U.S. patent application number 14/658120 was filed with the patent office on 2016-09-15 for ready meals shipping.
The applicant listed for this patent is TableRunner, LLC. Invention is credited to Tyler Brown, Kyle Desautels, Ryan Tu.
Application Number | 20160264340 14/658120 |
Document ID | / |
Family ID | 56887412 |
Filed Date | 2016-09-15 |
United States Patent
Application |
20160264340 |
Kind Code |
A1 |
Tu; Ryan ; et al. |
September 15, 2016 |
Ready Meals Shipping
Abstract
A ready-meal shipping container includes: a housing comprising a
plurality of walls bounding an interior cavity and a
food-tray-retention assembly. The food-tray-retention assembly
includes a plurality of racks arranged in a stacked configuration
within the interior cavity of the housing, and an elongated sleeve
aligned with the racks.
Inventors: |
Tu; Ryan; (Benicia, CA)
; Brown; Tyler; (Petaluma, CA) ; Desautels;
Kyle; (Livermore, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TableRunner, LLC |
Emeryville |
CA |
US |
|
|
Family ID: |
56887412 |
Appl. No.: |
14/658120 |
Filed: |
March 13, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 5/5038 20130101;
B65D 5/46144 20130101; B65D 5/46112 20130101; B65D 77/0433
20130101 |
International
Class: |
B65D 81/38 20060101
B65D081/38; B65D 65/38 20060101 B65D065/38; B65D 77/04 20060101
B65D077/04; B65D 25/10 20060101 B65D025/10; B65D 21/02 20060101
B65D021/02 |
Claims
1. A ready-meal shipping container, comprising: a housing
comprising a plurality of walls bounding an interior cavity; and a
food-tray-retention assembly, comprising: a plurality of racks
arranged in a stacked configuration within the interior cavity of
the housing, each of the racks including one or more discrete
bounded cells for receiving modular food trays; and an elongated
sleeve aligned with the racks and configured to receive a
temperature control member in a position to promote heat transfer
between the temperature control member and modular food trays
received in the cells, wherein each of the racks is configured and
arranged within the interior cavity such that, during shipping
operations, the modular food trays are retained in a fixed position
relative to each other, the walls of the housing, and the elongated
sleeve.
2. The ready-meal shipping container of claim 1, wherein the
housing further comprises a non-planar gable structure enclosing a
top portion of the interior cavity.
3. The ready-meal shipping container of claim 2, wherein the gable
structure comprises an upstanding ridge spanning at least a portion
of the length of the housing.
4. The ready-meal shipping container of claim 3, wherein the ridge
extends to a maximum height that is at least about 10% of the
overall height of the housing.
5. The ready-meal shipping container of claim 4, wherein the ridge
extends to a maximum height that is between about 15% and 45% of
the overall height of the housing.
6. The ready-meal shipping container of claim 5, wherein the ridge
extends to a maximum height that is about 40% of the overall height
of the housing.
7. The ready-meal shipping container of claim 3, wherein the
upstanding ridge defines a handhold aperture therethrough.
8. The ready-meal shipping container of claim 3, wherein the gable
structure further comprises a pair of upstanding panels located
proximate opposing ends of the ridge.
9. The ready-meal shipping container of claim 8, wherein each of
the panels includes a slot opening for receiving a corresponding
end of the ridge.
10. The ready-meal shipping container of claim 1, wherein the
housing, the racks, and the sleeve are manufactured from a
recyclable material.
11. The ready-meal shipping container of claim 1, wherein each of
the discrete cells defines a rounded rectangular shape.
12. The ready-meal shipping container of claim 1, wherein at least
one of the discrete bounded cells of a rack located immediately
above the sleeve comprises a throughhole aperture to expose a
bottom portion of the food tray received therein to the elongated
sleeve.
13. The ready-meal shipping container of claim 12, wherein at least
one of the modular food trays is supported in one of the racks,
such that a bottom surface of the tray is suspended at a distance
from the elongated sleeve.
14. The ready-meal shipping container of claim 1, further
comprising a plurality of insulators positioned between the walls
of the housing and the food-tray-retention assembly.
15. The ready-meal shipping container of claim 14, wherein at least
one of the insulators comprises a cushioned pad encased in
insulating material.
