Abstract
In accordance with at least one aspect of this disclosure, a display tray system includes a first tray and a second tray. Each of the first tray and second tray can include at least three outer walls defining a portion of an outer perimeter of the display tray system including an end wall, a joining wall defining an inner border with a second tray, a first side wall having a first length, a second side wall having a second length longer than the first length and extending beyond the joining wall configured to be inserted into the other tray, a first corner having a first height at a junction of the first side wall and the end wall, a second corner having a height equal to the first corner at a junction of the second side wall and the end wall.
Claims
1. A display tray system comprising: a first tray having at least three outer walls defining a portion of an outer perimeter of the display tray system including an end wall, a joining wall defining an inner border with a second tray, a first side wall having a first length, a second side wall having a second length longer than the first length and extending beyond the joining wall configured to be inserted into the second tray, a first corner having a first height at a junction of the first side wall and the end wall, a second corner having a height equal to the first corner at a junction of the second side wall and the end wall, the second tray having at least three outer walls defining a portion of an outer perimeter of the display tray system including an end wall, a joining wall defining an inner border with a second tray, a first side wall having a first length, a second side wall having a second length longer than the first length and extending beyond the joining wall configured to be inserted into the first tray, a first corner having a first height at a junction of the first side wall and the end wall, a second corner having a height equal to the first corner at a junction of the second side wall and the end wall.
2. The system of claim 1, wherein the first tray includes a bottom wall, wherein the first side wall extends from a first fold line on a first side of the bottom wall and the joining wall extends from a third fold line on a third side of the bottom wall, wherein an offset is defined between the first fold line and the third fold line such that in a set up tray a gap is formed between the first side wall and the joining wall for receiving the second side wall of the second tray.
3. The system of claim 1, wherein the second tray includes a bottom wall, wherein the first side wall extends from a first fold line on a first side of the bottom wall and the joining wall extends from a third fold line on a third side of the bottom wall, wherein an offset is defined between the first fold line and the third fold line such that in a set up tray a gap is formed between the first side wall and the joining wall for receiving the second side wall of the first tray.
4. The system of claim 1, wherein each of the first tray and second tray are asymmetric, wherein with the first and second trays joined in the display tray system, the display tray system is symmetric about at least two axes of symmetry.
5. The system of claim 1, wherein the joining wall of each of the first tray and the second tray further includes a respective slot configured to receive a joining member for joining the first tray and second tray together, and further comprising a joining member coupled to the joining wall of the first tray and coupled to the joining wall of the second tray to couple the first and second trays together and provide vertical support.
6. The system of claim 5, wherein the first support includes a pair of support wings hingedly attached thereto and the second support includes a pair of wings hingedly attached thereto, wherein the first support wing of the first support and the first support wing of the second support is within the first tray and the second support wing of the first support and the second support wing of the second support are within the second tray.
7. The system of claim 1, wherein the first corner of the first tray includes a first corner post, wherein the second corner of the first tray includes a second corner post, wherein the first corner post and the second corner post extend above a height of each of the end wall, the first side wall, the second side wall, and the joining wall, and the first tray further comprising: a third corner defined by the junction of the first side wall and the joining wall; and a fourth corner defined by the junction of the second side wall and the joining wall, wherein a height of the third corner and the fourth corner is less than the height of the first corner post and the second corner post.
8. The system of claim 7, wherein the height of the third corner of the first tray and the fourth corner of the first tray are equal to the height of the first side wall, the second side wall, and the joining wall of the first tray.
9. The system of claim 7, wherein the first corner of the second tray includes a first corner post, wherein the second corner of the second tray includes a second corner post, wherein the first corner post and the second corner post extend above a height of each of the end wall, the first side wall, the second side wall, and the joining wall, and the second tray further comprising: a third corner defined by the junction of the first side wall and the joining wall; and a fourth corner defined by the junction of the second side wall and the joining wall, wherein a height of the third corner and the fourth corner is less than the height of the first corner post and the second corner post.
