Abstract:
The invention provides an open topped tray having upright peripheral side and end walls. The end walls are inwardly positioned by use of an inwardly offset score design which permits the optimization of the dimensions of the tray. This scoring technique may be employed in conventional trays designs at minimal cost for stable housing of bottles or other items.

Description:
RELATED APPLICATION 
   This application claims priority from U.S. Provisional Applications Ser. Nos. 60/400,323, filed Aug. 2, 2002 and 60/401,667 filed Aug. 7, 2002. 

   FIELD OF THE INVENTION 
   The present invention relates to a corrugated tray, erected from a unitary paperboard blank, for the holding, stacking and transporting of items such as beverage cans and bottles. In particular, the present invention relates to a corrugated tray with inwardly positioned end walls extending upright from centrally located offset score lines in opposing ends of the tray, such that the dimensional space within the tray is optimized, and unwanted shifting of items transported within the tray is minimized. 
   BACKGROUND OF THE INVENTION 
   Corrugated paperboard is typically used in many different applications, for example, to form trays, containers, boxes, cartons, or dividers for holding, storing, stacking or shipping various items. 
   Frequently, corrugated trays are utilized for holding commercial products, such as beverage bottles and cans, to be shipped to stores, kiosks or non-commercial locations for the sale, display or use of the products. Typically, the bottles and cans are shipped in standard shaped trays that tend to have a high length/width to height ratio, that is, the lengths and widths of the bottom panels are significantly larger than the heights of the attached upright side and end walls, resulting in a tray that is ideally suited for carrying one or a multiplicity of items having a short height. 
   These trays are generally erected from blanks scored with score or cut lines. The blanks are most often scored by automated machines in a continuous in-line process involving cutting, scoring and molding continuous sheets of paperboard. The paperboard is then erected by the automated machine along the score or cut lines to form the tray. Alternatively, the blanks may be erected into a tray by a user or other manual means. The trays may be covered with a removable lid, but are typically used without one. 
   The side and end walls must be held secure on an upright position when the tray is erected. To achieve this, a standard tray has side flaps foldably attached to opposing edges of the side walls. The side flaps fold inward and adhere to an interior portion of the end walls, thereby connecting and stabilizing the side and end walls into position. Generally, in order to save materials and costs, the side flaps only cover a small portion of the interior of the end wall, for example, a portion that is significantly less than one half the length of the end wall. Thus, when the two opposing side flaps of each opposing side wall are attached to an end wall, a gap is left by the end walls between the two side flaps. 
   The addition of side flaps that overlap interior portions of the end walls result in a tray wherein the length between the opposing end walls changes depending on the location within the interior space of the tray. Specifically, the tray has a narrower interior space between the end walls where the side flaps overlap the end walls than the space at the center of the tray where no side flaps are present. This results in an uneven space within the tray that causes items such as bottles and cans to shift in transit, namely the row or rows of items located between the end walls in the center of the tray. 
   The uneven space can potentially be eliminated by attaching the side flaps to an exterior portion of the end wall, thereby having a flat interior within the container. However, this creates an uneven exterior, which can create an unattractive display and has ridges on the outside of the tray that may get caught on other objects, hindering shipment of the goods. Alternatively, the side flaps could be lengthened so that each flap covers about one half of the end wall. Thus, when two opposing side flaps are placed together on the same end wall, the interior gap is eliminated. However, this requires additional raw material and increases production costs. 
   Therefore, it is an object of this invention to provide a tray that optimizes the space within the tray while maintaining cost and shipping efficiency. 
   SUMMARY OF THE INVENTION 
   Accordingly, it is an object of the present invention to provide improvements in a tray design which optimize the tray dimensions for particularly sized items and to stabilize housed items against movement during transport. 
   It is a further object of the invention to provide such stable arrangements in tray structures without the use of excess paperboard or paperboard inserts and associated costs. 
   The present invention provides an improved open-topped tray having upright peripheral side and end walls. A central portion of the opposing end walls is inwardly positioned by use of an inwardly offset central portion of the end score line that permits optimization of the tray dimensions at minimal cost. 
