Tray for supporting containers and a blank for making the same

A blank for forming a tray includes a bottom panel, end panels, and side panels. A first divider panel assembly is defined within the bottom panel and an end panel. The first divider panel assembly includes an upper panel defined within the end panel and an inner panel defined within the bottom panel. The upper panel is configured to be at an angle to the bottom panel, and the inner panel is configured to be at an angle to the end panel in an erected configuration. A second divider panel assembly is defined within the bottom panel and a side panel. The second divider panel assembly includes an upper panel defined within the side panel and an inner panel is defined within the bottom panel. The panels of the second divider panel assembly are configured similarly to the panels of the first divider panel assembly in the erected configuration.

BACKGROUND OF THE INVENTION

The embodiments described herein relate generally to a tray formed from a blank of sheet material and, more particularly, to a tray for supporting a plurality of containers included within the tray.

At least some known trays are configured to hold a plurality of containers therein. Most of these known trays are formed from a relatively large blank having a plurality of panels that fold and/or wrap to define container holders. More specifically, the plurality of panels form a rectangular tube having cutouts into which the containers are inserted. Because these trays are formed from a relatively large blank of sheet material they can be expensive to make. Moreover, because of the plurality of panels, they can be complicated to form.

Another known tray includes single-thickness side and end walls having a cup holder that extends outwardly from each end wall. The end walls of such a tray include side flaps that couple to an adjacent side wall. The end walls and side flaps are taller than the side walls. As such, when a cup is positioned in the tray, the cup is secured by the combination of the cup holder, the end wall, and the side flap. Notably, the retractable cup holders only extend from the end walls because the end wall and side flap cooperate with the cup holder to secure the cup in the tray. Further, the central portion of the tray is configured to allow for other food items to be positioned therein. As such, this other known tray is limited in the number of containers it is able to support therein.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, a blank for forming a tray is provided. The blank includes a bottom panel, a pair of opposing end panels connected to the bottom panel, and a pair of opposing side panels connected to the bottom panel. A first divider panel assembly is defined within the bottom panel and a first end panel of the pair of end panels. The first divider panel assembly includes a first upper panel and a first inner panel connected at a first fold line. The first upper panel is defined within the first end panel and the first inner panel is defined within the bottom panel. In an erect configuration, the first upper panel is configured to be at a first angle to the bottom panel, and the first inner panel is configured to be a second angle to the first end panel. A second divider panel assembly is defined within the bottom panel and a first side panel of the pair of side panels. The second divider panel assembly includes a second upper panel and a second inner panel connected at a second fold line. The second upper panel is defined within the first side panel, and the second inner panel is defined within the bottom panel. In the erect configuration, the second upper panel is configured to be at a third angle to the bottom panel, and the second inner panel is configured to be at a fourth angle to the first side panel.

In another aspect, a tray formed from a blank of sheet material is provided. The tray includes a bottom wall, a pair of opposing end walls connected to the bottom wall, and a pair of opposing side walls connected to the bottom walls. A first divider structure extends from the bottom wall and a first end wall of the pair of end walls. The first divider structure includes a first upper panel and a first inner panel connected at a first fold line. The first upper panel is at a first angle to the bottom wall, and the first inner panel is at a second angle to the first end wall. A second divider structure extends from the bottom wall and a first side wall of the pair of side walls. The second divider structure includes a second upper panel and a second inner panel connected at a second fold line. The second upper panel is at a third angle to the bottom wall, and the second inner panel is at a fourth angle to the first side wall.

In yet another aspect, a method for forming a tray from a blank of sheet material is provided. The blank of sheet material includes a bottom panel, a pair of opposing end panels connected to the bottom panel, a pair of opposing side panels connected to the bottom panel, a first divider panel assembly defined within the bottom panel and a first side panel of the pair of side panels, and a second divider panel assembly defined within the bottom panel and a first end panel of the pair of end panels. The first divider panel assembly includes a first upper panel defined within the first side panel and a first inner panel defined within the bottom panel. The second divider panel assembly includes a second upper panel defined within the first end panel and a second inner panel defined within the bottom panel. The method includes rotating the pair of side panels toward the bottom panel to form a pair of opposing side walls, rotating the first upper panel with respect to the first side panel and the first inner panel with respect to the bottom panel to form a first divider structure, rotating the pair of end panels toward the bottom panel to form a pair of opposing end walls, and rotating the second upper panel with respect to the first end panel and the second inner panel with respect to the bottom panel to form a second divider structure.

