A TRAY CONTAINER AND BLANK

Abstract: A tray and a blank (10) for forming the tray for holding foodstuff or the like which tray is formed from paperboard or like foldable sheet material and can be erected from a flat collapsed condition into a position of use, the tray comprising a plurality of tray walls including a base wall (18), opposed side and end walls (16, 20; 58, 70), wherein there further comprises a gusset panel structure (74, 78) spanning each side wall (16, 20) and either end wall (58, 70) to prevent egress of fluid from the base wall (18) at each corner of the tray, and wherein the gusset structure (74, 78) and the end walls (58, 70) are automatically erected in response to folding of the opposed side walls (16, 20) towards each other.

Description: A TRAY CONTAINER AND BLANK Background of the Invention The present invention relates to a carton (or tray) for accommodating foodstuff, for example fish or meat, and more particularly, to a carton formed from one or more blanks of paperboard or other suitable foldable sheet material. Tray structures formed from board generally lack strength when compared to trays formed from plastics material, so more commonly trays are formed from polystyrene or other plastics material. It is known from WO 93/15962 to provide a fluid tight packaging tray formed from cardboard comprising a single base panel surrounded by side and end wall structures and connected by an enclosure arrangement to maintain a foodtight seal and to prevent liquid from rising by capillarity. A further fluid tight tray is disclosed in US 5 183 201. The tray comprises a single base panel with side and end panels hingedly connected thereto. The side wall panels are greater in length than the base panel and are connected to the end panels. Prior art trays do not appear to lend themselves to mechanised construction, and in particular the automatic erection of the side/end walls. Summary of the Invention The present invention in its preferred embodiment seek to overcome or at least mitigate the problems of the prior art. Accordingly, a first aspect of the present invention provides a tray for holding foodstuff or the like which tray is formed from paperboard or like foldable sheet material and can be erected from a flat collapsed condition into a position of use, the tray comprising a plurality of panels including a base panel, opposed side and end panels and wherein there further comprises a gusset structure spanning the side and end panels to prevent egress of fluid from the base panel at each said corner of the tray, wherein the gusset structure and end panels are automatically deployed in response to the folding of the opposed side wall panels towards each other. Preferably, the panels forming the tray are a composite structure comprising inner and outer panels forming the base, side and end walls. More preferably, the inner and outer side wall panels are separated by a spacer panel to improve rigidity of the side walls. According to an optional feature of this aspect of the invention there may further comprise a beam support structure formed at one end of the tray from the inner end panel foldably connected along a first fold line to the lateral margin of the inner base panel and the outer end panel foldably connected along a second fold line to the outer base panel, wherein the first and second fold lines are offset such that the inner end panel extends upwardly to abut the outer end panel thereby to define the beam. According to another optional feature of this aspect of the invention the gusset structures may comprise at least one gusset panel foldably interconnecting the inner end panel to its adjacent inner side wall panel. Preferably, the at least one gusset panel is triangular in shape and wherein said adjacent side wall panels includes a bevelled edge to which the triangular gusset panel is foldably connected. According to a further optional feature of this aspect of the invention the angle between the fold lines for defining the at least one gusset panel may be less than 45 degrees. According to a still further optional feature of this aspect of the invention the gusset panel may project outwardly from the inner end wall panel. Preferably, the outer end wall panel and outer side wall panel may cover the gusset panel. According to yet another optional feature of this aspect of the invention the outer panels may be formed from a first blank and the inner panels are formed from a second blank. A second aspect of the invention provides a blank for forming a tray comprising a plurality of first side wall panels, an inner base panel, a second side wall panel and an outer base panel hingedly connected together in series and opposed inner and outer end panels hingedly connected to the inner and outer base panels respectively wherein there further comprises a gusset panel spanning the side and inner end panels to prevent egress of fluid from the base panel at