BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention generally relates to a preconstructed folding food tray which is adapted to open and close easily and, more particularly, to a foldable tray blank and method of erecting the blank to form the constructed tray. The present invention is an improvement of the prior art invented by DeMay and filed with the US Patent & Trademark Office in 1995, U.S. Pat. No. 5,411,204.

2. Brief Description of the Prior Art

Fast, convenient take-out and prepared food services have become a way of life in modern society. There many food trays, containers have been made and distributed to retails where food are served and delivered. Furthermore, many gift shops have used verity of such containers as gift wrapping and decorations. The most commonly used food tray is the Chinese food pail that is universally known in the take-out food industry. It is preconstructed at the manufacturing plant by folding a precut blank and fastening the gusset flaps with glue or metallic wire. Commercial products of this type have been offered by Fold-Pak Corporation since approximately 1977. Hundreds of millions such food pails are manufactured and distributed worldwide annually.

The food pails fastened by adhesive (glue) are easily break open during stacking and shipping and adhesive is deposited on the interior surface of the blank, specifically between the adjacent panels which form each corner of the carton. When exposed to high temperature, this adhesive can cause undesirable contamination of the contents and once opened, it is quite a hassle to reclose. Those that are using metal wire are not microwave resistant if the metal wire is not removed, as well, it is not convenient to open for pouring out of food or use it as disposable dinning container. Without opening the tray, food or contents is almost invisible from other angles unless directly peak from top opening. In addition, they all are pre-constructed at manufactures and take certain amount of space for packaging, shipping and storing. The DeMay's 1990 invention of the recloseable food tray only offered the previously existing food pail a top recloseable panels. The present invention permits the food pail re-open and reclose from both top and side as end user desires.

This disclosure indicates a clear need for a folding food carton which overcomes the deficiencies of earlier art-recognized techniques. Furthermore, the current computer guided precision cut and laser cut technologies have made the present invention easily manufactured and cost effective possible.

Accordingly, it is a primary object of the present invention to provide a blank, reclosable food tray which is substantially leak-proof and adapted for exposure to microwave and other high temperature applications.

It is another object of the present invention to provide a convenient, reusable container for an assorted selection of take-out and prepared foods

Another object is to provide a food tray which can be shipped in blank to the end user. It is cost effective on manufacturing, wrapping, shipping and storing.

It is a further object of the present invention to provide a food tray which has improved operability and improved â€œcloseabilityâ€ and which affords improved protection to the food contents after reclosing.

Another object is to provide an easy reopen/recloseable container that make the content transferred from, or to other containers easily. As well, make food or content in tray more visible from opening.

A further object of the present invention is to provide a container that can be easily opened and served as a temporary, informal food plate and make-shift dinning containers for casual occasions.

A further object of the present invention is to provide folding tray blanks which can be constructed in a simple and efficient manner. Optimally, it can be stored as tray blank and constructed by end user at last minute when needed.

Another object of the present invention is to provide tray blanks of varying configurations which are adapted with cuts and score lines to form an assembled tray container for take-out and prepared foods.

Another object of the present invention is to provide an environmentally attractive food tray made from biodegradable material. Less material is used, less energy consumed when manufacturing it. In result, less packing material and less cargo space when shipping.

A further object of the present invention is to provide tray blanks which are adapted for manufacture from paperboard sheet stock using high-speed cutting and scoring machines.

It is a further object of the present invention to provide tray blanks using a minimum amount of stock during the cutting and scoring operations.

A further object of the present invention is to provide a method of erecting the food tray without high speed operations involved.

Another object of the present invention is to provide end user a carrying strap that is capable carrying multiple containers at same time as very commonly that people taking out several different food containers on a single trip.

A further objective of the present invention is to minimize, or even eliminate, the usage of extra brown, plastic bags that are commonly provided to host multiple containers.

A further objective of the present invention is to expose exterior surface which could be utilized for retail logos, advertisements, art work/decoration, identification marks and social awareness communications, etc.

Based on this disclosure, additional objects of the present invention will be apparent to those with ordinary skill in the pertinent art.

SUMMARY OF THE INVENTION

A reclosable food tray is provided by one aspect of the present invention. The tray is constructed from a single unitary blank, and comprises a receptacle portion and first and second pair of opposing closure flaps.