In still another aspect, a blank for forming a tray is provided. The blank includes a bottom panel, a pair of opposing end panels connected to the bottom panel, a pair of opposing side panels connected to the bottom panel, and a plurality of divider panel assemblies defined within the bottom panel and a first side panel of the pair of side panels. Each divider panel assembly of the plurality of divider panel assemblies includes an upper panel and an inner panel connected at a fold line. The upper panel is defined within the first side panel, and the inner panel is defined within the bottom panel. The upper panel is configured to be at a first angle to the bottom panel, and the inner panel is configured to be at a second angle to the first side panel in an erected configuration.

DETAILED DESCRIPTION OF THE INVENTION

The embodiments described herein provide a tray configured to support and/or contain a plurality of containers and/or products. For example, the trays described herein can be used to contain a plurality of cylindrical and/or tub-shaped containers, such as dairy containers, during transport through an assembly line and/or to a store and/or during storage of the containers. An alternative tray is configured to contain a plurality of elongated products, such as cards and/or blister packs, during transport and/or storage.

The following detailed description illustrates the disclosure by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the disclosure, describes several embodiments, adaptations, variations, alternatives, and use of the disclosure, including what is presently believed to be the best mode of carrying out the disclosure.

A tray formed from a single sheet of material and a method and machine for constructing the container is described herein. The tray may be constructed from a blank of sheet material using a machine. In one embodiment, the tray is fabricated from a cardboard material. The tray, however, may be fabricated using any suitable material, and therefore is not limited to a specific type of material. In alternative embodiments, the tray is fabricated using cardboard, plastic, fiberboard, paperboard, foamboard, corrugated paper, and/or any suitable material known to those skilled in the art and guided by the teachings herein provided.

In an example embodiment, the tray includes at least one marking thereon including, without limitation, indicia that communicates the product stored in the tray, a manufacturer of the product and/or a seller of the product. For example, the marking may include printed text that indicates a product's name and briefly describes the product, logos and/or trademarks that indicate a manufacturer and/or seller of the product, and/or designs and/or ornamentation that attract attention. “Printing,” “printed,” and/or any other form of “print” as used herein may include, but is not limited to including, ink jet printing, laser printing, screen printing, giclée, pen and ink, painting, offset lithography, flexography, relief print, rotogravure, dye transfer, and/or any suitable printing technique known to those skilled in the art and guided by the teachings herein provided. In another embodiment, the tray is void of markings, such as, without limitation, indicia that communicates the product, a manufacturer of the product and/or a seller of the product.

Referring now to the drawings,FIG. 1is a top view of an exemplary blank10of sheet material for forming a tray, such as a tray100(shown inFIG. 6). Blank10has a first or interior surface12and an opposing second or exterior surface14. Further, blank10defines a first edge16and an opposing second edge18. In one embodiment, blank10includes, in series from first edge16to second edge18, a first end panel20, a bottom panel22, and a second end panel24coupled together along preformed, generally parallel, fold lines26and28, respectively. More specifically, first end panel20extends from first edge16to fold line26, bottom panel22extends from first end panel20along fold line26, second end panel24extends from bottom panel22along fold line28to second edge18. Fold lines26and/or28, as well as other fold lines and/or hinge lines described herein, may include any suitable line of weakening and/or line of separation known to those skilled in the art and guided by the teachings herein provided. In the exemplary embodiment, each end panel20and24includes free side edges30. When tray100is formed from blank10, fold line26defines a bottom edge of first end panel20and a first end edge of bottom panel22; fold line28defines a second end edge of bottom panel22and a bottom edge of second end panel24; first edge16defines a top edge of first end panel20; and second edge18defines a top edge of second end panel24.

