TRAY FOR HOLDING ARTICLES

Abstract

A tray for holding articles includes a plurality of panels extending at least partially around an interior of the tray, the tray having a bottom panel, at least one side panel, at least one end panel, and at least one corner panel forming a curved corner between the at least one side panel and the at least one end panel. The tray includes a first ply, a second ply, and a fluted layer positioned between the first ply and the second ply, the fluted layer arranged along a flute direction, the curved corner extending upwardly from the bottom panel along the flute direction.

Claims

1. A tray for holding articles, the tray comprising: a plurality of panels extending at least partially around an interior of the tray, the tray comprising a bottom panel, at least one side panel, at least one end panel, and at least one corner panel forming a curved corner between the at least one side panel and the at least one end panel, the tray comprising a first ply, a second ply, and a fluted layer positioned between the first ply and the second ply, the fluted layer arranged along a flute direction, the curved corner extending upwardly from the bottom panel along the flute direction.

2. The tray of claim 1, wherein the at least one corner panel comprises a plurality of spaced apart fold lines extending therealong facilitating at least partial formation of the curved corner.

3. The tray of claim 2, wherein the plurality of spaced apart fold lines are oriented along the flute direction.

4. The tray of claim 1, further comprising a plurality of end flaps foldably connected to a respective panel of the plurality of panels, the plurality of end flaps comprising at least one end flap foldably connected to the at least one corner panel and attached to the at least one end panel to form at least one end wall of the tray.

5. The tray of claim 4, wherein the bottom panel comprises at least one corner edge aligned with the curved corner of the tray.

6. The tray of claim 5, wherein the at least one corner panel is foldably connected to the at least one side panel, and the at least one end flap is foldably connected to the at least one corner panel.

7. The tray of claim 6, wherein the at least one side panel is a first side panel, the plurality of panels further comprises a second side panel, the at least one end panel is a first end panel, the plurality of panels further comprises a second end panel, the at least one corner panel is a first corner panel, the plurality of panels further comprises a second corner panel, a third corner panel, and a fourth corner panel.

8. The tray of claim 6, wherein the curved corner is a first curved corner of the tray between the first side panel and the first end panel, and each of the second corner panel, the third corner panel, and the fourth corner panel comprises a plurality of a plurality of spaced apart fold lines extending therealong facilitating at least partial formation of a second curved corner between the first side panel and the second end panel, a third curved corner between the second end panel and the second side panel, and a fourth curved corner between the second side panel and the first end panel.

9. A blank for forming a tray for holding articles, the blank comprising: a plurality of panels extending for at least partially around an interior of the tray formed from the blank, the tray comprising a bottom panel, at least one side panel, at least one end panel, and at least one corner panel for forming a curved corner between the at least one side panel and the at least one end panel when the tray is formed from the blank, the blank comprising a first ply, a second ply, and a fluted layer positioned between the first ply and the second ply, the fluted layer arranged along a flute direction such that the curved corner is for extending upwardly from the bottom panel along the flute direction when the tray is formed from the blank.

10. The blank of claim 9, wherein the at least one corner panel comprises a plurality of spaced apart fold lines extending therealong facilitating at least partial formation of the curved corner.

11. The blank of claim 10, wherein the plurality of spaced apart fold lines are oriented along the flute direction.

12. The blank of claim 9, further comprising a plurality of end flaps foldably connected to a respective panel of the plurality of panels, the plurality of end flaps comprising at least one end flap foldably connected to the at least one corner panel and for being attached to the at least one end panel to form at least one end wall of the tray.

13. The blank of claim 12, wherein the bottom panel comprises at least one corner edge for being aligned with the curved corner of the tray when the tray is formed from the blank.

14. The blank of claim 13, wherein the at least one corner panel is foldably connected to the at least one side panel, and the at least one end flap is foldably connected to the at least one corner panel.

15. The blank of claim 14, wherein the at least one side panel is a first side panel, the plurality of panels further comprises a second side panel, the at least one end panel is a first end panel, the plurality of panels further comprises a second end panel, the at least one corner panel is a first corner panel, the plurality of panels further comprises a second corner panel, a third corner panel, and a fourth corner panel.