   The tray is formed from a blank having a bottom panel defined by two opposing end score lines and two opposing side score lines, wherein a central portion of each opposing end score line is inwardly offset or positioned. The blank has additional score and cut lines that define opposing end panels, opposing side panels, and side flaps foldably attached to the edges of each of the side panels. The blank is folded and the opposing end and side panels are folded into an upright position, providing the outer walls of the tray. The side flaps fold inward, toward the interior of the tray, and adhere to the interior side of the end panels, holding all upright side and end panels secure. The side flaps line in the same plane as the inwardly offset portions of the end score lines, such that a dimensional space within the interior of the tray is effectively the same between the side flaps on opposing end panels as it is between the inwardly offset central portions of the end score lines at the opposing ends of the tray. Essentially, the inwardly positioned portions of the end score lines move central portions of the end walls inward to fill the gaps between opposing side flaps, equalizing the interior dimensions of the tray. 
   In other embodiments, the erected trays are of dimensions to accommodate beverage bottles or cans arranged in four rows of six or three rows of four. The outer rows of bottles are flanked on the top and bottom by the side flaps adhered to the end walls. The center row or rows of bottles are flanked by the offset score lines and the inwardly positioned end walls. Thus, all rows of bottles are held secure within the space of the tray regardless of which row they are located in. 
   Other objects, embodiments, features and advantages of the present invention will be apparent when the description of a preferred embodiment of the invention is considered in conjunction with the annexed drawings, which should be construed in an illustrative and not limiting sense. 

   
     BRIEF DESCRIPTION OF THE FIGURES/DRAWINGS 
       FIG. 1  is a plan view of a paperboard blank for forming an open topped container having inwardly spaced offset score lines. 
       FIG. 2   a  is a top perspective view of an erected container having end walls inwardly spaced along offset end score lines. 
       FIG. 2   b  is an enlarged, fragmentary perspective view of the interior of one end of an erected container having end walls inwardly spaced along offset end score lines. 
       FIG. 2   c  is a bottom perspective view of the exterior of an erected container having end walls inwardly spaced along offset end score lines. 
       FIG. 3  is a plan view of a paperboard blank having alternate corner cut-outs. 
       FIG. 4  is a plan view of a paperboard blank having arcuate offset end score lines. 
   

   DETAILED DESCRIPTION 
   A paper or paperboard tray in accordance with one embodiment of the invention is shown in  FIG. 1 . Blank  10  is scored for the purpose of folding into an open-topped tray suitable for holding, shipping or stacking a wide variety of objects, such as beverage bottles and cans. The blank is preferably a flat corrugated paper or paperboard made of any material known in the art that is suitable for the shipping and transporting of a particular item. For example, if one were to package heavier materials, a thicker grade may be advisable. 
   Bottom panel  12  is a substantially rectangular panel bordered by end score lines  18 , offset score lines  32  and side score lines  16 . End panels  22  foldably connect to bottom panel  12  along end score lines  18  and offset score lines  32 , and side panels  20  foldably connect to bottom panel  12  along side score lines  16 . The bottom panel may have angled side corners  14  that extend diagonally from the end of score lines  18  to the end of score line  16 . The corners create corner cut-outs  48  between the side flaps  44  and the end panels  22 . In the present invention, panel  12  has a width of 10½ inches between side score lines, a length of 14⅛ inches between the end score lines  18 , and a length of 13¾ inches between inwardly positioned score lines  34 . However, the dimensions of the bottom panel can be customized to any particularly shipped item, and thus can vary significantly while maintaining the spirit of the invention. In other embodiments, holes are provided alongside the score lines to provide breathing holes and access for an automated machine to manipulate and fold the blank into a fully erect tray. 
   Side panels  20  are generally rectangular panels each bordered on four sides by an upper edge  40 , lower score line  16 , and side score lines  24 . Side panels  20  correspond to the side walls when the tray is fully erected. Accordingly, the width of side panels  20  (from score line  16  to outer edge  40 ) in blank  10  generally corresponds to the height of the side walls of the erected tray in  FIGS. 2   a – 2   c . Ideally, the height of the side panels is the same as the height of end panels  22 . In the present example, the width of the side panels is 2⅝ inches, and the height of the erected container is 2 9/15 inches. 
   Side flaps  44  are foldably connected to side panels  20  along opposing score lines  24 . In the present embodiment, each side flap is comprised of two foldably attached sections attached in series. Score lines  24  and  26  define an inner side flap section  28  and an outer side flap section  30 . Inner side flap section  28  is generally rectangular in shape and may include angled corner  42 . Further, the width of the inner section is slightly less than the width of the side panel  20  to facilitate folding of the side flaps inward, over the bottom panel, without encountering resistance. This slight difference is length can vary, but is preferably about ⅛ of an inch. Outer side flap section  30  generally has a longer length and a shorter width than the inner side flap section. As a result of the shorter width, the height of the outer side flap when the tray is erected is slightly less than the side and end walls of the tray. Outer side flap section  30  may also have a tapered bottom edge  54 . 
