MOLDED FIBER TRAY

Description

TECHNICAL FIELD

This disclosure relates to packaging and in particular, to molded fiber trays.

BACKGROUND

Environmental and sustainable packaging is being used in an effort to eliminate and or reduce plastic and other environmentally unfriendly materials, including for example, polystyrene or polyethylene terephthalate (PET).

SUMMARY

Disclosed herein are molded fiber tray packages and packaging. In an implementation, a molded fiber tray includes a base, a sidewall extending from the base to form a content holding structure, an edge extending from the sidewall configured for holding the molded fiber tray, and a barrier layer formed on an internal surface of the base, the sidewall, and the edge, the barrier layer configured to be substantially chemically inert with respect to contents in the content holding structure

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings and are incorporated into and thus constitute a part of this specification. It is emphasized that, according to common practice, the various features of the drawings are not to-scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity.

FIG. 1 is a perspective view of an example molded fiber tray in accordance with implementations.

FIGS. 2A-C are top, side, and another side views of the example molded fiber tray of FIG. 1 in accordance with implementations.

FIG. 3 is a perspective view of an example molded fiber tray in accordance with implementations.

FIGS. 4A-C are top, side, and another side views of the example molded fiber tray of FIG. 3 in accordance with implementations.

FIG. 5 is a perspective view of an example molded fiber tray in accordance with implementations.

FIG. 5A is an exploded view of the example molded fiber tray of FIG. 5 in accordance with implementations.

FIGS. 6A-C are top, side, and another side views of the example molded fiber tray of FIG. 5 in accordance with implementations.

FIG. 7 is a cross-sectional view taken along A-A of the example molded fiber tray of FIG. 6A in accordance with implementations.

FIG. 8 is a cross-sectional view taken along C-C of the example molded fiber tray of FIG. 6A in accordance with implementations.

FIG. 9 is a method for forming a molded fiber tray in accordance with implementations.

DETAILED DESCRIPTION

The figures and descriptions provided herein may be simplified to illustrate aspects of the described embodiments that are relevant for a clear understanding of the herein disclosed processes, machines, manufactures, and/or compositions of matter, while eliminating for the purpose of clarity other aspects that may be found in typical similar devices, systems, compositions and methods. Those of ordinary skill may thus recognize that other elements and/or steps may be desirable or necessary to implement the devices, systems, compositions, and methods described herein. However, because such elements and steps do not facilitate a better understanding of the disclosed embodiments, a discussion of such elements and steps may not be provided herein. However, the present disclosure is deemed to inherently include all such elements, variations, and modifications to the described aspects that would be known to those of ordinary skill in the pertinent art in light of the discussion herein.

Embodiments are provided throughout so that this disclosure is sufficiently thorough and fully conveys the scope of the disclosed embodiments to those who are skilled in the art. Numerous specific details are set forth, such as examples of specific aspects, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. Nevertheless, it will be apparent to those skilled in the art that certain specific disclosed details need not be employed, and that embodiments may be embodied in different forms. As such, the exemplary embodiments set forth should not be construed to limit the scope of the disclosure.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. For example, as used herein, the singular forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

The steps, processes, and operations described herein are thus not to be construed as necessarily requiring their respective performance in the particular order discussed or illustrated, unless specifically identified as a preferred or required order of performance. It is also to be understood that additional or alternative steps may be employed, in place of or in conjunction with the disclosed aspects.

Yet further, although the terms first, second, third, etc. may be used herein to describe various elements, steps or aspects, these elements, steps, or aspects should not be limited by these terms. These terms may be only used to distinguish one element or aspect from another. Thus, terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, step, component, region, layer, or section discussed below could be termed a second element, step, component, region, layer, or section without departing from the teachings of the disclosure.

The non-limiting embodiments described herein are with respect to molded fiber trays and methods for making the molded fiber trays. The molded fiber trays and methods for making the molded fiber trays may be modified for a variety of applications and uses while remaining within the spirit and scope of the claims. The embodiments and variations described herein, and/or shown in the drawings, are presented by way of example only and are not limiting as to the scope and spirit. The descriptions herein may be applicable to all embodiments of the fusion packages and the methods for making the fusion packages.

Disclosed herein are implementations of molded fiber trays and methods for making the molded fiber trays. The implementations shown are illustrative and other implementations are within the scope of the specification and claims described herein. For purposes of illustration, certain aspects, features, and the like are described with respect to implementations. These aspects, features, and the like are appropriately applicable to and interchangeable with other implementations described herein.

