AU2019200997B2

AU2019200997B2 - Baking tray and blank for a baking tray

Info

Publication number: AU2019200997B2
Application number: AU2019200997A
Authority: AU
Inventors: Tony Christophersen
Original assignee: Dane Pty Ltd
Current assignee: Dane Pty Ltd
Priority date: 2018-02-22
Filing date: 2019-02-13
Publication date: 2024-03-21
Anticipated expiration: 2039-02-13
Also published as: AU2019200997A1

Abstract

A baking tray for baking food in the tray, the tray comprising: a quadrilateral base extending between a first pair of opposed upright side walls and a second pair of upright side walls, a locking arrangement for maintaining the first and second pairs of side walls in upright positions with the corners of the tray wherein the locking arrangement releasably holds together the first and second pairs of the side walls so that at least one of the sidewalls can be folded outwardly and downwardly to provide access to the food product that has been baked in the tray; wherein at least one of the first pair of side walls comprises at least one foldable flap that is adapted to be positioned along one of the second pair of side walls in a folded configuration to allow a tab portion of said one of the second pair of side walls to be folded above the flap to position the flap in between the tab portion and the said one of the second pair of side walls, the flap being positioned to overlap with a shoulder portion of the tab to retain the shoulder portion behind a retaining portion of the flap. 112 12 110B 122 125 120B 00,, 5120A 1 5 122 114 11A114 12 112 FIGURE 1

Description

12 1 0B 122

125

120B 00,, 5120A

1 5

122 114 11A114 12

112

FIGURE 1

BAKING TRAY AND BLANK FOR A BAKING TRAY TECHNICAL FIELD

This invention relates generally to a baking tray. The present invention also relates to

a corrugated or other suitable carton board blank for forming the baking tray.

BACKGROUND

Any references to methods, apparatus or documents of the prior art are not to be taken

as constituting any evidence or admission that they formed, or form part of the

common general knowledge.

Bakeries often cut baked food products, such as cakes, into smaller portions for sale

at retail outlets. For commercial reasons, one of the considerations is that the cut

portions be a uniform size and shape. Metal baking trays, which are the main type of

baking trays that are currently used in bakeries, can be made to a high degree of

dimensional accuracy. However, traditionally, metal baking trays have tapered side

walls and rounded corners to facilitate the manufacturing process of pressing the trays

and to facilitate removing baked products from the trays. Thus, the corners of the

baked products are not straight and squared. The applicant's earlier patent application

AU2011203032 addresses this issue by providing a baking tray formed from a

cardboard blank that has straight and squared corners. However, another important

commercial consideration relates to whether such cardboard blanks are easily

erectable by using machinery. The applicant has found that the use of baking trays

formed from cardboard blanks typically requires manual handling which can have a

significant impact on overall costs.

In view of the above problems, it is desirable to provide baking trays which are not

only dimensionally accurate but also allow these trays to be easily erected using

machinery.

SUMMARY OF INVENTION

In one aspect, the invention provides a baking tray for baking food in the tray, the tray

comprising:

a quadrilateral base extending between a first pair of opposed upright

side walls and a second pair of upright side walls,

a locking arrangement for maintaining the first and second pairs of side

walls in upright positions with the corners of the tray wherein the locking arrangement

releasably holds together the first and second pairs of the side walls so that at least

one of the sidewalls can be folded outwardly and downwardly to provide access to the

food product that has been baked in the tray;

wherein at least one of the first pair of side walls comprises at least one foldable

flap that is adapted to be positioned along one of the second pair of side walls in a

folded configuration to allow a tab portion of said one of the second pair of side walls

to be folded above the flap to position the flap in between the tab portion and the said

one of the second pair of side walls, the flap being positioned to overlap with a shoulder

portion of the tab to retain the shoulder portion behind a retaining portion of the flap

wherein the retaining portion is hinged along a fold line provided in the flap by being

hingedly attached to the flap, the retaining portion being biased against the shoulder

portion for retaining the shoulder portion behind the retaining member

In an embodiment, each of the first pair of side walls comprises a respective tab portion

for interlocking with two of said flaps folded along each of the first pair of side walls.

In an embodiment, the flap comprises an upwardly extending member for being

received and interlocked in a corresponding opening in said one of the second pair of

side walls.

Preferably, the upwardly extending member further comprises a notched portion for

engaging an edge portion of the corresponding opening to maintain said one of the

second pair of side walls in a substantially upright position.

In an embodiment, releasing the locking arrangement allows at least one of said

second pair of side walls to be folded in an outwardly direction.

In an embodiment, releasing the locking arrangement allows at least one of the first

pair and at least one of the second pair of side walls to be folded in an outwardly

direction.