10. The system of claim 9, wherein the height of the third corner of the second tray and the fourth corner second tray are equal to the height of the first side wall, the second side wall, and the joining wall of the second tray.
11. The system of claim 9, wherein with the first tray and the second tray joined to form the display tray system, the first corner post of the first tray forms a first corner post of the display tray system, the second corner post of the first tray forms a second corner post of the display tray system, the first corner post of the second tray forms a third corner post of the display tray system, and the second corner post of the second tray forms a fourth corner post of the display tray system.
12. The system of claim 11, wherein each of the first, second, third, and fourth corner posts of the display tray system include a respective stacking tab extending from the respective corner post configured to slot into a respective receiving slot of a second display tray system to allow the second display tray system to stack atop the display tray system.
13. A blank for forming a tray comprising: a bottom panel defining a bottom wall of the tray; a first end panel hingedly coupled to a first end of the bottom panel for defining an end wall of the tray, wherein the second end panel includes a first group of a plurality of sub panels extending from a first side of the first end panel and hingedly connected to one another configured to fold into a first corner post and a second group of a plurality of sub panels extending from a second side of the first end panel and hingedly connected to one another configured to fold into a second corner post; a first side panel hingedly coupled to a first side of the bottom panel for defining a first side wall of the tray, the first side panel having a length approximately equal to a length of the first side of the bottom panel; a second side panel hingedly coupled to a second side of the bottom panel for defining a second side wall of the tray, the second side panel having a length that is longer than a length of the second side of the bottom panel; and a second end panel hingedly coupled to a second end of the bottom panel for defining a joining wall of the tray.
14. The blank of claim 13, wherein the length of the second side panel is greater than the length of second side of the bottom plus a length of the first end panel.
15. The blank of claim 13, wherein the first side panel includes first side outer panel and a first side inner panel hingedly coupled to the first side outer panel, wherein in a set up tray, the first side outer panel and the first side inner panel are configured to sandwich a portion of a second side wall of a second tray.
16. The blank of claim 15, wherein an offset is defined at a junction between the first side panel and the second end panel such that in a set up tray a gap is formed between a first side wall formed form the first side panel and a joining wall formed from the second end panel, wherein the gap is configured for receiving the portion of the second side wall of the second tray.
17. The blank of claim 13, wherein the second side panel includes second side outer panel and a second side inner panel hingedly coupled to the second side outer panel, wherein in a set up tray, the second side inner panel is folded inward onto the second side outer panel to form a double walled second side panel.
18. A method of forming a display tray system from a blank, comprising: folding a first blank into a first tray and folding a second blank into a second tray, where folding the first tray and folding the second tray includes: folding a first end panel across a first end fold line forming a first end wall; folding an outer panel of a first side wall across a first side fold line forming a partial first side wall; folding an outer panel of a second side wall across a second side fold line and folding an inner panel of the second side wall across a second side middle fold line forming a second side wall; and folding a second end panel across a second end fold line forming a joining wall such that a gap exists between the first side wall and the joining wall; inserting a portion of the second side wall of the first tray into the gap between the first side wall and the joining wall of the second tray such that the portion of the second side wall of the first tray extends along and abuts a portion of the first side wall of the second tray, and inserting a portion of the second side wall of the second tray into the gap between the first side wall and the joining wall of the first tray such that the portion of the second side wall of the second tray extends along and abuts a portion of the first side wall of the first tray.
19. The method of claim 18, further comprising: folding an inner panel of the first side wall of the first tray across a first side middle fold line to enclose the portion of the second side wall of the second tray between the inner panel of the first side wall and the outer panel of the first side wall of the first tray forming a complete first side wall of the display system, and folding an inner panel of the first side wall of the second tray across a first side middle fold line to enclose the portion of the second side wall of the first tray between the inner panel of the first side wall and the outer panel of the first side wall of the second tray forming a complete second side wall of the display system.
