TRAY FOR SECURING A UNIT LOAD

Abstract

Disclosed is a blank that is foldable into multiple configurations. The folded blank may be useful as a tray or cap to support a plurality of packages stacked to form a floor loaded unit load. In other embodiments the tray may be used to support a unit load stacked onto a pallet for storage and transport. The various tray configurations each have different dimensions to accommodate and secure a range of unit load dimensions.

Claims

1. A folded tray comprising: a. a bottom panel having horizontal and vertical opposing edges; b. a pair of side walls extending from the bottom panel and separated therefrom by first and second spaced apart and substantially horizontally oriented fold lines, each side wall further comprising a first and a second pair of slots, each slot having a first and a second end; c. a pair of end walls extending from the bottom panel and separated therefrom by first and second spaced apart and substantially vertically oriented fold lines, each end wall comprising a first and a second end and a tab disposed at the first and second ends, each tab separated from the end wall by a third and fourth substantially horizontally oriented fold line; wherein each tab and each side wall is foldable along the first and second pair of horizontal fold lines and each end wall is foldable along the first and second pair of vertical fold lines such that each tab may be received by a slot.

2. The folded tray of claim 1 wherein each of the first slot ends terminates at a first or a second substantially horizontally oriented fold line separating the side wall from the bottom panel.

3. The folded tray of claim 1 wherein the third substantially horizontally oriented fold line is continuous with the first substantially horizontally oriented fold line separating the side wall from the bottom panel.

4. The folded tray of claim 1 wherein the fourth substantially horizontally oriented fold line is continuous with the second substantially horizontally oriented fold line separating the side wall from the bottom panel.

5. The folded tray of claim 1 wherein a portion of the end walls is separate from and discontinuous with the bottom panel.

6. The folded tray of claim 1 wherein the slots have a curvilinear portion, a substantially horizontally oriented linear portion and a substantially vertically oriented linear portion.

7. The folded tray of claim 1 wherein the first and second spaced apart and substantially horizontally oriented fold lines are spaced apart a distance from about 5 to about 10 cm and the first and second spaced apart and substantially vertically oriented fold lines are spaced apart a distance from about 5 to about 10 cm.

8. The folded tray of claim 1 wherein folding along first substantially horizontally oriented fold lines and first substantially vertically oriented fold lines results in a folded tray having a first surface area and wherein folding along second substantially horizontally oriented fold lines and second substantially vertically oriented fold lines results in a folded tray having a second surface area, wherein the second surface area is from about 5 to about 10 percent greater than the first surface area.

9. A tray comprising: a. a substantially rectilinear bottom panel having horizontal and vertical opposing edges; b. a pair of opposed side walls extending from the bottom panel; and c. a pair of opposed end walls extending from the bottom panel; wherein the side walls and end walls are foldable relative to the bottom panel to at least two fold positions such that at least a part of each folded wall defines a wall extending upwardly from the bottom wall and wherein folding of the walls to different fold positions varies the position of adjacent wall ends relative to each other; the end walls comprising tabs disposed at a first and a second end of the wall and separated therefrom by a pair of spaced apart substantially horizontal fold lines, the tabs engageable in at least two different position with slots disposed on the side walls when the walls are folded to their at least two folded positions.

10. The folded tray of claim 9 wherein the slots have a curvilinear portion, a substantially horizontally oriented linear portion and a substantially vertically oriented linear portion.

11. The tray of claim 9 wherein each slot has a first slot end that terminates at a first or a second substantially horizontally oriented fold line separating the side wall from the bottom panel.

12. The folded tray of claim 9 wherein a portion of the end walls is separate from and discontinuous with the bottom panel.

13. The folded tray of claim 9 wherein the pair of spaced apart and substantially horizontally oriented fold lines are spaced apart a distance from about 5 to about 10 cm.

14. The folded tray of claim 9 wherein first fold position results in a folded tray having a first surface area and wherein a second fold position results in a folded tray having a second surface area, wherein the second surface area is from about 5 to about 10 percent greater than the first surface area.

