US20100307116A1 - Multiple-Atmosphere, Nested Food Container - Google Patents

Abstract

A multi-atmosphere, nested food container having an opaque, thermoformed top tray with a modified atmosphere other than air for storing unpackaged, perishable food items therein nested within a transparent, thermoformed bottom tray having a non-modified atmosphere for prepackaged food items. The top tray is sealed with a transparent common air impermeable flexible film to allow for viewing of the food items therethrough. The top tray nests inside of the bottom tray such that a bottom surface of the top tray is placed inside of an opening at the top surface of the bottom tray. This orientation allows for the top tray to remain in a relatively upright position such that the top surface of the top tray remains visible to consumers.

Description

FIELD
• This application generally relates to a multiple-atmosphere, nested food container for enclosing food items therein, and, in particular, a multiple-atmosphere, nested food container that comprises a food tray having an atmosphere filled with a gas other than air for packaging perishable food items therein and nested within another tray having a different atmosphere.
BACKGROUND
• Food packages are known to comprise multiple compartments within a single main tray. Multiple trays may also be used and packaged together, each tray having a different food component therewithin and at least one tray may have multiple compartments. When food packages are sold to consumers, it is often preferred that some portion of the package be clear or partially transparent so that the food product within can be visible to the consumer.
• However, when multiple trays are packaged together they each can often have their own closure film or lid. This entails extra material within the package, as well as an extra piece of packaging to be removed by the consumer, and an additional manufacturing step when packaging the food. Furthermore, where it is desired to package two trays together in a snap-fit manner, they are often placed in a “face-to-face” orientation, such that each tray is separately sealed at its opening at which the trays are in contact. Therefore, when the outside perimeter of the assembled package is viewed, whether it is from the top or bottom, only the outside bottom surface of the trays are visible. If the trays are relatively clear or transparent, the food packaged therein may be visible. However, the food is typically packaged such that the bottom or back of the food product rests adjacent to the bottom of the tray with the film seal or lid placed over the top of the food product. Thus, when the trays are placed in face to face contact, the top of the food products are hidden from view within the interior of the package leaving only the bottom of the food product visible through the package.
• This face to face orientation does not provide a proper view of the food product to the consumer. Many times a consumer makes the decision to purchase a packaged food product based upon its appearance in the package. If the consumer is not able to see the front or top side of the food product, which is typically also the side viewed when eating, the consumer may be hesitant to purchase the product thinking that perhaps what they cannot see is not good.
• To somewhat alleviate this problem, an all clear tray and lidding film have been employed to seal the openings of the trays. This permits a consumer to look through the bottom-end of a the top tray compartment, i.e., the bottom end is on top when packaged in a face to face orientation, through the lidding film of both trays, and into the bottom tray compartment to see the top surface of the food product in the bottom tray compartment. However, the top tray still only displays the bottom surface of the food product due to the face to face orientation of the two trays, thus hiding the top surface from view.
• Nesting of compartment trays within each other has been employed where both trays can be oriented in the same direction, with one inside the other. For instance, the top compartment tray will remain in an upright position and can nest or be placed into the bottom compartment tray. However, these nested trays either share a common cover or lid, or the top tray is used as a cover for the bottom tray. In both instances, neither is packaged in a separate modified atmosphere, rather both the top and bottom are packaged in similar atmospheres. Thus, packaging food products together that have differing shelf-life requirements in nested packages often requires that the food products be packaged in the same environment. Thus, if a perishable food is present, then the non-perishable food must also be packaged under the same conditions as is required for maintaining the perishable food. This proves a waste of resources if not needed for non-perishable or prepackaged items, as well as the non-perishable food item taking up space in the package that could be used by another perishable food product.
SUMMARY
• A multiple-atmosphere, nested food container or package having at least one tray packaged in a modified atmosphere environment and at least one tray is not, is provided. This type of multi-atmosphere food container allows for improved shelf appearance for differing shelf-life food products and frontal product visibility through the trays to allow consumers clear visibility of the unpackaged, perishable food items. This type of container further allows packaging food products together that would not be obvious to package due to having different shelf lives, such as a cheese product and a dessert bar. The multi-atmosphere, nested food container is provided having an opaque, thermoformed top tray nested within a transparent, thermoformed bottom tray, the top tray comprising multiple compartments sealed with a transparent common, air impermeable flexible film while packaged in a modified atmosphere (“MAP”). The bottom tray is not MAP-sealed. The top tray further contains perishable food items that are not prepackaged or wrapped before placement into the compartments. The bottom tray does contain prepackaged food items and can optionally include non-food items, such as eating utensils.
