Multiple-Atmosphere, Nested Food Container

Abstract

A multi-atmosphere, nested food container having an opaque, thermoformed top tray with a modified atmosphere other than air for storing unpackaged, perishable food items therein nested within a transparent, thermoformed bottom tray having a non-modified atmosphere for prepackaged food items. The top tray is sealed with a transparent common air impermeable flexible film to allow for viewing of the food items therethrough. The top tray nests inside of the bottom tray such that a bottom surface of the top tray is placed inside of an opening at the top surface of the bottom tray. This orientation allows for the top tray to remain in a relatively upright position such that the top surface of the top tray remains visible to consumers.

1 . A multi-atmosphere, nested food container containing a plurality of individual food items having differing shelf-lives, the food container comprising:
 a transparent, thermoformed bottom tray having a bottom wall, a peripheral side wall extending upwardly from the bottom wall and having an uppermost peripheral rim surrounding an open end opposite the bottom wall, the side wall and bottom wall defining an interior containing prepackaged food items in a non-modified atmosphere;   an opaque, thermoformed top tray having an uppermost generally planar flange surrounding a plurality of openings and surrounding a periphery of the tray, the openings corresponding to separate compartments each having a depending sidewall and a bottom wall defining an interior for containing discrete, unpackaged perishable food items directly therein and filled with a modified atmosphere gas other than air, the top tray insertable into the bottom tray in an upright position such that the top tray nests inside a portion of an interior of the bottom tray with the portion of the flange surrouding the periphery of the top tray resting on the peripheral rim surrounding the opening of the bottom tray; and   a transparent common, air impermeable flexible film affixed to a portion of the flange surrounding the periphery of the top tray such that the interiors of the separate compartments are each visible through the flexible film and hermetically sealing each of the compartments.   
     
     
         2 . The food container according to  claim 1 , wherein the top tray and the bottom tray are both made from a rigid material. 
     
     
         3 . The food container according to  claim 1 , wherein the top tray is made from an oxygen barrier material and the bottom tray is made from a non-oxygen barrier material. 
     
     
         4 . The food container according to  claim 1 , wherein the gas is about 70% to about 85% nitrogen. 
     
     
         5 . The food container according to  claim 4 , wherein the gas is about 75% nitrogen with the balance carbon dioxide. 
     
     
         6 . The food container according to  claim 4 , wherein the top tray has an oxygen transmission rate of about 0.2 to about 0.4 cc/100 in 2 /24 h at a temperature of about 73° F. 
     
     
         7 . The food container according to  claim 1 , wherein a sleeve extends around the top and bottom trays to hold the trays together against unintentional separation until removal of the sleeve. 
     
     
         8 . The food container according to  claim 7 , wherein a portion of each of the compartments remains visible and uncovered upon application of the sleeve. 
     
     
         9 . The food container according to  claim 7 , wherein about less than 50% of an uppermost surface of the top tray remains visible and uncovered upon application of the sleeve. 
     
     
         10 . The food container according to  claim 7 , wherein the sleeve is not transparent. 
     
     
         11 . The food container according to  claim 1 , wherein the top tray has at least two or three compartments. 
     
     
         12 . The food container according to  claim 11 , wherein at least one of the compartments has a generally circular side. 
     
     
         13 . The food container according to  claim 1 , wherein the top tray has at least six compartments. 
     
     
         14 . The food container according to  claim 13 , wherein the at least six compartments are all generally rectangular. 
     
     
         15 . The food container according to  claim 13 , wherein at least two of the six compartments have a depressed common sidewall to allow for inserting a finger or other removal tool therein. 
     
     
         16 . The food container according to  claim 13 , wherein the at least six compartments are generally the same size. 
     
     
         17 . The food container according to  claim 1 , wherein the bottom wall of at least one compartment in the top tray has a raised portion for supporting food thereon above a bottommost portion of the bottom wall. 
     
     
         18 . The food container according to  claim 1 , wherein at least one of the compartments has a recess or notch for inserting a finger or other removal tool therein to provide for easier removal of the food item. 
     
     
         19 . The method of assembling a ready-to-eat food from a plurality of individual food items having differing shelf-lives, the steps comprising:
 providing a multi-atmosphere, nested food package having an opaque, thermoformed top tray having an uppermost generally planar flange surrounding a plurality of openings and surrounding a periphery of the tray, the openings corresponding to separate compartments each having a depending sidewall and a bottom wall defining an interior, the top tray sealed with a transparent common, air impermeable flexible film affixed to a portion of the flange surrounding the periphery of the top tray, such that the interiors of the separate compartments are each visible through the flexible film and hermetically sealing each of the compartments, the top tray insertable into a transparent, thermoformed bottom tray in an upright position such that the top tray nests inside a portion of an interior of the bottom tray, the bottom tray having a bottom wall, a peripheral sidewall extending upwardly from the bottom wall and having an uppermost peripheral rim surrounding an open end opposite the bottom wall, the sidewall and bottom wall defining an interior compartment, with the portion of the flange surrounding the periphery of the top tray resting on the peripheral rim surrounding the opening of the bottom tray;   removing the flexible film from the portion of the flange surrounding the periphery of the top tray to expose discrete, unpackaged perishable food items stored directly in the interior of compartments therein and containing a modified atmosphere other than air;   removing the top tray from the bottom tray to expose the interior compartment of the bottom tray filled with prepackaged food items in a non-modified atmosphere; and   assembling the ready-to-eat food from the plurality of individual food items in the top tray compartments.   
     
     
         20 . The method according to  claim 19 , further comprising the step of removing an outer sleeve that extends around the top and bottom trays to hold the trays together against unintentional separation until removal of the sleeve.