Tray For Food Products

Abstract

A tray for holding at least one food product includes a plurality of panels extending at least partially around an interior of the tray, the plurality of panels comprising a bottom panel, a front panel, a back panel, and at least one side panel, a plurality of end flaps foldably connected to a respective panel of the plurality of panels and cooperating to form a rim extending outwardly from the plurality of panels, and denesting features comprising at least one denesting tab extending into the interior of the tray.

Description

INCORPORATION BY REFERENCE

The disclosures of each of U.S. Provisional Patent Application No. 63/110,578, filed on Nov. 6, 2020, U.S. Provisional Patent Application No. 63/110,582, filed on Nov. 6, 2020, U.S. Provisional Patent Application No. 63/110,587, filed on Nov. 6, 2020, U.S. Provisional Patent Application No. 63/126,157, filed on Dec. 16, 2020, U.S. Provisional Patent Application No. 63/128,418, filed on Dec. 21, 2020, U.S. Provisional Patent Application No. 63/139,341, filed on Jan. 20, 2021, U.S. Provisional Patent Application No. 63/169,302, filed on Apr. 1, 2021, U.S. Provisional Patent Application No. 63/169,418, filed on Apr. 1, 2021, U.S. Provisional Patent Application No. 63/174,724, filed on Apr. 14, 2021, U.S. Provisional Patent Application No. 63/178,116, filed on Apr. 22, 2021, and U.S. Provisional Patent Application No. 63/191,412, filed on Jun. 1, 2021, are hereby incorporated by reference for all purposes as if presented herein in their entirety.

BACKGROUND OF THE DISCLOSURE

The present disclosure generally relates to trays for holding at least one food product.

SUMMARY OF THE DISCLOSURE

According to one aspect, the disclosure is generally directed to a tray for holding at least one food product, the tray comprising a plurality of panels extending at least partially around an interior of the tray, the plurality of panels comprising a bottom panel, a front panel, a back panel, and at least one side panel, a plurality of end flaps foldably connected to a respective panel of the plurality of panels and cooperating to form a rim extending outwardly from the plurality of panels, and denesting features comprising at least one denesting tab extending into the interior of the tray.

According to another aspect, the disclosure is generally directed to a blank for forming a tray for holding at least one food product, the blank comprising a plurality of panels comprising a bottom panel, a front panel, a back panel, and at least one side panel, a plurality of end flaps foldably connected to a respective panel of the plurality of panels, the plurality of end flaps for cooperating to form a rim extending outwardly from the plurality of panels when the tray is formed from the blank, and denesting features comprising at least one denesting tab, the at least one denesting tab for being positioned extending into the interior of the tray when the tray is formed from the blank.

According to another aspect, the disclosure is generally directed to a method of forming a tray for holding at least one food product, the method comprising obtaining a blank for forming a tray for holding at least one food product, the blank comprising a plurality of panels comprising a bottom panel, a front panel, a back panel, and at least one side panel, a plurality of end flaps foldably connected to a respective panel of the plurality of panels, and denesting features comprising at least one denesting tab, folding the plurality of panels at least partially around the interior of the tray, folding the plurality of end flaps for form a rim of the tray, and positioning the at least one denesting tab extending into the interior of the tray.

Those skilled in the art will appreciate the above-stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.

FIG. 1 is a plan view of an exterior surface of a blank used to form a tray according to a first exemplary embodiment of the disclosure.

FIG. 2 is a perspective view of a tray formed from the blank of FIG. 1 according to the first exemplary embodiment of the disclosure.

FIG. 3 is another perspective view of the tray of FIG. 2.

FIG. 4 is a top plan view of the tray of FIG. 2.

FIG. 5 is a perspective view of the tray of FIG. 2 at least partially nested in another tray with the configuration shown in FIG. 2.

FIG. 6 is a plan view of an exterior surface of a blank for forming a tray according to an alternative configuration of the first exemplary embodiment.

FIG. 7 is a plan view of an exterior surface of a blank used to form a tray according to a second exemplary embodiment of the disclosure.

FIG. 8 is a perspective view of a tray formed from the blank of FIG. 7 according to the second exemplary embodiment of the disclosure.

FIG. 9 is a perspective view of the tray of FIG. 8 at least partially nested in another tray with the configuration shown in FIG. 8.