15. A blank foldable into a tray comprising: a. a substantially rectilinear bottom panel having horizontal and vertical opposing edges; b. a pair of opposed side panels extending from the bottom panel and arranged symmetrically about a centerline extending along a transverse axis perpendicular to the longitudinal axis of the opposed side panels; c. a pair of opposed end panels having first and second ends and tabs extending therefrom, the tabs having first and second longitudinal extending fold lines; d. a first pair of longitudinal extending fold lines for folding the opposed side panels relative to the bottom panel; e. a first pair of transversely extending fold lines for folding the opposed end panels relative to the bottom panel; and f. a pair of slots disposed on each of the opposed side panels and spaced apart from one another in a direction along the longitudinal axis of the side panel and in a direction along a transverse axis perpendicular to the longitudinal axis.

16. The blank of claim 15 wherein the slots are shaped to receive the tabs.

17. The blank of claim 15 wherein the slots have a curvilinear portion, a substantially horizontally oriented linear portion and a substantially vertically oriented linear portion.

18. The blank of claim 17 wherein the substantially vertically oriented linear portion terminates at a longitudinal extending fold line.

19. The blank of claim 15 wherein the longitudinal extending fold lines and the transversely extending fold lines are spaced apart from one another substantially equal distances.

20. The blank of claim 19 wherein the fold lines are spaced apart a distance from about 5 to about 10 cm.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0012] FIG. 1 is a top plane view of a blank useful in forming a tray according to the present invention;

[0013] FIG. 2 is a perspective view of a tray according to one embodiment of the present invention;

[0014] FIG. 3 is a detail view of a portion of the tray of FIG. 2;

[0015] FIG. 4 is a detail view of a portion of the tray of FIG. 2;

[0016] FIG. 5 is a perspective view of a portion of a tray according to another embodiment of the present invention;

[0017] FIG. 6 is a detail view of a portion of the tray of FIG. 5;

[0018] FIGS. 7 through 9 are perspective views showing different stages of construction of a unit load according to the present invention.

DETAILED DESCRIPTION OF PARTICULAR EMBODIMENTS

[0019] The present invention provides a blank that is foldable into a tray, also referred to herein alternatively as a cap, of varying dimensions. The tray of the present invention is useful in securing a unit load and may be used either as a bottom tray or a top cap for securing a unit load. In certain instances the tray is useful as a bottom tray placed between a stack of packages and the floor or a pallet and comprises one or more side walls, also referred to herein as flaps, that are folded upwardly around one or more sides of the bottom edge of the stack. The side walls include multiple fold lines to facilitate folding the tray into multiple configurations. The side walls further comprise end tabs and slits, which facilitate the folded side walls to be secured to one another and to completely surround the bottom edge of the stack.

[0020] In certain preferred embodiments the blank is foldable into a tray having two or more different areas and a perimeter defined by a continuous side wall that is folded upwards, or downwards depending on the orientation of the tray, to completely surround a stack of packages. For example, a single blank may be foldable into a first configuration having a surface area, defined as the length between opposed end walls multiplied by the width between opposed side walls, from about 0.5 to about 2.0 square meters and a second configuration having a surface area that is about 2 to about 20 percent greater that the surface area of the first configuration, such as from about 5 to about 10 percent greater. In both configurations the corners, defined by a folded tab extending from an end of the end wall which has been inserted into a slot disposed on the side wall to join the end and side wall together, may be continuous and therefore eliminate the need for corner posts, which are commonly used in securing unit loads. Further, the resulting folded tray may have continuous sidewalls that may be printed with graphics, such as branding or logos, to communicate the contents of the unit load.

[0021] The blank may be made of any suitable material such as, for example, fiberboard, containerboard, corrugated containerboard, corrugated cardboard, paperboard, or the like. Corrugated containerboard is particularly useful because it is light weight yet sufficiently rigid, and can also be cut in a flat shape to form a blank 10, such as that illustrated in FIG. 1, consisting of four flaps—a pair of opposed side flaps 20, 22 and opposed end flaps 21, 23, extending from a bottom panel 30. Each opposed side flap 20, 22 is symmetrical about a centerline extending along a transverse axis perpendicular to the longitudinal axis of the side flap. Generally a portion of the blank extending parallel to the longitudinal axis of the flap will be referred to herein as having a generally horizontal orientation, while a portion extending along the transverse axis will be referred to as having a generally vertical orientation.