• The top tray is nested within the bottom tray in an upright position such that the bottom surface of the top tray is placed into the bottom tray at an upper opening thereat. Thus the top surface of the top tray remains visible and in a face-forward orientation. This orientation avoids a face to face positioning of the two trays, ensuring that the top of the food products remains visible.
• Food packaged within the multi-atmosphere, nested food container allows for packaging foods together that have differing shelf lives and that may not have been obvious to package in the same container. For instance, packaging a perishable food item with a non-perishable food item, where both would be packaged in its separate required atmosphere, is provided with the multi-atmosphere, nested container. Furthermore, the food container disclosed herein allows for the top tray to face forward when nested in the bottom tray, so that the perishable foods can be viewed from their upper surface, or the surface visible when eating. This allows for improved product presentation because the consumer can see the top surface of the food they are getting and can be confident in the quality of that food. This container also allows for improved shelf appearance of the food products therein because the products can be packaged in their appropriate atmospheres to maintain their freshness qualities and attractive appearance. Since the bottom tray is also transparent, the consumer can also view the contents of the bottom tray.
• Additionally, less packaging material is required since the lid or cover to the bottom tray is simply the top tray itself. This further provides for less manufacturing steps since each tray does not need to be separately sealed.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a perspective view of a multi-atmosphere, nested food container;
• FIG. 2 is a cross-sectional view of the container ofFIG. 1, taken along the line2-2;
• FIG. 3 is an exploded view of the container ofFIG. 1;
• FIG. 4A is a top plan view of a top tray of the container ofFIG. 1;
• FIG. 4B is a bottom plan view of the top tray ofFIG. 4A;
• FIG. 5 is a top plan view of a bottom tray of the container ofFIG. 1;
• FIG. 6 is a perspective view of a fully assembled multi-atmosphere, nested food container;
• FIG. 7 is a perspective view of a second embodiment of a multi-atmosphere, nested food container;
• FIG. 8 is a cross-sectional view of the container ofFIG. 7, taken along the line8-8;
• FIG. 9 is an exploded view of the container ofFIG. 7;
• FIG. 10 is a top plan view of a top tray of the container ofFIG. 7;
• FIG. 11 is a top plan view of a bottom tray of the container ofFIG. 7;
• FIG. 12 is a perspective view of a fully assembled multi-atmosphere, nested food container of the second embodiment; and
• FIG. 13 is a top plan view of a third embodiment of a top tray of a multi-atmosphere, nested food container.
DETAILED DESCRIPTION OF THE DRAWINGS
• A multiple-atmosphere, nested food container is provided with a food tray packaged in a modified atmosphere and hermetically sealed, and nested inside of another food tray, as illustrated inFIGS. 1-13. The food package or container can have a top tray and a bottom tray, where the top tray can contain multiple compartments for receiving unpackaged, perishable food. The top tray can be covered with a common transparent flexible film that hermetically seals the food items therein. The top tray can further contain a modified atmosphere comprising a gas other than air that is maintained in the compartments once the flexible film is placed thereon. The bottom tray can contain a main compartment for receiving prepackaged food and/or non-food items therein. Since the food items are prepackaged, the bottom tray does not need to be sealed with film or filled with a modified atmosphere. The top tray can provide a closure for the compartment of the bottom tray by snapping into the opening of the bottom tray.FIGS. 1-6 represent a first aspect of the food container with a first design of the top and bottom trays.FIGS. 7-12 represent a second aspect of the food container with a second design of the top and bottom trays.FIG. 13 represents a third design of the top tray. All different tray components can be interchangeable with one another.
• Turning toFIG. 1, a first embodiment of afood container10 is shown in its assembled form. Thefood container10 has an opaque, thermoformedtop tray12 and a transparent,thermoformed bottom tray14, thetop tray12 insertable into thebottom tray14, and further comprising a transparent common, air impermeableflexible film16 placed over the top surface of thetop tray12 and forming a hermetic seal over thetop tray12. Thetop tray12 can comprise a plurality of openings or compartments for receiving food directly therein. The food items placed in the top tray compartments do not need to be prepackaged since they are sealed with the common flexible film to preserve the food's freshness, to be discussed in more detail herein.
• Thetop tray12 can comprise at least two compartments, or as shown inFIGS. 1-6, can have at least sixcompartments18ato22bin one aspect of thefood container10. The compartments can have any shape, such as square, rectangular, any rectilinear shape, or circular, to name a few, and can be oriented in any manner, such as similarly shaped pairs arranged in a column or multiple single compartments arranged randomly and having different shapes. In another aspect, atop tray212 can comprise only two compartments, as shown inFIG. 13. Both compartments can be shaped differently from each other, with one being generally circular and the other generally rectilinear. In yet another aspect, thetop tray121 can comprise three compartments, as shown inFIG. 7. Each compartment can again have a different shape from the other compartments, with one being generally circular and the other two having a generally curved rectilinear compartment. However, any number of compartments can be provided on the top tray and in any shape or configuration.
