Blanks, trays, and associated methods for holding food products

Abstract

A tray for holding one or more food products includes a plurality of panels extending at least partially around the interior of the tray, the plurality of panels including a central panel and a plurality of side panels in at least partial face-to-face contact with respective portions of the central panel, the plurality of panels arranged to form a tray bottom, a sidewall extending upwardly from the tray bottom, and a flange extending outwardly from the sidewall, each panel of the plurality of panels having a laminate structure, the laminate structure including a base layer and a barrier layer, the plurality of side panels positioned at least partially reinforcing the flange of the tray.

What is claimed is: 
     
         1 . A tray for holding one or more food products, the tray comprising:
 a plurality of panels extending at least partially around the interior of the tray, the plurality of panels comprising a central panel and a plurality of side panels in at least partial face-to-face contact with respective portions of the central panel,   the plurality of panels arranged to form a tray bottom, a sidewall extending upwardly from the tray bottom, and a flange extending outwardly from the sidewall, each panel of the plurality of panels comprising a laminate structure, the laminate structure comprising a base layer and a barrier layer,   the plurality of side panels positioned at least partially reinforcing the flange of the tray.   
     
     
         2 . The tray of  claim 1 , wherein the central panel comprises a central portion and a marginal portion extending at least partially around the central portion, the central portion of the central panel at least partially forming the tray bottom and the sidewall of the tray. 
     
     
         3 . The tray of  claim 2 , wherein each side panel of the plurality of side panels is in at least partial face-to-face contact with the marginal portion of the central panel to at least partially form and reinforce the flange of the tray. 
     
     
         4 . The tray of  claim 3 , wherein each side panel of the plurality of side panels is in at least partial face-to-face contact with the central portion of the central panel to at least partially form and reinforce the sidewall of the tray. 
     
     
         5 . The tray of  claim 4 , wherein each side panel of the plurality of side panels at least partially form and reinforce the tray bottom of the tray. 
     
     
         6 . The tray of  claim 2 , wherein the central panel further comprises a plurality of corner portions, the plurality of corner portions at least partially forming respective corners of a plurality of corners of the tray. 
     
     
         7 . The tray of  claim 6 , wherein the plurality of corner portions comprises a respective plurality of lines of weakening facilitating formation of the respective corners of the plurality of corners of the tray. 
     
     
         8 . The tray of  claim 2 , wherein the plurality of side panels comprises a first side panel and a second side panel. 
     
     
         9 . The tray of  claim 8 , wherein the plurality of side panels further comprises a third side panel and a fourth side panel. 
     
     
         10 . The tray of  claim 9 , wherein each side panel of the plurality of side panels have a generally tapered configuration. 
     
     
         11 . The tray of  claim 9 , wherein the tray further comprises a plurality of corner gussets foldably connected to the central panel, each corner gusset of the plurality of corner gussets foldably connected to a respective side panel of the plurality of side panels. 
     
     
         12 . The tray of  claim 11 , wherein at least one corner gusset of the plurality of corner gussets comprises a central portion and at least one outer portion foldably connected to the central portion of the at least one corner gusset, the central portion of the at least one corner gusset foldably connected to the central panel, the at least one outer portion of the corner gusset foldably connected to the respective side panel of the plurality of side panels. 
     
     
         13 . The tray of  claim 8 , further comprising handle features, the handle features comprising a plurality of handle flaps forming a plurality of handles, each handle repositionable between a first position, in which each handle is at least partially coextensive with a respective side panel of the plurality of side panels, and a second position, in which each handle is separated from the respective side panel of the plurality of side panels. 
     
     
         14 . The tray of  claim 13 , wherein each handle flap is foldably connected to the respective side panel of the plurality of side panels. 
     
     
         15 . The tray of  claim 13 , wherein each handle flap is foldably connected to the central panel. 
     
     
         16 . A blank for forming a tray for holding one or more food products, the blank comprising:
 a plurality of panels for extending at least partially around the interior of the tray formed from the blank, the plurality of panels comprising a central panel and a plurality of side panels for being positioned in at least partial face-to-face contact with respective portions of the central panel when the tray is formed from the blank,   the plurality of panels for being arranged to form a tray bottom, a sidewall extending upwardly from the tray bottom, and a flange extending outwardly from the sidewall when the tray is formed from the blank, each panel of the plurality of panels comprising a laminate structure, the laminate structure comprising a base layer and a barrier layer,   the plurality of side panels for being positioned at least partially reinforcing the flange of the tray formed from the blank.   
     
     
         17 . The blank of  claim 16 , wherein the central panel comprises a central portion and a marginal portion extending at least partially around the central portion, the central portion of the central panel for at least partially forming the tray bottom and the sidewall of the tray formed from the blank. 
     
     
         18 . The blank of  claim 17 , wherein each side panel of the plurality of side panels is for being positioned in at least partial face-to-face contact with the marginal portion of the central panel to at least partially form and reinforce the flange of the tray formed from the blank. 
     
     
         19 . The blank of  claim 18 , wherein each side panel of the plurality of side panels is for being positioned in at least partial face-to-face contact with the central portion of the central panel to at least partially form and reinforce the sidewall of the tray formed from the blank. 
     
     
         20 . The blank of  claim 19 , wherein each side panel of the plurality of side panels is for being positioned at least partially forming and reinforcing the tray bottom of the tray formed from the blank. 
     
     
         21 . The blank of  claim 17 , wherein the central panel further comprises a plurality of corner portions for at least partially forming respective corners of a plurality of corners of the tray formed from the blank. 
     
