Tray with integrated support structures

Abstract

The present invention is to an integrated tray for holding and retaining a plurality of articles contained therein. The integrated tray comprises a tubular open-ended tray having a floor panel and an article support panel that is foldably joined to the floor panel in a spaced apart relationship. The article support panel includes a plurality of apertures formed therein to securely retain the plurality of articles therein. A girder is foldably joined to the floor panel and extending upwardly therefrom and is engaged with the article support panel to form the tubular open-ended tray. At least one divider is configured to be removably attached to the tubular open-ended tray. The at least one divider has at least one web panel extending transversely across the tray and at least one flange panel extending longitudinally of the tray.

Claims

1. A tubular open-ended tray for holding and retaining a plurality of articles contained therein, comprising: a floor panel, an article support panel being foldably joined to the floor panel in a spaced apart relationship, the article support panel includes a plurality of apertures formed therein to securely retain the plurality of articles therein, wherein the article support panel and the floor panel are foldably joined to one another via two opposed side walls each of which extends from respective longitudinal edges of the floor panel and the article support panel, a girder foldably joined to the floor panel and extending upwardly therefrom and being engaged with the article support panel to form the tubular open-ended tray; at least one divider is configured to be removably attached to the tubular open-ended tray wherein the at least one divider having at least one web panel extending transversely across the tray and at least one flange panel extending longitudinally of the tray; and a plurality of slots formed on each of the two opposed side walls wherein the plurality of slots are used to engage with the at least one divider.

2. The tubular open-ended tray of claim 1 wherein the at least one divider includes two identical dividers each of which is transversely mounted onto a longitudinal axis of the tubular open-ended tray.

3. The tubular open-ended tray of claim 1 wherein at least one web panel and the at least one flange panel are foldably joined to one another and wherein the web panel is defined by two rectangular-shaped panels coextensively folded onto one another and wherein the least one flange panel includes four flange panels each of which foldably extend from respective ends of each rectangular-shaped panels.

4. The tubular open-ended tray of claim 3 wherein each of the four flange panels includes a locking tab projected from respective free edges thereof and is inserted into the respective plurality of the slots formed on each of the opposed side walls.

5. The tubular open-ended tray of claim 3 wherein the at least one divider further comprises a male slot used to engage with the girder.

6. The tubular open-ended tray of claim 5 wherein the male slot is formed onto each of the rectangular-shaped panels.

7. The tubular open-ended tray of claim 1 wherein the article support panel includes an elongated slot formed in a central portion thereof to permit the girder being inserted through the elongated slot.

8. The tubular open-ended tray of claim 5 wherein the girder includes a female slot that receives the male slot of the at least one divider to securely affix the at least one divider to the tubular open-ended tray.

9. The tubular open-ended tray of claim 1 wherein the girder is a carry handle panel having two hand holes formed therein to permit a user to carry the integrated tray.

10. The tubular open-ended tray of claim 7 wherein the girder is defined by two identical carry handle panels foldably joined to the floor panel and extending upwardly in contiguous relationship to one another through the elongated slot in the article support panel.

11. A tubular open-ended shipping and display tray for holding and retaining a plurality of articles contained therein in an upright position at a point of sale, the tray formed from a single unitary blank, comprising: an article support panel having a plurality of apertures therein for supporting articles in the upright position, opposite side walls foldably joined to longitudinal opposite sides of the article support panel and extending downwardly therefrom, floor panels foldably joined to each of the side walls, the floor panels extending inwardly from the respective side walls toward one another beneath the article support panel in spaced relationship to the article support panel, wherein the article support panel and the floor panel are foldably joined to one another via two opposed side walls each of which extends from respective longitudinal edges of the floor panel and the article support panel and a handle panel foldably joined to each floor panel and extending upwardly in contiguous relationship to one another through a slot in the article support panel to form a carry handle for the tray, and at least one divider removably attached to the tray so as to provide compression capability when a plurality of said trays are stacked on top of one another, the at least one divider having at least one web panel extending transversely across the tray and at least one flange extending longitudinally of the tray and a plurality of slots formed on each of the two opposed side walls wherein the plurality of slots are used to engage with the at least one divider.

