NZ776403A - Preformed sustainable and environmentally considerate paperboard tray with removable and recyclable plastic layers - Google Patents

Abstract

The invention relates to a blank (1) for a tray (2),said blank comprising an upper circumferential rim member (3) with three, four or more webs(4, 5, 6, 7), lateral wings (8, 9, 10, 11), each wing extending outwardly and downwardly foldable from a web (4, 5, 6, 7), each wing comprising a side wall part (12, 13, 14, 15) and a bottom part (16, 17, 18, 19), wherein the blank further comprises edge wings (20, 21, 22, 23) extending inwardly and downwardly foldable from an edge portion (24, 25, 26, 27) where the webs are connected.

Description

The invention relates to a blank (1) for a tray (2),said blank comprising an upper circumferential rim member (3) with three, four or more webs(4, 5, 6, 7), l wings (8, 9, 10, 11), each wing extending outwardly and downwardly foldable from a web (4, 5, 6, 7), each wing comprising a side wall part (12, 13, 14, 15) and a bottom part (16, 17, 18, 19), wherein the blank r comprises edge wings (20, 21, 22, 23) extending inwardly and downwardly foldable from an edge portion (24, , 26, 27) where the webs are connected NZ 776403 Performed Sustainable and environmentally considerate paperboard tray with removable and recyclable plastic layers The present ation is directed to a blank for a tray or a packaging comprising a number of foldable parts which are folded in such a way that a tray is formed to provide a tray suitable for wet, moist, frozen or ambient applications including but not limited to meat, cheese, y, dairy, cook-in ations, seafood, etc. The tray may have different forms, such that it has a rical or non-symmetrical form for different applications, wherein also wedge forms are possible. The corresponding blank comprises an upper circumferential rim member with 3, 4, or more webs, lateral wings, each wing extending outwardly and downwardly foldable from a web, and each wing sing a side wall part and a bottom part. Furthermore, the blank comprises edge wings extending inwardly and rdly foldable from an edge portion of the rim member where the webs are connected.

The corresponding lateral wings will be folded downwardly, such that the side wall parts form the side walls of the corresponding tray and in such a way that the bottom parts from the corresponding bottom wall of the tray. The edge wings are also folded downwardly to supplement the lateral wings at the edge portions and, in particular, to provide addition strength in such edge portions.

The corresponding web of the blank is lly made of one layer of corresponding material and it might be recommendable to strength such web. For such a reason, each wing might comprise a web strengthening part which is also foldably connected to an outer edge of the web and which can be folded to be arranged underneath a corresponding part of the web, such that the finished tray then comprises a two-layer construction of the web. Such two-layer construction may be provided for all of the webs or for all of the upper ferential rim member. It is also feasible that those web strengthening parts are only ed in ular portions of the webs.

In an advantageous embodiment, corresponding web strengthening parts may be directly connected to an outer edge of the corresponding web and they are foldably connected as part of the corresponding l wings. This means that the first part of each wing is the web strengthening part directly connected to the outer edge of the corresponding web and then sidewall part and bottom part of each wing are foldably connected to the corresponding web thening part.

It further has to be considered that the corresponding web also comprises edge portions where the webs are connected. It is also possible to strengthen such edge portions, wherein, for example, said web thening part of at least two opposite wings comprise at least one end projection corresponding to a corresponding edge portion. Such end projection will then be folded underneath the edge portion, such that also this is strengthened and have a two-layer construction. It is, of course, also possible that all edge ns are strengthened in such a way.

The finished tray will then, of course, comprise a tray bottom wall and, according to the present invention, it is considered as advantageous if said bottom part of each wing is inwardly le to form a tray bottom wall, wherein the bottom parts of all of the wings will partially overlap and be connected to each other to form such essentially closed tray bottom wall.

To provide a corresponding overlap, at least in some parts of the corresponding tray bottom wall, it is possible that all or at least some of the bottom part se a laterally extending first bottom part and a second bottom part with a smaller width than the first bottom part. This means that the first bottom part further extends in lateral direction than a second bottom part that, in particular, in the area of the first bottom part there will be corresponding overlap that also might be used for connecting the corresponding bottom parts to a obtain an essentially closed tray bottom wall.

