1 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Name of Applicant Amcor Limited Actual Inventor David Carter Address for Service: CULLEN & CO Patent & Trade Mark Attorneys, 239 George Street Brisbane Qld 4000 Australia Invention Title: Improved Tray and Blank Therefor The following statement is a full description of this invention, including the best method of performing it, known to us: 2 Field of the Invention The present invention relates generally to trays and, in particular, to trays of the type that are erected from a blank of foldable material. 5 Brief Discussion of the Prior Art Trays of the type which are erected from a blank of foldable material sometimes include a bottom wall panel, a pair of opposing end wall panels hinged to opposite ends of the bottom wall panel by fold lines, a pair of opposing outer side wall panels hinged to opposite sides of the bottom wall panel by fold lines and 10 secured relative to the end wall panels, a respective inner side wall panel overlying an interior surface of each outer side wall panel and hinged thereto by a fold line, a respective pair of corner post panels hinged to opposite ends of each inner side wall panel by fold lines, a respective securing flap hinged to each corner post panel by a fold line and secured relative to the end wall panels such that the corner post panels is extend obliquely between the inner side wall panels and the end wall panels. The corner post panels function to increase the compressive strength of the tray particularly at the corners thereof so that the tray is able to adequately support loads such as, for example, a stack of other trays. Although the compressive strength at the corners of the aforementioned prior 20 art tray is increased by the presence of the corner post panels, it would nevertheless be desirable to provide an improved tray which has even greater compressive strength particularly at the corners thereof. It is an object of the present invention to overcome, or at least ameliorate, one or more of the deficiencies of the prior art mentioned above, or to provide the 25 consumer with a useful or commercial choice. Other objects and advantages of the present invention will become apparent from the following description, taken in connection with the accompanying illustrations, wherein, by way of illustration and example, a preferred embodiment of the present invention is disclosed. 30 Summary of the Invention According to an aspect of the present invention there is provided a tray 3 erected from a blank of foldable material, the tray comprising a bottom wall panel, a pair of opposing outer side wall panels hinged to opposite sides of the bottom wall panel by fold lines, a respective inner side wall panel overlying an interior surface of each outer side wall panel and hinged thereto by a fold line, a respective pair of 5 opposing first corner post panels hinged to opposite ends of each inner side wall panel by fold lines, a respective second corner post panel overlying each first corner post panel and hinged thereto by a fold line, a respective securing flap hinged to each second corner post panel by a fold line and captured between either pair of hinged outer and inner side wall panels, and a pair of opposing outer end wall panels hinged 10 to opposite ends of the bottom wall panel by fold lines and secured relative to the outer side wall panels, wherein the overlying first and second corner post panels extend obliquely between the inner side wall panels and the outer end wall panels. Overlaying each first corner post panel with a respective second corner post panel reinforces the first corner post panels and thereby increases the compressive 15 strength of the corners of the tray. The tray may be either a stackable or a non-stackable tray. The tray may be a manually-erectable tray, or a machine-erectable tray. The tray may be any suitable size. Preferably, the tray is 150 mm to 1000 mm long, 100 mm to 800 mm wide, and 50 mm to 500 mm high. In a particular 20 preferred form, the tray is 570 mm long, 400 mm wide and 170 mm high. In a another particular preferred form, the tray is 570 mm long, 400 mm wide, and 90 mm high. In a further preferred form, the tray is 380 mm long, 290 mm wide and 90 mm high. In another particular preferred form, the tray is 380 mm long, 290 mm wide and 170 mm high. 25 The blank from which the tray is erected is preferably fabricated from a single sheet of foldable material. The blank may be fabricated from any suitable foldable material. Preferably, the blank is fabricated from a paper-based foldable material. For example, the blank may be fabricated from cardboard or corrugated fibreboard. In a particular preferred 30 form, the blank is fabricated from Xitex@ fibreboard which is a type of twin-cushion corrugated fibreboard. The bottom wall panel may be any suitable shape. In a preferred form, the 4 bottom wall panel is generally rectangular in shape. The bottom wall panel may be any suitable size. Preferably, the bottom wall panel is 150 mm to 1000 mm long and 100 mm to 800 mm wide. In one particular preferred form, the bottom wall panel is 570 mm long and 400 mm wide. In another 5 particular preferred form, the bottom wall panel is 380 mm long and 290 mm wide. Preferably, the bottom wall panel includes a plurality of comer stacking tab receiving recesses. It is preferred that the bottom wall panel includes a plurality of stacking tab receiving apertures. 