U.S. patent application number 10/543551 was filed with the patent office on 2006-12-14 for food preparation and distribution tray.
Invention is credited to Tony Christophersen, Ronald Geoffrey Hamblin.
Application Number | 20060278559 10/543551 |
Document ID | / |
Family ID | 30005087 |
Filed Date | 2006-12-14 |
United States Patent
Application |
20060278559 |
Kind Code |
A1 |
Hamblin; Ronald Geoffrey ;
et al. |
December 14, 2006 |
Food preparation and distribution tray
Abstract
A food preparation and distribution tray is disclosed. The tray
is adapted to receive and support cups, such as paper "patty" cups,
for preparing food products. The tray has a plurality of openings
for receiving cups. The tray also includes a support means for
supporting the sides of the cups at two or more heights of the
cups. The sides of the cups are not otherwise supported. In use,
the cups are positioned in the openings and the sides are supported
at two or more heights of the cups by the support means. The
support means may, in effect, suspend the cups above a base of the
tray. Alternatively, the tray may be formed so that the cups are
supported by the tray base and the support means.
Inventors: |
Hamblin; Ronald Geoffrey;
(Willoughby, AU) ; Christophersen; Tony; (Chelmer,
AU) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Family ID: |
30005087 |
Appl. No.: |
10/543551 |
Filed: |
January 30, 2004 |
PCT Filed: |
January 30, 2004 |
PCT NO: |
PCT/AU04/00106 |
371 Date: |
May 11, 2006 |
Current U.S.
Class: |
206/562 |
Current CPC
Class: |
B65D 71/72 20130101 |
Class at
Publication: |
206/562 |
International
Class: |
B65D 6/04 20060101
B65D006/04 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 30, 2003 |
AU |
2003900386 |
Claims
1. A food preparation and distribution tray for receiving and
supporting cups, such as paper "patty" cups, for preparing food
products, which tray includes a means for supporting the sides of a
plurality of food preparation cups at two or more spaced-apart
heights of the cups.
2. The tray defined in claim 1 wherein the support means for the
sides of the cups includes an upper wall and a lower wall of the
tray, with the walls having aligned openings for receiving the
plurality of cups and supporting the sides of the cups at two or
more heights of the cups.
3. The tray defined in claim 1 wherein the upper wall is adapted to
support the cups at a position that is 2/3 of the height of the
cups.
4. The tray defined in claim 1 wherein the lower wall is adapted to
support the cups at a position that is 1/3 of the height of the
cups.
5. The tray defined in claim 1 wherein the cups include an open top
end, a base, and downwardly and inwardly tapering sides and the
openings in the upper wall are larger than the openings in the
lower wall.
6. The tray defined in claim 1 is a box-type construction.
7. The tray defined in claim 6 wherein the upper wall forms an
upper wall of the box.
8. The tray defined in claim 6 wherein lower wall forms a lower
wall of the box.
9. The tray defined in claim 6 includes a base wall that forms a
base wall of the box and the lower wall is parallel to and between
the upper and base walls.
10. The tray defined in claim 1 includes side walls.
11. The tray defined claim 10 wherein at least one of the side
walls includes openings to allow hot air to circulate into and from
the tray to facilitate baking of products in the cups.
12. The tray defined claim 1 includes end walls.
13. The tray defined claim 10 wherein at least one of the end walls
includes openings to allow air to circulate into and from the tray
to facilitate baking of products in the cups.
14. The tray defined in claim 1 includes downwardly depending legs
to space the lower wall of the tray above a base surface.
15. The tray defined in claim 14 wherein one of the legs is a
downward extension of one of the side walls.
16. The tray defined in claim 1 includes internal partitions that
space apart the upper and lower walls.
17. A carton board preform for forming the tray defined in claim 1
includes (a) a sleeve having a plurality of panels that form at
least the upper, lower, and side walls of the tray and (b) flaps
extending from the ends of the sleeve that form the end walls of
the tray.
18. The preform defined in claim 17 wherein the preform is
manufactured in a flat form to facilitate packaging and
transportation of the preform and can be erected into the tray as
required.
