U.S. patent application number 15/144694 was filed with the patent office on 2016-11-03 for strong nestable paper food tray.
The applicant listed for this patent is Perk-Up, Inc. d/b/a Kari-Out Co., Perk-Up, Inc. d/b/a Kari-Out Co.. Invention is credited to John Daines, Paul Epstein.
Application Number | 20160318650 15/144694 |
Document ID | / |
Family ID | 57204539 |
Filed Date | 2016-11-03 |
United States Patent
Application |
20160318650 |
Kind Code |
A1 |
Epstein; Paul ; et
al. |
November 3, 2016 |
STRONG NESTABLE PAPER FOOD TRAY
Abstract
Paper food trays that are able to be compactly stacked together
and that contain side walls and a bottom with gusset corners formed
by overlapping gusset panels and paperboard blanks for forming the
trays are described herein. These nestable food trays are stronger
than nestable food trays that do not contain a gusset corner.
Further, they are particularly useful to carry and hold foods that
include a sauce or other liquid. The food trays are generally
temporarily leak proof, such as for at least about 5 minutes,
preferably for at least about 10 minutes, more preferably for at
least about 15 minutes, after the food is placed in the tray.
Inventors: |
Epstein; Paul; (Larchmont,
NY) ; Daines; John; (Stanley, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Perk-Up, Inc. d/b/a Kari-Out Co. |
White Plains |
NY |
US |
|
|
Family ID: |
57204539 |
Appl. No.: |
15/144694 |
Filed: |
May 2, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62155340 |
Apr 30, 2015 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 5/244 20130101;
B65D 21/0233 20130101 |
International
Class: |
B65D 5/24 20060101
B65D005/24; A47G 23/06 20060101 A47G023/06; B65D 21/02 20060101
B65D021/02 |
Claims
1. A paper food tray comprising side walls and a bottom, wherein
each side wall is connected to the adjacent side wall with a gusset
corner, wherein each gusset corner adheres to one of the side
walls.
2. The tray of claim 1, wherein the tray does not contain a
flange.
3. The tray of claim 1, wherein each gusset corner is formed from a
pair of gusset panels connected by a first fold line defining one
side of each gusset panel, and wherein a second side of each gusset
panel is defined by a second fold line, wherein each of the second
fold lines is located between one of the gusset panels and the side
wall that is adjacent to the gusset panel.
4. The tray of claim 3, wherein one of the gusset panels in each
pair of gusset panels comprises a cut-out portion and the other
gusset panel in each pair does not contain a cut-out portion.
5. The tray of claim 1, wherein the bottom is in the shape of a
rectangle.
6. The tray of claim 1, wherein each of the side walls is located
at an angle of greater than 90.degree. with respect to the
bottom.
7. The tray of claim 6, wherein the angle ranges from about
100.degree. to about 120.degree..
8. A plurality of food trays as defined in claim 1, wherein all of
the food trays have the same size and shape, and wherein each of
the plurality of food trays is able to be stacked within another of
the food trays, such that the bottom of one tray is next to the
bottom of the adjacent tray.
9. A paperboard blank for forming the food tray of claim 1.
10. The paperboard blank of claim 9, comprising a plurality of
score lines defining a central polygonal bottom panel having a
plurality of bottom edges, wherein each bottom edge is foldably
connected to one edge of a radially outwardly extending trapezoidal
side wall-forming panel, wherein each side wall-forming panel is
attached to an adjacent side wall-forming panel by a pair of gusset
panels, wherein each gusset panel in the pair is attached to the
other gusset panel in the pair via a first fold line, and wherein
each gusset panel in the pair is attached to the adjacent side
wall-forming panel via a second fold line.
11. The paperboard blank of claim 10, wherein one gusset panel in a
pair of gusset panels comprises a cut-out portion and the other
gusset panel does not contain a cut-out portion.
12. The paperboard blank of claim 10, wherein each gusset panel
terminates in a straight edge that is connected to an angled edge,
wherein each side wall terminates in a straight edge, and wherein
each angled edge is attached to the straight edge of the adjacent
side wall.
13. The paperboard blank of claim 10, wherein the central polygonal
bottom panel is in the shape of a rectangle.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. provisional
application No. 62/155,340, filed Apr. 30, 2015, the disclosure of
which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The invention is generally directed to food packaging,
particularly nestable paper trays.
BACKGROUND OF THE INVENTION
[0003] A variety of disposable paper trays for food exist. Nestable
containers fit inside each other, and allow a large number of
containers to fit inside each other, taking up less space for
storage and/or shipment. Currently nestable food trays are
generally formed from a blank that contains a flap attached to one
side wall panel which can be glued to an adjacent side wall panel.
However, these trays leak if liquid, such as a sauce or soup, is
placed in the tray.
[0004] Therefore, there is a need for improved nestable paper trays
which do not leak when liquids are placed in the tray.