10 The bottom wall panel preferably includes a plurality of locking tab receiving apertures. The outer side wall panels may be any suitable shape. In a preferred form, the outer side wall panels are generally rectangular in shape. The outer side wall panels may be any suitable size. Preferably, the outer 15 side wall panels are 150 mm to 1000 mm long and 50 mm to 500 mm high. In a particular preferred form, the outer side wall panels are 570 mm long and 170 mm high. In another particular preferred form, the outer side wall panels are 570 mm long and 90 mm high. In a further particular preferred form, the outer side wall panels are 380 mm long and 90 mm high. In another particular preferred form, the outer side 20 wall panels are 380 mm long and 170 mm high. It is preferred that the outer side wall panels are identical to each other. Preferably, at least one ventilation aperture extends through each outer side wall panel. Preferably, a respective pair of score lines is located adjacent to each end of 25 the outer side wall panels. It is preferred that a respective pair of opposing end wall flaps is hinged to opposite ends of each outer side wall panel by fold lines. The end wall flaps hinged to each outer side wall panel preferably overlie a respective outer end wall panel of the tray. The end wall flaps are preferably secured relative to the outer end wall 30 panels. The end wall flaps may be any suitable shape. Preferably, the end wall flaps are generally rectangular in shape.
5 The end wall flaps may be any suitable size. Preferably, the end wall flaps are 50 mnm to 400 mm wide, and 50 mm to 500 mm high. In a particular preferred form, the end wall flaps are 190 mm wide and 170 mm high. In another particular preferred form, the end wall flaps are 190 mm wide and 90 mm high. In a further 5 particular preferred form, the end wall flaps are 140 mm wide and 90 mm high. In another particular preferred form, the end wall flaps are 140 mm wide and 170 mm high. Preferably, a respective catch extends from each end wall flap. It is preferred that a respective corner stacking tab extends from adjacent 10 each end of each outer side wall panel and each end wall flap. At least one respective ventilation aperture may extend through each end wall flap. The end wall flaps are preferably identical to each other. The inner side wall panels may be any suitable shape. In a preferred form, 15 the inner side wall panels are generally rectangular in shape. The inner side wall panels may be any suitable size. Preferably, the inner side wall panels are 150 mm to 1000 mm long and 50 mm to 500 mm high. In a particular preferred form, the inner side wall panels are 490 mm long and 150 mm high. In another particular preferred form, the inner side wall panels are 390 mm long 20 and 70 mm high. In a further particular preferred form, the inner side wall panels are 300 mm long and 70 mm high. In another particular preferred form, the inner side wall panels are 300 mm long and 150 mm high. In an additional preferred form, the inner side wall panels are 200 mm long and 150 mm high. It is preferred that the inner side wall panels are identical to each other. 25 Preferably, at least one ventilation aperture extends through each inner side wall panel. The inner side wall panels are preferably hinged to the outer side wall panels by double fold lines. Preferably, there is at least one aperture extending between each pair of 30 hinged outer and inner side wall panels. The apertures preferably form discontinuities in the fold lines hinging the outer and inner side wall panels together. In a particular preferred form, a respective pair of apertures extends between each pair of hinged 6 outer and inner side wall panels. Each aperture preferably receives at least one catch extending from one or more of the securing flaps such that the securing flaps are thereby prevented from moving from between the side wall panels. The apertures may be any suitable size and shape. 5 At least one respective locking tab may extend from a free edge of each inner side wall panel. In a particular preferred form, a respective pair of locking tabs extends from a free edge of each inner side wall panel. The locking tabs are preferably received by locking tab receiving apertures in the bottom wall panel. Preferably, each inner side wall panel has a stacking tab receiving recess in a 10 free edge thereof. The first corner post panels may be any suitable shape. In a preferred form, the first corner post panels are rectangular in shape. The first corner post panels may be any suitable size. Preferably, the first corner post panels are 20 mm to 100 mm wide and 50 mm to 500 mm high. In a 15 particular preferred form, the first corner post panels are 30 mm wide and 150 mm high. In another particular preferred form, the first corner post panels are 30 mm wide and 70 mm high. It is preferred that the first corner post panels are identical to each other. The second corner post panels may be any suitable shape. In a preferred 20 form, the second corner post panels are rectangular in shape. The second corner post panels may be any suitable size. Preferably, the second corner post panels are 20 mm to 100 mm wide and 50 mm to 500 mm high. In a particular preferred form, the second corner post panels are 35 mm wide and 150 mm high. In another particular preferred form, the second corner post panels are 35 25 mm wide and 70 mm high. It is preferred that the second corner post panels are identical to each other. The securing flaps may be any suitable shape. Preferably, the securing flaps are generally rectangular in shape. The securing flaps may be any suitable size. Preferably, the securing flaps 30 are 50 mm to 400 mm long, and 50 to 500 mm high. In a particular preferred form, the securing flaps are 150 mm high. In another particular preferred form, the securing flaps are 70 mm high.
