A TRAY CONTAINER AND BLANK

Abstract: A tray and a blank for forming 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 comprises a plurality of panels for forming a base, opposed side and end walls wherein the panels forming the tray are a composite structure comprising inner and outer panels forming the base, side and end walls. The insert (80) is retained in the tray (T) by means of a securing tab (38, 40) formed from the tray and engaged by an upper edge of the insert.

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 of other suitable foldable sheet material. Tray structures for meat are commonly formed from plastics material, for example polystyrene. There can be excess food liquid, for example blood or water from foodstuff which is undesirable. One solution is illustrated in US 3 156402 which shows a food products support tray including two layers in which the liquid is stored. The liquid passes through openings and is held between the layers. It is apparent that handling of the tray will push liquid back through the openings. Further, if the tray is stored in an upright position, the liquid will collect along the edges and at the corners. 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. Summary of the Invention The present invention and its preferred embodiments seek to overcome or at least mitigate the problems of the prior art. One aspect of the 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 for forming a base, opposed side and end walls wherein the panels forming the tray are a composite structure comprising inner and outer panels forming the base, side and end walls. Preferably, the inner panels forming the base, side and end walls are provided by an insert. According to an optional feature of this aspect of the invention, the insert is retained in the tray by means of a securing tab formed from one of the insert or the tray and engaged with the other one of the insert or the tray. The securing tab may be struck from the outer side panel and is adapted to protrude inwardly thereby to abut an upper edge of the inner side wall panel of the insert. According to another optional feature of this aspect of the invention, there further comprises a beam support structure formed along one side of the tray from the inner side panel foldably connected along a first fold line to the outer base panel and the outer side 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 side panel extends upwardly to abut the outer end panel thereby to define the beam. A spacer panel may hingedly interconnect the inner and outer end panels to form the beam. The securing tab may extend from the spacer panel. Preferably, the insert may be provided with an end panel, which end panel extends outwardly beyond the base panel to be sandwiched between the end of the side wall structure and the end wall of the tray to restrict movement of the insert within the tray. According to a further optional feature of this aspect of the invention, there is a deformable portion hinged to the adjacent side and end panels between the base panel and the securing means, said deformable portion deformed when the tray is erected to provide a ply of material spanning the side and end panels to inhibit egress of fluid from the base panel at each said corner of the tray. The deformable portion may be hingedly connected to the adjacent side panel by a fold line in an obtuse angular relationship with the fold line connecting the end panel and base panel. According to an optional feature of this aspect of the invention, the securing means comprises a flap hingedly connected to one of said side and end panels and foldable to be superposed with the other said side and end panels to be secured therewith, which flap is severed from the deformable portion. The deformable portion may be provided by a gusset panel. According to another optional feature of this aspect of the invention, the inner and outer walls forming the base and the side and end walls define one or more skinned zones providing one or more voids wherein means are provided to give fluid communication between the internal surface of the base and said void so that fluid present in the tray can drain into the voids in the base and in the side and end walls. Preferably, the fluid communication means comprises a plurality of perforations distributed along at least one edge of the inner base wall. Optionally, the voids include absorbing means to absorb said liquid. The absorbing means may be provided by a layer of liquid absorbing material placed in at least one of the voids. Preferably, the internal surface of the base is impermeable. A second aspect of the invention provides a unitary blank for forming a tray comprising a blank for forming a tray for holding foodstuff or the like which tray is formed from paperboard or like foldable sheet material comprising a plurality of panels for forming an outer base, opposed side and end walls and an insert comprising a plurality of panel forming the inner base, side and end walls. A third aspect of the invention provides a blank for forming a tray for holding foodstuff or the like which tray is formed from paperboard or like foldable sheet material comprising a plurality of panels for forming an outer base, opposed side and