Abstract:
A product tray having a back panel that is higher than the front and side panels is described. The product tray surprisingly has excellent compressive strength when filled with product and allows for good product visibility from the front and side without comprising the stability of the product within the tray.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention is directed to a product tray. More particularly, the invention is directed to a product tray having a back panel that is higher than the front and side panels. The product tray surprisingly has excellent compressive strength when filled with product, notwithstanding the fact that it uses less material (e.g., paperboard) than conventional product boxes. Moreover, the product tray of this invention allows for good product visibility from the front and side without compromising the stability of the product within the tray.  
         BACKGROUND OF THE INVENTION  
         [0002]    Many consumer products are displayed and sold in the conventional boxes or trays they are shipped in. Displaying and selling products in the boxes or trays they are shipped in are desirable because products do not have to be unpacked and individually placed on shelves prior to selling. Moreover, many club-stores do not bag products for consumers, and selling products in the boxes or trays they are shipped in makes handling of the products significantly easier for consumers.  
           [0003]    While conventional boxes or trays have some desirable characteristics, they also have many drawbacks. For example, many conventional trays have front and side panels that are about 25% of the height of the products that are packed in them. While such conventional trays do allow for product visibility and paperboard conservation, they typically are incapable of supporting products in the upright position and do not offer any strength from a compression standpoint.  
           [0004]    Conventional boxes, on the otherhand, have front and side panels that cover the products that are packed in them. These conventional boxes may support the compressive load imposed during shipping and warehousing; however, they utilize significant amounts of paperboard and make visibility of the products packed therein very difficult, especially from the front and sides.  
           [0005]    It is of increasing interest to develop a product tray that can support products in an upright position, offer strength from a compression standpoint, and that allows for product visibility without using excessive amounts of material. This invention, therefore, is directed to a product tray having a back panel that is higher than the front and side panels. The product tray has excellent compressive strength when filled with product, notwithstanding the fact that it uses less material than conventional product boxes.  
           [0006]    Additional Information  
           [0007]    Efforts have been disclosed for making cartons. In U.S. Pat. No. 6,435,403, a display carton suitable for heavy consumer products is disclosed.  
           [0008]    Other efforts have been disclosed for making cartons. In U.S. Pat. No. 5,918,801, a shipping case with advertising matter is described.  
           [0009]    Still other efforts have been disclosed for making cartons. In U.S. Pat. No. 5,577,612, fabric softener sheet dispenser cartons are disclosed.  
           [0010]    None of the additional information above describes a product tray that offers excellent compressive strength and product stability, while at the same time offering good product visibility from the front and sides.  
         SUMMARY OF THE INVENTION  
         [0011]    The present invention is directed to a product tray comprising, when unfolded:  
           [0012]    (a) a flat surface comprising a front and back edge, a left and right side edge and a first and second parallel hinge, both the first and second parallel hinge run parallel to the front and back edges and to each other, the first parallel hinge being a distance (d 1 ) from the front edge and the second parallel hinge being a distance (d 2 ) from the back edge;  
           [0013]    (b) a first and second perpendicular hinge running perpendicular to the front and back edge and first and second parallel hinge and parallel to the left and right edges, the first perpendicular hinge being a distance (d 3 ) from the left side edges and the second perpendicular hinge being a distance (d 4 ) from the right side edges;  
           [0014]    (c) points of intersection where the first perpendicular hinge intersects the first and second parallel hinge, and where the second perpendicular hinge intersects the first and second parallel hinge  
           [0015]    wherein d 2 &gt;d 1 , and d 3  and d 4 &lt;d 2  and a distinct slot converging towards each point of intersection and diverging towards the side edges so that the first and second parallel hinge have, as end points, a point of intersection, and product packed in the product tray, when folded, has a product height H that is substantially the same as product tray height h.  
           [0016]    In a second aspect, the present invention is directed to the product tray of the first aspect in folded form and packed with product.  