16. The blank of claim 14, wherein the curved corner is a first curved corner of the tray formed from the blank between the first side panel and the first end panel, and each of the second corner panel, the third corner panel, and the fourth corner panel comprises a plurality of a plurality of spaced apart fold lines extending therealong facilitating at least partial formation of a second curved corner between the first side panel and the second end panel when the tray is formed from the blank, a third curved corner between the second end panel and the second side panel when the tray is formed from the blank, and a fourth curved corner between the second side panel and the first end panel when the tray is formed from the blank.

17. A method of forming a tray for holding articles, the method comprising: obtaining a blank, the blank comprising a plurality of panels comprising a bottom panel, at least one side panel, at least one end panel, and at least one corner panel, the tray comprising a first ply, a second ply, and a fluted layer positioned between the first ply and the second ply, the fluted layer arranged along a flute direction; positioning the plurality of panels extending at least partially around an interior of the tray; and positioning the at least one corner panel forming a curved corner between the at least one side panel and the at least one end panel, the curved corner extending upwardly from the bottom panel along the flute direction.

18. The method of claim 17, wherein the at least one corner panel comprises a plurality of spaced apart fold lines extending therealong facilitating at least partial formation of the curved corner.

19. The method of claim 18, wherein the plurality of spaced apart fold lines are oriented along the flute direction.

20. The method of claim 17, the blank further comprising a plurality of end flaps foldably connected to a respective panel of the plurality of panels, the plurality of end flaps comprising at least one end flap foldably connected to the at least one corner panel, and the method further comprises attaching the at least one end flap to the at least one end panel to form at least one end wall of the tray.

21. The method of claim 20, wherein the bottom panel comprises at least one corner edge, and the method further comprises aligning the at least one corner edge with the curved corner of the tray.

22. The method of claim 21, wherein the at least one corner panel is foldably connected to the at least one side panel, and the at least one end flap is foldably connected to the at least one corner panel.

23. The method of claim 22, wherein the at least one side panel is a first side panel, the plurality of panels further comprises a second side panel, the at least one end panel is a first end panel, the plurality of panels further comprises a second end panel, the at least one corner panel is a first corner panel, the plurality of panels further comprises a second corner panel, a third corner panel, and a fourth corner panel.

24. The method of claim 22, wherein the curved corner is a first curved corner of the tray between the first side panel and the first end panel, and each of the second corner panel, the third corner panel, and the fourth corner panel comprises a plurality of a plurality of spaced apart fold lines extending therealong, and the method further comprises at least partially forming a second curved corner between the first side panel and the second end panel, at least partially forming a third curved corner between the second end panel and the second side panel, and at least partially forming a fourth curved corner between the second side panel and the first end panel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.

[0009] FIG. 1 is an exterior plan view of a blank used to form a tray according to an exemplary embodiment of the present disclosure.

[0010] FIG. 2 is a top perspective view of an erected tray formed from the blank of FIG. 1 according to the exemplary embodiment of the present disclosure.

[0011] FIG. 3 is another top perspective view of the tray of FIG. 3.

[0012] FIG. 3A is an enlarged view of the area of detail identified in FIG. 3.

[0013] FIG. 4 is a perspective side view of the tray of FIG. 2 holding a plurality of packages according to an exemplary embodiment of the disclosure.

[0014] FIG. 5 is a perspective end view of the tray and the plurality of packages of FIG. 4.

[0015] FIG. 6 is a perspective view of a corner portion of the tray and packages of FIG. 3.

[0016] FIG. 7 is a perspective view of another corner portion of the tray and packages of FIG. 3.

[0017] Corresponding parts are designated by corresponding reference numbers throughout the drawings.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0018] The present disclosure generally relates to various features for trays or carriers that contain articles such as containers, cans, bottles, etc., such as during production, storage, and/or distribution. The articles can be used for packaging food and beverage products, for example. The articles can be made from materials suitable in composition for packaging the particular food or beverage item, and the materials include, but are not limited to, plastics such as PET, LDPE, LLDPE, HDPE, PP, PS, PVC, EVOH, and Nylon; glass; aluminum and/or other metals; and the like, or any combination thereof.

