An apparatus and method utilizes a forming machine which includes a mandrel and forming plate each shaped to conform the paperboard and/or corrugated material blank passing through the mandrel into the desired configuration for a leak-proof tray. The blank includes a layer of a suitable paperboard and/or corrugated material, and a layer of leak-proof plastic or paper material disposed over one side of the corrugated material. The corrugated material includes cutouts at each corner of the blank that enable the sides and ends of the blank to be folded relative to one another. The paper material continuously overlaps the surface of the corrugated layer and these cutouts to provide a continuous leak-proof barrier layer within the formed tray and at the corners of the blank when folded to form the tray, as the paper material is folded over itself to form a bellows corner in the tray.
B31B 50/73 - Uniting opposed surfaces or edgesTaping by mechanically interlocking integral parts, e.g. by tongues and slots
B65D 5/00 - Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
B65D 5/24 - Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form with adjacent sides interconnected by gusset folds
B65D 5/26 - Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form with extensions of opposite sides mutually interlocking to lie against other sides
B65D 5/42 - Details of containers or of foldable or erectable container blanks
An apparatus and method utilizes a forming machine which includes a mandrel and forming plate each shaped to conform the paperboard and/or corrugated material blank passing through the mandrel into the desired configuration for a leak-proof tray. The blank includes a layer of a suitable paperboard and/or corrugated material, and a layer of leak-proof plastic or paper material disposed over one side of the corrugated material. The corrugated material includes cutouts at each corner of the blank that enable the sides and ends of the blank to be folded relative to one another. The paper material continuously overlaps the surface of the corrugated layer and these cutouts to provide a continuous leak-proof barrier layer within the formed tray and at the corners of the blank when folded to form the tray, as the paper material is folded over itself to form a bellows corner in the tray.
B31B 50/73 - Uniting opposed surfaces or edgesTaping by mechanically interlocking integral parts, e.g. by tongues and slots
B65D 5/00 - Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
B65D 5/24 - Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form with adjacent sides interconnected by gusset folds
B65D 5/26 - Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form with extensions of opposite sides mutually interlocking to lie against other sides
B65D 5/42 - Details of containers or of foldable or erectable container blanks
A compostable food tray is provided including an upper layer formed of a flexible and compostable material that is secured to a lower layer formed of a foldable and compostable material. The lower layer can be folded to form a tray including an interior for holding a food item therein, while the upper layer extends beyond the periphery of the lower layer and can be wrapped over or around the food item in order to provide a package for the food item in conjunction with the lower layer.
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
B32B 27/10 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance of paper or cardboard
B32B 29/00 - Layered products essentially comprising paper or cardboard
B32B 3/08 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
B65B 7/28 - Closing semi-rigid or rigid containers or receptacles not deformed by, or not taking-up shape of, contents, e.g. boxes or cartons by applying separate preformed closures, e.g. lids, covers
B65D 65/46 - Applications of disintegrable, dissolvable or edible materials
The present invention is a container for use in baking and shipping food items. The container is formed of a paperboard material and includes a heat-resistant coating applied to all of the interior surfaces of the container. The coating enables a number of food items to be positioned within the container in contact with the coating such that the container and food items can be baked to properly prepare the food items therein. After baking, the container and food items can then be wrapped or otherwise packaged for shipment without transferring the food items to a separate shipping container. The container also includes a pair of end walls that are movable with respect to the container between retaining and dispensing positions to enable the container to be configured as serving tray for the items contained therein.
B65D 5/00 - Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
B65D 5/28 - Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form with extensions of sides permanently secured to adjacent sides, with sides permanently secured together by adhesive strips, or with sides held in place solely by rigidity of material
B65D 17/00 - Rigid or semi-rigid containers specially constructed to be opened by cutting or piercing, or by tearing of frangible members or portions