Corresponding parts are designated by corresponding reference numbers throughout the drawings.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

Trays according to the present disclosure can accommodate articles of numerous different shapes. For the purpose of illustration and not for the purpose of limiting the scope of the disclosure, the following detailed description describes articles such as food products, e.g., fruit or vegetable items. In one embodiment, articles described herein can be fruits such as tomatoes (e.g., cherry tomatoes, etc.), berries (e.g., blueberries, raspberries, blackberries, strawberries, etc.), apples, oranges, tangerines, clementines, lemons, limes, cherries, etc. In another embodiment, articles described herein can be product packages, containers, bottles, cans, etc., that are at least partially disposed within the tray embodiments. The articles can be used for packaging food and beverage products, for example. Packaged articles can be made from materials suitable in composition for packaging the particular food or beverage item, and the materials include, but are not limited to, glass; aluminum and/or other metals; plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and Nylon; composite materials; and the like, or any combination thereof.

The articles described herein can include different types of food or beverage products, containers thereof, and/or having different shapes, without departing from the disclosure. In this specification, the terms “lower,” “bottom,” “upper,” and “top” indicate orientations determined in relation to fully erected and upright trays. As described herein, trays can be formed from blanks by overlapping multiple panels, portions, and/or end flaps. Such panels, portions and/or end flaps may be designated herein in terms relative to one another, e.g., “first”, “second”, “third”, etc., in sequential or non-sequential reference, without departing from the disclosure.

FIG. 1 is a plan view of an exterior surface 101 of a blank, generally indicated at 103, used to form a container assembly or tray 105 (FIG. 2) according to a first exemplary embodiment of the disclosure. In embodiments, the trays 105 described herein can have a generally square/rectangular tapered configuration with a flanged rim. It will be understood that the trays described herein can have a different configuration without departing from the disclosure, such as a carton or other construct.

As described further herein, the blank 103 can include engagement features for forming engagement features of the tray 105 that provide one or more surfaces for engaging a machine element or other component of a system associated with the formation, loading, and/or packaging of the tray 105. In addition, the engagement features of the blank 103/tray 105 provide one or more surfaces for receiving a covering or lidding film, e.g., a polymeric film or other cover overlying the tray 105 to maintain one or more conditions of food products held therein.

The blank 103 can also include reinforcement features for forming reinforcement features of the tray 105 that reinforce, e.g., rigidize, stabilize, and/or otherwise minimize, inhibit, prevent, and/or resist deformation of the engagement features. It will be understood that, in some embodiments, one or more of the reinforcement features of the blank 103/tray 105 can be considered part of the engagement features of the tray 105, or vice versa.

The blank 103 can further include denesting or spacing/separation features to minimize, inhibit, resist, and/or avoid an undesired degree of nesting or coupling between multiple trays 105 formed from the blank 103 in a stacked arrangement, and/or can facilitate separation of such trays 105 in a stacked arrangement.

As shown, the blank 103 has a longitudinal axis L1 and a lateral axis L2 and includes a plurality of panels for extending at least partially around an interior 107 of the tray 105 when the tray 105 is formed from the blank 103. The panels can include a bottom panel 121, a front panel 123 foldably connected to the bottom panel 121 at a lateral fold line 125, a back panel 127 foldably connected to the bottom panel 121 at a lateral fold line 129, a first side panel 131 foldably connected to the bottom panel 121 at a longitudinal fold line 133, and a second side panel 135 foldably connected to the bottom panel 121 at a longitudinal fold line 137.

The plurality of panels of the blank 103 can also include a plurality of end flaps foldably connected to respective panels of the plurality of panels of the blank 103. In the illustrated embodiment, the end flaps can include a side end flap 139 foldably connected to the front panel 123 at an oblique fold line 141 and a side end flap 143 foldably connected to the front panel 123 at an oblique fold line 145. Similarly, a side end flap 147 can be foldably connected to the back panel 127 at an oblique fold line 149, and a side end flap 151 can be foldably connected to the back panel 129 at an oblique fold line 153.

Respective reinforcement tabs 155, 157, 159, 161 can be foldably connected to the respective side end flaps 139, 143, 147, 151 at respective oblique fold lines 163, 165, 167, 169. As described further herein, the reinforcement tabs 155, 157, 159, 161 can be positioned to engage one or more of the engagement features of the tray 105 formed from the blank 103, such that at least the reinforcement tabs 155, 157, 159, 161 and associated features can be considered reinforcement features of the blank 103/tray 105.

With continued reference to FIG. 1, the end flaps can further include a front top end flap 171 foldably connected to the front panel 123 at a lateral fold line 173, and, similarly, a back top end flap 177 can be foldably connected to the back panel 127 at a lateral fold line 179.