In implementations, the molded fiber trays described herein can be manufactured using combinations of injection molding (IM), in-mold labeling (IML), die cutting, compression blow molding, thermoform molding, and the like processing (collectively “structure forming process”) to form a molded fiber tray and the like.

In implementations, the molded fiber tray can be configured to contain foodstuffs, meat, liquid, concentrated liquid, powder, granules, dry content or materials, or non-dry content or materials, for example.

In implementations, the molded fiber tray can be made using the structure forming processes from sustainable materials, recyclable materials, biodegradable materials, bio-based resins, weight-optimized biodegradable plastic, molded fiber, molded paper, molded pulp, fiber, paper, pulp, paperboard, pressed pulp, fiber based, pressed fiber, paper, starch, cellulose, biodegradable resins such as Polylactic acid (PLA), Polyhydroxyalkanoates (PHA), Polyhydroxybutyrate (PHB), Polyethylene Furanoate (PEF), and combinations thereof (collectively “structure forming materials”).

In implementations, the molded fiber trays can efficiently use recyclable, biodegradable, and the like structure forming materials for improved sustainability.

In implementations, the molded fiber trays are environmentally friendly, compostable, and recyclable.

In implementations, the molded fiber tray can include a barrier layer or film on an internal or inside surface, where the barrier layer is impervious or substantially impervious to the content or material in the molded fiber tray and/or chemically inert or substantially chemically inert with respect to the content or material in the molded fiber tray. In implementations, the molded fiber tray can include an integrated or integrally formed barrier layer or film. In some implementations, the barrier layer can include one or more of a vapor barrier, a liquid barrier, an oxygen barrier, a moisture barrier, a grease barrier, a gas barrier, an oil barrier, and other barrier relevant to the content or material in the molded fiber tray. In some implementations, the oxygen barrier, the moisture barrier, the grease barrier, the gas barrier, the oil barrier, and the other barrier can be integral to or integrated with the molded fiber tray. In some implementations, the oxygen barrier, the moisture barrier, the grease barrier, the gas barrier, the oil barrier, and the other barrier can be separate layers formed on the internal or inside surface of the molded fiber tray.

In implementations, the molded fiber tray can include a barrier layer or film on an external or outer surface of the molded fiber tray. The barrier layer is as described herein.

In implementations, the molded fiber trays can be laminated or coated on the internal or inside surface, the external or outer surface, or both with one or more barrier materials or layers.

In implementations, the molded fiber trays can be molded into a variety of shapes, including but not limited to, oval, round, and/or rectangular shapes using the described and/or disclosed materials.

In implementations, the molded fiber trays can include a tessellated pattern on a base to prevent hinging and bending.

In implementations, the molded fiber trays can be stackable and nestable during shipping to a content dispensing location.

FIG. 1 is a perspective view of an example molded fiber tray 1000 in accordance with implementations. FIGS. 2A-C are top, side, and another side views of the example molded fiber tray 1000 of FIG. 1 in accordance with implementations.

The molded fiber tray 1000 is made from the structure forming materials using the structure forming processes.

The molded fiber tray 1000 includes a base 1100, a sidewall 1200 angularly extending from the base 1100 to form a contents placement and/or holding structure 1300, and an edge 1400 angularly extending from the sidewall 1200. The edge 1400 can be used for holding the molded fiber tray 1000, attaching a lid to the molded fiber tray 1000, attaching stretch wrap or other sealing materials to the molded fiber tray 1000, and/or combinations thereof.

In some implementations, a barrier layer 1500 can be laminated, coated, and/or otherwise formed on an internal surface 1110 of the base 1100, the sidewall 1200, and the edge 1400. In some implementations, the barrier layer 1500 can be integrally formed on the base 1100, the sidewall 1200, and the edge 1400. The barrier layer 1500 can prevent or substantially prevent fiber to food contact. In some implementations, the barrier layer 1500 can keep or substantially keep the molded fiber tray 1000 from absorbing liquid from the contents in the contents placement and/or holding structure 1300.

In some implementations, a barrier layer 1600 can be laminated, coated, and/or otherwise formed on an external surface 1120 of the base 1100, the sidewall 1200, and the edge 1400. In some implementations, the barrier layer 1600 can be integrally formed on the base 1100, the sidewall 1200, and the edge 1400. In some implementations, the barrier layer 1600 can keep or substantially keep the molded fiber tray 1000 from absorbing liquid due to moisture wicking or condensation when stretch wrap or a lid is placed on the molded fiber tray 1000. For example, moisture can travel along the stretch wrap and/or lid and otherwise soak into the external surface 1120 of the base 1100 of the molded fiber tray 1000.