The receptacle portion has access openings, from top or from side, which permits introduction of food. Its volume is defined by a rectangular shaped bottom panel and two substantially upstanding pair of opposing side panels. The two pair of opposing side panels extend substantially upright from the bottom panel and define four pair of adjacent side panels at the corners of the bottom panel. Each pair of adjacent side panels are hingedly connected in a liquid-sealed manner, by a folded gusset unitary with the respective adjacent side panels, and is secured by Yang's notch cuts on the folded gussets. The first pair of opposing closure flaps that have Yang's notch cut extend from one pair of opposing side panels and are capable of covering or closing off a portion of the access opening. The second pair of opposing closure flaps that have Yang's notch cut extend from the other pair of opposing side panels and are interlocked by Yang's notch cuts to cooperate with each other, overlap a portion of the first pair of opposing closure flaps that can be interlocked by Yang's notch cut, and cover the remaining portion of the access opening. Each folded gusset is suitably dimensioned so that the receptacle portion is capable of retaining liquids or semi-solid consumables without leakage. Each folded gusset is also bearing Yang's notch cut that serves as interlock mechanism to hold the tray in shape.

In the preferred embodiment, the food tray is erected from a paperboard or stiff plastic material which is substantially resistant to microwave and other heat radiation. With the food tray of the present invention, food can be safely and efficiently heated in a microwave or convection oven.

According to another aspect of the present invention, a tray blank is provided having a planar unitary construction and a substantially rectangular gross geometry. The blank generally comprises a bottom panel; first and second pair of opposing side panels; four foldable gussets with Yang's notch cut and first and second pair of opposing closure panels with Yang's notch cut.

The bottom panel has a rectangular shape and a surface area defined by a first and second pair of opposing bottom fold lines. The first and second pair of opposing side panels are hingedly connected to the bottom panel at the first and second pair of opposing bottom fold lines, respectively. These opposing panels define four pair of adjacent side panels, each adjoining at a corner of the bottom panel. Each foldable gusset is hingedly connected to each pair of adjacent side panels. When the first and second opposing side panels are folded substantially upright with respect to the bottom panel, the tray receptacle with an access opening is formed, each gusset is folded adjacent toward an exterior portion of one side panel and interlock with an opposing gusset through Yang's notch cuts. With Yang's notch cut on said gusset, it permits gussets detach from each other that also permits one side panel tilt open as side receptacle access. Each side panel is disposed substantially upright at a predetermined obtuse angle with respect to the bottom panel.

The first pair of opposing closure panels is hingedly connected to the first pair of opposing side panels. Each closure panel has a said Yang's notch cut at its top edge, is adapted to close off a portion of the access opening when folded and disposed substantially parallel to the bottom panel. The second pair of opposing closure panels is hingedly connected to the second pair of opposing side panels, and adapted to overlay a portion of the first pair of opposing closure panels and close off the remaining portion of the access opening through Yang's notch cut. A fastening means may be provided for selectively opening and closing the second pair of closure panels.

Another aspect of the present invention concerns a novel method of erecting a food tray from a blank in a simple, yet highly efficient manner with a minimum number of folding operations.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference is made to the following description of the preferred embodiment in connection with the accompanying drawings. With FIG. 1 as the reference, all the numbers and letters on different illustrations of the first present invention, the food tray, are intent to be consistent with FIG. 1; With FIG. 7 as the reference, all the letters and numbers on different illustrations of the second present invention, the carrying strap, are intend to be consistent with FIG. 7, wherein:

FIG. 1 is a plan view of the new and improved tray blank of the present invention.

1, 2, 3 and 4 are Yang's notch cut on top closure panels; 5 through 12 are Yang's notch cut in back to back fashion on gussets 21,22, 23 and 24; 26 through 33 are optional short line cut that associate with Yang's notch cuts for easy insertion and security of Yang's notch cut when erected the tray blank to shape; 25 is the bottom panel; 17, 18, 19 and 20 are substantially upstanding side panels; 13, 14, 15 and 16 are closure panels; 34 through 53 are foldable lines.

FIG. 2 is a perspective view of the new and improved tray, in erected and half-way enclosed stage of the present invention; it illustrates the second stage of erecting a tray blank to tray container. Visible Yang's notch cuts, 5, 6, 9, 10, 11 and 12 on visible gussets 21, 23 and 24; Yang's notch cuts 1, 2, 3 and 4 on closure panels 13, 14, 15 and 16. All Yang's notch cuts are not yet hooked into each other to fully close the food tray at this stage.

