Food tray with condiment compartment

[0002] This application claims the benefit of the U.S. Provisional Patent Application No. 60/265,125, filed on Jan. 31, 2001, the contents of which are incorporated herein by reference.

[0003] This application is also a continuation-in-part application of U.S. Application Ser. No. 09/892,653, filed Jun. 28, 2001 now pending.

[0004] One popular manner of serving foodstuffs, particularly in a “fast food” environment, involves the use of open top trays which can easily accommodate french fries, onion rings, chicken nuggets, popcorn shrimp, and like finger foods.

[0005] It is often desirable to accompany such foodstuffs with an appropriate condiment which may either be dispensed directly onto the foodstuff within the tray, particularly if consumed immediately, or more likely provided in a separate small container or cup which may be placed within the tray with the foodstuff, if there is sufficient room, or, more likely, carried separately. It has also been proposed to provide food trays which are actually incorporated into the main tray, note for example, U.S. Pat. No. 4,126,261, issued Nov. 21, 1978.

[0006] The provision of such food trays with incorporated condiment pockets, while a particularly desirable feature, does give rise to problems. More specifically, fast food containers, to be both practical and economically feasible must be both inexpensive as they are throwaway items and must be extremely easy to manipulate both by the vendor and by the customer.

[0007] As a practical matter, the tray, for both shipping and storage purposes, must present a compact package. Pursuant thereto, two basic forms of tray have been used, formed trays which are formed at the time of manufacture into a fully erected position for stacking within compact stacks of duplicate trays. Alternatively, and sometimes preferred, the trays leave the manufacturing process as a flat folded item allowing for a flat overlying packing of multiple folded trays. Both the preformed tray and the folded tray have particular advantages.

[0008] The present invention comprises a foldable tray, that is a tray which at the end of the manufacturing procedure is a flat folded item, which, notwithstanding the folded nature thereof, incorporates an integral condiment compartment or pocket internally within the main compartment of the tray. A significant aspect of the condiment pocket as proposed by the present invention is the additional utilization of the pocket, or more particularly the partition panel which defines the pocket to rigidify the collapsible walls of the tray in the erected position thereof at the time of use. Thus, the erected tray has a stability which closely approaches that of a preformed tray, while incorporating all of the advantages of a flat folded manufactured item.

[0009] The folded tray of the invention is what is referred to in carton manufacturing as a straight line glued folding carton. This differs from a formed tray which requires the use of a forming tool that is only adapted for use with a single size product. As the design of the tray of the invention does not need a forming tool in its production, size changes can be easily made in accord with customer desires. Further, it is noted that most packaging companies utilize “straight line gluers” as opposed to “formers”. As such, the carton or tray as proposed herein is considered particularly practical.

[0010] The tray, folded from a unitary sheet of paperboard or the like, includes a rectangular bottom or bottom panel with opposed side walls and opposed end walls projecting upwardly from the bottom to form an open top container. The walls are end joined by appropriate glue flaps. The opposed side walls include end sections defined by fold lines extending diagonally upward from the corners of the bottom, forming the end sections and a rather wider central section therebetween. In folding the tray, the side walls, and more particularly the central sections thereof, fold inward over the bottom with the side wall end sections first folding outward relative to the corresponding central sections and then inward over the collapsing central sections.

[0011] The condiment pocket of the invention includes a partition or partition panel which is coextensive with one of the end walls and foldably joined to the bottom along the base edge of the end wall. A triangular end panel is foldably joined to each end of the partition panel with these ends panels overlying the adjacent end sections of the two side walls. Each of these end panels in turn includes a glue flap foldably joined thereto and adhesively bonded to the corresponding end sections inward of the end section defining fold line. The partition panel, so mounted, will be movable between a collapsed position lying against the end wall and an open position remote from the end wall. In the collapsed position of the partition panel each end panel and corresponding glue flap are coplanar for a collapsible folding of the end panel and glue flap with the corresponding side wall end section inward of the partition panel and end wall. The folding of the carton is completed with the partition panel and end walls folding downward over the side walls to a fully collapsed position.

[0012] In the open position of the tray and condiment pocket, the partition panel is flipped inward relative to the end wall with the end panels at the opposite ends of the partition panel inverting to overlie the glue flaps. In this position, the partition panel exerts a stabilizing outward force on the opposed side walls whereby an inward collapsing of the side walls is precluded, and an upwardly opening condiment pocket is defined. With inward movement of the side walls precluded by the transverse partition panel in its open position, a substantial degree of rigidity is introduced into the open tray, notwithstanding the forming of the tray from a flat folded manufactured configuration.

[0013] The tray, including the pocket-defining partition, is formed from a single blank with that portion of the blank forming the partition severing from the remainder of the blank only at such time as the tray is completely formed, and preferably as the tray and pocket are opened at the point of use.