• As can be seen fromFIG. 4A, thetop tray12 can have at least three pairs of food compartments, for a total of six compartments, with each pair comprising similarly shaped compartments. Afirst compartment pair18aand18bcan each have a generally square shape with similar dimensions. Asecond compartment pair20aand20bcan also have a generally square shape and athird compartment pair22aand22bcan have a generally rectangular shape with similar dimensions. However, any shape compartments may be provided and the compartment pairs do not need to all be similarly shaped and sized.
• Various food items can be placed directly into the desiredcompartments18ato22bof thetop tray12 without requiring the food items to be prepackaged, and can be covered with a common air impermeableflexible film layer16. Theflexible film16 can be affixed to thetop tray12 to hermetically seal the openings to eachcompartment18ato22b. Theflexible film16 can further be provided as a clear or transparent film to allow viewing therethrough of the food items in theirrespective compartments18ato22bsuch that the contents or interiors of the separate compartments are each visible from anupper surface30 of thefood container10 through theflexible film16. Theflexible film layer16 can be sealed to a portion of an uppermost generallyplanar flange54 surrounding the periphery of thetop tray12 at anupper surface30 of thetop tray12 to hermetically seal each of the compartments, as shown inFIG. 3. Theplanar flange54 can surround a plurality of the openings or compartments of thetop tray12 and can surround a periphery of thetray12. Theflexible film16 can maintain the shelf-life of the food items thus preserving the food items' freshness. Theflexible film16 can further be a peelable seal, such that it can be removed easily from thetop tray12 without cutting.
• Furthermore, as theflexible film16 is being sealed to thetop tray12, the food compartments18ato22bcan relatively simultaneously be flushed and/or filled with a modified atmosphere gas other than air to provide a packaging environment that can also extend the shelf-life of the food items and help the food items maintain a desirable appearance during retail display. Such a packaging environment may include a modified atmosphere package (“MAP”) that includes, without limitation, atmospheres comprising oxygen, nitrogen, carbon dioxide, carbon monoxide, and combinations thereof. In one aspect, the modified atmosphere environment may comprise a mixture of gases comprising about 25% carbon dioxide (CO₂) and about 75% nitrogen (N₂). In general, the modified atmosphere can contain about 70% to about 85% nitrogen, and preferably the balance can be carbon dioxide.
• Thetop tray12 can also have avertical flange56 depending from theplanar flange54 and generally extending about the entire perimeter of thetop tray12. Thevertical flange56 can further terminate in ahorizontal flange portion58. These flange portions can cooperate with similarly situated flange portions of thebottom tray14 when in the closed configuration to provide aclosed container10, to be discussed in further detail herein below.
• Each compartment of thetop tray12 can have a depending sidewall and a bottom wall, as seen inFIGS. 1 and 2, with an opening opposite the bottom wall and defining an interior for containing discrete, unpackaged perishable food items directly therein. Any variation on the number of sidewalls can be provided and typically four upstanding sidewalls are provided when the compartment has a generally rectilinear shape, as inFIG. 1. If the compartment has a generally circular shape it can have at least one upstanding sidewall, or at least two upstanding sidewalls. In one aspect,compartment20bhas abottom wall34 and threeupstanding sidewalls40a,40band40cand one partial upstanding sidewall havingsidewall portions40dand40d′ adjacent tocompartment20a. The partialupstanding sidewall40dand40d′ can be divided by an optional notch ordepression44 positioned betweencompartments20aand20bin a common sidewall. Thenotch44 can be used as a finger insert that allows the consumer to insert a finger or other removal means or tool to assist in removal of the food item therein. Thus, at least two of the six total compartments can have this common depressed sidewall that provides for a finger insert or other removal tool.
• Another pair ofcompartments22aand22bcan also contain a bottom wall with four upstanding sidewalls. For instance,compartment22bhas abottom wall36 and fourupstanding sidewalls42a,42b,42cand42d.Sidewall42acan similarly contain an optional finger insert in the form of a recess or anindentation46. Theindentation46 can span a portion of thesidewall42a, such that it can span at least enough of a distance to allow a consumer access to the interior of thecompartment22bto make removal of the food item easier. In one aspect, theindentation46 can be positioned at about a midpoint of thesidewall42aand can make up about ⅓ of the length of thesidewall42a. Similarly,compartment22aalso can contain anoptional indentation48 in itssidewall42a′.
• The final pair ofcompartments18aand18bcan have a multi-level bottom wall due to a raisedportion26 in the bottom of eachcompartment18aand18b. The raisedportion26 at the bottom interior of thecompartment18aor18bcan be provided to allow a smaller height food item or stack to be packaged and stored therein and still be at the same final height as food items inadjacent compartments20a,20b,22aand22b. The food compartments18ato22bcan each have a similar depth compartment. It is further desired that the food items are placed in the food compartments at the same visible elevation, such that the top surface of the uppermost food item can be viewed from the top of the tray. The food items preferably are packaged such that the uppermost food item is almost flush with thetop surface30 of thetop tray12. All of the food items are preferably placed in their respective compartments at approximately the same height. Where the food item or stack of food items is not tall enough, the bottom wall32 of thefood compartment18aand18bcan contain raisedportion26 for supporting food thereon, which can slightly elevate the food therein to a height that is generally equivalent to the height of the other food items in the adjacent compartments, and above a bottommost portion of the bottom wall32.