20. The method of claim 18, further comprising folding a first group of a plurality of sub panels extending from a first side of a first end panel into a first corner post; and folding a second group of a plurality of sub panels extending from a second side of the first end panel into a second corner post, wherein the first corner post and the second corner post extend above a height of the first end wall, the second end wall, the first side wall, and the second side wall.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, embodiments thereof will be described in detail herein below with reference to certain figures, wherein:
[0032] FIG. 1A is a perspective view of an exemplary embodiment of a tray system according to the disclosure;
[0033] FIG. 1B is a front view of an exemplary embodiment of a tray system according to the disclosure;
[0034] FIG. 1C is a side view of an exemplary embodiment of a tray system according to the disclosure showing a window between the middle support and the joining wall;
[0035] FIG. 2 is a front view of an exemplary embodiment of a pair of trays of the tray system of FIG. 1A;
[0036] FIG. 3A is a perspective view of an exemplary embodiment of a pair of trays of the tray system of FIG. 1A showing an attachment of the joining member;
[0037] FIG. 3B is a perspective view of an exemplary embodiment of a single tray of the tray system of FIG. 1A;
[0038] FIG. 4 is a plan view of a blank for constructing the single tray of FIG. 3B;
[0039] FIG. 5A is a front view of a tray of an exemplary embodiment of a tray system according to the disclosure;
[0040] FIG. 5B is a perspective view of the system of FIG. 5A;
[0041] FIG. 5C is a side view of a tray system of FIG. 5A showing a window between the middle support and the joining wall;
[0042] FIG. 6A is a perspective view of an exemplary embodiment of a pair of trays of the tray system of FIG. 5A showing an attachment of the joining member;
[0043] FIG. 6B is a Side view of an exemplary embodiment of a pair of trays of the tray system of FIG. 5A;
[0044] FIG. 7 is a plan view of a blank for constructing the single tray of FIG. 6B;
[0045] FIG. 8 is a plan view of a blank for constructing the joining member of FIGS. 1A and 5A;
[0046] FIG. 9A is a perspective view of an exemplary embodiment of a tray system according to the disclosure;
[0047] FIG. 9B is a perspective view of the tray system of FIG. 9A with a joining member being placed in place;
[0048] FIG. 9C is a perspective view of the tray system of FIG. 9A with an alternative joining member being placed in place;
[0049] FIG. 9D is a perspective view of a tray system of FIG. 9A with the alternative joining member of FIG. 9C;
[0050] FIG. 9E is a perspective view of an exemplary embodiment of a tray system employing a divider showing in 9D;
[0051] FIG. 10A is a perspective view of an open corner post with stacking tabs;
[0052] FIG. 10B is a plan view of a blank for constructing the corner post of FIG. 10A;
[0053] FIG. 10C is a perspective view of an open corner post without stacking tabs;
[0054] FIG. 10D is a plan view of a blank for constructing the corner post of FIG. 10C;
[0055] FIG. 10E is a perspective view of a closed corner post with stacking tabs;
[0056] FIG. 10F is a plan view of a blank for constructing the closed corner post of FIG. 10E;
[0057] FIG. 10G is a perspective view of an L corner post:
[0058] FIG. 10H is a plan view of a blank for constructing the corner post of FIG. 10G;
[0059] FIG. 10I is a perspective view of a five-panel complex corner post;
[0060] FIG. 10J is a plan view of a blank for constructing the complex corner post of FIG. 10I;
[0061] FIG. 11a is a perspective view of a self-locking tray;
[0062] FIG. 11b is a perspective view of the self-locking tray of FIG. 11a showing a reverse side of the tray;
[0063] FIG. 11c is a plan view of the a blank for constructing the self-locking tray of FIG. 11a;
[0064] FIGS. 12A and 12B are a perspective view of the trays of FIG. 1a filled with product;
[0065] FIG. 13 is a plan view of another embodiment of a blank for forming a display tray of a display tray system;
[0066] FIG. 13A is an enlarged partial view of the blank shown in FIG. 13, showing an offset defined in the blank;
[0067] FIG. 14 is a perspective view of a display tray formed form the blank of FIG. 13;
[0068] FIG. 15 is a perspective view of a first and second display tray formed from the blank of FIG. 13, showing the first and second display trays coming together to form the display tray system;
[0069] FIG. 16 is a perspective view a first and second display tray formed from the blank of FIG. 13, showing the first and second display trays being assembled to form the display tray system; and
[0070] FIG. 17 is a perspective view of a display tray system assembled from the first and second trays shown in FIG. 15.