In the illustrated embodiment, a front reinforcement flap 172 can be foldably connected to a portion of the front top end flap 171 at a lateral fold line 174, and a back reinforcement flap 176 can be foldably connected to a portion of the back top end flap 177 at a lateral fold line 178. While the reinforcement flaps 172, 176 are illustrated as having a generally rectangular arrangement foldably connected to a central portion of the respective top end flaps 171, 177, it will be understood that one or both of the reinforcement flaps 172, 176 can have a different configuration and/or arrangement without departing from the disclosure. As described further herein, the arrangement of the front reinforcement flap 172 and the back reinforcement flap 176 relative to the respective top end flaps 171, 177 is such to provide additional stiffness/rigidity to one or more portions of the tray 105. In this regard, the front reinforcement flap 172 and the back reinforcement flap 176 can additionally or alternatively be considered reinforcement features of the blank 103/tray 105.

Still referring to FIG. 1, a first side top end flap 181 can be foldably connected to the first side panel 131 at a longitudinal fold line 183, and a second side top end flap 185 can be foldably connected to the second side panel 135 at a longitudinal fold line 187.

The blank 103 can also include product visibility features for forming product visibility features of the tray 105. In the illustrated embodiment, at least partially curved and/or angled cuts 180 can be formed at least partially along respective portions of the front panel 123, the back panel 127, and the side panels 131, 135. The product visibility features can provide a customer with line-of-sight passages into the interior 107 of the tray 105, for example, to inspect food products held therein. In addition, one or more of the product visibility features can provide a path of egress for moisture, e.g., condensation, runoff, etc., to exit the interior 107 of the tray 105.

As shown, spacing/separating/denesting features of the blank 103/tray 105 can include a plurality of denesting tabs or denesting tabs 191 (broadly, “first denesting tab”, “second denesting tab”) extending from the respective panels 131, 135 into the interior 107 of the tray 105. In the illustrated arrangement, a pair of denesting tabs 191 can be foldably connected to the first side panel 131 at a respective pair of oblique fold lines 193, and a pair of denesting tabs 191 can be foldably connected to the second side panel 135 at a respective pair of the oblique fold lines 193. Each denesting tab 191 can be at least partially formed by a respective cut 195 in the respective panels 131, 135 intersecting respective endpoints of the respective fold lines 193 and respective portions of the front panel 123, the back panel 127, and the side end flaps 139, 143, 147, 151. It will be understood that one or more of the tabs 191, fold lines 193, and/or cuts 195 can have a different arrangement without departing from the disclosure.

In this regard, and as described further herein, the denesting tabs 191 are foldably movable away from the respective side panels 131, 135 to extend into the interior 107 of the tray 105 when the tray 105 is formed from the blank 103. It will be understood that a different number, arrangement, configuration of denesting tabs 191 and associated features can be provided without departing from the disclosure.

Referring to FIGS. 2-4, according to one embodiment of the disclosure, formation of the tray 105 from the blank 103 can be performed by inverting the blank 103 such that the exterior surface 101 is positioned on a supporting surface and such that the interior surface of the blank 103 can be positioned facing upwardly.

The front panel 123, the back panel 127, the first side panel 131, and the second side panel 135 can be folded upwardly relative to the bottom panel 121 at the respective fold lines 125, 129, 133, 137.

The side end flap 139 can be folded at the fold line 141 into at least partial face-to-face contact with the exterior surface of the first side panel 131 and the side end flap 143 can be folded at the fold line 145 into at least partial face-to-face contact with the exterior surface of the second side panel 135. Similarly, the side end flap 147 can be folded at the fold line 149 into at least partial face-to-face contact with the exterior surface of the first side panel 131 and the side end flap 151 can be folded at the fold line 153 into at least partial face-to-face contact with the exterior surface of the second side panel 135.

Simultaneously or thereafter, the denesting tabs 191 can be at least partially separated from the respective side panels 131, 135 at the respective cuts 195 and folded away from the respective side panels 131, 135 at the respective fold lines 193 to extend at least partially across the bottom panel 121 in the interior 107 of the tray 105. In one embodiment, one or more of the denesting tabs 191 can contact the bottom panel 121. In another embodiment, one or more of the denesting tabs 191 can be spaced at least partially above the bottom panel 121.

In the aforementioned arrangement, the reinforcement tabs 155, 159 can be positioned generally facing the top end flap 181 and the reinforcement tabs 157, 161 can be positioned generally facing the top end flap 185.

