Abstract:
A one-piece, collapsible, tray type, paperboard container with one or more truncated corners, each of which includes a pair of vertical side walls, with adjacent ends spaced from each other and interconnected by a three-piece gusset. The gusset includes first and second sections, foldably joined to each of the side walls, and a corner section, foldably joined to each side section. The corner section is folded in face-to-face relation with one of the side sections and positioned against an inner surface of one of side walls in interlocking engagement therewith.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to tray type containers and, more particularly, to an improved corner arrangement for a tray type container with truncated corners. 
     2. Description of the Background Art 
     A background art search directed to the subject matter of this invention conducted in the United States Patent and Trademark Office disclosed the following United States Letters Patent: U.S. Pat. Nos. 4,765,534, 5,110,039, 5,211,329. 
     None of the patents uncovered in the search discloses a one-piece, collapsible, tray type, paperboard container with one or more truncated corners, each including a pair of side wall panels, with adjacent ends spaced from each other and interconnected by a three-piece gusset including first and second sections, foldably joined to respective side wall panels, and a corner section, foldably joined to respective side sections, and which is folded in face-to-face relation with one of the side sections and interlocked with a retaining flap on one of the side wall panels. 
     SUMMARY OF THE INVENTION 
     It is a primary object of the invention to provide a collapsible, tray type container, having one or more truncated corners, and which is formed from a unitary blank of foldable paperboard. 
     Another object of the invention is the provision of a container of the type described wherein the front wall has an interlocking connection with the side walls, but which can be easily and quickly erected manually. 
     A more specific object of the invention is to provide a tray type container with truncated front corners wherein the front and side wall panels are interconnected by a three section gusset member, a portion of which has interlocking engagement with a front wall retaining flap. 
    
    
     These and other objects of the invention will be apparent from an examination of the following description and drawings. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an isometric view of a tray type container embodying features of the present invention, shown in a closed condition; 
     FIGS. 2A-2F are isometric views illustrating the sequential steps required to erect the container illustrated in FIG. 1; and 
     FIG. 3 is a plan view of the blank of sheet material used to form the container illustrated in the other views. 
    
    
     It will be understood that, for purposes of clarity, certain elements may have been omitted from certain views where they are believed to be illustrated to better advantage in other views. 
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the drawings for a better understanding of the invention, it will be seen that the tray type container, embodying features of the invention and indicated generally at C in FIG. 1, may be formed from the unitary blank of foldable paperboard indicated generally at B in FIG. 3. 
     Although container C, as illustrated in the drawings of this application, includes both a tray 10 and an integral cover 40, the essential feature of the present invention resides in the novel construction of the truncated corners of the tray, as hereinafter described. Thus, it should be understood that the tray illustrated and described herein, may be formed with or without a cover or lid. 
     As best seen in FIG. 2B, tray 10 includes a hexagonal bottom wall panel 12 with a front wall panel 14 and a rear wall panel 16 foldably joined to front and rear edges along fold lines 15 and 17, respectively; and a pair of side wall panels 18, foldably joined to opposed side edges thereof along fold lines 19. Panel 12 has a pair of truncated front corners defined by diagonal edges 13. 
     A retaining flap 20 is foldably joined to front wall panel 14 along fold line 21 to form an L-shaped front wall 22. Again referring to FIG. 3, it will be seen that portions of the front wall retaining flap are cut out to provide a pair of lock tab receiving recesses 23, located adjacent fold line 21. 
     As best seen in FIGS. 2A and 3, the front ends of the tray side wall panels are spaced from the adjacent ends of the front wall panel but are connected thereto by unique three-section gussets, indicated generally at 30. 
     It will be seen that the gussets are each generally V-shaped, with inboard edges separated from adjacent front corner edges 13 of the tray bottom wall panel 12 to define an opening 25 therebetween. 
     Each gusset 30 includes a first or side section 32, foldably joined along a fold line 31, to a front edge of tray said wall panel 18; a second or front section 34, foldably joined along a fold line 35, to a side edge of tray front wall panel 14; and a third or corner section 36, foldably joined along a fold line 37 to first section 32, and foldably joined along a fold line 39 to second section 34. 
     The lower edge of each first section 32 may be recessed, as indicated at 33a, for receipt of a locking tab, and the upper edge may be recessed, as at 33b, for receipt of a portion of front wall retaining flap 20, as hereinafter described. 
     Each gusset third section may be provided, at its upper edge, with a projection 38 that serves as a lock tab which is receivable within an opening 23 in the tray front wall retaining flap 20 to provide an interlocking connection between the tray side wall panel and the front wall, as hereinafter described. 
     As previously mentioned, the tray of the present invention may be formed with any type of cover, or without a cover. In this application tray 10 is illustrated with a cover indicated at 40. 
     As seen in FIGS. 2D and 3, cover 40 includes a top wall panel 42, foldably joined along fold line 43 to the upper edge of tray rear wall panel 16; and a pair of side wall panels, 44 foldably joined along fold lines 45, to opposed side edges of top wall panel 42. 
     Cover 40 includes a pair of locking flaps 50, foldably joined, on fold lines 51, to front corner edges of cover top wall panel 42. As seen in FIG. 3, each locking flap 50 has a straight side edge 53 and a curved side edge 55. A locking tab 56 is foldably joined, on a fold line 57, to the outer end of locking flap 50. 
     Although the tray side wall panels may be connected to the tray rear wall panel in different ways, in this application the tray side wall panels 18 are shown connected to the tray rear wall panel 16 by a pair of unique webs, indicated generally at 60. 
     Each web 60, includes three triangular sections: a first section 62, foldably joined on a fold line 61 to a related tray side wall panel 18; a second section 64, foldably joined on a fold line 63 to a related cover side wall panel 44; and a third section 66, foldably joined on a fold line 65 to tray rear wall panel 16. 
     Web third section 66 is also foldably joined along fold lines 67a and 67b to adjacent edges of web first and second sections 62 and 64, respectively. Also, web first section is separated from web second section by a cut line 67c. 
     To facilitate folding of the web sections on closure of the cover, a pair of openings may be provided in blank B at opposite ends of fold lines 65, where they intersect fold lines 61 and 63. 
     In order to erect the tray, the front wall panel 14 and the side wall panels 18 are folded upwardly from the bottom wall panel. At the same time gusset second and third sections 34 and 36 are folded inwardly until second section 34 lies against the inner or rear surface of front wall panel 14, and third section 36 lies against portions of the inner or rear surfaces of both second section 34 and front wall panel 14. As this occurs gusset first sections 32 are folded inwardly to lie over the front corners of tray bottom wall panel 12 inboardly of diagonal corner edges 13. 
     At this time tray front wall retaining flap 20 is folded inwardly 90 degrees with the gusset third section lock tabs being engaged in the respective front wall recesses 23, and the ends of the retaining flap being received within the respective gusset first section recesses 33b. 
     In order to close the container cover, after the container has been filled, the tray rear wall panel 16 is folded to the vertical position. As this occurs the webs 60 interconnecting the tray rear and side wall panels will automatically move inwardly with the web second and third sections 64 and 66 lying in face-to-face relation with each other between the web first section 62 and the tray rear wall panel 16. 
     The cover can then be locked to the tray by folding the locking flaps 50 downwardly and folding the locking tabs 56 inwardly and inserting them under the respective gusset first sections 32 in related recesses 33a.