BACKGROUND

[0001] Trays can be used for transporting food in multiple temperature states and between multiple locations. Deformation of trays during transport can result in inefficient food preparation, damage to food held by the trays, and other issues affecting cost and safety of food preparation.

SUMMARY

[0002] This summary is provided solely as an introduction to subject matter that is fully described in the detailed description and drawings. The summary should not be considered to describe essential features nor be used to determine the scope of the claims. Moreover, it is to be understood that both the summary and the detailed description are examples and explanatory only and are not necessarily restrictive of the subject matter claimed.

[0003] Convertible trays are disclosed with features that facilitate preparation, transportation, and presentation of food items. In one aspect, an example convertible tray system includes, but is not limited to, a convertible tray for holding a food item and a serving container for substantially enclosing the convertible tray while holding the food item. The convertible tray includes a first separation feature defined by the substrate on a first edge of the convertible tray adjacent to the at least one aperture, the first separation feature defining a boundary between the convertible tray and a second convertible tray detached from a blank forming each of the convertible tray and the second convertible tray, a plurality of flaps defined by the substrate by folding along at least one fold feature defined by the substrate, the plurality of flaps providing support of the at least one aperture of the convertible tray above a support surface, and at least one tray stabilizer defined by the substrate, the at least one tray stabilizer configured to hinge along the at least one fold feature to raise a section of the substrate above the at least one aperture. The serving container includes a bottom shell rotatably coupled to a top shell via at least one hinge, the bottom shell having a plurality of interior sidewalls and including the support surface, wherein at least one flap of the plurality of flaps conforms to at least one interior sidewall of the plurality of interior sidewalls, wherein the top shell rotates via the at least one hinge to substantially enclose the convertible tray while holding the food item within an interior volume defined by the bottom shell and the top shell.

[0004] In one aspect, a convertible tray includes, but is not limited to a substrate defining a plurality of apertures, each aperture for holding a food item; a first separation feature defined by the substrate on a first side of the convertible tray adjacent to at least one aperture of the plurality of apertures; a plurality of flaps foldable to support the first side of the convertible tray above a support surface, wherein at least one of the substrate and at least one flap of the plurality of flaps can be divided at the first separation feature to remove an individual tray that includes the at least one aperture of the plurality of apertures; and at least one tray stabilizer defined by the substrate, the at least one tray stabilizer configured to hinge along the at least one fold feature to raise a section of the substrate above the at least one aperture.

DRAWINGS

[0005] The Detailed Description is described with reference to the accompanying figures. Any dimensions included in the accompanying figures are provided by way of example only and are not meant to limit the present disclosure.

[0006] FIG. 1 is an isometric view illustrating a convertible tray and food bowl products held in the convertible tray in accordance with example embodiments of the present disclosure.

[0007] FIG. 2 is another isometric view of the convertible tray and food bowl products of FIG. 1, where the convertible tray is separated into individual trays.

[0008] FIG. 3A is an isometric view illustrating an individual tray and food bowl products separated from a convertible tray, such as the convertible tray shown in FIG. 1, where the individual tray and food bowl products are to be introduced to a serving container in accordance with example embodiments of the present disclosure.

[0009] FIG. 3B is an isometric view illustrating an individual tray and food bowl products separated from a convertible tray, such as the convertible tray shown in FIG. 1, where the individual tray and food bowl products are nested in a serving container in accordance with example embodiments of the present disclosure. [0010] FIG. 4A is a top plan view of a blank for constructing a convertible tray, such as the convertible tray illustrated in FIG. 1, in accordance with example embodiments of the present disclosure.

[0011] FIG. 4B is a top plan view of a blank for constructing a convertible tray in accordance with example embodiments of the present disclosure.

[0012] FIG. 4C is a top plan view of a blank for constructing a convertible tray in accordance with example embodiments of the present disclosure.

[0013] FIG. 4D is a top plan view of a blank for constructing a convertible tray in accordance with example embodiments of the present disclosure.

[0014] FIG. 5 is an isometric view of the blank illustrated in FIG. 4A, where the blank is constructed to form a convertible tray.

[0015] FIG. 6A is an exploded isometric view of illustrating multiple convertible trays, such as the convertible tray illustrated in FIG. 5, with food bowl products held thereby, where such convertible trays are held in a shipping container for transportation in accordance with example embodiments of the present disclosure.

[0016] FIG. 6B is an exploded isometric view of illustrating multiple convertible trays, such as the convertible tray illustrated in FIG. 5, with food bowl products held thereby, where such convertible trays are held in a shipping container for transportation in accordance with example embodiments of the present disclosure.