19. The preform defined in claim 17 wherein the flaps include
locking tabs that can engage the upper, lower, and side walls or
are otherwise formed to form the end walls of the tray.
20. The preform defined in claim 17 wherein the panels of the
sleeve include a panel that forms the base wall of the tray.
21. A food preparation and distribution tray for receiving and
supporting cups, such as paper "patty" cups, for preparing food
products, which tray includes a means for supporting the sides a
plurality of food preparation cups at least one height of the
cups.
22. A food preparation and distribution tray assembly for preparing
food products, includes: (a) a tray that includes a base wall, at
least one wall positioned above the base wall and having a
plurality of openings for receiving and supporting the side of a
plurality of food preparation cups, and (b) a plurality of empty
cups located in the openings in the wall of the tray and supported
by upper wall ready for food preparation in the tray.
23. The tray assembly defined in claim 21 includes an upper wall
and a lower wall positioned above the base wall with the upper and
lower walls having aligned openings receiving and supporting the
plurality of food preparation cups.
Description
[0001] The present invention relates to a food preparation and
distribution tray.
[0002] The present invention relates particularly, although by no
means exclusively, to a food preparation and distribution tray for
baked products such as muffins, cakes, scones and other such
products that are made by depositing a product mixture into "cups",
such as paper "patty" cups and baking the products in an oven.
[0003] The present invention relates particularly, although by no
means exclusively, to a baking tray that is suited to the
manufacture of large and small numbers of such products in
commercial operations.
[0004] The present invention relates particularly, although by no
means exclusively, to a baking tray that can be manufactured from
carton board using conventional in-line cutting, folding and gluing
machinery.
[0005] The food preparation and distribution tray of the present
invention is not confined to use in food baking applications and
can be used in other applications. One such application is the
preparation and distribution of cold-set desserts.
[0006] A widespread current practice for baking muffins (and other
such "batter"-based products) in commercial operations involves
depositing muffin mixture in cup-shaped moulds of metal baking
trays and baking the muffins in an oven, allowing the muffins to
cool in the baking trays, removing the cooled muffins from the
baking trays, and packaging the muffins in suitable packaging for
distribution to commercial outlets. The baking trays are cleaned
and re-used to produce more muffins.
[0007] There are a number of problems associated with the
above-described practice.
[0008] One problem is that the cleaning process involves the use of
a considerable amount of detergent for large volume production
runs. There are environmental and cost issues associated with the
use of detergents.
[0009] Another problem is that there is a significant amount of
labour-intensive product double handling associated with removing
muffins from metal baking trays and packaging the muffins for
distribution to commercial outlets. In addition to being labour
intensive, inevitably, there is a risk of damaging the muffins in
the process of carrying out this packaging step. Product damage to
consumable products such as muffins is a serious issue from a
commercial viewpoint.
[0010] The present invention provides an alternative baking
tray.
[0011] In general terms, the food preparation and distribution tray
of the present invention is adapted to receive and support cups,
such as paper "patty" cups, for preparing food products. The tray
has a plurality of openings for receiving cups. The tray also
includes and is characterised by a support means for supporting the
sides of the cups at two or more spaced-apart heights of the cups.
The sides of the cups are not otherwise supported. In use, the cups
are positioned in the openings and the sides are supported at two
or more heights of the cups by the support means. The support means
may, in effect, suspend the cups above a base of the tray.
Alternatively, the tray may be formed so that the cups are
supported by the tray base and the support means.
[0012] According to the present invention there is provided a food
preparation and distribution tray for receiving and supporting
cups, such as paper "patty" cups, for preparing food products,
which tray includes a plurality of openings for receiving cups and
a means for supporting the sides of the cups at two or more
spaced-apart heights of the cups.
[0013] The food products may include products such as muffins,
cakes, scones and other such products that are baked in an oven.
The food products may include products non-baked food products such
as cold desserts.
[0014] The above described tray has a number of important
advantages over other trays known to the applicant.