end walls and a blank for forming an insert comprising a plurality of panel forming the inner base, side and end walls. The securing tab is struck from the outer side panel and is adapted to protrude inwardly thereby to abut an upper edge of the inner side wall panel of the insert. There may further comprise a beam support structure formed along one side of the tray from the inner side panel foldably connected along a first fold line to the outer base panel and the outer side 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 side panel extends upwardly to abut the outer end panel thereby to define the beam in a set up tray. According to an optional feature of the second or third aspects of the invention, there further comprises a spacer panel hingedly interconnecting the inner and outer end panels to form the beam in a set up condition. According to an optional feature of the second or third aspects of the invention, there further comprises a deformable portion hinged to the adjacent side and end panels between the base panel and the securing means, said deformable portion deformed when the tray is erected to provide a ply of material spanning the side and end panels to inhibit egress of fluid from the base panel at each said corner of the tray. Preferably, the deformable portion is hingedly connected to the adjacent side panel by a fold line in an obtuse angular relationship with the fold line connecting the end panel and base panel. According to an optional feature of the second or third aspects of the invention, the securing means comprises a flap hingedly connected to one of said side and end panels and foldable to be superposed with the other said side and end panels to be secured therewith, which flap is severed from the deformable portion. According to a further optional feature of the second or third aspects of the invention, said deformable portion is provided by a gusset panel. There may further comprise a plurality of perforations distributed along at least one edge of the base. A fourth aspect of the invention provides a method of forming a tray from a blank which method comprises the steps: - (i) forming a two ply base, end and side wall structures; (ii) 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 (iii) 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. 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 an outer tray according to a preferred embodiment of the invention; FIGURE 1 A is a plan view of the blank for forming an insert for the tray shown in Figure 1 ; FIGURES 2, 3, 4 and 5 illustrate formation of the tray from the blank of Figures 1 and 2; FIGURE 6 is a perspective view of the tray and insert shown during folding of the side walls; FIGURE 7 is a cross-sectional view X - X of the carton formed from a blank shown in Figure 6; FIGURES 8, 9 and 10 illustrate the construction of the end structures; FIGURE 11 is a perspective view of a set up tray; FIGURE 12 is a plan view of a unitary blank for forming a fray according to a second embodiment; FIGURES 13 and 14 illustrate the construction of the tray from the blank of Figure 12; FIGURE 15 is a perspective view of the tray shown during folding of the side walls; and FIGURE 16 is a cross sectional view x'-x' of the tray shown in Figure 16. Detailed Description of the Preferred Embodiments Referring first to 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 foldable sheet material. The blank 10 comprises a plurality of panels for forming an outer tray. A separate insert blank 80 is provided which is described in more detail below. In this embodiment the outer tray blank 10 comprises a first outer side wall panel 12, base panel 14, and second outer side wall panel 16 hingedly connected together in series along foldlines 18, 20 respectively. There further comprises an inner side wall structure 22, 22a hingedly connected to side wall panels 16 and 12 respectively along fold lines 32 and 32a. Turning to the construction of inner side wall structure 22, there comprises a securing flap 27 and an inner side wall panel 26 hingedly connected together along fold line 30. In some embodiments the inner side wall panel 26 is connected to outer side wall panel, although in the illustrated embodiment, there may further comprise spacer panel 24 hingedly interconnecting outer side wall panel 16 to inner side wall panel 26 along fold lines 32 and 28 respectively. There further comprises one or more tabs 38, 40 that extend from the inner side wall panel 26 or, in this embodiment, spacer panel 24 and into inner side wall panel 26. The free edges of tabs 38, 40 are defined by cut lines 34 and 36 respectively, the opposing ends of which cut lines intersect with interrupted fold line 28. The opposing inner wall structure 22a is identical in construction to inner wall panel 22 and like parts have been designated by the same reference numeral with the addition of the letter "a": therefore they are not described in any greater detail. End structures 42, 42a are hingedly connected to the opposing ends of base panel 14 along fold lines 50 and 50a respectively. The construction of each end structure 42, 42a is identical and like references have been used. Therefore, describing the end structure 42 in more detail, there comprises