US20190375534A1

US20190375534A1 - Meat patty tray and method of packaging and display

Info

Publication number: US20190375534A1
Application number: US16/005,208
Authority: US
Inventors: Mark A. Bergeron; Babu Kuruvilla
Original assignee: Tekni Plex Inc
Current assignee: Tekni Plex Inc
Priority date: 2018-06-11
Filing date: 2018-06-11
Publication date: 2019-12-12

Abstract

A molded plastic tray is provided according to the invention adapted to display meat or other perishable thawed food patty products in a disc configuration, and designed to withstand movement of the patties during shipping and display. The tray is designed to hold the meat products in a flat disc configuration while being loaded, wrapped, shipped and displayed on one side edge. The tray is designed to provide structural rigidity that resists warping and breakage, thus enabling the loaded and sealed tray to be handled, shipped, and displayed with minimal leakage or breakage. In some embodiments the tray includes features that facilitate de-nesting of a stack of empty trays, and is adapted to facilitate movement of the wrapped package on a moving conveyor line. The tray is easy to manufacture and provides a lightweight and cost effective packaging product. Preferably the tray has a generally rectangular shape (with rounded corners) that provides for consistent wrapping strength and can be handled on standard processing equipment.

Description

FIELD OF THE INVENTION

The invention relates to packaging and, more particularly, to trays for packaging frozen or thawed food products having a patty configuration for secure storage, shipping and display.

BACKGROUND OF THE INVENTION

Various plastic trays for packaging food are known in the prior art. In designing a tray, inner surface area, capacity, sidewall rigidity, and weight are key considerations. These trays are typically packed with perishable food items and then surrounded with a plastic film overwrap to seal the food within the package. Once wrapped the tray is ready to be placed in a container for shipment; typically, multiple wrapped trays are stacked one upon another and the weight of the packaged trays may cause the plastic film of underlying trays to be stretched and loosened during shipment. As a result the wrapped trays may leak water, juices, blood, etc. from the products packaged therein, leading to a loss of aesthetic appeal, loss of shelf life, contamination of adjacent packages, and difficulty in handling.
Another consideration for the packaging of patty shaped food products, such as breakfast sausage patties, is the desire to present each sausage patty in a uniform disc shape as this is the shape expected by the consumer and is generally considered more pleasing. Although the sausage patties generally start out frozen and of uniform disc shape, they must be handled either manually or by mechanical means while being packaged and as they begin to thaw the patties may spread out, lose shape and/or leak water/fluid. As the wrapped trays are then shipped to stores in refrigerated trucks, they may continue to thaw. Finally once at the store, the grocer/retailer needs to maximize the use of limited refrigerated display cases, by displaying the wrapped trays on their side, in an inclined position, where the thawed (refrigerated but no longer frozen) meat patties further soften and lose shape as they sink down within the inclined package. As a worst case, multiple patties end up merged on the lowermost side edge of the package. The customer finds this unattractive and will pass by such a product, even if the meat is otherwise fine.
In summary, it is difficult to place frozen food patties in a tray, and in particular to maintain their disc like configuration as the patties thaw.
Thus it would be desirable to provide a tray which can maintain meat (and other perishable food) patty products in a disc configuration during packing, shipment and display.
It would be desirable to provide such a tray that can maintain a plastic film as a top seal or wrapped thereabout in a taut state.
It would be desirable to provide such a tray having substantial structural rigidity.
It would be desirable to provide such a tray that is easy and inexpensive to manufacture, easy to load (fill with product), and easy to stack and un-stack (de-nest) both empty and filled.

