Patent Publication Number: US-9883753-B2

Title: Expandable retail shelf tray

Description:
BACKGROUND 
     Field of the Invention 
     This patent relates to a retail product shipping and display tray. More particularly, this patent relates to a retail product shipping and display tray that can expand laterally. 
     Description of the Related Art 
     Shipping trays that double as retail display trays can be time and labor saving for the retailer. However, retailers sometimes need or want to fill shelves of varying widths with the same display tray, but the display trays usually come in a single width. A display tray is needed that can be expanded to take up additional, excess lateral shelf space. 
     SUMMARY OF THE INVENTION 
     The present invention is a shipping and display tray that can be expanded to take up additional, excess lateral shelf space. The tray may be made from a unitary blank that has been cut and provided with fold lines and tabs so that the tray may be assembled without tools or adhesives. 
     In one embodiment the tray comprises a bottom panel, a front panel assembly, a rear panel assembly and at least one side panel assembly. The bottom panel extends laterally from one side edge to an opposite side edge and rearwardly from a front fold line to a rear fold line. The front panel assembly is hingedly attached to the bottom panel along the front fold line and extends upwardly from the bottom panel. The rear panel assembly is hingedly attached to the bottom panel along a rear fold line and extends upwardly from the bottom panel. The side panel assembly comprises an intermediate side panel interposed between an inner side panel and an outer side panel. The intermediate side panel is attached orthogonally to the rear panel assembly along a side fold line. The inner side panel is attached to the intermediate side panel along a fold line. The outer side panel is hingedly attached to the inner side panel along a rotational fold line. The tray may further comprise a top panel hingedly attached to each outer side panel along a top fold line, with the top panel oriented perpendicularly to the outer side panel and parallel to the bottom panel. 
     In a key aspect of the tray, the outer side panel is moveable between a first, unexpanded position in which the outer side panel is in a flat, abutting relationship with the intermediate side panel and a second, expanded position in which the outer side panel rotated outwardly away from the inner side panel and the intermediate side panel. In the expanded position that outer side panel forms an angle of rotation (β) with the intermediate side panel. 
     The front panel assembly may comprise an outer front panel hingedly attached to the bottom panel along a front fold line and an inner front panel attached to the outer front panel along a double fold line and affixed to the bottom panel. 
     The bottom panel may be reinforced with a second bottom layer comprising two partial bottom panels. Each partial bottom panel may be foldably connected to an intermediate side panel along a fold line and may extend inwardly from the fold line. 
     The rear panel assembly may comprise an outer rear panel and an inner rear panel hingedly attached to the outer rear panel along a double fold line and attached to the bottom panel. 
     A locking panel may be hingedly connected to the outer side panel along a fold line, and may be configured to fit between the partial bottom panel and the bottom panel when the tray is in the first, unexpanded position. 
     The locking panel may be substantially triangular and may have a first free edge that forms a locking panel angle (α) with the fold line. The locking panel angle (α) may be the same as the angle of rotation (β). 
     The intermediate side panel may define a locking opening into which a locking tab may be inserted. The locking tab may extend from the free edge of the locking panel, and is configured to fit into the locking opening to lock the outer side panel in place when the outer side panel is in the second, expanded position. 
     In another aspect, the disclosure relates to a single, unitary blank for making a laterally expandable tray. The blank may comprise a number of major panels, including bottom panel, an outer front panel, an inner front panel, an outer rear panel, an inner rear panel, two intermediate side panels, two inner side panels, two outer side panels and two top panels. The bottom panel may extend laterally from a side cut line to an opposite side cut line and rearwardly from a front fold line to a rear fold line. The outer front panel may be connected to the bottom panel along the front fold line. The inner front panel may be connected to the outer front panel along a double fold line. The outer rear panel may be connected to the bottom panel along the rear fold line and may extend laterally from a side fold line to an opposite side fold line. The inner rear panel may be connected to the outer rear panel along a rear double fold line, and may extends laterally from a side cut line to an opposite side cut line. Each intermediate side panel may be connected to an outer rear panel by a fold line. Each inner side panel may be connected to an intermediate side panel along a fold line. Each outer side panel may be connected to an inner side panel along a fold line. Each top panel may be connected to an outer side panel along a fold line. 