The finished trays are provided in a stacked arrangement. For r sing, there might be some problem with denesting of corresponding trays. For this reason, it is possible that at least sidewall parts of two wings, in particular, arranged opposite to each other comprise lly extending denesting projections. Those denesting projections form corresponding denesting means that are quite helpful to use corresponding trays on high-speed production lines and, of , they will support easy separation of the trays from one r.

According to one embodiment of the invention, it is possible that each sidewall portion comprises two nose-like denesting projections arranged on opposite sides of the ll part, in particular directly adjacent to the web strengthening part. It is also possible that such nose-like denesting projections or legs are arranged on all sidewall parts of all of the lateral wings.

It was already said that the edge wings are used for providing further strength in the edge portions of the web and, of course, also in the corresponding edges of the finished tray. To allow an easy arrangement of such edge wings with respect to the adjacent lateral wings and, in particular, sidewall parts of same, it might be recommendable that each wing comprises three edge wing portions foldably connected to each other in length ion. This allows an easy adaptable of the edge wings with respect to any curvature n neighboring lateral wings in case the tray is finished. Corresponding edge wing portions will then comprise two lateral edge wing portions and one intermediate edge wing portion. With respect to the two lateral edge wing portions, it might be recommendable that they are to contact the corresponding side wall portions of the adjacent lateral wings if the tray if formed. It is, of course, possible that there is a connection between those l edge wing portions and the sidewall portions, at least where they overlap and are in contact.

Moreover, it is possible that all of the edge wing portions have the same length, but there are other embodiments where they have different lengths and, in particular, one embodiment may be advantageous in which the edge wing portion intermediate the l edge wing ns has a length longer than the lateral edge wing portions. This might help in the arrangement of the edge wing portions in close contact to the sidewall portions and to further press the intermediate edge wing portion in a corresponding position with frictional force between such intermediate edge wing portion and the tray bottom wall. Consequently, it might not be necessary to connect the lateral edge wing portions to the corresponding sidewall portions, for example by gluing, heat sealing or the like. Instead, the edge wing portions are just held in position by this frictional force between the intermediate edge wing portion and the tray bottom wall.

To further improve such arrangement of the edge wings in the tray, it might be further recommendable that the intermediate edge wing portion has a protruding edge at its free end used to snap into a recess or the like formed in the tray bottom wall.

This protruding edge is something like a locking tap, which will snap into the corresponding recess to negate the requirement for such edge wing portions to be glued with respect to the ll parts to stay in place.

A corresponding recess might be formed between the bottom parts of the adjacent lateral wings.

Generally, the tray is suitable for wet, moist, frozen and other applications, and to fulfill requirements for a sustainable tray solution which is advantageous with respect to recycling. It is possible according to the t application that the blank is made of paper, cardboard, or r material that can be ed with a, in particular, impervious foil layer. This foil layer is provided, for example, on one side of the blank. This side is, in particular, forming an inside of the corresponding tray.

Here it might be possible to remove the fluid-impervious foil layer from the corresponding other material of the blank to e recycling. To provide the user with some means for supporting such separation, it is possible that at least one removable or impressible wall portion is ed in a wing to allow such separation of the foil layer from the other al of the tray. This means that the user is provided some means for ease of removing such foil layer, which is generally a plastic film layer, for separate recycling of the paper, cardboard, or similar material and the plastic film layer.

Corresponding wall portion may be defined by a perforation, which at least partially surrounds the wall portion, wherein this wall portion may be pressed to the inside by the user to start the separation of the corresponding foil layer and to then use this wall portion to completely remove the foil layer from the other material of the tray.

With respect to the present invention, it also has to be considered that the corresponding webs of the circumferential rim member form and rrupted and continuous flange for optimal sealing of the corresponding tray through any high-speed automatic tray sealing lines, which provide the tray with an upper sealing layer after the tray is filled with the corresponding product, like meat, cheese, poultry, or the like.

The corresponding movable or impressible wall portion further provides the user with a particular means to remove this plastic film layer, such that the user or customer will not need further corresponding ent for separate recycling of the different materials. The corresponding perforation at least partially surrounding the wall portion will, of course, assist the film removal.

It will be further advantageous if the lateral edge wing portions are foldably connected to the web, such that then only the intermediate edge wing n is directly assigned to the corresponding edge portion of the rim. In the ed tray, the lateral edge wing portions will then contact the sidewall parts, such they also support a thening of ponding edge portions rmore, the present application is direction a blank according to any one of the corresponding claims substantially as herein described with nce to any embodiment disclosed.

