Patent Publication Number: US-11643244-B2

Title: Flat pack tray with curve on set-up and blank for forming the same

Description:
REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of priority under 35 U.S.C. § 119(e) of U.S. provisional application Ser. No. 62/613,097 filed on Jan. 3, 2018 which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     The field of the invention relates generally to trays and blanks for forming the same. 
     Due to their tendency to roll, rounded items may present difficulties for, for example, shipping production lines that assemble and pack a variety of items for shipping. Thus, it would be desirable to provide a tray for holding items, including but not limited to rounded or cylindrical items, in place as they move along a production line. It would be desirable to provide a tray that is inexpensive to manufacture. It would also be desirable to provide a tray that can be shipped in a compact, knocked-down-flat configuration and quickly erected on site by hand or machine. It would also be desirable to provide a tray that can accommodate a variety of objects of different sizes, weights, and shapes. 
     SUMMARY 
     According to a first aspect of the invention, there is provided a tray formed from a blank of sheet material. The tray includes a bottom panel forming a bottom wall of the tray, a top panel forming a top wall of the tray, first and second side panels forming first and second side walls of the tray and extending between the top and bottom panels on opposite sides thereof, and a locking band connected to the bottom panel at opposite upper and lower edges thereof. The locking band extends across the top panel and holds an underlying portion of the top panel in face-contacting relationship with the bottom panel. The tray is configured to transition from a first configuration in which the tray is substantially flat into a second or erect configuration in which the top panel defines a concave surface configured to hold in place a rounded item. The tray is configured to be transitioned from the first configuration to the second configuration by sliding the top panel relative to the bottom panel. 
     Optionally, the locking band overlies a generally central portion of the top panel when the tray is in the second configuration. 
     Optionally, the top panel has a first width and the bottom panel has a second width, and the first width is smaller than the second width. 
     Optionally, the locking band is formed from overlapping first and second locking arm flaps. The first locking arm flap is hingedly connected to the upper edge of the bottom panel, and the second locking arm flap is hingedly connected to the lower edge of the bottom panel. 
     Optionally, at least one finger cutout is formed in the top panel. 
     Optionally, the tray includes a first finger cutout formed along a first side edge of the top panel and a second finger cutout formed along a second opposite side edge of the top panel. 
     Optionally, a plurality of strengthening creases are formed in the first and second side panels. 
     Optionally, the top panel includes a top center panel hingedly connected to a first top side panel and a second top side panel. 
     Optionally, the locking band comprises first and second locking tabs configured to be received within respective first and second locking apertures formed in the top panel so as to resist collapsing of the tray when the tray is in the second configuration. 
     According to a second aspect of the invention, there is provided a blank of sheet material for forming a tray. The blank includes a plurality of panels hingedly connected in series. The plurality of panels include a top panel configured to form a top wall in a set-up tray, a first side panel configured to form a first side wall in the set-up tray, a bottom panel configured to form a bottom wall in the set-up tray, and a second side panel configured to form a second side wall in the set-up tray. The tray also includes a first locking arm flap hingedly connected to the bottom panel along an upper edge thereof and a second locking arm flap hingedly connected to the bottom panel along a lower edge thereof. The first and second locking arm flaps are configured to be secured together to form a locking band in the set-up tray. The locking band extends across the top panel and holds an underlying portion of the top panel in face-contacting relationship with the bottom panel. The set-up tray is configured to transition from a first configuration in which the set-up tray is substantially flat, into a second or erect configuration in which the top wall defines a concave surface configured to hold in place a curved item. The set-up tray is configured to be transitioned from the first configuration to the second configuration by sliding the top panel relative to the bottom panel. 
     Optionally, the plurality of panels includes a glue flap panel configured to be secured in face-contacting relationship to the second side panel in the set-up tray. 
     Optionally, the locking band overlies a generally central portion of the top panel when the tray is in the second configuration. 
     Optionally, the top panel has a first width and the bottom panel has a second width, and the first width is smaller than the second width. 
     Optionally, at least one finger cutout is formed in the top panel. 
