CA1167420A - Insulated food tray and lid therefore - Google Patents

Insulated food tray and lid therefore

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Publication number
CA1167420A
CA1167420A CA000360288A CA360288A CA1167420A CA 1167420 A CA1167420 A CA 1167420A CA 000360288 A CA000360288 A CA 000360288A CA 360288 A CA360288 A CA 360288A CA 1167420 A CA1167420 A CA 1167420A
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CA
Canada
Prior art keywords
lid
tray
insulator
panels
set forth
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000360288A
Other languages
French (fr)
Inventor
Walter B. Herbst
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Allegiance Corp
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Application granted granted Critical
Publication of CA1167420A publication Critical patent/CA1167420A/en
Expired legal-status Critical Current

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Abstract

INSULATED FOOD TRAY AND LID THEREFORE

ABSTRACT OF THE DISCLOSURE

An insulated food serving tray and lid, each of which includes a preformed foam insulator with laterally spaced dish cavities. Each foam insulator is permanently sealed between two preformed panels, one of which has compli-mentary dish cavities. The insulator is of a generally rigid polystyrene bead foam and has a construction fitting around the plural cavities. This construction provides at least a portion of the insulator which is spaced from the preformed panels to reduce internal pressure at peripheral seams joining the panels. Such gap allows the space between the two panels to absorb dimensional variations due to manufacturing tolerance, dimensional changes with temperature, etc. The presence of such gap can be verified by manually squeezing certain areas of the tray or lid after permanently sealing in the insulator.

Description

I 1 67~2~

sACKGROUND
Insulated food serving trays and complimentary lids have been used in the past for serving hot and cold foods to hospital patients where the foods are prepared at one location in the hospital and then delivered later on carts to the particular floors a~d rooms. Examples of such insulated trays ~1,5.
are described ln Patents 3,532,247 issued October 6, 1970 to J.~.
Bridges and 3~799,386 issued March 26,]974 to W.A Madalin et al. These trays have included a hollow shell structure for the tray and lid. Because of the intricate inner passages in the she:Ll structure, the shell structure was first formed, and then an insulating material was injected through a small opening in the shell and then expanded to fill the voids in the shell.
This was frequently a "foamed-in-place" polyurethane or other material. The problem ~ith such structure is that the lnsulated "foamed-in-place" material caused an internal pressure on the shell structure oE the tray and lid, particularly at the peripheral seam area. Also, polyurethane foams tended to gradually expand with time~ causing an even greater internal pressure.
Subjecting the trays and lids to hot water washing also caused increased internal pressure, splitting apart the seams in several instances.
It has also been proposed to preform substantially rigid foam contain-ers such as in U.S. Patents 3,484,015 issued December 16, 1969 to D.~. Rowan and 3,799,143 issued February 26, 1974 to J.A. Bridges. Although the latter patent mentions a cover could be provided, there is no indication this is any more than a removable plastic cover over the top of the Eoam insulator to prevent food spillage, etc. It has also been proposed to preform insulat-ed dishes, etc., with an integral food resistant 1'skin" caused by a reduced expansion of the foam at the surface area during manufacture of the foamed article.
In the trays with multi-dishcavities, such as used for hospitals, it is necessary to keep some food dishes hot and some food dishes cold with an in-sulating material in be-tween. Ilowever~ preformed foam inserts do not mini-mize the internal pressure caused by heating. Filling the insulating spacein the tray or lid with a loose insulating material caused problems because of .~ - 2 --" ~ 1 67~0 shifting or rustling ~f the insulating material. Preformed3 intricately shaped`insulators ~ere not used because any slight varlance in fit ~70uld crea~e an internal pressure in a tray that could causP ~ frac~ure of the ~ray.
U.S. Patent 2,6563946 iss~ed'October 27, 1953 to H.~. Clarke deseribes a simple cylindrical lunch pail il~ which spun glass, glass wool, wool, fiber or loosely formed felt is preformed and packed in~o a space be-tween two cylindrical shells and an abutment ring controls the spacing be-tween the shells. Such a construction would not be suitable for hospital food serving trays ~ecause it does not have the intricate insulator config-uration required f,or mult~-cavity ~rays and lids to segregate hot and cold food. Also, the spacers 70a would prevent any squeeze test to determine if internal pressure of the tray or lid after the insulating material was per-manently sealed between the spaced panels.
SU M MARY OF THEINVENTION

The present invention overcomes the above problems by providing an insulated tray and lid system for serving hot and cold hospital foods with sn intr:icately shaped insulator having insulating material spacing the different cavities, but which does not provide excessive internal pressure in the tray or lid.
Each tray or lid includes a preformed foam insulator with a plurality of spaced ap~rt dish cavities ~Id this insulator is permanently sealed between two pre-formed panels, one of which has complimentary dish cavities. When sealed between the panels, the insulator has at least a portion which is spaced from a panel to provide a gap for controlling any slight expansion on the fosm material, as well as manufacturing tolerances.between the insulator and sealed panels.