[0019] Trays according to the present disclosure can accommodate articles of any shape. For the purpose of illustration and not for the purpose of limiting the scope of the disclosure, the following detailed description describes beverage containers (e.g., plastic, glass, and/or other bottles; beverage cans; food cans; etc.) as disposed at least partially within the tray embodiments. In this specification, the terms inner, interior, outer, exterior, lower, bottom, upper, and top indicate orientations determined in relation to fully erected and upright cartons. As described herein, constructs can be formed with multiple walls, panels, portions, tabs, flaps, lines of weakening, and/or other aspects, which may be designated herein in terms relative to one another, e.g., first, second, third, etc., in sequential or nonsequential reference, without departing from the disclosure.

[0020] FIG. 1 is a plan view of a blank, generally indicated at 103, used to form a construct or tray 105 (FIG. 2) according to an exemplary embodiment of the disclosure. In embodiments, the tray can be configured to hold containers or other articles A (FIG. 4). In the illustrated embodiments, tray 105 can hold one or more packages P, each including a carton, clip, carrier, wrap, and/or other suitable packaging C engaged with a plurality of the articles A. The tray 105 can include rounded or curved corners 109, each at least partially conforming to one or more of the articles A located at the corners. In the illustrated embodiment, the blank 103 and the tray 105 can have an interior surface 101 (FIG. 2) and an exterior surface 102 (FIGS. 1 and 2).

[0021] The tray 105 can be used to hold and/or support the articles A and/or the packages P during production, storage, distribution, etc. of the articles A and/or the packages P. As shown in FIGS. 3-6, the tray 105 can be sized to hold four packages P in a 22 arrangement, each package P including a carton C engaged with six articles A in a 23 arrangement (e.g., so that the tray 105 holds 24 articles A in a 46 arrangement), but it is understood that the tray 105 may be sized and shaped to hold packages and/or articles of a different or same quantity in more than one layer and/or in different row/column arrangements (e.g., 12, 16, 26, 33, 34, 56, 38, 262, 342, 29, 36, etc.), or just a single package and/or article. Further, each of the cartons C may be sized and shaped to hold articles of a different or same quantity in more than one layer and/or in different row/column arrangements (e.g., 12, 16, 26, 33, 34, 56, 38, 262, 342, 29, 36, etc.), or just a single article. In exemplary embodiments, the tray 105 could hold the articles A without cartons C, such as prior to applying the cartons C to the articles A in a packaging system.

[0022] The blank 103 has a longitudinal axis L1 and a lateral axis L2. The blank 103 includes a central or bottom panel 110 foldably connected to a first side panel 112 (broadly, second side panel) at a first longitudinal fold line 114. A second side panel 116 (broadly, first side panel) is foldably connected to the bottom panel 110 along a second longitudinal fold line 118 opposite to the first side panel 112 and the first longitudinal fold line 114. A first end panel 120 (broadly, second end panel) is foldably connected to the bottom panel 110 along a first lateral fold line 122, and a second end panel 124 (broadly, first end panel) is foldably connected to the bottom panel 110 along a second lateral fold line 126 opposite to the first end panel 120 and the first lateral fold line 122.

[0023] In embodiments, the blank 103 can include end flaps 130, 132 (broadly, first end flap, second end flap, third end flap, or fourth end flap) connected to respective ends of the first side panel 112 by respective folding panels or corner panels 134, 136 (broadly first corner panel, second corner panel, third corner panel, or fourth corner panel) and end flaps 138, 140 (broadly, first end flap, second end flap, third end flap, or fourth end flap) are respectively connected to respective ends of the second side panel 116 by respective folding panels or corner panels 142, 144 (broadly first corner panel, second corner panel, third corner panel, or fourth corner panel). In the illustrated embodiments, the corner panels 134, 136 can be foldably connected to opposite ends of the first side panel 112 along respective lateral fold lines 146, 148, and the corner panels 138, 140 can be foldably connected to opposite ends of the second side panel 116 along respective lateral fold lines 150, 152. As shown in FIG. 1, each of the end flaps 130, 132, 138, 140 can be foldably connected to the respective corner panels 134, 136, 142, 144 along respective lateral fold lines 154, 156, 158, 160.