[0022] While in certain embodiments the blank 10 advantageously has four flaps 20, 21, 22, 23 extending from each side of the bottom panel 30, as exemplarily illustrated in FIG. 1, other configurations are possible. For example a given flap may comprise two smaller flaps separated by a gap instead of a single flap continuously extending across the length of one side of the bottom panel. The length of the flaps 20, 21, 22, 23 in the outward direction away from the bottom panel 30 may vary depending on the desired dimensions of the folded tray, generally it is expected that a length of between about 10 and 40 cm will be suitable, for example from about 20 to about 30 cm, such as from about 22 to about 25 cm.

[0023] The opposed side flaps 20, 22 extending from the bottom panel 30 are separated therefrom by first and second spaced apart and substantially horizontally oriented fold lines 40, 42 (illustrated as dotted lines, although they may be either continuous or discontinuous, as discussed in more detail below). The first and second fold lines 40, 42 are provided parallel to edge 12 in blank 10 and spaced therefrom to provide the desired depth of the folded tray. The fold lines are generally parallel to one another and linear and each defines a line along which a given side flap may be folded relative to the bottom panel. Further, the fold lines 40, 42 are arranged such that the inner most fold line 40 defines a first outer edge 13 of bottom panel 30 and the outer most fold line 40 defines a first folded edge 14 of the flap 20.

[0024] The horizontal oriented fold lines can be made in any suitable manner and can comprise a continuous or discontinuous fold line. Preferably the fold lines are made by creasing the material and/or perforating portions of the material along the fold lines. Fold lines may be provided between each side flap and the bottom panel of the bottom tray for making the folding of the side walls around the bottom edge of the stack easier. Depending on the final dimensions of the folded tray the horizontally extending fold lines 40, 42 may be spaced apart from one another about 3 to about 15 cm, such as from about 5 to about 10 cm. Further, while the illustrated embodiment comprises two horizontally oriented fold lines, the invention is not so limited and the blank may comprise two or more horizontally oriented fold lines dividing the bottom panel and a side panel, such as 2, 3, 4 or 5 fold lines.

[0025] A pair of substantially vertically oriented fold lines 44, 46 separate the end flaps 21, 23 from the bottom panel 30. The fold lines 44, 46 are generally parallel to one another and linear and each defines a line along which a given side flap 20, 22 may be folded relative to the bottom panel 30. Further, the fold lines 44, 46 are arranged such that the inner most fold line 44 defines a first outer edge 15 of bottom panel 30 and the outer most fold line 46 defines a first folded edge 18 of the flap 21.

[0026] Like the horizontally extending fold lines 40, 42, the vertical fold lines 44, 46 may be formed by any one of the well-known techniques in the art and may be either continuous or discontinuous and are generally provided to facilitate folding of the end walls 21, 23. Depending on the final dimensions of the folded tray the vertically extending fold lines 44, 46 may be spaced apart from about 3 to about 15 cm, such as from about 5 to about 10 cm. Further, while the illustrated embodiment comprises two vertically oriented fold lines, the invention is not so limited and the blank may comprise two or more vertically oriented fold lines dividing the bottom panel and an end panel, such as 2, 3, 4 or 5 fold lines.

[0027] In certain embodiments the bottom panel 30 of the blank 10 may be shaped and sized to be generally contiguous with the surface of a pallet. For example, the bottom panel may be substantially rectangular having a length (I) extending between opposed first vertically oriented fold lines and a width (w) extending between opposed first horizontally oriented fold lines. The bottom panel may have a surface area of at least about 0.5 square meters, such as from about 0.5 to about 2.0 square meters. Further, in certain embodiments, the fold lines may be disposed relative to the bottom panel and one another such that the footprint of the stack (i.e. the surface of the first layer of packages in a unit layer) matches approximately the upper surface area of the pallet and the surface of the bottom panel. In other embodiments the stack and the upper surface area of the pallet may exceed the area of the bottom panel such that a portion of the flaps are disposed between the pallet and the stack. In other embodiments the footprint of the stack and the bottom panel may be smaller than the surface of the pallet. For example, the area of the bottom panel may be about 5 percent less than surface area of the pallet and in certain embodiments 10 percent less than surface area of the pallet.

