WO2007120966A2

WO2007120966A2 - Composite tray structure

Info

Publication number: WO2007120966A2
Application number: PCT/US2007/061621
Authority: WO
Inventors: Jean-Michel Auclair
Original assignee: Meadwestvaco Packaging Systems LLC
Current assignee: WestRock Packaging Systems LLC
Priority date: 2006-02-03
Filing date: 2007-02-05
Publication date: 2007-10-25
Anticipated expiration: 2008-08-03
Also published as: WO2007120966A3; GB0602202D0

Abstract

A composite tray structure (1) for containing articles (A). The composite tray formed from a structural first part (2) providing a basic tray element having walls (14, 18) to provide protection and containment of the tray s contents, and a reinforcing second part (4) that cooperates with the said first part to overlie a substantial portion of the inner surface of the said first part. The composite tray structure is adaptable from a first configuration in which the second part augments the protection, of the tray contents, afforded by the said first part to a second configuration in which the walls of the basic tray element are put into an enhanced multi-ply form that further reinforces the basic tray element.

Description

structure

The present invention relates parhcuiarly though not exclusively io trays containing articles, and more- particularly though not exclusively to trays \ha\ offer a high degree of external aesthetic quality so as to be suitable for use sn a retail environment

Trays capable of containing and ir&nsporisng articles (Al are well known in ^he art; see, for example, US 4.709,852 Such trays, however, are not sizable for use on display in a retail environment as the low cost material employed does not permit a clean finish nor the printing of graphics on the external surfaces.

The cos? o? producing known designs of such trays using materials o? sufficient quaisly so as to aPow, for example, printed graphics and advertising, is prohibitive given the high production volumes and low profit margins inherent in the packaging industry.

The present invention seeks *o solve or at least rrmsgate the problem of the prior art through providing a composite tray structure of two parts {hat may be reconfigured from a first, transportation configuration, into a second, vending configuration, suitable for use at a ooint-of-sale.

A i^'srst aspect of the present invention provides a composite tray for containing articles, which composite fray structure ss formed from a fast pan providing a basic tray element structure having walls to provide slacking strength and containment of the tray^'s contents, and a second part that reinforces and cooperates with the first pars to overlie a substantial portion of the inner surface of the first part, wherein the Hrst and second parrs, together, have a first configuration sn which the second part augments the protection of the iray contents afforded by >'ne wails of Uie first part, and a second configuration sn which the second part is manipulated to $υt the waiis of the basso tray element structure into an enhanced multi-ply form fnar further re^foroes the waUs of the basic tray element sfrυc^ure

Preferably, wherem the second pan is formed of a materia! of greater aesthetic quality than that of the firs! part

Preferably, wheresn the first part comprises a base panei hinged to opposing Side waiis and to opposing end walls which side wails and end wails are shaped so as to provide reinforced corner posts at each comer of the base panei, thereby facihtahng stacking o* the composite tray with other trays.

Preferably, wherein outer surfaces of opposing side or end wsiis of the fsrsi part, when it is in said second configuration . are become internal surfaces when if is in said first configuration, thus serving to protect said outer surfaces from damage during transport

Preferably, wherein the reinforced corner posts are provided by portions of me end walls, side walis and aiso by end Haps that are hmged to the end wafe and fastened, in copianar contact, to those portions of the ssde walls that form the corner posts.

Preferably, wherein rhe end walls of ihe firsi pan. are formed from a linear senes of end wall panels hinged one to the next, and wherein the linear senes of end wall panels are folded so as to provide multiply end waϋs.

Preferably, wheresn the second part comprises a base lining panel hinged, along at least one end, to a linear senes of end wall lining panels Preferably, wherein said linear series of end wail lining panels comprises an inner end wail lining panel disposed substantially sn coplanar contact with an inner surface of an end wali of the first part, and wherein the inner end wali lining panel is hinged io an outer end wall lining panel which outer end wall lining panel ss disposed substantially in copianar contact wι?h the outer surface of an end way of the first part

Preferably, wherein the outer end wail hnsng panel of rhe second pan comprises a handle flap aligned with a first aperture struck at least in part from the inner end wall lining pane! of the second part and wsih a second aperture struck, at least m part, from the end wail of the first part said first and second aperture being in registry with one another the handle flap may be folded inienor of the tray through the ahgned first and second apertures

Preferably, wherein the second part comprises a base lining panel hinged, along at least one Side, to a iinear series of side wall lining panels.