According to the present ation, any ements for a sustainable tray are easily fulfilled, even in case there is a tray with three layers of material like, for example, corresponding foil layers on both side of the blank. The tray filled with the corresponding product can be easily sed from a supermarket. It might be directly arranged in a microwave oven or the like and then even be used for eating a corresponding product. The foil layers or liners and corresponding other material of the tray can be separated and discarded into recycling.

In the following, an advantageous embodiment of the invention will be bed with respect to the enclosed figures, see the following detailed description.

Fig. 1 is a top view of a blank according to the invention, and Fig.2 is a top view of a tray or packaging manufactured from a blank according to Fig.1.

Fig. 1 is a top view of a corresponding blank 1 for a tray or packaging 2. Such a tray 2 may have a rectangular cross-section, but it is also possible that the cross-section is non-symmetrical, is wedge-like, has a square cross-section, triangular section, or the like.

The corresponding blank 1 according to the embodiment in Fig. 1 comprises an upper circumferential rim member 3 with four sides and corresponding edge portions 24, 25, 26 and 27.

The four sides are made by four corresponding webs 4, 5, 6 and 7, which form an upper flange of the rim member in case the tray is finished. This upper flange will generally be used to seal the corresponding upper opening of the tray after corresponding product is filled into the tray. The tray according to the invention has an uninterrupted and continuous upper flange or rim member for optimal g h any high-speed automatic tray g lines. The tray can be used to receive a number of products and is suitable for wet, moist, frozen, and ambient applications including but not limited to meat cheese, poultry, dairy, cook-in application, seafood, etc.

The blank is formed of paper, paperboard, or the like, which is a generally compostable material and this material will be provided with a removable plastic film layer or foil layer to allow arrangement of the product as mentioned above within the tray.

The corresponding four webs 4, 5, 6 and 7 of the rim member 3 generally extend linearly and are ed perpendicular to each other with corresponding edge portions 24, 25, 26 and 27 between adjacent webs.

The blank further comprises four wings 8, 9, 10 and 11 outwardly ing from corresponding webs and foldably connected to the webs and also comprising a number of parts. Two opposite wings 8 and 10 comprise a sidewall part 12 or 14 and a bottom part 16 or 18. Moreover, both of the wings 8 and 10 further comprise a web strengthening part 28 or 30. This web strengthening part 28, 30 is directly and foldably ted to an outer edge 32 of the corresponding webs 4 or 6. The web strengthening wing parts 28 and 30 further comprise end projections 33, 34 and 35, 36. In case the web strengthening parts 28 and 30 are downwardly folded and then folded beneath the corresponding webs 4 or 6, the ponding end projections 33, 34 or 35, 36 would be arranged beneath corresponding edge ns 24, 27 or 25, 26. In such a way, not only the wings, but also the edge portions are thened such that the rim member in those areas has a twolayer construction. It is possible according to the present application that the web strengthening parts 28 and 30 with corresponding end projections 33, 34 and 35, 36 is connected to the webs and edge ns by , hot sealing or the like.

The corresponding sidewall parts 12 or 14 form a sidewall of the tray and the bottom parts 16 and 18 form part of a tray bottom wall 37. Each bottom part 16 or 18 comprises a first bottom portion 38, 39 and a second bottom portion 40, 41. First bottom portions 38 and 39 have a truncated form and generally a width longer than a corresponding width 46 of the second bottom portions 40, 41.

In a similar way, there are two r wings 9 and 11 arranged opposite to each other also comprising a web strengthening part 29, 31, a side wall part 13, 15 and bottom part 17, 19. The corresponding web strengthening parts 29 and 31 will also be folded underneath the corresponding webs 5 and 7, respectively, and will increase the strength of the rim member 3 in the same way as already ed with respect the other web strengthening parts 28 and 30.

In general, all of the web strengthening parts 28, 29, 30 and 31 form a complete second layer of the rim member for the finished tray 2 that they have the same shape and extension as the corresponding webs forming the rim member.