In another aspect, the invention comprises a blank for constructing a baking tray, the

blank comprising:

a quadrilateral base panel extending between a first pair of opposed side wall

panels and a second pair of opposed side wall panels;

at least one of the first pair of side wall panels comprising at least one foldable

flap;

at least one of the second pair of side wall panels comprising a foldable tab;

wherein during use, when said at least one of the first pair of side walls panels and

one of the second pair of side wall panels are folded to into an upright position, the

flap is adapted to be folded and positioned along one of the second pair of side wall

panels to allow the tab to be folded above the flap to position the flap in between the

tab and said one of the second pair of side walls to maintain the said at least one of

the first and second pairs of side walls in an upright configuration, the flap being

positioned to overlap with a shoulder portion of the tab to retain the shoulder portion

behind a retaining portion of the flap;

portion for retaining the shoulder portion behind the retaining member.

In an embodiment, the tab further comprises a narrower upper portion and a broader

lower portion, said lower portion forming at least a part of the shoulder portion.

In an embodiment, each of the first pair of side wall panels comprises the tab, said tab

being adapted to be interlocked with two of said flaps folded along each of the first pair

of side wall panels.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred features, embodiments and variations of the invention may be discerned

from the following Detailed Description which provides sufficient information for those

skilled in the art to perform the invention. The Detailed Description is not to be

regarded as limiting the scope of the preceding Summary of the Invention in any way.

The Detailed Description will make reference to a number of drawings as follows:

Figure 1 is a top view of a blank 100 used for forming a baking tray in accordance with

an embodiment of the present invention.

Figure 2 is a first perspective view of the blank 100, the blank 100 being shown in a

partially erected configuration.

Figure 3 is an end perspective view of the blank 100 being shown in a partially erected

configuration.

Figure 4 is an enlarged end view of the blank 100 shown in which three side walls

120A, 120B and 110A have been erected and one of the side walls 11OB is shown in

an outwardly folded non-erect configuration.

Figure 5 is a perspective view of baking tray formed by erecting all four side walls

110A, 11OB, 120A and 120B of the blank 100.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The baking tray shown in Figures 1 to 5 is formed from corrugated or any other suitable

carton board blank 100 which comprises a bleached lining on the surfaces of the board

that form the interior and an upper section of the exterior of the box, and a heat

resistant polymeric coating (such as a polyolefin coating) on the bleached lining. The

invention is no way limited to a polymeric coating and other heat resistant coatings may

also be used without departing from the scope of the invention.

The carton blank 100 tray is used for constructing a baking tray. The blank 100

comprises a rectangular base panel 105 extending between a first pair of side wall

panels 120A and 120B and a second pair of side wall panels 110A and 11OB.

The first and second pairs of side wall panels 110A, 11OB and 120A, 120B can be

folded upwards upward relative to the base 105 along fold lines to form substantially

upright side walls of the baking tray during use. Similarly, the side wall panels 110A,

11OB and 120A, 120B can also be folded outwards so that the upper edges of these

walls form generally smooth surfaces.

As is described in more detail hereinafter, the tray is formed so that the corners

between the base 105 and each of the side wall panels 110A, 11OB, 120A and 120B

are straight and square. This construction ensures that a baked product produced in

the tray has straight sides and squared corners and therefore has a high degree of

dimensional accuracy. The provision of relatively accurate squared corners and

straight sides allows the baked product into smaller portions that have a uniform size

and shape. Furthermore, side wall panels 110A, 11OB, 120A and 120B that can be

folded outwardly and downwardly provides access to the food product that has been

baked in the tray and once small portions of the baked food product have been taken

away, the side walls panels can once again be erected into an upright position.

The blank 100 comprises a locking arrangement 150 for maintaining the first and

second pairs of side walls (110A, 11OB and 120A, 120B) in upright positions with the

corners of the base panel 105. The locking arrangement 150 releasably holds together

the first and second pairs of the side walls (110A, 11OB and 120A, 120B) in an upright

configuration to form the baking tray during use. The locking arrangement 150 will be

described in the foregoing sections in further detail.

Each of the first pair of side wall panels 120A and 120B includes two oppositely

arranged foldable flaps 122. Side wall panel 120A includes two oppositely arranged

flaps 122 that are hingedly fastened to the side wall panel 120A along a fold line 125.

Similarly side wall panel 120B is also provided with foldable flaps 122 that are hingedly

fastened to the side wall panel 120B. In a folded configuration, the foldable flaps 122

in each of the side walls panels 120A and 120B can positioned along each of the second pair of side walls 11OA and 11OB respectively. Each of the second pair of side wall panels 11OA and 11OB is provided with a tab 112. The tab 112 can be folded relative the wall forming portion of the wall panels 11OA and 110 along fold lines 115.

At either end of the baking tray (when erected from the blank 100), each tab 112 is

used for engaging and interlocking two opposed flaps 122 along a side wall at both

ends (along sidewalls 110A and 110B) in between the tab 112 and the respective

sidewall (11OA and 11OB).