     The blank may further comprise two rear edge panels, each rear edge panel connected to an outer side panel along a fold line. 
     The blank may further comprise two partial bottom panels, each partial bottom panel connected to an intermediate side panel along a fold line. 
     The blank may further comprise two substantially triangular locking panels, each locking panel connected to an outer side panel along a fold line. 
    
    
     
       THE DRAWINGS 
         FIG. 1  is a perspective view of a product tray according to the disclosure, shown in a first, unexpanded, configuration. 
         FIG. 2  is a perspective view of the product tray of  FIG. 1  shown in a fully expanded configuration. 
         FIG. 3  is a perspective view of a blank used to make the tray of  FIG. 1 . 
         FIGS. 4-11  are perspective views of the tray of  FIG. 1  shown in various stages of assembly. 
         FIG. 4  is a perspective view of the blank of  FIG. 3  shown partially folded to create a partially assembled tray. 
         FIG. 5  is a perspective view of the partially assembled tray of  FIG. 4  after further folding. 
         FIG. 6  is a perspective view of the partially assembled tray of  FIG. 5  after further folding. 
         FIG. 7  is a perspective view of the partially assembled tray of  FIG. 6  after further folding. 
         FIG. 8  is a perspective view of the partially assembled tray of  FIG. 7  after further folding. 
         FIG. 9  is a perspective view of the partially assembled tray of  FIG. 8  after further folding. 
         FIG. 10  is a perspective view of the partially assembled tray of  FIG. 9  after further folding. 
         FIG. 11  is a perspective view of the partially assembled tray of  FIG. 10  after further folding. 
         FIG. 12  is a top perspective view of the tray of  FIG. 11  after further folding to create a fully assembled tray. 
         FIG. 13  is a perspective view of the tray of  FIG. 12  after the left side has been expanded. 
         FIG. 14  is a partial rear perspective view of the tray of  FIG. 12  showing the right side expanded. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While the invention described herein may be embodied in many forms, there is shown in the drawings and will herein be described in detail one or more embodiments with the understanding that this disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the disclosure to the illustrated embodiments. 
     As will be appreciated, terms such as “above” and “below”, “rearward”, “outward”, “horizontal,” “left,” “right,” “up,” “down,” “top,” “bottom,” “front” and “back,” and “inward” (etc.), used as nouns, adjectives or adverbs (e.g. “rearwardly”, “outwardly”, “horizontally”, “laterally” etc.) generally refer in this description to the orientation of the structure of the tray  10  as it is illustrated in the front perspective views, such as  FIGS. 1, 2 and 12 . For example, “rearwardly” generally refers to the direction toward the rear of the tray and “upwardly” generally refers to the direction toward the top of the tray. Such terms are not intended to limit the invention to a particular orientation. Similarly, the terms “lateral” and “longitudinal” generally refer to the orientation of surfaces or other structures relative to an axis of elongation or axis of rotation, as appropriate. 
     Finally, like structures and features may be given the same element number in both the assembled tray and the tray blank. 
     The Expandable Product Tray 
     Turning to the drawings,  FIG. 1  is a perspective view of an expandable product tray  10  according to the disclosure, shown in a first, unexpanded, configuration. The tray  10  is formed from a single blank  100  ( FIG. 3 ) and comprises the following major components: a bottom panel  12  (obscured by the two partial bottom panels  40  in  FIG. 1  and best shown in  FIG. 3 ), a double thickness front panel assembly  14 , a double thickness rear panel assembly  18 , two triple thickness side panel assemblies  19  and two top panels  34 . 