SUMMARY OF THE INVENTION
[0005] Paper food trays having side walls and a bottom with gusset
corners formed by overlapping gusset panels and paperboard blanks
for forming the trays are described herein. When assembled, the
side walls are generally at an angle that is greater than
90.degree. from the bottom of the tray. These food trays are able
to be stacked one on top of the other, where the bottom of one tray
is typically in contact with or very close to the bottom of another
tray. These trays are particularly useful to carry and hold foods
that include a sauce or other liquid. The food trays are generally
temporarily leak proof; such as for at least about 5 minutes,
preferably for at least about 10 minutes, more preferably for at
least about 15 minutes, after the food is placed in the tray.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIGS. 1A-1E are different views of an exemplary paper food
tray. FIG. 1A is a top perspective view. FIG. 1B is a side
perspective view. FIG. 1C is a bottom view. FIG. 1D is a side view
of a short side of the tray, the opposite side being a mirror image
thereof. FIG. 1E is a side view of the long side of the tray, the
opposite side being a mirror image thereof.
[0007] FIG. 2 is an exemplary paperboard blank that can be used to
form the tray depicted in FIGS. 1A-1E.
[0008] FIG. 3 is another example, paperboard blank that can be used
to form a paper food tray with gusset corners.
[0009] FIG. 4 is another exemplary paperboard blank that can be
used to form a paper food tray with gusset corners.
DETAILED DESCRIPTION OF THE INVENTION
I. Assembled Food Tray
[0010] The paperboards described herein can be assembled to form a
food tray with four sidewalk and a bottom, where each sidewall is
attached to an adjacent side wall via a gusset corner. Preferably
the trays do not contain a flange at the upper portion of the
tray.
[0011] These food trays are nestable, such that they are able to be
compactly stored, and are stronger than currently available
nestable food trays that do not contain a gusset corner. Further,
the food trays described herein are particularly useful to carry
and hold foods that include a sauce or other liquid, and prevent
leakage of the fluid out of the tray.
[0012] The gusset corners are formed by folding the gusset panels
at a suitable angle to allow the side walls to align at an angle
greater than 90.degree., typically at an angle ranging from
100.degree.-120.degree., relative to the bottom of the tray. In
preferred embodiments, the walls are located at an angle of about
110.degree. from the bottom of the tray.
[0013] As shown in FIGS. 1A-1E, when assembled, the food tray
contains four side walls, where two are shorter 21a and 21b and two
are longer 20a and 20b and a rectangular bottom 18. Optionally, the
bottom is in the shape of a square and all four side walls have
substantially the same dimensions.
[0014] Each side wall attaches to an adjacent side wall via a
gusset corner 30. As shown in FIG. 1A and 1B, preferably the gusset
corners are adhered to the shorter sides 21a and 21b. However, one
of ordinary skill in the art will appreciate that the blank can be
modified to accommodate adhering the gusset corners to the longer
sides or to a combination of the shorter and longer sides (e.g. one
gusset corner adhering to each side).
[0015] The side walls may have substantially the same height when
assembled. Alternatively, a set of two parallel side walls may be
slightly taller than the other set of two parallel side walls. As
shown in FIGS. 1B and 1E, the set of parallel side walls 21a and
21b, Which correspond with the shorter side of the bottom
rectangle, are slightly taller than the other set of parallel side
walls, 20a and 20b.
[0016] The gusset corners are attached to a side wall using a
suitable adhesive, such as a food grade glue.
II. Nested Food Trays
[0017] A plurality of food trays described herein that have the
same dimensions can be nested, i.e. stacked on top of each other
such that the bottom of one food tray touches, or is very close to
the bottom of the adjacent food tray. In this manner, a large
number of food trays can fit in a relatively small space, for ease
of storage and/or shipping.
[0018] In contrast to the trays described herein, food trays that
are configured with a side wall that is substantially straight,
e.g. at an angle of approximately 90.degree. relative to the bottom
of the tray, take up a larger volume of space when stacked. Further
when food trays having the same dimensions and with substantially
perpendicular side walls relative to the bottom of the tray are
stacked on top of each other, the bottom of one food tray is not
able to touch the bottom of the adjacent food tray, rather the
bottom of one food tray lies substantially at or near the top of
the food tray that is beneath it.
III. Paperboard Blank
[0019] A paperboard blank is used to form the single use,
disposable paper tray described herein.
[0020] Different types of food grade paperboard may be used to form
the blank and ultimately the tray. The paperboard is optionally
ovenable paperboard suitable for use in conventional and microwave
ovens. The paperboard may be coated with a suitable food grade
material to reduce leakage, such as a polyester resin film.
Optionally, the side of the paperboard blank that forms the inside
surface of the resulting tray is coated with a liquid impervious
polymer film.
[0021] The paperboard blank contains a plurality of score lines
that define a central polygonal bottom panel, which forms the
bottom of the tray, when it is assembled. The score lines on the
bottom panel form a plurality of bottom edges, which also serve as
the bottom edge of an adjacent side wall-forming panel. The side
wall-forming panels extend outward from the bottom panel and are
generally trapezoid-shaped. The bottom edges can be folded to
assemble the side wails such that they are angled away from the
bottom at an angle greater than 90.degree..
