US20250289612A1

US20250289612A1 - Packaging Tray

Info

Publication number: US20250289612A1
Application number: US18/608,026
Authority: US
Inventors: Nolan David Peterson
Original assignee: Delkor Systems Inc
Current assignee: Delkor Systems Inc
Priority date: 2024-03-18
Filing date: 2024-03-18
Publication date: 2025-09-18

Abstract

A tray has a base, a right sidewall, a left sidewall, front end wall and a rear end wall. Each sidewall is positioned along opposite sides of the base, each end wall along the remaining sides, Right and left sidewalls include front and rear side flaps. A portion of the front side flap is engaged to a portion of the front end wall and a portion of the rear side flap is engaged to a portion of the rear end wall. Each sidewall includes a top flap extending from its top and over the each of the side flaps. The top flaps each include a front wing and a rear wing, wherein a portion of the front wing is engaged to a portion of the front side flap, and a portion of the rear wing is engaged to a portion of the rear side flap.

Description

BACKGROUND OF THE DISCLOSURE

Embodiments described herein are directed to packaging trays suitable for the shipping and retail display of product items contained within the packaging tray, as well as the blank from which the packaging tray is assembled, and the method for folding and assembling the packaging tray from the blank.
Trays and cartons to ship and display articles are known. Typically, these tray are formed from at least one blank of corrugated paper/fiber board which is suitably shaped, such as by folding, and assembled into a box suitable for containing products for transport and shipping. Such tray are often configured such that they are not only suitable for the shipping of articles contained therein, but to display those articles once placed in a retail setting, such as on the shelf of a display.
The requirements of providing the tray with sufficient strength durability to accommodate the conditions associated with shipping (e.g., palletization or stacking of the trays, containment and protection of the goods within the tray, etc.) while also providing a tray suitable for retail use (e.g., configured to allow the products contained within the tray to be visible and accessible to the consumer), result in trays that often utilize excessive amounts of packaging material (specifically, of corrugated paper/fiber board) to meet these diverse requirements. While such trays may be functional in their dual roles, because of their excessive use of corrugated, they tend to be expensive.
Accordingly, it is desirable to provide a tray that makes efficient, if not minimal, use of packaging material, while being sufficiently rugged to act as a shipping container, while also having an accessible form which allows it to perform equally well as a retail display. Embodiments shown in the figures and described herein are directed to such a tray and the blank from which the tray is assembled.

SUMMARY

A product tray is shown and described herein which has a base upon which multiple product items may be contained. The tray has a pair of vertical sidewalls that have sufficient height to allow product items to be stacked within the tray while being contained therein, and sufficient columnar strength to allow multiple trays to be stacked one atop the other during shipping as well as in the retail setting. The tray includes front and rear end walls which are lower in vertical height than the sidewalls, which results in the interior of the tray, and the product items contained therein to be largely exposed and easily accessible from the front, rear and top of the tray, while providing sufficient definition to secure product items within the confines of the tray interior.
In at least one embodiment, the tray includes inserts that may be used to provide additional columnar strength to the vertical sidewalls.
In at least one embodiment the tray is assembled from a single blank of packaging material such as corrugated paper/fiber board; each insert is formed from a separate blank.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of a shipping and display tray assembled from a single blank of packaging material.

FIG. 2 is a top-down view of the blank used to assemble the tray of FIG. 1 .

FIG. 3 is a top-down view of the blank shown in FIG. 2 with adhesive shown applied to select locations of the inside surface of the blank.

FIG. 4 . is a top-down view of the blank shown in FIG. 2 with adhesive shown applied to select locations of the outside surface of the blank.

FIG. 5 is a perspective view of the blank shown in FIGS. 2-4 , showing a first step in the folding process that will lead to the assembled tray shown in FIG. 1 .

FIG. 6 is a perspective view of the blank shown in FIGS. 2-5 , showing a second step in the folding process that will lead to the assembled tray shown in FIG. 1 .

FIG. 7 is a perspective view of the blank shown in FIGS. 2-6 , showing a third step in the folding process that will lead to the assembled tray shown in FIG. 1 .

FIG. 8 is a perspective view of an alternative embodiment of the tray shown in FIG. 1 , which incorporates supplemental inserts; each insert being formed of a separate blank, the insert blanks being shown unfolded.

FIG. 9 is a perspective view of the embodiment shown in FIG. 8 , wherein the insert blanks are shown in their formed or unfolded state.

FIG. 10 is a perspective view of the embodiment shown in FIG. 9 , wherein the insert blanks are shown in their folded state, but prior to insertion onto the tray base.