Preferably, wherein said linear series or side wail ϋnsng panels comprises an inner side wall lining panel disposed substantially In copianar contact with an mner surface of a side wall of rhe first pad, and wherein the inner side wail lining panel is hinged to an outer side wail lining panel which may be disposed substantially m coplaπar contact with the outer surface of a side wali of the first part

Preferably, wherein the outer side wall isning panel of the second part compnses a handle flap aligned With an aperture struck, at least in part, from the inner side wail iϊnsng panel of the second part and with an aperture struck, at ieas^ in part, from the side wali of the first part such that the handle flap may Pe folded interior of the tray through the hrs* and second apertures said hrsr and second apertures bemg in registry with one another

Preferably, wherein the second configuration allows graphics and information to be to be displayed and printed on a surface display panel to an end user. A second aspect of the present invention provides a two-part blank for forming a composite tray structure for containing articles, which composite tray structure ss formed from a first part and a second pan, which firsr. part forms a basic tray element structure having waiis to provide protection and containment of the tray^'s contents, and which second pad reinforces and cooperates wsth rhe said first part to overhe a substantia? portion of the inner surface of the said first part, wherein the first and second parts, together, have a first configuration in whsch the second pan. augments the protection, of the tray contents, afforded by the said first part and a second configuration in which the walls of the basic tray element structure are put into an enhanced muiti-ρ!y form that further reinforces the basic fray element structure.

A third aspect of the invention provides a method of transporting and storing articies which is also suitable for displaying the articles in a retail environment, comprising the steps of;

a) forming a composite tray for containing the articles, which composite tray is formed from a first part providing a basic tray element structure having walls to provide protection and containment of the tray^'s contents, and a second part that reinforces and cooperates with the said first part to overiie a substantial portion of the inner surface of the said first part, wherein the ftrs! and second parts, together, have a first configuration in which the second part augments the protection, of the tray contents, afforded by the said first part and a second configuration in which the walls of the bassc tray element structure are put into an enhanced multl-piy form that further reinforces [he basic tray element structure; b) loading the composite tray structures with adieles, c) transporting and storing the loaded composite tray structure as necessary, wherein the composite tray structures are in said first configuration; and 6} disposing the composite tray structure in a retasi environment and putting said first and second parts sn to said second configuration. Brsef Description of the Drawings

Exemplary embodiment of the present invention will now be descπoed with reference to the accompanying drawings In which

Figure IA illustrates a plan view of a Sirs* blank lor forming a first par? of a composite nay stmeture. according to a preferred embodiment of the present invention;

Figure 16 illustrates a pian vsew of a second blank fof forming a second part of a composite iray structure, according to a preferred embodiment of the present invention,

Figure 2 is a perspective view showing the insertion o< a partially set up blank of Figure 18 snto a fully set up blank of Figure i A;

Figure 3 ^iusiraies a top-side perspective vsew of a composite tray structure, according to a preferred embodiment of the present invention, sn 3 ϋOϊϊhgsjratOn suitable tor the storage and transport of articles conrained therein,

Figure 4 illustrates a too -Side perspective vsew of a composite tray structure, according to a preferred embodiment of the present invention, \r\ a configuration suitable for placement in a retail environment and dispensation of the artscies contained therein'

Figure 5 illustrates a top-end perspective view of a composite tray structure, according to a preferred embodiment of the present invention, in a configuration simaoie for ihe storage and transport of articles contained rherein, and

Figure *$ illustrates a top-end perspective vsew of a composite trϊiy structure, according to a preferred embodiment of me present invention, sn a configuration susiabiθ for placement in a retail environment and osspensanoo of lhe articles contained therein

Delated Description of the Invention

Referring to Figures 2 and 3, a preferred embodiment of the present invention takes the form of a composite tray 1 , comprised of two pads; a first pan 2 formed from a fsrsl ølank 10, as shown ;n Figure IA. and a second part 4 formed from a second blank 50, as shown ;n Figure 18.

illustrated

Figure IA; the first blank ^'10 may be produced from a foidable shee* material such as paperboard or similar foidabie sheet material, and composes a base panel 12 hinged, along opposed sides, to respective Side wall panels 14 and. along opposed ends, Io respective linear series of end wail panels 16/18

Each side wail panel 14 ss hinged to the base panel 1 ? along a fold line 34 and comprises a first aperture 40, defined by a cut-line 44.

Each linear series of end wall paneis 16/18 comprises an end wall panel 16 lunged at one end to the base panel 12, by fold line 32_; and at an opposing end to an reinforcing panel 18. by fold line 36.

Astride each fold line 32, is a second aperture 42 defined by cut-line 46. The seco :n SU aperture 42 is struck sπ part form end wali panel 16 and in part from base panel >2

Each reinforcing panel 18 composes a free edge furthest from the Dase panel 12, which >s shaped so as to mirror, about fold line 36, that portion of out-Hne 46 whsch extends wslhin end wall panel 16.