A first side panel32extends from a first side edge of bottom panel22at a fold line34, and a second side panel36extends from a second side edge of bottom panel22at a fold line38. Fold lines34and38are substantially parallel. First side panel32has a free edge40that defines a top edge of first side panel32when tray100is formed, and second side panel36has a free edge42that defines a top edge of second side panel36when tray100is formed. A first end flap44extends from an end edge of first side panel32at a fold line46, and a second end flap48extends from an opposing end edge of first side panel32at a fold line50. Each end flap44and48includes free edges52,54, and56. Similarly, a third end flap58extends from an end edge of second side panel36at a fold line60, and a fourth end flap62extends from an opposing end edge of second side panel36at a fold line64. Each end flap58and62includes free edges52,54, and56. In the exemplary embodiment, each end flap44,48,58, and62is separated from an adjacent end panel20or24by a gap66; however, it should be understood that any of end flaps44,48,58, and/or62can be separated from an adjacent end panel20or24by a cut line without gap66.

Each end panel20and24has a height H1, and each side panel32and36has a height H2. In the exemplary embodiment, height H1is substantially equal to height H2. Alternatively, height H1is other than substantially equal to height H2, for example less than or greater than height H2. In the exemplary embodiment, end flaps44,48,58, and62each have a height H3that is approximately equal to, or slight smaller than height H1. Further, end panels20and24each have a width W1, and side panels32and36each have a width W2that is larger than width W1. Alternatively, width W2is equal to or less than width W1depending on what type and/or how many products tray100supports therein.

Blank10further includes a plurality of divider panel assemblies68. In the exemplary embodiment, blank10includes a first divider panel assembly68adefined within at least one end panel20and/or24and a second divider panel assembly68bdefined within at least one side panel32and/or36. Each divider panel assembly68aand68bis configured similarly and is referred to generically as divider panel assembly68for the sake of simplicity. In the exemplary embodiment, each end panel20and24includes one divider panel assembly68, and each side panel32and36includes a plurality of divider panel assemblies68. Alternatively, each side panel32and36includes one divider panel assembly68such that tray100is configured to support four containers. In the exemplary embodiment, divider panel assemblies68have any suitable size and/or configuration based on the containers supported by tray100. Further, divider panel assemblies68are configured to cooperate with an adjacent divider panel assembly68to secure the containers within tray100. For example, each of the containers is contacted by two divider panel assemblies68.

In the exemplary embodiment, each divider panel assembly68includes an upper panel70defined within a panel20,24,32, and/or36and an inner panel72defined within bottom panel22. More specifically, upper panel70is defined within a panel20,24,32, and/or36by side cut lines74and a fold line76. Inner panel72is defined within bottom panel22by side cut lines78and a fold line80. Side cut lines78are continuous with side cut lines74across a respective fold line26,28,34, and/or38. Upper panel70and inner panel72are connected to each other at a fold line82that is substantially collinear with a respective fold line26,28,34, or38. Alternatively, fold line82is offset from a respective fold line26,28,34, or38. In the exemplary embodiment, a depth D1of upper panel70is substantially equal to a height H4of inner panel72such that upper panel70is substantially perpendicular to inner panel72when a divider structure212(shown inFIG. 6). In an alternative embodiment, depth D1is other than equal to height H4such that upper panel70is at an acute or an obtuse angle to inner panel72.

Upper side cut lines74include at least a curved portion84to correspond to a shape of the products supported by tray100. In the exemplary embodiment, upper side cut lines74include curved portion84and a substantially straight portion86. More specifically, curved portion84has an edge configured to interface with or engage a container supported within tray100. As such, curved portion84of upper side cut lines74defines an engagement edge of divider panel assembly68. Engagement edges of adjacent divider panel assemblies68are configured to cooperate with each other to secure a container within in tray100, as described in more detail below. In the exemplary embodiment, first divider panel assembly68aincludes a first engagement edge defined by curved portion84and second divider panel assembly68bincludes a second engagement edge defined by curved portion84adjacent to the first engagement edge. The first engagement edge and the second engagement edge are configured to cooperate with each other to secure a product between first divider panel assembly68aand second divider panel assembly68bin the erected configuration. Further, substantially straight portion86is configured to space the products from a wall of tray100. Upper side cut lines74define free side edges of upper panel70when tray100is formed as described below. Inner side cut lines78are substantially straight and define free side edges of inner panel72when tray100is formed. Inner panel72has a width between side cut lines78based on a size of the containers supported by tray100.