• The raisedportion26 can be present in one compartment, more than one, or all, however, the presence of a raisedportion26 within the compartments is optional and does not need to be present at all. The use of a raisedportion26 can be dependant upon the food item to be stored therein and whether or not the food item will be tall enough to be substantially fully viewed from its upper surface when placed in the compartment. In one aspect,compartment18b, as shown inFIG. 2, can have a bottom wall32 that has threeportions32a,32band32c. Themiddle portion32bof the bottom wall32 can form the raisedportion26 within the interior of thecompartment18b, and the two outer portions of thebottom wall32aand32ccan be flush with the otherbottom walls34 and36 of the outer compartments. Thecompartment18balso can have fourupstanding sidewalls38a,38b,38cand38d. Along a portion ofsidewall38ba finger insert can be provided, such as anindentation50, similar to theindentations46 or48 atcompartments22aand22b. Likewise,compartment18acan also have anindentation52 in a portion of itssidewall38b′. Thus, at least one compartment, and preferably all, can contain a recess or notch for inserting a finger or other removal tool therein to provide for easier removal of the food item stored in the compartment.
• Thebottom tray14 can comprise abottom wall62 and a peripheral sidewall extending upwardly from thebottom wall62. In one aspect, thebottom wall62 can have fourupstanding sidewalls64a,64b,64cand64d, as shown inFIG. 5. Opposite thebottom wall62, there can be anopen end66 surrounded by an uppermostperipheral rim68 at an upper end of the sidewalls64. The sidewall and bottom wall can define an interior24 of thebottom tray14, which can be filled with prepackaged food items or non-food items, such as plastic eating utensils, napkins, and the like, in a non-modified atmosphere. Thebottom tray14 does not need to be hermetically sealed and/or MAP-sealed due to the food items therein already being prepackaged. Thus, theopening66 of thebottom tray14 does not need to be sealed with a film or other air-tight seal, rather a lid or other enclosure can be used to close the interior24 of thebottom tray14 to prevent the contents therein from spilling out.
• Theperipheral rim68 of thebottom tray14 has avertical flange portion70 that depends therefrom and generally extends about the entire perimeter of theopening66 of thebottom tray14. Thevertical flange portion70 can terminate in ahorizontal flange portion72. Thevertical flange portion70 can contact thevertical flange portion56 of the top tray when thecontainer10 is placed in a closed configuration. Similarly, the respectivehorizontal flange portions58 and72 can also contact one another upon closing.
• To place thecontainer10 in a closed configuration, the sealedtop tray12 can be inserted into thebottom tray14 in an upright position such that thetop tray12 can nest just inside a portion of the interior24 of thebottom tray14 to provide a durable enclosure that covers theopening66 of thebottom tray14 and can act as a lid for thebottom tray14. Thetop tray12 can snap into thebottom tray14 while in an upright position, with thetop surface30 of thetop tray12 facing outward and fully visible when displayed. The upright position of thetop tray12 is achieved by inserting a bottom surface of thetop tray12 into theopening66 at the top surface of thebottom tray14, such that a portion of theflange54 surrounding the periphery of thetop tray12 rests on theperipheral rim68 surrounding theopening66 of thebottom tray14. The term “upright position” refers to thetop surface30 of thetop tray12 being visible in relation to thebottom tray14, such that thetop surface30 faces forward. It is to be understood that the closed and fully assembledcontainer10 can be displayed on its side, or in any other manner, yet the top surface will still remain visible and can be considered to be in an “upright position” in relation to thebottom tray14. When thecontainer10 is closed, the underside of theplanar flange54 can be adjacent the top surface of theperipheral rim68 of thebottom tray14. Similarly, the underside of thevertical flange56 andhorizontal flange58 of thetop tray12 can be adjacent to thevertical flange70 andhorizontal flange72, respectively, of thebottom tray14.
• In order to achieve a snap-fit of thetop tray12 over thebottom tray14, as well as an audible snapping sound, the top andbottom trays12 and14 can have elastic engagement of their respective edge. This can be provided by a rib and groove pair positioned in at least one corner of thecontainer10, and preferably one in each corner of thecontainer10, that cooperate to fit thetop tray12 andbottom tray14 together. In one aspect, there can be agroove80 and81 in eachcorner82 and83 of thebottom tray14. Thesegrooves80 and81 can be positioned along a portion of thevertical flange70 that cooperate withcorresponding ribs84 and85, respectively, positioned on thetop tray12 along a portion of thevertical flange56 incorners86 and87, respectively, on the underside thereof, as seen inFIG. 4B. Thelarge grooves80 can be positioned inopposite corners82 adjacent anoptional tab extension74. Theselarge grooves80 can be larger in size than thesmall grooves81 inadjacent corners83, and can have a larger size and length indent due to being positioned adjacent thetab extensions74. As theribs84 and85 from thetop tray12 slide over and into theirrespective grooves80 or81, at a minimum thecorners86 and87 of thetop tray12 can deform and snap back into place, snapping into theirrespective groove80 or81. Thefood container10 can have arib84 or85 and correspondinggroove80 or81 in each of its four corners, however, less than that number can be supplied and at least one of each can be provided. Alternatively, the opposite configuration may also be provided where the ribs are located on thebottom tray14 and the grooves are located on thetop tray12.
• The items located inside the interior24 of thebottom tray14 can be arranged at a height that does not interfere with the underside of thebottom walls32,34, and36 of thetop tray12 when placed over the opening66 of thebottom tray14. Depending on what the depth of thetop tray12compartments18ato22dare, the items packaged in theinterior24 of thebottom tray14 should be packaged at least this distance below thetop flange68 of thebottom tray14.