FIG. 11 is a perspective view of the embodiment shown in FIG. 10 , wherein the folded inserts are shown prior to being positioned within the interior of the tray.

FIG. 12 is a perspective view of the embodiment shown in FIG. 9-11 , wherein the inserts are shown positioned within the interior of the completed tray.

DETAILED DESCRIPTION

With initial reference to FIG. 1 , a tray 10 constructed in accordance with the goals described above is shown. In general, tray 10 includes a four sided base 12, which is surrounded on opposite sides by a right sidewall 14 and a left sidewall 16, with a front end wall 18 and a rear end wall 20 on correspondingly opposite sides of the tray 10 and extending between the sidewalls 14 and 16.
The sidewalls 14 and 16 extend vertically from the base 12 to a first height h1. End walls 18 and 20 extend vertically from the base 12 to a second height h2 that is less than the first height h1. By differentiating the height of the sidewalls 14 and 16 from the height of the end walls 18 and 20 in this manner, the interior 22 of the tray 10 is made more easily accessible by the end user (not shown).
As mentioned above, the tray 10 is assembled from a single (first) blank 11 of packaging material, such as corrugated paper/fiber board, an example of which is shown in FIGS. 2-4 . The folding/assembly sequence for assembling the tray 10 from blank 11, is shown in FIGS. 5-7 .
Turning to FIGS. 2-4 , the components or panels of the blank 11 are shown prior to assembly of the blank 11 into tray 10. Each of the blank 11 panels are separated by fold lines 24 a-24 j. As an example, the base 12 is a panel having four sides, each of which is defined by a fold line 24 a, 24 b, 24 c and 24 d. Along opposite (right and left) fold lines 24 a and 24 c are positioned the right sidewall 14 and a left sidewall 16. Positioned between the sidewalls 14, and 16 and along the remaining opposite fold lines 24 b and 24 d, extend the front end wall 18 and a rear end wall 20 respectively.
Each of the sidewalls 14 and 16, are like the base 12, a panel having four sides, each of which is defined by a fold line (24 e, 24 f, 24 g), one which (24 a or 24 c) is shared with the base 12. Along fold lines 24 e and 24 f, on opposite sides of the sidewall panel, extend a front side flap 26 and a rear side flap 28 respectively. Along fold line 24 g, opposite the fold line (24 a or 24 c) shared with the base 12, is a top flap 30.
Each of the side flaps 26 and 28 has three exposed edges, which are not shared by other components of the blank 11: a first edge 32, a second edge 34, and a third edge 36 that extends between the first edge 32 and the second edge 34. The first edge 32 has a first length 32 a and the second edge 34 has a second length 34 a; the first length 32 a is smaller/shorter than the second length 34 a. The third edge 36 has a third length 36 a; the third length 36 a is greater/longer than either the first length 32 a and second length and 34 a. In some embodiments, the third length 36 a is greater than both the combined lengths 32 a and 34 a of the first edge 32 and second edge 34.
As mentioned above, adjacent to each side flap 26 and 28, a top flap 30 is positioned along fold line 24 g, opposite the fold line (24 a or 24 c) that is shared with the base 12. In the embodiment shown, each top flap 30 is a four sided component defined on three sides by fold lines 24 g, 24 h, and 24 i, and a top edge 37. In at least some embodiments, the top edge 37 extends along the top flap 30 and is parallel to and opposite fold line 24 g. In some embodiments the top edge 37 may define one or more convex or concave curves relative fold line 24 g and/or may define a regular or irregular geometric pattern (e.g., a sawtooth pattern, one or more elongate tabs, etc.).
A front wing 38 extends from the top flap 30 along fold line 24 h and a rear wing 40 extends from fold line 24 i. Each of the wings 38 and 40 has three exposed edges, which are not shared by other components of the blank 11: a first edge 42, a second edge 44, and a third edge 46 that extends between the first edge 42 and the second edge 44. In the embodiment shown, first edge 42 and second edge 44 each form an obtuse angle with the third edge 46, and taper outward until they intersect with fold line (24 h or 24 i), such that each wing 38 and 40 form a tongue shaped panel. In at least one embodiment, one or both wing 38 and 40 have an isosceles trapezoidal shape.
Returning now to the front end wall 18 and the rear end wall 20, as may be seen in FIG. 2 , a portion of each end wall 18 and 20 includes a fold line 24 j, from which an end wall flap 48 extends. In at least some embodiments, each end wall flap 48 has a length 50, which is less than the length 52 of the front end wall 18 and the rear end wall 20, respectively. In some embodiments, length 50 and length 52 may be the same.
