Note: Descriptions are shown in the official language in which they were submitted.
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STACKABLE AND INDEXABLE PACKING TRAY
BACKGROUND OF THE INVENTION
10
Field of the Invention:
This invention relates to stackable, open-topped, shipping and/or display
container, and
more particularly to a corrugated paperboard, stackable container having
indexable projections
for shipping and displaying products such as, for example, agricultural
produce.
Background of the Invention:
Containers made from corrugated paperboard are commonly used for shipping and
storing various products, including agricultural produce. One preferred
container includes a
bottom wall, opposite sidewalls, opposite end walls, and an open top. Stacking
tabs on the
upper edges of the side and/or end walls engage in slots or openings in the
bottom of another
tray when the trays are stacked on top of one another to achieve stacking
stability. These
trays offer good stacking strength and stability, and provide excellent
product presentation
due to the open top, and the side panel surfaces that permit display of
graphics and the like.
Further, recent improvements to these trays have included inwardly inclined
side or end panels
with correspondingly inclined stacking tabs to provide greater resistance to
nesting or
telescoping of stacked trays, and to allow units to be easily palletized.
Typically, these trays are formed from a single blank of corrugated paperboard
scored
with score lines or cut lines, and folded into a finished tray by automated
machines or by
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hand. Machine forming can be accomplished in a continuous in-line process
involving cutting,
scoring and folding the trays from continuous sheets of paperboard. In order
to achieve a
desired stacking strength in conventional produce trays, different weights
(thicknesses) of
material are used in the construction of the tray.
Conventional produce trays have inner and outer side wall panels that form
square outer
corners and angled or diagonal inner corners. The diagonal inner corners
extend into the tray
interior space and limit to a certain extent the type, style or number of
clamshell grape lugs, for
example, that can be placed in the tray.
It would be desirable to have a tray with the advantages of the conventional
produce
tray, but that utilizes less material in its construction through further
reduction in material in
the indexing wall flap thus reducing the size of the blank. A final desirable
objective is
improved production and runnability in manufacture of a tray.
SUMMARY OF THE INVENTION
The present invention is a produce style tray with improved stacking strength
and
increased interior space, while requiring less material to make than prior art
trays. The tray of
the invention has inner and outer wall panels that form diagonal comers both
inside and outside
the tray. In one embodiment, the diagonal corner is single ply and is formed
on an outer side
wall panel, thus increasing the interior space of the tray while maintaining
the diagonal corner
configuration, and in another embodiment the inner and outer wall panels each
has diagonal
corner panels, thus forming double ply diagonal corners. A plurality of
indexing stacking tabs
are provided which extend above the transition between the respective inner
and outer wall
panels. Additional embodiments are obviously contemplated and included in
variations of the
disclosed embodiments.
The trays according to preferred embodiments of the invention are formed from
blanks
of corrugated paperboard cut and scored to form a bottom panel with an end
wall panel
foldably joined to opposite end edges thereof. Opposite outer side wall panels
are foldably
joined to the opposite side edges of the bottom panel, and an inner side wall
panel is foldably
joined to the outer or upper edge of each outer side wall panel. A minor flap
is foldably joined
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along a pair of spaced apart fold lines to each of the opposite ends of at
least the outer side wall
panels. These minor flaps comprise sealing flaps that are secured relative to
respective end
wall panels, and the spaced apart fold lines of each minor flap define between
them diagonal
corner panels in the erected tray.
In one embodiment, diagonal corner panels are formed only in the outer side
wall
panels. Provision of the diagonal comer panels in the outer side wall panels
moves the
diagonal corner panels farther out relative to the interior of the tray, thus
increasing the interior
space over that available in conventional produce trays, wherein the diagonal
corner panels are
formed on the inner wall panels. Additionally, the outer side wall panels may
be devoid of
minor flaps extending from their ends, reducing the amount of material
required to produce the
tray.
In another embodiment, minor flaps are foldably joined along pairs of spaced
apart fold
lines to opposite ends of both the inner and outer side wall panels, forming
diagonal comer
panels on both the inner and outer side wall panels, resulting in double ply
diagonal corners.
This construction permits a lighter weight material to be used in forming the
tray, while
achieving the same strength as obtained in conventional trays that require a
heavier weight
material.
