AU2006246536A1 - An Improved Tray and Blank Therefor - Google Patents

Description

Name of Applicant Actual Inventor Address for Service: Invention Title:

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Amcor Limited David Carter CULLEN CO Patent Trade Mark Attorneys, 239 George Street Brisbane Qld 4000 Australia An Improved Tray and Blank Therefor Details of Associated Provisional Applications 2005906770 filed 2 December 2005 The following statement is a full description of this invention, including the best method of performing it, known to us: N 2

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Technical Field The present invention relates generally to trays and, in particular, to trays of Z the type which are erected from a foldable blank.

Although the invention will be described with particular reference to machine-erected trays which are erected from a foldable blank, it will be appreciated IN that this is by way of example only and that the invention is not limited to machine- V erected trays.

Background Art 0 I 10 Trays of the type which are able to be erected from a foldable blank by a machine are commonly referred to as machine-erected trays. A typical machineerected tray includes a bottom wall panel, end wall panels hinged to the bottom wall panel, side wall panels hinged to the bottom wall panel, and a plurality of corner posts secured relative to the end wall panels and the side wall panels.

Some machine-erected trays suffer from the deficiency that they have a low burst strength. This means that the side wall panels and end wall panels of such trays tend to separate from each other if a load is stacked on top of the tray. The contents of a machine-erected tray may be damaged if a side wall panel and an end wall panel of the tray separate from each other while the tray is supporting a load which is stacked on top of the tray. Therefore, it is usually desirable for machine-erected trays to have a high burst strength.

It would therefore be desirable to provide a machine-erected tray which has a high burst strength.

Disclosure of the Invention 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 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 I3 the present invention is disclosed.

According to a first broad aspect of the present invention there is provided a Z tray erected from a foldable blank, the tray comprising a bottom wall panel, a plurality of end wall panels hinged to the bottom wall panel, a plurality of side wall panels hinged to the bottom wall panel, a plurality of corner posts secured relative to the end ID wall panels and the side wall panels, a plurality of end wall flaps hinged to the end Vwall panels, wherein the end wall flaps overlie the end wall panels, and a plurality of N securing flaps hinged to the end wall flaps, wherein the securing flaps overlie and are secured to the corner posts.

Securing the securing flaps to the corner posts secures the end wall flaps and the end wall panels relative to the corner posts, and increases the burst strength of the tray.

The tray may be any type of tray but is preferably a machine-erected tray.

The blank is preferably fabricated from a foldable sheet of paper-based material. For example, the blank may be fabricated from a foldable sheet of corrugated fibreboard. In a particular preferred form, the blank is fabricated from a foldable sheet of double-faced corrugated fibreboard.

The bottom wall panel may be any suitable shape. Preferably, the bottom wall panel is generally rectangular. It is preferred that the bottom wall panel includes a plurality of stacking tab receiving recesses.

The end wall panels may be any suitable shape. Preferably, the end wall panels are generally rectangular. Each end wall panel preferably includes at least one ventilation aperture so that air is able to flow into and out of the interior of the tray through the ventilation aperture. In a particular preferred form, each end wall panel includes a pair of ventilation apertures. It is also preferred that each end wall panel includes at least one holding aperture.

The side wall panels may be any suitable shape. Preferably, the side wall panels are generally rectangular. Each side wall panel preferably includes at least one ventilation aperture so that air is able to flow into and out of the interior of the tray through the ventilation aperture. In a particular preferred form, each side wall panel includes three ventilation apertures.

IND 4 4 The comer posts are preferably hinged to the side wall panels. Each of the Scomer posts preferably includes a first corner post panel, and a second comer post Z panel hinged to the first corner post panel.

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The first comer post panels preferably overlie the end wall panels. The first corner post panels are preferably glued to the end wall panels. The first comer post Ipanels may be any suitable shape. Preferably, the first corner post panels are generally ,O rectangular.

The second comer post panels preferably extend obliquely between the first Scorner post panels and the side wall panels. The second comer post panels may be

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NI 10 any suitable shape. Preferably, the second corner post panels are generally rectangular. Preferably, the securing flaps overlie and are secured to the second comer post panels. In a particular preferred form, the securing flaps are glued to the second corner post panels.