12. A plurality of blanks attached to one another for making an integrated tray, the plurality of blanks comprising: a first blank comprising an article support panel having a plurality of apertures formed therein, the article support panel includes an elongated slot formed in a central portion thereof, opposite side wall panels being foldably joined to longitudinal opposite sides of the article support panel via first fold lines, floor panels each of which being foldably joined to each of the respective side wall panels via second fold lines, and girder panels each of which having two female slots formed therein and being foldably joined to the respective floor panels via third fold lines to form a tubular open-ended tray when the first blank being constructed; and two identical blanks being defined by second and third blanks each of which comprises two identical rectangular-shaped panels foldably joined to one another, each of the two rectangular-shaped panels includes two flange panels each of which foldably extends from respective opposed ends of the rectangular-shaped panel, each of the two rectangular-shaped panels includes a male slot formed therein which engaged with the female slot of the girder panels when the blanks being constructed and wherein each of the two flange panels includes a locking tab projected from respective free edges thereof.

13. The plurality of blanks of claim 12 wherein each of the opposed side wall panels includes four spaced apart slots formed on respective longitudinal edges thereof.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:

(2) FIG. 1 is an exploded perspective view of an integrated tray having a tubular open-ended tray in spaced relationship with articles, two dividers, and an optional support pad in accordance to a preferred embodiment of the invention;

(3) FIG. 2 is a top perspective view of the integrated tray of FIG. 1 in an assembled position, and illustrating the integrated tray loaded with articles therein according to the invention;

(4) FIG. 3 is a plan view of a paperboard blank B1 for making the tubular open-ended tray 102 shown in FIGS. 1 and 2;

(5) FIGS. 4A-4D illustrate the folding sequences of the blank B1 shown in FIG. 3 for constructing the tubular open-ended tray in accordance to the preferred embodiment of the present invention;

(6) FIGS. 5A and 5B are respective plan view of paperboard blanks B2 for making the respective dividers 104a, 104b shown in FIGS. 1 and 2;

(7) FIGS. 6A-6D illustrate the manner in which the respective blanks B2 for making dividers are folded and configured to be attached to the tubular open-ended tray; and

(8) FIG. 7 is a cross-sectional view taken along line 7-7 in FIG. 2.

DETAIL DESCRIPTION OF THE INVENTION

(9) While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. In the present invention the use of prime character in the numeral references in the drawings directed to the different embodiment indicate that those elements are either the same or at least function the same or those elements are in the unfolded position.

(10) FIG. 1 is an exploded perspective view of an integrated tray 100 having a tubular open-ended tray 102, two horizontal dividers 104a &104b, articles 106, and a support pad 108 all in spaced relationship with one another in accordance to a preferred embodiment of the invention. The tubular open-ended tray 102 includes an article support panel 110 comprises a plurality of apertures 112 formed therein for supporting articles 106 in an upright position. Opposite side walls 114a, 114b are foldably joined to opposite longitudinal sides of the article support panel 110 and extending downwardly therefrom and are foldably joined to floor panels 116a, 116b. The floor panels 116a, 116b extend inwardly from the respective side walls 114a, 114b toward one another beneath the article support panel 110 in spaced relationship to the article support panel 110. Girder or carry handle panels 118 is defined by two identical girders or carry handle panels 118a, 118b as best seen in FIG. 3. The girders or carry handle panels 118a, 118b are foldably joined to the respective floor panels 116a, 116b and extending upwardly in contiguous relationship to one another through an elongated slot 120 in the article support panel 110 to form a carry handle for the integrated tray 100 as will be discussed in greater detail hereinafter. At least one divider or preferably two identical dividers 104a, 104b each of which is removably attached to the tubular open-ended tray 102 so as to provide compression capability when the integrated tray 100 are stacked on top of one another. Each of the two dividers 104a, 104b has respective web panels 122, 124 extending transversely across the tubular open-ended tray 102 and respective flanges 126, 128 extending longitudinally of the tubular open-ended tray 102 as will be discussed in greater detail hereinafter. Each of the web panels 122, 124 comprises a respective male slot 136, 138 used to engage with a respective female slot 140, 142 of the girder or carry handle panel 118. The respective female slot 140, 142 receives the respective male slot 136, 138 of the respective two dividers 104a, 104b to securely affix the dividers to the tubular open-ended tray 102. The flange 126 is defined by four flanges 126a, 126b, 126c, 126d and the flange 128 is defined by flanges 128a, 128b, 128c, and 128d.