• FIGS. 7-12 illustrate another aspect of the food container.FIG. 7 shows afood container100 comprising atop tray121 and abottom tray141. Thetop tray121 can contain threecompartments102,104, and106 in the aspect shown. The threecompartments102,104, and106 can all be shaped or sized differently from one another. At least one compartment can have a generally circular side. In one aspect, afirst compartment102 can be sized generally circular, with abottom wall132 and at least two upstanding sidewalls. Thefirst compartment102 can also be the largest sized compartment for storing a large food item or items. The nextlargest compartment104 can be generally rectilinear in shape with generally rounded edges. Thecompartment104 can have abottom wall134 and four upstanding sidewalls. Thelast compartment106 can be the smallest sized compartment and it can generally comprise a parallelogram shape. Thecompartment106 can have a bottom wall136 and four upstanding sidewalls.
• Thetop tray121 can have compartments at a similar depth as those of theprevious container10, however, raised portions at the bottom of the compartments do not need to be provided. Alternatively, the raised portions may be provided where the food item stored therein is small in height and needs an increased display height in order to reach the same display height of adjacent food items. Additionally, thecompartments102,104 and106 are shown without indentations or notches therein for a finger or other removal tool to be inserted, however, this feature may optionally be provided in one or more of the compartments.
• Thebottom tray141 can be similarly sized and shaped as thebottom tray14 in the previous embodiment. The outer surface of thebottom tray141 can have a different ribbing design along its sidewalls and a portion of itsbottom wall132 than theprevious bottom tray14, as shown inFIG. 7, can be the same, or it may not contain any ribbing at all. All of the remaining aspects of thefood container100 are the same as thefood container10 previously described. Similarly labeled reference numerals relate to the same features in both.
• Another aspect is shown, inFIG. 13, where thetop tray212 can comprise twocompartments202 and204. Thecompartments202 and204 are both sized larger than if there were more than two compartments provided. This allows for storing larger sized food items. Thetop tray212 can likewise snap and fit into thebottom tray14 or141 of the previous embodiments. Aflexible film16 is sealed over theplanar flange254 of thetop tray212 to enclose the food items directly stored within thecompartments202 and204. The bottom tray can contain prepackaged food and/or non-food items, as previously discussed.
• Thetop tray12,121 or212 andbottom tray14 or141 can both optionally contain atab extension60 and74, respectively, at one or two opposingcorners82 and86 of thefood container10. Thesetab extensions60 and74 can assist in opening thefood container10. The consumer can grasp thetab extension60 located at thecorner86 of thetop tray12 and apply an upward force to separate thetab extension60 from thetab extension74 below it, in an effort to remove thetop tray12 from thebottom tray14. Furthermore, an optional raisedprotuberance88, such as a half circle, can be provided on the upper surface of thetab extension74 on thebottom tray14. This raisedprotuberance88 can aid in separating thetab extension60 from thelower tab extension74 by keeping a slight space between the two, and allow easier grasping of theupper tab extension60 upon removal of thetop tray12.
• Furthermore, where the top andbottom trays12 and14 containtab extensions60 and74, respectively, thecompartments18aand22bin thetop tray12 adjacent thetab extensions60 can have a curved corner edge, as can be seen inFIG. 4. For instance, thefirst compartment18ahas a generally rectilinear shape that is similar to the adjacent generallyrectilinear compartment18b. The only difference being between the twocompartments18aand18bis that of the shape of thefirst compartment18a, which has one corner edge of itsrectilinear compartment18acurved rather than meeting at a generally 90 degree angle, as in theadjacent compartment18b.Compartments22aand22bare similarly configured with a corner ofcompartment22bhaving one rounded corner adjacent thetab extensions60 and74.
• Thefood container10 or100 can also optionally contain apaperboard sleeve28 that extends and wraps around thetop tray12,121, or212 and thebottom tray14 or141 when in the closed configuration, as shown inFIGS. 6 and 12. Thesleeve28 can hold the trays together against unintentional separation until removal of thesleeve28. Thesleeve28 can also contain atear strip76 for easy removal of thesleeve28 without requiring cutting or tearing through thesleeve28. Thetear strip76 can have atab78 at one end for grasping, which the consumer can use to pull along thetear strip76 to separate thesleeve28 at scored lines of thetear strip76. Optionally, thesleeve28 can also contain writing or graphics printed on it.
• Still optionally, thesleeve28 can be adhered to a portion of thefood container10 or100 to ensure that thesleeve28 cannot slide off of thecontainer10 or100 or be removed unintentionally. Thus, an underside of thesleeve28 can be glued or adhered to a portion of thecontainer10, such as a small section of thebottom tray14 or141. Thesleeve28 remaining intact helps to ensure that the top and bottom trays remain together.
• The top andbottom trays12,121 or212 and14 or141 may be thermoformed trays made from a rigid material. The term “rigid” is used herein to indicate that the structures made of these materials have the ability to generally retain their respective shapes during normal handling, such as polyester, polypropylene, high impact polystyrene, high density polyethylene, amorphous polyethylene terephthalate, or a combination thereof. Thebottom tray14 or141 can preferably be made from a transparent or translucent material such that the contents therein can be viewed by the consumer when looking through thebottom tray14 or141 when thecontainer10 or100 is in the closed configuration. However, thetop tray12,121 or212 does not need to also be transparent. Thetop tray12,121 or212 can comprise a non-transparent material, a colored material, or it can be transparent. Thetop tray12,121 or212 can comprise an oxygen barrier material, such as high impact polystyrene (“HIPS”). The top tray can have an oxygen transmission rate of about 0.2 to about 0.4 cc/100 in²/24 h at a temperature of about 73° F. Thebottom tray14 or141 can comprise a non-barrier material, such as amorphous polyethylene terephthalate (“APET”).