an end panel 46 hingedly connected to base panel 14. In this embodiment, there may comprise an intermediate panel 44 hingedly interconnecting end panel 46 to base panel 16. Intermediate panel 44 is connected to end panel 46 along fold line 52. The intermediate panel 44 is used when a fluid retaining structure is employed, described in more detail below. There may further comprise an end support flap 48 hingedly interconnected to end wall panel 46 along fold line 54 to support stretch film placed over the tray. Suitable securing means for connecting the end and the side wall panels is provided. In this embodiment there comprises a pair of oppositely disposed securing flaps 56, extending from corresponding ends of the side wall panels 16 and 12 and are connected thereto along a co- linear extension of fold line 50, designated by reference numeral 57. The securing flaps 56 are adjacent end wall panel 46 and are separated in part from end wall panel 46 by cut lines 59. A second pair of identical securing flaps 56a are hingedly connected to the opposite ends of side wall panels 12 and 16 along fold line 57a. In this embodiment, there comprises one or more fluid retaining structures. It will be seen from Figure 1 that the fluid retention structure comprises a tab 58 formed from end flap 56 and hingedly connected thereto along fold line 60. In use, the tab 58 forms a deformable portion that prevents egress of fluid. Fold line 60 extends outwardly from the intersection of the fold lines 18, 50 connecting the side wall and end wall to the base panel 14. A cut line 61 extends from the cut line 59 to the edge of fold line 60. Preferably, tab 58 is hingedly connected to end wall panel 46 along an extension of fold line 18 or 20 respectively. There usually comprises a fluid retaining structure positioned in each of the corners of the side and end walls of the tray, although these are not shown in Figures 2 to 11. As mentioned above, there further comprises a separate insert 80 to be used with tray blank 10, which insert comprising a base panel 82, opposed side wall panels 84, 86 hingedly connected to base panel 82 along fold lines 88 and 90 and opposed end wall panels 92 and 96 hingedly connected to the base panel along fold lines 94 and 98 respectively. Preferably, the end wall panels 92, 96 are wider than base panel 82 such that the opposite ends of the end wall panels project outwardly beyond the side edges of the base panel. Although there are shown separate blanks for the tray and insert, it is envisaged that a unitary blank for both parts could be used without departing from the scope of invention, for example in the second embodiment shown in Figure 12, the blank 110 comprises panels for forming the outer tray T and the insert I is connected to the outer tray. The second embodiment is similar to the first embodiment with like parts being designated by the same reference numerals with the addition of "1". Only the differences will now be described in any greater detail. The side wall 184 of the insert is to connected to spacer panel 124a along fold line 128a; thus in this embodiment, the insert side wall panel 184 also functions as the inner side wall of the outer tray. The insert I further comprises opposed side wall panel 186, base panel 182 and opposed end wall panels 196 which are preferably aligned with the end wall structures of the outer tray. The securing tabs 138, 140 are struck from one side wall only, as the insert is joined to the fray. The outer tray structure T is in other respects identical to the first embodiment, referred to above. The construction of the fray is described by reference to Figures 2 to 11 and 13 to 16. It is envisaged that the construction of a flat collapsed carton and final construction and loading of the tray of the present invention can be formed by a series of sequential folding and gluing operations which can be performed in one or more straight line machines, so that the tray 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 particular manufacturing requirements. In the first embodiment, the side walls are constructed, as illustrated in Figures 2 and 3 whereby the inner side wall structures 22 and 22a of the outer tray are folded inwardly along fold lines 32 and 32a respectively in directions Y and Z and are secured to the base panel 14. In the embodiment illustrated, securing panels 28 and 28a are secured to base wall panel 14 by glue or other suitable securing means known in the art. Thus, the tray T is in a flat collapsed form as shown in Figure 3 to be supplied to the user so it can be erected. In order to erect the tray T (Figure 11), the outer side wall panels 12 and 16 are folded inwardly which causes the inner and outer side wall panels to be separated and spaced therefrom by the spacer panels 24 and 24a, and because fold lines 20 and 30 are spaced. This action causes the tabs 38, 40; 38a, 40a to become separated from the respective inner side wall panels 26 and 26a thereby to protrude inwardly with respect to the side walls, as shown in Figure 4. Preferably, support structure is provided at each side, defined by inner and outer side wall panels 26, 26a; 12, 16, the spacer panel and part of outer base panel 14 of the outer fray which forms a beam B (Figures 4 and 6). It is envisaged that the support structure could be incorporated into the invention with or without the presence of fluid retaining structures. Insert tray 80 is placed on base panel 14 by relative vertical movement between the insert and tray in a packaging machine, as is well known. Preferably, side wall panels 84 and 86 are folded inwardly along fold lines 88 and 90, as shown in Figure 5. In one class of embodiments, base panel 82 is secured to base panel 14 by glue or other suitable means known in the art, although it is advantageous not to secure the aforementioned panels together so as to provide a void Nl illustrated in Figure 7. The insert 80 is prevented from being separated from the tray T by the protruding portions 38, 40, 38a, 40a that are adapted to abut the upper edges of side panels 84 and 86, shown in Figure 6. The outer side walls 12, 16 continue to be pushed inwardly in directions W and Wl until the side wall panels are placed in an erected condition. In this embodiment, the inner and outer side wall panels 16, 26; 12, 26a of the tray T are in a substantially perpendicular arrangement with respect to the base panel 14, as shown in Figure 7. The ends of the tray T is constructed and described with reference to Figures 8, 9 and 10. Each end wall structure is constructed in like manner and therefore only one end will be described in any detail. In the illustrated embodiment, end wall panel 92 is first folded inwardly in direction U along fold line 94 thereafter end support flaps 56 and 56a are folded inwardly as shown in Figure 9 and end wall panel 46 is secured to the end flaps 56, 56a and, optionally, to the inner end wall panel 92 by glue or other suitable means known in the art. Finally, the end support flap 48 is folded out of alignment with end wall panel 46 along fold line 54 to be placed in overlapping arrangement with spacer panels 24 and 24a, as shown in Figure 10. In those embodiments where the inner end wall panel 92 is not secured to the end wall panel 46 then the end support flap 48 functions in a similar manner to the securing tabs 38, 40 in that the upper edge of inner end wall panel 92 abuts the end support flap 48 to prevent it from being moved in an upward direction. Thus, the corner structure is disposed internally of the outer panels of the tray to provide a more aesthetically pleasing carrier and to allow promotional material to be viewed with ease. In other embodiments, the inner and outer end wall panels 92, 46 are folded inwardly together along fold lines 94 and 50 respectively and thereafter the end securing flaps 56 are secured to the outer face of the end wall panels 46 by glue or other suitable means known in the art. In those embodiments with a fluid retaining structure, the tab 58 is folded out of alignment with respect to the end flap 56 along fold lines 60 and 18, so that as end flap 56 is secured to end wall panel 46, the tab 58 is placed in overlapping relationship with end flap 56 and end wall panel 46 to provide a structure that prevents egress of liquid from the corners. In one class of embodiments the tab forms a deformable portion that extends outwardly of the corner. The tray T is prevented from moving laterally with respect to the outer fray T because the inner end wall panels 92 and 96 are provided with end portions that extend beyond the inner side walls 16, 12 of the inner tray and to abut the end edges of the side wall panels. Thus, the tray T is in a set up condition ready to receive an article, as shown in Figure 11. Turning to the construction of the second embodiment shown in Figures 13 to 16, the tray is constructed in similar manner as the first embodiment. The first side wall structure of the outer fray is constructed whereby inner side wall panel 126 and space panel 124 are folded inwardly in direction X' along fold line 132 so that securing flap 127 is secured to base panel 114 by glue or other suitable means known in the art. Thus the carton is at an intermediate stage of construction as shown in Figure 14. Thereafter the insert structure I is folded inwardly along fold line 132a into face contacting arrangement with the corresponding panels forming the outer tray T. In order to construct the fray, the side wall panels are folded inwardly as shown in Figure 15 whereby protruding tabs 138 and 140 are folded out of alignment with respect to inner side wall panel 126 so that the upper edge of side wall panel 186 abuts the protruding tabs 138, 140. In the second embodiment, as the insert is foldably connected to the outer fray, the second set of tabs along the opposing side wall are not required. The side walls are folded inwardly in direction W2 and W3 along fold lines 120, 130, 120a and 130a so as to set up the beam B as shown in Figure 16. The end wall structures are formed, in like manner to that described above and the tray is in a completed and set up condition similar to the tray shown in Figure 11 ready to receive one or more articles. One or more articles are placed on the inner tray and the structure is placed over the article and tray to retain the article within the tray, as is well known. 