     Optionally, the blank includes a first finger cutout formed along a first side edge of the top panel and a second finger cutout formed along a second opposite side edge of the top panel. 
     Optionally, a plurality of strengthening creases are formed in the first and second side panels. 
     Optionally, the top panel includes a top center panel hingedly connected to a first top side panel and a second top side panel. 
     Optionally, the locking band includes first and second locking tabs configured to be received within respective first and second locking apertures formed in the top panel so as to resist collapsing of the set-up tray when the set-up tray is in the second configuration. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which: 
         FIG.  1    is a top plan view of an exemplary blank of sheet material according to a first embodiment of the invention; 
         FIG.  2    is a perspective view of a tray formed from the blank shown in  FIG.  1   ; 
         FIG.  3    is a top view of the tray of  FIG.  2   ; 
         FIG.  4    is a end view of the tray of  FIG.  2   ; 
         FIG.  5    shows an intermediate step in the construction of the tray of  FIG.  2   ; 
         FIG.  6    shows a top view of the tray of  FIG.  2    in a first, substantially flat configuration; 
         FIG.  7    shows a perspective view of the tray of  FIG.  2    being used to hold an item; 
         FIG.  8    shows a top view of the tray and item of  FIG.  7   ; 
         FIG.  9    shows an end view of the tray and item of  FIG.  7   . 
         FIG.  10    is a top plan view of an exemplary blank of sheet material according to a second embodiment of the invention; 
         FIG.  11    is a perspective view of a tray formed from the blank shown in  FIG.  10   ; 
         FIG.  12    is a second perspective view of the tray of  FIG.  11   ; 
         FIG.  13    is a top view of the tray of  FIG.  11   ; 
         FIG.  14    is a bottom view of the tray of  FIG.  11   . 
     
    
    
     DETAILED DESCRIPTION 
     Detailed descriptions of specific embodiments of trays and blanks are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. Indeed, it will be understood that the trays and blanks described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention. 
     Referring to  FIG.  1   , there is shown a first blank  10  for forming a tray  90  (see  FIGS.  2 - 4   ). The blank  10  is formed from a sheet of suitable substrate. It is to be understood that, as used herein, the term “suitable substrate” includes all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. It should be recognized that one or other numbers of blanks may be employed, for example, to provide the trays described in more detail below. 
     Referring to  FIG.  1   , blank  10  is generally rectangular in shape and has a first or interior surface  6  and a second or exterior surface  8 . Blank  10  is generally symmetrical about a central longitudinal axis. In a set-up condition, the tray  90  forms a structure having a bottom wall  92 , concave top wall  94 , and first and second side walls  96 ,  98 . 
     Blank  10  includes a plurality of panels hingedly connected together in series. Glue flap panel  12  is hingedly connected to a bottom panel  14  via transverse fold line  11 . Top panel  14  is hingedly connected to a first side panel  16  via transverse fold line  13 . First side panel  16  is hingedly connected to a bottom panel  18  via transverse fold line  15 . Bottom panel  18  is hingedly connected to a second side panel  20  via transverse fold line  17 . Glue flap panel  12 , top panel  14 , first side panel  16 , bottom panel  18 , and second side panel  20  may each be generally rectangular in shape. In the illustrated embodiment, first side panel  14  and second side panel  20  are mirror images of one another and generally trapezoidal in shape. In the illustrated embodiment, top panel  14  has a width W 1  that is slightly less than a width W 2  of bottom panel  18 . Cutouts C that serve as finger holes are formed in opposite ends of the top panel  14  along fold lines  11  and  33 , and in opposite ends of the bottom panel  18  along fold lines  15  and  17 . In the illustrated embodiments, cutouts C are semi-circular in shape although other shapes can be used 
     A first locking arm flap  22  is hingedly connected to an upper edge of bottom panel  18  via longitudinal fold line  19 . A second locking arm flap  24  is hingedly connected to a lower edge of bottom panel  18  via longitudinal fold line  21 . In the illustrated embodiment, first and second locking arm flaps  22 ,  24  are generally rectangular in shape. In the illustrated embodiment, an outermost portion  23  of first locking arm flap  22  is slightly tapered. Outermost portion  23  may be used as a glue-receiving portion. First locking arm flap  22  has a length L 1  measured between fold line  19  and an outermost edge  25  of first locking arm flap  22 . Second locking arm flap  24  has a length L 2  measured between fold line  21  and an outermost edge  27  of second locking arm flap  24 . Lengths L 1  and L 2  may be equal or substantially equal to one another. First and second locking arm flaps  22 ,  24  are configured such that their combined length (L 1 +L 2 ) is greater than the width W 2  of bottom flap  18  so as to allow the glue-receiving portion  23  of first locking arm flap  22  to overlap with an outermost portion of second locking arm flap  24  when the tray  90  is constructed. 