SUMMARY OF THE INVENTION

A molded plastic tray is provided according to the invention adapted to display meat or other perishable thawed food patty products in a disc configuration, and designed to withstand movement of the patties during shipping and display. The tray is designed to hold the meat products in a flat disc configuration while being loaded, wrapped, shipped and displayed on one side edge. The tray is designed to provide structural rigidity that resists warping and breakage, thus enabling the loaded and sealed tray to be handled, shipped, and displayed with minimal leakage or breakage. In some embodiments the tray includes features that facilitate de-nesting of a stack of empty trays, and is adapted to facilitate movement of the wrapped package on a moving conveyor line. The tray is easy to manufacture and provides a lightweight and cost effective packaging product. Preferably the tray has a generally rectangular shape (with rounded corners) that provides for consistent wrapping strength and can be handled on standard processing equipment.
In one embodiment, a molded plastic tray is provided for displaying each of a plurality of refrigerated food products in spaced apart relation when displayed on a side edge, the tray comprising:
an integrally formed plastic tray having an upper cavity;
the upper cavity forming an open top end of the tray and comprising opposing front and rear elongated sidewalls and opposing first and second end walls, the sidewalls and end walls being a connected by rounded corners to form a rectangular shaped upper cavity;
an array of recessed pockets formed in the upper cavity and each configured to receive a disc-shaped food product, the array including a front row FR of pockets adjacent the front sidewall and a rear row RR of pockets adjacent the rear sidewall;
a rectangular shaped flange disposed at an upper end of the sidewalls, end walls and corners forming the open top end of the tray for attaching an overwrap film or top seal film to secure food products loaded into the pockets;
the array of pockets in the upper cavity being formed by:

- a central divider wall CDW extending between the first and second end walls, the CDW including a plurality of spaced apart center posts, each center post being disposed at a juncture between four adjacent pockets in two adjacent rows of the array, each center post having inwardly curved sidewalls extending from the divider wall for engaging a periphery of a disc-shaped product in each of the four adjacent pockets as the product thaws, expands and/or moves into contact with the center post sidewalls,
- the front and rear side walls of the tray each having a plurality of spaced apart edge posts, each edge post begin disposed at a juncture between two adjacent pockets in a row of the array, each edge post having curved sidewalls extending from the front or rear side wall for engaging a periphery of a disc-shaped product in each of the adjacent pockets as the product thaws, expands and/or moves into contact with the edge post sidewalls,
- the CDW having wall portions extending between two adjacent center posts, or between a center post and the first or second end wall respectively, for engaging a periphery of a disc-shaped product in each of the adjacent pockets as the product thaws, expands and/or moves into contact with the wall portions,
- the flange and uppermost surfaces of the center posts lying in a top reference plane TRP that defines an uppermost surface of the tray, and
- each pocket having a pocket height that is less than a product height such that plastic film attached to the flange of the loaded tray engages the uppermost surfaces of the products to hold each product securely in an individual pocket when the tray is turned on edge and rests on the front or rear side wall of the tray.

In one embodiment, each center post includes a transverse groove that strengthens the central divider wall against bending of the tray.
In one embodiment, each center post has base portion adjacent a bottom wall of the cavity.
In one embodiment, the curved sidewalls of the center post taper inwardly moving away from the widened base portion.
In one embodiment, the tray has a central longitudinal axis CLA and a transverse axis TA perpendicular to the CLA.
In one embodiment, the CDW lies on the CLA.
In one embodiment, one or more center posts and edge posts are aligned along the TA.
In one embodiment, one center post is disposed equal distance between two edge posts on the front and rear sidewalls respectively and aligned on the TA.
In one embodiment, the center post and edge posts each have a widened base portion extending along the TA.
In one embodiment, the CDW has an end post adjacent each of the end walls, wherein the end posts each have a widened base portion in a direction parallel to the TA.
In one embodiment, the center posts each have a diamond shaped top wall that lies in the TRP.
In one embodiment, each center post has a diamond shaped top wall having a first axis on the CLA and a second axis on the TA.
In one embodiment, the center posts, end posts and edge posts each have a widened base portion adjacent a bottom wall of the cavity.
In one embodiment, the pocket height is configured to hold one or more disc shaped products in a vertical stack in the pocket.
In one embodiment, the pocket height is in a range of 60 to 90% of the product height.
In one embodiment, the pocket height is in a range of 65 to 85% of the product height.
In one embodiment, the pockets are aligned in a parallel series, in each row, between the first and second end walls of the tray.
In one embodiment, the flange forms the perimeter of the tray, the flange having a top surface coextensive with the TRP, an exterior side edge coextensive with the perimeter, and a bottom surface on an underside surface of the tray.
In one embodiment, a stack of trays is provided, the stack comprising:
a first tray and one or more nested trays;
a second tray nested within the first tray;
wherein a topside surface of the first tray engages an underside surface of the second tray, and each remaining tray in the stack likewise engaging an adjacent tray.
In one embodiment, the plastic material comprises one or more of polystyrene (EPS), polyester, polyolefin, polypropylene (PP), or polylactic acid (PLA), including homopolymers, copolymers, mixtures and blends thereof, and including virgin and reclaimed (recycled) materials, and whether solid or foamed.
In one embodiment, the plastic foam tray comprises polystyrene foam.
In one embodiment, a method of packing the tray for display and storage is provided, the method comprising:
providing a plurality of disc shaped food products;
depositing each food product into a respective pocket, a lower portion of the food product being deposited on a bottom wall of the pocket and an upper portion of the food product extending at or above the TRP;
providing a sheet of wrapping or top seal film and positioning it over the tray and the food product deposited therein;
pulling the sheet taut to engage the surface of each product deposited within the tray and the tray flange; and
securing the sheet to the tray.
In one embodiment, the film is an overwrap film that is wrapped around the product and an undersurface of the tray.
In one embodiment, the film is a top seal film and is sealed to the flange.
These and other features of the invention will be better understood from the following detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of an empty tray according to a first embodiment of the invention, including a central divider wall CDW having three central posts.