each said corner of the erected tray, wherein the gusset and inner and outer end panels are so constructed and arranged to be automatically deployed in response to the folding of the opposed side wall panels towards each other during set up of the carton. Preferably, the panels forming the tray may be a composite structure comprising inner and outer panels forming the side walls. Preferably, the inner and outer side walls may be separated by a spacer panel. According to an optional feature of the second aspect of the invention there may further comprise a beam support structure formed from the inner end panel foldably connected along a first fold line to the lateral margin of the inner base panel and the outer end panel foldably connected along a second fold line to the outer base panel, wherein the first and second fold lines are offset such that when erected the inner end panel extends upwardly to abut the outer end panel thereby to define the beam. According to another optional feature of the second aspect of the invention the gusset structures may comprise at least one gusset panel foldably interconnecting the inner end panel to its adjacent inner side wall panel. Preferably, the at least one gusset panel may be triangular in shape and wherein said adjacent side wall panels includes a bevelled edge to which the triangular gusset panel is foldably connected. According to a further optional feature of the second aspect of the invention the angle between the fold lines for defining the at least one gusset panel may be less than 45 degrees. According to a still further optional feature of the second aspect of the invention the gusset panel may project outwardly from the inner end wall panel. Preferably, the outer end wall panel and outer side wall panel may cover the gusset panel. According to yet another optional feature of the second aspect of the invention the inner panels may be provided by a second blank. A third aspect of the invention provides a method of forming a tray from a blank, which method comprises the steps: forming a two ply base, end and side wall structures; folding the side walls out of alignment with the base such that the inner end panels are automatically erected in response to folding the opposed side walls towards each other; and folding the outer end panels to abut a portion of the inner end walls to be secured to the side walls thereby to complete construction of the tray. Preferably, the gusset panels may be automatically folded inwardly and upwardly in response to folding the side walls. According to an optional feature of the third aspect of the invention the gusset panels may be pre- folded prior to final folding of the side and end walls. Brief Description of the Drawings Exemplary embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: FIGURE 1 is a plan view of a blank for forming a carton according to a preferred embodiment of the invention; FIGURE 2 illustrates an underside view of a part- formed carton of the blank illustrated in Figure 1; FIGURE 3 illustrates the top plan view of a part- formed carton of the blank illustrated in Figure 1; FIGURES 4 and 5 are perspective views of the carton shown during folding; FIGURE 6 is a plan view of a blank for forming a carton according to a second preferred embodiment of the invention; FIGURES 7 and 8 are perspective views of the carton formed from the blank shown in Figure 6; FIGURES 9A and 9B is a plan view of a two part blank for forming a carton according to a third embodiment of the invention; FIGURES 10A, 10B and IOC illustrate the formation of the carton from the blanks of Figures 9 A and 9B; and FIGURES 11 and 12 are perspective views of the carton formed from the blank shown in Figures 9 A and 9B. Detailed Description of the Preferred Embodiments Referring first to the first embodiment shown in Figure 1, there is shown a blank 10 for forming a collapsible tray or carton made from one or more blanks of paperboard or similar foldably sheet material. In this embodiment, the blank 10 comprises first outer base wall flap 12, outer and inner side wall panels 14, 16, inner base wall panel 18, a second pair of inner and outer side wall panels 20, 22 and an outer base wall panel 24 hingably connected together in series along foldlines 26, 28, 30, 32, 34 and 36 respectively. In other embodiments, separate blanks may be used to form the two ply structure or indeed a single ply structure incorporating the invention is envisaged. There further comprises outer end wall panel 38 hingably connected to an end edge of outer base wall panel 24 along fold line 40 and a second outer end wall panel 42 hingably connected to opposing end edge of outer base wall panel 24 along fold line 44. Preferably, each outer end wall panel 38, 42 may each further comprise a support flap 39, 43 to support the stretch film positioned along outer edges of outer end flaps 34, 36 respectively along fold lines 41 and 45 described