Patent Description:
According to a second aspect, the present disclosure relates to an assembly of a cardboard tray according to the first aspect of the present disclosure and a foil.

According to a third aspect, the present disclosure relates to a sheet of cardboard arranged for being folded into a cardboard tray according to the first aspect of the present disclosure.

Foldable cardboard trays are available in a lot of types, for example re-usable or disposable, composite or single-ply structured and with small or large dimensions. Cardboard trays are suitable for packaging and/or displaying materials and goods, such as vegetables or other kind of food. Cardboard trays have the property that the top of the tray is open, but in some cases, for example during transportation, there is a need for the ability to efficiently close the top of the tray. Document <CIT> shows a foldable cardboard tray having an uninterrupted flange directed away from the receiving space of the tray and which flange is formed by an adhesive connection between neighbouring flange parts. Documents <CIT>, <CIT> and <CIT> show examples of foldable cardboard trays having an uninterrupted flange directed towards the receiving space of the tray and which flange is formed by a locking connection between neighbouring flange parts.

A disadvantage of known cardboard trays available in the market is that there is a need for additional means, either mechanical, like tacks and strings, or chemical, like an adhesive, in order to ensure sufficient strength of the cardboard tray. In terms of recycling, environment and cost efficiency this is undesired. Therefore, there is furthermore a need for a foldable cardboard tray with improved strength, without additional adhering means.

It is therefore an objective of the present disclosure to provide a cardboard tray folded from a sheet of cardboard with improved strength, without additional adhering means. In particular, it is an objective of the present disclosure to provide a cardboard tray folded from a sheet of cardboard which can be closed at an upper side of the cardboard tray.

In a first aspect, there is provided a cardboard tray folded from a sheet of cardboard, wherein said cardboard tray comprises sheet portions defining a bottom wall and side walls defining a receiving space of said cardboard tray, said side walls being connected, via respective first folding lines, to said bottom wall, wherein said cardboard tray further comprises flange parts connected, via respective second folding lines, to said side walls at a side of said side walls facing away from said bottom wall, wherein neighbouring flange parts of said flange parts are connected to each other via a locking sheet portion of one of said neighbouring flange parts, wherein said locking sheet portion is connected, via a third folding line, to said one of said neighbouring flange parts and extends at least partly through a locking opening provided in said sheet of cardboard, which locking opening is preferably provided in the other of said neighbouring flange parts, for said connecting of said neighbouring flange parts and realizing an uninterrupted flange along a circumference of said cardboard tray, wherein said uninterrupted flange is directed away from said receiving space.

The term cardboard may refer to a variety of heavy paper-like materials, including but not limited to, card stock, corrugated fibreboard or paperboard. Cardboard is a recyclable and/or reusable material. Producing the cardboard tray from a single sheet of cardboard prevents unnecessary waste of materials of which the cardboard is produced.

Preferably, the sheet of cardboard consists of one piece. Because the sheet of cardboard comprises folding lines, the sheet of cardboard can easily by folded into its final shape of the cardboard tray, either manually by hand or with the use of machinery. It was the insight of the inventor to design the bottom wall, side walls and flange parts according to the invention for improved strength of the cardboard tray, while waste of materials is minimized.

It was further the insight of the inventor to add and design the locking mechanism provided in the flange parts for improved strength of the cardboard tray. Neighbouring flange parts are adhered to each other by means of the locking mechanism comprising the locking sheet portion and the locking opening, for realizing an uninterrupted flange along a circumference of the cardboard tray, which is both advantageous for improved strength and provides a sufficient area for connecting a foil for closing the cardboard tray at an upper side. With closing the cardboard is meant that the bottom wall, the side walls and the foil bound the receiving space of the cardboard tray.

A further advantage of the cardboard tray is that there is no need for additional means, either mechanical, like tacks and strings or the like, or chemical, like an adhesive or the like in order to retain the cardboard tray in its folded position, while maintaining improved strength. This is environmentally beneficial, cost efficient and less time-consuming and labour-intensive during manufacturing of the cardboard tray from the sheet of cardboard. Furthermore, this allows for a more simple and less error-prone automated manufacturing process.

A further advantage of the cardboard tray according to the present disclosure is that the cardboard tray is formed of a single sheet of cardboard. This is beneficial for realising a relative cost effective cardboard tray by using a relative little amount of material. In addition, using only a relative little amount of material is beneficial for realising a cardboard tray having a relative low weight. A relative low weight is advantageous for realising relative low cost for distributing cardboard trays according to the present disclosure.