FIG. 2 is an end elevational view of the tray of FIG. 1.

FIG. 3A is a front side elevational view of the tray of FIG. 1.

FIG. 3B is a cross-sectional side view of the tray taken along line 3B-3B of FIG. 1.

FIG. 4A is a cross-sectional end view of the tray taken along line 4A-4A of FIG. 1.

FIG. 4B is a cross-sectional end view of the tray taken along line 4B-4B of FIG. 1.

FIG. 4C is a cross-sectional side view of two empty trays in a stacked (nested) arrangement.

FIG. 5 is a bottom plan view of the tray of FIG. 1.

FIG. 6 is a top perspective view of the tray of FIG. 1.

FIG. 7 is a top plan view of the tray of FIG. 1 with meat patties P1-P8 loaded in the tray.

FIG. 8A is a front side view (and partial sectional view of the pockets) of the loaded tray of FIG. 7 with plastic film wrapped around the loaded tray.

FIG. 8B is an enlarged partial sectional front side view of the loaded wrapped tray of FIG. 8A.

FIG. 9A is a partially sectional end view of the loaded and wrapped tray of FIG. 8A.

FIG. 10 is a perspective view of a plurality of loaded and wrapped trays of FIG. 8A stacked in a row on their front side edges for display.

FIG. 11 is a top plan view of an empty tray according to a second embodiment of the invention, including a central divider wall CDW having central recessed grooves formed in three central post areas.

FIG. 12 is an end elevational view of the tray of FIG. 11.

FIG. 13A is a front side elevational view of the tray of FIG. 11.

FIG. 13B is a cross-sectional side view of the tray taken along line 13B-13B of FIG. 11.

FIG. 13C is a cross-sectional perspective side view of the tray, similar to FIG. 13B.

FIG. 14A is a cross-sectional end view of the tray taken along line 14A-14A of FIG. 11.

FIG. 14B is a cross-sectional end view of the tray taken along line 14B-14B of FIG. 11.

FIG. 14C is a cross-sectional end view of three empty trays in a stacked (nested) arrangement.

FIG. 15 is a bottom plan view of the tray of FIG. 11.

FIG. 16 is a top perspective view of the tray of FIG. 11.

FIG. 17 is a top plan view of the tray of FIG. 11 with meat patties loaded in the tray.

FIG. 18A is a front side view (and partial sectional view of the pockets) of the loaded tray of FIG. 17 with plastic film wrapped around the loaded tray.

FIG. 18B is an enlarged partial cross-sectional side view of the loaded wrapped tray of FIG. 18A.

FIG. 19 is an end elevational view of the loaded and wrapped tray of FIG. 18A.

FIG. 20 is a perspective view of a plurality of loaded and wrapped trays of FIG. 18A stacked in a row on their front side edges for display.

FIG. 21 is an end elevational view of a loaded tray with a film top seal, rather than a film overwrap.