Preferably, a plurality of comer post securing flaps are hinged to the comer posts. The corner post securing flaps preferably overlie and are secured to the side wall panels. The comer post securing flaps may be glued to the side wall panels. The comer post securing flaps may be any suitable shape. Preferably, the corner post securing flaps are generally rectangular. The corner post securing flaps preferably include at least one ventilation aperture.

Preferably, the tray also includes a plurality of side wall flaps which are hinged to the side wall panels and which overlie the side wall panels. The side wall flaps may be any suitable shape. Preferably, the side wall flaps are generally rectangular.

Preferably, a plurality of corner stacking tabs extend from the corner posts and the side wall panels.

The end wall flaps may be any suitable shape. Preferably, the end wall flaps are generally rectangular. Each end wall flap preferably includes a recess in an edge thereof.

The securing flaps which are hinged to the end wall flaps may be any suitable shape. Preferably, the securing flaps are generally rectangular. In a preferred form, the securing flaps are hinged to the end wall flaps along double fold lines. The O securing flaps may be secured to the corner posts in any suitable manner. Preferably, >the securing flaps are glued to the corner posts.

Z According to a second broad aspect of the present invention there is provided Cc a foldable blank from which the above-defined tray is able to be erected.

O Brief Description of the Illustrations In order that the invention may be more fully understood and put into N practice, a preferred embodiment thereof will now be described with reference to the

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accompanying illustrations, in which: I 10 Figure 1 is a plan view of a foldable blank from which a tray according to a first preferred embodiment of the present invention is able to be erected; Figure 2 depicts an initial stage in the erection of the tray from the blank illustrated in figure 1; Figure 3 depicts a further stage in the erection of the tray from the blank illustrated in figure 1; Figure 4 depicts the completed tray according to the first preferred embodiment of the present invention; Figure 5 is a plan view of a blank from which a tray according to a second preferred embodiment of the present invention is able to be erected; and Figure 6 depicts the completed tray according to the second preferred embodiment of the present invention.

Best Modes for Carrying Out the Invention Referring to figure 1, a blank 10 from which a tray is able to be erected is fabricated from a single foldable sheet of double sided corrugated fibreboard.

Blank 10 includes a generally rectangular bottom wall panel 11. Two generally rectangular and opposing side wall panels 12 are hinged to the bottom wall panel 11 along fold lines 13. Each side wall panel 12 includes a plurality of ventilation apertures 14. A respective pair of generally rectangular first corner post panels 15 is hinged to each of the side wall panels 12 along fold lines 16. Corner stacking tabs 17 extend from the side wall panels 12 and the first comer post panels ND 6

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A respective second comer post panel 18 is hinged to each of the first comer post panels 15 along a fold line 19. A respective comer post securing flap 20 is hinged to

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Z each of the second comer post panels 18 along a fold line 21. Each comer post securing flap 20 includes a ventilation aperture 22.

Two generally rectangular and opposing end wall panels 23 are hinged to the ID bottom wall panel 11 along fold lines 24. Each end wall panel 23 includes a pair of V ventilation apertures 25 and a holding aperture 26. A respective stacking tab receiving recess 27 is located at each comer of the bottom wall panel 11. A respective end wall flap 28 is hinged to each of the end wall panels 23 along a fold line 29. Each ,I 10 end wall flap 28 includes a recess 30 in an edge thereof. A respective pair of opposing securing flaps 31 is hinged to each end wall flap 28 along double fold lines 32.

Referring to figure 2, a tray is erected from the blank 10 by folding the first comer post panels 15 relative to the side wall panels 12 along the fold lines 16 so that the first comer post panels 15 extend perpendicularly with respect to the side wall panels 12. The second corner post panels 18 are then folded relative to the first comer post panels 15 along the fold lines 19, and the comer post securing flaps 20 are folded relative to the second corner post panels 18 along the fold lines 21 so that the corner post securing flaps 20 overlie the side wall panels 12, and so that the second corner post panels 18 extend obliquely between the first comer post panels 15 and the side wall panels 12. The comer post securing flaps 20 are glued to the side wall panels 12 so that the comer post securing flaps 20 are thereby secured to the side wall panels 12.

