CONTAINER FOR PRODUCTS

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to U.S. Provisional Ser. No. 63/733,508 filed on Dec. 13, 2024.

INCORPORATION BY REFERENCE

The disclosures of U.S. Provisional Ser. No. 63/733,508 , filed Dec. 13, 2024, U.S. Provisional Ser. No. 63/728,774 , filed Dec. 6, 2024, U.S. patent application Ser. No. 18/912,820, filed Oct. 11, 2024, U.S. Provisional Ser. No. 63/543,560, filed Oct. 11, 2023, U.S. patent application Ser. No. 16/037,425, filed Jul. 17, 2018, U.S. patent application Ser. No. 15/654,814, filed Jul. 20, 2017, and U.S. patent application Ser. No. 12/992,131, filed Feb. 11, 2011, are hereby incorporated by reference for all purposes as if presented herein in their entirety.

TECHNICAL FIELD

The disclosure relates to containers and packaging systems. More particularly, the disclosure relates to foldable containers having base constructs with integrated tray and carton portions and crown constructs for forming multi-component packaging assemblies.

BACKGROUND OF THE DISCLOSURE

Conventional packaging systems may require multiple separate components that must be assembled independently, leading to increased manufacturing complexity and assembly time. Existing container designs may lack integrated structures that can transform between different configurations during use. Traditional packaging approaches may suffer from limited space efficiency during storage and transportation, requiring separate handling of individual packaging elements.

SUMMARY OF THE DISCLOSURE

According to one aspect, the disclosure may be generally directed to a container comprising a base construct and a crown construct. The base construct may include a tray having a tray bottom panel foldably coupled to a plurality of tray side panels to define a tray cavity. The base construct may include a carton having a carton bottom panel foldably connected to a carton side panel along a lateral fold line, wherein the carton bottom panel and the carton side panel may cooperate with one or more of the plurality of tray panels to define a carton cavity. The crown construct may include a flange panel extending at least partially around a perimeter of the crown construct and a plurality of side flaps foldably connected to the flange panel. The crown construct may be positioned at least partially within the tray cavity such that at least one of the plurality of side flaps may be in face-to-face alignment with at least one of the plurality of tray side panels.

In some embodiments, the carton may be configured to transform between an erected configuration and a collapsed configuration. The carton may include additional panels such as a distal bottom panel and a carton top panel connected via lateral fold lines to provide enhanced structural flexibility.

According to another aspect, the disclosure may be directed to a combination of blanks for forming the container. The combination may include a base blank having a tray portion for forming the tray and a carton portion for forming the carton. The combination may include a crown blank for forming the crown construct with the flange panel and side flaps configured for alignment with the tray components.

According to a further aspect, the disclosure may be directed to methods for forming the container using the base blank and crown blank, including steps for erecting the blanks and positioning the crown construct within the tray cavity.

Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures. It is within the scope of the present disclosure that the above-discussed aspects be provided both individually and in various combinations.

BRIEF DESCRIPTION OF THE DRAWINGS

According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.

FIG. 1A illustrates a perspective view of a container showing a base that includes a tray and a carton assembled with a crown.

FIG. 1B illustrates a bottom perspective view of the container shown in FIG. 1A with the carton of the base in an open state.

FIG. 2 illustrates a plan view of a base blank defining a tray portion and a carton portion.

FIG. 3A illustrates a perspective view of a base formed from the base blank shown in FIG. 2, showing the tray and carton portion in a partially erected configuration with lateral fold lines visible.

FIG. 3B illustrates a bottom view of the base, showing the tray portion in an erected configuration and the carton portion in an erected and open configuration.

FIG. 4 illustrates a plan view of a crown blank.

FIG. 5 illustrates a perspective view of a crown formed from the crown blank shown in FIG. 4.

FIGS. 6A-6C illustrate perspective views of the container showing the carton portion transitioning between erect and collapsed configurations, with FIG. 6A showing the erect configuration, FIG. 6B showing the intermediate transition with the crown accommodating the transformation via fold line, and FIG. 6C showing the collapsed configuration prior to application of a liner for the container.

FIG. 7 illustrates a flow diagram of a process for forming a container.

FIG. 8 illustrates a perspective view of the container showing the carton in a partially erected state.

FIG. 9 illustrates a top isometric view of the container shown in FIG. 8.

FIG. 10 illustrates a bottom perspective view of the container showing the base and crown.