Referring to Figures 1 to 3 in particular, it is important to appreciate that an opening or

slot 114 is provided along (in a substantially collinear arrangement) the fold line 115

in between the tab 112 and each corresponding side wall 11OA or 11OB. During use,

when either of the side walls 11OA or 11OB are erected to be positioned in an upright

configuration, followed by folding the flaps 122 (in the same manner, as discussed in

previous passages), an in-use upwardly extending locking portion 124 is received into

the opening 114 (See Figures 4 and 5). The locking portion 124 further includes a

notch for receiving and locking an upper edge portion of the side wall panel 11OA or

110B. A typical folding step requires the flaps 122 to be folded inwardly to be

positioned along an outer wall of an upright (or partially upright) side wall panel 11OA

or 110B. Engaging the upwardly extending locking portion 124 into the notch of the

flap 122 against an edge portion of the opening 114 ensures that the locking portion

124 remains positioned within the opening 114 thereby maintaining the side walls

11OA in an upright position relative to the base 105 and relative to each of the two

other side walls 120A and 120B.

Referring to Figures 4 and 5 in particular, the next step involves folding the tab 112 in

a downwardly direction above each of the folded flaps 122 positioned along the

sidewalls 11OA or 11OB to position the tab 112 in a substantially parallel orientation

relative to the folded flaps 112 and the adjacent sidewall 110A or 110B. The tab 112

comprises a divergent configuration whereby an in-use lower section of increased

length 112A overlaps with a retaining portion 128 of each flap 122. Specifically, the

lower portion 112A of the tab 112 includes shoulder portions 117. Each shoulder

portion 117 is adapted to be retained behind the adjacent and overlapping retaining

portion 128 of each flap 122. It is important to note that in the preferred embodiment,

the retaining portion 128 is hingedly attached to the flap 122 along a fold line 129. The

fold line 129 is partially scored along the way to allow the triangular retaining portion

to be easily folded in one direction and not in the opposite direction. The retaining

portion 128 is triangular in shape and partially overlaps with the shoulder portion 117

of the tab 112. The triangular retaining portion 128 is biased against the shoulder

portion. The aforementioned configuration is very useful particularly when erecting

baking trays from the blank 100 by using machinery. Specifically, the provision of the

overlapping shoulder portions 117 and respective resilient retaining portions 128

allows a pulling member from tray erecting machinery (not shown) to apply a known

amount of force to pull the triangular retaining portions 128 past the shoulder portion

117 so that the retaining portions 128 are moved from an initial position (behind the

shoulder 117) to a retaining position (in front of the shoulders 117). The retaining

portions 128 are biased to apply a pushing force against the corresponding shoulders

117 to retain the shoulder 117 behind the retaining portion 128.

The shoulders 117 may be released from the retained position by applying a pulling

force on the lower portion 112A of the tab 112 to overcome the bias of the triangular

retaining members 128. Once again, a pulling member from tray erecting machinery

(not shown) may be used to apply a known amount of force to pull the lower portion of

the tab 112A from the retained position (shoulder 117 behind the retaining portion 128)

to a released position (shoulder 117 in front of the retaining portion 128).

The provision of a locking arrangement 150 comprising the shoulders 117 in each tab

112 in combination with the biased retaining portions 128 provided on each flap 122

provides an important advantage over the prior art in that these feature allow erecting

machinery to be easily used for retaining and releasing the tab 112 relative to the flap

122 by applying a known level of force. As a result, the baking trays formed from the

blank 100 can be erected or dismantled using erecting machinery without any

assistance from handlers.

It is also important to note that the invention is in no way limited to use with erecting

machinery. The locking arrangement 150 comprising the shoulders 117 in each tab

can be used manually for retaining or releasing the shoulders 117 of the tabs 112 by

users.

In use in a bakery, a predetermined amount of unbaked food product mix is deposited

in the above described tray (as shown in Figure 5) and the tray and food product mix

are thereafter placed in an oven and the food product is baked in the tray. At the end of a required baking time, the tray and baked food product are removed from the oven and the food product is allowed to cool to a required extent in the tray. Thereafter, the cooled food product is cut into smaller portions of uniform size and shape using laser or other suitable precision cutting equipment. At his point, the tray forms part of the packaging of the now cut baked food product. The packaging of the baked food product located in the tray is completed as required the packaged product is ready to be transported to an end use location for use at the location. The locking arrangement

150 allows some portions of baked food to be easily removed whilst the sidewalls

(11OA, 11B, 120A, 120B) are folded downwards. Once the desired amount of baked

food is removed, the side walls can be erected back up to an upright position and

maintained in the upright position by utilising the locking arrangement. The locking

arrangement 150 allows the baking tray to be easily erected using machinery during

the baking and packaging process. The locking arrangement 150 is also useful in

recycling the baking trays for further use by easily dismantling the trays by using

machinery in a manner as explained in previous sections. It is important to note the

invention in at least some embodiments is primarily directed towards the unique

configuration of the locking arrangement 150 and is no way limited to use in

conjunction with erecting machinery.