DETAILED DESCRIPTION
[0071] Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an exemplary tray system in accordance with the disclosure is shown in FIG. 1 and is designated generally by reference character 100. Other embodiments of the tray system, methods of constructing trays in accordance with the disclosure, or aspects thereof, are provided in FIGS. 2-12B, as will be described. The tray systems presented and described below improve product visibility in a display unit common in Club and other large format point of purchase applications, and improve stacking performance and reduce cost to use.
[0072] FIGS. 1a and 1b are perspective views of an exemplary embodiment of a tray system 100 according to the disclosure. The tray system 100 shows a first tray 102 having three outer walls 104, 106, 108, a first corner 110 having a first height (h1) at a junction of two of the outer walls 104/106, a second corner 112 having a height equal to the first corner 110 at a junction of two other outer walls 106/108, a joining wall 114 defining an inner border with a second tray 116, a third corner 118 at a junction of the joining wall 114 and outer wall 104, a fourth corner 120 at a junction of the joining wall 114 and outer wall 108. The second tray 116 similarly includes three outer walls 122, 124, 126, a first corner 128, a second corner 130, a joining wall 132, a third corner 134, and a fourth corner 136. A joining member 138 coupled to the joining wall of the first tray 114 and coupled to the joining wall of the second tray 132 to couple the first 102 and second 116 trays and provide vertical support to the tray system 100 when other trays loaded with product are stacked on top. It is also considered that four trays can be combined with a joining member joining them all together and supported by a single joining member or a system of joining members.
[0073] FIG. 1c is a side view the tray system 100. The joining member 138 includes a flat upper wall 142 level to the height of the first corners 110 and second corners 112 of the first tray 102. The upper wall 142 of the saddle shaped joining member 138 joins a first support 144 and a second support 146. The first support 144 and the second support 146 each straddle the joining walls 114/132 of each of the trays and are partially within the first tray 102 and partially within the second tray 116. Each of the supports 146/144 includes a pair of support wings 146a/146b and 144a/144b respectively hingedly attached thereto. The supports wings 146a/146b and 144a/144b allow for better stability and flexibility in filling the trays with product. The support wings 146a/146b and 144a/144b can be positioned at a variety of angles in order to accommodate packages of various shapes and sizes while still providing support against vertical pressures.
[0074] Joining member 138 can be self-locking or pre-glued. It is also considered that the joining member can join four quarter trays together using various slit combinations. The supports 146/144 can also include rolled-up 3D self-locked or glued supports that will give further vertical support.
[0075] FIG. 1C further shows a window 140 between the joining wall 114 and joining member 138. An underside of the upper wall 146 of the joining member 138 and the upper edge 146 of the joining walls 114/132 of the first tray 114 and the second tray 132 define a top and a bottom of the window 140. The window 140 allows a user to see from one side of the tray system to the other. Not only can a customer see around the joining member 138 to see what is in the back of the tray, but the customer can also see through the joining member 138 to see what is on the other side of the tray, and if needed extract product from that side over the abutting tray walls. Another feature improving sight lines across the tray is having the joining walls 114/132 along with the third corner 118 and fourth corner 120 are below the heights of the first corner 110 and second corner 112.
[0076] As seen in FIG. 2, the upper wall 142 includes a plurality of tabs 148 which couple to slots 150 of a floor 152 of a tray 154 above the first tray 102 and the second tray 116. The tabs 148 provide further stability to the tray system seen in FIGS. 1a-1c. The joining member 138 extends 60% or less into the width of each of the trays: This combination allows for the desired staging of products shown in FIGS. 12A and 12B.