• The air impermeableflexible film16 that seals thetop tray12,121 or212 can comprise a transparent film to permit viewing therethrough of the food items within their respective compartments. The material of construction of theflexible film16 may be polyethylene, polyethylene terephthalate, ethylene vinyl alcohol, ethylene vinyl acetate, polyester, polyolefin, polypropylene or a combination thereof. In one aspect, aflexible film16 is provided comprising polyethylene terephthalate coextruded with a combination of polyethylene, ethylene vinyl alcohol and ethylene vinyl acetate. Theflexible film16 can preferably comprise an oxygen barrier film material, such that the food items sealed within the compartments of thetop tray12,121, or212 are hermetically sealed therein. The flexible film material used may have a barrier layer added to it that keeps out oxygen, has an antifog feature, and provides for easy open of theflexible film16 from the top trayperipheral flange54,154, or254. Theflexible film16 can be heat sealed to the top trayperipheral flange54,154 or254 or any similar method of adhering theflexible film16 to the top tray may be used.
• Typical overall dimensions of thecontainer10 or100 can comprise a length and width of about 5 inches to about 10 inches in length and of about 4.5 inches to about 6.5 inches in width. The length and width of the top and bottom trays should be similarly sized so that the two trays can fit together snugly when placed in the closed configuration. The dimensions of thecontainer10 or100 are provided such that various sizes can be accommodated. For instance, it may be desirable to size thecontainer10 or100 so that it can hold a pizza snack product, or in another instance, a cracker snack product, where both may require a different depth tray.
• The bottom and top trays can have a length from about 5 inches to about 10 inches, and in particular, a length of about 7 inches to about 9 inches. The width of the two trays can be from about 4.5 inches to about 6.5 inches, and in particular, a width between about 5 inches and 6 inches.
• A depth of the bottom tray compartment can be from about 2 inches to about 3.5 inches, and in particular, from about 2.5 inches to about 3 inches deep. A depth of the top tray compartments can be from about 0.5 inches to about 2 inches deep, and in particular, from about 0.5 inches to about 1 inch deep.
• In one aspect, as shown inFIGS. 1-6, thecontainer10 can have similar dimensions of length and width for both the top andbottom trays12 and14 comprising about 7.7 inches in length and about 5.2 inches in width. Thetop tray12 can have compartment depths of about 0.7 inches deep, and thebottom tray14 can have a compartment depth of about 2.6 inches deep. In another aspect, as shown inFIGS. 7-12, thetop tray121 can have compartment depths of about 0.9 inches deep, and thebottom tray compartment141 can have a depth of about 2.8 inches deep.
• The thickness of thebottom tray14 or141 can be about 15 mil to about 25 mil, and in particular, about 22 mil. The thickness of thetop tray12,121 or212 can be about 4 mil to about 16 mil, and in particular, about 4 mil after the tray has been formed. The thickness of theflexible film16 can be about 0.5 mil to about 2 mil, and in particular, about 1.5 mil.
• Thepaperboard sleeve28 can comprise a solid bleached sulfate paperboard material that is not transparent. Thesleeve28 can have a length of about 4 inches to about 5 inches, and in particular, about 4.5 inches. The width of thesleeve28 can be about 4.5 inches to about 6 inches, and in particular, about 5.3 inches. The length and width of thesleeve28 can be provided as a constant between various products, since similar length and width trays can be used across the board of product choices, however, the height or depth of trays can vary depending on the food item packaged therein. Therefore, the height of thesleeve28 can vary depending on the product packaged and can be from about 2 inches to about 3 inches. In one aspect, where a cracker snack is packaged, thecontainer10 can have asleeve28 height of about 2.7 inches. In another aspect, where a pizza snack is packaged, thecontainer100 can have asleeve28 height of about 2.9 inches.
• When thesleeve28 is placed around the trays, about less than half of thetop tray12,121, or212 remains visible and uncovered. Thus, less than about 50% of theuppermost surface30 and compartments of thetop tray12,121, or212 remain visible and uncovered upon application of thesleeve28. Where thetop tray12 has six compartments, some of thecompartments20aand20bmay be completely covered by thesleeve28 and thus are not visible. Where thetop tray121 or212 has two or three compartments, a portion of each compartment can remain visible and uncovered upon application of thesleeve28. In one aspect, about 42% of thetop tray12 can remain visible and uncovered after thesleeve28 is placed around the container.
• Thefood container10 or100 described herein may be used to package any variety of ready to eat foods that may or may not require further minimal assembly of the food items before consuming. Ready to eat food varieties may include pizza snacks, cracker snacks, desserts, lunch kits, sandwich kits, meal kits, pasta kits, snack mixes, and other food varieties. The food items packaged together in thefood container10 or100 are typically associated food products depending upon the ready to eat food that is being sold. For instance, if a pizza product is being sold in thefood container100, then at a minimum, food items that are typical for a pizza can be included in thecontainer100, such as tomato sauce, cheese and a meat topping.