     The bottom panel  12  extends laterally (side to side) from one inner side panel  22  to the opposite inner side panel  22  and rearwardly (front to back) from the front panel assembly  14  to the rear panel assembly  18 . 
     The double thickness front panel assembly  14  comprises an outer front panel  28  hingedly attached to the bottom panel  12  along a front fold line  16  and an inner front panel  26  hingedly attached to the outer front panel along a double fold lines  44 . The inner front panel  26  is folded over the outer front panel  28  to provide the double thickness. The front panel assembly  14  is hingedly attached to the bottom panel  12  along the front fold line  16 . The front panel assembly  14  preferably has a height substantially less than the height of the rear panel assembly  18  to better display products in the tray  10 . 
     The double thickness rear panel assembly  18  comprises an outer rear panel  32  and an inner rear panel  30  and is hingedly attached to the bottom panel  12  along a rear fold line  20 . The inner rear panel  30  is folded over the outer rear panel  32  to provide the double thickness. The rear panel assembly  18  is hingedly attached to the bottom panel  12  along a rear fold line  20 . 
     Each triple thickness side panel assembly  19  comprises an intermediate side panel  36  sandwiched between an inner side panel  22  and an outer side panel  24 . The intermediate side panel  36  is hingedly attached to the outer rear panel  32  along a fold line  74 . Each outer side panel  24  is moveable between a first position in which the outer side panel  24  is perpendicular to the rear panel assembly  18  ( FIGS. 1 and 12 ) and a second position in which the outer side panel  24  is rotated outwardly along a rotational fold line  58  (which functions as an axis of rotation) to increase the width of the tray ( FIGS. 2, 13 and 14 ). 
     Each top panel  34  is hingedly attached to a corresponding side panel assembly  19  and, more particularly, to a corresponding outer side panel  24 , by a top fold line  62 . In the assembled tray  10  each top panel  34  is oriented perpendicular to the outer side panel  24  and parallel to the bottom panel  12  and provides partial covering for the products in the tray  10 . 
     In summary, the tray  10  may be sued to hold and transport products for retail display. Once on the retail shelf, one or both outer side panels  24  may be pulled or rotated outwardly along front fold lines  58  to take up additional shelf space and to provide a more eye catching display. 
       FIG. 2  is a perspective view of the product tray  10  of  FIG. 1  shown in a fully expanded configuration. Both outer side panels  24  have been rotated outwardly along their respective front fold lines  58  to provide a fully expanded tray  10 . The top panels  34  are connected to the outer side panels  24  and thus rotate along with the outer side panels  24 . As described in more detail below with respect to  FIG. 14 , each locking tab  104  (obscured in  FIG. 2 ) may be inserted through a locking opening  102  (also obscured) in the intermediate side panel  36  and a corresponding aligned opening  103  defined by the inner side panel  22  to engage an inner facing surface of the inner side panel  22  to hold the outer side panels  24  in the expanded position. 
     Tray Blank 
       FIG. 3  is a perspective view of a blank  100  that may be used to make the tray  10  of  FIGS. 1 and 2 . The tray  10  may be constructed from a single piece, i.e. unitary, blank; there are no separate components required to facilitate the assembly or expansion process. Preferably the tray  10  is constructed from corrugated board, although any suitable material may be used. 
     The blank  100  comprises the following main panels: a bottom panel  12 , an inner front panel  26 , an outer front panel  28 , an inner rear panel  30 , an outer rear panel  32 , two inner side panels  22 , two outer side panels  24 , two top panels  34 , two intermediate side panels  36 , two rear edge panels  38  and two partial bottom panels  40 . The blank  100  may be symmetrical about a line running front to rear and bisecting the bottom panel  12 . 