The front top end flap 171 can be folded downwardly at the fold line 173 to extend outwardly from the front panel 123, e.g., in a generally horizontal orientation parallel to the bottom panel 121. Similarly, the back top end flap 177 can be folded downwardly at the fold line 179 to extend outwardly from the back panel 127, the first side top end flap 181 can be folded downwardly at the fold line 183 to extend outwardly from the first side panel 131, and the second side top end flap 185 can be folded downwardly at the fold line 187 to extend outwardly from the second side panel 135.

In such an arrangement the top end flaps 181, 185 can be positioned overlapping, e.g., in at least partial face-to-face contact with, respective portions of the top end flaps 171, 177 to cooperate and form an upper rim/flange 189 of the tray 105. In one embodiment, longitudinally outer marginal portions of the top end flaps 181, 185 can overlap respective laterally outer marginal portions of the top end flaps 171, 177.

As shown, the aforementioned downward folding of the top end flap 181 at the fold line 183 can cause the reinforcement tabs 155, 159 to fold downwardly at the respective fold lines 163, 167 and the downward folding of the top end flap 185 at the fold line 187 can cause the reinforcement tabs 157, 161 to fold downwardly at the respective fold lines 165, 169. In such an arrangement, the reinforcement tabs 155, 159 can be positioned in at least partial face-to-face contact with the top end flap 181 and the reinforcement tabs 157, 161 can be positioned in at least partial face-to-face contact with the top end flap 185.

The positioning of the reinforcement tabs 155, 159 engaging the top end flap 181 and the positioning of the reinforcement tabs 157, 161 engaging the top end flap 185 is such that the reinforcement tabs 155, 157, 159, 161 can reinforce, e.g., brace, support, bolster, provide pressure points/backpressure, and/or otherwise maintain the configuration of the rim/flange 189 of the tray 105, for example, by minimizing, inhibiting, preventing, and/or otherwise resisting downward movement/deflection and/or deformation of the respective top end flaps 181, 185.

Simultaneously or thereafter, the front reinforcement flap 172 can be folded at the fold line 174 into at least partial face-to-face contact with the top end flap 171, and the back reinforcement flap 176 can be folded at the fold line 178 into at least partial face-to-face contact with the top end flap 177. The aforementioned arrangement of the reinforcement flaps 172, 176 overlying the respective top end flaps 171, 177 is such that a reinforced arrangement of the rim/flange 189 is provided by the two-ply layering of reinforcement flaps 172, 176 atop the respective top end flaps 171, 177.

In this regard, the arrangement of the reinforcement flaps 172, 176 overlying the respective top end flaps 171, 177 provides the rim/flange 189 with an increased capacity to minimize, inhibit, avoid, prevent, and/or otherwise resist bending, bowing, flexing, buckling, curling, deflection, and/or other deformation of the rim/flange 189.

The aforementioned arrangement of the tray 105 can be maintained with an adhesive such as glue. Such adhesion of the reinforcement tabs 155, 157, 159, 161 to the rim/flange 189 of the tray 105 can further reinforce the rim/flange 189 and tray 105. In one embodiment, the reinforcement flap 172 can be adhered to the top end flap 171, and the reinforcement flap 176 can be adhered to the top end flap 177.

In the illustrated embodiment of the tray 105, the panels 123, 127, 131, 135 can extend generally upwardly and obliquely outwardly from the bottom panel 121 such that the tray 105 has a generally tapered configuration, e.g., such that a top opening defined by the upper edges of the panels 123, 127, 131, 135 is larger than the bottom panel 121.

In this regard, and with additional reference to FIG. 5, the tray 105 can be provided with a configuration suitable for nesting with vertically adjacent trays 105, for example, to optimize space savings during transport and/or storage. In such nested arrangements, the denesting tabs 191 extending into the interior 107 of the tray 105 from the respective side walls 131, 135 can provide a suitable clearance between the panels of a tray 105 and another tray 105 at least partially nested therein, e.g., to minimize, inhibit, and/or prevent substantial face-to-face contact between the trays 105 that would tend to interfere with efficient and low-resistance separation thereof.

A shown in FIG. 5, a lower or receiving tray 105 can be positioned to at least partially receive an upper or nested tray 105 therein. In this regard, the upper tray 105 can be lowered into the interior 107 of the lower tray 105, and the positioning of the denesting tabs 191 in the interior 107 of the lower tray 105 is such to provide a stop/spacing between the bottom panel 121 of the upper tray 105 and the bottom panel 121 of the lower tray 105 to minimize, inhibit, resist, avoid and/or prevent unwanted coupling/connection between the trays 105 that would tend to resist the efficient and low-resistance separation thereof. In one embodiment, such spacing can be measured as a distance D between the rims 189 of the nested trays 105, and can be at least ⅜^th of an inch. The distance D can be a different distance without departing from the disclosure.