FIG. 11 illustrates a perspective view of the container in an inverted orientation.

FIG. 12 illustrates a perspective view of the container.

FIG. 13 illustrates a plan view of a base blank of an alternative embodiment defining a tray portion and a carton portion.

Corresponding parts are designated by corresponding reference numbers throughout the drawings.

DETAILED DESCRIPTION

In the following description, various embodiments will be described. For purposes of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the embodiments. However, it will also be apparent to one skilled in the art that the embodiments may be practiced without the specific details. Furthermore, well-known features may be omitted or simplified in order not to obscure the embodiment being described.

Techniques disclosed herein relate generally to container systems. More specifically, techniques disclosed herein relate to a container that includes a tray and carton. The container systems may include a tray, a carton, and a crown that can be formed from flat blanks and assembled into a unified package. Various embodiments are described herein, including methods, processes, systems, devices, and the like.

In order to better appreciate the features and aspects of the present disclosure, further context for the disclosure is provided in the following section by discussing one particular implementation of a dual-compartment container that includes a tray and carton according to embodiments of the disclosure. These embodiments are for explanatory purposes only and other embodiments may be employed in other container systems. For example, embodiments of the disclosure can be used with any container that stores or separates food products, consumer goods, or related items. In some instances, embodiments of the disclosure are particularly well suited for use with food packaging applications because of their potentially efficient manufacturing and separation capabilities.

The disclosed container may hold two sets of items in one unified structure. A first part may be a tray that may receive a primary product, such as a food item, liquid, or display article. A second part may be an attached carton that may receive separate items, such as utensils, condiments, cables, or other accessories that may remain separated from the primary product. Both the tray and the carton may be formed from flat blanks that may be folded and joined so that the finished package may appear as a single, compact unit that may be easy to handle, stack, and display.

In many embodiments, the tray may be formed from a crown construct so that a continuous flange may extend around the top of the tray. This flange may be formed by a flange panel of the crown that may overlap flange portions of the tray, and a liner or film may be sealed to that flange to protect the product in the tray. The tray sidewall may be built from overlapping layers of panels and flaps that may be folded together so that the sidewall may remain rigid while still being made from foldable sheet material. A polymer liner may be disposed in the tray to protect the paperboard from exposure to moist products and may later be peeled away from the underlying paperboard so that the paperboard and liner may be sent to different disposal or recycling streams.

The carton may share a wall with the tray and may extend along one side of the tray so that both parts may be formed from a common base blank. A bottom panel of the carton may extend under at least part of the tray and may be glued in face-to-face contact with a tray bottom panel so that the tray and carton may support each other. Ends of the carton may be closed either by a tab-and-slot arrangement that may allow manual closing without glue, or by overlapping and gluing end flaps for machine packing. In use, a manufacturer or consumer may place a main product in the tray and accessory items in the carton, may close the ends, and may, if desired, seal a film across the flange so that the main product may be protected or held under a modified atmosphere while the accessories may remain dry and accessible when the carton ends may be opened.

It will be understood that one or more of the blanks, product containers, trays, cartons, base constructs, and crown constructs, and portions thereof, can have a different arrangement and/or configuration without departing from the disclosure.

Any of the features of the various embodiments of the disclosure can be combined with, replaced by, or otherwise configured with other features of other embodiments of the disclosure without departing from the scope of this disclosure.

FIG. 1A illustrates a container 105 in an erected configuration that includes a tray 111 and a carton 113 according to embodiments of the disclosure. As shown in FIG. 1A, the container 105 may comprise a base construct 130 attached to a crown construct 132. The tray 111 may be defined at least partially by a bottom panel 125, tray side panels 135, 139, and tray end panels 127, 131. The tray 111 may include a sidewall 136 that may extend upwardly from the bottom panel 125 and may be defined at least partially by the tray side panels 135, 139 and the tray end panels 127, 131. The tray 111 may define an interior 140 that may be bounded by the sidewall 136 and the bottom panel 125 and that may be configured to receive one or more products. The crown 132 may comprise a flange panel 106 that may extend around an upper perimeter of the tray 111 to form a flange 138. The flange 138 may extend outwardly from an upper edge of the sidewall 136 and may provide a generally continuous sealing surface. The flange panel 106 may include an extended portion 134 that may project outwardly beyond at least one of the tray end panels 127, 131 and may at least partially overlie a portion of the carton 113. The crown 132 may further include an end flap 110 and a side flap 116 that may extend downwardly from the flange panel 106 and may cooperate with the tray side panels 135, 139 and the tray end panels 127, 131 to at least partially define the sidewall 136.