   Each opposing end panel  22  is bordered on four sides by an upper edge  46 , score line  18 , offset score lines  32 , which comprise of inwardly positioned scores  34  and  36 , and two side edges  48 . The end panels  22  are generally rectangular panels that correspond to end walls when the container is fully erected. Accordingly, the width of end panels  22  in blank  10  generally corresponds to the height of the end wall  22  in an erected container, as seen in  FIGS. 2   a–c . In the present example, the width of the end panel is 2⅝ inches between the upper edge  46  and score line  18 , and 3 inches between the upper edge and score lines  34 . However, the width of the panel, and corresponding height of the erected container, can vary widely within the scope of the invention. For example, the height of the erected tray is preferably between 1 and 4 inches. Other features, such as stacking tabs, may extend outwardly from the top edge of the end or side walls. 
   The score line that foldably connects an end panel  22  with the bottom panel  10  is a generally straight score line  18  with an inwardly offset centrally located score line portion  32 . Angled score lines  36  connect score line  18  with the inwardly offset or positioned score line  34 . Score line  18  forms a typical bending base line about which the end panel folds upright, such that the base line is the base of the end panel and the outermost side edge of the tray bottom. The inwardly positioned score line  34  is positioned inside the base line, slightly shrinking a central portion of the base panel. Correspondingly, the size of the end panel increases an equivalent area. Thus, the base line is altered where the score line is inwardly positioned, advantageously creating a sculpted score line about which the end panel can fold upright. 
   In the present embodiment, the spatial difference between base score line  18  and inwardly positioned score line  34  is ⅜ inches. However, as with the other dimensions of the tray, this can vary within the spirit of the invention. In general, however the difference in thickness should be equivalent to the thickness of the paper or paperboard stock, specifically the side flaps. Thus, the offset score lines offset the thickness of the side flaps when the side flaps are adhered to interior portions of the end walls. 
   The container is erected either manually or by an automated machine. Generally it is done with an automated machine, wherein opposing side panels  20  are simultaneously folded upwards to form side walls  20  along side score lines  16 , score lines  24  are folded such that inner side flap section extends upwardly from angled corners  14 , and the outer side flaps are folded along score lines  26  just inside score lines  18 . Exterior sides of the outer side flap sections should virtually border score lines  18  such that the outer side flap sections generally fill a vertical space that is bordered on two sides by score line  18  and angled score lines  36 . It is important that the edges of outer side flap sections  30  do not extend past angled score lines  36 . 
   After the side flaps are folded, the end panels are folded upward along score lines  18  and offset score lines  32 , forming end walls  18  as seen in  FIGS. 2   a–c . An exterior side of each outer side flaps section  30  is adhered to an interior portions of the end panel along score line  18 , holding the end and side panels secure on an upright formation. Attachment of the side flaps to the end panels may be accomplished using well known hot melt glues, staples, or other fastening techniques, and may be performed by an automated machine or a user. 
   Due to offset score lines  32 , the width of the end panel is greater between upper edge  46  and inwardly positioned score lines  34  and  36  than between edge  46  and score line  18 . However, this extra width in the central portion of the end wall is compensated for with a slight inward curve of the central portion of the end wall, resulting in additional distance traveled. Consequently, the height of the end panel along upper edge  46  is the same for the entire end wall, even though the width of the end panel differs from location to location. Further, due to the combination of the offset score lines and the outer side flap portions, the interior of the tray is effectively equidistant from each other across the entire base of the end wall. 
   One embodiment of the tray as erected is seen in  FIG. 2   a . In this embodiment, the length and width of bottom panel  12  is larger than the height of the side and end walls  20  and  22 , resulting in a thin, open-topped tray that is ideally suited for carrying one or a multiplicity of items having a short height. Further, the corners of the containers are angled, creating a non-equilateral octagon interior and exterior best suited for transporting curved items such as cans or bottles. In other embodiments, however, the angles can be accentuated, minimized, or eliminated to best suit a particularly desired type of item. Further, the dimensions of the tray can change dramatically while still maintaining the spirit of the invention, for example, the height of the end and side walls can be increased to hold significantly taller items. Further, it may be preferable to seal tray cartons with shrink wrap for shipment and later storage at warehouses and other retail locations, as the tops of the items held within the tray may extend past the upper edges of the end and side walls. 