16. The ready-meal shipping container of claim 1, wherein the
sleeve is positioned between adjacent racks in the stacked
configuration.
17. The ready-meal shipping container of claim 1, wherein the
sleeve is positioned immediately on top of a topmost rack in the
stacked configuration.
18. The ready-meal shipping container of claim 1, wherein each of
the racks includes a face panel extending across a space between
two opposing side walls, and wherein the cells comprise apertures
bounded by surface material of the face panel.
19. The ready-meal shipping container of claim 1, wherein the
temperature control member comprises a cooling element located
within an interior space of the sleeve.
20. The ready-meal shipping container of claim 1, wherein at least
one of the modular food trays comprises a main body and a lip
extending outwardly from the main body, and wherein the main body
is received within an open space of one of the cells of one of the
racks, with the lip overhanging a surface of the rack between
adjacent cells.
21. The ready-meal shipping container of claim 1, wherein each of
the racks consists essentially of a single contiguous planar blank
folded into a three dimensional structure.
22. The ready-meal shipping container of claim 1, wherein the
housing consists essentially of a single contiguous planar blank
folded into a three dimensional structure.
23. The ready-meal shipping container of claim 1, wherein the
sleeve is located in a position to promote heat transfer via
natural convection current.
24. A ready-meal shipping container, comprising: a housing
comprising a plurality of walls bounding an interior cavity; and a
food-tray-retention assembly, comprising: at least one rack located
within the interior cavity of the housing, the rack including one
or more discrete bounded cells for receiving modular food trays;
and an elongated sleeve positioned adjacent the rack and configured
to receive a temperature control member in a position to promote
heat transfer between the temperature control member and modular
food trays received in the cells, wherein the housing further
comprises a non-planar gable structure enclosing a top portion of
the interior cavity.
25. The ready-meal shipping container of claim 24, wherein the
gable structure comprises an upstanding ridge spanning at least a
portion of the length of the housing.
26. The ready-meal shipping container of claim 25, wherein the
ridge extends to a maximum height that is at least about 10% of the
overall height of the housing.
27. The ready-meal shipping container of claim 26, wherein the
ridge extends to a maximum height that is about 40% of the overall
height of the housing.
28. A packaged ready-meal assembly, comprising: a housing
comprising a plurality of walls bounding an interior cavity; and at
least one rack located within the interior cavity of the housing,
the rack having a planar surface defining one or more discrete
openings; one or more food trays containing pre-cooked food and
positioned in the one or more openings and held spaced from one
another by the rack; and an elongated sleeve spanning the rack and
positioning a cooled substance in spaced relation to the one or
more food trays.
29. The packaged ready-meal assembly of claim 28, wherein the
housing further comprises a non-planar gable structure enclosing a
top portion of the interior cavity.
30. The packaged ready-meal assembly of claim 28, wherein the
sleeve is exposed to a surface of each of the one or more food
trays.
31. The packaged ready-meal assembly of claim 28, wherein the
sleeve is located in a position to promote heat transfer between
the cooled substance and the one or more food trays via natural
convection current.
Description
TECHNICAL FIELD
[0001] The present disclosure generally relates to containers for
facilitating the shipping of ready meals.
BACKGROUND
[0002] Ready-to-eat meals ("ready meals") are pre-cooked measured
food portions. Cooled (e.g., frozen) ready meals may require
nothing more than rethermalization (e.g., reheating) before
serving. In many cases, the pre-cooked food is stored in modular
food trays sealed with a removable covering film. The modular food
trays are often conveniently designed to facilitate both reheating
(e.g., via microwave or conventional ovens), when required, and
serving. Traditionally, ready meals have been sold primarily at
retail outlets (e.g., grocery stores). However, in recent years,
on-demand food preparation services have entered the market,
providing ready meals for home order (e.g., via shipping
services).
SUMMARY
[0003] In one or more aspects of the present disclosure, a
ready-meal shipping container includes: a housing including a
plurality of walls bounding an interior cavity; and a
food-tray-retention assembly. The food-tray-retention assembly
includes: a plurality of racks arranged in a stacked configuration
within the interior cavity of the housing, each of the racks
including one or more discrete bounded cells for receiving modular
food trays; and an elongated sleeve aligned with the racks and
configured to receive a temperature control member in a position to
promote heat transfer between the temperature control member and
modular food trays received in the cells. Each of the racks is
configured and arranged within the interior cavity such that,
during shipping operations, the modular food trays are retained in
a fixed position relative to each other, the walls of the housing,
and the elongated sleeve.