DETAILED DESCRIPTION OF THE INVENTION

Referring generally to FIGS. 1-10, a first embodiment of a tray of the invention is depicted therein and generally designated with the numeral 10, including a central divider wall CDW 40 having three central posts 42A-C. FIGS. 1-6 show the empty (unloaded and unwrapped) tray 10. FIG. 7 shows the same tray 10 loaded with eight disc shaped meat products P1-8, here sausage patties. FIGS. 8A-9 show the loaded tray 10 with a clear plastic film wrap F surrounding the tray and patties, and FIG. 10 shows a plurality of such loaded and wrapped trays each inclined on its front side edge 14 and aligned in a row for display (e.g. in an open ended refrigerated storage case at a grocer/retailer).
The tray 10 may be formed of various plastic materials, foam or non-foam, including polystyrene PS, polypropylene PP, and polyester (e.g., polyethylene terephthalate PET). In one embodiment the tray is formed of a plastic foam material, such as polystyrene foam, for light weight, ease of manufacture and low cost. The tray includes a base wall 12, and extending upwardly from (generally transverse to) the base wall, a pair of opposing front and rear longitudinal sidewalls 14, 16, a pair of left and right opposing end walls 18, 20 and four rounded (curved) corners 22, 24, 26, 28 joining the sidewalls and end walls. The tray has an uppermost (top) planar flange 30, lying in a top reference plane TRP; the flange 30 extends transversely outwardly from uppermost wall portions of the sidewalls 14, 16, end walls 18, 20, and corners 22-28. In this embodiment, the TRP lies parallel to a base reference plane (BRP) on which a lowermost undersurface (back) 13 of the base wall 12 rests.
The tray 10 is shown in the Figs. to have a generally rectangular shape, with equal length LSW and opposing longitudinal front and rear sidewalls 14, 16 being longer than the length LEW of the equal length and opposing left and right end walls 18, 20 (FIG. 1). The tray 10, however, can be formed with sidewalls and end walls having equal length to have a generally square appearance. It is desirable that the sidewalls and end walls have a straight (linear) flange 30 for improved wrapping capability, while the flange at the corners is rounded to avoid undue stress on the wrapping film.
In forming the tray 10 it is preferred that the tray 10 be unitarily formed from a single sheet of plastic foam material that is molded to define the features described herein. The embodiment shown is formed from molding procedures which utilize matched mating male and female dies. The inner and outer surfaces of the elements of the tray are shown to be generally parallel (the thickness of the tray is substantially equal throughout). However, during manufacturing the foam material may compress differently at various locations, resulting in some thickness variations in the tray (see for example the thickness variations between the base wall 12 and central divider wall CDW 40, as shown in FIGS. 4A-4B). Alternatively, the tray may be formed with various portions which do not have parallel inner and outer surfaces. Additionally, the tray may be lined or coated with barrier film.
As best shown in FIGS. 3B, 4A-4B and 6, the inner/upper surface of the tray defines an interior cavity 60 that includes the inner/upper surfaces of the sidewalls, end walls and corners, and by a central divider wall CDW 40. The CDW is longitudinally disposed on a central longitudinal axis CLA of the tray and extends from and between the left and right end walls 18, 20. The CDW includes:
a) a plurality (here three) of spaced apart center posts CP's 42A, 42B and 42C, each CP having a relatively flat (planar) top wall 43A, 43B and 43C respectively that lies in the TRP (see FIG. 3B). Each CP aligns, in a transverse direction (see transverse axis TA that extends perpendicular to the CLA), with (and is spaced an equal distance between) a pair of front and rear edge posts 62F and 62R, 63F and 63R, 64F and 64R respectively disposed on the opposing front and rear sidewalls 14, 16 (see FIG. 1). Each edge post EP has a top wall EPTW that lies in a plane EPP spaced a distance D1 below the TRP (see FIGS. 4A-4B). The vertical center posts 42 and edge posts 66 both have a widened base portion 42BP and 62BP (adjacent the bottom wall 12), extending in the transverse TA direction, and the post sidewalls 42SW and 62SW taper (narrow) inwardly (toward the CLA) going vertically up toward the TRP and EPP respectively. In this embodiment the center posts have a diamond shape (in horizontal cross section), with axes in the CLA and TA directions, and with four inwardly curved (rounded) sidewall portions 42SW that form the rounded pocket corners 80 (see e.g., the inwardly curved post sidewalls 80C and 80B in pocket 72F as shown in FIGS. 1 and 7);
