Note: Descriptions are shown in the official language in which they were submitted.
CA 02467607 2004-05-19
CONVERTIBLE TRAY BLANK AND CONTAINER
FIELD OF THE INVENTION
This invention relates generally to containers and container blanks and, more
specifically to convertible cap and tray type containers and tie sheets for
bulk products.
BACKGROUND OF THE INVENTION
Shipping goods in bulk is known in the art. In fact, an entire industry of
club
stores and warehouse stores has developed to provide customers with cost
savings
associated with large volume purchases. Often, the goods are shipped in bulk
to the
various stores. Often the bulk shipments are shipped on pallets. These bulk
goods are
often fairly unstable, especially as shoppers mill through the goods. As a
result, a large
quantity of blank containerboard material is used to try and stabilize the
goods. Typically,
the stabilization is achieved by blank, non-die cut containerboard material
placed in flat
sheets within the goods. As the goods are purchased, the successive layers of
tie sheets
are removed from the bulk pile of goods.
This practice creates a business problem. The blank tie sheets have no other
utility. Consequently, there is a considerable amount of expense associated
with tie sheet
that work well to stabilized bulk shipments, but have no other utility. A
specific utility not
met by the blank tie sheet is the ability to convert the tie sheet into
individual carrying
trays. Also, the blank tie sheet is not functional as a cap or bottom tray for
the bulk goods.
SUMMARY OF THE INVENTION
The present invention is directed to a convertible tray container and blank.
In
accordance with the present invention, a single sheet of foldable .material is
cut and scored
to define container blank. The blank includes a plurality of substantially
identical and
separable units, each unit includes a bottom panel, a pair of first opposed
side panels
attached to the bottom panel and a pair of second opposed side panels attached
to the
bottom panel. Additionally, a corner flap is connected with each of the first
opposed side
panels. Further, a locking tab is connected with the corner flap. Still
further a side panel
slot formed in the second opposed side panels and a bottom stacking slot is
form in the
bottom panel.
The present invention further includes a container having a bottom panel with
a
pair of first opposed side panels connected with the bottom panel and a pair
of second
opposed side panels connected with the bottom panel. A corner flap is
connected with
each of the first opposed side panels. Also, a locking tab is connected with
the corner
flap. Further, the container includes a bottom slot is formed in the bottom
panel.
a side panel slat formed in the second opposed side panels, said locking tab
passing through said side panel slot and engaging said bottom slot.
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BRIEF DESCRIPTION OF THE DRAWINGS
The preferred and alternative embodiments of the present invention are
described
in detail below with reference to the following drawings.
FIGURE 1 is a plan view of a single piece container blank formed according to
the
present invention;
FIGURE 2 is a plan view of an aspect of the container blank formed according
to
the presentinvention;
FIGURE 3 is a perspective view of a partially assembled collection of units of
a
container formed in accordance with the present invention;
FIGURE 4 is perspective view of a formed container made in accordance with the
present invention;
FIGURE 5 is a perspective view of a pair of convertible tray containers in
use;
and,
FIGURE 6 is perspective view of another aspect of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described with reference to the accompanying
drawings. The present invention is directed to a multi-section container cap
that may be
used as a unitary piece or be broken down into separate, identical units. By
way of
overview and with reference to FIGURES 1-8, one suitable embodiment of the
present
invention includes a single piece blank 20 of foldable material arranged to
form a
convertible tray container 50. Specific details of the blank 20 and
convertible tray
container 50 are described with more particularity below.
The blank 20 is cut scored, perforated or otherwise formed to include a
plurality of
panels which, when assembled, create the convertible tray container 50 of the
present
invention. Wherever possible the same number is used in related panels of the
blank 20
and convertible tray container 50. More specifically, in all FIGURES, like
numbers
indicate like parts. Additionally, cuts are shown are solid lines, score lines
as dashed lines
and lines of perforation as broken lines.
For the purposes of this description herein, the downward direction is defined
as
the direction perpendicular to a bottom panel 22 that corresponds to the outer
surface of
the bottom panel 22 when the convertible tray container 50 has been erected.
The upward
direction is defined as the direction perpendicular to the bottom panel 22
that corresponds
to the inner surface of the bottom panel 22 when the convertible tray
container 50 has
been erected.
CA 02467607 2004-05-19
The blank 20 and convertible tray container 50, as shown in the FIGURES are
made from any suitable material used in shipping. By Way of non-limiting
example, the
present invention may be constructed from containerboard, paperboard,
fiberboard,
corrugated containerboard, plastics or combinations thereof. Further, any
other foldable
material may be used to create the present invention.
Referring now to FIGURES 1 and 2, the blank 20 includes a plurality of
substantially identical units 23 that are separable along a separation lines
34. For
simplicity purposes only, a single unit 21 will be described. However, it will
be
appreciated that any discussion of one unit is equally applicable the all
units 23 and to the
convertible tray container.