     The bottom panel  12  may be rectangular and extends laterally (side to side) from one side cut line  42  to an opposite side cut line  42  and front to back from the front fold line  16  to the rear fold line  20 . The bottom panel  12  may define a number of slots  88 ,  90  used for assembly purposed as described below. In the assembled tray  10  the bottom panel  12  may be reinforced with a second bottom layer comprising two partial bottom panels  40 , thereby providing a tray bottom having a double thickness along most or all of its load supporting surface. 
     As noted above, the front panel assembly  14  comprises an outer front panel  28  and an inner front panel  26 . As best seen in  FIG. 3 , the outer front panel  28  is foldably or hingedly connected to the bottom panel  12  along the front fold line  16 . In the assembled tray  10  the outer front panel  28  extends upwardly to a front panel top edge  44 . The top edge  44  may comprise a single fold line or, preferably, a double fold line as shown in  FIG. 3 . 
     The inner front panel  26  may be foldably or hingedly connected to the outer front panel  28  along the double fold line  44  and extends to a front panel free edge  46 . 
     The rear panel assembly  18  comprises the outer rear panel  32  and the inner rear panel  30 . The outer rear panel  32  is foldably or hingedly connected to the bottom panel  12  along the rear fold line  20  and, in the assembled tray  10 , extends upwardly to a rear panel top edge  50 . The rear panel top edge  50  may be defined by a fold line or preferably a double fold line as perhaps best shown in  FIG. 3 . The outer rear panel  32  is substantially rectangular and extends laterally from one side fold line  74  to the opposite side fold line  74 . 
     The inner rear panel  30  is about the same size and dimensions as the outer rear panel  32 . The inner rear panel  30  is hingedly (foldably) connected to the outer rear panel  32  along the rear double fold line  50  and extends from the double fold line  50  to a rear panel free edge  52 . The inner rear panel  30  extends laterally from one side cut line  56  to the opposite side cut line  56 . 
     Each inner side panel  22  is foldably connected to an intermediate side panel  36  along a fold line  56  and to an outer side panel  24  along a fold line  58 . Each inner side panel  22  extends downward from the fold line  56  to a free bottom edge  60  and front to back from the fold line  58  to a cut line  57 . 
     Each outer side panel  24  is foldably connected to an inner side panel  22  along the fold line  58  and to a top panel  34  along a fold line  62 . In the assembled tray  10  each outer side panel  24  extends downward from the fold line  62  to a fold line  64  and front to back from the double fold line  58  to a fold line  66 . 
     Each top panel  34  is foldably connected to an outer side panel  24  along the fold line  62 . In the assembled tray  10  each top panel  34  extends laterally inward (toward the other top panel  34 ) from the fold line  62  to an inner free edge  68  and rearwardly from a front free edge  70  to a rear free edge  72 . 
     Each intermediate side panel  36  is foldably connected to an inner side panel  22  along the fold line  56  and to the outer rear panel  32  by a fold line  74 . In the assembled tray  10  each intermediate side panel  36  extends downward from the fold line  56  to an intermediate side panel fold line  76  and front to back from free edge  70  to the fold line  74 . 
     Each rear edge panel  38  is foldably connected to an outer side panel  24  along the fold line  66 . In the assembled tray  10  each rear edge panel  38  extends downward from a rear edge tab fold line  78  to a free edge  80  and inwardly from the fold line  66  to a free edge  82 . 
     Each partial bottom panel  40  is foldably connected to an intermediate side panel  36  along the fold line  76 . In the assembled tray  10  each partial bottom panel  40  extends inwardly from the fold line  76  to a free edge  84  and rearwardly from a free edge  86  to a side cut line  42 . The partial bottom panels  40  provide an additional layer of material to reinforce the tray bottom. 
     A substantially triangular locking panel  108  is foldably, that is, hingedly, connected to each outer side panel  24  along a fold line  64 . The locking panel  108  may be triangular and may have a first free edge  109  that forms a locking panel angle (a) with the fold line  64  as shown in  FIGS. 3 and 14 . 