The sidewall parts 13 and 15 have a slightly truncated form decreasing in width in the direction away from the corresponding webs strengthening part 29, 31. The further bottom parts 17 and 19 also comprise the first bottom portion 52, 53 and a second portion 44, 45. The first bottom ns 42 and 43 have an extension in the lateral direction greater than the ponding second bottom portions 44 and 45. However, with respect to all of the bottom parts, it has to be considered that there is a continuous tion between the corresponding bottom portion without any interruption or the like.

All of the parts of the wings are connected to each other in a foldable manner and the wings in total are also foldable with respect to the webs, see the connections between the web strengthening parts and the corresponding outer edge 32 of the webs.

The corresponding wings further comprise denesting means in the form of nose-like projections, which are arranged directly adjacent to the web strengthening parts 28, 29, 30 and 31, see corresponding denesting projections 47, 48, 49, 50, 51, 52, 53 and 53, ing from upper ends of the ponding sidewall parts 12, 13, 14 and 15.

In case the tray is ed, those denesting projections would be used to support denesting of trays ed one in the other to form a nested stack of corresponding trays.

It is also possible that, for example, only some of the denesting projections are used, see for example the denesting projections 47, 48 and 51, 52 of the sidewall parts 15 and 13 of wings 9 and 11.

The blank further comprises four other wings, see the edge wings 20, 21, 22 and 23. Those are inwardly extending from the corresponding webs 4, 5, 6, or 7 and corresponding edge portions 24, 25, 26, 27. The corresponding edge wings 20, 21, 22, 23 generally comprise three edge wing portions 55, 56, 57 are foldably connected to the rim member 3 and which are also foldably connected to each other. The edge wing portions 55, 56 and 57 comprise two lateral edge wing ns 55 and 57 and one intermediate edge wing portion 56. In particular, the intermediate edge wing portion 56 is foldably connected to an inner edge of corresponding edge portion and the two lateral edge wing portions 55 and 57 are foldably connected to the intermediate edge wing portion and may also be foldably connected to an inner edge of the webs adjacent to this corresponding edge portion.

In the finished tray, those edge portions are downwardly folded to be in abutment with adjacent wings, wherein, in ular, the corresponding lateral edge wing portions will contact the sidewall parts of the corresponding wings.

The l edge wing portions 55 and 57 have an end edge 59, which is arranged in such a way that they may easily be inwardly folded and will just contact an upper surface of the corresponding tray bottom wall 37. The ediate edge wing portions have a length 60 in length direction 58, which is longer than the corresponding length of the lateral edge wing portion, such that they se a lower protruding edge 61 at a corresponding free end 62. This protruding edge 61 will snap into a ponding recess formed in the finished tray bottom wall 37, in particular between the ponding bottom parts of two adjacent wings.

In general, such a recess will be formed between the first bottom portions 38 and 39 of the wings 8 and 10 and the first bottom portions 42 and 43 of the further wings 9 and 11. Those first bottom portions will provide such a recess between the corresponding parts.

To support the separation of a corresponding fluid-impervious foil layer provided on the further material of the blank, see paper, cardboard, or the like, the application further proposed to use at least one removable or sible wall portion provided in a wing. This ular wall portion 64 is arranged in a bottom part 17 of wing 9. r, the wall portion may also be arranged in any other bottom part or sidewall part of any wing and it is also le to provide more than one of such wall portion 64.

Wall portion provides an easy-peel part for removing such an impervious foil layer in the form of a plastic film layer or the like for te recycling of the different materials of the tray. The wall portion 64 is, in particular, defined by a perforation at least partially surrounding this wall portion.

The corresponding edge wings are, in particular, used to e strength by anchoring against the tray bottom wall 37, see the snapping in of the lower protruding edge 61 in a corresponding recess. Such means allowed fixing of the corresponding edge wings without any glue or the like to stay in place.

Furthermore, the tray or blank according to the present application is made of compostable al just folded and formed and further uses a removable barrier layer, see the impervious foil layer, to render the tray le for wet, moist, frozen and ambient applications, including but not limited to meat, cheese, poultry, dairy, cook-in applications, seafood, etc.

It is again emphasized that the particular shape of the tray according to Fig. 1 is just an example and it is also le to use blanks for a tray which will have other symmetrical or also nonsymmetrical forms for different applications.

In Fig. 2, a top view of a tray or ing manufactured from a blank as described above is illustrated.