[0015] One advantage is a result of being able to support the sides
of cups at two or more spaced-apart cup heights. Supporting the
sides of cups at two different cup heights prevents outward bulging
of the cups as products bake (and thereby expand) in the cups. This
is an advantage because outward bulging can hinder the removal of
cups containing baked products in the cups from baking trays, and
can result in damage to the products in the course of removing the
products from trays. It is also an advantage because outward
bulging can detract from the overall appearance and therefore
commercial value of the products.
[0016] Another advantage is that the tray can be used as part of
the packaging of baked products for distributing the products from
a manufacturing operation to commercial outlets. This an important
advantage over the current practice of baking products (such as
muffins) in metal baking trays, removing the baked products from
the metal baking trays, and packaging the baked products in
separate packaging for distribution to commercial outlets.
[0017] A further advantage, which is related to the previous
advantage, is that the tray can be used to display the food
products at commercial outlets, thereby avoiding handling of the
products at the commercial outlets.
[0018] A further advantage is that the tray can be reused to
prepare further products. This is an important advantage in
situations where re-packaging of baked) or cold-set) products is
necessary--for example to meet orders for products that require
fewer than the number of products in the trays.
[0019] Preferably the support means for the sides of the cups
includes an upper wall and a lower wall of the tray, with the walls
having aligned openings that define the tray openings for receiving
the plurality of cups and supporting the sides of the cups at two
or more heights of the cups.
[0020] Preferably the upper and lower walls are parallel.
[0021] The tray may include more than two walls with aligned
cup-supporting openings. However, it is believed that two
appropriately positioned walls should provide sufficient support in
most situations.
[0022] Preferably the upper wall is adapted to support the cups at
a position that is 2/3 of the height of the cups.
[0023] Preferably the lower wall is adapted to support the cups at
a position that is 1/3 of the height of the cups.
[0024] Preferably the cups include an open top end, a base, and
downwardly and inwardly tapering sides. The sides of the cups may
be corrugated.
[0025] With this arrangement, preferably the openings in the upper
wall are larger than the openings in the lower wall.
[0026] Preferably the tray is a box-type construction.
[0027] Preferably the upper wall forms an upper wall of the
box.
[0028] The lower wall may form a lower wall of the box.
[0029] In an alternative, although not the only other possible
alternative, the tray includes a base wall that forms a base wall
of the box and the lower wall is positioned between the upper and
base walls.
[0030] Preferably the tray includes side walls.
[0031] Preferably at least one of the side walls includes openings
to allow air to circulate into and from the tray.
[0032] Preferably the openings in the side walls are formed to
allow hot air to circulate into and from the tray to facilitate
baking of products in the cups.
[0033] Preferably the tray includes end walls.
[0034] Preferably at least one of the end walls includes openings
to allow air to circulate into and from the tray.
[0035] Preferably the openings in the end walls are formed to allow
hot air to circulate into and from the tray to facilitate baking of
products in the cups.
[0036] Preferably the tray includes downwardly depending legs to
space the lower wall of the tray above a base surface.
[0037] Preferably one of the legs is a downward extension of one of
the side walls.
[0038] Preferably the tray includes internal partitions that space
apart the upper and lower walls.
[0039] Preferably at least one of the side and end walls extends
above the plane of the upper wall to form a barrier at least
partially around the periphery of the tray to protect product baked
in the tray.
[0040] Preferably both side walls and both end walls include upward
extensions that define a peripheral barrier around the upper wall
of the tray.
[0041] Preferably the tray is formed from carton board.
[0042] Preferably the carton board includes a coating of a
non-stick material on at least an outer surface of the tray.
[0043] Preferably the carton board includes a coating of a heat
resistant material on at least an outer surface of the tray in
situations in which the tray is intended for use in baking food
products.
[0044] The tray may be formed from a carton board blank that is
cut, folded and glued to form a tray preform that includes (a) a
sleeve having a plurality of panels that form at least the upper,
lower, and side walls of the tray and (b) flaps extending from the
ends of the sleeve that form the end walls of the tray.
[0045] Preferably the tray preform is manufactured in a flat form
to facilitate packaging and transportation of the preform and can
be erected into the tray as required.