[0004] In one or more aspects of the present disclosure, a
ready-meal shipping container includes: a housing including a
plurality of walls bounding an interior cavity; and a
food-tray-retention assembly. The food-tray-retention assembly
includes at least one rack located within the interior cavity of
the housing, the rack including one or more discrete bounded cells
for receiving modular food trays; and an elongated sleeve
positioned adjacent the rack and configured to receive a
temperature control member in a position to promote heat transfer
between the temperature control member and modular food trays
received in the cells. The housing further includes a non-planar
gable structure enclosing a top portion of the interior cavity.
[0005] In one or more aspects of the present disclosure, a packaged
ready-meal assembly includes: a housing including a plurality of
walls bounding an interior cavity; and at least one rack located
within the interior cavity of the housing, the rack having a planar
surface defining one or more discrete openings; one or more food
trays containing pre-cooked food and positioned in the one or more
openings and held spaced from one another by the rack; and an
elongated sleeve spanning the rack and positioning a cooled
substance in spaced relation to the one or more food trays.
[0006] In one or more of the above-described aspects, the housing
further includes a non-planar gable structure enclosing a top
portion of the interior cavity. In one or more of the
above-described aspects, the gable structure includes an upstanding
ridge spanning at least a portion of the length of the housing. In
one or more of the above-described aspects, the ridge extends to a
maximum height that is at least about 10% of the overall height of
the housing. In one or more of the above-described aspects, the
ridge extends to a maximum height that is between about 15% and 45%
of the overall height of the housing. In one or more of the
above-described aspects, the ridge extends to a maximum height that
is about 40% of the overall height of the housing. In one or more
of the above-described aspects, the upstanding ridge defines a
handhold aperture therethrough. In one or more of the
above-described aspects, the gable structure further includes a
pair of upstanding panels located proximate opposing ends of the
ridge. In one or more of the above-described aspects, each of the
panels includes a slot opening for receiving a corresponding end of
the ridge.
[0007] In one or more of the above-described aspects, the housing,
the racks, and the sleeve are manufactured from a recyclable
material.
[0008] In one or more of the above-described aspects, each of the
discrete cells defines a rounded rectangular shape.
[0009] In one or more of the above-described aspects, at least one
of the discrete bounded cells of a rack located immediately above
the sleeve includes a throughhole aperture to expose a bottom
portion of the food tray received therein to the elongated sleeve.
In one or more of the above-described aspects, at least one of the
modular food trays is supported in one of the racks, such that the
bottom surface of the tray is suspended at a distance from the
elongated sleeve.
[0010] In one or more of the above-described aspects, the shipping
container further includes a plurality of insulators positioned
between the walls of the housing and the food-tray-retention
assembly. In one or more of the above-described aspects, at least
one of the insulators includes a cushioned pad encased in
insulating material.
[0011] In one or more of the above-described aspects, the sleeve is
positioned between adjacent racks in the stacked configuration.
[0012] In one or more of the above-described aspects, the sleeve is
positioned immediately on top of the topmost rack in the stacked
configuration.
[0013] In one or more of the above-described aspects, each of the
racks includes a face panel extending across the space between two
opposing side walls, and the cells include apertures bounded by
surface material of the face panel.
[0014] In one or more of the above-described aspects, the
temperature control member includes a cooling element located
within an interior space of the sleeve.
[0015] In one or more of the above-described aspects, at least one
of the modular food trays includes a main body and a lip extending
outwardly from the main body, and the main body is received within
an open space of one of the cells of one of the racks, with the lip
overhanging a surface of the rack between adjacent cells.
[0016] In one or more of the above-described aspects, each of the
racks consists essentially of a single contiguous planar blank
folded into a three dimensional structure.
[0017] In one or more of the above-described aspects, the housing
consists essentially of a single contiguous planar blank folded
into a three dimensional structure.
[0018] In one or more of the above-described aspects, the sleeve is
exposed to a surface of each of the one or more food trays.