Each end wall flap 48 defines at least one base engagement tab 56. Each base engagement tab 56 is configured to be received into and engaged a base tab opening 58 defined by the base 12. In some embodiments, each base tab opening 58 is positioned within the base 12 and immediately adjacent to the respective end wall 18 and 20 from which the flap 48 extends. In some embodiments the fold line 24 b and/or 24 d are interrupted by one or more base tab openings 58.
As is best shown in FIGS. 2-4 , each engagement tab 56 has a size and shape corresponding to the size and shape of the base tab opening 58. During assembly of the tray 10 shown in FIG. 1 , according to the folding steps shown in FIGS. 5-7 , when the end wall flap 48 is folded along fold line 24 j, over the corresponding front end wall 18 or the rear end wall 20 and toward the base 12, each engagement tab 56 will engage a tab opening 58 to secure the end wall flap 48 against the respective end wall 18 or 20 and retain the flap 48 in the folded configuration of the tray 10.
Embodiments of tray 10/blank 11 may include engagement tabs 56 of any size, shape, configuration, or number; base tab openings 58 are provided in corresponding numbers and configurations.
Turning now to FIGS. 3 and 4 , it may be seen that in at least some embodiments, assembly of the tray 10 shown in FIG. 1 , requires use of discrete portions of adhesive 60 prior to the folding of the blank 11 into the tray 10. As shown in FIG. 3 , adhesive 60 is applied to application regions 62 of the inside or interior surface 64 of each of the front end wall 18 and rear end walls. In FIG. 4 , discrete portions of adhesive 60 are applied to application regions 66 of the outside or exterior surfaces 68 of each of the front side flaps 26 and rear side flaps 28.
As is depicted in the folding/assembly sequence of FIGS. 5-7 and 1 , in the initial folding step shown in FIG. 5 , the following folding steps occur:
Front end wall 18 is folded vertically along fold line 24 b in a vertically upward direction and toward rear end wall 20, and rear end wall 20 is folded vertically along fold line 24 d in a vertically upward direction and toward front end wall 18. In at least some embodiments, the end walls 18 and 20 will be substantially perpendicular to base 12 when in the folded tray configuration shown in FIG. 1 .
The right sidewall 14 and left sidewall 16 of the blank 11, are folded vertically relative to the base 12 along their respective fold lines 24 a and 24 c. Each of the front side flaps 26 and rear side flaps 28 are folded inward along fold lines 24 e and 24 f respectively.
As a result of such folding, such as is shown in FIGS. 5 and 6 , the application regions 62, as well as the discrete portions of adhesive 60 applied thereto of the front end wall 18 (shown in FIG. 3 ) will come into contact with a portion of each front side flap 26, and the application regions 62, as well as the discrete portions of adhesive 60 applied thereto of the rear end wall 20 (also shown in FIG. 3 ) will come into contact with a portion of each rear side flap 26.
As a result of the presence of the adhesive 60, each of the front side flaps 26 will be adhesively engaged to the front end wall 18, and each of the rear side flaps 28 will be adhesively engaged to the rear end wall 20 in the manner shown in FIGS. 6-7 .
As shown in the sequence of FIG. 6 and FIG. 7 , once the side flaps 26 and 28 are adhered to the end walls 18 and 20 respectively (in the manner shown in FIG. 6 ), the front and rear end wall flaps 48 are folded along fold line 24 j over the respective front end wall 18 and rear end wall 20, in the manner described above and the engagement tabs 56 (not visible in FIG. 7 ) are received into the tab openings 58.
In the final folding step shown in the transition of FIG. 7 to FIG. 1 , each of the top flaps 30 are folded along fold lines 24 g toward one another and vertically downward so that each top flap 30 intersects with one of each of the front side flaps 26 and rear side flaps 28. Each of the front wings 38 are folded along fold lines 24 h downward over the application regions 66 of a front side flap 26, and each of the rear wings 40 are folded along fold lines 24 i downward over the application regions 66 of a rear side flap 26. The adhesive 60 present on the application region 66 of each front side flap 26 will result in a front wing 38 being adhesively secured thereto; likewise each rear side flap 28 will be adhesively engaged to a rear wing 40 in the manner shown in FIG. 1 .
