# US 8,540,111 B2 · Container having a rim or other feature encapsulated by or formed from injection-molded material > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,540,111 B2 - Document ID: US8540111B2 - Status: Granted - Kind: B2 - Application number: 11/787,769 - Filed: 2007-04-18 - Published: 2007-08-23 - Granted: 2013-09-24 - Earliest claimed: 2002-03-15 - Assignees: Graphic Packaging International, Inc. - Applicants: Scott William Middleton; Mark Richard Sinclair; Brian Robert O'Hagan; Patrick Henry Wnek; Terrence Philip Lafferty; Peter Walrave Blaas; Kevin James Hjort; Patrick James Smith - Inventors: Scott William Middleton; Mark Richard Sinclair; Brian Robert O'Hagan; Patrick Henry Wnek; Terrence Philip Lafferty; Peter Walrave Blaas; Kevin James Hjort; Patrick James Smith - Web page: https://patentgrep.com/patent/US8540111B2 ## CPC - B65D 77/2088: {attached to the cover} - B29C 45/14336: {Coating a portion of the article, e.g. the edge of the article (B29C45/14573 and B29C45/14598 take precedence)} - B29C 45/14467: {Joining articles or parts of a single article (B29C45/14377, B29C45/14385, B29C45/14581, B29C45/14614 and B29C45/006 take precedence)} - B65D 1/48: Reinforcements of dissimilar materials, e.g. metal frames in plastic walls - B65D 5/209: {the adjacent edges of folded-up portions being joined by moulding seams in situ} - B65D 43/162: {the container, the lid and the hinge being made of one piece (B65D43/161 takes precedence)} - B65D 43/169: {the lid, the hinge and the element connecting them to the container being made of one piece} - B65D 77/2016: {the cover being maintained by projections or recesses on the container} - B65D 77/208: {the cover having a cap-like or plug-like shape} - B65D 81/3453: {Rigid containers, e.g. trays, bottles, boxes, cups} - B29C 2045/14237: {the inserts being deformed or preformed outside the mould or mould cavity} - B29C 2045/14918: {in-mould-labelling} - B65D 2581/344: Geometry or shape factors influencing the microwave heating properties - B65D 2581/3498: attached to the base surface - B65D: CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) ## Abstract A container or tray having various features. The container or tray comprises at least one sidewall having a top edge, the top edge of the at least one sidewall corresponding to a top surface of the tray and a bottom surface adjacent to the sidewall. A flange extends laterally outward from the top edge and is foldably connected to the sidewall at the top edge. The flange comprises at least a portion of the top surface of the tray. An injection-molded feature at least partially encapsulates the flange. The injection-molded feature comprising resin and has a first region in contact with the sidewall and at least a portion of the flange, and a second region adjacent the first region and extending laterally outward from the first region to a free edge of the injection-molded feature. The first region has a greater cross-sectional area than the second region. ## Claims ### Claim 1 A tray having an at least partially encapsulated flange, the tray comprising: at least three sidewalls each having a top edge, the top edge of the at least three sidewalls corresponding to a top surface of the tray; a bottom surface adjacent to the at least three sidewalls; a flange extending laterally outward from the top edge and being foldably connected to the at least three sidewalls at the top edge, the flange comprising at least a portion of the top surface of the tray; a junction between the sidewalls and the flange at the top edge of the at least three sidewalls, the flange extends laterally outward from the junction and is foldably connected to the sidewalls at the junction; an injection-molded feature at least partially encapsulating the flange, the injection-molded feature comprising resin and having a first region in contact with the at least three sidewalls and at least a portion of the flange, and a second region adjacent the first region and extending laterally outward from the first region to a free edge of the injection-molded feature, the first region has a greater cross-sectional area than the second region; at least two corners, wherein each of the at least three sidewalls has two curved portions and an intermediate portion between the two curved portions, adjacent curved portions of each of the sidewalls form a respective corner of the at least two corners, the first region and the second region of the injection-molded feature extend around a perimeter of the tray with the first region in contact with the intermediate portion and the two curved portions of each of the at least three sidewalls. ### Claim 2 (depends