Internal pressure in-ci3rtain areas of the trays can be tested by manually squeezing those panel sections against the insulator. Since the insulator is preformed, it need not fill every cavity of the tray and lid, s.nd hence cost and weight are reduced by not insulating spaced panel sec$ions used for structural strength and support of the tray and lid in the utensil and beverage portion.

~ 1 ~7~20 TH~ DRAWINGS

Figure 1 is a top plan view of an assembled tray and lid;

Figure 2 is a sectional view taken along line 2-2 of Figure 1 showing a first embodiment of the lid;

Figure 3 is a sectional view OI the second embodiment of the lid;

Figure 4 is an enlarged fragmentary view showing the insulated joint at the right end of Figure 2;

Figure 5 is a still further enlarged fragmentary view showing the relationship between the two panels and insulator at the bottom of a dish cavity;
10 and Pigure 6 is a view similar to Figure 5, showing how the panels are squeezed to test the internal pressure of the tray or lid.

DETAILED DESCRIPTION
-In Figures 1 and 2, a lid 1 is superimposed on a tray 2. The tray 2 includes a preformed insulator 3 of a rigid foam material, preferably of the polystyrene bead type~ This preformed insulator 3 has a plurality of dish cavities 4 and 5 shown in Figure 2. Preferably the tray would include at least four such dish cavities, two of which would be located immediately behind those cavities shown in Figure 2. Because one cavity may control a hot entre dish 6 directly 20 beside a cold ice cream dish 7, it is important to keep areas between the dish cavities insulated. For this reason the insulator 3 has a specific shape that includes upstanding insulator sections 9, 10, and 11.

1 ~ 67~20 Completely encasing the insulator is a top panel 13 and a bottom panel 14 that are bonded together at a peripheral seal ~ 5. The construction and method I t I~
of forming seal 15 is a subject of separate~co-pending, c~owned application, S.N.
q, filed the same date as the present application.

It has been found that excellent insulating properties of a hospital food service tray for hot and cold foods can be obtained when the insulator is preformed and does not fill every precise space between the tray's toD panel 13 and its bottom panel 14. There is a space 20 along at least some areas of the insulator and its encasing panels. Such space relieves internal pressure between the two panels, particularly in the peripheral joint area 15. Although it is notintended that space or gap 20 has to be located over the entire surface area of the insulator, the spaces at different locations within the tray permit the insulator to slightly shift or distort to relieve internal pressure between the panels. Thus, if manufacturing tolerances cause the insulator to contact opposing panel areas at a particular location, a continual slight pressure by the panels on the insulator can cause the insulator to slightly relieve at that particular location. This is substantially different from the pressuri2ed foamed-in-place insulator that gen-erates an internal pressure in the space between the trays' panels 13 and 14.

The preformed rigid foam panels also can precisely control the areas where the insulating material is located. For instance, the space 23 which is incorporated in the tray for structural rigidity need not be filled with insulating foam material. This saves the cost of the foam, reduces the weight of the tray, and simplifies manufacturing procedure. Also, the preformed ~oam insulator permits the formation of a noninsulated utensil or beverage section where areas 24 and 25 of the panels can come in direct contact with each other. It has been found that a cold drink 26 and a hot coffee 27 can be conveniently placed in thesame compartment without providing insulation between them.

In Figure 2 the mating lid 1 is of a construction similar to tray 2 and has a top panel 30, a bottom panel 31 and an insulator 32. As with the tray, _ 5 _ 1 3 ~;7~2~

insulator 32 has at least a portion which is spaced from the respective panel such as shown at 33. The first embodiment of the lid is shown in Figure 2 where it covers the complete tray. An alternate version of a lid shown generally at 35 in Figure 3 covers only the insulated food portion of the tray leaving the utensil and 5 beverage section of the tray open. Here again the lid 35 has a preformed foarn insulator 36.

Pigure 4 shows an enlarged version of the joint between the lid 1 and tray 2. In certain areas of the tra~ and lid, the internal pressure exerted by the insulator 3 can be determined by pinching the tray panels 13 and 14 together. The 10 same can be done with the lid 1. As shown in Figure 5, a gap 20 is present along certain areas of the tray. To test for the presence of such gap, panels 13 and 14 are squeezed as shown in Figure 6. The panels being of a thermoplastic material have a certain "give" and the operator can feel the contact with the insulator 3.
Release of the panels 13 and 14 causes them to spring back away from the 15 insulator.