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 end panels. Thus, a tray T for holding foodstuff or the like is provided 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 and includes a double skinned zone around the side and end walls and the base wall to provide a void Nl, N2, N3, shown in Figures 7 and 11 or N4, N5 and N6 in Figure 16. In use, excess liquid (or exudate) from the foodstuff is retained in the tray because the base is impermeable. Preferably, the panels providing an internal surface, for example the inner base 82, side and end walls 84, 86; 90, 92 are coated with an impermeable layer. In the embodiment described above the impermeable layer is a co-polymer for example carboxylated styrene or butadiene. When the tray is stacked in an upright position, for example on a supermarket shelf, excess liquid tends to collect at the edges and in the corners. In order to remove excess fluid from the tray, a void Nl is provided by the double skinned zone, shown in more detail in Figure 7. The resulting void N2 and N3 is between the side (and end) panels 12, 16 and the support panels 32, 34 and 40, 42 which can be used to receive surplus food liquid (e.g. blood or water) present in the tray by means to give fluid communication between the internal surface of the base and the void. It is envisaged that the or each void Nl, N2, N3, N4, N5 or N6 could be adapted to receive suitable absorbing material, for example absorbing stamp or bag, preferably during the initial set up process or by the application of absorbing polymer gel, for example polyacrylamide, during the set up or gluing steps of carton construction. More preferably, liquid can be absorbed directly by the inner surfaces 49 of the panels providing the double skinned zone as shown in Figure 7. In one class of embodiments the effect of capillarity encourages movement of the liquid away from fluid communication means in the void. Preferably, the means to give fluid communication is provided by a plurality of cuts or perforations 19 struck from the inner base panel 82 to assist in movement of liquid from the upper surface of the inner base panel 22 into the or each void Nl, N2, N3. In those embodiments where fold lines 88, 90, 189, 190 are defined in part by a series of cuts 19, 119 the cuts can assist in fluid movement. 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 frays formed from plastics material and the tray can include printed matter for marketing purposes, as the board can be recycled. The arrangement of the panels for the tray in the embodiment described above allows printed matter to be placed on the internal and external side and end walls of the tray. A further advantage of the arrangement described above is that the material used for the tray and insert can differ. For example a different caliper of paper can be used, or the insert could be a food grade material, whilst the outer tray could be a material that is more suited to the application of printed matter. It will be recognised that as used herein, directional references such as "top", "base", "end", "side", "inner", "outer", "upper" and "lower" 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 a fray 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 structure with longer sides and end panels to receive larger cuts of meat. Furthermore, the double skinned zones can be formed on the inner panels of the carton, without departing from the scope of invention.

Claims: CLAIMS 1. A fray 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 fray comprising a plurality of panels for forming a base, opposed side and end walls wherein the panels forming the tray are a composite structure comprising inner and outer panels forming the base, side and end walls. 2. A tray as claimed in claim 1 wherein the inner panels forming the base, side and end walls are provided by an insert. 3. A fray as claimed in claim 2 wherein the insert is retained in the fray by means of a securing tab formed from one of the insert or the tray and engaged with the other one of the insert or the tray. 4. A fray as claimed in claim 3 wherein the securing tab is struck from the outer side panel and is adapted to protrude inwardly thereby to abut an upper edge of the inner side wall panel of the insert. 5. A tray according to any one of claims 1 to 4 further comprising a beam support structure formed along one side of the tray from the inner side panel hingedly connected along a first fold line to the outer base panel and the outer side panel hingedly connected along a second fold line to the outer base panel, wherein the first and second fold lines are offset such that the inner side panel extends upwardly to abut the outer end panel thereby to define the beam. 6. A tray according to claim 5 wherein there further comprises a spacer panel hingedly interconnecting the inner and outer end panels to form the beam. 7. A fray as claimed in claim 6, when dependent on any of claims 2 to 4 wherein the securing tab extends from the spacer panel. 