on 1) The tray of claim 1, wherein the injection-molded feature comprises at least one handle. ### Claim 3 (depends on 2) The tray of claim 2, wherein the at least one handle is hinged to allow the at least one handle to fold over the interior surface of the tray. ### Claim 4 (depends on 1) The tray of claim 1 further comprising an interior coating at least partially covering the bottom surface and the at least one sidewall. ### Claim 5 (depends on 4) The tray of claim 4, further comprising an injection-molded interior divider situated atop the bottom surface and dividing the bottom surface into at least a first interior cavity and a second interior cavity. ### Claim 6 (depends on 5) The tray of claim 5, further comprising: a first material located in the first interior cavity between the interior coating and the bottom surface, the first material being selected from the group comprising microwave transparent materials, microwave reflective materials, and microwave absorbing materials; and a second material located in the second interior cavity between the interior coating and the bottom surface, the second material being selected from the group comprising microwave transparent materials, microwave reflective materials, and microwave absorbing materials. ### Claim 7 (depends on 6) The tray of claim 6, wherein said first material has a first microwave interactive property, wherein said second material has a second microwave interactive property, and wherein the first microwave interactive property is different from the second microwave interactive property. ### Claim 8 (depends on 1) The tray of claim 1 wherein the first region is an advanced-flow section shaped to correspond to an advance-flow section of an injection cavity of a tool for forming the injection molded feature and the second region is a delayed-flow section shaped to correspond to a delayed-flow section of the injection cavity. ### Claim 9 (depends on 8) The tray of claim 8 wherein the delayed-flow section comprises a flange-section below and in contact with at least a portion of the flange. ### Claim 10 (depends on 9) The tray of claim 9 wherein the delayed-flow section comprises a resin-only section that extends beyond a free edge of the flange. ### Claim 11 (depends on 10) The tray of claim 10 wherein the resin-only section, a top surface of the flange, and the top edge of the sidewall comprises the top surface of the tray. ### Claim 12 (depends on 11) The tray of claim 11 wherein the top surface is a planar surface having a continuous surface extending across the top edge of the sidewall, the top surface of the flange, and the resin-only section. ### Claim 13 (depends on 1) The tray of claim 1, wherein said injection-molded feature is formed from a resin impregnated with glass fibers. ### Claim 14 (depends on 13) The tray of claim 13, wherein said glass fibers minimize shrinkage of said resin. ### Claim 15 (depends on 14) The tray of claim 14, wherein said resin shrinks in response to cooling. ### Claim 16 (depends on 13) The tray of claim 13, wherein said glass fibers minimize distortion of said tray due to shrinkage of said resin. ### Claim 17 (depends on 1) The tray of claim 1, wherein the tray is formed of fiberboard capable of withstanding heat up to approximately four hundred degrees Fahrenheit; and the injection-molded feature substantially retains its shape and rigidity in heat up to approximately four hundred twenty-five degrees Fahrenheit. ### Claim 18 (depends on 1) The tray of claim 1 wherein the first region is in contact with an upper portion of the sidewall that is adjacent to the top edge of the sidewall. ### Claim 19 (depends on 1) The tray of claim 1 wherein the tray comprises paperboard and the junction comprises a fold in the paperboard that foldably connects the flange and the sidewall. ### Claim 20 (depends on 1) The tray of claim 1 wherein the junction extends continuously around an entire perimeter of the tray. ### Claim 21 (depends on 1) The tray of claim 1 wherein the first region and the second region of the injection-molded feature extends continuously around the perimeter of the tray with the first region being in contact with the underside of the flange along the perimeter of the flange between the at least two corners. ### Claim 22 (depends on 1) The tray of claim 1 wherein the at least three side panels comprises four side panels and the at least two corners comprises four corners, the first region and the second region of the injection-molded feature extends continuously around the perimeter of the tray with the first region being in contact with the underside of the flange along the entire perimeter of the flange.