Each end vvaN panel 16 is further hsnged on both sides, along toid bnes 38, to end flaps 20 Each side wail panel I^ and end wall panel 16 is shaped such thai when set up, as Hhjsirated m Figure 2, the heights of the side wail and end wall panels 14/16 substantially are greater at each corner of the base panel 12, than at points substantially closer to the middle of the side and end edges of the base panel 12. such thai corner posts are formed at each comer of the base panel 12 when the first pan 10 is assembled es shown in Figure 2

Figure IA and 3 illustrate the way In which the shape of a free edge of end flaps 20, which nee edge opposes fold line 38, follows ?hat of a portion of the ssde wail panel 14 with which it is In coplanar contact when the fir&t blank 10 is set up. Thus one side of each set up corner post Is reinforced by the end flap 20. wherein a portion ol a side wail panel 14 and the end flap 20 form a multiply corner post

Figure 18 illustrates the second blank 50 comprising a octagonal base lining panel 52 hmged, along opposed ends, to end wail lining panels 58. The base lining panel 52 is also hinged along opposed Sides, to a Side lining panel 54

Each end ϋπsng panel 56 ;s hsnged at one end to the base lining panel 52. by a respective one of ibid hnes 72 Each end lining panel 56 ss then hinged, at an opposing end, \o an end faαa panel SS, by parallel spaced fold lines 76a and 76b. Each end faesa panel 58 is then, in turn, hinged to a handle flap 60, by parallel spaced fold lines 78a and 78b End facia panel 58 forms an ou?e? end wail hnlng panel whereas end lining panel 56 forms an inner end wail lining panel when the tray Is in a set up condition

Astride each fold line ?2, ss a first handle aperture 90 mat ss defined by a cut-line 92. extending into portions of both base isnlng panel 52 and end lining panel 56 Such that first handle aperture 90 is struck in part form base linsng panel 52 and inner end lining panel ό Handle flaps 80 are defined, by Nd isπes ?8a and cut-lines 61 and shaped so as to form a rrwror image of the shape of that portion of cut-lines 92 Withm the end lining panels 56

Each side lining panel 54 is hsnged to the base lining pane! 52 at one end. along fold line 74. Each side lining panel 54 :s then hnged, at an opposing end, to a side facia pane! 55, Dy parallel spaced fold lines 70a and 70b.

Side facia panel 55 forms an outer sκ1e lining panel 55 when the composite tray 1 is assembled.

Defined within each side lining panel 54 is 3 side lining aperture 86 rhai Is defined by csjt-li ne 88

Defined within each Side facia panel 55 is a retaining flap 82 that is defined by cut- hne 84 and hinged to side faαa panel SS along fold Ones 80

Referring to Figures IA and 2 together; the process of erecting the isrst par? 2, from the first blank 10, rs accomplished by folding each of the side wail panels 14 and end wall panels 18 perpendicular to the base panei 12, about the respective fold lines 32, 34. End flaps 20 are then folded perpendicular to the end wall panels 16 so as to come inio coplarw contact with portions of the side wail panels 14, which contact ss secured through the use of some fastening means known ;n the art, such as adhesive agent or mechanical fastener. The reinforcing panels 18 are rhen folded internally of the first part 2 and Into oopianar contact with the inner surface of the end wail panels 16 Figure 2 further Pluslrates the way in which corner posts are created from portions of the side and end wall panels 14, 16 and end flaps 20. The comer post^ allow the slacMng of one tray upon another, without causing damage to the conies of the lower tray.

Referring to Figure I B and 2 together. Figure 2 ϋkjsiraies the way h whsch the second part 4, is formed from the second hiaπk 50. by toldsng the end kmng panels 56 perpendicular to the base lining panel 52 Ssde hnlng panels 54 are iheπ similarly folded perpendsoϋlar Io ihe base linsng panel 52.

Figure 2 also Illustrates the way m which the fsrsr and second pans 2, 4 are nested together heading to the configu ration of the composite iray sirucmre 1 illustrated m Figures 3 and 5.

Figures 3 and 5 illustrate the loaded composite lray structure I ₁ once articles (A) have been inserted The second part 4, nested w-ihin the first pad 2, is held in position by the weigh! of the articles (A) and therefore does not need to be fastened by any other means, although it may, in other embodiments, be adhered or fastened in some way known ;n the art The configuration Illustrated In Figures 3 and 5 ss that Suitable for transporting and stacking the uays.