     A plurality of parallel creases and/or engraved lines  30  running perpendicular to the grain of the blank  10  may be formed in the first and second side walls  16 ,  20 . Similarly a plurality of parallel creases and/or engraved lines  32  may be formed in bottom panel  18 . Creases  30 ,  32  may provide better strength and prevent unwanted creasing under load. 
     Turning to the construction of the tray  90  as illustrated in  FIG.  2   , the tray  90  can be formed by a series of sequential folding operations. The folding process is not limited to that described below and may be altered according to particular manufacturing requirements. 
     Blank  10  is positioned with its interior surface  6  facing up. Top panel  18  is rotated inwardly about fold line  13 , bringing the interior surface  6  of top panel  18  into face-contacting relationship with the interior surface  6  of bottom panel  18  and first side panel  16 , and the interior surface  6  of glue flap panel  12  into face-contacting relationship with the interior surface  6  of bottom panel  18 . Glue G is applied to the exterior surface  8  of glue flap panel  12 . Second side panel  20  is folded inwardly about fold line  17 , bringing the interior surface  6  of second side panel  20  into face-contacting relationship with the exterior surface  8  of glue flap panel  12  and secured thereto. First locking arm flap  22  is folded inwardly about fold line  19 , bringing the interior surface  6  of first locking arm flap  22  into face-contacting relationship with the exterior surface of top panel  14 . Glue G is applied to the exterior surface  8  of the outermost portion  23  of first-locking arm flap  22 . Second locking arm flap  24  is folded inwardly about fold line  21 , bringing the interior surface  6  of the outermost portion of second locking arm flap  24  into contact with the exterior surface  8  of outermost portion  23  and securing it thereto. This results in the collapsed tray  90  shown in  FIG.  6   . First and second locking arm flaps  22 ,  24  together form a locking band  36  that maintains an underlying portion of top panel  14  in face-contacting relationship with bottom panel  18 . In this configuration, the collapsed tray is substantially flattened as shown so that it can be transported or shipped in a compact form for erection and use elsewhere. 
     To erect the tray  90  for use, a user slides top panel  14  relative to bottom panel  18  until the top panel  14  is substantially aligned with bottom panel  18 , locking band  30  is substantially aligned with and overlies a central portion of top panel  14 , and first and second side panels  16 ,  20  are in a relatively perpendicular, but slightly inwardly-angled, relationship with respect to bottom panel  18 . This results in the erected tray  90  shown in  FIGS.  2 - 4   . Finger cutouts can be used to facilitate grasping the top panel  14  and/or bottom panel  18  when sliding them relative to one another to erect the tray  90 . The pressure applied by locking band  30  causes top panel  14  to form a concave curve as shown. This pressure may also cause bottom panel  18  to bow slightly prior to loading tray  90  with an item  40 . Preferably however, bottom panel  18  is configured to resist such bowing as a result of its greater width W 2  and the use of creases  30 . 
     As shown in  FIGS.  7 - 9   , a cylindrical or rounded item  40  may be loaded onto the erected tray  90  to hold the item  40  in place temporarily as, e.g., the item  40  moves along a production line. The weight of the item  40  will tend to further flatten bottom panel  18  into a substantially planar configuration while increasing the bowing of top panel  14 . The bowing/concave shape of top panel  14  form rounded side walls that help hold the item  40  in place. Item  40  is preferably loaded onto tray  90  with its longitudinal axis substantially aligned with locking band  36  such that the rounded outer surface of item  40  is substantially aligned with or parallel to the rounded surface of top panel  14 . 