7 Preferably, a respective catch extends from each securing flap. At least one ventilation aperture may extend through each securing flap. The securing flaps are preferably identical to each other. The outer end wall panels may be any suitable shape. In a preferred form, 5 the outer end wall panels are generally rectangular in shape. The outer end wall panels may be any suitable size. Preferably, the outer end wall panels are 100 mm to 800 mm wide and 50 mm to 500 mm high. In a particular preferred form, the outer end wall panels are 370 mm wide and 150 mm high. In another particular preferred form, the outer end wall panels are 370 mm wide and 70 10 mm high. In a further particular preferred form, the outer end wall panels are 270 mm wide and 70 mm high. In another particular preferred form, the outer end wall panels are 270 mm wide and 150 mm high. In a further preferred form, the outer end wall panels are 370 mm wide and 150 mm high. It is preferred that the outer end wall panels are identical to each other. 15 Preferably, a respective inner end wall panel is hinged to each outer end wall panel by a fold line and overlies an interior surface of the outer end wall panel. The inner end wall panels may be any suitable shape. Preferably, the inner end wall panels are generally rectangular in shape. The inner end wall panels may be any suitable size. Preferably, the inner end 20 wall panels are 100 mm to 800 mm wide and 50 to 500 mm high. In a particular preferred form, the inner end wall panels are 370 mm wide and 55 mm high. In another particular preferred form, the inner end wall panels are 370 mm wide and 70 mm high. In a further particular preferred form, the inner end wall panels are 270 mm wide and 70 mm high. In another particular preferred form, the inner end wall panels 25 are 270 mm wide and 55 nn high. In a further particular preferred form, the inner end wall panels are 370 mm wide and 55 mm high. It is preferred that the inner end wall panels are identical to each other. The inner end wall panels are preferably hinged to the outer end wall panels by double fold lines. 30 Each pair of hinged outer and inner end wall panels preferably captures end wall flaps which are hinged to the inner side wall panels by fold lines. Preferably, there is at least one respective aperture extending between each 8 pair of hinged outer and inner end wall panels. The apertures preferably form discontinuities in the fold lines hinging the outer and inner end wall panels together. In a particular preferred form, a respective pair of apertures extends between each pair of hinged outer and inner end wall panels. Each aperture preferably receives at least 5 one catch extending from one or more end wall flaps hinged to the outer side wall panels by fold lines such that the outer side wall panels are thereby prevented from moving away from the end wall panels. The apertures may be any suitable size and shape. 10 Brief Description of the Drawings In order that the invention may be more fully understood and put into practice, a preferred embodiment thereof will now be described with reference to the accompanying illustrations, in which: Figure 1 is a plan view of a blank from which a tray according to a preferred 15 embodiment of the present invention is able to be erected; and Figure 2 is a perspective of a tray erected from the blank depicted in figure 1. Detailed Description of the Drawings Figure 1 depicts a blank 20 of foldable material from which a tray according 20 to a first embodiment of the present invention is able to be erected. The foldable material from which the blank 20 is fabricated is Xitex@ corrugated fibreboard. Blank 20 includes a generally rectangular bottom wall panel 21 which includes a plurality of L-shaped corner stacking tab receiving recesses 22, a pair of T 25 shaped stacking tab receiving apertures 23, and a plurality of locking tab receiving apertures 24. A pair of opposing outer side wall panels 25 is hinged to opposite sides of the bottom wall panel 21 by discontinuous fold lines 26. The corner stacking tab receiving recesses 22, stacking tab receiving apertures 23 and locking tab receiving 30 apertures 24 extend into the outer side wall panels 25. A respective pair of ventilation apertures 27 extends through each outer side wall panel 25. A respective pair of end wall flaps 28 is hinged to opposite ends of each 9 outer side wall panel 25 by fold lines 29. Each end wall flap 28 has a respective catch 30 extending therefrom. A respective corner stacking tab 31 extends from adjacent each end of each outer side wall panel 25 and the end wall flaps 28. Each end wall flap 28 also has a recess 32 in a corner thereof. A respective pair of parallel score 5 lines 33 is located adjacent each fold line 29 and extends across each outer side wall panel 25. A respective inner side wall panel 34 is hinged to each outer side wall panel 25 by a double fold line 35. A respective pair of apertures 36 extends between each pair of hinged outer and inner side wall panels 25, 34 and form discontinuities in the 10 double fold lines 35. A respective pair of locking tabs 37 extends from a free edge 38 of each inner side wall panel 34. Each inner side wall panel 34 has a stacking tab receiving recess 39 extending into the panel 34 from the free edge 38 thereof. A respective pair of ventilation apertures 40 extends through each inner side wall panel 34. 