Preferably, the uninterrupted flange are of such dimensions, that the area of the uninterrupted flange is large enough for receiving the foil. Preferably the uninterrupted flange has a width in the range of minimal <NUM> - <NUM>, more preferably in the range of <NUM> - <NUM>. This is beneficial for realising a relative strong cardboard tray while using only a relative little amount of cardboard and while providing a relative large surface area for attachment of the foil.

In an example, said neighbouring flange parts of said flange parts are only connected to each other via said bottom wall, said side walls and said locking sheet portion of said one of said neighbouring flange parts. This is beneficial for realising a relative strong cardboard tray while using only a relative little amount of cardboard.

In an example, said one of said neighbouring flange parts is provided with a further locking opening and said other of said neighbouring flange parts is provided with a further locking sheet portion, wherein said further locking sheet portion extends at least partly through said further locking opening for said connecting and realizing an uninterrupted flange along said circumference of said cardboard tray. This is beneficial for arriving at a cardboard tray having an increased strength.

In an example, said connection to each other of said neighbouring flange parts of said flange parts is free of an adhesive. This is environmentally beneficial and more cost efficient. Furthermore, this allows for a more simple and less error-prone automated manufacturing process.

In an example, said locking sheet portion and said locking opening of said neighbouring flange parts are connected via form locking. This is beneficial, as there is no need for additional means, either mechanical, like tacks and strings or the like, or chemical, like an adhesive or the like in order to retain the cardboard tray in its folded position.

In an example, said one of said neighbouring flange parts comprises at least two of said locking sheet portions, preferably three or more of said locking sheet portions, and wherein said other of said neighbouring flange parts comprises a corresponding number of locking openings. Preferably, each side wall is connected to each of its neighbouring side wall via one of said locking sheet portion and one of said locking opening.

In an example, said locking sheet portion comprises an extension part extending through said locking opening.

The extension part is produced of the same sheet of cardboard, resulting in efficient use of the sheet of cardboard, minimizing waste of cardboard material and resulting in additional strength of the resulting cardboard tray.

In an example, said extension part is connected to a main sheet part of said locking sheet portion via a fourth folding line thereof.

In an example, said side walls are only connected to each other via said first folding lines and via said second folding lines. In other words, neighbouring side walls are not directly mutually connected, for instance via a further locking arrangement that may be applied for locking the neighbouring side walls to each other. The neighbouring side walls are maintained in a position relative to each other only via the bottom wall and the uninterrupted flange. This is beneficial for realising a relative strong cardboard tray while using only a relative little amount of cardboard.

In an example, first flange parts of said flange parts are connected to opposite side walls of said side walls, wherein said first flange parts comprise a centre flange part, and wherein said locking sheet portions are provided at opposite sides of said centre flange part, wherein a length of said centre flange part corresponds substantially to a length of said second folding line and wherein said locking sheet portions are extensions of said centre flange part beyond said second folding line.

Preferably, said connecting flange parts are connected to said second folding line via said centre flange part.

In an example, each of said respective first folding lines is interrupted by cut-outs provided in said bottom wall and said side walls.

Preferably, the dimensions of the cut-outs are adapted to the size of the products, for which the specific cardboard tray is arranged. More preferably, the dimensions of the cut-outs are substantially smaller than the dimensions of the products, for which the specific cardboard tray is arranged.

The cut-outs ensure supply of fresh air which is particular advantageous the product, for which the specific cardboard tray is arranged, is food, for example vegetables or the like.

The uninterrupted flange is directed away from said receiving space. This maximizes the dimensions of the open end of the receiving space.

Preferably, said side walls define a height of said cardboard tray.

Preferably, said sheet of cardboard has mass per unit area in the range of <NUM> gram/m<NUM> to <NUM> gram/m<NUM>, wherein said mass per unit area is determined according to ISO <NUM>:<NUM>. A mass per unit area in this range is beneficial for In addition, using only a relative little amount of material is beneficial for realising a cardboard tray having a relative low weight while being relative strong. A relative low weight is advantageous for realising relative low cost for distributing cardboard trays according to the present disclosure.

Preferably, a stiffness of said sheet of cardboard in a first cardboard direction is in a range of <NUM> mNm and <NUM> mNm, wherein said stiffness is determined according to DIN <NUM>:<NUM>.