           [0017]    Material, as used herein, means any substance suitable to make a product box for packaging consumer products. Illustrative examples of such material are plastic, paperboard, (both corrugated and non-corrugated) as well as light-weight wood and a mixture thereof. Substantially perpendicular as used herein means greater than 45 degrees and less than 90 degrees; and preferably, from about 70 degrees to about 89 degrees. Rest or resting on is defined to mean making at least some contact. 
       
    
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0018]    The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which:  
         [0019]    [0019]FIG. 1 depicts a perspective view of the product tray of this invention in unfolded form;  
         [0020]    [0020]FIG. 2 depicts the product tray of this invention with sides folded upright;  
         [0021]    [0021]FIG. 3 depicts the product tray of this invention folded with sides folded and supported by front and rear flaps;  
         [0022]    [0022]FIG. 4 depicts the product tray of this invention with sides folded and supporting front and rear flaps;  
         [0023]    [0023]FIG. 5 depicts the product tray of this invention with product packed and shrink-wrapped therein;  
         [0024]    [0024]FIG. 6 depicts the product tray of the present invention unassembled and in two piece form;  
         [0025]    [0025]FIG. 7 depicts the product tray of this invention assembled in two piece form;  
         [0026]    [0026]FIGS. 8 and 9 show two preferred slots for use in the product tray; and  
         [0027]    [0027]FIG. 10 shows the product tray having a back panel folded and perpendicular to the side.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0028]    The only limitation with respect to the material used to make the product tray of this invention is that the material is suitable for use in packaging associated with consumer products. Illustrative examples of the material that may be used to make the product tray of this invention is plastic, corrugated and solid fiber paperboard as well as light weight wood. The material used to make the product tray may be new, recycled or a mixture thereof. In a preferred embodiment, the product tray of this invention comprises at least about 50.0% by weight recycled material. In a most preferred embodiment, the product tray of this invention comprises at least about 50.0% by weight recycled material and is corrugated paperboard.  
         [0029]    Turning to FIG. 1, shown is an unfolded product tray  10  comprising a flat surface  12  having back, middle and front flat surfaces  12   a,    12   b  and  12   c,  respectively, a front edge  14 , a back edge  16 , back, middle and front left side edges  18   a,    18   b  and  18   c,  respectively, back, middle and front right side edges  20   a,    20   b  and  20   c,  respectively, and a first and second parallel hinge  22  and  24 , respectively, which can be, for example, perforations, bends or scores in the flat surface  12 . The first parallel hinge  22  and second parallel hinge  24  run parallel to the front and back edges,  14  and  16 , respectively, and to each other, whereby the first parallel hinge  22  is a distance (d 1 ) from the front edge  14  and the second parallel hinge is a distance (d 2 ) from the back edge  16 .  
         [0030]    The unfolded product tray  10  further comprises first and second perpendicular hinges,  26  and  28 , respectively, which can be, for example, perforations, bends or scores in the flat surface  12  and that run perpendicular to the front and back edges,  14  and  16 , respectively, and first and second parallel hinges  22  and  24 , respectively, and parallel to left edges  18   a - c  and right edges  20   a - c.  The first perpendicular hinge  26  is a distance (d 3 ) from left side edges  18   a - c  and the second perpendicular hinge  28  is a distance (d 4 ) from right side edges  20   a - c.  First and second left slot,  30   a  and  30   b , respectively, converge towards first and second left points of intersection  30   a′  and  30   b′,  respectively, and first and second right slots  32   a  and  32   b,  respectively, converge towards first and second left and right points of intersection  32   a′  and  32   b′,  respectively, wherein first left slot  30   a  forms a void between back left side edge  18   a  and middle left side edge  18   b  and back left panel  18   a′  and middle left panel  18   b′  and second left slot  30   b  forms a void between middle left side edge  18   b  and front left side edge  18   c  and middle left panel  18   b′  and front left panel  18   c′.  Middle surface  12   b  is a length (L) that can vary, but preferably is less than (d 2 ) and greater than (d 1 ), thereby providing adequate advertising space on back flat surface  12   a.  Distance (d 2 ) is greater than distance (d 1 ) and distance (d 3 ) and distance (d 4 ) are preferably equal, and greater than or equal to distance (d 1 ). In a preferred embodiment, distance (d 2 ) is about 5.0 to about 50.0% greater than length (L), and distance (d 2 ) is about 2.0 to about 4.0 times greater than distances (d 1 ), (d 3 ) and (d 4 ).  