[0077] FIGS. 3A and 3B show a single tray 102 of the tray system of FIGS. 1A-1C. The tray 102 is coupled with the joining member 138 by matching the slots of the joining member 160 with the slots 162 of the joining walls 114/132. FIG. 4 is a plan view of a blank 400 for constructing the single tray shown in FIG. 3B. The blank 400 includes a first panel 402 which defines the joining wall 114 of tray 102. A second panel 406 is hingedly attached to the first panel 402 which defines a floor 152 of tray 102 and outer walls 104 and 108 of tray 102. A third panel 408 is hingedly attached to the second panel 406 and defines the third outer wall 106 of tray 102. The third panel 408 includes a first foursome 410 of sections extended across the third panel 408 hingedly attached to each other and to a first end 412 of the third panel 408. The first foursome 410 defines a first corner post 110 of tray 102. A second foursome of sections 414 at a second end 416 define the second corner post 112. It should be understood to one of ordinary skill in the art that multiple variations and combinations of corners. Details of possible corners are shown and discussed in FIGS. 10A-10J.
[0078] The second panel 406 includes a first tab 418 hingedly attached at a first end 420 and a second tab 422 hingedly attached at a second end 424. Each tab includes a respective fold-out portion 422a/418a to partially detach from the respective tab 422/418 and fold inwards in order to define a portion of a respective outer wall 104/108 and to support the outer wall. The second panel 406 is generally wider than the first panel 402, and the second panel 406 is generally wider than the third panel 408. However, it should be understood that various configurations and dimensional combinations can be used to create a desired tray. The third panel 408 includes a fold-out tab 426 hingedly attached at a first edge 428 to partially detach from the third panel 408 and fold inwards in order to define a portion of outer wall 406 and to provide added thickness to outer wall 406.
[0079] FIG. 5A-6B show another possible features of the previously discussed tray system. It should be understood that the tray system 500 shown here includes all of the features previously discussed but adds height to the third corner post 518 and the fourth corner post 520. The height of the third corner 518 and fourth corner 520 is equal to the height of the first corner 510 and the second corner 512. In sacrificing visibility and lines of sight the higher corner posts 518 allows for greater weight support in the tray system 500. The added stability also allows the joining member 538 to forgo tabs that get placed within the above tray.
[0080] FIG. 7 shows a plan view of a blank 700 for constructing the single tray of FIGS. 5A-6B. Similarly to the previously discussed blank 400, the blank 700 includes a first panel 702 which defines the joining wall 514 of tray 502. A second panel 706 is hingedly attached to the first panel 702 which defines a floor 552 of tray 502 and outer walls 504 and 508 of tray 502. A third panel 708 is hingedly attached to the second panel 706 and defines the third outer wall 506 of tray 502. The first panel 702 and third panel 708 each includes a respective foursome 710/711 of sections extended across the respective panels hingedly attached to each other and to a first end 712. The first foursomes 710/711 define the first corner post 510 and third corner post 518 of tray 502. A second foursome of sections 714/715 at a second end 716 define the second corner post 512 and fourth corner post 520.
[0081] FIG. 8 is a plan view of a blank 800 for constructing the joining member previously shown in FIGS. 1a and 5a. The blank 800 includes a first panel 802 forming the first support 144 of tray 102, a first end tab 804 hingedly attached to the first end 806 forming the first support wing 144a and a second end tab 808 hingedly attached to the second end 810 forming the second support wing 144b, a second panel 812 hingedly attached to the first panel defining the upper wall 142 of joining member 138 of tray 102. A third panel 814 includes a first end tab 816 defining the first support wing 146a hingedly attached to the first end 818 and a second end tab 820 defining the second support wing 146b hingedly attached to the second end 822. The second panel 812 includes a plurality of tabs 824 which bend in and out of the page to create the tabs 148 of tray 102. The first panel 802 and the second panel 814 each include a respective slot 802a/814a partially bisecting the respective panel in order to couple to the joining walls of tray 102.