(11) Each of the four flange panels 126a, 126b, 126c, 126d includes a respective locking tab 132 projected from respective free edges thereof and is inserted into a respective plurality of the slots 130 formed on each of the opposed side walls 114a, 114b. Similarly, each of the four flange panels 128a, 128b, 128c, 128d includes a respective locking tab 132 projected from respective free edges thereof and is inserted into a respective plurality of the slots 130 formed on each of the opposed side walls 114a, 114b. The girder 118 is also function as a carry handle panel having two hand holes 144, 146 formed therein to permit a user to carry the integrated tray 100. In use, the tubular open-ended tray 102 is placed onto the support pad 108, then the article 106 is put into the tubular open-ended tray 102 and finally each of the dividers 104a, 104b is attached to the tray 102 as seen best in FIG. 2. The support pad 108 is used for stacking the integrated trays on top of one another. As illustrated in FIG. 2, the integrated tray 100 contains articles 106 such as packages of candy canes, but one of ordinary skill in the art would appreciate that other articles such as, but not limited to, groups of DVD's, CD's or other type of digital media, plastic cases containing product for sale, and various types of consumer and industrial products, or the like, may also be contained therein.

(12) FIG. 3 is a plan view of a cut and scored paperboard blank B1 for forming the tubular open-ended tray 102 depicted in FIGS. 1 and 2. The blank B1 is substantially flat symmetrical with respect to its lateral or longitudinal axis thereof. The blank B1 is preferably an integral piece of a material such as continuous sheet of conventional corrugated paperboard. The blank B1 is cut along its outer margins to form its specific shape. The blank B1 is divided into girders or carry handle panels 118a′, 118b′, floor panels 116a′, 116b′, Opposite side walls 114a′, 114b′, and an article support panel 110′ by parallel fold lines 148, 150, 152, 154, 156 and 158. For example, the respective girders or carry handle panels 118a′, 118b′ are defined by respective fold lines 148 and 156. The floor panel 116a′ is defined by the two fold lines 148, 150 and the floor plan 116b′ is defined by the two fold lines 156, 158. The opposed side walls 114a′, 114b′ are defined by fold line 150, 152 and fold line 154, 156, respectively. Finally, the article support panel 110′ is defined by the two parallel fold lines 152 and 154. The elongated slot 120′ is formed in the central portion of article support panel 110′. The length of the elongated slot 120′ is formed so that it corresponds to a length (L) of the respective girders 118a′, 118b′ which permits the girders 118a′, 118b′ be inserted through the elongated slot 120′. The plurality of apertures 112 are formed onto the article support panel 110 for supporting articles 106 in an upright position when the blank B1 is fully constructed. The shape, size, and number of the slots or apertures 112 are not limited, but depend on shape and size of the articles supported by the integrated tray.

(13) The plurality of the slots 130 are formed on the respective longitudinal edges of each of the opposed side walls 114a, 114b that correspond to the number of the respective locking tabs 132 projected from respective free edges of the four flange panels 126a, 126b, 126c, 126d. Each of the respective girders or carry handle panels 118a′, 118b′ includes a respective pair of spaced apart female slot 140′, 142′ formed from respective free edges toward the center of the girders. Each of the respective girders or carry handle panels 118a′, 118b′ includes a respective pair of spaced apart hand holes 144′, 146′ formed therein to permit a user to carry the integrated tray 100. Each of the respective girders or carry handle panels 118a′, 118b′ further includes a respective pair of ledges 160a, 160b each of which extends outwardly from length (L) and terminates at the respective side edges of the girders 118a′, 118b′. When the blank B1 is fully constructed, the ledges 160a′, 160b′ rest underneath of the article support panel 110′ so as to form the tubular open-ended tray 102 and support the floor panels 116a′, 116b′. The weight of the articles 106 contained in the integrated tray 100 are supported by the floor panels 116a′, 116b′ and the ledges 160a′, 160b′.