As shown in FIG. 1A, the carton 113 may be attached laterally to the tray 111 and may share at least a portion of the base 130. The carton 113 may be at least partially defined by at least one carton end panel 171b that may extend outwardly from the container 105 adjacent one of the tray end panels 131. The carton end panel 171b may be configured to fold over an open end of the carton 113 when the carton 113 may be closed. The base 130 may comprise the bottom panel 125 and the tray side panels 135, 139 and the tray end panels 127, 131, and may cooperate with the crown 132 to form the tray 111 and to support the carton 113. In use, the interior 140 of the tray 111 may be lined with a polymer film and receive a primary product, such as a food item, while the carton 113 may receive one or more secondary items, such as accompaniments or utensils. The flange 138 may receive a lidding film to seal the interior 140, and the flange panel 106 and the extended portion 134 may provide a broad sealing land that may permit modified atmosphere packaging. The end flap 110 and the side flap 116 may overlap inner surfaces of the tray end panels 127, 131 and the tray side panels 135, 139 and may increase rigidity of the sidewall 136 during handling, display, and heating.

FIG. 1B illustrates a container 105 in an bottom perspective view showing the carton 113 and a multi-layer bottom construction according to embodiments. As shown in FIG. 1B, the flange panel 106 may extend around the tray 111 to form the flange 138 and may include the extended portion 134 that may overlie at least a portion of a carton top region. The carton 113 may include a carton side panel 163 that may extend generally downwardly from a carton top panel 261 (not shown in FIG. 1B, see FIGS. 2 and 3) and may be positioned opposite the tray side panel 139. A carton bottom panel 167 may be foldably connected to the carton side panel 163 and may extend underneath at least a portion of the tray 111. A distal bottom panel 193 may be foldably connected to the carton bottom panel 167 and may be arranged in face-to-face alignment with the bottom panel 125 of the tray 111 to form a multi-layer base in the region of the tray 111.

As shown in FIG. 1B, the carton 113 may further comprise carton end panels 179a, 179b that may be foldably connected to the carton bottom panel 167 and may be configured to close lower ends of the carton 113. Carton end panels 171a, 171b may be foldably connected to the carton top panel 261 (see FIG. 2) and may close upper ends of the carton 113. Carton end flaps 175a, 175b may extend from the carton side panel 163 and may be arranged to fold inwardly between the respective carton end panels 171a, 171b and 179a, 179b during closure. Locking tabs 187 may extend from the carton end panels 171a, 171b and may be configured to engage locking slots in the carton end panels 179a, 179b to secure the ends of the carton 113. The base construct 130 and the crown construct 132 may cooperate to form the tray 111 while the carton 113 may be formed integrally from the same base blank as the tray 111 and may provide a separate accessory compartment. During use, a user may fold the carton end flaps 175a, 175b inwardly, then fold the carton end panels 179a, 179b and 171a, 171b to close the carton 113 and may insert the locking tabs 187 into the locking slots to retain the ends closed without adhesive.

FIG. 2 illustrates a base blank 203 in a flat configuration that can be used for forming the base construct 130 shown in FIGS. 1A and 1B, according to embodiments of the disclosure. As shown in FIG. 2, the base blank 203 may have a longitudinal direction L1 and a lateral direction L2. A tray portion 215 may be positioned on one side of the base blank 203 and may include the bottom panel 125 located centrally. The tray side panels 135, 139 may be foldably connected to opposite lateral edges of the bottom panel 125 along respective lateral fold lines 237, 241. The tray end panels 127, 131 may be foldably connected to opposite longitudinal edges of the bottom panel 125 along respective longitudinal fold lines 229, 233.

As shown in FIG. 2, flange portions 243, 245, 251 may extend outwardly from respective tray end panels 127, 131 and the tray side panel 135 and may be foldably connected along longitudinal and longitudinal fold lines 247, 249 and lateral fold line 253. Flange portions 243, 245 may extend from respective tray end panels 127, 131 along respective longitudinal fold lines 247, 249. Similarly, the flange portion 251 may extend from the tray side panel 135 along the lateral fold line 253. The flange portions 243, 245, 251 may cooperate with the flange panel 106 of the crown construct 132 during assembly to form the flange 138.