[0082] FIG. 9A-9E are perspective views of an exemplary embodiment of a tray system according to the disclosure showing a variety of joining members being placed. FIG. 9B shows a two panel joining member 938 being folded over the joining walls 914 of the trays 902 and 904. Joining member 938 further includes a slit 908 placed in the middle of the panels not reaching the end, that slides over the joining walls 914 of trays 904 and 902. FIGS. 9C and 9D show joining member being placed over the joining walls 914. FIG. 9E shows a tray stack, with each tray having the joining member 938.
[0083] FIGS. 10A-10J shows a variety of corner posts that can be used with each of the tray systems discussed previously. FIG. 10a is a perspective view of an open corner post 1010 with stacking tab 1012 and FIG. 10B is a plan view of a blank 1020 for constructing the corner post of FIG. 10A. The outermost panel 1022 with the stacking tab 1012 folds inwards and attaches to the portion of the panel 1024 responsible for creating an outer wall of the tray in an inner-to-inner relationship. FIG. 10C is a perspective view of an open corner post 1032 and FIG. 10D is a plan view of a blank for constructing the corner post of FIG. 10C. Similarly, the outermost panel 1042 folds inwards and attaches to the portion of the panel 1044 responsible for creating an outer wall of the tray. FIG. 10E shows a perspective view of a closed corner post 1060 with stacking tabs 1062 and FIG. 10F is a plan view of a blank 1064 for constructing the corner post of FIG. 10E wherein the outermost panel 1066 folds inward and attaches to the main panel 1068, in an outer to inner relationship. FIG. 10G shows a perspective view of an L corner post 1070 and FIG. 10H is a plan view of a blank 1072 for constructing the corner post of FIG. 10G. Here the two outer most panels 1074 and 1076 both fold inward to form an inner-to-inner side relationship with the inner most panel 1078 and the main panel 1079. FIG. 10I shows a perspective view of a five-panel corner post 1080 and FIG. 10J is a plan view of a blank 1082 for constructing the corner post 1080 of FIG. 10I. This corner post 1080 employs five panels with the middle panels 1084 being in mitered position.
[0084] FIGS. 11a and 11b are perspective views of a self-locking tray 1100. The tray 1100 is similar to tray 102 shown previously, but all of the folding is secured by tabs being placed into slots as a locking feature. FIG. 11c is a plan view of a blank for constructing the self-locking tray of FIGS. 11a and 11b. The tabs 1102 are meant to be placed into slots 1104 when the blank is folded in a manner similar to that of blank 102.
[0085] Turning now to FIGS. 13-17, another embodiment of a blank 1300, a display tray 1400, and display tray system 1500 is shown. The blank 1300 and display tray system 1500 can be similar to and can have similar components and features with respect to the blanks and display tray systems described herein. For brevity, the description of common elements that have been described above will not be repeated with respect to blank 1300 and display tray system 1500 as shown in FIGS. 13-17. While the tray 1400 and display system 1500 are shown and described with respect to blank 1300, it should be appreciated by those having ordinary skill in the art that the blank 1300 could be adapted to any one of the trays and display systems described herein.
[0086] FIG. 13 shows a blank having a bottom panel 1301, a first end panel 1303, a second end panel 1305, a first side panel 1307, and a second side panel 1309. A first side 1311 of the first end panel 1303 includes a first group of sub panels 1313 configured to fold into a first corner post 1413, e.g., as shown in the set-up tray 1400. A second side 1315 of the first end panel 1303 includes a second group of sub panels 1317 configured to fold into a second corner post 1417, e.g., as shown in the set-up tray 1400. The first end panel 1303 is hingedly coupled to the bottom panel 1301 at a first end fold line 1319. For clarity, it should be understood that the blank 1300 shows an outer surface of the blank, or in other words, the blank 1300 folds into the page when folding into the tray 1400.
[0087] The first side panel 1307 is hingedly coupled to the bottom panel 1301 at a first side fold line 1321. The first side panel 1307 includes a first side outer panel 1307a and a first side inner panel 1307b hingedly coupled at a first side middle fold line 1323. In the set-up tray 1400, the first side inner panel 1307b is folded along fold line 1323 to abut the first side outer panel 1307a to form the first side wall 1407.