In the foregoing description, specific examples have been used $o illustrate the in~ention. However, it is understood by those skilled in the art that certain modifications can be made to these examples without departing from the spirit and scope OI the invention.

Claims (17)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY OR PRIVILEGE
IS CLAIMED ARE DEFINED AS FOLLOWS:
1. An insulated food tray comprising:
a preformed foam insulator having a plurality of spaced apart dish cavities formed in its top surface;
a preformed top panel having a corresponding plurality of spaced apart dish cavities formed therein which fit within said insulator dish cavities;

a preformed bottom panel sealed to said top panel to permanently encase said insulator therebetween;
said top and bottom panels being separated at the bottom of said dish cavities to permit a portion of said insulator to extend therebetween to provide insulation at said dish cavity bottoms and to permit said insulator to be formed as a unitary, self-sup-porting sheet; and said insulator being formed so as to provide a space substan-tially about said dish cavities between said top and bottom panels so as to minimize internal pressure between said panels.
2. A tray as set forth in Claim 1 which tray supports a removable lid comprising:
a preformed foam lid insulator having a plurality of spaced apart dish cavities formed in its bottom surface;
a preformed bottom lid panel having a corresponding plurality of spaced apart dish cavities formed therein which fit within said insulator dish cavities and which correspond to the dish cavities formed in said tray;
a preformed top lid panel sealed to said bottom panel to permanently encase said insulator therebetween;
said top and bottom lid panels being separated at the top of said dish cavities to permit a portion of said insulator to extend therebetween to provide insulation at said dish cavity tops and to permit said lid insulator to be formed as a unitary, self-sup-porting sheet; and said lid insulator being formed so as to provide a space sub-stantially about said dish cavities between said top and bottom lid panels so as to minimize internal pressure between said panels.
3. A tray as set forth in Claim 1, wherein the panels are sealed together about a peripheral seal.
4. A tray as set forth in Claim 3, wherein the panels have opposed portions that are squeezable to test the presence of a gap between the insulator and panels.
5. A tray as set forth in Claim 1. wherein the insulator is a generally rigid polystyrene bead foam.
6. A tray as set forth in Claim 1, wherein the panels are of a thermoplastic material.
7. A tray as set forth in Claim 1, wherein the tray has a food section that includes the insulated dish cavities and an uninsulated utensil area formed by the two panels in close proximity to each other along a base of the utensil area, said utensil area extending laterally beyond the insulated dish cavities.
8. A tray as set forth in Claim 7, wherein the utensil area has receptacles for beverage containers.
9. A tray as set forth in Claim 7, wherein the two panels are in contact with each other at a base of the uninsulated utensil area,
10. A tray as set forth in Claim 1, wherein the tray has a side portion with spaced apart upstanding panel sections which are free of insulation material and which are structurally suited to support a lid on the tray.
11. A tray and lid as set forth in Claim 2, wherein the lid panels are joined together about a peripheral seal.
12. A tray and lid as set forth in Claim 11, wherein the lid panels have opposed portions that are squeezable to test the presence of a gap between the insulator and lid panels.
13. A tray and lid as set forth in Claim 2, wherein the lid insulator is a generally rigid polystyrene bead foam.
14. A tray and lid as set forth in Claim 2, wherein the lid panels are of a thermoplastic material.
15. A tray and lid as set forth in Claim 2. wherein the tray lid has the food section with the insulated dish cavities for covering food, and the lid has an uninsulated utensil area for covering utensils and the utensil area is formed by two portions of the lid panels in close proximity to each other and extending laterally beyond the insulated portion of the lid.
16. A tray and lid as set forth in Claim 15, wherein the lid panels are in direct contact with each other directly over the utensil area.
17. A tray and lid as set forth in Claim 2, wherein the lid has the side portion with spaced apart downwardly extending sections of the panels which are free of insulation therebetween and which form a structural support for the lid when the lid is fitted to a tray therebelow.
CA000360288A 1979-09-17 1980-09-16 Insulated food tray and lid therefore Expired CA1167420A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US7651779A 1979-09-17 1979-09-17
US076,517 1979-09-17

Publications (1)

Publication Number Publication Date
CA1167420A true CA1167420A (en) 1984-05-15

Family

ID=22132513

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000360288A Expired CA1167420A (en) 1979-09-17 1980-09-16 Insulated food tray and lid therefore

Country Status (1)

Country Link
CA (1) CA1167420A (en)

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