As further shown in FIG. 2, a carton portion 217 may be positioned adjacent the tray portion 215 and may be foldably connected to the tray side panel 139 along a lateral fold line 219. The carton portion 217 may include a carton top panel 261 foldably connected to the tray side panel 139 along the lateral fold line 219. The carton top panel 261 may be foldably connected to a carton side panel 163 along a lateral fold line 265, and the carton side panel 163 may be foldably connected to the carton bottom panel 167 along a lateral fold line 269. The carton bottom panel 167 may be foldably connected to the distal bottom panel 193 along a lateral fold line 295.

As shown in FIG. 2, the carton bottom panel 167 may be foldably connected to carton end panels 179a, 179b that may be foldably connected along longitudinal fold lines 281. The carton top panel 261 may be foldably connected to carton end panels 171a, 171b that may be foldably connected along longitudinal fold lines 273. Carton end flaps 175a, 175b may extend from opposite longitudinal edges of the carton side panel 163 and may be foldably connected along oblique fold lines 277. Additional carton end flaps 283a, 283b may extend from opposite longitudinal edges of the tray side panel 139 and may be foldably connected along oblique fold lines 285. The carton end panels 179a, 179b may include locking slots 291 that may interrupt portions of the longitudinal fold lines 281. The carton end panels 171a, 171b may carry locking tabs 187 that may be foldably connected along longitudinal fold lines 289.

In assembly, the tray portion 215 may be erected by folding the tray side panels 135, 139 and the tray end panels 127, 131 upwardly about the respective fold lines 237, 241, 229, 233 to form a tray cavity. The flange portions 243, 245, 251 may be folded outwardly about the fold lines 247, 249, 253 to form outer flange segments. The carton portion 217 may then be folded about the lateral fold lines 219, 265, 269, 295 so that the carton top panel 261 may extend laterally from the tray side panel 139, the carton side panel 163 may depend downwardly, and the carton bottom panel 167 and the distal bottom panel 193 may extend beneath the bottom panel 125. The distal bottom panel 193 may be secured in face-to-face contact with the bottom panel 125, for example by glue, to form a reinforced base for the tray 111. Products may thereafter be loaded into both the tray portion 215 and the carton portion 217 before the carton end panels 171a, 171b, 179a, 179b and the carton end flaps 175a, 175b, 283a, 283b may be folded and locked to close the carton 113.

FIG. 3A illustrates a partially erected base construct 130 formed from the base blank 203 shown in FIG. 2, according to embodiments of the disclosure. As shown in FIG. 3A, the tray 111 may be at least partially erected with the bottom panel 125 and the tray side panels 135, 139 and the tray end panels 127, 131 folded upwardly to define a tray cavity. The flange portions 243, 245, 251 may be folded outwardly from the respective tray panels 127, 131, 135 to form peripheral flange ledges. The carton portion 217 may remain generally planar or partially folded and may extend from the tray side panel 139.

FIG. 3B illustrates the base construct 130 in a further erected configuration showing the carton portion 217 in an open, erect configuration. As shown in FIG. 3B, the carton top panel 261) may extend laterally from the tray side panel 139, and the carton side panel 163 may fold downwardly from the carton top panel 261 along lateral fold line 265. The distal bottom panel 193 may be positioned in face-to-face contact with the tray bottom panel 125 (not shown in FIG. 3B, see FIG. 3A) as the carton portion 217 transitions from its flat configuration toward its erected tubular form. The tray portion 215 may remain in its erected configuration with the flange portions 243, 245, 251 extending outwardly to receive the crown construct 132.

FIG. 4 illustrates a crown blank 403 in a flat configuration for forming the crown construct 132 shown in FIGS. 1A and 1B, according to embodiments of the disclosure. As shown in FIG. 4, the crown blank 403 may have a longitudinal direction L1 and a lateral direction L2. The crown blank 403 may comprise the flange panel 106 that may extend around a central opening 408. The flange panel 106 may include the extended portion 134 that may project outwardly beyond one side of the central opening 408 and may later overlie at least a portion of the carton 113. A longitudinal fold line 426 may at least partially define a boundary between the extended portion 134 and an adjacent region of the flange panel 106.