(14) Referring to FIGS. 4A-4D, manual set-up of the tubular open-ended tray 102 is easily accomplished. However, a person of ordinary skill in the art would appreciate that generally a folding machine may alternatively perform the forming operations. The blank B1 is laid horizontally and then the girders or carry handle panels 118a′, 118b′ and the floor panels 116a′, 116b′ are simultaneously folded along the respective fold lines 152 and 154 while carry handle panels 118a′, 118b′ are folded along respective fold lines 148, 158 so that the carry handle panels 118a′, 118b′ are inserted into the elongated slot 120′ as depicted in FIGS. 4A-4B. It should be noted that the two girders or carry handle panels 118a′, 118b′ are identical and they are in registry with one another when they are extending upwardly through the elongated slot 120′ as illustrated in FIGS. 4B-4D. The girder or handle panel 118 functions like a center beam having two handle panels extending upwardly in contiguous relationship to one another. This center beam provides for longitudinal stability of the tray and forms a structure onto which separate parts can be easily attached. The girder or handle panel or center beam 118 can incorporate hand-holds 144, 146, if desired, to allow for the integrated tray 100 to be easily moved, either during the production process, or when placing it on the final pallet for shipment. The girder or handle panel or center beam 118 is formed with female slots 140, 142 in it which horizontal dividers 104a, 104b could be inserted, thus firmly affixing these dividers to the tubular open-ended tray 102 and providing top to bottom compression capability. The tubular open-ended tray 102, when fully constructed, forms two identical rectangular tubes separated by the vertically formed girder or carry handle panel 118. The heights of the rectangular tubes are determined by the width of the respective side walls 114a, 114b and they help in retaining the articles 106 in an upright position and preventing from falling forward or backward.

(15) FIGS. 5A and 5B are respective plan view of the respective paperboard blanks 104a′ and 104b′ for making the respective dividers 104a and 104b as shown in FIGS. 1 and 2. The two identical blanks being defined by second and third blanks 104a′, 104b′ each of which comprises two identical rectangular-shaped panels foldably joined to one another. Since the respective blanks 104a′ and 104b′ are identical in shape, form, and their intended function, then one of blanks, for example, the second blank or blank 104a′ is described in greater detail hereinafter in which the description for the blank 104a′ is equally applicable to the blank 104b′. The blank 104a′ includes respective web panels 122a′, 122b′ defined by two parallel score lines 160. Each of the web panels 122a′, 122b′ comprises a respective male slot 136 used to engage with a respective female slot 140 of the girder or carry handle panel 118. Each of the web panels 122a′, 122b′ includes a respective pair flanges 126a′, 126b′ and 126c′, 126d′. For example, each of the flanges 126a′ and 126b′ foldably extends from respective lateral edges of the web panels 122a′ via fold lines 162 and each of the flanges 126c′ and 126d′ foldably extends from respective lateral edges of the web panels 122b′ via fold lines 164. Each of the respective flanges 126a′, 126b′, 126c′, and 126d′ includes a respective locking tab 132 foldably projected from respective free edges of the respective flanges 126a′, 126b′, 126c′, and 126d′ via respective fold lines 166. It should be noted that the respective flanges 126a′ and 126c′ are formed apart from one another so that each of them can be rotated independently. The distance between the flanges 126a′ and 126c′ correspond to the distance between the two parallel score lines 160. Similarly, the respective flanges 126b′ and 126d′ are formed apart from one another so that each of them can be rotated independently. The distance between the flanges 126b′ and 126d′ correspond to the distance between the two parallel score lines 160. As noted hereinabove, the description for the blank 104b′ is the same as the blank 104a′ and will not be repeated herein to avoid redundancy.