[0046] Preferably the flaps include locking tabs that can engage
the upper, lower, and side walls or are otherwise formed to form
the end walls of the tray.
[0047] Preferably the panels of the sleeve include a panel that
forms the base wall of the tray.
[0048] The present invention is described further with reference to
the accompanying drawings, of which:
[0049] FIG. 1 is a perspective view of one embodiment of a tray in
accordance with the present invention illustrating the upper wall
and one side wall of the tray;
[0050] FIG. 2 is a perspective view of the tray illustrating the
upper wall and one end wall of the tray;
[0051] FIG. 3 is a section through the line 3-3 of FIG. 2;
[0052] FIG. 4 is a perspective view of the tray illustrating the
lower wall and one side wall of the tray;
[0053] FIG. 5 is a side view of the tray;
[0054] FIG. 6 is an end view of the tray;
[0055] FIG. 7 is a top plan view of a preform of the tray shown in
FIGS. 1 to 5; and
[0056] FIG. 8 is a top plan view of a blank for forming another
embodiment of a tray in accordance with the present invention.
[0057] With reference to FIGS. 1 to 6, the tray is essentially a
rectangular carton board box that includes an upper wall 3, a lower
wall 5, side walls 7, and end walls 9.
[0058] The upper and lower walls 3, 5 define a means for supporting
the sides of each cup at different heights of the cups.
Specifically, the upper walls 3 include six openings 11 for
receiving cups (not shown) for baking muffins. The lower walls 5
also include six openings 13 that are aligned with the upper
openings 11 for receiving the cups (not shown). The spacing between
the upper and lower walls 3, 5 and the size of the openings 11, 13
is selected so that:
(a) the upper wall 3 supports the cups around the circumference of
the cups at locations that are approximately 2/3 of the height of
the cups; and
(b) the lower wall 5 supports the cups around the circumference of
the cups at locations that are approximately 1/3 of the height of
the cups.
[0059] The basis of the selection of these locations is to provide
support for the cups to prevent outward bulging of the cups as
product mix, such as muffin mix, bakes in the cups.
[0060] The side and end walls 7, 9 include a series of openings 15
to enable hot air to flow into and from the tray to facilitate
efficient heat transfer to the product mix in the cups. The
applicant has found that, in the absence of such openings, the tray
can act as an insulator to a certain extent and result in slower
baking times compared with trays that have the openings.
[0061] The tray may be formed with openings (not shown) in the
upper wall, other than the openings 11, for further improving hot
air circulation. However, such openings have one potential drawback
in that the openings may facilitate a loss of product mix as baking
progresses in the cups and are not preferred on this basis.
[0062] The tray also includes legs 17 that lift the lower wall 5
clear of a base surface. The legs 17 are provided around the edge
of the lower wall. There are also legs 17 that are inboard of the
edge of lower wall 5.
[0063] One side of the tray is formed with a continuous leg 17 that
extends along the length of the side. This leg is provides
stability for the tray and contributes to the rigidity of the
tray.
[0064] The other side of the tray has a corresponding upstanding
"leg" which forms an upward extension 21 of the side wall above the
plane of the upper wall 3. This side wall extension also
contributes to the rigidity of the tray and provides a convenient
glue region in the manufacture of the tray. In addition, the side
wall extension forms a partial barrier around the upper wall 3 and
can thereby shield the parts of baked products that extend above
the upper wall. The remaining legs 17 of the tray are downwardly
depending tabs.
[0065] The tray also includes a series of internal tabs 19 that are
connected to the upper and lower walls 3, 5 and assist in
maintaining the selected spacing between the upper and lower walls
3, 5. Each tab 19 is integrally formed with one of the inboard legs
17.
[0066] The preferred embodiment of the tray shown in FIGS. 1 to 6
is manufactured from a carton board blank on a conventional
cutting, folding and glueing machine.
[0067] The carton board blank is cut, folded and glued to form a
tray preform that includes a sleeve and flaps extending from
opposite ends of the sleeve, as shown in FIG. 7.
[0068] The sleeve has six panels that are separated by fold lines.