Each side lining aperture 86 is disposed within Ihe side ϋnsng panels 54 in such a posstion so as to align Itself with the outer retaining flap apertures ^O disposed within ihe side wail panels 14 (as shown sn Figure 3), Figure 3 further illustrates the alignment of fold lsnes 70a wsrh Ihe edges of side wall panels 14, and also how the fold hnes ?0a and ?0b are spaced by an amount substantially equal to the thickness of side panels 14.

Each lining handle aperture 90 is disposed within the end lining panels 56 m such a posshoπ so as to ahgπ itself with a handle aperture 42 disposed within each end wall panel 16 (as shown in Figure 5} Foid lines ?6a are aligned with the edges of end wail panels 16, and are spaced from fold line ?βb by an amount substantially equal to the thicKness of the combination of the end wali panels 16 and reinforcing panels 18

When the composite tray structure 1 , as shown in Figures 3 and 5, ss to be used in a retail environment, Its configuration may be altered to lhai. illustrated In Figures 4 and Considering Figure 4, this a'ternahve retail configuration ss achieved by folding side facia panels 55 about parallel spaced Foκ1 lines 70a and 70b so as DΠΠQ them into eoplanar contact wϊh i^e external surface of end wall panels 14, illustrated in Figure IA₁ and persons of end flaps 20. This contact ss secured Dy the msertion of each regaining flap 82, illustrated sn Figure I B, through a respective one of the side apertures 40 and then a respective one of the side iinsng apertures 86 as a result of folding along one of fold lines 80 Thus portions of retaining Raps 82 are brought substantially into coplaπar contact with an inner face o?^" Side lining panels 54 In an alternative embodiment it is conceivable that the retaining flaps 82 would be ravened to the side lining panels 54 through adhesive or other means known m the an.

Considering Figure 6; end facia panels 58 are folded about parallel spaced fold lines 76a and ?6b so as to come into copianar coniact with the external surface of end wall panels 16. This contact is maintained by the insertion of handle flaps 60, illustrated in Figure 1A. through a respective one of handle apertures 42 ar*ϋ then a respective one of lining handle apertures S2 as a result of folding along parallel spaced fold lines ?8a and ?8b, illustrated m Figure 18. Thus the handle ϊiaps 60 are brought substantially into copianar contact with end ϋmng panels 56, illustrated in Figure 18. Handle flaps 60 are chamfered outward from fold lines 78a, as illustrated in Figure 18, and thus resist passing hack through the aforementioned apertures 42. 90 once folded into position Nonetheless, sn an alsernative embodiment It is conceivable that the handle Flaps 60 would be fastened to the end lining panels 56 through tor example adhesive or other means known *n me art.

As Illustrated m Figures 4 and 6; tne alternative configuration of the composite tray structure 1 aiiows the aesthetic quality of the external surface of the tray to be greatly enhanced, and allows for the presentation of graphics or textual information over she majority of the extenor surfaces of the second part. Furthermore, the interior of the composite rray structure I is also given greater aesihetsc appeal and a large area for further graphics and information, which will be incrementally uncovered as the articles (A) are removed. The above description refers to a preferred embodiment of the present Invention. :i is conceivable thai the inventive concept may be applied to other packaging deigns wherein it is necessary to enhance the aesthetic appeal of a package without substantially increasing unst cost

The exact geometry of the tray detailed above is exemplary and does not hm;t the scope of the invention herein described. For example, the nurnber or shapes o? the panels of either blank may weii be altered to suit different articles (Ai or retail environments.. Furthermore, whilst the above exemplary embodiment is described as being formed from two blanks, it is contemplated wtthin the scope of the invention rhat a unaary, two part blank may De employed

it will be recognised that as used herein, direcrsonal references such as ^'lop¹, 'base^', ^vend\ ^'ssde\ 'inner^' and ^'ouier^' do not limit the respective panels to such orientation, but merely serve to distinguish these panels from one another Similarly, references to lifst^' and 'second^' parts are Included to distinguish elements of rhe design and are not intended to limit the soope In any way Any reference to hinged connection should not be construed as necessarily referring to a single fold line only: indeed it ss envisaged that a hinged connection can be formed from one or more of rhe following/ a score line, a frangible line or fold hπe, without departing from the scope of the invention.

Claims

1 A composite tray for containing articles, which composite tray structure is formed from a hrst part providing a basic tray element structure having walls to provsde stacking strength and containment of the tray's contents, and a second pan that re;nforces and cooperates with the first part Io overise a substantial portion of the inner surface of the first part, wheresn the first and second parts, together have a fsrsr configuration sn which the second part augments the pro^jection of the tray contents afforded by the waNs of the first part, and a second configuration m which the second pad is. manipulated to put the walis of the basso tray element structure snto an enhanced multiply form that further remforees the walls of the basic tray element structure.