As shown in FIG. 4, the crown blank 403 may further comprise the end flap 110 and an end flap 412 foldably connected to the flange panel 106 along opposite sides of the central opening 408. The end flap 110 may be foldably connected along a longitudinal edge of the central opening 408, and the end flap 412 may be foldably connected along an opposite longitudinal edge of the central opening 408. Side flaps 116, 414 may be foldably connected to the flange panel 106 along lateral edges of the central opening 408. The fold lines connecting the end flaps 110, 412 and the side flaps 116, 414 to the flange panel 106 may be oriented generally parallel to the longitudinal direction L1 and the lateral direction L2, respectively. During assembly, the end flaps 110, 412 and the side flaps 116, 414 may be folded downwardly along the fold lines adjacent the central opening 408 to extend into the tray 111 and may overlap inner surfaces of the tray side panels 135, 139 and the tray end panels 127, 131.

FIG. 5 illustrates the crown construct 132 formed from the crown blank 403 shown in FIG. 4 and ready for application to the base construct 130 according to embodiments of the disclosure. As shown in FIG. 5, the flange panel 106 may define a generally planar frame surrounding the central opening 408. The extended portion 134 of the flange panel 106 may extend outwardly along one side of the crown 132 and may be configured to align with and overlie at least a portion of the carton 113 when the crown 132 may be installed on the tray 111. The side flap 116, the side flap 414, the end flap 110, and the end flap 412 may extend generally downwardly from the flange panel 106 around the central opening 408.

As shown in FIG. 5, the downwardly extending side flaps 116, 414 and end flaps 110, 412 may be dimensioned to fit within the interior 140 of the tray 111 and may be positioned in face-to-face alignment with the tray side panels 135, 139 and the tray end panels 127, 131 when installed. In use, a forming tool may lower the crown 132 over the partially erected tray 111 so that the central opening 408 may receive the upper portion of the sidewall 136 and the flaps 110, 412, 116, 414 may slide along the inner surfaces of the tray panels. A liner 606 (not shown in FIG. 5, see FIG. 6C), described below, may then be applied to the interior of the tray 111 so that the liner 606 may overlie the flaps 110, 412, 116, 414 and the corresponding tray panels and may bond these elements together to form a composite sidewall 136.

FIG. 6A illustrates the container 105 during a liner application sequence according to embodiments of the disclosure. As shown in FIG. 6A, the tray 111 and the carton 113 may be formed, and the crown construct 132 (see FIG. 5) with the flange panel 106 and the extended portion 134 may be positioned over the tray 111. The container 105 may include the flange 138 extending around the upper edge of the tray 111. The end flap 412 may extend downwardly inside the tray 111 adjacent the tray end panel 131, and a longitudinal fold line 426 may separate an inner portion of the flange panel 106 over the tray 111 from the extended portion 134 over the carton 113. The carton 113 may include a carton end panel 171a, a carton end panel 179a, a carton end flap 175a, and a carton end flap 283a extending from the tray side panel 139. A locking tab 187 may extend from the carton end panel 171a.

FIG. 6B illustrates the container 105 and the carton 113 as it transitions from an erected configuration to a collapsed configuration according to embodiments of the disclosure. As shown in FIG. 6B the carton 113 moves from the fully erected configuration of FIG. 6A toward the collapsed configuration of FIG. 6C. In this transitional state, the carton panels begin to fold inward while the tray 111 maintains its structural integrity. During this transition, the carton bottom panel 167 (not shown in FIG. 6B, see FIG. 8) begins folding toward the tray cavity via lateral fold line 269, while the carton side panel 163 (not shown in FIG. 6B, see FIG. 8) simultaneously folds toward the extended portion 134 of the flange panel 106 via the lateral fold line 265. The fold line 426 in the crown 420 accommodates this dual folding motion by allowing the crown structure to flex and maintain proper alignment with both moving carton components.

As the transformation progresses toward the collapsed configuration, the carton bottom panel 167 moves into position for face-to-face contact with a tray side panel (such as, tray side panel 139 for example), while the carton side panel 163 approaches a parallel orientation relative to the extended portion 134 of the flange panel 106. The fold line 426 serves as a hinge mechanism that enables the crown 420 to accommodate both simultaneous movements without structural interference. This intermediate state demonstrates how the integrated design allows the carton 113 to transform via coordinated folding along multiple lateral fold lines while the crown construct maintains its structural relationship with the tray 111.