15 A respective pair of opposing first corner post panels 41 is hinged to opposite ends of each inner side wall panel 34 by fold lines 42. The first corner post panels 41 are rectangular in shape. A respective rectangular second corner post panel 43 is hinged to each first corner post panel 41 by a fold line 44. 20 A respective securing flap 45 is hinged to each second corner post panel 43 by a fold line 46. Each securing flap 45 has a catch 47 extending therefrom and a recess 48 located beside the catch 47, A respective ventilation aperture 49 extends through each securing flap 45. A pair of opposing outer end wall panels 50 is hinged to opposite ends of the 25 bottom wall panel 21 by fold lines 51. A respective inner end wall panel 52 is hinged to each outer end wall panel 50 by a double fold line 53. A respective pair of ventilation apertures 54 extends between each pair of hinged outer and inner side wall panels 50, 52 and form discontinuities in the double fold lines 53. 30 Each aperture 36 includes a respective notch 55, and each ventilation aperture 54 includes a respective pair of opposing notches 56. Referring to figure 2 a tray 60 is erected from the blank 20 by firstly folding 10 the outer side wall panels 25 relative to the bottom wall panel 21 along the fold lines 26 until the outer side wall panels 25 are upstanding with respect to the bottom wall panel 21. The end wall flaps 28 are then fold with respect to the outer side wall panels 5 25 along the fold lines 29 until the end wall flaps 28 hinged to each outer side wall panel 25 are perpendicular with respect to the outer side wall panel 25 and extend towards the other outer side wall panel 25. The outer end wall panels 50 are then folded relative to the bottom wall panel 21 along the fold lines 51 until the outer end wall panels 50 are upstanding with 10 respect to the bottom wall panel 21 and are overlying the end wall flaps 28. The inner end wall panels 52 are folded relative to the outer end wall panels 50 along the fold lines 53 until each inner end wall panel 52 overlies the end wall flaps 28 which overlie the outer end wall panel 50 to which the inner end wall panel 52 is hinged. The catches 30 of the end wall flaps 28 are each captured by a 15 respective notch 56 to prevent the outer side wall panels 25 from moving away from the outer end wall panels 50. The ends of the inner end wall panels 52 each frictionally engage with the outer end wall panels 25 such that each end of each inner end wall panel 52 is located adjacent a respective pair of score lines 33. The second corner post panels 43 are then fold relative to the first corner post 20 panels 41 along the fold lines 44 until each second corner post panel 43 overlies the first corner post panel 41 to which it is hinged and until the securing flaps 45 overlie the inner side wall panels 34. The first and second corner post panels 41, 43 are then fold relative to the inner side wall panels 34 and securing flaps 45 along the fold lines 42, 46 so that the corner post panels 41, 43 extend obliquely from the inner side wall 25 panels 34 and securing flaps 45. The inner side wall panels 34 are subsequently folded relative to the outer side wall panels 25 along the fold lines 35 until the inner side wall panels 34 overlie the outer side wall panels 25 and the securing flaps 45 are captured between the inner side wall panels 34 and the outer side wall panels 25. The catches 47 of the securing 30 flaps 45 are each captured by a respective notch 55 to prevent the securing flaps 45 from moving from between the outer and inner side wall panels 25, 34. Each locking tab 37 is received by a respective locking tab receiving aperture 24 so as to thereby 11 secure the inner side wall panels 37 to the bottom wall panel 21. The overlying first and second corner post panels 41, 43 extend obliquely between the inner side wall panels 34 and the end wall panels 50, 52. The corner stacking tab receiving recesses 22, stacking tab receiving 5 apertures 23 and corner stacking tabs 31 enable the tray 60 to be stacked with other trays which are the same as the tray 60 or which are different from the tray 60 but are nevertheless able to be stacked with the tray 60. Throughout the specification and the claims (if any), unless the context requires otherwise, the term "comprise", or variations such as "comprises" or 10 "comprising", will be understood to apply the inclusion of the stated integer or group of integers but not the exclusion of any other integer or group of integers. Throughout the specification and claims (if any), unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms. 15 It will be appreciated by those skilled in the art that variations and modifications to the invention described herein will be apparent without departing from the spirit and scope thereof. The variations and modifications as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein set forth. 20