[0028] With continued reference to FIG. 1 each side flap 20, 22 comprises a first and a second pair of slits, or tuck tab slots, or simply slots, 50, 52. The slits may be a continuous opening or may be formed of interrupted slits, perforations or incisions which can readily be severed so as to form a depressible tab aided by the continuation of the slit at the lines of incision. The slots 50, 52 are laterally spaced from each other relative to a longitudinal axis of the side panel, and are also preferably spaced from each other relative to an axis transverse to the longitudinal axis. This construction enables the operator to secure the side panel and end panel together according to the size of the articles being packaged by selecting the appropriate slot to insert the folded tab into, as will be describe in more detail below.

[0029] In a particularly preferred embodiment, such as that illustrated in FIG. 1, the slots 50, 52 are a continuous opening having a curvilinear portion 51 connecting two linear portions 53, 55. The first linear portion 53 comprises a horizontally oriented segment terminating at a first end 56. The second linear portion 55 comprises a vertically oriented segment terminating at a second end 58. In certain preferred embodiments a first tuck tab slot 50 has a vertically oriented portion 53 that terminates at a first horizontally oriented fold line 40 and a second tuck tab slot 52 has vertically oriented portion 53 that terminates at a second horizontally oriented fold line 42. In other embodiments the ends of the slots may extend beyond the fold lines or may terminate short of the fold lines.

[0030] First and second tuck tab slots 50, 52 are generally configured to receive tabs 27, 29 disposed at each of the first and second ends 24, 25 of the opposed end flaps 21, 23. First and second tabs 27, 29 may be formed by cutting away a portion of the blank 10. For example, a portion of the blank adjacent to the ends of the first and second fold lines may be cut away to form the tabs and a gap between the side flaps and the tabs. In certain preferred embodiments the tabs may be notched to facilitate interlocking of the tab when it is inserted into the tuck tab slot.

[0031] Each tab 27, 29 is hingedly connected to an end flap 21, 23 by substantially horizontally oriented fold lines 47, 48. Depending on the final dimensions of the folded tray the horizontally extending fold lines 47, 48 may be spaced apart from about 3 to about 15 cm, such as from about 5 to about 10 cm. Further, while the illustrated embodiment comprises two horizontally oriented fold lines 47, 48 the invention is not so limited and the blank may comprise two or more horizontally oriented fold lines dividing the end flap and the tabs, such as 2, 3, 4 or 5 fold lines. In certain preferred embodiments the fold lines 47, 48 are spaced and arranged substantially similarly to the horizontal fold lines 40, 42 separating the bottom panel 30 and the side flaps 20, 22.

[0032] With reference now to FIG. 2, the blank 10 of FIG. 1 is shown in a folded configuration to form a tray 100. In the illustrated embodiment the blank 10 has been folded along first vertical and horizontal fold lines 40, 44 respectively. The resulting folded tray 100 has four the side walls 120, 121, 122, 123 extending from, and attached to, a bottom panel 130. The side walls 120, 121, 122, 123 are separated from the bottom panel 130 by first and second substantially horizontally oriented fold lines 140, 142 and first and second vertically oriented fold lines 144, 146. The fold lines facilitate folding the side walls around one or more, advantageously all four, of the sides of the bottom edge, or top edge, of a stack of packages as will be discussed in more detail below. The side walls 120, 121, 122, 123 are generally folded upwardly, or alternatively downwardly when forming a cap, and may form one or more angles relative to the bottom panel 130, depending upon which fold line the walls are folded. In certain instances the folded sidewalls may be disposed at an angle from about 45 to about 90 degrees relative to the bottom panel. The folding of the flaps may be done manually or by a machine.

[0033] The folded tray 100 has four folded corners 150, 151, 152, 153, which are generally formed by folding tabs 160, 161, 162, 163 about first and/or second fold lines 175, 176. With reference to one of the corners 152, the corner is secured by tucking the first end 165 of the tab 161 into a slot 170 disposed on the side wall 122. In the illustrated embodiment, where the tray is formed by folding along both a first and second fold line 140, 144 the corner is formed by folding along both a first and second fold line 175, 176 and tucking the tab 161 into the first 170 of a pair of slots 170, 171 disposed on the side wall 122. In this embodiment the tray is folded to its smallest configuration, as measured by the area of the bottom panel 130, with sidewalls 120, 121, 122, 123 having their maximum height.