It will be understood that one or more food products can be dropped, placed, or otherwise positioned in the interior 107 of the tray 105 during or subsequent to the aforementioned steps. In one embodiment, the food products can be tomatoes, though one or more of the food products can be a different food product without departing from the disclosure. The tray 105 can be provided with one or more food products as a package.

Still referring to FIGS. 1-5, engagement features of the tray 105 include the arrangement of the top end flaps 171, 177, 181, 185 and the reinforcement flaps 172, 176, together or in subcombinations. As shown, the folded arrangement of the top end flaps 171, 177, 181, 185 and the reinforcement flaps 172, 176 extending outwardly from the respective panels forms the rim 189 and one or more engagement surfaces for being engaged/supported by an element associated with a forming apparatus for the tray 105, for example a machine element such as a grasper, fork, pincer, rail, etc. In one embodiment, the exterior (e.g., downward facing) surface of the top end flaps can present engagement surfaces for being engaged/supported by such a machine component. In other embodiments, engagement surfaces can include any combination of one or more of the exterior, interior (e.g., upward facing), and/or side-facing surfaces of one or more of the top end flaps 171, 177, 181, 185 and the reinforcement flaps 172, 176.

The positioning of the top end flaps 171, 177, 181, 185 and the reinforcement flaps 172, 176 extending away from the panels of the tray 105, also presents a plurality of engagement/support surfaces for engaging/supporting a covering or lidding film, e.g., a plastic or other polymeric film, or other covering structure. In one embodiment, the lidding film can be provided as a polymeric layer that at least partially deforms in the presence of a heat source, e.g., a heat sealable film. The lidding film can thus be positioned extending across a top opening of the tray 105 in contact with one or more surfaces of one or more of the top end flaps 171, 177, 181, 185 and one or more of the reinforcement flaps 172, 176 to cover the interior 107 of the tray 105 and maintain one or more conditions of the food products held therein, e.g., freshness, ripeness, moisture content, etc. It will be understood that the lidding film can minimize, inhibit, and/or prevent the passage of one or more materials into the interior 107 of the tray 105, for example, condensation or other moisture, insects or other pests, dirt, debris, etc. In one embodiment, the tray 105 can be provided together with the lidding film and one or more food products as a package.

Furthermore, the reinforcement features of the tray 105 can include at least the reinforcement tabs 155, 157, 159, 161, the positioning of which under and at least partially contacting the respective top end flaps 181, 185 can minimize, inhibit, avoid, prevent, and/or otherwise resist bending, bowing, flexing, buckling, curling, deflection, and/or other deformation of the rim/flange 189. The reinforcement features of the tray 105 can additionally include the overlapping arrangement of the reinforcement flaps 172, 176 with the respective top end flaps 171, 177. In this regard, forces exerted on the rim/flange 189 via tension applied through a covering or lidding film disposed thereon can minimize, inhibit, and/or prevent deformation of the rim/flange 189, e.g., to avoid undesirable product aesthetics, to avoid at least partial disengagement of the lidding film with the rim/flange 189, to maintain a generally planar configuration of the rim/flange 189 for stacking, storage, transport, etc. In this regard, the reinforcement flaps 172, 176 can be both engagement features and reinforcement features of the tray 105.

It will be understood that one or more of the panels, flaps, and associated features of the blank 103/tray 105 can have a different arrangement or configuration without departing from the disclosure.

For example, and with additional reference to FIG. 6, a blank for forming a tray according to an alternative configuration of the first exemplary embodiment is generally designated 103A. The blank 103A (and the resulting tray formed therefrom) can have one or more features similar to those described above with regard to the blank 103/tray 105 described above, and like or similar features are designated with like or similar reference numerals.

As shown, the blank 103A can be generally similar to the blank 103, but the reinforcement tabs 191 can have a different configuration (e.g., length and relative positioning with regard to the bottom panel 121). In addition, the blank 103A could be devoid of the reinforcement tabs 176, 178, though the tabs 176, 178 could be provided without departing from the disclosure.

Turning to FIG. 7, a plan view of an exterior surface 201 of a blank, generally indicated at 203, used to form a container assembly or tray 205 (FIG. 8) according to a second exemplary embodiment of the disclosure is illustrated.