[0014] Other objects, features and advantages of the invention will become apparent as the details of the invention are more fully hereinafter set forth.

[0015] FIG. 1 is a plan view of the food tray folded in its flat shipping and storage position;

[0016] FIG. 2 is a top perspective of the open tray and prior to an opening of the condiment pocket;

[0017] FIG. 3 is a top perspective view similar to FIG. 2 with the condiment pocket open and the pocket forming partition panel extending between and bracing the opposed collapsible side walls.

[0018] FIG. 4 is a perspective detail of the corner of the tray at one end of the partition panel with a portion of the end panel and glue flap folded back to more clearly illustrate the structural arrangement of the overlapped components;

[0019] FIG. 5 is a side elevational view of the open tray; and

[0020] FIG. 6 is a plan view of the blank from which the tray is folded.

[0021] Referring now more specifically to the drawings, the tray 10 of the invention basically includes a planar preferably rectangular bottom 12 with opposed side walls 14 coextensive with opposed longitudinal edges 16 of the bottom 12 and upwardly folded therefrom along fold lines defined along these edges.

[0022] First and second end walls 18 and 20 are coextensive with end edges 22 and 24 of the bottom 12 and are upwardly folded about fold lines defined along these edges 22 and 24. The side and end walls are joined end to end to define a continuous peripheral wall by glue flaps 26 on the opposite ends of end wall 18 and similar glue flaps 28 on the opposite ends of end wall 24. These glue flaps 26 and 28 overlie the inner faces of the opposed side walls 14 at the end portions thereof and are bonded thereto. As will be noted in the blank of FIG. 6, both the side walls 14 and the end walls 18 and 20 are of a generally trapezoidal configuration widening outward from the side and end edges 16, 22 and 24 of the bottom 12, thereby providing for an outward flaring of the tray walls upward from the bottom 12 thereof.

[0023] In order to provide for the desired inward folding of these walls 14, 18 and 20, each of the side walls 14 is provided with a pair of fold lines 30 extending diagonally upward from each of the lower end corners thereof at the corresponding corner of the bottom 12 defined by the bottom side edges 16 and each end edge 22 and 24. The fold lines 30 divide each of the side walls 14 into a generally trapezoidal central section 32 and two smaller inverted triangular end sections 34. As will be noted particularly in FIG. 3, the end walls glue flaps 26 and 28 overlie and are bonded to the end sections 34 of the side walls 14 and thus inwardly fold therewith in a manner which would be best appreciated from FIG. 2. Basically, the center sections 32 of the opposed side walls 14 fold inwardly about the longitudinal edges 16 of the bottom 12 while the triangular side wall end sections 34 inwardly move therewith and outwardly fold to overlie the outer surfaces of the central sections 32 and simultaneously inwardly fold the end walls 18 and 20 to overlie the folded and collapsed side walls 14 as will be noted in FIG. 1.

[0024] Noting FIG. 3, the foldable tray 10 includes a collapsible condiment pocket 36 formed at one end thereof in conjunction with end wall 18. The pocket 36 is basically defined by a movable partition panel 38 which extends between the end sections 34 of the side walls 32 and is coextensive with end wall 18 across the width thereof and for substantially the full height thereof.

[0025] The partition panel 38 in its collapsed position prior to an opening of the pocket 36, as noted in FIG. 2, directly overlies the end wall 18. The lower edge 40 of the partition panel 38 lies along the end edge 22 of the bottom 12 with this lower edge 40 being fixed to the bottom 12 by a laterally directed glue flap 42 integral with the lower edge 40 of the panel 38 and bonded to the adjacent portion of the bottom 12. The partition panel 38, so positioned, is foldable with the end wall 18 between the collapsed folded position of the tray and the open position thereof.

[0026] A pair of inverted triangular end panels 44 are integral with the opposed end edges of the partition panel 38 along fold lines 46. Each end panel 44 freely overlies the inner face of the corresponding side wall end section 34 with the fold line 46 extending upward from the corresponding corner of the bottom 12 and within the corner defined between the end wall 18 and the corresponding side wall 14.

[0027] Each end panel 44 in turn has a glue flap 48 integral with the end panel 44 along a fold line 50 extending upward from the corresponding corner of the bottom 12 and defining, with the fold line 46, the apex of the inverted triangular configuration of the end panel 44. The glue flap 48, coplanar with the end panel 44, overlies the inner face of the corresponding end section 34 of the adjacent side wall 14 and is bonded to this section 34. This bonded area is generally indicated at reference numeral 52 in FIGS. 2 and 4. As desired, each of the glue flaps 48 can depend below the diagonal fold line 30 which defines the corresponding side wall end section 34, as indicated at 54, to freely overlie that portion of the central section 32 of the side wall 14 immediately below the fold line 30 to provide additional stability in the opened tray as shall be described subsequently.