2 A composite tray as claimed in claim 1 wherein the second part is formed of a matenal of greater aesthetic quality than that of the first part.

3. A composite tray according io eRher one of claims 1 or 2 wherein !he first part comprises a base paπei hsnged to opposing side walls and to opposing end walls which side walls and end walls are shaped so as to provide reinforced comer posts at each corner of the base panel thereby facilitating stacking of the composite fray with other trays.

4. A composite tray according to any one of ciaims 1 or 3 wheresn outer surfaces of opposing side or end waϋs of the first part, when it is in said second configuration, are become snternai surfaces when it is In said first configuration, thus serving to protect said outer surfaces from damage during transport.

5. A composite tray according to either one of claims 3 or 4 wheresn me reinforced corner posts are provided by porπons of the end wails side wails and also by end flaps that are hinged to the end walls and fastened, sn copianar contact, to those portions of the side walls that form the corner posts.

6. A composite tray according to any one of claims 3, 4 or 5 wherein the end wails of she first part are formed from a Nnear series of end wail panels hinged one to the next, and wherein the linear series of end wail panels are folded so as to provide muiϊi-piy end walls

7 A composite tray according to any one of claims 1 to ? wherein the second parr, comprises a base lining pane! hsnged, along at least one end, Io a linear series of end wail lining panels.

8. A composite tray of claim ?, wherem said linear series of end wail hning panels comprises an inner end wall lining panel disposed substantially in coplanar contact with an inner surface of an end wall of the first part, and wheresn the snner end wail lining panel ss hinged to an outer end wall hning panel, which outer end waii hning panel is disposed sunsianisaUy in copianar contact with the outer surface of an end wall of the first part.

9 A composite tray of claim S wherein she outer end wail lining panel of the second part eompnses a handle slap aligned with a first s pert u re struck at least in part, from the inner end waii lining panel of the second pan and with a second aperture struck, at least in pan, from the end wall of she first part said first and second aperture being In registry vvsth one another ihe handle flap may be folded interior of ?ne tray through the aligned first and second apertures.

10. A composite tray according \o any one of claims ^"Mo 9 therein the second part comprises a base iimng panei hinged, along a! least one side, to a linear ser.es of Side waii linsnq panels.

1 1 A composite tray according to claim 10, wherem said linear senes or side wail lining panels comprises an inner side wall lining panel disposed substantially in copianar contec? with an inner surface of a side waii of the first part, and wherein the inner side wall lining panel ss hinged to an outer side wail hning panel which may he disposed substantially in coplanar contact with the outer surface of a side wail of the- first part

12. A composite tray according to claim I i wherein the outer side wau lining panel of the second part comprises a handle flap aligned with an aperture struck, at least in part, from the inner side wail lining panel of the second part and With an aperture struck, at least in part, from the side wail of the first pan such that the handle flap may be folded Interior of the tray through the first and second apertures said first and second apertures being in registry with one another,

13. A composite tray according to any one claims 1 to 13 wherein the second configuration allows graphics and information to be to De displayed and printed on a surface display panel to an end user.

14. A two-part blank for forming a composite tray structure for containing articles, which composite tray structure is formed from a first part and a second part, which first part forms a basic tray element structure having wails to provide protection and containment of the tray's contents, and which second part reinforces and cooperates with the said first part to overlie a substantial portion of the inner surface of the said first part, wherein the first and second parts, together, have a first configuration in which the second part augments the protection, of the tray contents, afforded by the said first part and a second configuration in which the walls of the basic tray element structure ere put into an enhanced multi-ply form that further reinforces the basic tray element structure.

15. A method or transporting and storing articles which is also suitable for displaying the articles in a retail environment, comprising the steps of: a) forming a composite tray for containing the articles, which composite tray is formed from a first part providing a basic tray element structure having wails fo provide protection and containment of the fray^'s contents, and a second part that reinforces and cooperates with the said first part to overlie a substantial portion of the Inner surface of the said first part wherein the first and second parts, together, have a fust configuration In which the second part augments the protection, of the tray contents_^ afforαed by the said Hrst part and a second configuration sn which the ^aHs of the bsssc tray element structure are put into an enhanced rnυiii-pry form that fϋither reinforces the Dasic tray element structure; D) loading the composite tray structures with articles: c) transporting and storing the loaded composite tray structure as necessary, wherein the composite tray structures are in said first configuration-, and d) disposing the composite tray structure in a retail environment and putting said fsπss arid second parts sn to sasd second configuration.