• Thetop tray12,121 or212 can comprise any number of various food items that are directly filled into their respective compartments and sealed with theflexible film16 in a MAP environment, with no additional packaging and no prepackaging of the food items required. Food items packaged in thetop tray12,121 or212 may comprise deli meats, deli cheeses, cheese shreds, meat, bread, pizza crust, crackers, any farinaceous food product, vegetables, fruits, and any other food item that may have a shelf-life packaging requirement and may require hermetic and/or gas-flushed packaging.
• In one aspect, thefood container10 may comprise a cracker snack that includes crackers, meat and cheese in thetop tray12. For instance, meat slices90 may be stored and stacked upon one another in the first pair ofcompartments18aand18band cheese slices92 may be stored and stacked in the last pair ofcompartments22aand22b. Thecrackers94 may be stored and stacked in the middle pair ofcompartments20aand20b. The food items may be cut to any shape or thickness such that the food items are shaped to fit in their respective compartment and are not taller than theupper surface30 of thetop tray12 when the food items are stacked upon one another. In the aspect shown inFIG. 6, the meat slices90 may be cut to a circular shape and placed on the raisedbottom portion26 of thecompartments18aand18bsuch that the upper surface of the meat slices90 can be positioned relatively flush with the opening of the compartment adjacent theupper surface30 of thetop tray12 and at a similar height to thecheese92 andcrackers94. The cheese slices92 can be cut into rectangular shapes and thecracker94 may be circular in shape. However, any shape may be provided as long as the food item can fit into its compartment.
• In another aspect, thefood container100 may comprise a meat pizza snack. For instance, a bread orcrust product108 may be stored in the circular shapedcompartment102 with the toppings stored in the other adjacent compartments. In the embodiment shown inFIG. 12, themeat product110 may comprise pepperoni slices stored and stacked in onecompartment106 andcheese shreds112 stored in anadjacent compartment104. In yet another aspect, the food container may comprise a cheese pizza snack with only two compartments in thetop tray212, onecircular compartment202 for the bread orcrust product108 and anothercompartment204 for the cheese shreds112. The pizza sauce used in both pizza snack products can be prepackaged and stored in thebottom tray14 or141.
• Thebottom tray14 or141 can comprise any number of different prepackaged food items and non-food items that do not require a MAP environment. Thebottom tray14 or141 may contain a drink item, a dessert item, a dessert cup, an apple sauce, condiment packets, a yogurt, a pizza sauce pouch, an eating utensil, a napkin, a cup, a bag of chips, a bag of crackers, any other type of prepackaged food item that does not have any special packaging requirements that impact its shelf life, or any other type of non-food item that would be relevant to a ready to eat food container.
• In the aspect shown inFIG. 6, thebottom tray14 can contain a bottle of water, a prepackaged apple sauce, a prepackaged dessert bar and a spoon. In the aspect shown inFIG. 12, thebottom tray141 can contain a bottle of water, a prepackaged pouch of pizza sauce and a prepackaged dessert item, such as cookies. However, thebottom tray14 or141 is not limited to the combinations disclosed herein and any number of food and non-food item combinations may be provided within thebottom tray14 or141.
• Three differenttop tray12,121, and212 embodiments were disclosed where any top tray design is insertable into anybottom tray14 or141 design, such that the top and bottom tray designs can be mixed and matched. Additionally, other variations on the top tray and associated compartments can be provided such as different arrangements or orientations on the two or more compartment designs disclosed herein, and so forth.
• The food package orcontainers10 or100 disclosed herein can contain various ready to eat food kits or packages that can be assembled by the consumer prior to eating. Thefood package10 or100 can first be opened to expose the food items stored therein. To open the food package, the consumer can first remove thesleeve28, if one is present, by grasping at thepull tab78 and separating the sleeve along itstear strip76 to allow it to be removed from around thetop tray12,121 or212 and thebottom tray14 or141. Next, thetop tray12,121 or212 can be removed from thebottom tray14 or141 by grasping thetop tray12,121 or212 at itscorner tab extension60 and pulling up while separating it from thebottom tray14 or141. The bottomtray tab extension74 can also be grasped and pulled in the opposite direction to enact a separation of the top and bottom trays. Once the trays are separated, the bottomtray interior compartment24 is exposed and the prepackaged food items and/or non-food items are accessible.
• Theflexible film16 can then be removed from thetop tray12,121 or212 by peeling it away from the top trayperipheral flange54,154, or254, respectively, to expose the food compartments therein. The food items that are packaged within the food compartments of the top tray are then exposed and can be removed from the compartments. The consumer can then assemble the ready to eat food product by removing its component food parts from the compartments and assembling them into the final food product. The bottom tray can contain food items that are associated with the final food product and can compliment the final food product.
• From the foregoing, it will be appreciated a multiple-atmosphere, nested food container is provided that allows for packaging various food products together having different shelf lives and having improved product visibility, and methods of removal and assembly of the food product thereof. However, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the food container and method set forth in the claims. Therefore, the disclosure is not limited to the aspects and embodiments described hereinabove, or to any particular embodiments. Various modifications to the food container and the method of removal and assembly of the food product could be made which can result in substantially the same food container and method of removal and assembly.