[0028] With the end panels 44 of the partition and the glue flaps 48 solely bonded, through the glue flaps 48, to the side wall end sections 34, each end panel 44 and companion glue flap 48 will fold with the corresponding side wall end section 34 in the manner previously described for the end section alone and as suggested in FIG. 2. Thus, the partition panel is effectively accommodated in the folded or collapsed position of the food tray.

[0029] Noting specifically FIG. 3, when it is desired to open the pocket 36 after an outward folding of the tray walls, one need merely engage the upper edge portion 56, suitably configured for easy access thereto, and move this upper edge inwardly relatively to the interior of the tray whereby the partition panel 38 is pivoted away from the end wall 18 about the lower edge 40 thereof. In doing so, the triangular end panels 44, foldably joined to the opposite ends of the partition panel 38, inwardly rotate 180° about fold lines 50, such folding being accommodated by fold lines 46 which define the end panels, to a position whereby the end panels 44 overlie the corresponding glue flaps 48 inward of the end wall 18. In this position, the partition panel 38 forcibly engages against the opposed side walls 14 generally at the adjacent side wall fold lines 30 to preclude any tendency for the opposed side walls 14 to inwardly fold. It will be noted that this engagement is principally with the corresponding side wall end sections 34, thus preventing an inward flexing of these end sections 34 toward each other as would be required for an inward movement of the side wall central sections 32 to the collapsed position thereof. With continued reference to FIG. 3, it will be noted that the lower sections 54 of the glue flaps 48 are also forcibly retained against the central section 32 of the side walls 14 by the partition panel 38 as a further rigidification of the opposed side walls against inward collapse toward each other.

[0030] As will be recognized, the combined width of the partition panel 38 and the two associated end panels 44 is greater than the width of the tray. As such, movement of the partition panel between the closed and open positions thereof, and the inverting or over center movement of the end panels 44, is accommodated by the inherent resilient flexible nature of the material. Further, the partition panel, in each of its positions, is physically fixed against accidental movement and requires a positive manual manipulation to move over center, particularly from its collapsed position of FIG. 2 to its open position of FIG. 3. Once in its open position of FIG. 3, the partition panel will remain open and provide a positive intermediate brace between the opposed side walls resulting in a rigid food tray, notwithstanding the collapsible nature thereof. There is thus achieved a tray with internal pocket which incorporates all of the desirable features of a folded carton, along with the rigidity and stability of a formed carton.

[0031] Referring now to FIG. 6, the unitary blank from which the tray of the invention is formed has been illustrated therein. All of the above described walls, panels, sections, and the like, of the tray have been designated by like reference numerals for ready comparison.

[0032] One feature of the invention best illustrated in the blank is the integral nature of the partition panel 38 which, in the blank, is longitudinally aligned with the end wall 18 along a parting line therebetween including a central arcuate segment 60 in the nature of a cut line which, upon a folding of the partition panel 38 over the end wall 18 provides the desired upward gripping area or lip 56 for the inward flipping of the partition panel. The parting line also includes, to the opposite ends of the central arcuate cut 60, longitudinally extending severance or readily separable parting lengths 62 which retain the partition panel 38 and adjoining end panel during the folding thereof. Such severance lines 62, if not parted before, will readily part upon an inward flipping of the partition panel from the position of FIG. 2 to the position of FIG. 3.

[0033] As will be noted, the blank, in order to avoid waste and maximize the use of material, is of a generally rectangular configuration with the end walls, bottom and partition panel longitudinally aligned and with the opposed side walls extending along the opposed edges of the bottom 12 and in turn aligning with the tray glue flaps 26 and 28 as well as the partition panel end panels 44 and associated glue flaps 48. The side walls 14, as previously described with regard to the tray itself, each include a pair of diagonal fold lines 30 which extend from the corresponding corners of the bottom 12 and divide each side wall 14 into three foldably related sections. Other than for these side walls, the remaining walls and panels, while interconnected by appropriate fold lines, are in themselves non-folding panels.

[0034] It is to be appreciated that in the above detailed description of the invention, the terms side wall and end wall have been used to facilitate illustration of the features of the invention. The tray can, as desired, be square with the four walls thereof equal. Further, the described pocket can equally be mounted relative to a longer side wall as opposed to a relatively shorter end wall. It should also be recognized that opposed pockets can similarly be provided on a pair of opposed walls, whether end walls or side walls. Basically, while preferred embodiments have been set forth, various modifications, changes and the like, as fall within the scope of the invention set forth in the claims following hereinafter are also contemplated.