[0024] As shown in FIG. 1, the bottom panel 110 can include four corner edges 162 extending between the side panels 112, 116 and the end panels 120, 124. For example, one of the corner edges 162 can extend from each end of the first longitudinal fold line 114 to an end of the respective lateral fold lines 122, 126 and one of the corner edges 162 can extend from each end of the second longitudinal fold line 118 to an opposing end of the respective lateral fold lines 122, 126. In embodiments, the corner edges 162 can be curved, such as so that the curved corner edges 162 generally follow a characteristic curve or circumference of the articles A held in the tray 105.

[0025] As shown in FIG. 1, each of the corner panels 134, 136, 142, 144 can include one or more lateral corner fold lines 164 (e.g., three corner fold lines 164 or any suitable number of corner fold lines) so that the segments of the corner panels 134, 136, 142, 144 defined by the corner fold lines 164 can fold relative to one another along the corner fold lines 164 to at least partially conform to the curve of the corner edges 162 of the bottom panel 110 when the tray 105 is formed from the blank 103. In the illustrated embodiments, the corner fold lines 164 can be evenly spaced in the respective corner panels 134, 136, 142, 144 or could have any suitable spacing. In embodiments, the folding of the segments of the corner panels 134, 136, 142, 144 can allow the corner panels to at least partially curve along the corners 109 (broadly first corner, second corner, third corner, or fourth corner) of the tray 105 between respective side panels and end panels thereof so that the corner panels 134, 136, 142, 144 at least partially conform to the shape of the articles A at the corners 109 of the tray 105, which can help the tray 105 hold the articles A more tightly.

[0026] In embodiments, the blank 103 can be a corrugated material (e.g., B flute or C flute corrugated board and/or any other suitable corrugated material with any suitable flute size) having a flute direction F (e.g., so that the flutes extend in the lateral direction L2). In other embodiments, the flute direction lines up with the longitudinal direction L1. However, in the illustrated embodiments, the flute direction Fis parallel to the lateral direction L2, which can allow the corner fold lines 164 to be aligned with the flutes of the corrugated material. The alignment of the corner fold lines 164 with the flute direction F can facilitate folding of the corner panels 134, 136, 142, 144 along the corners 109 of the tray 105 and/or can facilitate conforming of the corner panels 134, 136, 142, 144 with one or more of the articles A at the corners 109. In alternative embodiments, the blank 103 can be made of a paperboard material that is not corrugated and/or any other suitable packaging material.

[0027] The blank 103 could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure. For example, the end flaps 130, 132, 138, 140 and/or the corner panels 134, 136, 142, 144 could be foldably connected to the respective end panels 120, 124.

[0028] As shown in FIGS. 2 and 3, the tray 105 can be formed from the blank 103 by upwardly folding the side panels 112, 116 and the end panels 120, 124 along the respective fold lines 114, 118, 122, 126. Each of the corner panels 134, 142 can be folded along the respective fold lines 146, 154, 164 and 150, 158, 164 so that the corner panels 134, 142 at least partially curve along the respectively adjacent corner edges 162. In embodiments, the end flaps 130, 138 can be positioned in an overlapping relationship with the end panel 120. In the illustrated embodiments, the end flaps 130, 138 can be glued in face-to-face contact with the interior surface of the end panel 120. The end flaps 130, 138 could be otherwise secured to the interior and/or exterior surface of the end panel 120 without departing from the disclosure. In embodiments, the end flaps 130, 138 and the end panel 120 can cooperate to form an end wall 172 (broadly, first end wall or second end wall) of the tray 105.

[0029] As shown in FIG. 2, an opposing end wall 174 (broadly, first end wall or second end wall) can be formed in a similar or identical manner as the end wall 170 by folding the corner panels 136, 144 and positioning the end flaps 132, 140 and the end panel 124 in an overlapping relationship (e.g., gluing the end flaps 132, 140 in face-to-face contact with the end panel 124). In embodiments, the end flaps 130, 138, 132, 140 can be folded into position before the end panels 120, 124 are folded upwardly, and the end panels can be moved into overlapping relationship with the respective end flaps when the end panels are folded upwardly. In the illustrated embodiments, the bottom panel 110, the side panels 112, 116, the corner panels 134, 142, 136, 144, and the end walls 172, 174 can extend at least partially around an interior 170 of the tray 105. The aforementioned arrangement of the tray 105 can be at least partially maintained with one or more applications of an adhesive such as glue. In some embodiments, glue can be applied to one or more of the end flaps 130, 132, 138, 140.