The panels form the upper wall, 3, the lower wall 5 and the side
walls 7 of the tray. The panels are marked A, B, C, D, E, and F in
FIG. 3. With reference to FIG. 3, panels C and D are glued together
to form the leg 17 on that side of the tray and the panels A and F
are glued together to form the upstanding "leg" on that side of the
tray.
[0069] The flaps form the end walls 9 of the tray.
[0070] In the manufacturing operation the blank is cut to form:
(a) the openings 11, 13, 15 in the panels that form the upper,
lower, side and end walls 3, 5, 7, 9; and
(b) the legs 17 and the internal tabs 19 from the panel that forms
the lower wall 5; and
(c) the flaps that form the end walls 9.
[0071] The tray preform shown in FIG. 7 is a flat unit that is
suitable for packing and distributing a plurality of the preforms
to retail outlets or commercial baking operations.
[0072] The tray preform shown in FIG. 7 can readily be erected into
the tray shown in FIGS. 1 to 6 by manipulating the sleeve from the
flat form shown in FIG. 7 into a box-like form, with parallel upper
and lower walls and parallel side walls, and folding the flaps
inwardly to form the end walls of the tray.
[0073] A carton board blank for forming another, although not the
only other, embodiment of a tray in accordance with the present
invention is shown in FIG. 8.
[0074] The carton board blank is formed so that it can be folded
and glued to form a tray preform that includes a sleeve and flaps
extending from opposite ends of the sleeve.
[0075] The preform can be erected to form a tray having parallel
upper, lower and base walls, with the lower wall positioned between
the upper and base walls, parallel side walls and parallel end
walls, with the end walls having end flaps.
[0076] The blank shown in FIG. 8 includes (a) a central panel 31
that forms the upper wall of the tray, (b) a first outer panel 33
on one side of the central panel that forms the base wall of the
tray, (c) a first intermediate panel 35 interconnecting the central
and first outer panels 31, 33 that forms one of the side walls of
the tray, (d) a second outer panel 37 on the other side of the
central panel 31 that forms the lower wall of the tray, (e) a
second intermediate panel 39 interconnecting the central panel 31
and the second outer panel 37, (f) outer edge panels 41, 43 that
form part of the other side wall of the tray, and (g) end panels
45, 47 connected to opposite ends of the central panel 31 that form
the end walls of the tray.
[0077] The blank also includes a series of openings 49 in the
central and second outer panels that form the aligned cup-receiving
openings of the tray.
[0078] The blank also includes a series of openings 51 in the first
intermediate panel 35 and the outer edge panel 43 that form air
circulation vents for the tray.
[0079] Many modifications may be made to the embodiments of the
tray described above with reference to the Figures without
departing from the spirit and scope of the present invention.
[0080] By way of example, the present invention is not limited to
trays having upper and lower walls that define a means for
supporting the sides of each cup at different heights of the cups,
and the present invention extends to any suitable such support
means.
[0081] In addition, the present invention is not limited to trays
having legs and to the location, type and number of legs shown in
the Figures.
[0082] In addition, the present invention is not limited to the
particular shape of the tray, including the particular number and
location of the openings for receiving baking cups, shown in the
Figures.
[0083] In addition, the present invention is not limited to trays
having hot air circulation openings and to the location, type and
number of these openings shown in the Figures.
[0084] In addition, the present invention is not limited to trays
that have upper and lower walls that support baking cups around the
circumference of the cups at locations that are 2/3 and 1/3 of the
height of the cups. The walls may be formed to support the cups at
any suitable heights of the cups that provides adequate support
against outward bulging of cups during baking of products in the
cups.
[0085] In addition, whilst the preferred embodiment is made from
carton board, and it is convenient for the tray to be made from
this material in conventional in-line cutting, folding and glueing
machinery, the present invention is not so limited and the tray may
be made from any suitable material by any suitable means.
[0086] In addition, the present invention is not limited to trays
for baking food products and extends to any food products that are
prepared in "cups".
[0087] In addition, the present invention is not limited to trays
having multiple cup support at different heights of the cups and,
in its broadest terms, extends to arrangements in which the cups
are supported at one height of the cups.
* * * * *