below. Suitable securing means for connecting the end and side wall panels is provided. In this embodiment, there comprises a pair of oppositely disposed securing flaps 46, 48 extending from opposite ends of side wall panel 22 and are connected thereto along co-linear extensions of fold lines 40 and 44 respectively. The securing flaps 46, 48 are adjacent the end panels 38, 42 and are separated therefrom by cut lines. Similarly a second pair of securing flaps 50, 54 are foldably connected to opposite ends of outer side wall panel 14 along fold lines 52, 56 respectively. In this embodiment, a first liquid retaining structure 57, shown in Figure 4 is provided by an end flap 58 foldably connected to base wall panel 18 along fold line 60. Turning again to Figure 1, the first liquid retaining structure is provided by end flap 58 which is connected to opposing inner side wall panels 16 and 20 respectively by a corner structure. In this embodiment the corner structures are provided by gusset panels 62 and 66. Gusset panel 62 is foldably connected to a side edge of end flap 58 along an extension of fold line 30 and is foldably connected to inner side wall panel 16 along fold line 64. Optionally, fold line 64 is configured to converge towards the intersection of fold lines 30 and 60, so that gusset panel 62 is substantially triangular in shape. Similarly, gusset panel 66 is foldably connected to the opposing side edge of end flap 58 along an extension of fold line 32. Gusset panel 66 is connected to inner side wall panel 20 along fold line 68. Fold line 68 may converge towards the intersection of fold lines 60 and 32, so that gusset panel 66 is preferably triangular in shape. In some embodiments the fold lines connecting the end flap 58 to the gusset panels 62, 66 will be offset from the fold lines 30, 32 connecting the side and base wall panels. Preferably, there further comprises a second liquid retaining structure 71 , which in this embodiment is struck from the opposing end edge of inner base wall panel 18. The second structure is similar to the first structure and is provided by an end flap 70 foldably connected to base wall panel 18 along fold line 72. End flap 70 is also connected to opposing inner side wall panels 16, 20 respectively by gusset panels 74 and 78. Gusset panel 74 is foldably connected to a side edge of end flap 70 along an extension of fold line 30 and is foldably connected to inner side wall panel 16 along fold line 76. In this embodiment, fold line 76 is configured to converge towards intersection of fold lines 30 and 72 so that gusset panel 74 is substantially triangular in shape. Similarly, gusset panel 78 is foldably connected to the opposing side edge of end flap 70 along an extension of fold line 32. Gusset panel 74 is connected to inner side wall panel 20 along fold line 80. Fold line 80 converges towards the intersection of fold lines 72 and 32 so that gusset panel 78 is preferably a triangular shape. Turning to the construction of the inner base wall panel 18, it will be seen that inner side wall panels 16, 20 are greater in length than the inner base wall panel 18 such that the opposite ends of the inner side wall panels projects outwardly beyond the end edges of the inner base wall panel. Each projecting end portions of each inner side wall panel has a bevelled edge to which the adjacent gusset panel is foldably connected. This configuration encourages automatic folding to occur during the tray set up to which a liquid retaining structure is formed, to inhibit egress of fluid from the tray. Thus, gusset panels 62, 66 and 76, 78 provide a fluid retaining structure that can prevent egress of liquid contained in the tray and allow the end panels to be deployed automatically in the sense that it causes the adjacent inner end flap in this embodiment to be erected automatically in response to erection (or folding) of the adjacent inner side wall panel. Preferably, the angle between the fold lines defining each gusset panel is less than 45 degrees, although it is envisaged that in some embodiments the angle could be greater. The construction of the tray of the first embodiment is described by reference to Figures 2 to 5. It is envisaged that forming the flat collapsed carton, the blank and final construction and loading carton of the present invention can be formed by a series of sequential folding and gluing operations which can be formed in one or more straight line machines, so that the carton is not required to be rotated or inverted to complete its construction. The folding process is not limited to that described below and can be altered according to the particular manufacturing requirements. The outer side 1 and base wall panels, 22, 24 are first folded inwardly about fold line 34 and into superposed relationship with respective inner side and base wall panels 20, 18. Outer base wall panel 24 may be secured to inner base wall panel 18 by glue or other securing