DETAILED DESCRIPTION

[0017] Aspects of the disclosure are described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, example features. The features can, however, be embodied in many different forms and should not be construed as limited to the combinations set forth herein; rather, these combinations are provided so that this disclosure will be thorough and complete, and will fully convey the scope. The following detailed description is, therefore, not to be taken in a limiting sense.

[0018] Packaging for food items can influence the amount and types of interaction between equipment or individuals and the food items during preparation, cooking, and serving processes. As a food item is transferred between different packaging, such as being removed from one package and inserted into another package (e.g., for the purposes of preparing, forming, cooking, cooling, freezing, preserving/stabilizing, serving, etc.), the likelihood that the food item can be deformed, damaged, or otherwise altered, can be increased.

[0019] Referring generally to FIGS. 1 through 6B, convertible trays 100 are described in accordance with example embodiments of the present disclosure. As described herein, a convertible tray 100 can be formed or erected from one or more blanks 102 (e.g., a foldable, unitary, single-sheet paperboard, corrugated, and/or plastic substrate, as illustrated in FIGS. 4A through 4D, and/or multiple paperboard, corrugated, and/or plastic substrates joined (e.g., glued, formed) together). The convertible trays 100 and the blanks 102 used to form the convertible trays 100 include features that facilitate preparation, transportation, and presentation of food items across multiple locations while providing support and stabilization of food items held by the convertible trays 100. For example, the convertible trays 100 can adopt a first configuration (e.g., shown in FIG. 1) to carry several food items 50 at a time, where the food items 50 can be held, supported, and/or retained by the convertible tray 100. Convertible trays 100 in the first configuration can be stacked with other convertible trays 100 for bulk transport (e.g., to a food handling facility), as shown for example, in FIGS. 6 A and 6B. The convertible trays 100 can adopt a second configuration (e.g., shown in FIG. 2), where individual trays 104 can be separated from other trays or other portions of the convertible tray 100. Each individual tray 104 can hold one or more food items 50. While the individual trays shown in FIG. 2 each include two food items 50, the disclosure is not limited to two food items for an individual tray 104, where individual trays 104 can support fewer food items (i.e., less than two food items) or more food items (e.g., three food items, four food items, five food items, and greater). Blanks 102 configured to support different numbers of food items 50 are described further herein with respect to FIGS. 4 A through 4D. For example, FIG. 4C shows a blank 102 where each individual tray 104 can support up to twelve food items, FIG. 4D shows a blank 102 where each individual tray 104 can support up to six food items, and so forth. The individual trays 104 can be combined with additional packaging (e.g., shown in FIGS. 3A and 3B), such as in a food handling facility for presentation to an end consumer. [0020] The convertible tray 100 defines multiple apertures 106, where each aperture 106 can hold a food item 50. Example food items include, but are not necessarily limited to: food bowl products, cup products, cone products, and so forth (e.g., where the items may or may not be edible and/or may or may not be filled with additional food product). The example food items 50 shown can include a potato-based product formed via pressing food product into a mold to define a cavity 52 in the food product. The cavity 52 can be filled with additional food product, such as at a food handling facility, which can be separate from the location where the food items 50 are initially prepared. In some embodiments, multiple food items can be carried by a convertible tray 100 through one or more cooking processes, preservation/stabilizing processes, transportation processes, and so forth. For instance, a convertible tray 100 can be filled with food items and processed at a high temperature, a freezing temperature, through various thermal transitions (e.g., high temperature to freezing temperature), and so forth. The convertible tray 100 filled with the food items 50 can then be stacked with other convertible trays 100 and transported (e.g., to a food handling facility), as shown for example, in FIGS. 6A and 6B.

[0021] In an example process, multiple food items 50 are prepared at a production facility and introduced to a convertible tray 100 in the first configuration (e.g., shown in FIG. 1) while the food items 50 are in a first preparation state (e.g., at an elevated temperature state following forming into a bowl shape and cooking). The convertible tray 100 is then transferred in the first configuration to transition the food items 50 to a second preparation state (e.g., at a reduced or frozen temperature state). Multiple convertible trays 100 are then stacked (e.g., as shown in FIGS. 6A and 6B) for transport to a food-handling facility. At the food-handling facility, individual trays 104 having the food items 50 supported thereby are separated from the convertible trays 100 to provide the second configuration (e.g., shown in FIG. 2). The individual trays 104 can be prepared on demand to transition the food items 50 to a third preparation state (e.g., ready for consumption by a consumer, which can include introducing additional food items into the cavity 52 formed by the bowl shape, transfer of the individual tray 104 into a serving container (e.g., shown in FIGS. 3A, 3B), and the like). The example process described herein is an example embodiment of the present disclosure, and not limiting to the configurations or processes applicable to the convertible tray 100. [0022] In some embodiments, one or more sides of the blank 102 can be coated with a material coating 108 for withstanding a heating process and/or a cooling process without substantial deformation and/or substantial loss of structural integrity. The coating 108 can also provide a barrier for food retained by a convertible tray 100. For example, the blank 102 has a polyethylene coating, a polypropylene coating, a polyester coating, a susceptor coating, and/or another type of coating that provides a moisture and/or a grease barrier. Such a coating may also reduce warping of the paperboard, corrugated, or plastic substrate(s).