         [0031]    First right slot  32   a  forms a void between back right side edge  20   a  and middle right side edge  20   b  and back right panel  20   a′  and middle right panel  20   b′  and second right slot  32   b  forms a void between middle right side edge  20   b  and front right side edge  20   c  and middle right panel  20   b′  and front right panel  20   c′.    
         [0032]    Turning to FIG. 2, shown is product tray  10  with middle left panel  18   b′  and middle right panel  20   b′  folded or pivoted (clockwise and counter clockwise, respectively) preferably perpendicular to middle flat surface  12   b  via first and second perpendicular hinges  26  and  28 , respectively, wherein middle left panel  18   b′  and middle right panel  20   b′  are the sides of the product tray  10  when folded or pivoted perpendicular to flat surface  12   b,  exposing middle left side edge  18   b  and middle right side edge  20   b  from the top as well as left back and front flap walls  34  and  36  (respectively) and right back and front flap walls  38  and  40  (respectively).  
         [0033]    [0033]FIG. 3 shows front flat surface  12   c  folded or pivoted upward via first parallel hinge  22  and substantially perpendicular to middle flat surface  12   b  so that front flat surface  12   c  preferably rests on left front flap wall  36  and right front flap wall  40 . Front left panel  18   c′  and front right panel  20   c′  may be folded inward by pivoting the same on first perpendicular hinge  26  and second perpendicular hinge  28 , respectively, ensuring that front left panel  18   c′  contacts left exterior side wall  18   d  and that front right panel  20   c′  contacts right exterior side wall  20   d  when front panel  18   c′  contacts left exterior side wall  18   d  and front right panel  20   c′  contacts right exterior side wall  20   d.  Fastening means, like glue, staples or tape, may be used to secure all points of contact.  
         [0034]    Back flat surface  12   a  may be pivoted or folded upward via second parallel hinge  24  so that back flat surface  12   a  is substantially perpendicular to middle flat surface  12   b,  and preferably, resting on left back flap wall  34  and right back flap wall  38 . Back left panel  18   a′  and back right panel  20   a′  may be folded inward by pivoting the same on first perpendicular hinge  26  and second perpendicular hinge  28 , respectively, ensuring that back left panel  18   a′  contacts left exterior side wall  18   d  and that back right panel  20   a′  contacts right exterior side wall  20   d.  When back left panel  18   a′  contacts left exterior side wall  18   d  and back right panel  20   a′  contacts right exterior side wall  20   d,  fastening means, as defined above, may be used to secure all points of contact.  
         [0035]    Subsequent to folding product tray  10 , as shown in FIG. 3, left upper corner support  40  and right upper corner support  42  are formed to significantly enhance the strength of the product tray from a compression or stacking standpoint whereby back edge  16  and the combination of back left panel  18   a′,  back flat surface  12   a,  and back right panel  20   a′  take on a C-shape to assist in stabilizing product (not shown), especially in the upright position.  
         [0036]    [0036]FIG. 4 shows product tray  10  of the present invention in folded form with, however, middle left panel  18   b′  and middle right panel  20   b′  folded or pivoted upward and supporting, (from the exterior) back left panel  18   a′  and back right panel  20   a′  and front, left panel  18   c′  and front right panel  20   c′  in lieu of the reverse as shown in FIG. 3. In an especially preferred embodiment, middle left side edge  18   b  and middle right side edge  20   b  are parallel to each other, horizontal and not extending upward to the top of the back of the product tray  10  in folded form to ensure excellent visability from the sides.  