means known in the art. Commonly, one or more glue lines may be applied to the lower surface of inner base wall panel to provide an adhesive surface. At the same time, or thereafter, outer side wall panel 14 and outer base flap 12 are folded inwardly about fold line 28 and into face contacting relationship with inner side wall panel 16 and inner base wall panel 18 respectively. Outer base flap 12 is secured inner base wall panel 18 by glue or other suitable means. Optionally, outer base flap 12 is aligned with outer base wall panel 24, which, in this embodiment, is assisted by the provision of complementary protruding and recessed portions, shown in Figure 2. Thus, the carton is in a flat collapsed form as shown in Figures 2 and 3 to be supplied to the user, to be erected into a tray. Preferably, the end wall flaps 58, 70 and gusset panels 62, 66; 76, 78 of inner base wall panel 18 are not secured to outer base wall panel 24 or respective outer end wall panels 38, 42 and are therefore moveable with respect to those panels. In one class of embodiments, the gusset panels or corner structures are pre-folded to assist in final folding of the side and end walls. To erect the carton, the sides and ends are formed by folding side wall panels 14/16; 20/22 inwardly about fold lines 30 and 32 respectively, as shown in Figure 4. There is a tendency for the folding action "X" to cause the gusset panels 62, 66 and 74, 78 to be folded in an upward and inward direction and into face contacting relationship with the respective inner side wall panels 16, 20 such that the inner end wall flaps 58, 70 are automatically folded inwardly and upwardly into an erected condition, as shown in Figure 4. Beneficially, this reduces construction time of the carton which is an important factor in automated packaging. In this embodiment, the inner end wall flaps 58, 70 are positioned in an acute angle with respect to the base wall panel 18 to define part of a support structure referred to below. Thereafter, outer end wall panels 38, 42 are inwardly folded in direction Y along fold lines 40, 44 to abut the inner end wall flaps 58, 70 respectively and are secured in place by securing flaps 46, 50 and 48, 54 thereto to retain the tray in a set up condition, as illustrated in Figure 5. Turning to the second embodiment illustrated in Figures 6, 7 and 8, there is shown a blank 110 for forming a tray shown in Figure 8 which blank is formed from paperboard of similar foldable sheet material. The blank is substantially the same as the first embodiment and like parts are designated by the same reference numeral with the prefix of numeral "1". Therefore, only the differences between the two embodiments will be described in any detail. It will be seen that inner and outer side wall panels 114 and 116 are separated by a spacer panel 115 which is hingedly connected thereto along fold lines 128 and 129 respectively. Similarly, a second pair of inner and outer side wall panels 120, 122 is also separated by a spacer panel 121 and hingedly connected thereto along fold lines 134 and 135. In use, these panels provide a beam structure along each side wall thereby to improve the rigidity of the tray, as shown in Figures 7 and 8. A further difference relates to the fold lines 164, 168, 176 and 180 connecting the gusset panels 162, 166, 174, 178 to their respective side wall panels 116, 120. It will be seen that these fold lines are still preferably divergent, but that their orientation with respect to the adjacent fold lines 130 and 132 have been altered. This construction advantageously allows the automatic deployment of the inner end wall panels 158 and 170 and the gusset panels 162, 166, 174 and 178 so that the gusset panels 162, 166, 174 and 178 are folded into the voids formed by the side wall beam structures; with the result that the respective end panels 158, 170 can be placed in face contacting relationship with their adjacent gusset panels 164, 168; 174, 178 to provide a corner structure whereby the inner side and end panels abut to provide flush corners as shown in Figure 8. The third embodiment of the invention is illustrated by reference to Figures 9 A, 9B, 10 A, 10B, 10C and 11 and 12. The third embodiment is substantially the same as first and second embodiments and therefore like parts are designated by the same reference numerals but with the prefix "2". Therefore, only those differences with the first and second embodiments will be described in any greater detail. It will be seen from Figures 9 A and 9B that the third embodiment differs from the second embodiment in that it is formed from a two part blank. Beneficially, this allows those panels forming the inner tray structure to be coated with the suitable waterproof and/or greaseproof agents to enable it to receive foodstuffs. Therefore, the panels forming the outer tray are not required to go through that same process with the consequent cost savings. However, the