The blank 203 and the tray 205 formed therefrom can have one or more features similar to those described above with regard to the blank 103, 103A and tray 105, and like or similar features are designated with like or similar reference numerals.

As shown, the blank 203 has the longitudinal axis L1 and the lateral axis L2, the bottom panel 121, the front panel 123, the back panel 127, the first side panel 131, the second side panel 135, the side end flap 139, the side end flap 143, the side end flap 147, the side end flap 151, the reinforcement tabs 155, 157, 159, 161 can be foldably connected to the respective side end flaps 139, 143, 147, 151, the front top end flap 171, the back top end flap 177, the first side top end flap 181, the second side top end flap 185, and associated features. The blank 203 can be devoid of the tabs 191 and the tabs 172, 176, though the blank 203 could be provided in a different configuration without departing from the disclosure.

As shown, spacing/separating/denesting features of the blank 203/tray 205 can include a pair of spacing or denesting tabs 291 at least partially formed by a pair of laterally spaced cuts 275 interrupting the fold line 173 such that the tabs 291 extend away from the top end flap 171 into the interior 207 of the tray 205. Similarly, pairs of spaced apart denesting tabs 291 can extend away from the respective top end flaps 177, 181, 185 into the interior of the tray 205 and are defined by respective cuts 275, 284 interrupting the respective fold lines 179, 183, 187.

Turning to FIG. 8, the tray 205 can be formed in a substantially similar manner to that described above with respect to the tray 105. Upon downward folding of the top end flaps 171, 177, 181, 185 at the respective fold lines 173, 179, 183, 187, the denesting tabs 291 can separate from the respective panels 123, 127, 131, 135 at the respective cuts 275, 284 to extend from the respective top end flaps 171, 177, 181, 185 toward/into the interior 207 of the tray 205. In this regard, the denesting tabs 291 can be coplanar with the remainder of the respective top end flaps 171, 177, 181, 185.

In this regard, and with additional reference to FIG. 6, the tray 205 can be provided with a configuration suitable for nesting with vertically adjacent trays 205, for example, to optimize space savings during transport and/or storage. In such nested arrangements, the denesting tabs 291 extending into the interior 107 of the tray 105 from the respective end flaps 171, 177, 181, 185 can provide a suitable clearance between the panels of a tray 205 and another tray 205 at least partially nested therein, e.g., to minimize, inhibit, and/or prevent substantial face-to-face contact between the trays 105 that would tend to interfere with efficient and low-resistance separation thereof, as described above with regard to the trays 105.

A shown in FIG. 9, a lower or receiving tray 205 can be positioned to at least partially receive an upper or nested tray 205 therein. In this regard, the upper tray 205 can be lowered into the interior 207 of the lower tray 205, and the positioning of the denesting tabs 291 extending toward the interior 207 of the lower tray 105 is such to engage the outer surface of respective panels 123, 137, 131, 135 to provide a stop/spacing between the bottom panel 121 of the upper tray 105 and the bottom panel 121 of the lower tray 205 to minimize, inhibit, resist, avoid and/or prevent unwanted coupling/connection between the trays 205 that would tend to resist the efficient and low-resistance separation thereof. In one embodiment, such spacing can be measured as a distance D between the rims 289 of the nested trays 205, and can be at least ⅜^th of an inch. The distance D can be a different distance without departing from the disclosure.

It will be understood that one or more food products can be dropped, placed, or otherwise positioned in the interior 207 of the tray 205 during or subsequent to the aforementioned steps. In one embodiment, the food products can be tomatoes, though one or more of the food products can be a different food product without departing from the disclosure. The tray 105 can be provided with one or more food products as a package. It will be further understood that a lidding film can be applied to the tray 205 as described above with regard to the tray 105.

In accordance with the foregoing, the engagement features of the tray 205 include the arrangement of the top end flaps 171, 177, 181, 185 and the reinforcement flaps 172, 176, together or in subcombinations, which presents a plurality of engagement/support surfaces for engaging/supporting a covering or lidding film and/or for engaging forming equipment/tools machinery associated with the tray 205.

Furthermore, the reinforcement features of the tray 205 can include at least the reinforcement tabs 155, 157, 159, 161, the positioning of which under and at least partially contacting the respective top end flaps 181, 185 can minimize, inhibit, avoid, prevent, and/or otherwise resist bending, bowing, flexing, buckling, curling, deflection, and/or other deformation of the rim/flange 289.