     
         22 . The blank of  claim 21 , wherein the plurality of corner portions comprises a respective plurality of lines of weakening. 
     
     
         23 . The blank of  claim 17 , wherein the plurality of side panels comprises a first side panel and a second side panel. 
     
     
         24 . The blank of  claim 23 , wherein the plurality of side panels further comprises a third side panel and a fourth side panel. 
     
     
         25 . The blank of  claim 24 , wherein each side panel of the plurality of side panels have a generally tapered configuration. 
     
     
         26 . The blank of  claim 24 , wherein the tray further comprises a plurality of corner gussets foldably connected to the central panel, each corner gusset of the plurality of corner gussets foldably connected to a respective side panel of the plurality of side panels. 
     
     
         27 . The blank of  claim 26 , wherein at least one corner gusset of the plurality of corner gussets comprises a central portion and at least one outer portion foldably connected to the central portion of the at least one corner gusset, the central portion of the at least one corner gusset foldably connected to the central panel, the at least one outer portion of the corner gusset foldably connected to the respective side panel of the plurality of side panels. 
     
     
         28 . The blank of  claim 23 , further comprising handle features, the handle features comprising a plurality of handle flaps for forming a plurality of handles when the tray is formed from the blank, each handle repositionable between a first position when the tray is formed from the blank, in which each handle is at least partially coextensive with a respective side panel of the plurality of side panels, and a second position when the tray is formed from the blank, in which each handle is separated from the respective side panel of the plurality of side panels. 
     
     
         29 . The blank of  claim 28 , wherein each handle flap is foldably connected to the respective side panel of the plurality of side panels. 
     
     
         30 . The blank of  claim 28 , wherein each handle flap is foldably connected to the central panel. 
     
     
         31 . A method of forming a tray for holding one or more food products, the method comprising:
 obtaining a blank comprising a plurality of panels, the plurality of panels comprising a central panel and a plurality of side panels, each panel of the plurality of panels comprising a laminate structure, the laminate structure comprising a base layer and a barrier layer;   positioning the plurality of panels extending at least partially around an interior of the tray;   positioning the plurality of side panels in at least partial face-to-face contact with respective portions of the central panel;   arranging the plurality of panels to form a tray bottom, a sidewall extending upwardly from the tray bottom, and a flange extending outwardly from the sidewall; and   at least partially reinforcing the flange of the tray with the plurality of side panels.   
     
     
         32 . The method of  claim 31 , further comprising press-forming the blank to at least partially form the tray. 
     
     
         33 . The method of  claim 32 , comprising positioning the plurality of side panels in at least partial face-to-face contact with respective portions of the central panel prior to press-forming the blank. 
     
     
         34 . The method of  claim 33 , wherein the central panel comprises a central portion and a marginal portion extending at least partially around the central portion, and the blank is press-formed such that the central portion of the central panel at least partially forms the tray bottom and the sidewall of the tray extending upwardly from the tray bottom. 
     
     
         35 . The method of  claim 34 , comprising positioning each side panel of the plurality of side panels in at least partial face-to-face contact with the marginal portion of the central panel such that the blank is press-formed such that each side panel of the plurality of side panels at least partially forms and reinforces the flange of the tray extending outwardly from the sidewall. 
     
     
         36 . The method of  claim 35 , comprising positioning each side panel of the plurality of side panels in at least partial face-to-face contact with the central portion of the central panel to at least partially form and reinforce the sidewall of the tray. 
     
     
         37 . The method of  claim 36 , comprising positioning each side panel of the plurality of side panels at least partially forming and reinforcing the tray bottom of the tray. 
     
     
         38 . The method of  claim 34 , wherein the central panel further comprises a plurality of corner portions, the plurality of corner portions press-formed to at least partially form respective corners of a plurality of corners of the tray. 
     
     
         39 . The method of  claim 38 , wherein the plurality of corner portions comprises a respective plurality of lines of weakening facilitating formation of the respective corners of the plurality of corners of the tray. 
     
     
         40 . The method of  claim 34 , wherein the plurality of side panels comprises a first side panel and a second side panel. 
     
     
         41 . The method of  claim 40 , wherein the plurality of side panels further comprises a third side panel and a fourth side panel. 
     
     
         42 . The method of  claim 41 , wherein each side panel of the plurality of side panels have a generally tapered configuration. 
     
     
         43 . The method of  claim 41 , wherein the tray further comprises a plurality of corner gussets foldably connected to the central panel, each corner gusset of the plurality of corner gussets foldably connected to a respective side panel of the plurality of side panels. 
     
     
         44 . The method of  claim 43 , wherein at least one corner gusset of the plurality of corner gussets comprises a central portion and at least one outer portion foldably connected to the central portion of the at least one corner gusset, the central portion of the at least one corner gusset foldably connected to the central panel, the at least one outer portion of the corner gusset foldably connected to the respective side panel of the plurality of side panels. 
     
     
         45 . The method of  claim 40 , further comprising handle features, the handle features comprising a plurality of handle flaps forming a plurality of handles, each handle repositionable between a first position, in which each handle is at least partially coextensive with a respective side panel of the plurality of side panels, and a second position, in which each handle is separated from the respective side panel of the plurality of side panels. 
     
     
         46 . The method of  claim 45 , wherein each handle flap is foldably connected to the respective side panel of the plurality of side panels. 
     
     
         47 . The method of  claim 45 , wherein each handle flap is foldably connected to the central panel.