FIG. 6C illustrates the container 105 in a perspective view with the carton 113 collapsed for application of a liner 606 according to embodiments. By collapsing the carton 113 prior to application of the liner 606, the carton 113 and the tray 111 may be protected from damage. More specifically, in some embodiments the liner 606 may be applied to the interior of the tray 111 via blow-forming where the liner 606 is positioned above the tray 111 and air pressure is applied to the liner such that the liner expands within the tray and pushes against the sidewalls. Because the carton is in the collapsed state, tooling can be positioned against the collapsed tray 111 to support sidewall 139 (see FIG. 3) from being forced into the tray 111 area. The liner 606 may conform to the bottom panel 125 and the sidewall 136 and may cover the end flap 412 and the side flaps within the tray 111. The liner 606 may also extend over at least a portion of the flange panel 106 and the flange 138 to provide a continuous sealing surface for a subsequent lidding film.

As shown in FIG. 6C, the liner 606 may conform to the interior surfaces of the tray 111, including the bottom panel 125, the tray end panels 127, 131, and any side flaps such as the end flap 412. The flange 138 and the flange panel 106 may be covered by the liner 606 along the extended portion 134 so that a sealing film may adhere to a plastic-to-plastic interface. The longitudinal fold line 426 may delineate the transition between a portion of the flange panel 106 that may overlie the tray 111 and the extended portion 134 that may overlie the carton 113.

In some embodiments the liner 606 may be removable such that a user may grip the liner 606 at the flange 138 and may peel the liner 606 away from the base layer along the tray 111 after product use, while the flange panel 106 and the extended portion 134 may remain attached to the base 130. The separated liner 606 may be directed to a plastic waste stream while the remaining paperboard structure including the tray 111, the carton 113, the base 130, and the crown 132 may be directed to a paper recycling stream.

FIG. 7 illustrates a process 700 for applying a liner to a container with a tray portion and a container portion according to embodiments. As shown in FIG. 7, the process 700 may include a step 702 of forming a base construct with a tray portion and a container portion, wherein the container portion may be in a collapsed configuration. During step 702, the base blank 203 may be folded to erect the tray portion 215 while the carton portion 217 may be formed but not yet collapsed. The process 700 may further include a step 704 of forming a crown construct. During step 704, the crown blank 403 may be folded so that the end flaps 110, 412 and the side flaps 116, 414 may extend downwardly from the flange panel 106 to form the crown 132.

As shown in FIG. 7, the process 700 may further include a step 706 of at least partially inserting the crown construct within an interior of the tray portion of the base construct. During step 706, the crown 132 may be lowered so that the central opening 408 may receive an upper portion of the tray sidewall 136 and the flaps 110, 412, 116, 414 may align with and contact inner surfaces of the tray end panels 127, 131 and the tray side panels 135, 139. A step 708 may include collapsing the carton portion. In step 708, the carton portion 217 may be folded into a collapsed configuration to protect it during liner application, with the longitudinal fold line 426 in the crown construct allowing the crown to accommodate the carton's transition to the collapsed state without structural interference. A step 710 may include supporting the tray portion with tooling. In step 710, forming tooling may contact the outer surfaces of the bottom panel 125 and the sidewall 136 to resist deformation during liner application.

As shown in FIG. 7, the process 700 may further include a step 712 of applying a liner to the interior of the tray portion. During step 712, the liner 606 may be placed or blow-molded into the interior 140, may be pressed against the bottom panel 125 and the sidewall 136, and may be sealed or adhered to the underlying paperboard and the flaps of the crown 132. The liner 606 may simultaneously bond the crown 132 to the tray 111 and may form a continuous food-contact surface. A subsequent step 714 may include transforming the carton portion to an erected configuration. During step 714, the carton portion 217 may be folded along the lateral fold lines 219, 265, 269, 295 so that the carton 113 may assume its erected tubular configuration, ready for loading secondary products and closure of the carton ends. The process may involve less steps, additional steps, or the steps or aspects of the steps may be performed in any order.

FIG. 8 illustrates an isometric bottom view of the container 105 with the carton 113 in the collapsed configuration after application of the liner 606 according to embodiments. As shown in FIG. 8, the tray end panel 127 may form one end of the tray 111, and the flange panel 106 and the flange 138 may extend around the upper perimeter of the tray 111. The extended portion 134 of the flange panel 106 may overlie at least part of the carton 113. The carton 113 may include the carton side panel 163, the carton bottom panel 167, and the distal bottom panel 193 extending below the tray 111. Carton end panels 179a, 179b may extend upwardly from the carton bottom panel 167, and carton end panels 171a, 171b may extend downwardly from the carton top panel 261.