It will be understood that one or more of the panels, flaps, and associated features of the blank 203/tray 205 can have a different arrangement or configuration without departing from the disclosure.

The blanks according to the present disclosure can be, for example, formed from coated paperboard and similar materials. For example, the interior and/or exterior sides of the blanks can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blank. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. In accordance with the above-described embodiments, the blank may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the trays, to function at least generally as described above. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.

In accordance with the above-described embodiments of the present disclosure, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features.

As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the spaced apart slits to be replaced with a continuous slit, a continuous score, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure. Also, a tear line can be a series of cut scores passing completely, or partially, through the material, that are separated by nicks.

The term “glue” is intended to encompass all manner of adhesives commonly used to secure tray panels in place.

The foregoing description of the disclosure illustrates and describes various exemplary embodiments. Various additions, modifications, changes, etc., could be made to the exemplary embodiments without departing from the spirit and scope of the disclosure. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.

Claims

1. A tray for holding at least one food product, the tray comprising: a plurality of panels extending at least partially around an interior of the tray, the plurality of panels comprising a bottom panel, a front panel, a back panel, and at least one side panel;a plurality of end flaps foldably connected to a respective panel of the plurality of panels and cooperating to form a rim extending outwardly from the plurality of panels; anddenesting features comprising at least one denesting tab extending into the interior of the tray.

2. The tray of claim 1, wherein the at least one denesting tab is foldably connected to the at least one side panel.

3. The tray of claim 2, wherein the at least one denesting tab is spaced above the bottom panel.

4. The tray of claim 2, wherein the at least one denesting tab is at least partially formed by a cut in the at least one side panel.

5. The tray of claim 2, wherein the at least one denesting tab is a first denesting tab foldably connected to the at least one side panel, and the denesting features further comprise a second denesting tab foldably connected to the at least one side panel.

6. The tray of claim 5, wherein the at least one side panel is a first side panel and the plurality of panels further comprises a second side panel, and the denesting features further comprise a first denesting tab and a second denesting tab each foldably connected to the second side panel and extending into the interior of the tray.

7. The tray of claim 2, wherein the plurality of end flaps comprises a front top end flap foldably connected to the front panel, a back top end flap foldably connected to the back panel, and a side top end flap foldably connected to the at least one side panel, the side top end flap overlaps respective portions of the front top end flap and the back top end flap.

8. The tray of claim 7, further comprising a front reinforcement flap foldably connected to the front top end flap and at least partially overlapping the front top end flap for reinforcing the rim, the tray further comprising a back reinforcement flap foldably connected to the back top end flap and at least partially overlapping the back top end flap for reinforcing the rim.

9. The tray of claim 1, wherein the at least one denesting tab extends from at least one end flap of the plurality of end flaps.

10. The tray of claim 9, wherein the at least one denesting tab is coplanar with a remainder of the at least one end flap.

11. The tray of claim 9, wherein the at least one end flap is foldably connected to a respective panel of the plurality of panels at a fold line, the at least one denesting tab is at least partially formed by a cut interrupting the fold line.

12. The tray of claim 9, wherein the at least one denesting tab is a first denesting tab extending from the at least one end flap into the interior of the tray, and the denesting features further comprise a second denesting tab extending from the at least one end flap into the interior of the tray.

13. The tray of claim 9, wherein the at least one end flap of the plurality of end flaps is a front top end flap foldably connected to the front panel, the plurality of end flaps further comprises a back top end flap foldably connected to the back panel and a side top end flap foldably connected to the at least one side panel, and the denesting features further comprise at least one denesting tab extending from each of the back top end flap and the side top end flap into the interior of the tray.

14. A blank for forming a tray for holding at least one food product, the blank comprising: a plurality of panels comprising a bottom panel, a front panel, a back panel, and at least one side panel;a plurality of end flaps foldably connected to a respective panel of the plurality of panels, the plurality of end flaps for cooperating to form a rim extending outwardly from the plurality of panels when the tray is formed from the blank; anddenesting features comprising at least one denesting tab, the at least one denesting tab for being positioned extending into the interior of the tray when the tray is formed from the blank.

15. The blank of claim 14, wherein the at least one denesting tab is foldably connected to the at least one side panel.

16. The blank of claim 15, wherein the at least one denesting tab is at least partially formed by a cut in the at least one side panel.

17. The blank of claim 15, wherein the at least one denesting tab is a first denesting tab foldably connected to the at least one side panel, and the denesting features further comprise a second denesting tab foldably connected to the at least one side panel.