FIG. 3 is a perspective view of an example molded fiber tray 3000 in accordance with implementations. FIGS. 4A-C are top, side, and another side views of the example molded fiber tray 3000 of FIG. 3 in accordance with implementations.

The molded fiber tray 3000 is made from the structure forming materials using the structure forming processes.

The molded fiber tray 3000 includes a base 3100, a sidewall 3200 angularly extending from the base 3100 to form a contents placement and/or holding structure 3300, and an edge 3400 angularly extending from the sidewall 3200. The edge 3400 can be used for holding the molded fiber tray 3000, attaching a lid to the molded fiber tray 3000, attaching stretch wrap or other sealing materials to the molded fiber tray 3000, and/or combinations thereof.

In some implementations, a barrier layer 3500 can be laminated, coated, and/or otherwise formed on an internal surface 3110 of the base 3100, the sidewall 3200, and the edge 3400. In some implementations, the barrier layer 3500 can be integrally formed on the base 3100, the sidewall 3200, and the edge 3400. The barrier layer 3500 can prevent or substantially prevent fiber to food contact. In some implementations, the barrier layer 3500 can keep or substantially keep the molded fiber tray 3000 from absorbing liquid from the contents in the contents placement and/or holding structure 3300.

In some implementations, a barrier layer 3600 can be laminated, coated, and/or otherwise formed on an external surface 3120 of the base 3100, the sidewall 3200, and the edge 3400. In some implementations, the barrier layer 3600 can be integrally formed on the base 3100, the sidewall 3200, and the edge 3400. In some implementations, the barrier layer 3600 can keep or substantially keep the molded fiber tray 3000 from absorbing liquid due to moisture wicking or condensation when stretch wrap or a lid is placed on the molded fiber tray 3000. For example, moisture can travel along the stretch wrap and/or lid and otherwise soak into the external surface 3120 of the base 3100 of the molded fiber tray 3000.

In some implementations, the base 3100 has a geometric pattern 3130 for reinforcement of the molded fiber tray 3000 structure. The geometric pattern 3130 is suitable or substantially suitable for use of structure forming processes and for integration and/or application of the barrier layer 3500, the barrier layer 3600, and/or combinations thereof.

In some implementations, the geometric pattern 3130 prevents or substantially prevents hinging, bending, buckling, and/or collapsing of the molded fiber tray 3000 as the geometric pattern 3130 interrupts or substantially interrupts fold lines in the molded fiber tray 3000. For example, some users of the molded fiber tray 3000 use one hand to hold the molded fiber tray 3000 while it contains the contents, creating a large, cantilevered load. These loads are larger than typical food service applications. The molded fiber tray 3000 is suitable for such uses. In some implementations, the molded fiber tray 3000 is suitable to withstand or substantially withstand collapsing or buckling when the molded fiber tray 3000 is covered with stretch wrap after being filled with contents such as meat.

In some implementations, the geometric pattern 3130 prevents or substantially prevents a liquid portion of contents from a solid portion of the contents. For example, meat is substantially kept above the juice that can drip off the meat.

In some implementations, the geometric pattern 3130 is a tessellated geometric pattern. In some implementations, the geometric pattern 3130 is a tessellated hexagonal geometric pattern. In some implementations, the geometric pattern 3130 is a tessellated polygon geometric pattern. In some implementations, the geometric pattern 3130 is a three-dimensional (3-D) geometric pattern. In some implementations, the geometric pattern 3130 is a tessellated 3-D geometric pattern. In some implementations, the geometric pattern 3130 is a tessellated hexagonal 3-D geometric pattern. In some implementations, the geometric pattern 3130 is a tessellated polygon 3-D geometric pattern.

FIG. 5 is a perspective view of an example molded fiber tray 5000 in accordance with implementations. FIG. 5A is an exploded view of the example molded fiber tray 5000 of FIG. 5 in accordance with implementations. FIGS. 6A-C are top, side, and another side views of the example molded fiber tray 5000 of FIG. 5 in accordance with implementations. FIG. 7 is a cross-sectional view taken along A-A of the example molded fiber tray 5000 of FIG. 6A in accordance with implementations. FIG. 8 is a cross-sectional view taken along C-C of the example molded fiber tray 5000 of FIG. 6A in accordance with implementations.

The molded fiber tray 5000 is made from the structure forming materials using the structure forming processes.

The molded fiber tray 5000 includes a base 5100, a sidewall 5200 angularly extending from the base 5100 to form a contents placement and/or holding structure 5300, and an edge 5400 angularly extending from the sidewall 5200. The edge 5400 can be used for holding the molded fiber tray 5000, attaching a lid to the molded fiber tray 5000, attaching stretch wrap or other sealing materials to the molded fiber tray 5000, and/or combinations thereof.

