 124 relative to the plane P2 formed by the rim 140 may be greater than a distance of a portion of the inside surface of the second leg 136 at or adjacent the position 148b distal of the median M116 of the second wall 116.
With reference to
The first and second legs 132, 136 can be shorter, taller, wider, or deeper than what is depicted in
Due at least in part to the substantially constant height of the cavity 144 between the third wall 120 and the fourth wall 124 of the tray 110, the food product 2 can be disposed along substantially the entire height of the tray 110. For example, placement of the food product 2 in the cavity 144 can be maintained between the third and fourth walls 120, 124 of the tray 110 (e.g., due at least in part to a vacuum formed in the cavity 144 as described below).
The depth of the first and second legs 132, 136 can be varied according to the height of the package 100 and/or the center of gravity of the package 100. For example, a package having a greater height may include first and second legs having greater depths. Furthermore, the shape and/or the packing arrangement (e.g., the placement) of the food product 2 may affect the center of gravity of the package 100. For example, if the food product 2 is packed at or adjacent a lower portion of the package 100 and/or the tray 110 (i.e., when the package 100 and/or the tray 110 is in the standing configuration) the depth of the first and second legs 132, 136 may be less than in a package and/or a tray wherein the food product in packed at or adjacent an upper portion of the package and/or the tray.
As shown, the package 200 can include a tray 210. The tray 210 can include a central portion 228 that is disposed between each of first, second, third, and fourth walls 212, 216, 220, 224. The tray 210 can also include a first leg 232 disposed at or adjacent a junction of the first and fourth walls 212, 224 and a second leg 236 disposed at or adjacent a junction of the second and fourth walls 216, 224. The tray 210 can also include one or more ridges 246 (or ribs). The ridges 246 may extend from a plane formed by the central portion 228 toward a plane formed by a rim 240 of the tray 210. Furthermore, the ridges 246 may extend (e.g., longitudinally) between each of the first wall 212 and the second wall 216 or between each of the first leg 232 and the second leg 234.
In some embodiments, the tray 210 may include five ridges 246. In some other embodiments, the tray 210 may include one, two, three, four, six, seven, eight, nine, ten, or more ridges 246. Other suitable numbers of ridges 246 are also within the scope of this disclosure. As depicted, the ridges 246 can be elongate and substantially parallel to each other. In certain embodiments, the ridges 246 may be wavy, scalloped, or resemble a dashed line. Other shapes and/or patterns of the ridges 246 are also within the scope of this disclosure. The one or more ridges 246 may be configured to engage with a food product that is disposed within a cavity 244 of the tray 210. For example, when the tray 210 is in a standing configuration as depicted, the one or more ridges 246 may engage at least a portion of the food product such that the food product does not migrate or slide down toward a lower portion of the tray 210 (e.g., due to gravity). In certain embodiments, the one or more ridges 246 may be configured to collect or hold grease or oil that may be released by a food product that is disposed within the package 200.
Methods of assembling, forming, or manufacturing a tray as disclosed herein (e.g., trays 110, 210) are also provided herein. In some embodiments, the method of manufacturing the tray can include disposing a polymer web on a mold. A contour or shape of the mold can include first, second, third, and fourth walls as described above. The contour of the mold can also include a central portion disposed between each of the first, second, third, and fourth walls. Furthermore, the contour of the mold can include a first leg disposed at or adjacent a junction of the first and fourth walls and a second leg disposed at or adjacent a junction of the second and fourth walls. The contour of the mold can conform to any of the components of the trays 110, 210 as described above (e.g., the contour may include a rim, ridges, etc.). The method of manufacturing the tray can further include conforming the polymer web to at least a portion of the contour of the mold. The polymer web may then be removed from the mold. The polymer web may include a multi-layer film as discussed above.
Methods of loading a package as disclosed herein (e.g., packages 100, 200) are also provided herein. In some embodiments, the method of loading the package can include placing a food product (e.g., meat, cheese, etc.) in a cavity of a tray. A lid may then be coupled or sealed to the tray. For example, the lid may be coupled to a rim of the tray. The method of loading the package may also include forming a vacuum in the cavity. In some embodiments, the vacuum within the cavity may be between about 999 mBar and about 500 mBar, between about 980 mBar and about 750 mBar, about 960 mBar, or another suitable value. Upon formation of the vacuum, a central portion of the tray may exert a first force on a first surface of the food product and the lid may exert a second force on a second surface of the food product. In some embodiments, the first force may be in a first direction and the second force may be in a second direction, wherein the first direction may be substantially opposite of the second direction. The first and second forces on the food product may maintain or partially maintain the position or placement of the food product within the package, for example, when the package is in a standing configuration. In embodiments wherein the central portion includes one or more ridges, the ridges may also aid in maintaining the position of the food product within the package in combination with the forces provided by the vacuum seal in the cavity.
As can be appreciated, the package can be shorter, taller, narrower, or wider than what is depicted in
Any methods disclosed herein include one or more steps or actions for performing the described method. The method steps and/or actions may be interchanged with one another. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order and/or use of specific steps and/or actions may be modified.
References to approximations are made throughout this specification, such as by use of one or more of the terms “about,” “approximately,” “substantially,” and “generally.” For each such reference, it is to be understood that, in some embodiments, the value, feature, or characteristic may be specified without approximation. For example, where such a qualifier is used, the term includes within its scope the qualified word in the absence of the qualifier.
Reference throughout this specification to “an embodiment” or “the embodiment” means that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the quoted phrases, or variations thereof, as recited throughout this specification are not necessarily all referring to the same embodiment. Similarly, it should be appreciated that in the above description of embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any embodiment requires every feature shown in a particular drawing.
Unless otherwise noted, the terms “a” or “an” are to be construed as meaning “at least one of.” In addition, for ease of use, the words “including” and “having” are interchangeable with and have the same meaning as the word “comprising.” Recitation of the term “first” with respect to a feature or element does not necessarily imply the existence of a second or additional such feature or element.
The claims following this written disclosure are hereby expressly incorporated into the present written disclosure, with each claim standing on its own as a separate embodiment. This disclosure includes all permutations of the independent claims with their dependent claims. Moreover, additional embodiments capable of derivation from the independent and dependent claims that follow are also expressly incorporated into the present written description.
Without further elaboration, it is believed that one skilled in the art can use the preceding description to utilize the invention to its fullest extent. The claims and embodiments disclosed herein are to be construed as merely illustrative and exemplary, and not a limitation of the scope of the present disclosure in any way. It will be apparent to those having ordinary skill in the art, with the aid of the present disclosure, that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the disclosure herein. In other words, various modifications and improvements of the embodiments specifically disclosed in the description above are within the scope of the appended claims. The scope of the invention is therefore defined by the following claims and their equivalents.
Number | Date | Country | |
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62628883 | Feb 2018 | US |