[0034] FIGS. 3 and 4 illustrate a detail view of inside (FIG. 3) and outside (FIG. 4) corners of the folded tray. With reference specifically to FIG. 3, the tab 162, which is folded along fold lines 175, 176, has a first end 167 tucked into a first slot 170 on the side wall 120. In this manner the folded tab 162 forms a relatively rigid corner 153 between the side wall 120 and an end wall 123. Further, as shown in FIG. 3, the corner 153 formed by the tab 162 is not necessarily square and may have several angles as a result of folding along both fold lines 175, 176 that hingedly connect the tab 162 to the side wall 120. Further, although not illustrated in FIG. 3, an auxiliary tab may be disposed on the first end of the folded tab to further engage and retain the tab in the slot.

[0035] With reference to FIGS. 5 and 6, which illustrates the tray 100 folded in configuration to minimize the surface area of the bottom panel 130 and to maximize the height of the walls 120, 121, 122, 123. To construct the tray of FIGS. 5 and 6, end walls 121, 123 are folded upwardly along the inner most fold lines 144 and side walls 120, 122 are also folded upwardly along the inner most fold lines 140. In this folded configuration the side and end walls 120, 123 are substantially perpendicular to the bottom panel 130. The walls 120, 123 are secured to one another by a folded tab 162, which is an extension of the end wall 123 folded along fold line 176 and forms the corner 153 of the tray 100. The end of the tab 167 is inserted in a second slot 171 disposed on the side wall 120. This functions to secure the walls 120, 123 together.

[0036] The ability to configure a single blank into trays having different dimensions is particularly useful for fitting stacks of packages, such as packages of consumer goods, having different dimensions and further to provide the stacks with a tray, either a bottom tray or top cap, that completely surrounds and protects the stacks and which may be configured without the use of adhesives. Such a tray or cap is represented in FIG. 7, which illustrates one means of constructing a unit load according to the present invention. It should be understood however, that a unit load may be constructed without a pallet to form a floor loaded unit load in which the tray of the present invention is disposed between the floor and the stack of packaged goods.

[0037] In the embodiment of FIG. 7, the blank 10 to be folded into a tray has a bottom panel 30, which is smaller than the upper surface of the pallet 180 on which it is intended to be used, for example less than about 5 percent or less than about 10 percent of the upper surface of the pallet 180. The size and properties of pallets are normally standardized in a given region. However, the present invention is not limited to a specific type of pallet but is applicable across a wide range of pallet types. Pallets normally comprise grooves for allowing manipulation of the unit load by a fork lift.

[0038] With continued reference to FIG. 7, the blank 10 comprises two pairs of opposed flaps 20, 22 and 21, 23 extending from the bottom panel 30 and separated therefrom by first and second spaced apart fold lines 40, 42 (horizontally oriented) and 44, 46 (vertically oriented). The fold lines 40, 42, 44, 46 may be parallel and extend the entire length of each of the side and end flaps 20, 21, 22, 23. The plurality of fold lines—side flap fold lines 40, 42, end flap fold lines 44, 46 and tab fold lines 47, 48—enable the blank 10 to be folded into a plurality of configurations, which can therefore be adapted for stacks having different dimensions. The fold lines may be separated by a regular distance such as, for example, a distance of about 5 to about 10 cm.

[0039] The fold lines and flaps may be arranged in a variety of configurations relative to the top surface of the pallet depending upon the size to the pallet and the dimensions of the stack to be retained. For example, in the illustrated embodiment the fold lines 40, 42, 44, 46 separating the bottom panel 30 from the flaps 20, 21, 22, 23 all lie within upper surface 181 of the pallet 180. Further, the fold lines 40, 42, 44, 46 are arranged such that a portion of each of the flaps 20, 21, 22, 23 overlays a portion of the upper surface 181 of the pallet 180 and a portion extends beyond the pallet surface 181. The portion of the flaps that extends beyond the pallet may be equal to or less than the flap portion within the surface of the pallet.

[0040] As shown in FIG. 8, a first layer 210 of a stack 205 of packages 200 may be placed on the bottom panel of the bottom tray 10, with the flaps 20, 21, 22, 23 in their horizontal configuration. It is also envisaged that instead of having a bottom tray initially in a completely flat configuration, a bottom tray with already folded walls may be provided. For example, the side and end flaps may be easily folded upwardly along the fold lines and the tray may be secured by further folding the end tabs and inserting into the appropriate slot to form the folded tray.