Preferably, a stiffness of said sheet of cardboard in a second cardboard direction, perpendicular to said first cardboard direction, is in a range of <NUM> mNm and <NUM> mNm, wherein said stiffness is determined according to DIN <NUM>:<NUM>.

In this regard, it is beneficial if said stiffness of said sheet of cardboard in said first cardboard direction is lower than said stiffness of said sheet of cardboard in said second cardboard direction.

Preferably, said second cardboard direction is substantially perpendicular, preferably perpendicular, to said third folding line and/or substantially parallel, preferably parallel to said locking opening. This is beneficial for realising a relative reliable connection between said neighbouring side walls.

Preferably, a thickness variation of said sheet of cardboard is in the range of <NUM> to <NUM>, wherein said thickness variation is determined according to ISO <NUM>:<NUM>.

Preferably, a ratio of a width of said uninterrupted flange and said height of said cardboard tray is in the range of <NUM> to <NUM>, more preferably in the range of <NUM> to <NUM>. A ratio in this range is beneficial for realising a relative strong cardboard tray while using only a relative small amount of cardboard.

Preferably, a ratio of a surface area of the uninterrupted flange and the bottom wall is in the range of <NUM> to <NUM>, more preferably in the range of <NUM> to <NUM>. A ratio in this range is beneficial for realising a relative strong cardboard tray while using only a relative small amount of cardboard.

In a second aspect, there is provided an assembly of a cardboard tray as described above and a foil, wherein said foil is adhered to said uninterrupted flange, such that said bottom wall, said side walls and said foil bound said receiving space of said cardboard tray.

Abovementioned embodiments of the cardboard tray according to the first aspect can be applied mutatis mutandis to embodiments of the assembly according to the second aspect of the present disclosure. Advantages of the cardboard tray according to the first aspect presented previously can be applied mutatis mutandis to advantages of the assembly according to the second aspect of the present disclosure.

Preferably, the foil is adhered to the uninterrupted flange after addition of products. Closing the upper side of the box prevents the products to unintentionally leave the tray, for example during transport.

In an example, said foil is adhered to said uninterrupted flange ) by heating and pressing said foil to said uninterrupted flange.

Friction welding is a solid-state welding process that generates heat through mechanical friction between the foil and the uninterrupted flange in relative motion to one another in order to fuse the materials. This ensures strong connection between the foil and uninterrupted flange.

Preferably, the foil is produced of a transparent material, enabling visibility of the products contained in the closed cardboard tray.

In a third aspect, there is provided a sheet of cardboard arranged for being folded into a cardboard tray as described above, said sheet of cardboard comprising a bottom wall sheet portion, side wall sheet portions connected, via first folding lines, to said bottom wall sheet portion, and wherein said sheet of cardboard further comprises flange part sheet portions connected, via second folding lines, to said side wall sheet portions at a side of said side wall sheet portions facing away from said bottom wall sheet portion, wherein first flange part sheet portions of said flange part sheet portions are provided with a locking sheet portion and wherein second flange part sheet portions of said flange part sheet portions are provided with a locking opening.

Abovementioned embodiments of the cardboard tray according to the first aspect can be applied mutatis mutandis to embodiments of the sheet of cardboard according to the third aspect of the present disclosure. Advantages of the cardboard tray according to the first aspect presented previously can be applied mutatis mutandis to advantages of the sheet of cardboard according to the third aspect of the present disclosure.

The term cardboard may refer to a variety of heavy paper-like materials, including but not limited to, card stock, corrugated fibreboard, or paperboard. The sheet of cardboard arranged for being folded into a cardboard tray prevents unnecessary waste of materials of which the cardboard is produced. Because cardboard furthermore is a recyclable material, the resulting tray is beneficial for the environment.

Providing the sheet of cardboard according to the third aspect enables efficient transport of a plurality of the sheets of cardboard and furthermore reduces cost of manufacturing, transportation, manipulation by a middle- or end-user, as well as other costs. The sheets of cardboard can efficiently be stacked on for example a flat transport structure like a pallet. The sheets of cardboard are transported to intermediate or end users, where the sheet of cardboard is folded into its final shape of the cardboard tray according to the first aspect, either manually by hand or with the use of machinery. Eventually, preferably after products are added to the cardboard tray, the cardboard tray is closed at an upper side, by adhering a foil to the uninterrupted flange, such that the bottom wall, the side walls and the foil bound a receiving space of the cardboard tray. This prevents, that the products unintentionally leave the tray, for example during transport to a further user, like a distributor, a shop, or the like.