b) a plurality (here four) of CDW wall portions 41A, 41B, 41C and 41D each having a top wall CDTW that lies in a plane CDP spaced a second distance D2 below the TRP (see FIG. 3B). The central posts CP's of the CDW are separated from one another, and from the left and right sidewalls 18, 20 of the tray, by the CDW wall portions 41A-D. The CDW wall portions 41A-D each have a flat planar top wall CDTW and tapering downwardly and outwardly (on each side of the CDTW) opposing sidewalls that connect to the inner surface of the base wall 12;
c) a pair of end posts 66A, 66B are formed in the CDW adjacent the end walls 18, 20 respectively, the end posts connecting the CDW wall portions 41A and 41D to the flange 30 adjacent the right and wall 20 and left end wall 18 respectively; similar to the center posts 42 and edge posts 62, the end posts have a similar widened base portion 66BP adjacent the bottom wall 12, and curved sidewalls 66SW that taper inwardly going up toward the CDP; the curved sidewall portions 66SW form the rounded pocket corners 80 (see e.g., rounded corner 80D of end post 66A, in FIGS. 1 and 7).
The side walls 14 and 16, end walls 18 and 20, corners 22-28, central divider wall 40 (with central posts 42A-C, end posts 66A-B, and connecting wall portions 41A-D) and the base wall 12 collectively form the inner surfaces of a series of eight recessed pockets 72F and 72R, 73F and 73R, 74F and 74R, 75F and 75R, each configured to hold a disc-shaped meat product P1-P8 in a spaced apart configuration (see FIGS. 7-10 showing the loaded tray). The CDW central and end posts 42 and 66, the front and rear edge posts 62, and the corners 22-28 are all rounded (curved) to provide a somewhat rounded periphery to each pocket (to match the patty disc periphery). The product may be placed into the pockets either manually or by appropriate mechanical means. Each meat product is held in place in one of the pockets 76A-H, but extends above the pocket (above the TRP as shown in FIGS. 8A-9. The loaded tray is then wrapped with a plastic film F to secure a product in each pocket as described further below.
In accordance with one embodiment of the present invention, a plurality of initially frozen disc-shaped meat products P are removed from a freezer and one P is placed in each pocket 72-75F and 72-75R of the tray (as shown in FIG. 7). As the meat product P begins to thaw (during the packaging process or later during shipment and display) the patty softens and spreads out in a radial direction R wherein it may engage the relatively planar (linear) front and rear edges 78F and 78R of the pocket, left and right side edges 78L and 78R, and/or the curved corner edges 80A, 80B, 80 C 80D, of the pocket (see FIGS. 1 and 7). This movement and potential flattening of some of the patty periphery is limited by engagement with the pocket edges and each patty maintains a substantially circular periphery, while being securely held in the pocket (as shown in FIG. 7).
Each pocket has a relatively shallow recessed pocket height RPH (see FIG. 8B) compared to the length L and width W of the tray (see FIG. 1). The pocket recess has a generally circular periphery (in transverse TA direction) for holding a disc-shaped meat patty P. As noted above (with respect to FIG. 7), each recess periphery has opposing flattened sidewall surfaces 78F, 78R (see FIGS. 1, 6) defined by the front and rear sidewalls 14, 16 and CDW wall portions 41. The pockets are arranged in two parallel rows RF, RR (front and rear) extending between the tray end walls 18 and 20 (parallel to the longitudinal tray CL). Between the two rows the longitudinal central divider wall 40 extends between the opposing tray end walls 18, 20, aligned with the central longitudinal tray axis CLA. The central divider 40 includes the three spaced apart center posts 42A-42C, each one located at a juncture of four adjacent pockets. Each center post has a top wall 43A, 43B, 43C lying in the TRP which together with the top wall 34 of the flange 30, also in the TRP, define the uppermost tray edge (UTE). The wall portions 41 between the center posts, and between the center posts and the end walls, lie below the TRP. The surfaces 43A-43C lying in the TRP define the uppermost surfaces that the overwrap film F can engage and are important to holding each patty in its own pocket, as described below.