8. A tray as claimed in any of claims 5 to 7 wherein the insert is provided with an end panel, which end panel extends outwardly beyond the base panel to be sandwiched between the end of the side wall structure and the end wall of the tray to restrict movement of the insert within the fray. 9. A fray as claimed in any of claims 1 to 8 further comprising a deformable portion hinged to the adjacent side and end panels between the base panel and the securing means, said deformable portion deformed when the tray is erected to provide a ply of material spanning the side and end panels to inhibit egress of fluid from the base panel at each said corner of the tray. 10. A tray as claimed in claim 9 wherein the deformable portion is hingedly connected to the adjacent side panel by a fold line in an obtuse angular relationship with the fold line connecting the end panel and base panel. 11. A fray as claimed in claim 9 or claim 10 wherein there further comprises an end securing flap hingedly connected to one of said side and end panels and foldable to be superposed with the other said side and end panels to be secured therewith, which flap is severed from said deformable portion. 12. A tray as claimed in any of claims 9 to 11 wherein said deformable portion is provided by a gusset panel. 13. A tray as claimed in any of claims 1 to 12 wherein the inner and outer walls forming the base and the side and end walls define one or more skinned zones providing one or more voids wherein means are provided to give fluid communication between the internal surface of the base and said void so that fluid present in the fray can drain into the voids in the base and in the side and end walls. 14. A tray according to claim 13 wherein said fluid communication means comprises a plurality of perforations distributed along at least one edge of the inner base wall. 15. A tray according to claim 13 or claim 14 wherein the voids include absorbing means to absorb said liquid. 16. A tray according to claim 15 wherein the absorbing means is provided by a layer of liquid absorbing material placed in at least one of the voids. 17. A fray according to any of claims 13 to 16 wherein the internal surface of the base is impermeable. 18. A unitary blank for forming a tray comprising a blank for forming a fray for holding foodstuff or the like which tray is formed from paperboard or like foldable sheet material comprising a plurality of panels for forming an outer base, opposed side and end walls and an insert comprising a plurality of panel forming the inner base, side and end walls. 19. A blank for forming a tray for holding foodstuff or the like which tray is formed from paperboard or like foldable sheet material comprising a plurality of panels for forming an outer base, opposed side and end walls and a blank for forming an insert comprising a plurality of panel forming the inner base, side and end walls. 20. A tray as claimed in claim 18 or claim 19 wherein a securing tab is struck from the outer side panel and is adapted to protrude inwardly thereby to abut an upper edge of the inner side wall panel of the insert. 21. A blank according to any of claims 18 to 20 further comprising a beam support structure formed along one side of the tray from the inner side panel foldably connected along a first fold line to the outer base panel and the outer side 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 side panel extends upwardly to abut the outer end panel thereby to define the beam in a set up tray. 22. A blank according to claim 21 wherein there further comprises a spacer panel hingedly interconnecting the inner and outer end panels to form the beam in a set up condition. 23. A blank as claimed in any of claims 18 to 22 further comprising a deformable portion hinged to the adjacent side and end panels between the base panel and the securing means, said deformable portion deformed when the tray is erected to provide a ply of material spanning the side and end panels to inhibit egress of fluid from the base panel at each said corner of the tray. 24. A blank as claimed in claim 23 wherein the deformable portion is hingedly connected to the adjacent side panel by a fold line in an obtuse angular relationship with the fold line connecting the end panel and base panel. 25. A blank as claimed in claim 23 or claim 24 wherein said securing means comprises a flap hingedly connected to one of said side and end panels and foldable to be supeφosed with the other said side and end panels to be secured therewith, which flap is severed from the deformable portion. 26. A blank as claimed in any of claims 18 to 25 wherein said deformable portion is provided by a gusset panel. 27. A blank according to claim 26 wherein there further comprises a plurality of perforations distributed along at least one edge of the base. 28. A method of forming a tray from a blank as claimed in any of claims 18 to 27, which method comprises the steps: - (i) forming a two ply base, end and side wall structures; (ii) 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 (iii) 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. 29. The method as claimed in claim 28 wherein the gusset panels are automatically folded inwardly and upwardly in response to folding the side walls in step (ii). 30. A method as claimed in claim 26 or claim 27 wherein the gusset panels are pre-folded prior to final folding of the side and end walls.

Inventors: LEBRAS PHILIPPE, LEBRAS, PHILIPPE
Applicants: LEBRAS PHILIPPE, MEAD CORP, LEBRAS, PHILIPPE, THE MEAD CORPORATION
Application year: 2001
Main classification: B65D5
IPC codes: B65D5, B65D81