Many modifications may be made to the preferred embodiment of the tray without

departing from the spirit and scope of the invention.

In compliance with the statute, the invention has been described in language more or

less specific to structural or methodical features. The term "comprises" and its variations, such as "comprising" and "comprised of' is used throughout in an inclusive sense and not to the exclusion of any additional features.

It is to be understood that the invention is not limited to specific features shown or

described since the means herein described comprises preferred forms of putting the

invention into effect.

The invention is, therefore, claimed in any of its forms or modifications within the

proper scope of the appended claims appropriately interpreted by those skilled in the

art.

Claims

1. A baking tray for baking food in the tray, the tray comprising:

a quadrilateral base extending between a first pair of opposed upright

side walls and a second pair of upright side walls,

a locking arrangement for maintaining the first and second pairs of side

walls in upright positions with the corners of the tray wherein the locking

arrangement releasably holds together the first and second pairs of the side

walls so that at least one of the sidewalls can be folded outwardly and

downwardly to provide access to the food product that has been baked in the

tray;

wherein at least one of the first pair of side walls comprises at least one

foldable flap that is adapted to be positioned along one of the second pair of

side walls in a folded configuration to allow a tab portion of said one of the

second pair of side walls to be folded above the flap to position the flap in

between the tab portion and the said one of the second pair of side walls, the

flap being positioned to overlap with a shoulder portion of the tab to retain the

shoulder portion behind a retaining portion of the flap

wherein the retaining portion is hinged along a fold line provided in the

flap by being hingedly attached to the flap, the retaining portion being biased

against the shoulder portion for retaining the shoulder portion behind the

retaining member.

2. A baking tray in accordance with any one of claim 1 or 2 wherein the tab further

comprises a narrower upper portion and a broader lower portion, said lower

portion forming at least a part of the shoulder portion.

3. A baking tray in accordance with any one of the preceding claims wherein each

of the first pair of side walls comprises a respective tab portion for interlocking

with two of said flaps folded along each of the first pair of side walls.

4. A baking tray in accordance with any one of the preceding claims wherein the

flap comprises an upwardly extending member for being received and

interlocked in a corresponding opening in said one of the second pair of side

walls.

5. A baking tray in accordance with claim 4 wherein the upwardly extending

member further comprises a notched portion for engaging an edge portion of

the corresponding opening to maintain said one of the second pair of side walls

in a substantially upright position.

6. A baking tray in accordance with any one of the preceding claims wherein

releasing the locking arrangement allows at least one of said second pair of

side walls to be folded in an outwardly direction.

7. A baking tray in accordance with any one of the preceding claims wherein

releasing the locking arrangement allows at least one of the first pair and at

least one of the second pair of side walls to be folded in an outwardly direction.

8. A blank for constructing a baking tray, the blank comprising:

a quadrilateral base panel extending between a first pair of opposed side

wall panels and a second pair of opposed side wall panels,

at least one of the first pair of side wall panels comprising at least one

foldable flap

at least one of the second pair of side wall panels comprising a foldable

tab

wherein during use, when said at least one of the first pair of side walls panels

and one of the second pair of side wall panels are folded to into an upright position,

the flap is adapted to be folded and positioned along one of the second pair of side

wall panels to allow the tab to be folded above the flap to position the flap in between

the tab and said one of the second pair of side walls to maintain the said at least one

of the first and second pairs of side walls in an upright configuration, the flap being

behind a retaining portion of the flap; and

wherein the retaining portion is hinged along a fold line provided in the flap by

being hingedly attached to the flap, the retaining portion being biased against the

shoulder portion for retaining the shoulder portion behind the retaining member.

9. A blank in accordance with claim 8 wherein the tab further comprises a narrower

upper portion and a broader lower portion, said lower portion forming at least a part of

the shoulder portion.

10. A blank in accordance with any one of claims 8 to 9 wherein each of the first pair

of side wall panels comprises the tab, said tab being adapted to be interlocked with

two of said flaps folded along each of the first pair of side wall panels.

117 117 112

115 114 115 122 122 124 110B 150 2019200997

125

120B 100 105 120A

125

150 110A 122 122 114 114 124 112 117 117

FIGURE 1

120B 2019200997

122 122 112 114 114 110B 105 120A 110A 122

112 122

FIGURE 2

150

110B 120A 112 105 110A 122 124 114 120B 122 128

FIGURE 3

110B 2019200997

120B 105 114 120A 110A 112B 129 129 122 122 128 112A 128

112

FIGURE 4

100

FIGURE 5