This particular packaging or tray is rectangular in shape and has an upper circumferential rim member 3 with corresponding webs, wherein the webs 4 and 6 are the longer sides of the rectangular shape. The edge portions 24, 25, 26, 27 are arranged in the edges of the rectangular shape and here edge wings 20, 21, 22, 23 are arranged which are inwardly and downwardly folded with corresponding lateral edge wing portions 55, 57 in nt with the downwardly and inwardly folded side wall parts 12, 13, 14, 15 of the wings 8, 9, 10, 11, see again Fig. 1.

In Fig. 2, the tray or packaging 2 is closed at the top by a transparent film 66 sealed to the tray or packaging along the rim member 3.

The term ‘comprising’ as used in this ication and claims means ‘consisting at least in part of’. When interpreting statements in this ication and claims which include the term ‘comprising’, other features besides the features prefaced by this term in each statement can also be present. Related terms such as ‘comprise’ and ‘comprised’ are to be interpreted in a similar manner.

Claims (19)

1. Blank (1) for a tray (2),said blank comprising an upper circumferential rim member (3) with three, four or more webs(4, 5, 6, 7), lateral wings (8, 9, 10, 11), each wing extending outwardly and downwardly foldable from a web (4, 5, 6, 7), each wing comprising a side wall part (12, 13, 14, 15) and a bottom part (16, 17, 18, 19), n the blank further comprises edge wings (20, 21, 22, 23) extending inwardly and downwardly foldable from an edge portion (24, 25, 26, 27) where the webs are connected.

2. Blank according to claim 1, wherein each wing (8, 9, 10, 11) further comprises a web strengthening part (28, 29, 30, 31).

3. Blank according to claim 2, wherein each web strengthening part is directly connected to an outer edge (32) of the corresponding web (4, 5, 6, 7)

4. Bank ing to claim 2 or 3, wherein said web strengthening part of at least two opposite wings comprise at least one end projection (33, 34, 35, 36) ponding to the edge portion.

5. Blank ing to any one of the previous claims, wherein said bottom part (16, 17, 18, 19) of each wing is inwardly le to form a tray bottom wall (37), n the bottom parts will partially overlap and be connected to each other to form the essentially closed tray bottom wall.

6. Blank according to claim 5, wherein the bottom part comprises a laterally extending first bottom part (38, 39) and a second bottom part with a smaller width (46) than the first bottom part.

7. Blank according to any one of the previous claims, wherein said side wall parts (12, 13, 14, 15) of at least two wings comprise laterally extending denesting projections (47, 48, 49, 50, 51, 52, 53, 54).

8. Blank according to claim 7,wherein each side wall portion (12, 13, 14, 15) comprises two nose-like denesting projections ed on opposite sides of the side wall part in particular directly adjacent to the web strengthening part.

9. Blank according to any one of the previous claims, n each edge wing (20, 21, 22, 23) comprises three edge wing portions (55, 56, 57) foldably connected to each other in length direction (58).

10. Blank according to claim 9, wherein two lateral edge wing portions are to contact the ponding side wall portions of the adjacent lateral wings if the tray is formed.

11. Blank according to claim 10, wherein the edge wing portion intermediate the two lateral edge wing portions has a length longer than the lateral edge wing portions.

12. Blank ing to claim 11,wherein the intermediate edge wing portion has a protruding edge (61) at its free end (62) used to snap into a recess formed in the tray bottom wall.

13. Blank according to any one of the previous claims, wherein the blank is made of paper, cardboard or the like with an in particular fluid-impervious foil layer.

14. Blank according to any one of the previous claims, wherein at least one removable or impressible wall portion (64) is provided in a wing to allow separation of the foil layer from the other material of the tray.

15. Blank according to any one of the previous claims, wherein the lateral edge wing portions (55, 56) are foldably connected to the webs.

16. Blank according to any one of the previous claims, wherein the wall portion (64) is d by a perforation at least partially surrounding the wall portion.

17. Packaging, in particular a tray, manufactured using a blank according to any one of previous claims.

18. ing ing to claim 17, wherein a fluid-impervious and/or oxygen-impervious film is applied to at least an inner surface of the packaging, preferably also to an upper flange of the packaging.

19. Blank or ing according to of any one of the us claims substantially as herein described with reference to any embodiment disclosed.