Collapsible tray and methods therefor

Patent metadata

Field	Value
Publication number	US-2025388360-A1
Application number	US-202519181118-A
Country	US
Kind code	A1
Filing date	Apr 16, 2025
Priority date	Jan 30, 2023
Publication date	Dec 25, 2025
Grant date	—

Abstract

A method of assembling a meal kit tray from a single blank including a bottom panel, wherein the bottom panel is configured to support a bag containing refrigerated items and a cold pack, wherein the single blank further comprises a bottom panel; a side panel extending outwardly from at least a portion of the bottom panel, the side panel joined to the bottom panel along a first fold line defining a joint, wherein the first fold line is interrupted by at least one perforation line segment defining a standoff; and a wing extending outwardly from the side panel, the wing joined to the side panel along a second fold line defining a joint, the wing defining a free end; wherein the method comprises the steps of rotating the side panel upwardly about the first fold line to cause the standoff to separate from the side panel; and rotating the wing downwardly about the second fold line.

First claim

That which is claimed is:

1 . A method of assembling a meal kit tray from a single tray blank comprising a bottom panel, wherein:
the bottom panel is configured to support a bag containing refrigerated items and a cold pack, the bottom panel defining a first end, a second end, a third end, and a fourth end; the single tray blank further comprises:
a side panel extending outwardly from at least a portion of the second end of the bottom panel, the side panel joined to the bottom panel along a first fold line defining a joint between the bottom panel and the side panel, the side panel defining a first end, a second end, a third end, and a fourth end;
wherein the first fold line is interrupted by at least one perforation line segment defining a standoff extending laterally from the first fold line and terminating in a standoff edge, the standoff configured to separate from the side panel as the side panel is rotated upwardly about the first fold line during assembly of the single tray blank into the meal kit tray; and
a wing extending outwardly from the third end of the side panel, the wing joined to the side panel along a second fold line defining a joint between the side panel and the wing, the wing defining a front end, a rear end, a proximal end, and a free end; and
the method comprises the steps of:
rotating the side panel upwardly about the first fold line to cause the standoff to separate from the side panel; and
rotating the wing downwardly about the second fold line.

2 . The method of claim 1 , wherein the single tray blank further comprises:
an end panel extending from the first end of the bottom panel, the end panel joined to the bottom panel along a third fold line defining a joint between the bottom panel and the end panel, the end panel defining a first end, a second end, a third end, and a fourth end; and a reinforcement panel extending from the fourth end of the end panel, the reinforcement panel joined to the end panel along a fourth fold line defining a joint between the reinforcement panel and the end panel, the reinforcement panel defining a proximal end, a distal end, a top end, and a separable end joined to at least a portion of the first end of the side panel along a perforation line segment.

3 . The method of claim 2 , wherein:
at least a portion of the perforation line segment outlines a front tab extending forward from the first end of the side panel, the perforation line segment configured to facilitate separation of the reinforcement panel from the side panel when the single tray blank is assembled into the meal kit tray; and the method further comprises the step of separating the reinforcement panel from the side panel along the perforation line segment, the separation of the reinforcement panel from the side panel forming the front tab, the front tab defining a leading edge formed from panel separation along the perforation line segment, the leading edge configured to engage a front inside wall of a front end of an outer box when the meal kit tray is inserted into the outer box.

4 . The method of claim 3 , wherein the step of separating the reinforcement panel occurs before the step of rotating the side panel upwardly.

5 . The method of claim 3 , wherein the step of separating the reinforcement panel from the side panel comprises the step of rotating the end panel upwardly about the third fold line.

6 . The method of claim 5 , wherein the step of separating the reinforcement panel from the side panel further comprises the step of rotating the reinforcement panel inwardly about the fourth fold line toward the end panel.

7 . The method of claim 3 , wherein:
the side panel defines a side panel outer surface, wherein the reinforcement panel defines a reinforcement panel outer surface, and the single tray blank further comprises an adhesive region on the side panel outer surface proximate the first end of the side panel; and the method further comprises the steps of:
rotating the reinforcement panel inwardly toward the end panel about the fourth fold line; and
bringing the reinforcement panel outer surface into contact with the adhesive region.

8 . A method of collapsing a meal kit tray assembled from a single tray blank comprising a bottom panel, wherein:
the bottom panel is configured to support a bag containing refrigerated items and a cold pack, the bottom panel defining a first end, a second end, a third end, and a fourth end; the single tray blank further comprises:
a side panel extending outwardly from at least a portion of the second end of the bottom panel, the side panel joined to the bottom panel along a first fold line defining a joint between the bottom panel and the side panel, the side panel defining a first end, a second end, a third end, and a fourth end;
a wing extending outwardly from the third end of the side panel, the wing joined to the side panel along a second fold line defining a joint between the side panel and the wing, the wing defining a front end, a rear end, a proximal end, and a free end; and
an end panel extending from the first end of the bottom panel, the end panel joined to the bottom panel along a third fold line defining a joint between the bottom panel and the end panel, the end panel defining a first end, a second end, a third end, and a fourth end;
wherein the end panel defines a corner located at an intersection of the first end of the end panel with the fourth end of the end panel; and
wherein a transverse fold line extends from the corner to the second end of the end panel, the transverse fold line subdividing the end panel into a primary section and a secondary section; and
the method comprises the step of causing the secondary section to be folded atop the primary section.

9 . The method of claim 8 , wherein:
the bottom panel further defines an upper surface; the single tray blank further comprises a reinforcement panel extending from the fourth end of the end panel, the reinforcement panel joined to the end panel along a fourth fold line defining a joint between the reinforcement panel and the end panel, the reinforcement panel defining a proximal end, a distal end, a top end, and a separable end joined to at least a portion of the first end of the side panel along a perforation line segment; the side panel defines a side panel outer surface, wherein the reinforcement panel defines a reinforcement panel outer surface, and the single tray blank further comprises an adhesive region on the side panel outer surface proximate the first end of the side panel; and the reinforcement panel is joined to the side panel due to contact between the reinforcement panel outer surface and the adhesive region; and the step of causing the secondary section to be folded atop the primary section comprises the step of rotating the side panel inwardly toward the upper surface of the bottom panel to cause the reinforcement panel to push the end panel outwardly until the secondary section is folded inwardly about the transverse fold line onto the primary section.

10 . The method of claim 9 , wherein the side panel outer surface is a first side panel outer surface, wherein the side panel further defines a second side panel outer surface opposite the first side panel outer surface, and wherein the method further comprises the step of rotating the wing downwardly about the second fold line until a surface of the wing contacts the second side panel outer surface.

Assignees

• Pratt Corrugated Holdings Inc

Inventors

• Sollie Greg
• Stanton Christopher M
• Armstrong Brad
• Ott Paul
• Tanner Alex
• Chen Shifeng

Classifications

• B65D77/04

  Articles or materials enclosed in two or more containers disposed one within another · CPC title

• B65D81/3888

  wrappers or flexible containers, e.g. pouches, bags (for shock absorbing purposes B65D81/03) · CPC title

• B65D81/3853

  formed with double walls, i.e. hollow · CPC title

• B65D81/09

  using flowable discrete elements of shock-absorbing material, e.g. pellets or popcorn · CPC title

• B65D5/5038

  Tray-like elements formed by folding a blank and presenting openings or recesses (without external box B65D71/72; external face of container provided with opening for receiving object in display position B65D5/5286) · CPC title