The present disclosure will now be explained by means of a description of embodiments of a cardboard tray in accordance to the first aspect of the present disclosure and embodiments of a sheet of cardboard according to the third aspect of the present disclosure, in which reference is made to the following schematic figures, in which:.

<FIG> disclose in subsequent steps the manufacturing of a cardboard tray <NUM> from a sheet of cardboard <NUM>.

<FIG> discloses the sheet of cardboard <NUM>, comprising a bottom wall <NUM> and side walls <NUM>. The side walls <NUM> are connected to the bottom wall <NUM> via first folding lines <NUM>. The cardboard tray <NUM> further comprises flange parts <NUM>, <NUM>, connected to the side walls <NUM> via second folding lines <NUM> and are positioned at a side of the side walls <NUM> facing away from the bottom wall <NUM>. The folding lines <NUM> are interrupted by cut-outs <NUM> provided in the bottom wall <NUM> and the side walls <NUM>.

The flange parts <NUM> of two side walls <NUM> are provided with a locking sheet portion <NUM>, connected via third folding lines <NUM>. The locking sheet portion <NUM> comprises an extension part <NUM>, connected to a main sheet part <NUM> of the locking sheet portion <NUM> via a fourth folding line <NUM>. The flange parts <NUM> are further provided with a further locking opening <NUM>. The flange parts <NUM> are provided with a locking opening <NUM> and a further locking sheet portion <NUM>.

By folding the side walls <NUM> about the first folding lines <NUM> relative to the bottom wall <NUM>, the cardboard receptacle of <FIG> is obtained, thereby defining a receiving space <NUM>. By folding the two flange parts <NUM> about the second folding lines <NUM>, the cardboard receptacle of <FIG> is obtained. By folding the two flange parts <NUM> about the second folding lines <NUM>, the cardboard receptacle of <FIG> is obtained. By subsequently folding the extension parts <NUM> about the fourth folding line <NUM> and locking sheet portions <NUM> about the third folding lines <NUM>, the cardboard receptacle of <FIG> is obtained.

By pressing the locking sheet portions <NUM> such that the extension parts <NUM>, provided in the flange parts <NUM>, extend through the locking opening <NUM>, provided in the flange parts <NUM>, and the further locking sheet portions <NUM>, provided in the flange parts <NUM>, extend through the further locking opening <NUM>, provided in the flange parts <NUM>, the flange parts <NUM>, <NUM> are firmly connected and the cardboard tray <NUM> of <FIG> is realized.

The bottom wall <NUM> and side walls <NUM> define the receiving space <NUM> of said cardboard tray <NUM>. By connecting the neighbouring flange parts <NUM>, <NUM> an uninterrupted flange <NUM> along a circumference of the cardboard tray <NUM> is realized.

<FIG> discloses the sheet of cardboard <NUM>, comprising sheet a bottom wall <NUM> and side walls <NUM>. The side walls <NUM> are connected to the bottom wall <NUM> via first folding lines <NUM>. The cardboard tray <NUM> further comprises flange parts <NUM>, <NUM>, connected to the side walls <NUM> via second folding lines <NUM> and are positioned at a side of the side walls <NUM> facing away from the bottom wall <NUM>. The folding lines <NUM> are interrupted by cut-outs <NUM> provided in the bottom wall <NUM> and the side walls <NUM>.

The flange parts <NUM> of two side walls <NUM> are provided with a locking sheet portion <NUM>, connected via third folding lines <NUM>. The flange parts <NUM> are provided with a locking opening <NUM>.

By folding the side walls <NUM> about the first folding lines <NUM> relative to the bottom wall <NUM>, the cardboard receptacle of <FIG> is obtained, thereby defining a receiving space <NUM>. By folding the two flange parts <NUM> about the second folding lines <NUM>, the cardboard receptacle of <FIG> is obtained.

By folding the two flange parts <NUM> about the second folding lines <NUM>, and subsequently folding the locking sheet portions <NUM> about the third folding line <NUM>, such that the locking sheet portions <NUM>, provided in the flange parts <NUM>, extend through the locking opening <NUM>, provided in the flange parts <NUM>, the flange parts <NUM>, <NUM> are firmly connected and the cardboard tray <NUM> of <FIG> is realized.

The flange parts <NUM> of two side walls <NUM> are provided with a locking sheet portion <NUM>, connected via third folding lines <NUM>. The flange parts <NUM> are further provided with a further locking opening <NUM>. The flange parts <NUM> are provided with a locking opening <NUM> and a further locking sheet portion <NUM>. The locking sheet portion <NUM> is provided with a cut <NUM> for allowing a part of the locking sheet portion <NUM> to extend through the locking opening <NUM>.