In some implementations, a barrier layer 5500 can be laminated, coated, and/or otherwise formed on an internal surface 5110 of the base 5100, the sidewall 5200, and the edge 5400. In some implementations, the barrier layer 5500 can be integrally formed on the base 5100, the sidewall 5200, and the edge 5400. The barrier layer 5500 can prevent or substantially prevent fiber to food contact. In some implementations, the barrier layer 5500 can keep or substantially keep the molded fiber tray 5000 from absorbing liquid from the contents in the contents placement and/or holding structure 5300.

In some implementations, a barrier layer 5600 can be laminated, coated, and/or otherwise formed on an external surface 5120 of the base 5100, the sidewall 5200, and the edge 5400. In some implementations, the barrier layer 5600 can be integrally formed on the base 5100, the sidewall 5200, and the edge 5400. In some implementations, the barrier layer 5600 can keep or substantially keep the molded fiber tray 5000 from absorbing liquid due to moisture wicking or condensation when stretch wrap or a lid is placed on the molded fiber tray 5000. For example, moisture can travel along the stretch wrap and/or lid and otherwise soak into the external surface 5120 of the base 5100 of the molded fiber tray 5000.

In some implementations, the base 5100 has a geometric pattern 5130 for reinforcement of the molded fiber tray 5000 structure. The geometric pattern 5130 is suitable or substantially suitable for use of structure forming processes and for integration and/or application of the barrier layer 5500, the barrier layer 5600, and/or combinations thereof. In some implementations, the geometric pattern 5130 prevents or substantially prevents hinging, bending, buckling, and/or collapsing of the molded fiber tray 5000 as the geometric pattern 5130 interrupts or substantially interrupts fold lines in the molded fiber tray 5000. For example, some users of the molded fiber tray 5000 use one hand to hold the molded fiber tray 5000 while it contains the contents, creating a large, cantilevered load. These loads are larger than typical food service applications. The molded fiber tray 5000 is suitable for such uses. In some implementations, the molded fiber tray 5000 is suitable to withstand or substantially withstand collapsing or buckling when the molded fiber tray 5000 is covered with stretch wrap after being filled with contents such as meat.

In some implementations, the geometric pattern 5130 prevents or substantially prevents a liquid portion of contents from a solid portion of the contents. For example, meat is substantially kept above the juice that can drip off the meat.

In some implementations, the geometric pattern 5130 is a tessellated geometric pattern. In some implementations, the geometric pattern 5130 is a tessellated hexagonal geometric pattern. In some implementations, the geometric pattern 5130 is a tessellated polygon geometric pattern. In some implementations, the geometric pattern 5130 is a three-dimensional (3-D) geometric pattern. In some implementations, the geometric pattern 5130 is a tessellated 3-D geometric pattern. In some implementations, the geometric pattern 5130 is a tessellated hexagonal 3-D geometric pattern. In some implementations, the geometric pattern 5130 is a tessellated polygon 3-D geometric pattern. In implementations, the geometric pattern 5130 can include a plurality of geometric sub-patterns 5132. In implementations, the geometric pattern 5130 and each geometric sub-pattern 5132 can be defined via dimensions, X, Y, and Z as shown in FIG. 5A, where X is a defined width of a geometric sub-pattern 5132, Y is a defined space between adjacent geometric sub-patterns 5132, and Z is a radial or curvature of a geometric sub-pattern 5132.

In some implementations, the sidewall 5200 has a step 5210. The step 5210 can add stiffness to the molded fiber tray 5000. In some implementations, step 5210 can allow multiple molded fiber trays 5000 to be singulated from a stack.

FIG. 9 is a method 9000 for forming a molded fiber tray in accordance with implementations. The method 9000 includes: forming 9100 a molded fiber tray from structure forming materials using a structure forming process; and forming 9200 a barrier layer on an internal surface of the molded fiber tray which is substantially chemically inert with respect to contents in the molded fiber tray.

The method 9000 includes forming 9100 a molded fiber tray from structure forming materials using a structure forming process. The molded fiber tray includes a base, a sidewall extending from the base to form a content holding structure, and an edge extending from the sidewall configured for holding the molded fiber tray. In implementations, the base can be formed with a geometric pattern.

The method 9000 includes forming 9200 a barrier layer on an internal surface of the molded fiber tray which is substantially chemically inert with respect to contents in the molded fiber tray. The barrier layer is formed on an internal surface of the base, the sidewall, and the edge of the molded fiber tray. The barrier layer is configured to be substantially chemically inert with respect to contents in a content holding structure of the molded fiber tray. In implementations, a second barrier layer can be formed on an external surface of the molded fiber tray.