[0019] In one or more of the above-described aspects, the sleeve is
located in a position to promote heat transfer between the cooled
substance and the one or more food trays via natural convection
current.
[0020] The details of one or more implementations of the subject
matter described in this specification are set forth in the
accompanying drawings and the description below. Other features,
aspects, and advantages of the subject matter will become apparent
from the description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIGS. 1A-1C are perspective, side and front views of an
example ready-meal shipping container housing with the gable
structure of the housing in a closed position.
[0022] FIG. 2 is a front view of the housing shown in FIGS. 1A-1C
with the gable structure in an opened condition.
[0023] FIG. 3 is a top view of an example ready-meal shipping
container packed with modular ready meals.
[0024] FIGS. 4A-4D are perspective, top, side and bottom views of a
first example food-tray-retention assembly.
[0025] FIG. 5 is a perspective view of a second example
food-tray-retention assembly.
[0026] Like reference numbers and designations in the various
drawings may indicate like elements.
DETAILED DESCRIPTION
[0027] The present disclosure generally relates to shipping
containers for facilitating the shipping of ready meals disposed in
module food trays. One or more aspects of the present disclosure
are drawn from an awareness that ready meals featuring non-frozen
food portions provide a substantially superior product in the eyes
of consumers (e.g., better taste, presentation and nutrition) as
compared to frozen food. Thus, a shipping container in accordance
with one or more embodiments of the present disclosure may be
configured to transport ready meals at a sustained chilled (but not
frozen) temperature or at a sustained serving temperature. As used
herein, the term "chilled temperature" is intended to mean that the
food portions are maintained at a cool temperature above freezing
(e.g., a temperature between about 40.degree. F. and about
32.degree. F.); and the term "serving temperature" is intended to
mean that the food portions are maintained at a warm temperature of
at least about 140.degree. F.
[0028] One or more aspects of the present disclosure are drawn from
a further awareness that the reheating of chilled ready meals via
stovetop or conventional oven tends to provide a superior consumer
product as compared to reheating by microwave. However, given a
choice, many consumers may choose to microwave ready meals merely
as a matter of convenience. To drive the consumer towards
conventional oven heating, the modular trays containing the chilled
food portions can be manufactured including a non-microwavable
material, such sheetform aluminum foil or other appropriate metals,
as opposed to microwavable plastic or paper. The high heat
conductivity of the metalized trays may also be advantageous for
facilitating heat transfer (e.g., heating or cooling) of the food
portions contained therein during transport within the shipping
container. The metalized trays may be particularly delicate and
prone to bruising during bulk shipping due to the relatively thin
walls of the structure combined with the pliable, non-elastic
nature of the materials and the relative softness of the non-frozen
food. Accordingly, in some embodiments, a ready-meal shipping
container includes a food-tray-retention assembly including
multiple racks appropriately configured to retain a plurality of
modular food trays in an effectively isolated condition during
shipping operations. Further, in some embodiments, a ready-meal
shipping container includes a housing featuring a non-planar gable
structure enclosing the top portion of an interior cavity
containing the modular food trays. As discussed below, the gable
structure is appropriately designed to inhibit service persons from
mishandling the read-meal shipping container during shipping
operations.
[0029] Referring first to FIGS. 1A-1C, a ready-meal shipping
container 100 includes a housing 102 featuring a base 106 and a
gable structure 108. The base 106 and the gable structure 108
define the bounds of a vacant interior cavity 105. In this example,
the base 106 includes a substantially flat floor 110, two opposing
elongated planar side walls 112, a front wall 114, and a rear wall
116. The front wall 114 and the rear wall 116 extend between the
edges of the side walls 112, forming the rectangular-shaped base
106. The thickness of the walls and floor of the base 106 provide
sufficient strength to carry a plurality of modular food trays
(e.g., six food trays) and a food-tray-retention assembly for
holding the trays (see FIGS. 3 and 4A-4D). For instance, in some
embodiments, one or more of the walls have a thickness of between
about 0.06 inch and 0.25 inch (e.g., about 0.12 inch). In some
embodiments, one or more walls of the base 106 are substantially
thicker than what is required to provide the necessary weight
carrying capacity for transporting the modular food trays contained
therein. The added thickness of the walls may provide an auxiliary
measure of insulation for maintaining the modular food trays at a
desired temperature.