Claims (20)

1. A multi-atmosphere, nested food container containing a plurality of individual food items having differing shelf-lives, the food container comprising:

a transparent, thermoformed bottom tray having a bottom wall, a peripheral side wall extending upwardly from the bottom wall and having an uppermost peripheral rim surrounding an open end opposite the bottom wall, the side wall and bottom wall defining an interior containing prepackaged food items in a non-modified atmosphere;

an opaque, thermoformed top tray having an uppermost generally planar flange surrounding a plurality of openings and surrounding a periphery of the tray, the openings corresponding to separate compartments each having a depending sidewall and a bottom wall defining an interior for containing discrete, unpackaged perishable food items directly therein and filled with a modified atmosphere gas other than air, the top tray insertable into the bottom tray in an upright position such that the top tray nests inside a portion of an interior of the bottom tray with the portion of the flange surrouding the periphery of the top tray resting on the peripheral rim surrounding the opening of the bottom tray; and

a transparent common, air impermeable flexible film affixed to a portion of the flange surrounding the periphery of the top tray such that the interiors of the separate compartments are each visible through the flexible film and hermetically sealing each of the compartments.

2. The food container according toclaim 1, wherein the top tray and the bottom tray are both made from a rigid material.

3. The food container according toclaim 1, wherein the top tray is made from an oxygen barrier material and the bottom tray is made from a non-oxygen barrier material.

4. The food container according toclaim 1, wherein the gas is about 70% to about 85% nitrogen.

5. The food container according toclaim 4, wherein the gas is about 75% nitrogen with the balance carbon dioxide.

6. The food container according toclaim 4, wherein the top tray has an oxygen transmission rate of about 0.2 to about 0.4 cc/100 in²/24 h at a temperature of about 73° F.

7. The food container according toclaim 1, wherein a sleeve extends around the top and bottom trays to hold the trays together against unintentional separation until removal of the sleeve.

8. The food container according toclaim 7, wherein a portion of each of the compartments remains visible and uncovered upon application of the sleeve.

9. The food container according toclaim 7, wherein about less than 50% of an uppermost surface of the top tray remains visible and uncovered upon application of the sleeve.

10. The food container according toclaim 7, wherein the sleeve is not transparent.

11. The food container according toclaim 1, wherein the top tray has at least two or three compartments.

12. The food container according toclaim 11, wherein at least one of the compartments has a generally circular side.

13. The food container according toclaim 1, wherein the top tray has at least six compartments.

14. The food container according toclaim 13, wherein the at least six compartments are all generally rectangular.

15. The food container according toclaim 13, wherein at least two of the six compartments have a depressed common sidewall to allow for inserting a finger or other removal tool therein.

16. The food container according toclaim 13, wherein the at least six compartments are generally the same size.

17. The food container according toclaim 1, wherein the bottom wall of at least one compartment in the top tray has a raised portion for supporting food thereon above a bottommost portion of the bottom wall.

18. The food container according toclaim 1, wherein at least one of the compartments has a recess or notch for inserting a finger or other removal tool therein to provide for easier removal of the food item.

19. The method of assembling a ready-to-eat food from a plurality of individual food items having differing shelf-lives, the steps comprising:

providing a multi-atmosphere, nested food package having an opaque, thermoformed top tray having an uppermost generally planar flange surrounding a plurality of openings and surrounding a periphery of the tray, the openings corresponding to separate compartments each having a depending sidewall and a bottom wall defining an interior, the top tray sealed with a transparent common, air impermeable flexible film affixed to a portion of the flange surrounding the periphery of the top tray, such that the interiors of the separate compartments are each visible through the flexible film and hermetically sealing each of the compartments, the top tray insertable into a transparent, thermoformed bottom tray in an upright position such that the top tray nests inside a portion of an interior of the bottom tray, the bottom tray having a bottom wall, a peripheral sidewall extending upwardly from the bottom wall and having an uppermost peripheral rim surrounding an open end opposite the bottom wall, the sidewall and bottom wall defining an interior compartment, with the portion of the flange surrounding the periphery of the top tray resting on the peripheral rim surrounding the opening of the bottom tray;

removing the flexible film from the portion of the flange surrounding the periphery of the top tray to expose discrete, unpackaged perishable food items stored directly in the interior of compartments therein and containing a modified atmosphere other than air;

removing the top tray from the bottom tray to expose the interior compartment of the bottom tray filled with prepackaged food items in a non-modified atmosphere; and

assembling the ready-to-eat food from the plurality of individual food items in the top tray compartments.

20. The method according toclaim 19, further comprising the step of removing an outer sleeve that extends around the top and bottom trays to hold the trays together against unintentional separation until removal of the sleeve.

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