In both embodiments and other disclosed variations, at least the bottom edges
of the
minor flaps can extend at an acute angle relative to the bottom edges of the
respective side wall
panels, whereby when the panels are folded to form an erected tray, the side
walls are inwardly
inclined, or lean in at their top edge, thus defining a smaller footprint at
the top of the tray than
at the bottom and helping to prevent an upper tray from telescoping or nesting
into a lower tray
when the trays are stacked on top of one another.
Additionally, the stacking tabs formed through cut-out portions on the upper
edges of
the side and/or end walls extend coplanar with the respective side and/or end
wall, i.e., the
stacking tabs are inwardly inclined or lean in at the same angle as the
respective side and/or
end wall, and are adapted to be received in and captured by tab receiving
slots or openings in the
bottom of another tray. In some embodiments, the stacking or indexing tabs
project upwardly
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from an upper edge of at least one of the side walls and end walls wherein
each of the indexing
tabs is flanked on either side (i) by a relatively short hinging transition
extending along the fold
line between inner and outer panels of the respective side or end walls, and
(ii) by a cut
extending between the relatively short hinging transitions on facing sides of
the indexing tabs
and by cuts extending from the hinging transitions on opposite sides of the
indexing tabs to the
ends of the inner and outer panels, defining cut edges extending transverse to
the flute run
direction and being above the level of the hinging transition. The use of cuts
on the indexing
tabs provide a hinging region that skirt either side of the cuts and provide
pop-up-type indexing
tabs. Depending on the form of a cut, the tabs are retained against the
indexing wall upon setup
and use. In one embodiment, a single ply internal stack tab is formed. By
reversing the direction
of the cut, an external, single-ply stack tab is formed. A "t"-shaped cut
provides for a key
portion or locking portion that can be tucked in-between the respective side
or end wall flaps
upon folding. A more straight line cut provides for a straighter tab portion
that can be folded
upon itself and a portion glued or otherwise attached to the remaining tab
portion or well such
that the tab projects above the transition of the respective side or end wall
flaps.
In a preferred construction, bendable tongues project into the tab-receiving
slots from
one side thereof and help define a friction lock mechanism to hold the
stacking tabs in the slots.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing, as well as other objects and advantages of the invention, will
become
apparent from the following detailed description when taken in conjunction
with the
accompanying drawings, wherein like reference characters designate like parts
throughout the
several views, and wherein:
FIG. 1 is a plan view of a blank for making a first embodiment of a tray in
accordance
with the invention;.
FIG. 2 is a plan view of a blank for making a second embodiment of a tray in
accordance with the invention;
FIG. 3 is a plan view of a blank for making a third embodiment of a tray in
accordance
with the invention;
FIG. 4 is a top perspective view of a tray according to the first embodiment
of the
invention;
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FIG. 5 is a top perspective view of a tray according to the second embodiment
of the
invention;
FIG. 6 is a partial top-side perspective close up view of the tab structure
according to
the third embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Like numerals used herein in reference to different embodiments refer to like
elements.
Referring first to FIG. 1, a blank 10 for producing a conventional produce
tray has a
bottom panel 11, outer side wall panels 12 and 13 foldably joined along fold
lines 14 and 15
to opposite side edges of the bottom panel, inner side wall panels 16 and 17
foldably joined
along a first line to the outer or upper edge of the outer side wall panels,
end wall panels 18
and 19 foldably joined along fold lines 20 and 21 to opposite ends of the
bottom panel, and
locking roll-over panels 22 and 23 foldably joined to the outer or upper edges
of the end wall
panels by spaced apart fold lines 2 and 4 . Minor flaps 24 and 25 are foldably
joined to
opposite ends of each of the outer side wall panels along spaced apart fold
lines 6 and 8, and
minor flaps 27 and 28 are foldably joined to opposite ends of each of the
inner side wall
panels along pairs of spaced apart fold lines 29 and 30.
The blank illustrated in FIG.1 is shown for use in hand set-ups of the
assembled
container or tray made from the blank. Locking tabs 34 project from one side
edge of the
minor flaps 27 and 28, and corresponding locking tabs 35 project from one side
edge of minor
flaps 24 and 25. These side edges correspond to the bottom sides of the minor
flaps in an
erected tray. In addition, locking tabs 36 and 37 project from opposite ends
of the free edge
of each of roll-over panels 22 and 23. These locking tabs may or may not be
omitted in
machine set-up versions of this blank embodiment.