FIG. 3 is a perspective view of the tray blank after it has been completely folded to form the food tray of the present invention, being shown in its erected position ready for stacking with other like trays and ready to be carried by the second invention, Carrying Strap, described in said claim 24 above;

FIG. 4 is a detailed plan view of one Yang's notch cut 1, in 2, one of the four closure gussets; Inner loop line 5 and outer loop line 6 merge into each other at tip point 3; 4 is optional rough edge (zigzag or teeth like lines) on inner loop line 5 to increase friction for more security when notch cut intertwined. Inner loop line 5 can be a smooth loop line without rough edge. This drawing illustrates only partial closure panel.

FIG. 5 is a detailed plan view of Yang's notch cut 1 and 2 on opposite side of gussets that have been folded together along folding line (not shown in this drawing), but before hook into each other.

FIG. 6 is detailed plan view of one foldable gusset with two Yang's notch cuts 1 and 2 are in back to back position before folding lines pressed. The two sections 8 and 9 divided by foldable line 5 are in equal size and mirror image. 3 and 4 represent the short line cut for more security after two notch cuts intertwined. When folded, the two sections 8 and 9 will become one section with two identical layers (see 9 and 10 in FIG. 7).

FIG. 7 is a detailed plan view of two gussets after folded becoming double layers, before intertwined to connect. 1 and 2 are Yang's notch cuts with two layers on two opposite gussets; 3 and 4 are short cuts with two layers; 9 and 10 are two opposite gussets after folded the illustration as FIG. 6.

FIG. 8 is a plan view of the new invention, the Carrying Strap, designed to carry single and/or multiple the new and improved food tray. Bottom rectangle panel A; triangle panels B and C; foldable lines J, J1, J2, J3, K, K1, K2 and K3 (folding lines can be selected based on needs); fish scale cut F, F1, F2, F3, G, G1, G2 and G3 (scale cut can be more or less based on needs); strap on opposite end E and D; short line cut H, H1, H2, H3, I, I1, I2 and I3 (short line can be selected based on needs); round tip M and N; 0, P, Q, R, S and T are edge lines.

FIG. 9 is a perspective view of the erected Carrying Strap with one said food tray sliding down toward to the bottom panel of the present invention, the Carrying Strap. To stack more said food trays, the same operation will be repeated.

FIG. 10 is a perspective view of multiple of the first present invention, the Food Tray fully erected and stacked in a fully erected and looped the second present invention, the Carrying Strap.

OPERATION (NUMBERS BELOW REFERRED TO FIG. 1)

- 1) Erect the pre-cut, pre-shaped flat single unitary blank paper/plastic sheet to box shape. Press the blank sheet along folding lines 34 through 53;
- 2) Push first pair of foldable gussets 21 and 22, and then second pair 23 and 24 toward to each other until they overlap to each other;
- 3) Gently twist and wiggle to snap double layered Yang's notch cuts, 5 and 6 pair to 7 and 8, then 9 and 10 pair to 11 and 12, into each other;
- 4) Pull back gently to make sure the two said notch cuts snug tightly and intertwined;
- 5) Put food or other contents into the food tray; (Note: food or contents can be introduced through unclosed side panel that has foldable gussets that are enclosed by Yang's notch cuts.)
- 6) Close the first pair of re-closable top closure panels 13 and 15 and then, 14 and 16, by Yang's notch cuts as described in Step 3 and 4 to close the tray;
- 7) Erect the second present invention, the carrying strap, from blank. Fold it along the foldable line to adjust bottom panel A to match the size of bottom panel of the food tray;
- 8) Slide in the carrying strap, from bottom to top, between intertwined two pairs of foldable gussets, 21 & 22 and 23 & 24 that have been connected and interlocked by Yang's notch cuts. Alternately, fold and interlock the guests after the carrying strap is in position;
- 9) Lock the carrying strap at two ends by using short line cut, H and I, into each other;
- 10) Push inward the fish scale cut(s), G and F, on the straps D and E, to add extra stability and security while carrying the food tray. The purpose of the fish scale cuts is to minimize trays' movement.
- 11) To access food or contents of the tray, remove food tray(s) from the Carrying Strap;
- 12) Twist and unlock Yang's notch cut to reopen the food tray from side or from top.

REFERENCE

Provisional patent application: U.S. 61/633,793, Filed Feb. 18, 2013 Receipt Date: Mar. 5, 2012

U.S. Patent Documents

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Foreign Patent Documents

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Other References

Fold-Pak, Chinese Food Pail Blank No. 1J, 1977.