In some embodiments of the tray 10, it may be desirable to provide vertical reinforcement to the sidewalls 14 and 16. For example where multiple trays are to be stacked or palletized, trays having reinforced sides may allow more trays to be vertically stacked upon one another than trays without such reinforcement. As such, tray 10 shown in FIG. 1 may be provided with a right side insert 70 and a left side insert 72 in the manner shown in FIGS. 8-12 .
Where a reinforced tray is desired, before the final folding step is completed right side insert 70 and left side insert 72 are placed against the right sidewall 14 and left sidewall 16 respectively, such as in the manner shown in FIG. 8 . Once the inserts are in position, the final folding step of securing the wings 38 and 40 to the side flaps 26 and 28, as already described is competed to provide the reinforced tray 10 shown in FIG. 12 .
FIGS. 9-11 illustrate in more detail the assembly of the inserts 70 and 72 and the manner in which they are inserted and oriented with the interior 22 of the tray 10/blank 11.
Each of the inserts 70 and 72 (shown in FIGS. 8 and 12 ) are each assembled from a single blank 13 and 15 of packaging material, such as corrugated paper/fiber board. In some embodiments, blanks 13 and 15 are manufactured of the same type of manufacturing material as blank 11. In some embodiments, blank 13 and 15 are manufactured of a packaging material that is different and/or has different material properties than the packaging material of blank 11 (e.g., greater rigidity or improved crush resistance).
Each insert blank 13 and 15 is made up of three panels, consisting of a central support member 74, a front support pillar 76 and a rear support pillar 78. The central support member 74 is a four sided polygon such as a square or rectangle. Two of the four sides of the central support member 74 are defined by a top edge 80, and a bottom edge 82. The remaining two sides are defined by fold lines 24 k, each of which extend between top edge 80 and bottom edge 82. The central support member 74 also defines an exterior surface 84 and an interior surface 86 (visible in FIG. 11 ).
Extending between top edge 80 and bottom edge 84, along the fold lines 24 k, and opposite one another are front support pillar 76 and rear support pillar 78.
The blanks 13 and 15 are assembled into the inserts 70 and 72, respectively, by first folding each of the front support pillar 76 and rear support pillar 78 along a fold line 24 k in a vertically upward direction toward the exterior surface 84, in the manner shown in FIG. 10 .
Next, each blank 13 and 15 is placed in a vertically upright position shown in FIG. 11 , wherein the interior surface 86 of each blank 13 and 15 is facing that of the other. The inserts 70 and 72 are then placed onto the base 12 within the interior 22 of the blank 11 (incomplete tray 10) against a respective right sidewall 14 and left sidewall 16, such that each front support pillar 76 is immediately adjacent to one of the front side flaps 26, and each rear support pillar 78 is immediately adjacent to one of the rear side flaps 28 and the interior surface 86 of each insert 70 and 72 face one another within the interior 22 of the tray 10 in the manner shown in FIGS. 8 and 12 . As has already been described, once the inserts 70 and 72 are positioned within the interior 22 of the tray 10 in this manner, the final folding step of securing the wings 38 and 40 to the side flaps 26 and 28, is competed to provide the reinforced tray 10 shown in FIG. 12 .
In at least one embodiment, when the inserts 70 and 72 are positioned within the interior 22 of the tray 10 in the manner shown in FIGS. 8 and 12 , the central support member 74 of insert 70 stands substantially parallel to the central support member 74 of insert 72.
As an alternative to the assembly sequence shown in FIGS. 9-11 , in some embodiments, the inserts 70 and 72 may be placed into position within the interior 22 of the tray 10 after the final folding step of the blank 11 has been completed. Looking to the completed tray of FIG. 1 , the assembled right sidewall 14, front side flap 26, rear side flap 28 and top flap 30 form a right side alcove 88. Similarly, the assembled left sidewall 16, front side flap 26, rear side flap 28 and top flap 30 form a left side alcove 90. Insert 70 may be positioned within alcove 88 in the same manner as previously described, and so to insert 72 within alcove 90 to form the completed reinforced tray 10 shown in FIG. 12 .
The many features and advantages of the invention are apparent from the above description. Numerous modifications and variations will readily occur to those skilled in the art. Since such modifications are possible, the invention is not to be limited to the exact construction and operation illustrated and described. Rather, the present invention should be limited only by the following claims.