Referring to figure 3, the side wall panels 12 are then folded relative to the bottom wall panel 11 along the fold lines 13 so that the side wall panels 12 are perpendicularly upstanding with respect to the bottom wall panel 11. The end wall panels 23 are then folded relative to the bottom wall panel 11 along the fold lines 24 so that the end wall panels 23 are perpendicularly upstanding with respect to the bottom wall panel 11, and so that the end wall panels 23 overlie the first comer post panels The end wall flaps 28 are then folded relative to the end wall panels 23 along the fold lines 29 so that the end wall flaps 28 overlie the end wall panels 23 as O 7 Ni depicted in figure 4. Also, the securing flaps 31 are folded relative to the end wall >flaps 28 along the fold lines 32 so that each securing flap 31 overlies a respective Z second comer post panel 18. The securing flaps 31 are secured to the second comer Cc post panels 18 by gluing them to the second corner post panels 18.

Figure 4 depicts the completed tray 40 which is erected from the blank IN Tray 40 includes a plurality of corner posts 41 which include the first comer post V) panels 15 and the second corner post panels 18.

N, The recesses 30 in the end wall flaps 28 prevent the end wall flaps 28 from obstructing the holding apertures 26 in the end wall panels 23. Also, each ventilation ,I 10 aperture 22 is aligned with a respective ventilation aperture 14.

Tray 40 is a stackable and machine-erectable tray. Two of the trays 40 are able to be stacked on top of each other such that the corner stacking tabs 17 of the lower tray 40 in the stack are received by the stacking tab receiving recesses 27 of the upper tray 40 in the stack.

Referring to figure 5, a blank 50 from which a tray is able to be erected is similar to the blank 10. Therefore, like features of the blank 50 and the blank 10 have been referenced using like reference numerals.

The main difference between the blank 50 and the blank 10 is that the blank also includes a respective generally rectangular side wall flap 51 hinged to each of the side wall panels 12 along double fold lines 52.

Referring to figure 6, a tray 60 is erected from the blank 50 in the same manner in which the tray 40 is erected from the blank 10. In addition, the side wall flaps 51 of the blank 50 are folded relative to the side wall panels 12 along the fold lines 52 so that the side wall flaps 51 overlie the side wall panels 12 and the corner post securing flaps 20. The side wall flaps 51 are secured to the side wall flaps with glue.

Throughout the specification and the claims, unless the context requires otherwise, the term "comprise", or variations such as "comprises" or "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, unless the context requires O 8 otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms. O Z 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 IND apparent to persons skilled in the art are deemed to fall within the broad scope and V)ambit of the invention as herein set forth.

N, Any reference herein to prior art is not to be taken as an admission that the referenced prior art is common general knowledge.

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Claims (12)

1. A tray erected from a foldable blank, the tray comprising a bottom wall Z panel, a plurality of end wall panels hinged to the bottom wall panel, a plurality of side wall panels hinged to the bottom wall panel, a plurality of corner posts secured relative to the end wall panels and the side wall panels, a plurality of end wall flaps IND hinged to the end wall panels, wherein the end wall flaps overlie the end wall panels, V) and a plurality of securing flaps hinged to the end wall flaps, wherein the securing N, flaps overlie and are secured to the corner posts.

2. The tray of claim 1, wherein the corner posts are hinged to the side wall S 10 panels.

3. The tray of any one of the preceding claims, wherein each of the corner posts includes a first comer post panel, and a second corner post panel hinged to the first comer post panel.

4. The tray of claim 3, wherein the first comer post panels overlie the end wall panels.

The tray of claim 3 or claim 4, wherein the second corner post panels extend obliquely between the first comer post panels and the side wall panels.

6. The tray of any one of claims 3 to 5, wherein the securing flaps overlie and are secured to the second corner post panels.

7. The tray of any one of the preceding claims, wherein a plurality of corner post securing flaps are hinged to the comer posts.

8. The tray of claim 7, wherein the comer post securing flaps overlie and are secured to the side wall panels.

9. The tray of any one of the preceding claims, wherein a plurality of side wall flaps are hinged to and overlie the side wall panels.

A tray erected from a foldable blank, the tray being substantially as herein described with reference to figure 4 or figure 6 of the illustrations.

11. A foldable blank from which the tray of any one of the preceding claims is able to be erected.

12. A foldable blank substantially as herein described with reference to figure 1 or figure 5 of the illustrations.