By folding the side walls <NUM> about the first folding lines <NUM> relative to the bottom wall <NUM>, the cardboard receptacle of <FIG> is obtained, thereby defining a receiving space <NUM>. By folding the two flange parts <NUM> about the second folding lines <NUM>, the cardboard receptacle of <FIG> is obtained. By folding the two flange parts <NUM> about the second folding lines <NUM>, the cardboard receptacle of <FIG> is obtained.

By subsequently folding the locking sheet portion <NUM> about the third folding line <NUM> and pressing the locking sheet portions <NUM> such that the locking sheet portions <NUM>, provided in the flange parts <NUM>, extend through the locking opening <NUM>, provided in the flange parts <NUM>, and the further locking sheet portions <NUM>, provided in the flange parts <NUM>, extend through the further locking opening <NUM>, provided in the flange parts <NUM>, the flange parts <NUM>, <NUM> are firmly connected and the cardboard tray <NUM> of <FIG> is realized.

It is noticed that the above description of the figures describe one variation of many embodiments of the present disclosure. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article, "a" or "an" does not exclude a plurality.

Elements of the sheet of cardboard <NUM> that are similar to elements of the sheet of cardboard <NUM> are provided with the same reference numbers. The sheet of cardboard <NUM> differs mainly from the sheet of cardboard <NUM> in that the respective locking openings <NUM> and locking openings <NUM>, and the respective locking sheet portions <NUM> and <NUM> are different.

The flange parts <NUM> of two side walls <NUM> of the cardboard <NUM> are provided with a locking sheet portion <NUM>, connected via third folding lines <NUM>. The locking sheet portion <NUM> comprises an extension part <NUM>, connected to a second main sheet part <NUM> of the locking sheet portion <NUM> via a fourth folding line <NUM>. The locking sheet portion <NUM> further comprises a first main sheet part <NUM>, connected to the second main sheet part <NUM> via a fifth folding line <NUM>. Locking openings <NUM> are provided in each of the two side walls <NUM> that are connected to the flange parts <NUM> via first folding lines <NUM>.

By folding the side walls <NUM> and the flange parts <NUM>, <NUM> in similar steps as described above and as illustrated in <FIG>, the cardboard receptacle of <FIG> is obtained. By subsequently folding the extension parts <NUM> about the fourth folding lines <NUM>, the second main sheet parts <NUM> about the fifth folding lines <NUM> and the first main sheet parts <NUM> about the third folding lines <NUM>, the cardboard receptacle of <FIG> is obtained.

Claim 1:
A cardboard tray (<NUM>, <NUM>, <NUM>) folded from a sheet of cardboard (<NUM>, <NUM>, <NUM>), wherein said cardboard tray (<NUM>, <NUM>, <NUM>) comprises sheet portions defining a bottom wall (<NUM>) and side walls (<NUM>) defining a receiving space (<NUM>) of said cardboard tray (<NUM>, <NUM>, <NUM>), said side walls (<NUM>) being connected, via respective first folding lines (<NUM>), to said bottom wall (<NUM>), wherein said cardboard tray (<NUM>, <NUM>, <NUM>) further comprises flange parts (<NUM>, <NUM>) connected, via respective second folding lines (<NUM>), to said side walls (<NUM>) at a side of said side walls (<NUM>) facing away from said bottom wall (<NUM>), characterised in that neighbouring flange parts (<NUM>, <NUM>) of said flange parts (<NUM>, <NUM>) are connected to each other via a locking sheet portion (<NUM>) of one of said neighbouring flange parts (<NUM>, <NUM>), wherein said locking sheet portion (<NUM>) is connected, via a third folding line (<NUM>), to said one of said neighbouring flange parts (<NUM>, <NUM>) and extends at least partly through a locking opening (<NUM>) provided in said sheet of cardboard (<NUM>, <NUM>, <NUM>), which locking opening (<NUM>) is preferably provided in the other of said neighbouring flange parts (<NUM>, <NUM>), for said connecting of said neighbouring flange parts (<NUM>, <NUM>) and realizing an uninterrupted flange (<NUM>) along a circumference of said cardboard tray (<NUM>, <NUM>, <NUM>), wherein said uninterrupted flange (<NUM>) is directed away from said receiving space (<NUM>).