[0088] The second side panel 1309 is hingedly coupled to the bottom panel 1301 at a second side fold line 1325. The second side panel 1309 includes a second side outer panel 1309a and a first side inner panel 1309b hingedly coupled at a second side middle fold line 1327. In the set-up tray 1400, the second side inner panel 1309b is folded along fold line 1327 to abut the second side outer panel 1309a to form the second side wall 1409. As shown, the second side panel 1309 is longer than the first side panel 1307, making the blank asymmetric.
[0089] The second end panel 1305 is hingedly coupled to the bottom panel 1301 at a second end fold line 1329. An offset 1331 is defined at the junction between the first side panel 1307 and the second end panel 1305. This is more clearly shown in FIG. 13a, for example, where a dotted line is drawn extending the first side fold line 1231 downwards, parallel to the second end panel 1305. In the set-up tray 1400, the first side panel 1307 is folded into the first side wall 1407 and the first end panel 1305 is folded into the joining wall 1405. The offset 1331 in the blank causes a gap 1333 to form between first side wall 1407 and the joining wall 1405 in the set-up tray. This is shown in FIGS. 14 and 15, for example.
[0090] FIG. 14 shows a set up tray 1400 folded from the blank 1300. The tray 1400 is a half pallet tray configured and adapted to mate with another half pallet tray to form a full pallet tray. As will be discussed, the design of the tray 1400 is such that mating with a second tray adds increased strength across the horizontal direction, to avoid the first and second trays from separating during transit or stocking. The set-up tray 1400 includes a bottom wall 1401, first end wall 1403, second end wall (or joining wall) 1405, first side wall 1407, and second side wall 1409. First end wall 1403 includes first and second corner posts 1413 and 1417, which extend above the height of the first and second side walls 1407, 1409.
[0091] As discussed above, the length of the second side wall 1409 is greater than the length of bottom panel 1401 meaning the second side wall 1409 extends beyond the joining wall 1405. This is shown in FIGS. 14 and 15, for example. When setting up the display system, e.g. two trays 1400 are folded from blank 1300. The trays 1400 when folded are identical trays. To join the trays, one tray 1400 is rotated 180 degrees so the joining walls 1405 of the two trays 1400 are facing one another. This places the second side walls 1409 diagonal from one another. This is shown in FIG. 15 for example. As shown, the extended portion of the second side wall 1409 of each tray 1400 is configured to be inserted into the gap 1333 of the other tray 1400.
[0092] FIG. 15 shows the two trays positioned for joining, but not yet joined, and FIG. 16 shows the two trays 1400 inserted into one another. At this stage in assembly, all panels have been folded with the exception of the first side inner panel 1307b. The first side inner panel 1307b is folded only after the two trays 1400 are inserted into one another. Folding the first side inner panels 1307b form the complete side walls of the display system. When in blank form, the blank 1300 is asymmetrical, however, when assembled into the display system, the display system is symmetric across at least two axes of symmetry.
[0093] It is also noted that when folded, the first side inner panel 1307b and the first side outer panel 1307a sandwich the extended portion of the second side wall 1309. This is shown in FIG. 17, for example. This sandwich results in a small section 1435 of four layers of corrugated paper, since the second side wall 1409 is double walled (e.g., comprising an inner panel folded over an outer panel) plus the first side inner panel 1307b and the first side outer panel 1307a. The extended length of the second side wall 1409 plus the four-layer stacked section 1435 gives the tray added strength across a horizontal direction to prevent the two trays from becoming dislodged. In particular, when the two trays 1400 are loaded with product, one cannot sink below the other because the first side inner panels 1307b are glued to the second side wall 1409 and the first side outer panel 1307a to keep both trays level with one another. In certain embodiments, a joining member (e.g., any embodiment as described above) can also be included to couple the two joining walls 1405 together for added strength and stability.
[0094] The methods and systems of the present disclosure, as described above and shown in the drawings, provide for a tray system and components thereof that allow for better stacking of trays and visibility within the trays. While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.