Claims

What is claimed is:

1. A tray formed from a blank of a packaging material, the tray comprising:

a base, the base having four sides, each side defining a fold line,

a right sidewall and a left sidewall, each sidewall positioned along opposite sides of the base and extending vertically from one fold line, and

a front end wall and a rear end wall, each end wall positioned along opposite sides of the base and extending vertically from one fold line;

each of the right sidewall and the left sidewall having two vertical sides and a top side, each vertical side and each top side defining a fold line, each of the right sidewall and the left sidewall having a front side flap and a rear side flap, the front side flap and the rear side flap each extending from one of the vertical sides, a portion of the front side flap being engaged to a portion of the front end wall and a portion of the rear side flap being engaged to a portion of the rear end wall,

each of the sidewalls having a top flap extending from the top side and over the front side flap and the rear side flap, the top flap having two horizontal sides, each horizontal side defining a fold line, the top flap having a front wing and a rear wing, the front wing and the rear wing each extending from one of the horizontal sides, a portion of the front wing being engaged to a portion of the front side flap, and a portion of the rear wing being engaged to a portion of the rear side flap, and

each of the front end wall and the rear end wall having a top edge, a portion of each top edge defining a fold line, a front end wall flap extending from the portion of the top edge defining the fold line of the front end wall, a rear end wall flap extending from the portion of the top edge defining the fold line of the rear end wall, each of the front end wall flap and the rear wall flap defining at least one base engagement tab, the at least one base engagement tab being engaged to an engagement tab opening defined by a portion of the base.

2. The tray of claim 1 further comprising a right side insert and a left side insert, each of the inserts comprising a central support member, a front support pillar and a rear support pillar,

the central support member having four sides, an interior surface and an exterior surface, two of the four sides defining a first fold line and a second fold line, the first fold line and the second fold line being on opposite sides of the central support member, the front support pillar extending from the first fold line, the rear support pillar extending from the second fold line.

3. The tray of claim 2, wherein the right sidewall, the front side flap, the rear side flap, and top flap of the right sidewall define a right side alcove over the base; and

the left sidewall, the front side flap, the rear side flap, and top flap of the left sidewall define a left side alcove over the base;

the right side insert being positioned within the right side alcove, and the left side insert being positioned within the left side alcove.

4. The tray of claim 3, wherein each central support member has an interior surface and an exterior surface, the interior surface of the right side insert and the interior surface of the left side insert facing each other.

5. The tray of claim 4, wherein the exterior surface of the right side insert is positioned adjacent to and parallel with the right sidewall, the exterior surface and the right sidewall forming a gab therebetween; and

the exterior surface of the left side insert is positioned adjacent to and parallel with the left sidewall, the exterior surface and the left sidewall forming a gab therebetween.

6. The tray of claim 1, wherein the portion of the front side flap is adhesively engaged to the portion of the front end wall, and the portion of the rear side flap is adhesively engaged to the portion of the rear end wall.

7. The tray of claim 1, wherein the portion of the front side flap is adhesively engaged to the portion of the front end wall, and the portion of the rear side flap is adhesively engaged to the portion of the rear end wall.

8. A blank of packaging material for forming a tray, the blank comprising:

a base, the base having four sides, each side defining a fold line,

a right sidewall and a left sidewall, each sidewall positioned along opposite sides of the base, and

a front end wall and a rear end wall, each end wall positioned along opposite sides of the base and extending between the right sidewall and left sidewall, an intersection of the front end wall and the base defining at least one front engagement tab opening, and an intersection of the rear end wall and the base defining at least one rear engagement tab opening,

each of the right sidewall and the left sidewall having two opposing sides and a top side, each opposing side and each top side defining a fold line, each sidewall having a front side flap and a rear side flap, the front side flap and the rear side flap each extending from one of the opposing sides,

each of the front side flap and the rear side flap being defined by a first edge, a second edge and a third edge extending between the first edge and the second edge, the first edge having a first length, the second edge having a second length and the third edge having a third length, the first length being smaller than the second length, the second length being smaller than the third length,

each of the sidewalls having a top flap extending from the top side, the top flap having two horizontal sides, each horizontal side defining a fold line, the top flap having a front wing and a rear wing, the front wing and the rear wing each extending from one of the horizontal sides, the front wing extending over and beyond the first edge of the front side flap, the rear wing extending over and beyond the first edge of the rear side flap,

each of the front end wall and the rear end wall having a top edge, a portion of each top edge defining a fold line, a front end wall flap extending from the portion of the top edge defining the fold line of the front end wall, a rear end wall flap extending from the portion of the top edge defining the fold line of the rear end wall, the front end wall flap defining at least on front engagement tab and the rear wall flap defining at least one rear engagement tab.

9. The blank of claim 8, wherein the front wing and the rear wing each have an isosceles trapezoidal shape.

10. The blank of claim 8, wherein the front end wall and the rear end wall each have an isosceles trapezoidal shape.