[0023] The blank 102 can be folded to form a convertible tray 100. In some embodiments, the blank 102 includes one or more fold features 110 to facilitate folding of the blank 102 into the convertible tray 100, the individual tray 104, or configurations of the convertible tray 100. The fold features 110 can be or can include a scoring feature cut into the substrate of the blank 102, a change in thickness of the blank 102 at the fold feature 110, and so forth to permit folding of the blank 102. A blank 102 or blanks may have one or more flaps 112 or other features that extend from the blank 102 and can be folded to form sides that support a first side 114 of the convertible tray 100 above a support surface (e.g., a counter, a box, another convertible tray 100). For example, the flaps 112 can be folded at one or more fold features 110 to support the first side 114 of the convertible tray above the support surface. The flaps 112 can be used to support the convertible tray 100 during transport and/or storage of food products retained in the apertures 106. In some embodiments (e.g., shown in FIG. 2), the flaps 112 extend from the first side 114 to contact and terminate at the support surface. For example, the blank 102 can include a first fold feature 110 to fold a first flap 112 extending from the first side 114 beneath the aperture 106 and a second fold feature 110 to fold a second flap 112 extending from the first side 114 beneath the aperture 106, generally opposing the first flap 112.

[0024] In some embodiments, the convertible tray 100 include two or more sides (e.g., flaps 112) and a top (e.g., first side 114), with no bottom portion. In some embodiments, the flaps 112 extend from a side of the blank 102 and can be folded and secured (e.g., glued or otherwise adhered) to another side and/or flap of the blank 102 to form a convertible tray 100 having a bottom formed from the flaps 112. Alternatively or additionally, the blank 102 may include a bottom portion to which the flaps 112 are secured to support the first side 114 of the convertible tray 100 above the bottom portion on the support surface. In some embodiments, the food items 50 may extend to a level below the first side 114 of the convertible tray 100 generally even with a bottom edge of the flaps 112 when folded to form the side of the convertible tray 100. The flaps 112 may also be used to support the first side 114 of an individual tray 104 which has been separated from a convertible tray 100.

[0025] A convertible tray 100 includes one or more first separation features (e.g., perforations 116) defined by the folded substrate blank 102 on the first side 114 of the convertible tray 100 adjacent to one or more of the apertures 106. As used herein, the term“perforations” shall refer to one or more small holes (e.g., a row of small holes) and/or“nicks” cut through the substrate so that a part can be torn off easily. It should be noted that the first separation feature may also be, and/or may include, one or more other features, such as“nicks,” a zipper, a tear strip, and so forth. The folded substrate can be divided at a perforation 116 to remove an individual tray 104 (FIGS. 2, 3A, 3B) from the convertible tray 100, where the individual tray 104 includes one or more apertures 106 adjacent to the perforation 116. An individual tray 104 can include a first separation feature (e.g., perforation 116) on a first edge 118 of the first side 114, where the first separation feature defines a boundary between the individual tray 104 and a second individual tray 104 detached from the individual tray 104 at the first separation feature.

[0026] A convertible tray 100 may include one or more locking tabs 120 extending from the flaps 112 and configured to be inserted into locking slots 122 included with an end flap 124. For example, an end flap 124 may be folded under a locking tab 120, and an end of the locking tab 120 may be inserted into the locking slot 122 defined by (e.g., cut through) the end flap 124. As described, the end flaps 124, the locking tabs 120, or combinations thereof may be removed from an individual tray 104 using perforations 116 as previously described. An individual tray can include a first separation feature (e.g., perforation 116) on a first edge 118 of the first side 114, where the first separation feature defines a boundary between the individual tray 104 and a second individual tray 104 detached from the individual tray 104 at the first separation feature, and can include a second separation feature (e.g., perforation 116) on a second edge 126 of the first side 114 which defines a boundary between the individual tray 104 and an end flap 124 removed from the individual tray 104 at the second separation feature (e.g., the transition between the first configuration shown in FIG. 1 and the second configuration shown in FIG. 2). In some embodiments, separation features between apertures 106 are not included in a convertible tray 100. The convertible tray 100 can include one or more separation features (e.g., perforations 116) between one or more apertures 106 and one or more end flaps 124 without separation features between the apertures 106. For example, a convertible tray 100 can include a separation feature at the second edge 126, but not the first edge 118.