     For assembly purposes, in addition to the main panels described above, the blank  100  may comprise the following additional components and features: 
     One or more rear panel tabs  54  may extend from the rear panel free edge  52 . 
     The bottom panel  12  may define slots  88  adjacent to the rear fold line  20  and positioned to receive rear panel tabs  54 . 
     One or more front panel tabs  48  may extend from the inner front panel free edge  46 . 
     The bottom panel  12  may define slots  90  adjacent to the front fold line  16  and positioned to receive the front panel tabs  48 . 
     Side panel tabs  94  may extend from the cut line  57  of each inner side panel  22 . 
     The outer rear panel  32  may define vertical slots  92  adjacent to the fold lines  74  and positioned to receive side panel tabs  94 . 
     A preferably hexagonal tab  98  extends from the free edge  80  of each rear edge panel  38 . 
     The outer rear panel  32  may also define slots  96  adjacent to the fold line  20  and positioned to receive hexagonal tabs  98 . 
     A locking tab  104  may extend from an edge  109  of the locking panel  108 . 
     Each intermediate side panel  36  may define a locking opening  102  adjacent to or overlapping the fold line  76 . 
     Each partial bottom panel  40  defines a cutout  105  located along the fold line  76  that communicates with the locking opening  102  in the intermediate side panel  36 . The cutout  105  may have the same configuration (shape and size) as the locking tab  104  for the reason explained below. 
     A top panel tab  35  is foldably connected to each top panel  34  along the free edge  72 . 
     A tab  39  is foldably connected to each rear edge panel  38  along the fold line  78  and defines an opening  106  adjacent to the fold line  78 . Each opening  106  is positioned to receive one of the top panel tabs  35 . 
     An elongated tab  110  is foldably connected to each intermediate side panel  36  along a fold line  112  and may be configured to fit between the outer front panel  28  and the inner front panel  26  in the assembled tray  10 . 
     Each partial bottom panel  40  may define a cutout  114  along its rear edge  42  to accommodate a tab  98  in the assembled tray  10 . 
     Tray Assembly 
     The tray  10  may be assembled in the following manner: 
     (a) Starting with the flat blank  100  of  FIG. 3 , fold the partial bottom panels  40  upward 90 degrees along fold lines  76  as indicated by arrow A. 
     (b) Fold the intermediate panels  36  inward toward each other along fold lines  74  as indicated by arrow B. 
     (c) Fold the bottom panel  12  upwards 90 degrees along fold line  16  until the bottom panel  12  abuts the partial bottom panels  40  as indicated by arrow C to achieve the partially folded structure shown in  FIG. 4 . 
     (d) Fold the elongated tabs  110  inward 90 degrees toward each other as indicated by arrow D. 
     (e) Fold the outer front panel  28  upwardly 90 degrees along front fold line  16  as indicated by arrow E. 
     (f) Fold the inner front panel  26  downward along double fold line  44  until tabs  48  fit into slots  90 . The elongated tabs  110  should be captured between the outer front panel  28  and the inner front panel  26 . The blank  100  should now look like the partially assembled tray  10  of  FIG. 5 . 
     (g) Fold each inner side panel  22  downward along fold line  56  as indicated by arrow F in  FIGS. 5 and 6 . 
     (h) Fold each locking panel  108  outwardly along fold line  64  as indicated by arrow G in  FIG. 6 . After each inner side panel  22  has been folded downwardly 180 degrees, the structure will look like the partially folded structure shown in  FIG. 7 . 
     (i) Fold the inner rear panel  30  forward and downward 180 degrees along double fold line  50  as indicated by arrow H and insert tabs  54  into slots  88  to achieve the partially folded structure of  FIG. 8 . 
     (j) Fold each outer side panel  24  outwardly and rearwardly along fold line  58  as indicated by arrow I in  FIGS. 8 and 9 . While continuing to rotate each outer side panel  24  along fold line  58 , insert the locking tab  104  into locking opening  102 . As the outer side panel  24  is further rotated along fold line  58 , the locking tab  104  will help guide the locking panel  108  between the partial bottom panel  40  and the bottom panel  12 . 