[0030] The gable structure 108 encloses the top portion of the
interior cavity 105. As noted above, the gable structure 108 is a
non-planar construction designed to inhibit service persons from
mishandling the ready-meal shipping container 100 in a way that may
damage the delicate modular food trays contained therein. In this
example, the gable structure 108 includes multiple components that
project vertically upward from the topmost edges of the base 106 to
create the non-planar construction. In particular, we have found
that the particular configuration (e.g., shapes and sizes) of the
components shown and described herein tends to inhibit service
persons from placing the ready-meal shipping container 100 in an
improper orientation (e.g., upside down) and from stacking other
packages on top of the shipping container 100.
[0031] In this example, the gable structure 108 includes two roof
panels 118, two gable panels 120, and two retention panels 122.
With the gable structure 108 in a closed condition, as illustrated
in FIGS. 1A-1C, each of the roof panels 118 extend inward along a
direction of the width "W" (see FIG. 1A) of the housing 102 from
the top edge of the opposing side walls 112. In some embodiments,
the width of the housing 102 is between about 10 inches and 14
inches (e.g., about 12 inches). As shown, the roof panels 118 meet
near the center of the housing 102, forming a substantially flat
closed lid to the base 106. In some implementations, the lay-flat
nature of the roof panels 118 when the gable structure 108 is
closed can be particularly advantageous because it preserves the
rectangular shape of interior cavity 105, making the housing 102
easier to pack snugly with insulation (see FIG. 3).
[0032] The gable panels 120 are pressed together along the seam
where the roof panels 118 meat to form an upstanding ridge 124, two
locking tabs 126 extending vertically upward the opposing ends of
the ridge 124, and a handhold opening 128 near the center of the
ridge 124. In this example, the ridge 124 extends lengthwise to
span the entire length "L" (see FIG. 1A) of the housing 102. In
some embodiments, the length of the housing 102 is between about 18
inches and 30 inches (e.g., about 24 inches). In some embodiments,
the ridge 124 extends across at least about 50% of the length of
the housing 102 (e.g., between about 70% and about 90%). In this
example, the ridge 124 has a semi-elliptical shape in the
lengthwise direction of the housing 102. However, other appropriate
shapes are also contemplated within the scope of the present
disclosure. As shown in FIG. 1C, the semi-elliptical ridge 124
extends upwards from the roof panels 118 to a maximum height "h"
near the center of the housing 102. In some embodiments, the
maximum height of the ridge is between about 0.5 inch and 5 inches
(e.g., between about 2 inches and about 4 inches, such as about 3.5
inches). In some embodiments, the maximum height of the ridge 124
is at least about 10% of the overall height "H" (see FIG. 1C) of
the housing 102 (e.g., between about 15% and about 45%, such as
about 25% or about 40%). In some embodiments, the height of the
housing 102 is between about 7 inches and 11 inches (e.g., about 9
inches).
[0033] With the gable structure 108 in the closed condition, the
locking tabs 126 of the gable panels 120 are received by the slot
openings 130 (see FIG. 2) of the retention panels 122, which are
folded inward in the lengthwise direction of the housing 102
towards the ridge 124. The locking tabs 126 engage the edges of the
slot openings 130 to inhibit the gable panels 120, and therefore
the roof panels 118, from being inadvertently pulled apart to
expose the interior cavity 105 of the housing 102 (e.g., when a
user lifts the housing 102 by grasping the ridge 124 via the
handhold opening 128). To open the gable structure 108, as shown in
FIG. 2, a user can press down on the gable panels 120 (or the roof
panels 118, which are coupled to the gable panels 120 in this
example) to disengage the locking tabs 126 from the slot openings
130 of the retention panels 122, and peal back the retention panels
122 to release the gable panels 120.
[0034] In some embodiments, the housing 102 is formed by
appropriately folding a contiguous and generally flat blank, and
securing the blank in the folded condition (e.g., via mechanical
fasteners or adhesive). The blank may include indented fold lines
or seams to facilitate assembly of the housing 102. In some
embodiments, one or more components of the housing 102 can be made
from a recyclable material, such as commercial grade corrugated
cardboard, paperboard and/or recyclable fibers or plastics.