Each unit 23 includes a bottom panel 22 and a first pair of opposed side
panels 24,
24' attached to the bottom panel 22. Additionally, a second pair of opposed
side panels
26, 26' are attached to the bottom panel 22, intermediate the first pair of
opposed side
panels 24, 24' . The relative length of the first pair of opposed side panels
24, 24' and the
second pair of opposed side panels 24", 24"' may be equal or unequal. As such,
the blank
may be configured such that each unit 23 is either substantially square or
substantially
rectangular in geometry.
In one embodiment, each unit 23 also includes a corner flap 28 attached to
opposed
ends of each of the first pair of opposed side panels 24, 24'. Additionally, a
locking tab 30
20 is attached to the corner flap 28. The second pair of side panels 26, 26'
includes side slots
42 that are suitably sized to accept the locking tab 30 when the blank 20 is
formed into the
container 50. Additionally, the bottom panel includes a bottom slot 40, that
works in
conjunction with the side slot 42 to receive the locking tab 30, as best
illustrated in
FIGURE 4. Still further, the bottom panel may optionally include a bottom
stacking slot
48. Those skilled in the art will appreciate the bottom stacking slot 48 may
be at any
orientation relative to the first and second pair of opposed side panels, 24,
24' and 26, 26'
respectively. Also, the bottom stacking slot 48 may be of any size or design.
The
principle purpose behind the stacking slot, among other things, is to provide
an attachment
base for internal support structure such as divider panels and the like.
FIGURES 2 & 3 illustrate certain aspects of the present invention.
Specifically,
the single blank 20 may be divided into a plurality of individual units 23. As
best seen in
FIGURE 2, each unit 23 is separable from each other along separation lines 34.
The units
23 may be completely separated from one another or the blank 20 may be divided
into a
pair of multiple unit sections (FIGURES 2 & 3). Additionally, a single unit 23
may be
separated from the convertible tray container 50 (FIGURE 2). Once separated,
the units
23, like the blank 20, may be formed into the convertible tray container 50 of
the present
invention, discussed in more detail below.
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As best seen in FIGURES 3 and 4, the erection of the blank 20 into the
convertible
tray container 50 of the present invention. It will be appreciated by those
skilled in the art
that a description of the erection of the convertible tray container 50 also
substantially
describes the erection of each unit 23 or collection of units 23 upon
separation from the
convertible tray container 50. As such, for simplicity purposes only, the
erection of only
the convertible tray container 50 is discussed herein.
Initially, the outer most first side panels 24 are folded upward relative to
the
bottom panel 22. Then, the outer most second side panels 26 are folded in the
same
manner and direction as the first side panel 24. In the example embodiment,
the corner
flap 28 is then folded about an end of the second side panel 26. The locking
tab 30 is then
inserted into the side slot 42 such that an end of the locking tab 30 engages
both the side
slot 42 and the bottom slot 40.
FIGURES 5 and 6 depict the additional aspects of the present invention.
Specifically, as best seen in FIGURE 5, the convertible tray container 50 may
be used as a
bottom tray, a top cap, or both. Still further, the blank 20 may be left flat
and inserted
between the layers of a product 52 to stabilize the product 52. Subsequently,
the blank 20
may be broken down and formed into the smaller units 23 and used to carry the
product in
smaller quantities. The product 52 is depicted in the FIGURES may be any
product 52,
and is merely shown as an array of material for simplicity purposes only and
is not in any
way intended to limit the scope of the present invention. Suitable, non-
limiting examples
of products that may be used with the convertible tray container 50 includes,
bulk food
products, clothing, or industrial products.
The utility of the convertible tray container 50 is considerable. As discussed
above, the convertible tray container 50 may be used as a cap, a base or a
flat insert for a
bulk shipping and display unit. In each case, the convertible tray container
50 may be
broken down into separate units 23 that may also be formed and used as a cap,
a base for
holding various products 52 or left as a blank 20 and used as a flat insert.
For example, a
bulk shipment of canned soup is sent to a store and is shipped with the
convertible tray
container used as a cap, tray or flat insert. The store may place the entire
bulk shipment
out for customer use and may break the convertible tray container 50 down to
smaller
units 23 as the product 52 is removed. These smaller units 23 may be used by
customers
as trays to carry their purchases home. Conversely, the store may initially
break the
convertible tray container 50 down into separate units 23 or a collection of
units 23 prior
to presenting the product to the customer. In this manner, a smaller amount of
product 52
may be presented to customers without using as much floor space, or allowing
easier
transport of the product 50.
While the preferred embodiment of the invention has been illustrated and
described, as noted above, many changes can be made without departing from the
spirit
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CA 02467607 2004-05-19
and scope of the invention. For example, other known locking stricture may be
used to
hold the various side panels in place. As corner locking constructions are
well known in
the art, their detailed description herein is not necessary to understand the
invention.
Accordingly, the scope of the invention is not limited by the disclosure of
the preferred
embodiment. Instead, the invention should be determined entirely by reference
to the
claims that follow.
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