When blank10is in a flat, unformed state, divider panel assemblies68are in a flat configuration. More specifically, upper panel70is coplanar with a respective panel20,24,32, or36and inner panel72is coplanar with bottom panel22in the flat configuration.

FIG. 2is a perspective view of blank10(shown inFIG. 1) at a first stage of construction.FIG. 3is a perspective view of blank10at a second stage of construction.FIG. 4is a perspective view of blank10at a third stage of construction.FIG. 5is a perspective view of blank10at a fourth stage of construction.FIG. 6is a perspective view of an exemplary tray100formed from blank10.FIG. 7is a perspective view of tray100having container and/or products102therein. The herein-described method for forming tray100from blank10can be performed manually and/or automatically.

Referring toFIGS. 1-7, to construct tray100from blank10, side panels32and36are rotated about fold lines34and38toward bottom panel22to be substantially perpendicular to bottom panel22to form a first side wall104and a second side wall106. Bottom panel22forms a bottom wall108. As side panels32and36are rotated, divider panel assemblies68begin to buckle inwardly at fold lines76,80, and82, as shown inFIGS. 2-4. More specifically, interior surface12of upper panel70rotates about fold line76toward interior surface12of a respective side panel32or36, and interior surface12of inner panel72rotates about fold line80toward interior surface12of bottom panel22. Upper panel70and inner panel72rotate with respect to each other at fold line82. As divider panel assemblies68begin to buckle, an opening110is formed at each divider panel assembly68in bottom wall108and a respective side wall104or106.

When side panels32and36are substantially perpendicular to bottom panel22, upper panels70are at an angle, such as a right angle, to a respective side wall104or106and inner panels72are at an angle, such as a right angle, to bottom wall108. In the exemplary embodiment shown inFIG. 5, upper panels70are substantially parallel to bottom wall108and inner panels72are substantially parallel to side walls104and106. As such, upper panels70are substantially perpendicular to inner panels72. Alternatively, upper panels70are at any suitable angle to inner panels72. Such a configuration of divider panel assemblies68is referred to as an erected configuration. In the erected configuration, divider panel assemblies68form divider structures112associated with side walls104and106.

End flaps44,48,58, and62are rotated about fold lines46,50,60, and64to be substantially perpendicular to a respective side panel32or36. In the exemplary embodiment as shown inFIGS. 2-5, end flaps44,48,58, and62are rotated as side panels32and36are rotated; however, it should be understood that end flaps44,48,58, and/or62can be additionally or alternatively rotated before and/or after side panels32and36are rotated. In a particular embodiment, end flaps44,48,58, and62are not rotated until end panels20and24are rotated as described below. In such an embodiment, end flaps44,48,58, and62are secured to exterior surface14of end panels20and24, rather than secured to interior surface12of end panels20and24, as described herein. In the exemplary embodiment, when side panels32and36are substantially perpendicular to bottom panel22, end flaps44,48,58, and62are also substantially perpendicular to bottom panel22, as shown inFIG. 5.

End panels20and24are rotated about fold lines26and28toward bottom panel22to be substantially perpendicular to bottom wall108. Exterior surface14of end flaps44,48,58, and62are coupled to interior surface12of an adjacent end panel20and/or24to form a first end wall114and a second end wall116. More specifically, first end wall114includes first end panel20, first end flap44, and third end flap58. Similarly, second end wall116includes second end panel24, second end flap48, and fourth end flap62. In the exemplary embodiment, end walls114and116and side walls104and106have substantially the same height.

As end panels20and24are rotated, divider panel assemblies68associated with end panels20and24begin to buckle inwardly at fold lines76,80, and82, as shown inFIG. 5. More specifically, interior surface12of upper panel70rotates about fold line76toward interior surface12of a respective end panel20or24, and interior surface12of inner panel72rotates about fold line80toward interior surface12of bottom panel22. Upper panel70and inner panel72rotate with respect to each other at fold line82. As divider panel assemblies68begin to buckle, opening110is formed at each divider panel assembly68in bottom wall108and a respective end wall114or116. When end panels20and24are substantially perpendicular to bottom wall108, upper panels70are at an angle, such as a right angle, to a respective end wall114or116and inner panels72are at an angle, such as a right angle, to bottom wall108. In the exemplary embodiment shown inFIG. 6, upper panels70are substantially parallel to bottom wall108and inner panels72are substantially parallel to end walls114and116. As such, upper panels70are substantially perpendicular to inner panels72. In the erected configuration, divider panel assemblies68form divider structures112associated with end walls114and116.