     (k) Fold each rear edge panel  38  along fold line  66  as indicated by arrow J in  FIG. 10  until the rear edge panel  38  abuts the outer rear panel  32  and tab  98  is inserted into slot  96 . Each tab  98  may reside in space created by a cutout  114  in a partial bottom panel  40 . 
     (l) Fold tabs  39  downward 90 degrees as indicated by arrow K in  FIG. 11 . 
     (m) Fold each top panel  34  downwardly along fold line  62  as indicated by arrow L in  FIG. 11  and insert tab  35  into a corresponding opening  106  along the fold line  78  located between the rear edge panel  38  and the fold tab  39 . The tabs  35  may be larger or differently shaped than the openings  106  in order to secure the top panels  34  in the horizontal position. The fully assembled tray  10  is shown in  FIGS. 1 and 12 . 
     It should be understood that the method of assembly described above is but one example of how to make the tray  10 . More or fewer steps in a same or different order than those described may be included in the method without departing from the scope of the present disclosure. 
     Tray Expansion 
     A method of expanding the tray  10  will now be described. 
     Starting with the tray  10  in its narrowest configuration as shown in  FIGS. 1 and 12 , pull one or both outer side panels  24  so that they rotate laterally outwardly along fold line  58 , away from the inner side panel  22 , in the direction shown by arrows M in  FIG. 12 . Tabs  98  will be withdrawn from slots  88  to release the rear edge panels  38  from their locked position. 
     As each outer side panel  24  is rotated, the corresponding top panel  34  and locking panel  108  also move laterally outward because they are attached to the outer side panel  24 . 
     Each outer side panel  24  may be rotated until the corresponding locking panel  108  is completely released from between the partial bottom panel  40  and the bottom panel  12  except for the locking tab  104  which resides in the cutout  105 . 
     The locking tab  104  may be lifted upwardly slightly to engage the inner facing surface  23  of the inner side panel  22  to prevent further rotation of the outer side panel  24  and to hold or lock the outer side panel  24  in the expanded position shown in  FIG. 2 . 
     In the expanded configuration the outer side panel  24  and the intermediate side panel  36  define an angle of rotation (β) as shown in  FIG. 11 . The angle of rotation (β) may be greater than 10 degrees and preferably greater than 45 degrees. When the locking tab  104  is inserted into the locking opening  102 , the angle of rotation (β) will be the same as the angle (α) defined by the locking panel  108 . 
     One or both outer side panels may be rotated to achieve either a partially expanded tray  10  (with only one side expanded) or the fully expanded tray  10  shown in  FIG. 2 . In this way the tray  10  can be reconfigured into at least three configurations: (1) narrow or unexpanded (as shown in  FIGS. 1 and 12 ), (2) fully expanded (as shown in  FIG. 2 ), and (3) partially expanded (in which only one side is expanded as shown in  FIG. 13 ). 
       FIG. 14  is a partial rear perspective view of the tray  10  of  FIG. 2  showing the right side expanded. The outer side panel  24  has been rotated outwardly away from the intermediate side panel  36  along the rotation fold line  58 . The outer side panel  24  and the intermediate side panel  36  define an angle of rotation (β) which is the same as the locking panel angle (α). In this view it can readily be seen that, after the tray  10  has been expanded on one side, the locking tab  104  extending from the free edge  109  of the locking panel  108  can be inserted into the locking opening  102  to maintain the outer panel  24  in the expanded position. 
     It should be understood that the embodiments of the invention described above are only particular examples which serve to illustrate the principles of the invention. Modifications and alternative embodiments of the invention are contemplated which do not depart from the scope of the invention as defined by the foregoing teachings and appended claims. It is intended that the claims cover all such modifications and alternative embodiments that fall within their scope.