[0030] As described above, and as shown further in the enlarged view of FIG. 3A, the blank 103 can be a corrugated or fluted material having a flute direction F along which peaked and curved portions of the fluted material between plies of the blank 103 are oriented to extend in a generally uniform fashion. In this regard, such fluted material can be a fluted layer 111 arranged in a generally repeating (e.g., sinusoidal) or otherwise fluted arrangement between a first ply 113 associated with the exterior surface 101 of the blank 103 and a second ply 115 associated with the interior surface 102 of the blank 103. In the illustrated arrangement, the plies 113, 115 can be positioned contacting respective portions of the fluted layer 111.

[0031] Accordingly, and with additional reference to FIGS. 6 and 7, when the tray 105 is formed from the blank 103, the corner panels 134, 136, 142, 144 fold at the respective fold lines 146 that are generally oriented along the flute direction F to facilitate the approximation of curving of the corners 109 of the tray 105. For example, the fold lines 146 can be positioned or adjacent to respective channels between curved peaks of the fluted layer 111 so as to advantageously make use of such empty space while the corner panels 134, 136, 142, 144 are foldably transitioned to the respective corners 109. In this regard, the curved corners 109 are positioned extending upwardly/vertically along from the bottom panel 170 in the flute direction F.

[0032] A first corner 109 (broadly second corner, third corner or fourth corner) can be formed between the side panel 112 and the end panel 120, a second corner 109 (broadly first corner, third corner or fourth corner) can be formed between the side panel 112 and the end panel 124, a third corner 109 (broadly first corner, second corner or fourth corner) can be formed between the end panel 124 and the side panel 116, and a fourth corner 109 (broadly first corner, second corner or third corner) can be formed between the side panel 116 and the end panel 120.

[0033] Furthermore, in some embodiments, the orientation of the fluted layer 111 along the flute direction F can provide a structurally load-bearing member to lend robustness to the tray 105, for example, in the course of tray formation, use, stacking, transport, etc.

[0034] As shown in FIGS. 4 and 5, the articles A and/or packages P can be loaded into the interior 170 of the tray 105. In an exemplary embodiment, the articles A can be inserted into the interior 170 prior to forming the packages P. The tray 105 can hold the articles A tightly in the interior 170 at least partially due to the corner panels 134, 142, 136, 144 at least partially conforming to the shape of the articles A at the respective curved corners 109. This can help reduce or prevent movement or shifting of the articles A (e.g., in distribution and/or transport). In exemplary embodiments, the tray 105 can hold the articles A while moving in a packaging system, in which cartons C (e.g., clip-style cartons) can be applied to respective groupings of the articles A in the tray 105. In embodiments, when the articles A are inhibited or prevented from shifting, the packaging system can efficiently apply the cartons C to the articles A to form the packages P.

[0035] Alternative assembling, loading, and closing steps may be used without departing from the scope of the disclosure. The blank 103, tray 105 formed therefrom, and/or one or more associated components could have a different configuration without departing from the disclosure.

[0036] In general, the blank may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blank can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carton to function at least generally as described above. The blank can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blank may then be coated with a varnish to protect information printed on the blanks. The blank may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blank can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.

[0037] In accordance with the exemplary embodiments, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding therealong. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed or depressed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features. In situations where cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line.

[0038] The above embodiments may be described as having one or more panels adhered together by glue during erection of the carton embodiments. The term glue is intended to encompass all manner of adhesives commonly used to secure carton panels in place.

[0039] The foregoing description of the disclosure illustrates and describes various exemplary embodiments. Various additions, modifications, changes, etc., could be made to the exemplary embodiments without departing from the spirit and scope of the disclosure. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.