As shown in FIG. 8, the carton end flaps 175a, 175b may extend from the carton side panel 163 and may be folded inwardly over respective open ends of the carton 113. The carton end panels 179a, 179b may be folded upwardly to at least partially overlap the carton end flaps 175a, 175b. The carton end panels 171a, 171b may then be folded downwardly to at least partially overlap the carton end panels 179a, 179b. Locking tabs 187 may be folded along their fold lines and may be inserted into corresponding locking slots in the carton end panels 179a, 179b to secure the overlapped panels and flaps and to retain the ends of the carton 113 in a closed configuration. In use, a user may perform this folding sequence manually for hand-packing operations, or a machine may perform the same sequence with automated folding and tab insertion for semi-automated operations.

FIG. 9 is a top isometric view of the container 105 with the tray 111 opened to reveal the interior 140 and the relationship between the tray 111 and the crown 132 according to embodiments. As shown in FIG. 9, the bottom panel 125 may form the floor of the tray 111, and the tray side panel 135 and the tray end panels 127, 131 may form portions of the sidewall 136. The flange panel 106 and the flange 138 may surround the tray interior 140, and the extended portion 134 of the flange panel 106 may project outwardly beyond the tray end panel 127 over the carton 113. The end flap 412 and the side flap 414 of the crown 132 may extend downwardly inside the tray 111 and may be covered by the liner 606.

As further shown in FIG. 9, the carton end panels 171a, 171b may extend from the carton top panel 261 adjacent the extended portion 134. Locking tabs 187 may project from the carton end panels 171a, 171b and may be configured to pass underneath the extended portion 134 when folded and engaged with corresponding locking slots. A user may load a primary product into the interior 140 of the tray 111 and may then seal the tray 111 with a film adhered to the flange 138 while the carton 113 remains accessible. The extended portion 134 may provide a transition region where the film may extend over the tray 111 while leaving the carton 113 unsealed, thereby allowing separate access to the carton contents.

FIG. 10 illustrates the container 105 inverted in a fully assembled configuration showing the interaction between the tray 111, the carton 113, and the crown 132 according to embodiments. As shown in FIG. 10, the tray 111 may be defined by the bottom panel 125 and the tray end panels 127 and 131. The carton 113 may be positioned laterally adjacent the tray 111 and may share the distal bottom panel 193 and the carton bottom panel 167 with the tray 111 to form a common container bottom. The carton side panel 163 may extend from the carton bottom panel 167 and may be spaced from the tray side panel 139 to define the interior of the carton 113.

As shown in FIG. 10, after applying the liner 606, the carton 113 may be transformed from the collapsed configuration to an open state in the erected configuration and contents can be inserted into the carton 113. To close the carton 113, the carton end panels 179a, 179b, 171a, 171b, and the carton end flaps 175a, 175b may be folded into overlapping face-to-face contact and may be retained by the locking tabs 187. The flange panel 106 and the flange 138 of the crown 132 may extend continuously around the upper perimeter of the tray 111, and the extended portion 134 may overlie a portion of the carton 113. The crown 132 may seat onto the tray 111 so that the side flaps and end flaps of the crown 132 may be located within the tray interior and may form an inner layer of the sidewall 136. In use, the container 105 may be placed on a flat surface with the distal bottom panel 193 and the carton bottom panel 167 providing a stable support for both the tray 111 and the carton 113.

FIG. 11 illustrates a bottom perspective view of the fully formed container 105 showing the relationship between the tray 111, the carton 113, and the flange portions according to embodiments. As shown in FIG. 11, the distal bottom panel 193 and the carton bottom panel 167 may extend beneath the tray 111 and the carton 113 and may form a unitary lower surface for the container 105. The tray end panel 127 may extend from the distal bottom panel 193 to form one end of the tray 111. The carton side panel 163 may extend upwardly from the carton bottom panel 167 to define one side of the carton 113, and the carton 113 may further include at least one carton end panel 171a at one end.