In the blank embodiment illustrated in FIG. 1, cuts 100 are made in the
material of the
inner and outer side wall panels, on one side of the fold line between them,
leaving
connecting webs that form stacking or indexing tabs 47 and 49 in a tray
erected from the
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blank. The direction of the cuts 100 and thus on which side of the fold line
they fall determines
whether the stacking tabs 47, 49 are formed on the inner side panels 16,17 or
the outer side
panels 12,13, depending upon the preference of the user. Separating the inner
and outer side
wall panels are cuts 101 which leaves hinging regions 102 skirting on either
side of the cuts 100
that provide the indexing pop-up projection. In a preferred form, axially
outwardly of the
endmost hinging region, a cut extends from between the inner and outer side
wall panels to
between the minor flaps 24, 27 and 25, 28, respectively, leaving an exposed
cut face provided.
Stacking tab-receiving openings 51 and 52 are formed in the bottom panel at
opposite
sides thereof adjacent to or contiguous with the fold lines 14 and 15 for
receiving the stacking
tabs on a subjacent tray when the trays are stacked on top of one another.
Locking tab-receiving slots or openings 38 and 39 are provided in the bottom
panel
closely adjacent to or contiguous with the respective fold lines 21 and 22 at
opposite ends of the
bottom panel, in positions to receive the locking tabs 34, 35 on the minor
flaps and locking tabs
36, 37 on the roll-over panels 22, 23 when the panels are folded into
operative erected position.
These locking tabs and slots function to hold the tray in its erected
position.
Bendable tongues 53 project into the openings 51 and 52 from the side thereof
opposite
the respective fold lines 14 and 15 and with the openings and stacking tabs
form a friction
locking mechanism that securely but releasably holds the stacking tabs in the
openings.
Crushed areas 54 may be formed in the material of the blank along the side of
the openings 51
and 52 opposite the side from which the tongues project, to provide additional
clearance for
stacking tabs extended into the openings.
Short relief cuts 60 preferably are made in the material of the blank along
opposite sides
of all the openings 51, 52 formed in the bottom panel, defining somewhat
flexible or bendable
tabs or tongues 53 in each of these openings to facilitate insertion of the
locking tabs into the
openings.
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Referring to FIGS. 1 and 4, To erect a tray from a blank, the panels 16 and 17
are folded
upwardly and inwardly to lie against the respective panels 12 and 13, and
these combined panels
are folded upwardly about respective fold lines 14 and 15 into an upright
position. The minor
flaps 24, 25 and 27, 28 are then folded inwardly about their respective fold
lines 6, 8 and 29, 30,
and the end wall panels 18 and 19 are then folded upwardly against the minor
flaps, followed by
folding the locking roll-over panels 22 and 23 inwardly and downwardly over
the minor flaps,
with the locking tabs 36 and 37 engaged in the openings 38, 39, with the minor
flaps sandwiched
between the end wall panels 18, 19 and the roll-over panels 22, 23.
It will be noted that the outermost fold line 29 of the pair of fold lines
joining minor flaps
27 and 28 to their respective inner side wall panels extends at a slight acute
angle relative to the
length axis of the respective side wall panels, and the outer fold line 8
joining minor flaps 24 and
25 to their respective outer side wall panels extend at a corresponding angle,
whereby each of the
minor flaps 24, 25, and 27, 28 extend at a slight acute angle relative to the
length axis of the
respective side wall panels when the minor flaps are inwardly folded.
Accordingly, when the
panels are all folded into their operative erected positions, the side wall
panels are slightly
inwardly inclined toward their upper edge.
It will also be noted that in example illustrated in FIGs. 1 and 4, the end
wall panels 18
and 19 and the associated roll-over panels 22 and 23 have less height than the
side wall panels
12, 13 and 16, 17, and the minor flaps 24, 25, 27 and 28 have recessed areas
or cut-outs 65, 66 in
their upper edges where the roll-over panel engages them. This construction
provides a
ventilation opening 70 in the upper edge of the end walls, as seen in FIG. 4.
Equal sized end
wall panels and side wall panels may of course be used.
Shallow cuts 41 and 42 are made in the outer free edge of inner side wall
panels 16 and
17 to provide clearance for the stacking tabs on a subjacent tray when the
trays are stacked on
top of one another.
A second embodiment of a blank for making a tray according to the invention is
illustrated in FIG. 2. This blank differs from that previously disclosed in
FIG. 1 in that the
stacking tabs 147, 149 are formed by generally trapezoidal or rectangular cuts
155 that span from
the outer side panels 12,13 through inner side panels 16,17 and the respective
fold lines between
such panels. As can be seen, each stacking tab 147, 149 is bisected and thus
further comprises
ascending portions 160, 164 and descending portions 162, 166, respectively.