     FIG. 2   b  shows the inwardly positioned offset score line  32  offsetting the thickness of outer side flap sections  30 . The offset score line moves a central portion of the end wall inward to compensate for and fill the gap between the opposing side flaps. At least the bottom of the central portion of the end wall extends to a point that is effectively on a same linear plane as the interior (visible) sides of flaps  30 . That is to say, the interior dimensions of the tray are effectively equalized even though side flaps are adhered to portions of, but not all of, the end walls. However, as seen in the  FIG. 2   b , the entirety of the central portion of the end wall need not extend to the same position s the interior portion of the side flaps  30 . Instead, only a bottom part of the central wall may be fully inwardly positioned. Thus, while the interior ends of the tray are effectively straight, they are not necessarily perfectly straight. Even so, the offset score permits precise dimensioning and support of the bottles in the tray by sufficiently narrowing the tray dimension along the base of the tray to securely bias the central rows of bottles or cans in a stable position. 
     FIG. 2   c  depicts the exterior side of the tray. Like the interior, the exterior may resemble a non-equilateral octagon. Further, the side flaps do not attach to the exterior sides of the end walls, resulting in a smooth outside end walls without ridges that may disadvantageously catch other trays or items during movement. 
     FIG. 3  shows an alternative embodiment wherein the blank and the corresponding tray does not have angled corners. A thin U-shaped corner cut out  52  is provided between the side flaps and the end walls. The side flaps  44  comprise of a single flap. Inner side flap section  28  is unnecessary in this embodiment, as there are no corresponding angled corners. Score line  26  is slightly inwardly positioned from score line  18  to aid effective folding and adherence of the side flap to the end panels. When the tray is erected, the exterior side of the outer side flap section virtually borders the score line  18  such that the flap section fills most of a space that is bordered on two sides by score line  18  and angled score line  36 . It is important that the edges of side flap  44  do not extend past score lines  36 . In the present embodiment, the length of side flap is 2¾ inches. The distance between score line  16  and the intersection of score lines  18  and  36  is also 2¾ inches. In other embodiments, the length of the side flap can be less than the distance between score lines  16  and  36 . 
     FIG. 4  shows an alternative embodiment wherein an offset score line  56  is arcuate. In this embodiment, a central portion of an end score line slopes inwardly along an arcuate curve toward the center of the tray. At minimum, an innermost point  50  is fully narrowed to a same lateral plane as the interior surface of the outer side flap section  30  when the tray is erected. In the present embodiment, innermost point  50  is inwardly positioned ⅜ inches as compared to score line  18 , which accounts for the ⅜ inch thickness of the outer side flap section  30 . Thus, the interior dimensions of the tray are equalized by accounting for the thickness of the side flaps to securely bias a central row or rows of items within the tray. The difference between score line  18  and offset score line  56  can be changed if a different thickness of paperboard is used. Other embodiments can include an arcuate score line with different paths, such as those with steeper or lesser slopes. Additional embodiments can include other non-arcuate score lines that fill the gap between opposing side flaps while maintaining the spirit of the invention. 
   The tray dimensions can vary depending on what types or how many items are being shipped. The preferred dimensions of the interior space within an erected tray is a length between 10 and 18 inches, a width between 7 and 12 inches, and a height between 1 and 4 inches. However, tray dimensions can exceed these preferred limits within the spirit of the invention if the item or items being shipped require the adjustments. 
   For example, in  FIG. 4 , the tray dimension have been altered to hold  24  twenty ounce bottles. Bottom panel  12  has a width of 11 11/16 inches between the side score lines, a length of 17 11/16 inches between the end score lines  18 , and a length of 17 5/16 inches between the end score lines  34 . The height of the side and end walls in the erected tray is 2⅛ inches. 
   Although the invention has been described with reference to preferred embodiments, it will be appreciated by one of ordinary skill in the art that numerous modifications are possible in light of the above disclosure. For example, the offset score lines can be on the base of the side wall if there are corresponding flaps on the end walls without departing from the spirit of the invention. All such variations and modifications are intended to be within the scope and spirit of the invention as defined in the claims appended hereto.