Disclosed herein are implementations of molded fiber trays and methods for making the molded fiber trays. In an implementation, a molded fiber tray includes a base, a sidewall extending from the base to form a content holding structure, an edge extending from the sidewall configured for holding the molded fiber tray, and a barrier layer formed on an internal surface of the base, the sidewall, and the edge, the barrier layer configured to be substantially chemically inert with respect to contents in the content holding structure.

In implementations, the molded fiber tray further includes another barrier layer formed on an external surface of the base, the sidewall, and the edge, the another barrier layer configured to substantially prevent moisture, condensation, or liquid from absorbing into the molded fiber tray. In implementations, the barrier layer includes at least one of a vapor barrier, a moisture barrier, a grease barrier, a gas barrier, or an oil barrier. In implementations, the barrier layer and the another barrier layer includes at least one of a vapor barrier, a moisture barrier, a grease barrier, a gas barrier, or an oil barrier. In implementations, the base includes a geometric pattern. In implementations, the geometric pattern is at least one of a tessellated geometric pattern, a tessellated hexagonal geometric pattern, a tessellated polygon geometric pattern, a three-dimensional (3-D) geometric pattern, a tessellated 3-D geometric pattern, a tessellated hexagonal 3-D geometric pattern, or a tessellated polygon 3-D geometric pattern. In implementations, the geometric pattern comprises a plurality of geometric sub-patterns. In implementations, the sidewall includes a step. In implementations, the molded fiber tray is comprised of at least one of sustainable materials, recyclable materials, biodegradable materials, bio-based resins, weight-optimized biodegradable plastic, molded fiber, molded paper, molded pulp, fiber, paper, pulp, paperboard, pressed pulp, fiber based, pressed fiber, paper, starch, cellulose, biodegradable resins such as Polylactic acid (PLA), Polyhydroxyalkanoates (PHA), Polyhydroxybutyrate (PHB), Polyethylene Furanoate (PEF).

Disclosed herein are implementations of molded fiber trays and methods for making the molded fiber trays. In an implementation, a method includes forming a molded fiber tray from structure forming materials using a structure forming process, wherein the molded fiber tray includes a base, a sidewall extending from the base to form a content holding structure, and an edge extending from the sidewall configured for holding the molded fiber tray, and forming a barrier layer on an internal surface of the base, the sidewall, and the edge, the barrier layer configured to be substantially chemically inert with respect to contents in the content holding structure.

In implementations, the method further includes forming another barrier layer on an external surface of the base, the sidewall, and the edge, the another barrier layer configured to substantially prevent moisture, condensation, or liquid from absorbing into the molded fiber tray. In implementations, the barrier layer includes at least one of a vapor barrier, a moisture barrier, a grease barrier, a gas barrier, or an oil barrier. In implementations, the barrier layer and the another barrier layer includes at least one of a vapor barrier, a moisture barrier, a grease barrier, a gas barrier, or an oil barrier. In implementations, the forming a molded fiber tray further includes forming a geometric pattern on the base. In implementations, the geometric pattern is at least one of a tessellated geometric pattern, a tessellated hexagonal geometric pattern, a tessellated polygon geometric pattern, a three-dimensional (3-D) geometric pattern, a tessellated 3-D geometric pattern, a tessellated hexagonal 3-D geometric pattern, or a tessellated polygon 3-D geometric pattern. In implementations, the sidewall includes a step. In implementations, the structure forming materials is at least one of sustainable materials, recyclable materials, biodegradable materials, bio-based resins, weight-optimized biodegradable plastic, molded fiber, molded paper, molded pulp, fiber, paper, pulp, paperboard, pressed pulp, fiber based, pressed fiber, paper, starch, cellulose, biodegradable resins such as Polylactic acid (PLA), Polyhydroxyalkanoates (PHA), Polyhydroxybutyrate (PHB), Polyethylene Furanoate (PEF).

The construction and arrangement of the methods as shown in the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials and components, colors, orientations, etc.). For example, the position of elements may be reversed or otherwise varied and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the exemplary embodiments without departing from the scope of the present disclosure.

Although the figures may show a specific order of method steps, the order of the steps may differ from what is depicted. Also two or more steps may be performed concurrently or with partial concurrence. Such variation will depend on the software and hardware systems chosen and on designer choice. All such variations are within the scope of the disclosure. Likewise, software implementations could be accomplished with standard programming techniques with rule-based logic and other logic to accomplish the various connection steps, processing steps, comparison steps, and decision steps.

While the disclosure has been described in connection with certain embodiments, it is to be understood that the disclosure is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.