Referring to FIG.
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5, when the tray is erected by folding the panels of the blank into their
operative positions,
generally as discussed above, ascending portions 160, 164, rise above the
transition between the
inner and outer panels. The descending portions 162, 166 are then fold down
from the ascending
portions and into gaps 170 formed in the inner side walls through the creation
of the stacking
tabs in the blank. The descending portions are then adhered or otherwise
attached to the inner
surface of the respective outer side walls, as shown in FIG. 5. One will note
that roll over
panels 22 and 23 are not shown in FIGS. 2 and 5, but may be used in this
embodiment.
The third embodiment of a blank for making a tray according to the invention
is
illustrated in FIG. 3. This third embodiment is a variation of the second
embodiment and
differs from that previously disclosed in FIG. 2 in that the stacking tabs
247, 249 are formed by
generally T-shaped cuts 255 that span from the outer side panels 12,13 through
inner side panels
16,17 and the respective fold lines between such panels. As can be seen, each
stacking tab 147,
149 is bisected and thus further comprises ascending portions 260, 264 and
descending and
locking portions 262, 266, respectively. Referring to FIG. 6, when the tray is
erected by folding
the panels of the blank into their operative positions, generally as discussed
above, ascending
portions 260, 264, rise above the transition between the inner and outer
panels. The descending
portions 262, 266 are then folded down from the ascending portions and into
gaps 270 formed in
the inner side walls through the creation of the stacking tabs in the blank.
The locking
extensions 268 of the descending portions inserted and retained between the
inner and outer side
panels, as shown in FIG. 6. One will again note that roll over panels 22 and
23 are not shown in
FIGS. 3 and 6, but may be used in this embodiment.
The stacking tabs can be positioned on either the end panels or the side
panels and
either the side walls or the end walls can be inwardly inclined. Further, the
tray can be sized to
be modular (half-sized or full sized) to allow interlocking with other trays
that have stacking
tabs properly positioned. The tray also can be made in various sizes
(footprints) to
accommodate two tabs per side or end or one tab per side or end.
The disclosed container also may have either a fully-lidded or partially-
lidded feature
that allows ventilation and/or access of goods contained therein to the
consumer and protects
the goods at the same time while in transport and/or during stacking, as
disclosed in co-pending
U.S. Patent Application Serial No. 11/495,147, having a publication number
2007/0051789
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In other embodiments, the width of the side and end walls, as well as the
major and
minor flaps may be smaller or larger than what is described herein. If larger,
then the inside
space of the constructed tray/container/packaging system would increase in
volume. One
example of such a conventional tray/container/packaging system is represented
in US
Published Patent Application 2006-0091194 having USSN 11/303,898, filed
November 19,
2005.
It should be noted that the walls (end or side) of the disclosed embodiments
of the
tray/container may contain more than one end panel and/or more than one minor
flap panel
and/or more than one major flap panel and/or more than one side wall panel
folded therein, as
well as any combinations thereof to form a multi-layered wall configuration.
The multilayered
or multiwalled end wall may have at least two walls, preferably three or more.
Further,
portions of the walls may be multiwalled, while other portions are single
walled structures. In
addition, the end walls may be longer and/or wider than the side walls.
Further, end wall
panels may be longer and/or wider than the side wall panels. Further, the side
walls may be
longer and/or wider than the end walls. Further, side wall panels may be
longer and/or wider
than the end wall panels. Accordingly, the relative length and width of the
side and end walls
may be of any relative length and width.
Further, while not required, it is preferred that the blank/tray/container
have vent holes
located therein. For example, at least one vent hole can be located in a side
wall of one
embodiment of a blank according to the present invention, at least one vent
hole can be located
in the side walls of one embodiment of a tray/container according to the
present invention. The
location, position, size and geometry of the vent hole within the
blank/tray/container may vary
greatly and in any manner so long as it does not destroy the operability of
any one or more of
the embodiments of the present invention
Pop up type indexing projection which extends above the transition between the
first
and second indexing wall flaps in the erected container could alternatively be
a different form
such as that utilized by a number of companies where an even greater cut out
has part thereof
folded back and adhesively or otherwise reattached to some part of the
indexing wall.
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