[0035] Referring now to FIG. 3, the interior cavity 105 of the
housing 102 can be packed with a shipping load including a
food-tray-retention assembly 200 supporting a plurality of modular
food trays 300 and a plurality of insulators 400 at least partially
surrounding the food-tray-retention assembly 200. In this example,
the insulators 400 include thermal-rated box liners featuring a
soft cushioning pad encased within metalized sleeves. During
shipping operations, the padding material may at least partially
absorb and dissipate shock and impact loads, as well as prolonged
vibrations. In some embodiments, the padding material includes a
shock absorbing foam (e.g., polyurethane foam). However, various
other types of insulators are also contemplated within the scope of
the present disclosure (e.g., metal-encased polystyrene or
Styrofoam).
[0036] As shown in FIGS. 4A-4D, a first example food-tray-retention
assembly 200 includes an upper rack 202a and a lower rack 202b
arranged in a stacked configuration with an elongated sleeve 204.
As described below, the racks 202a, 202b are appropriately
configured to carry one or more modular food trays (e.g., food
trays 300). In some implementations, stacking the racks of the
food-tray-retention assembly allows a plurality of food trays (six
trays in the illustrated examples) to be packed in a housing (e.g.,
the housing 102) with a structurally sound length to width aspect
ratio (e.g., a length to width aspect ratio of at most about 4:1).
For example, if the housing is too long, it may be structurally
weak near the middle when loaded with food trays, and therefore
become compromised during shipping operations. In this example, the
sleeve 204 is sandwiched between the racks 202a, 202b. Similar to
the housing 102, the racks 202a, 202b and the sleeve 204 may be
formed by appropriately folding a contiguous and generally flat
blank. With all of the structural elements of the ready-meal
shipping container 100 being constructible from generally flat
blanks, the constituent pieces can be readily manufactured and
shipped in bulk for remote assembly.
[0037] Each of the racks 202a, 202b includes a face panel 206, two
opposing side walls 208, two support rails 209, a front panel 210
and a rear panel 211. The support rails 209 extend partially inward
(e.g., by about 1.5 inches) in the widthwise direction of the racks
202a, 202b from the bottom edge of the side walls 208. The side
walls 208, front panel 210, and rear panel 211 extend downward from
the face panel 206 to partially bound a bottomless interior space
212. Thus, the cells 214 of the upper rack 202a are exposed to the
underlying sleeve 204 carrying the support rails 209.
[0038] The face panel 206 of the racks 202a, 202b includes a
plurality of discrete cells 214. As shown, the cells 214 are
located at regular intervals along the length of the racks 202a,
202b so that the weight of the food trays 300 retained therein is
uniformly distributed. In this example, the face panel 206 of each
rack 202a, 202b includes three discrete cells 214. However, other
configurations are also contemplated within the present disclosure
(e.g., the racks may include more--e.g., four, five or six--cells
or less--e.g., two or one--cells, and/or the respective racks may
include a different number of cells). The cells 214 are formed as
throughhole apertures bounded by the surrounding surface material
of the face panel 206. Thus, the cells 214 of the upper rack 202a
are exposed to the underlying sleeve 204 which carries the support
rails 209 of the rack 202a.
[0039] In this example, each of the cells 214 defines a rounded
rectangular shape, appropriately sized to accommodate the contour
of the modular food trays 300. In some embodiments, the cells 214
have a length of between about 6 inches and about 10 inches (e.g.,
about 8 inches), and width of between about 3 inches and about 7
inches (e.g., about 5 inches), and the radius of the rounded
corners is between about 0.12 inch and about 1 inch (e.g., about
0.5 inch). The food trays 300 fit relatively snug within the cells
214 such that lateral movement is inhibited. Thus, the food trays
300 are effectively isolated from one another and from the walls of
the base 106 of the housing 102. As shown in FIG. 3, each of the
food trays 300 includes an outer lip 302 extending beyond the
respective cell 214 to overhang the surrounding surface of the face
panel 206 when the main body of the tray 302 has been inserted into
the open space of the cell 214. Thus, the food trays 300 are at
least partially supported in the racks 202a, 202b by the lip 302
bearing on the surface of the face panel 206. In some embodiments,
the height "Hr" (see FIG. 4A) of the racks 202a, 202b, as defined
by the side walls 208, is greater than the height of the food trays
300, such that the food trays 300 entirely supported on the surface
of the face panel 206 as described above, such that the food trays
300 effectively "float" above the surface carrying the support
rails 209 of the respective rack 202a, 202b. This configuration may
be particularly advantageous during shipping operations, because
the delicate body of the food trays 300 can be vertically isolated
from surrounding structures (e.g., the sleeve 204) which may cause
bruising if bumped. This configuration may be further advantageous,
because the main body of the food trays 300 below the outwardly
projecting lip 302 remain free of any contact with the racks 202a,
202b, which may further inhibit potential bruising. In some
embodiments, the height of the racks 202a, 202b is between about
0.5 inch and 5 inches (e.g., between about 1 inch and about 4
inches, such as about 2 inches).