In the present embodiment the recessed pocket height RPH (see FIG. 8B) is about 75% of the product (patty) height PH; in various embodiments the recessed pocket height RPH ranges from 60-90% and more preferably 65-85% of the product height, so that when the loaded tray is wrapped in plastic film, each meat patty is held securely in its individual pocket 76 and does not travel outside of that pocket to engage with patties in other pockets. This recessed pocket height also provides for ease of insertion and removal of the meat product from the pocket. Preferably, the pocket cross section widens going toward the top flange 30, again for ease of insertion and removal.
As shown in FIGS. 8A-8B, when the loaded tray is wrapped in plastic film F, the film is held taught by the tray perimeter flange 30; the film also engages the exposed top surfaces of the patties to secure each patty in an individual pocket 76. The center posts 42A-42C create air spaces between the patties in adjacent pockets so that when the film is removed by the consumer, the patties are easier to separate from the film. The center posts 42A-42C, along with the front and rear edge posts 62-64F and 62-64R on the front and rear sidewalls, serve to hold each patty in its individual pocket, and the curved sidewalls (of the center, edge and end posts 42, 62, 66) help maintain a circular configuration (periphery) of each patty, even as it is partially thawed (softens and spreads, from the frozen state).
The processor tray of the invention is suitable for use with a variety of disc-shaped perishable food products such as breakfast patties, burger patties (beef or non-beef), potato pancakes, and the like. The tray is particularly adapted for use with frozen food products that tend to lose their shape and coherency as they thaw.
The trays comprising the present invention may vary in size for storage and display of various meat products of different sizes, e.g., in a range of 2 inch to 4 inches in product diameter, and from ¼ to 1 inches in product height PH. It is to be realized that the optimum dimensional relationship for the parts of the tray include variations in size, materials, shape, form, function, and manner of operation, assembly and use, and are deemed readily apparent and obvious to one skilled in the art. The present embodiment is intended to be just one example of the invention and not limiting.
Returning to FIGS. 1-4, the inner surfaces of the pockets 76A-H and of the base wall 12 define an open ended cavity 60 for holding the product P. The outer surfaces 13 of the pockets of base wall 12 define a lowermost standing surface that lies in the base reference plane BRP (see FIGS. 2-4C). The standing surface 13 is interrupted due to the molded configuration of the pockets and central divider wall 40.
The sidewalls and end walls 14, 16, 18, 20 of the upper cavity 60 may be angularly disposed relative to the base reference plane TRP to define an acute angle α relative to a transverse axis TA which is perpendicular to the TRP (FIG. 4B). The angle α is preferably in a range of 15° to 40°. The corners 22-28 may be similarly angularly disposed relative to the TRP.
A bead 66 may be provided that extends from the outer surfaces of the respective sidewalls, end walls and corners below the flange 30 (see FIG. 4C). The bead may be continuous or formed with interruptions and may be formed with an arcuate shape as shown. The bead assists in spaced stacking of empty trays, as shown in FIG. 4C, wherein the upper surface of the flange 30 of lower tray 10 is spaced a stacking height distance SH from the upper surface of the flange 30′ of the upper tray 10′. This spacing facilitates de-nesting of empty stacked trays.