In the exemplary embodiment, an upper surface118of each divider structure112is below a top edge120of walls104,106,114, and116. Further, each upper panel70is at angle to a respective wall104,106,114, or116, and each inner panel72is at an angle to bottom wall108. In the exemplary embodiment, the angles are substantially right angles; however, the angles can be any suitable angle that is other than 0° or 180°.

Products102are positioned within a cavity122of tray100between at least two divider structures112as shown inFIG. 7. When products102are positioned in tray100, the free side edges of upper panels70act as engagement edges and contact sides of products102to secure products102within tray100. In the exemplary embodiment, adjacent engagement edges of two adjacent divider structures112cooperate to secure product102within tray100. Further, products102are spaced from walls104,106,114, and116by upper panels70. Further, top edge120of walls104,106,114, and116is below a top124of products102. Although the exemplary embodiments are described herein as being configured to support six products102, it should be understood that blank10and tray100can be configured to contain four or more products102.

At least on divider structure112can be collapsed to provide tray100having at least one less opening110. More specifically, a force is applied to interior surface12around fold line82to rotate upper panel70about fold line76and inner panel72about fold line80until upper panel70is substantially coplanar with a respective panel20,24,32, or36and inner panel72is substantially coplanar with bottom panel22. Such a configuration is referred to as a collapsed configuration, and may be used to store or transport trays100. In the collapsed configuration, inner panel72forms a portion of bottom wall108, and upper panel70forms a portion of an associated wall104,106,114, or116. Divider structures112can be re-formed to the erected configuration by applying a force to exterior surface14around fold line82to rotate upper panel70about fold line76and inner panel72about fold line80until upper panel70is substantially perpendicular to a respective wall104,106,114, or116and inner panel72is substantially perpendicular to bottom wall108.

FIG. 8is a top view of a first alternative blank200of sheet material for forming a tray (not shown). Blank200is substantially similar to blank10(shown inFIG. 1), except blank200includes a plurality of divider panel assemblies202. As such, components shown inFIG. 8are labeled with the same reference numbers used inFIG. 1. In the exemplary embodiment, divider panel assembly202is substantially similar to divider panel assembly68(shown inFIG. 1), except divider panel assembly202includes side cut lines204that are arcuate and/or curved rather than being substantially straight, like side cut lines78(shown inFIG. 1). Inner side cut lines204are a continuous curved with upper side cut lines74. Alternatively, inner side cut lines204can have a different curve than, and/or a curve that is not continuous with, curved portion84of upper side cut lines74.

Side cut lines204are curved because an inner panel206of each divider panel assembly202has a height H5that is longer than depth D1of upper panel70. As such, inner panel206will be at acute angles to bottom panel22and upper panel70when a tray250(shown inFIGS. 9 and 10) is formed from blank200. In the exemplary embodiment, divider panel assemblies202are defined in side panels32and36, divider panel assemblies68are defined in end panels20and24. Alternatively, blank200includes divider panel assemblies202defined in side panels32and36and in end panels20and24. Because inner panel206slopes back to the side edges of bottom panel22when tray250is formed, side cuts lines204are configured to conform to a contour diagonally across a side wall of the products within tray250.

FIG. 9is a perspective view of tray250formed from blank200(shown inFIG. 8).FIG. 10is a perspective view of tray250having products102therein. Tray250is formed substantially similar to tray100(shown inFIG. 6), except tray250includes a plurality of divider structures252. As such, components shown inFIGS. 9 and 10are labeled with the same reference numbers used inFIGS. 6 and 7. In the exemplary embodiment, divider structures252extend from at least side walls104and106. Divider structures252are each configured such that upper panel70is at an acute angle α to a respective side wall104or106, and inner panel206is at an obtuse angle β with respect to bottom wall108. Further, each upper panel70is at a substantially right angle to a respective wall114or116, and each inner panel72is at a substantially right angle to bottom wall108. However, it should be understood that the angles can be any suitable angle that is other than 0° or 180°.

