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.

We claim: 
     
         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° with respect to the bottom. 
     
     
         7 . The tray of  claim 6 , wherein the angle ranges from about 100° to about 120°. 
     
     
         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.