The flange 30 (FIGS. 1-4) forms an uppermost top perimeter surface 32 of the tray and extends transversely from the outer surfaces of the sidewalls and end walls 14-20 and the outer surfaces of the corners 22-28. Preferably, the flange extends continuously about the top perimeter of the tray. The flange 30 has an upper surface 32 and an opposing bottom surface 33, each generally parallel to the TRP, and an edge surface 34, generally transverse to the TRP, extending between the upper and bottom surfaces. As can be seen in FIG. 4B, the edge surface 34 defines the flange height FH and the overall rectangular shape (perimeter) of the tray 10.
The flange 30 in the present embodiment lies in a top reference plane (TRP) substantially parallel to the base reference plane (BRP). In other embodiments, the flange may be inclined upwardly or downwardly with respect to the BRP. In the present embodiment, the flange 30 is formed with the edge surface 72 being planar, so as to evenly distribute the tension in the plastic film wrapped around the loaded tray.
Referring to FIGS. 7-10, there is shown a tray 10 loaded with meat patty products P and tightly wrapped plastic film F (shown to be transparent). The wrapping film may somewhat deflect the flange 30 from its original molded shape. With the plastic film F being maintained in a taut state, the trays of the present invention can be loaded, wrapped and stacked in a master container for shipment. With two of the trays being stacked one on top of the other, or included on the side edges in a row (FIG. 10), the flange 30 along the sidewalls and end walls apply force to the film F to maintain tautness. The patties themselves, because they extend above the TRP (as shown in FIGS. 8A-9) engage and help hold the film tight. The uppermost surfaces of the cell divider wall 40 (i.e., the top wall 43 of each cell post 42 and the top wall 32 of the flange 30) lie in the TRP. The height of the CDW 40, measured from the interior bottom wall 84 of the pocket 76 to the TRP, is in a range of 60 to 90% of the patty height (product height in direction TA), more preferably 65 to 85%, and in select embodiments may be 75%. The height of the central divider wall 40 may be in a range of 0.5 to 1.5 inches, more preferably 0.8 to 1.2, and still more preferably 0.8 to 1.0, again depending on the patty height.
In another embodiment, the pocket height may be configured to hold two or more patties in a vertical stack in the pocket.
In another embodiment, the film F may comprise a top seal film, that seals to the flange 30, but does not wrap around the bottom of the tray 10 (see e.g., FIG. 21).
In another embodiment, the center posts and/or the edge posts, may include a transverse groove recessed vertically from the TRP; this may provide further structural rigidity to the tray. The grooves may be provided in the embodiment of FIGS. 1-10, or in the further embodiment described below.
FIGS. 11-20 illustrate a second embodiment, in which like elements are labeled with like reference numbers, utilizing a “100” number series (i.e., tray 10 in FIGS. 1-10 is tray 110 in FIGS. 11-20). The views are substantially the same, as outlined above in the Brief Description of the Drawings, with differences noted therein.
In the second embodiment, tray 110, is substantially the same as the first embodiment tray 10, with the following differences:
a) a transverse groove TG is provided in each center post 142 and end post 166, to provide increased structural rigidity to the tray and e.g., to prevent the tray from folding inwardly along the CLA; the groove TG is vertically recessed from the TRP and extends a distance TGH from the TRP (see FIGS. 3B and 3C);
b) the wall portions 141 joining the center posts to the end posts lie in the TRP.
Variations may be provided in the materials, dimensions and features similar to the first embodiment as described above.
As is readily apparent, numerous modifications and changes may readily occur to the skilled person in the art, and hence it is not desired to limit the invention to the exact construction and operation as shown and described. All suitable modifications and equivalents may be considered to fall within the scope of the invention as claimed.