[0041] The stack 205 of packages 200 is gradually built, by stacking layer upon layer. This may be manually done or by machine means. The stack may also be placed in a single step over the bottom tray if a machine is provided with this capacity. One or more slip sheets may be optionally placed intermediate one, several, or all the layers of packages. Such slip sheet may be made of any material such as, for example, a sheet of paper, paperboard or cardboard.

[0042] Packages may be stacked one on top of another to complete a unit load, such as that illustrated in FIG. 9. The unit load comprises a pallet 180, a stack 205 of packages 200 loaded on the pallet 180, a bottom tray 100 placed between the pallet 180 and the stack 205. The stack may be comprised of several layers and have a generally cubic shape. The dimensions of the stack and the number of packages in the stack may be chosen to allow the maximum number of packages to be loaded on a given pallet, for economic reasons. The number of layers of packages is not critical and can vary, for example from 2 to 12 layers. If the unit load is to be shipped by truck or train, for example a number of 4 to 6 layers may be usual. For overseas shipment by boat, the stack may have a higher number of layers. The number of packages per layer is also not critical, and may be adapted to the circumstances such as the size of the package and the dimension of the pallet.

[0043] While the inventive blanks and trays have been described in detail with respect to the specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily conceive of alterations to, variations of, and equivalents to these embodiments. Accordingly, the scope of the present invention should be assessed as that of the appended claims and any equivalents thereto and the following embodiments:

[0044] In a first embodiment the present invention provides a folded tray comprising a bottom panel having horizontal and vertical opposing edges; a pair of side walls extending from the bottom panel and separated therefrom by first and second spaced apart and substantially horizontally oriented fold lines, each side wall further comprising a first and a second pair of slots, each slot having a first and a second end; a pair of end walls extending from the bottom panel and separated therefrom by first and second spaced apart and substantially vertically oriented fold lines, each end wall comprising a first and a second end and a tab disposed at the first and second ends, each tab separated from the end wall by a third and fourth substantially horizontally oriented fold line; wherein each tab and each side wall is foldable along the first and second pair of horizontal fold lines and each end wall is foldable along the first and second pair of vertical fold lines such that each tab may be received by a slot.

[0045] In a second embodiment the present invention provides the folded tray of the first embodiment wherein each of the first slot ends terminates at a first or a second substantially horizontally oriented fold line separating the side wall from the bottom panel.

[0046] In a third embodiment the present invention provides the folded tray of the first or the second embodiment wherein the third substantially horizontally oriented fold line is continuous with the first substantially horizontally oriented fold line separating the side wall from the bottom panel.

[0047] In a fourth embodiment the present invention provides the folded tray of any one of the first through third embodiments wherein the fourth substantially horizontally oriented fold line is not continuous with the second substantially horizontally oriented fold line separating the side wall from the bottom panel.

[0048] In a fifth embodiment the present invention provides the folded tray of any one of the first through fourth embodiments wherein a portion of the end walls is separate from and discontinuous with the bottom panel.

[0049] In a sixth embodiment the present invention provides the folded tray of any one of the first through fifth embodiments wherein the slots have a curvilinear portion, a substantially horizontally oriented linear portion and a substantially vertically oriented linear portion.

[0050] In a seventh embodiment the present invention provides the folded tray of any one of the first through sixth embodiments wherein the first and second spaced apart and substantially horizontally oriented fold lines are spaced apart a distance from about 5 to about 10 cm and the first and second spaced apart and substantially vertically oriented fold lines are spaced apart a distance from about 5 to about 10 cm.

[0051] In an eighth embodiment the present invention provides the folded tray of any one of the first through seventh embodiments wherein folding along first substantially horizontally oriented fold lines and first substantially vertically oriented fold lines results in a folded tray having a first surface area and wherein folding along second substantially horizontally oriented fold lines and second substantially vertically oriented fold lines results in a folded tray having a second surface area, wherein the second surface area is from about 5 to about 10 percent greater than the first surface area.

[0052] In a ninth embodiment the present invention provides the folded tray of any one of the first through eighth embodiments wherein the tray has four corners, each corner formed by a tab folded along a third and fourth substantially horizontally oriented fold line.