As shown in FIG. 11, the flange portion 243 may extend outwardly from the tray end panel 127 and may be covered by the flange panel 106 to form part of the flange 138. The tray 111 and the carton 113 may be integrally formed from the same base 130, and the crown 132 may be positioned on the tray 111 such that the flange panel 106 and the flange 138 may extend continuously around the tray perimeter. The extended portion 134 of the flange panel 106 may extend beyond the tray 111 above the carton 113. In use, the bottom configuration illustrated in FIG. 11 may permit automated conveyors to support the container 105 along the distal bottom panel 193 and the carton bottom panel 167 while allowing access to the tray 111 and the carton 113 from above for loading operations.

FIG. 12 illustrates the tray 111 of the fully formed container 105 in perspective view with the crown 132 in place and the tray interior 140 visible according to embodiments. As shown in FIG. 12, the bottom panel 125 may form a generally planar floor of the tray 111. The tray side panel 135 and the tray end panel 131 may extend generally upwardly to form portions of the sidewall 136. The side flap 414 and the end flap 412 of the crown 132 may extend downwardly inside the tray 111 and may be positioned in face-to-face contact with the interior surfaces of the tray side panel 135 and the tray end panel 131, respectively.

As shown in FIG. 12, the flange panel 106 may extend horizontally outward from an upper edge of the sidewall 136, and the flange 138 may be formed by the flange panel 106 and the underlying flange portions such as the flange portion 243. The interior 140 may be bounded by the bottom panel 125, the sidewall 136, and the crown flaps 414, 412 and may be configured to receive one or more primary products. The extended portion 134 of the flange panel 106 may project outwardly from one side of the tray 111 and may later cooperate with a sealing film to facilitate selective access to different compartments of the container 105. For example, a user may peel a portion of the film over the tray 111 to access a heated meal while leaving a remaining film area attached over the extended portion 134 as a gripping tab or as a barrier region above the carton 113.

FIG. 13 illustrates a base blank 1317 for another embodiment of a base construct that may cooperate with a crown similar to the crown 132 according to embodiments. As shown in FIG. 13, the base blank 1317 may have a longitudinal direction L1 and a lateral direction L2 and may include a tray portion 215 with the bottom panel 125, the tray side panels 135, 139, and the tray end panels 127, 131 foldably connected along longitudinal and lateral fold lines 229, 233, 237, 241. Flange portions 243, 245, 251 may extend from the tray end panels 127, 131 and the tray side panel 135 along fold lines 247, 249, 253.

As shown in FIG. 13, the carton portion may include the carton top panel 261 foldably connected to the tray side panel 139 along a lateral fold line 219. The carton side panel 163 may be foldably connected to the carton top panel 261 along a lateral fold line 265, and the carton bottom panel 167 may be foldably connected to the carton side panel 163 along a lateral fold line 269. A distal bottom panel 193 may be foldably connected to the carton bottom panel 167 along a lateral fold line 295. Carton end panels 1317a, 1317b may extend from the carton top panel 261 along longitudinal fold lines 273, and carton end panels 1379a, 1379b may extend from the carton bottom panel 167 along longitudinal fold lines 281.

As further shown in FIG. 13, carton end flaps 175a, 175b may extend from the carton side panel 163 along oblique fold lines 277, and carton end flaps 283a, 283b may extend from the tray side panel 139 along oblique fold lines 285; one or more of the end flaps may be secured with an adhesive. The arrangement illustrated in FIG. 13 may represent a variation in which geometries and dimensions of the panels and flaps may differ from those shown in FIG. 2 while maintaining similar functional relationships. For example, the tray portion 215 and the carton portion may be dimensioned to accommodate different product sizes or to adjust the relative capacities of the tray 111 and the carton 113. Fold lines 1381 may not include slots as described above. The base blank 1317 may still cooperate with a crown having a flange panel and inwardly extending flaps, and a liner may still be applied as described above to provide a separable, recyclable packaging system.

The blanks according to the present invention can be, for example, formed from coated paperboard and similar materials. For example, the interior and/or exterior sides of the blanks can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks.

In general, the blanks may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blank can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carton to function at least generally as described above. The blanks can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blanks may then be coated with a varnish to protect information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.

In accordance with the embodiments, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding there along. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed or depressed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features. In situations where cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line.

The above embodiments may be described as having one or more panels adhered together by glue during erection of the carton embodiments. The term “glue” is intended to encompass all manner of adhesives commonly used to secure carton panels in place.

The foregoing description illustrates and describes various embodiments of the present disclosure. As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, and alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are contemplated and are within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments without departing from the scope of the disclosure.