[0027] In some embodiments the convertible tray 100 may also include one or more additional separation features (e.g., a zipper or tear strip) defined by the folded substrate on a second side of the convertible tray 100 generally opposite the first separation feature/perforation 116. As used herein, the term“tear strip” shall refer to a scored band or added narrow ribbon that provides an easy and defined way of separating two adjacent parts of the substrate (e.g., by removing the strip). It should be noted that the second separation feature may also be, and/or may include, one or more other features, such as one or more perforations. As described, the tear strip can be separated from the folded substrate, and the folded substrate can be divided at the perforation 116 to remove an individual tray 104 from the convertible tray 100, where the individual tray 104 includes one or more apertures 106 adjacent to the perforation 116.

[0028] In some embodiments, the apertures 106 include rows of two or more apertures 106, e.g., where each aperture in a first row is arranged directly opposite a corresponding aperture of a second row. For example, each row may have two apertures, as shown in the convertible trays 100 or individual trays 106 shown in FIGS. 1-4A and 5-6B. In some embodiments, a row may have more than two apertures, for example as shown in FIG. 4C and 4D. In some embodiments, a row may have a single aperture, for example as shown in FIG. 4B. Further, adjacent rows may have different numbers of apertures, and the apertures may or may not be arranged across from one another. For example, FIG. 4D shows a blank 102 where apertures 106 in a first row 128 on an individual tray 104 are offset from apertures 106 in a second row 130 on the individual tray 104. In some embodiments, one or more of the multiple apertures 106 is a circular aperture. However, a circle is provided by way of example and is not meant to limit the present disclosure. In other embodiments, differently-shaped apertures may be used (e.g., square, rectangular, hexagonal, octagonal, etc.), where an individual tray 104 may include multiple differently-shaped apertures. Further, the apertures can include additional features for accessing and/or retaining the food items, such as fingerholes, a starburst-patterned shape, flaps, and so forth.

[0029] The convertible tray 100 may include features for accessing the tray, retaining the tray, and combinations thereof. For example, the convertible tray 100 can include one or more tray stabilizers 132. In embodiments, the tray stabilizers 132 hinge at the fold feature 110 to raise a section of the substrate material above the first side 114 of the convertible tray 100. When a second or another convertible tray 100 is stacked on the first convertible tray 100, the flaps 112 of the second convertible tray 100 can rest against the tray stabilizers 132 of the first convertible tray 100. For example, an exterior surface of a flap 112 can rest against an interior surface of a tray stabilizer 132. Example stacking arrangements are shown with respect to FIGS. 6A and 6B, where multiple convertible trays 100 can be stacked for transport within an exterior container 600. Further, the convertible tray 100 can include a recess 134 left in the convertible tray 100 when the tray stabilizer 132 is hinged at the fold feature 110 and raised above the first side 114. The recess 134 can provide an access point for a finger or tool to move one or more convertible trays 100, particularly where the apertures 106 are blocked or otherwise inaccessible from the first side 114 due to being filled with food items 50.

[0030] In embodiments of the disclosure, an individual tray 104 separated from the convertible tray 100 can be nested in a serving container 300. The food items 50 (e.g., frozen food items) carried in the individual tray 104 may be cooked within a container, such as the serving container 300; may be cooked prior to being placed in a container, such as the serving container 300; may be dethawed/defrosted prior to be placed within a container, such as the serving container 300, and then cooked; and so forth. The serving container 300 can substantially enclose an individual tray 104 while the individual tray 104 holds the food item(s) 50, or while one or more apertures 106 are empty. For example, the serving container 300 can include a bottom shell 302 coupled to a top shell 304 via at least one hinge 306. The top shell 304 can rotate with respect to the bottom shell 302 via the at least one hinge 306 to substantially enclose the individual tray 104 while holding the food item(s) 50 within an interior volume 308 defined by the bottom shell 302 and the top shell 304. In some embodiments, the bottom shell 302 includes a plurality of interior sidewalls 310 and a support surface 312 on which at least one flap 112 of the individual tray 104 rests. One or more flaps 112 of the individual tray 104 can conform to one or more of the interior sidewalls 310 of the serving container 300 during or following introduction of the individual tray 104 to the serving container 300. For example, one or more flaps 112 of the individual tray 104 can hinge about the fold feature 110 to conform one or more of the interior sidewalls 310 of the serving container 300, such as by bending to an angle with respect to the surface in which the aperture 106 is disposed to substantially match an angle of the interior sidewall 310 of the serving container 300. In some embodiments, a surface of the food item(s) 50 rests on the support surface 312 when the individual tray 104 is received within the interior volume 308 of the serving container 300.

[0031] Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.