[0022] In preferred embodiments, the bottom panel is in the shape
of a rectangle. Optionally, in some embodiments, the bottom panel
is in the shape of a square. However, the bottom may be in the
shape of other polygons.
[0023] Each side wall-forming panel is attached to an adjacent side
wall-forming panel via a pair of gusset panels. In a given pair of
gusset panels, each gusset panel is attached to the other gusset
panel in the pair via a first fold line, and each gusset panel in
the pair is attached to the adjacent side wall-forming panel via a
second fold line. The second fold line is at a suitable angle for
forming a tray with side walls that extend from the bottom at an
angle of greater than 90.degree., typically at an angle ranging
from 100 .degree. to 120 .degree..
[0024] In one embodiment, depicted in FIG. 2, the paperboard blank
10 contains a rectangular bottom panel 18 defined by fold lines
24a, 24b, 24e, and 24d, which are located on each side of the
rectangle. Each fold line also forms the inner edge of respective
side wall-forming panels, 20a and 20b for the long side panels, and
21a and 21b for the two short side panels. Each side wall-forming
panel is generally trapezoidal in form. The outer edges of each
side wall-forming panel 32a, 32b, 32c, and 32d, also correspond
with the top of the paper tray.
[0025] The gussets 30a, 30b, 30c, and 30d in the tray are formed
from overlapping gusset panels 40a and 40b connected by a fold line
42 that is substantially in the center between the two gusset
panels. Side fold lines 44 and 46 connect the respective gusset
panels to the side walls with sealing portions of the gusset panels
extending the full depth of the side walls,
[0026] Preferably the outer panel 40a side fold line 44 is located
approximately 115.degree. relative to the bottom panel fold line
24a. Similarly, the fold line 42 between the gusset panels is
preferably located approximately 135.degree. relative to the bottom
panel fold line 24a. Additionally, the outer inner panel side fold
line 46 is preferably located approximately 158.degree. relative to
the bottom panel fold line 24a.
[0027] The outer edges of the gusset panels for the blank depicted
in FIG. 2 are defined by a substantially straight line 45, which
connects on one side to the outer edge 32a of a first side panel
32a, and at the other end connects to an angled edge 43, which
connects to a corresponding angled edge 41 of a second adjacent
side panel 21b. The gusset angled edge 43 connects with side panel
angled edge 41 at an angle of approximately 144.degree.. Other
angles that allow the gusset panels to align and adhere to the side
panels are also envisioned.
[0028] In one embodiment, the paperboard blank contains a gusset
panel with a cut-out portion. The cut-out portion is located in the
inner gusset panel that attaches to the side wall. By including a
cut-out, adhesive is also placed on a portion, typically the upper
portion of the outer gusset, thereby directly sealing the outer
gusset to the side wall as well.
[0029] For example, as shown in FIG. 3, the paperboard blank 100
contains a rectangular bottom panel 180 defined by fold lines 240a,
240b, 240c, and 240d, which are located on each side of the
rectangle. Each fold line also forms the inner edge of respective
side forming panels, 200a and 200b for the long side panels, and
210a and 210b for the two short side panels. Each side panel is
generally trapezoidal in form. The outer edges of each side panel
320a, 320b, 320c, and 320d, also correspond with the top of the
paper tray.
[0030] The gussets 30a, 30b, 30c, and 30d in the tray are formed
from overlapping gusset panels 400 and 410, which are connected by
a fold line 420 that is substantially in the center between the two
gusset panels. Side fold lines 440 and 460 connect the respective
gusset panels (400 and 410, respectively) to the adjacent side
walls (200b, 210a, respectively) with sealing portions of the
gusset panels extending the full depth of the side walls.
[0031] One gusset panel 400 in each pair of gusset panels
optionally includes a cut-out portion 430, which allows bonding of
the outer gusset panel 410 against the outer surface of the
corresponding side wall strengthening the corner of the tray and
allowing the outer gusset panel to seal directly to the sidewall,
instead of sealing to the inner gusset portion.
[0032] The cut out portion 430 is defined by outer edges 415 and
414. As shown in FIG. 3, the outer edges 415 and 414 define the
cut-out portion in the shape of a V. Alternatively, the cut-out
portion 430 can be located on the corresponding gusset panel 410,
such as shown in FIG. 4. One of ordinary skill in the art would
understand that other geometries are suitable for the cut-out
portion, to allow the outer gusset to attach directly to the
outside surface of the side wall.
[0033] The outer edges of the gusset panels for the blank depicted
in FIGS. 3 and 4 are defined by a substantially straight line 413,
which connects on one side to an outer edge 414 of the cut-out
portion, and at the other end connects o an angled edge 412, which
connects to a corresponding angled edge 411 of an adjacent side
panel 210b. The angled edge is configured to allow the gusset
panels to align when the tray is assembled.
[0034] Unless defined otherwise, all technical terms used herein
have the same meanings as commonly understood by one of skill in
the art to which the disclosed invention belongs.
[0035] Those skilled in the art will recognize, or be able to
ascertain using no more than routine experimentation, many
equivalents to the specific embodiments of the invention described
herein. Such equivalents are intended to be encompassed by the
following claims.
* * * * *