formation of the third embodiment differs from the first and second embodiments in that the inner tray blank is applied to the outer tray blank whereby the inner and outer base wall panels 218, 224 are placed in aligned face contacting arrangement and secured each other by glue G or other suitable known means. Preferably, inner side wall panels 216 and 220 are secured to the inner side wall panels 219 and 217 respectively of the outer blank as shown in Figure 10B. The remaining panels are constructed in a like manner to these embodiments described above, thereby to provide a flat collapsed tray as shown in Figure 10C, which will be supplied to the user. In order to construct the tray, the side walls are constructed by folding in direction X" which causes the inner end wall panels 258 and 270 to be automatically deployed in a similar manner to that described above and the outer end panels 238, 242 are folded and secured to the next adjacent side wall panels 222; 214 thereby to provide a tray as shown in Figure 12. Preferably, a support structure is provided at each end, defined by inner and outer end wall panels and outer base wall panel which form a beam to improve the rigidity of the tray. It is envisaged that the support structure could be incorporated into the invention without there being fluid retaining structures present without departing from the scope of invention. Further, the comer structure is disposed internally of the outer panels of the tray (i.e. between inner and outer trays) to provide a more aesthetically pleasing tray and to allow promotional material to be viewed with ease. It is envisaged that the support structure can be erected automatically by employing configurations other than those described above, without departing from the scope of invention. For example, the or each support structure could be provided by the side wall panels or the end flap could be connected to the outer end panels to encourage automatic erection of the outer panels . In some embodiments, end flaps 58, 70 are prevented from being folded beyond a predetermined point by first folding flaps 39, 43 such that the fold lines 41, 45 function as limit stops. Thereafter, foodstuff is loaded into the tray from above and stretch film can be applied to the tray to seal the package. The flaps 39, 43 are folded prior to or at the time of applying the film to space the film from the product and to provide a surface to receive the film. Thus, Figures 5, 8 and 12 show a tray for holding foodstuff or the like which tray is formed from paperboard or like foldable sheet material and can be erected from a flat collapsed condition shown in Figures 2 and 10C, into a position of use. The tray comprises a plurality of panels including a base wall panel, opposed side and end panels and wherein there further comprises a gusset panel structure spanning the side and end panels to prevent egress of fluid from the base wall panel at each said comer of the tray, wherein the gusset structure and end panels are automatically erected in response to folding the opposed side wall panels towards each other. The resulting support structure 90, 190, 290 shown in Figures 5, 8 and 12 created by the inner end wall flap, the outer end wall panel and outer base wall panel provides additional support to improve the rigidity of the carton. Beneficially, the two ply embodiment hereinbefore described provides a structure that is strengthened to retain foodstuff. The use of paperboard material provides an "environmentally friendly" alternative to trays formed from plastics material and the tray can include printed matter for marketing purposes. It will be recognised that as used herein, directional references such as "top", "base", "end", and "side" do not limit the respective panels to such orientation, but merely serve to distinguish these panels from one another . Any reference to hinged connection should not be construed as necessarily referring to a single fold line only: indeed it is envisaged that hinged connection can be formed from one or more of one of the following, a score line, a frangible line or a fold line, without departing from the scope of invention. The present invention and its preferred embodiment relates to an article carrier which is shaped to provide satisfactory rigidity to hold items such as meat or fish securely but with a degree of flexibility. The shape of the blank minimises the amount of paperboard required for the carton. The items can be applied to the carrier by hand or automatic machinery. It is anticipated the invention can be applied to a variety of carton or tray types and not limited to those of the flat tubular sort, for example the flat tubular structure could be replaced by a stracture with longer sides and end panels to receive larger cuts of meat. Furthermore, the support structure(s) can be formed from the side wall panels of the carton or without departing from the scope of invention.