         [0037]    [0037]FIG. 5 shows the product tray  10  of this invention with product  44  packed therein and in an upright position. In a preferred embodiment of this invention, the height of the product H and the product box height h are substantially the same (i.e., within 3.0% of each other), and preferably, the same height. In another preferred embodiment, product tray  10  packed with product  44  is not covered with a material suitable to make a product tray (i.e. a product tray top) but is covered with a transparent or translucent shrink-wrap film  46  made of a polymeric material like polyethylene, polypropylene, polyolefin or a copolymer thereof. When covered with shrink wrap, product  44  is fully supported in product tray  10 , and particularly, in the upright position. In an especially preferred embodiment, product  44  packed in product tray  10  has a footprint area, defined as Fxf, that is from about 20 to about 50 percent smaller than the tray base area, defined as Bxb.  
         [0038]    [0038]FIG. 6 shows unassembled product tray  10 ′ having a base plate  48  and a four (4) hinged (a, b, c, d) foldable side panel  50 .  
         [0039]    [0039]FIG. 7 shows side panel  50  with each hinge rotated 90 degrees inward so that foldable side panel  50  may be folded for insertion into base plate  48  to form assembled product tray  10 ′. FIGS. 6 and 7, therefore, demonstrate that the product tray of the present invention may be one piece or two pieces when unfolded or unassembled. The relationship between distances (d 1 ′), (d 2 ′), (d 3 ′), (d 4 ′), and (L′) (as shown in FIG. 6) is identical to the relationship between distances (d 1 ), (d 2 ), (d 3 ), (d 4 ), and L. Distance (d 5 ), however, is often about equal to distance (d 1 ′) and distance (d 4 ′), and most preferably, about 5.0 to about 15.0% larger or smaller than distance (d 1 ′) and distance (d 4 ′).  
         [0040]    Turning to FIG. 8, shown is slot  30   a  and a portion of second parallel hinge  24 . Slot  30   a  is generally, and often, shaped like an isosceles triangle. It is within the scope of this invention, however, for all slots made within product tray  10  to be shaped like right angles as shown by slot  52  of FIG. 9. It is noted that when all slots are shaped like right angles, front surface  12   c  and back flat surface  12   a  will be perpendicular to middle flat surface  12   b  and standing parallel to each other. FIG. 10 shows back left panel  18   a′  resting on its back left footing edge  54 , whereby back left side edge  18   a  is perpendicular to middle left side edge  18   b,  resulting from a right triangular slot, not shown, being present in lieu of a slot that is isosceles triangle like.  
         [0041]    It should be understood that the specific forms of the invention herein illustrated and described are intended to be representative only and certain changes may be made therein without departing from the clear teachings of the disclosure. Accordingly, reference should be made to the following appended claims in determining the full scope of the invention. It should also be understood that the product packed in the product tray of this invention can be, for example, any consumer product suitable for filling in a box, can or bottle, like a box of detergent or a bottle of salad dressing.  
       EXAMPLE  
       [0042]    Three sets of pallets (about 40×48 inches) were assembled as follows:  
         [0043]    Set one had three pallets that were stacked with Unilever Bestfoods&#39; Wishbone Salad Dressing bottles (16 oz.) packed (and wrapped with polyethylene) in the product tray of this invention and as depicted in FIG. 5. Each pallet was stacked 5 product trays high (each layer separated by a slip sheet) and the three pallets were stacked on each other, also separated by a slip sheet.  
         [0044]    Set two was similar to set one except that conventional boxes with all four sides at the height of the bottles were used in lieu of the product tray of this invention and there were no slip sheets used between the layers of boxes.  
         [0045]    Set three was similar to set one except that conventional trays with all four sides at about 25% of the height of the bottles were used in lieu of the product tray of this invention.  
         [0046]    The three sets of pallets were shipped, and stacked for about a two week period. Visual observations, after shipping and stacking, unexpected 1 y revealed that the product trays of this invention performed as well as the conventional boxes of set two and significantly better than the conventional trays of set three, which fell over and/or were unable to maintain all product in the upright position. The results indicate that the product tray of this invention allows for efficient shipping and stacking of product and excellent visibility from three sides, even when the footprint area is from about 20 to about 50% smaller than the tray base area.