     The configuration of the disclosed blank  10  and tray  90  may provide certain advantages. In particular, the blank  10  is simple and inexpensive to manufacture. Tray  90  may be shipped in a compact, flattened configuration and quickly and easily erected on site to accommodate and securely hold in place a variety of items of different sizes, shapes, and weights. 
     Referring to  FIG.  10    there is shown a second embodiment of a tray blank  110  that forms a second embodiment of a tray  190  (shown in  FIGS.  11 - 14   ). Blank  110  and the corresponding tray  190  can be generally similar to the blank  10  and tray  90  discussed above, and like or similar reference numbers in the figures indicate like or similar elements. Top panel  114 , which forms a concave top wall  194  in set-up trap  190 , is formed from three panels hingedly connected together in series: first top side panel  140 , top center panel  142 , and second top side panel  144 . Top center panel  142  is hingedly connected to first top side panel  140  via transverse fold line  143 , and to second top side panel  144  via transverse fold line  145 . Upper and lower edges  170 ,  172  of top panel  114  can be slightly concave as shown. 
     A first locking aperture  180  is formed in first top side panel  140  along fold line  143 , and a second locking aperture  182  is formed in second top side panel  144  along fold line  145 . In the illustrated embodiment, locking apertures  180 ,  182  are generally rectangular in shape although other shapes can be used. First and second locking tabs  156 ,  158  project from opposite sides of outermost portion  123  of first locking arm flap  122 . Locking tabs  156 ,  158  and locking apertures  180 ,  182  are configured so as to resist unintentional collapsing of the tray  190  when in the set-up condition. When the tray  190  is in the set-up condition, the first locking tab  156  will tend to catch in the first locking aperture  180  if the top panel  114  is moved too far in a first direction relative to bottom panel  118 , thereby arresting further movement in that direction and maintaining the tray  190  in the set-up condition. Similarly, the second locking tab  158  will tend to catch in the second locking aperture  182  if the top panel  114  is moved too far in a second direction relative to bottom panel  118 , thereby arresting further movement in that direction and maintaining the tray  190  in the set-up condition. 
     A reinforcing flap  150  is formed in the bottom panel  118  along fold line  115  via cutline  153 . During assembly of tray  190 , reinforcing flap  150  is folded into face-contacting relationship with, and adhesively secured to, first side panel  116  so as to form a double-thickness first side wall to match the double-thickness of the second side wall created by the overlapping of glue panel  112  and second side panel  120 . A cutout  152  is formed in the bottom panel  118  along fold line  117  to mirror the opening created by reinforcing flap  150  when it is folded out of plane with respect to bottom panel  118 . 
     A plurality of parallel creases and/or engraved lines  130  running perpendicular to the grain of the blank  110  may be formed in the first and second side walls  116 ,  120 . Similarly a plurality of parallel creases and/or engraved lines  160  running perpendicular to the grain of the blank  110  may be formed in bottom panel  118 , as well as a plurality of parallel creases and/or engraved lines  162  running parallel to the grain, and a plurality of angled creases  164 . Creases  130 ,  160 ,  162 ,  164  may provide better strength and prevent unwanted creasing under load. 
     Top center panel  142  includes a plurality of cutouts  180 . First locking arm flap  122  includes a cutout  176 . Second locking arm flap  142  includes a cutout  178 . Bottom panel  174  includes a central cutout  174 . In the illustrated second embodiment, cutouts  180 ,  176 ,  178 , and  174  are circular in shape although other shapes may be used. Cutouts  180 ,  176 ,  178 , and  174  can be provided to reduce the weight of the blank  110  and the amount of blank material used. 
     Exemplary embodiments of blanks, trays, and methods of forming trays are described above in detail. The apparatus and methods are not limited to the specific embodiments described herein, but rather, components of apparatus and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, in alternative embodiments, the locking arm flaps may be secured to one another to form the locking band via mechanical interconnection rather than, or in addition to, being secured together via adhesive. 
     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. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.