Claims: CLAIMS 1. A tray for holding foodstuff or the like which tray is formed from paperboard or like foldable sheet material and can be erected from a flat collapsed condition into a position of use, the tray comprising a plurality of tray walls including a base wall, and opposed side and end walls, wherein there further comprises a gusset structure spanning the side and end walls to prevent egress of fluid from the base wall at each comer of the tray, and wherein the gusset stracture and the end walls are automatically deployed in response to folding of the opposed side walls towards each other. 2. A tray according to claim 1 wherein each of the tray walls forming the tray is a composite stracture comprising inner and outer wall panels . 3. A tray according to claim 2 wherein the inner and outer side wall panels of each side wall are separated by a spacer panel to improve rigidity of the side walls. 4. A tray according to claim 2 or claim 3 further comprising a beam support stracture formed at one end of the tray from the inner end wall panel foldably connected along a first fold line to the lateral margin of the inner base wall panel and the outer end wall panel foldably connected along a second fold line to the outer base wall panel, wherein the first and second fold lines are offset such that the inner end wall panel extends upwardly to abut the outer end wall panel thereby to define the beam. 5. A tray according to any of claims 2 to 4 wherein the gusset structures comprise at least one gusset panel foldably interconnecting the inner end wall panel to its adjacent inner side wall panel. 6. A tray according to claim 5 wherein the at least one gusset panel is triangular in shape and wherein said adjacent inner side wall panel includes a bevelled edge to which the triangular gusset panel is foldably connected. 7. A tray according to claim 5 or claim 6 wherein the angle between the fold lines for defining the at least one gusset panel is less than 45 degrees. 8. A tray according to any of claims 5 to 7 wherein the gusset panel projects outwardly from the inner end wall panel. 9. A tray according to claim 8 wherein the outer end wall panel and outer side wall panel cover the gusset panel. 10. A tray according to any of claims 2 to 9 wherein the outer panels are formed from a first blank and the inner panels are formed from a second blank. 11. A blank for forming a tray comprising a plurality of first side wall panels, an inner base wall panel, a plurality of second side wall panels and an outer base wall panel hingedly connected together in series, opposed inner wall panels hingedly connected to the inner base wall panel and opposed outer end wall panels hingedly connected to the outer base wall panel wherein there further comprises a gusset panel spanning each of the inner end wall panels and each of its adjacent first and second side wall panels to prevent egress of fluid from the inner base wall panel at each comer of the erected tray, wherein the gusset panel and the inner end wall panels are so constructed and arranged to be automatically deployed in response to the folding of the first and second side wall panels towards each other during set up of the carton. 12. A blank according to claim 1 1 wherein the first side wall panels form a first composite side wall, the inner and outer base wall panels form a composite base wall, the second side wall panels form a second composite side wall, and each inner end wall panel and its adjacent outer end wall panel form a composite end wall. 13. A blank according to claim 12 wherein the first side wall panels are separated by a first spacer panel, and the second side wall panels are separated by a second spacer panel. 14. A blank according to any of claims 11 to 13 further comprising a beam support stracture formed from each inner end wall panel foldably connected along a first fold line to the lateral margin of the inner base wall panel and its adjacent outer end wall panel foldably connected along a second fold line to the outer base wall panel, wherein the first and second fold lines are offset such that when erected the each inner end wall panel extends upwardly to abut the adjacent outer end wall panel thereby to define the beam. 15. A blank according to any of claims 12 to 14 wherein each gusset panel foldably interconnects its adjacent inner end wall panel and its adjacent side wall panel. 16. A blank according to claim 15 wherein the at least one gusset panel is triangular in shape and wherein said adjacent side wall panel includes a bevelled edge to which the triangular gusset panel is foldably connected. 17. A blank according to claim 15 or claim 16 wherein the angle between fold lines for defining the at least one gusset panel is less than 45 degrees. 18. A blank according to any of claims 15 to 17 wherein the gusset panel projects outwardly from the adjacent inner end wall panel when the blank is erected into the tray. 19. A blank according to claim 18 wherein the gusset panel is covered by its adjacent outer end wall panel and its adjacent outer side wall panel when the blank is erected into the tray. 20. A blank according to any of claims 1 1 to 19 wherein the inner wall panels are provided by a second blank. 21. A method of forming a tray from a blank as claimed in any of claims 11 to 19, which method comprises the steps: - (i) forming a two ply base wall, end and side walls ; (ii) folding the side walls out of alignment with the base wall such that the inner end wall panels are automatically erected in response to folding the opposed side walls towards each other; and (iii) folding the outer end wall panels to abut a portion of the inner end wall panels to be secured to the side walls thereby to complete construction of the tray. 22. The method as claimed in claim 21 wherein the gusset panels are automatically folded inwardly and upwardly in response to folding the side walls in step (ii). 23. A method as claimed in claim 21 or claim 22 wherein the gusset panels are pre-folded prior to final folding of the side walls. 24. A blank for forming a tray according to any one of claims 1 to 10.

Inventors: LEBRAS PHILIPPE, LEBRAS, PHILIPPE
Applicants: LEBRAS PHILIPPE, MEAD CORP, LEBRAS, PHILIPPE, THE MEAD CORPORATION
Application year: 2000
Main classification: B65D
IPC codes: B65D5