18. The blank of claim 17, wherein the at least one side panel is a first side panel and the plurality of panels further comprises a second side panel, and the denesting features further comprise a first denesting tab and a second denesting tab each foldably connected to the second side panel and for being positioned extending into the interior of the tray formed from the blank.

19. The blank of claim 15, wherein the plurality of end flaps comprises a front top end flap foldably connected to the front panel, a back top end flap foldably connected to the back panel, and a side top end flap foldably connected to the at least one side panel, the side top end flap for overlapping respective portions of the front top end flap and the back top end flap when the tray is formed from the blank.

20. The blank of claim 19, further comprising a front reinforcement flap foldably connected to the front top end flap and the tray further comprising a back reinforcement flap foldably connected to the back top end flap.

21. The blank of claim 14, wherein the at least one denesting tab extends from at least one end flap of the plurality of end flaps.

22. The blank of claim 21, wherein the at least one end flap is foldably connected to a respective panel of the plurality of panels at a fold line, the at least one denesting tab is at least partially formed by a cut interrupting the fold line.

23. The blank of claim 21, wherein the at least one denesting tab is a first denesting tab extending from the at least one end flap, and the denesting features further comprise a second denesting tab extending from the at least one end flap.

24. The blank of claim 21, wherein the at least one end flap of the plurality of end flaps is a front top end flap foldably connected to the front panel, the plurality of end flaps further comprises a back top end flap foldably connected to the back panel and a side top end flap foldably connected to the at least one side panel, and the denesting features further comprise at least one denesting tab extending from each of the back top end flap and the side top end flap.

25. A method of forming a tray for holding at least one food product, the method comprising: obtaining a blank for forming a tray for holding at least one food product, the blank comprising a plurality of panels comprising a bottom panel, a front panel, a back panel, and at least one side panel, a plurality of end flaps foldably connected to a respective panel of the plurality of panels, and denesting features comprising at least one denesting tab;folding the plurality of panels at least partially around the interior of the tray;folding the plurality of end flaps for form a rim of the tray;positioning the at least one denesting tab extending into the interior of the tray.

26. The method of claim 25, wherein the at least one denesting tab is foldably connected to the at least one side panel.

27. The method of claim 26, wherein the at least one denesting tab is spaced above the bottom panel.

28. The method of claim 26, wherein the at least one denesting tab is at least partially formed by a cut in the at least one side panel.

29. The method of claim 26, wherein the at least one denesting tab is a first denesting tab foldably connected to the at least one side panel, and the denesting features further comprise a second denesting tab foldably connected to the at least one side panel.

30. The method of claim 29, wherein the at least one side panel is a first side panel and the plurality of panels further comprises a second side panel, and the denesting features further comprise a first denesting tab and a second denesting tab each foldably connected to the second side panel, the method further comprises positioning the first denesting tab and the second denesting tab extending into the interior of the tray.

31. The method of claim 26, wherein the plurality of end flaps comprises a front top end flap foldably connected to the front panel, a back top end flap foldably connected to the back panel, and a side top end flap foldably connected to the at least one side panel, the folding the plurality of end flaps comprises positioning the side top end flap overlapping respective portions of the front top end flap and the back top end flap.

32. The method of claim 31, further comprising a reinforcement flap foldably connected to the front top end flap and a back reinforcement flap foldably connected to the back top end flap, the method further comprising positioning the front reinforcement flap at least partially overlapping the front top end flap and positioning the back reinforcement flap at least partially overlapping the back top end flap for reinforcing the rim.

33. The method of claim 25, wherein the at least one denesting tab extends from at least one end flap of the plurality of end flaps.

34. The method of claim 33, wherein the at least one denesting tab is positioned coplanar with a remainder of the at least one end flap.

35. The method of claim 33, wherein the at least one end flap is foldably connected to a respective panel of the plurality of panels at a fold line, the at least one denesting tab is at least partially formed by a cut interrupting the fold line.

36. The method of claim 33, wherein the at least one denesting tab is a first denesting tab extending from the at least one end flap into the interior of the tray, and the denesting features further comprise a second denesting tab extending from the at least one end flap into the interior of the tray.

37. The method of claim 33, wherein the at least one end flap of the plurality of end flaps is a front top end flap foldably connected to the front panel, the plurality of end flaps further comprises a back top end flap foldably connected to the back panel and a side top end flap foldably connected to the at least one side panel, and the denesting features further comprise at least one denesting tab extending from each of the back top end flap and the side top end flap positioned extending into the interior of the tray.