Claims

What is claimed is:

1. A molded plastic tray for displaying each of a plurality of refrigerated food products in spaced apart relation when displayed on a side edge, the tray comprising:

an integrally formed plastic tray having an upper cavity;

the upper cavity forming an open top end of the tray and comprising opposing front and rear elongated sidewalls and opposing first and second end walls, the sidewalls and end walls being a connected by rounded corners to form a rectangular shaped upper cavity;

an array of recessed pockets formed in the upper cavity and each configured to receive a disc-shaped food product, the array including a front row FR of pockets adjacent the front sidewall and a rear row RR of pockets adjacent the rear sidewall;

a rectangular shaped flange disposed at an upper end of the sidewalls, end walls and corners forming the open top end of the tray for attaching an overwrap film or top seal film to secure food products loaded into the pockets;

the array of pockets in the upper cavity being formed by:

a central divider wall CDW extending between the first and second end walls, the CDW including a plurality of spaced apart center posts, each center post being disposed at a juncture between four adjacent pockets in two adjacent rows of the array, each center post having inwardly curved sidewalls extending from the divider wall for engaging a periphery of a disc-shaped product in each of the four adjacent pockets as the product thaws, expands and/or moves into contact with the center post sidewalls,

the front and rear side walls of the tray each having a plurality of spaced apart edge posts, each edge post begin disposed at a juncture between two adjacent pockets in a row of the array, each edge post having curved sidewalls extending from the front or rear side wall for engaging a periphery of a disc-shaped product in each of the adjacent pockets as the product thaws, expands and/or moves into contact with the edge post sidewalls,

the CDW having wall portions extending between two adjacent center posts, or between a center post and the first or second end wall respectively, for engaging a periphery of a disc-shaped product in each of the adjacent pockets as the product thaws, expands and/or moves into contact with the wall portions,

the flange and uppermost surfaces of the center posts lying in a top reference plane TRP that defines an uppermost surface of the tray, and

each pocket having a pocket height that is less than a product height such that plastic film attached to the flange of the loaded tray engages the uppermost surfaces of the products to hold each product securely in an individual pocket when the tray is turned on edge and rests on the front or rear side wall of the tray.

2. The tray of claim 1, wherein each center post includes a transverse groove that strengthens the central divider wall against bending of the tray.

3. The tray of claim 1, wherein each center post has a widened base portion adjacent a bottom wall of the cavity.

4. The tray of claim 3, wherein the curved sidewalls of the center post taper inwardly moving away from the widened base portion.

5. The tray of claim 1, wherein the tray has a central longitudinal axis CLA and a transverse axis TA perpendicular to the CLA.

6. The tray of claim 5, wherein the CDW lies on the CLA.

7. The tray of claim 6, wherein one or more center posts and edge posts are aligned along the TA.

8. The tray of claim 7, wherein one center post is disposed equal distance between two edge posts on the front and rear sidewalls respectively and aligned on the TA.

9. The tray of claim 8, wherein the center post and edge posts each have a widened base portion extending along the TA.

10. The tray of claim 9, wherein the CDW has an end post adjacent each of the end walls, wherein the end posts each have a widened base portion in a direction parallel to the TA.

11. The tray of claim 1, wherein the center posts each have a diamond shaped top wall that lies in the TRP.

12. The tray of claim 5, wherein each center post has a diamond shaped top wall having a first axis on the CLA and a second axis on the TA.

13. The tray of claim 1, wherein the center posts, end posts and edge posts each have a widened base portion adjacent a bottom wall of the cavity.

14. The tray of claim 1, wherein the pocket height is configured to hold one or more disc shaped products in a vertical stack in the pocket.

15. The tray of claim 1 wherein the pocket height is in a range of 60 to 90% of the product height.

16. The tray of claim 15 wherein the pocket height is in a range of 65 to 85% of the product height.

17. The tray of claim 1, wherein the pockets are aligned in a parallel series, in each row, between the first and second end walls of the tray.

18. The tray of claim 1, wherein the flange forms the perimeter of the tray, the flange having a top surface coextensive with the TRP, an exterior side edge coextensive with the perimeter, and a bottom surface on an underside surface of the tray.

19. A stack of trays is provided, the stack comprising:

a first tray and one or more nested trays;

a second tray nested within the first tray;

wherein a topside surface of the first tray engages an underside surface of the second tray, and each remaining tray in the stack likewise engaging an adjacent tray.

20. The tray of claim 1, wherein the plastic material comprises one or more of polystyrene (EPS), polyester, polyolefin, polypropylene (PP), or polylactic acid (PLA), including homopolymers, copolymers, mixtures and blends thereof, and including virgin and reclaimed (recycled) materials, and whether solid or foamed.

21. The tray of claim 20, wherein the plastic foam tray comprises polystyrene foam.

22. A method of packing the tray for display and storage, the method comprising:

providing a plurality of disc shaped food products;

depositing each food product into a respective pocket, a lower portion of the food product being deposited on a bottom wall of the pocket and an upper portion of the food product extending at or above the TRP;

providing a sheet of wrapping or top seal film and positioning it over the tray and the food product deposited therein;

pulling the sheet taut to engage the surface of each product deposited within the tray and the tray flange; and

securing the sheet to the tray.

23. The method of claim 22, wherein the film is an overwrap film that is wrapped around the product and an undersurface of the tray.

24. The method of claim 22, wherein the film is a top seal film and is sealed to the flange.