(16) FIGS. 6A-6D illustrate the manner in which the respective blanks B2 for making horizontal dividers 104a, 104b are folded and configured to be attached to the tubular open-ended tray 102. First, each of the respective horizontal dividers 104a′, 104b′ are folded along their respective score lines 160. Next, each of the respective horizontal dividers 104a′, 104b′ are attached to the girder or carry handle panel 118 by engaging the respective male slot 136 with a respective female slot 140. Finally, the respective locking tabs 132 are inserted into the respective slot 130 to securely affix the respective dividers 104a, 104b to the tubular open-ended tray 102. When assembled, the respective dividers 104a, 104b would allow for several integrated trays to be stacked on top of one another in two or more rows. The horizontal dividers 104a′, 104b′ can be inserted at multiple points and in the number required for the needed top to bottom compression and horizontal stability.

(17) FIG. 7 is a cross-sectional view taken along line 7-7 in FIG. 2 which illustrates elevation and detail of engagement of the tubular open-ended tray 102, the divider 104a, articles 106, and a support pad 108 with respect to one another. For example, the height of the tubular open-ended tray 102 provides enough space for each article 106 to securely retain in the tray without falling forward or backward during transportation of the integrated tray. The size and shape of the apertures 112 in the article support panel 110 can be placed in any configuration, and the height between the floor panel 116 and the article support panel 110 can be either increased or decreased, depending on the type of product to be packaged, and the shape of the articles to be packed. It should also be noted that with respect to the position of the girder 118, one side of the tray is slightly wider than the other side of the tray since the tip of articles 106 in the first row are tilted a bit backward; therefore, it requires enough space for the bottom of the articles 106 to position forward. Although the support pad 108 has a U-shaped cross section, but one of ordinary skill in the art would appreciate that other support pads such as a plain paperboard sheet or the like may be used accordingly. When the integrated tray are stacked on top one another, the bottom edges of each of the flanges 126 and 128 sit on the support pad that are used to absorb the compression force exerted by the weight of the integrated tray 100. As an alternative embodiment, a single or double ply stacking tabs can be formed on the central portion of the two parallel score lines 160 on the boundary of the respective web panels 122a′, 122b′ so that the respective stacking tabs is inserted to the corresponding slots formed on the respective floor panels 116a′, 116b′. Each of the stacking tabs is projected upwardly from upper edge of the respective web panels 122 and 124. By using the stacking tabs configuration, the support pad 108 can be eliminated. The integrated tray 100 of the present invention is simple and economical in construction, requiring minimal parts and material, and effectively holds a plurality of articles 106 in upright position when displayed for sale.

(18) Three blanks are illustrated herein, one blank for the tubular open-ended tray 102 and two identical blanks for horizontal dividers 104a, 104b for the integrated tray 100 according to the present invention. In the blanks illustrations, unless otherwise indicated, the usual drawing conventions are applied, wherein solid lines on the interior of a blank, indicate an aperture or complete through cut, and broken lines indicate a fold line, a line of weakness such as a score, crease, perforation, or other means for weakening the blank, to permit breaking or folding.

(19) Any dimensions, distances or other numerical values, that may be given in the description herein, or in the Figures, are given by way of example, and the present invention is not to be considered limited thereto.

(20) This invention could be employed and practiced in a number of different ways. Among them are: The employment of the design in a retail display capacity, whereby an entire pallet of this product would be placed in the aisle of a retail establishment, displaying the product contained in the display to consumers. Given the ample incorporation of printable surfaces in any one of its multiple configurations, it provides for the ability to advertise the features, advantages and benefits of the product being sold in the display to consumers. As the various levels of the multi-level pallet display are emptied of product or “shopped down” a replacement level of product could be added to the display and therefore it could continue to be used in the retail display role.

(21) Depending on the types of products to be packaged into this item, apertures can be die cut into the article support panel 110. These apertures or openings, whether completely cut out, or including a flapped opening can be placed in multiple locations in the article support panel. Furthermore, the shapes of these apertures or openings can be configured to match the shape outline and geometry of the product to be packaged, thereby securing it in the overall design throughout the distribution cycle of the corrugated item and the product to be shipped.

(22) This corrugated article could be utilized to ship, among other possible items: small plastic cases containing product for sale, work-in-process components being transported from one location to another for the continuing of the manufacturing process of these items, groups of DVD's, CD's or other typed of digital media, various types of consumer and industrial products in addition to those previously mentioned.

(23) While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.