Divider structures252are beneficial to contact more of product102as compared to divider structures112and isolate a center round tub product102ain all directions in a horizontal plane.

FIG. 11is a top view of a second alternative blank300of sheet material for forming a tray350(shown inFIG. 12). Tray can350be configured to support a plurality of cards, blister packs, and/or other suitable elongated products, such as products352(shown inFIG. 12) therein. Blank300is substantially similar to blank10(shown inFIG. 1), except blank300includes a plurality of divider panel assemblies302. As such, components shown inFIG. 11are labeled with the same reference numbers used inFIG. 1.

In the exemplary embodiment, divider panel assembly302includes an upper panel304defined within side panel32or36and an inner panel306defined within bottom panel22. More specifically, upper panel304is defined within panel32or36by side cut lines308and a fold line310. Cut lines312separate upper panel304from bottom panel22. In the exemplary embodiment, cut lines312are substantially collinear with a respective fold line34or38; however, it should be understood that at least one cut line312can be offset from a respective fold line34or38. Side cut lines308are substantially straight and configured to space products from a wall104and/or106(shown inFIG. 12) of tray350. Upper side cut lines308define free side edges of upper panel304when tray350is formed.

In the exemplary embodiment, slots314are defined within upper panel304by cut lines316and cut lines312. More specifically, slots314extend inwardly a distance from cut line312toward fold line310. Slots314are substantially rectangular in the exemplary embodiment; however slots314can have any suitable configuration depending on a configuration of a product supported within the tray. In a particular embodiment, slots314are configured to contact a side edge of a product352supported in tray350to secure product352within tray350. In the exemplary embodiment, slots314are equally spaced apart along side panel32or36regardless of whether slots314are on same divider panel assembly302or on adjacent divider panel assemblies302. Alternatively, at least two adjacent slots314have a spacing different than the spacing between another two adjacent slots314. In the exemplary embodiment, each slot314defines an engagement edge of divider panel assembly302that is configured to engage a product positioned within tray350formed from blank300.

Inner panel306is defined within bottom panel22by side cut lines318and a fold line320. Side cut lines318are continuous with an adjacent slot cut line316across a respective fold line34or38. Upper panel304and inner panel306are connected to each other at a fold line322that is substantially collinear with cut lines312and/or fold line34or38. Alternatively, fold line322is offset from cut lines312and/or fold line34or38. In the exemplary embodiment, inner side cut lines318are substantially straight and define free side edges of inner panel306when the tray is formed. Inner panel306has a width between side cut lines318based on a size of the products supported by tray350.

FIG. 12is a perspective view of tray350having products352therein. Tray350is formed substantially similar to tray100(shown inFIG. 6), except tray350includes a plurality of divider structures354. As such, components shown inFIG. 12are labeled with the same reference numbers used inFIGS. 6 and 7. In the exemplary embodiment, divider structures354extend from at least side walls104and106. Divider structures354are each configured such that slots314of divider structures354contact a side edge region356of product352supported in tray350to secure product352within tray350. For example, opposing side edges356of product352are secured by opposing divider panel assemblies302at slots314. In the exemplary embodiment, each upper panel304is at angle to a respective wall104or106, and each inner panel306is at an angle to bottom wall108. In the exemplary embodiment, the angles are substantially right angles and, as such, upper panel304is substantially perpendicular to side wall104or106and inner panel306is substantially perpendicular to bottom wall108when divider structure354is formed. However, the angles can be any suitable angle that is other than 0° or 180°. For example, upper panel304is at an acute or obtuse angle to side wall104or106and inner panel306is at an acute or obtuse angle to bottom wall108when divider structure354is formed.

The above-described embodiments provide a tray for supporting a plurality of containers and/or products using less material than is used in known tube-type trays. More specifically, the divider panel assemblies defined within the side, end, and bottom panels do not require a plurality of panels to form a tube. Further, because each container is contacted by two divider structures configured to correspond to the shape of the container, the container is more securely supported within the tray, as compared to trays using the side and end walls in conjunction with one holder to secure a container.

Exemplary embodiments of a tray for supporting containers and a blank for making the same are described above in detail. The methods, blanks, and trays are not limited to the specific embodiments described herein, but rather, components of blanks and/or trays and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.