[0040] The elongated sleeve 204 is a rectangular shaped
construction with open ends, featuring an upper surface 215 and a
lower surface 216 connected by opposing side walls 218. The bounded
interior space 220 of the sleeve 204 is substantially void,
designed to receive an appropriate temperature control member (not
shown). The temperature control member is designed to create heat
transfer (e.g., conductive or convective heat transfer) with the
food trays carried in the racks. In various embodiments, the
temperature control member may include any suitable type of cooling
element and/or heating element. In some embodiments, the cooling
element may include one or more ice packs, ice blankets, ice
pouches, endothermic cold packs and/or refrigerant gel packs. In
some embodiments, the cooling element may include a vessel
containing dry ice. In some embodiments, the heating element may
include one or more exothermic hot packs and/or a battery-powered
heating pad. The positioning of the temperature control member
within the sleeve 204 located between the racks 202a, 202b promotes
heat transfer between the temperature control member and the food
trays 300 disposed in the cells 214. In this example, the
temperature control member draws in heat from the bottom of the
trays 300 located in the upper rack 202a and from the top of the
trays 300 located in the lower rack 202b.
[0041] FIG. 5 illustrates a second example food-tray-retention
assembly 200', which, similar to the first example
food-tray-retention assembly 200 of FIGS. 4A-4D, includes an upper
rack 202a' and a lower rack 202b' arranged in a stacked
configuration with an elongated sleeve 204'. However, in this
example, the racks 202a', 202b' are stacked in an immediately
adjacent arrangement, with the upper rack 202a' situated directly
on top of the lower rack 202b'. The elongated sleeve 204' is
stacked on top of the upper rack 202a', and directly exposed to the
trays carried therein. This configuration may be particularly
advantageous in various implementations where the temperature
control member includes a cooling element, because it tends to
increase the efficiency of convective heat transfer. For example,
positioning a cooling element at the top layer of the
food-tray-retention assembly may form a natural convection current
within the interior cavity of the housing that enhances the cooling
capacity of the temperature control member.
[0042] The use of terminology such as "front," "rear," "top,"
"bottom," "above," and "below" throughout the specification and
claims is for describing the relative positions of various
components of the ready-meal shipping container and other elements
described herein. Similarly, the use of any horizontal or vertical
terms to describe elements is for describing relative orientations
of the various components of the ready-meal shipping container and
other elements described herein. Unless otherwise stated
explicitly, the use of such terminology does not imply a particular
position or orientation of the ready-meal shipping container or any
other components relative to the direction of the Earth
gravitational force, or the Earth ground surface, or other
particular position or orientation that the ready-meal shipping
container or other elements may be placed in during operation,
manufacturing, and transportation.
[0043] A number of embodiments of the invention have been
described. Nevertheless, it will be understood that various
modifications may be made without departing from the spirit and
scope of the inventions. As one example, while the illustrated
examples feature a food-tray-retention assembly including two racks
arranged in various stacked arrangements, other suitable
configurations and arrangements are also contemplated within the
present disclosure. As one example, the elongated sleeve could be
positioned below the racks (e.g., if the temperature control member
includes a heating element). As another example, a suitable
food-tray-retention assembly may include multiple sleeves
positioned between different sets of two or more racks; and/or
multiple sleeves positioned above or below different sets of two or
more racks. Alternatively, a suitable food-tray-retention assembly
may include a single rack and a single sleeve, or a single rack
with multiple sleeves, where the sleeves sandwich the single rack
in the stacked configuration, a single rack with no sleeve, without
departing from the scope of the present disclosure.
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