GB1579535A

GB1579535A - Trays

Info

Publication number: GB1579535A
Application number: GB93877A
Authority: GB
Original assignee: Timpak Ltd
Current assignee: Timloc Building Products Ltd
Priority date: 1977-10-27
Filing date: 1977-10-27
Publication date: 1980-11-19

Description

(54) IMPROVEMENTS RELATING TO TRAYS (71) We, TIMPAK LIMITED, a British Company of Rawcliffe Road, Goole, North Humberside, DN14 6UQ, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: This invention relates to box trays suitable, for example, for the packaging and transport of mushrooms or other horticultural produce. It also relates to blanks of sheet material for forming such trays.

Trays in the form of open-topped boxes are commonly used for packaging and transport of horticultural produce, such as mushrooms or fruit, which is packed in the trays at the place where the produce is grown.

During transport, the packed trays are stacked one on top of another and only the uppermost tray in the stack is provided with a lid and even this is not always necessary.

Such trays are commonly made of timber and they suffer from the disadvantage that they take up as much space when returned empty for re-use as they take up when filled with produce. Another disadvantage of some such trays when used for the packaging and transport of mushrooms is that there is often inadequate ventilation of the lower trays in the stack and this may cause some deterioration of the mushrooms during transit.

The aim of the present invention is to provide a tray constructed so that a series of identical trays may be stacked one on top of another when filled with produce, but may also be nested one inside the other when empty so that they then take up substantially less room that they do when stacked. The invention also provides a blank of sheet material for forming such a tray.

According to this invention, such a tray comprises a rectangular base and side walls which extend upwards from the base with an outward inclination, at least the side walls being made of foldable sheet material which is folded at each corner of the tray about a corner fold-line which extends upwards from the corner of the base to the top edge of the side walls at the corner, and a pair of ledge-forming fold-lines are provided in the side walls at each corner of the tray, the ledge-forming fold-lines extending upwards from the corner of the base one on each side of the corner fold-line and the upper ends of each pair of ledge-forming fold-lines being joined by a ledge-forming slit extending arross the corner fold-line, whereby the portion of the side walls bounded by the ledge-forming fold-lines and the ledge-forming slit can be snapped inwards to form a ledge so that a number of identical trays so formed can be stacked one on top of the other with each tray supported on the ledges at the corners of the tray below.

The base of the tray may be made of rigid material with the side walls, which are made of foldable sheet material fixed to it along the edges of the base. Preferably, however, thew hole tray is made of sheet material which is of sufficient rigidity to support its contents in use, but which also has sufficient flexibility to enable it to be folded when scored or creased to provide a foldline.

The invention also consists, according to another of its aspects, in a blank for forming a tray, which has a rectangular base and side walls extending upwards from the base at an outward inclination, the blank comprising a substantially rectangular sheet of foldable material having four base foldlines spaced inwards from the edges of the sheet to define the edges of the base, four corner slits extending inwards from the edges of the sheet one to the junction of the pair of base fold-lines at each corner of the base, four corner fold-lines extending inwards from the edges of the sheet one to each of the said junctions, each corner fold-line with the adjacent corner slit defining a corner flap, and a pair of ledgeforming fold-lines extending outwards from each of the said junctions, one on each side of the corner fold-line at the junction, the outer ends of each pair of ledge-forming fold-lines being joined by a ledge-forming slit extending across the corner fold-line, whereby, when the edges of the sheet are folded upwards along the base fold-lines to form the side walls and each corner flap is fixed to a side wall on the side of the corner slit remote from the flap, each portion of the side wall and the adjacent flap bounded by the ledge-forming fold-lines and the ledgeforming slit can be snapped inwards to form a ledge so that a number of identical trays so formed can be stacked one on top of the other with each tray supported on the ledges at the corners of the tray below.

With a tray in accordance with the invention, or a tray formed from a blank in accordance with the invention, owing to the outward inclination of the side walls, the bottom part of each tray in a stack will fit within the top part of the tray below with a clearance between the lower parts of the side walls of the upper tray and the upper parts of the side walls of the lower tray.

This clearance leads to the space between the two trays so that this space which, in use, holds the contents of the trays, is adequately ventilated.

The ledges formed by snapping inwards the portions of the side walls bounded by the ledge-forming fold-lines and the ledgeforming slits can be removed by snapping these portions outwards so that they then lie in the planes of the side walls. When this is done, the trays can be nested one inside another when they are empty so that the total space which they then occupy is very much less than the total space occupied by the same number of trays when stacked.

When the trays are required to be stacked again, it is a simple matter to snap the ledge-forming portions of the side walls inwards again to form the ledges.

When the trays fore formed from blanks of sheet material in accordance with the invention, the blanks can initially be transported in a flat condition and the space then occupied is much less still than that occupied by the nested trays. Extraction of the blanks to form the trays is a simple matter and merely calls for the folding up of the side walls and the fixing of each of the flaps to the end of the adjacent side wall on the other side of the corner slit. The flaps can be fixed to the side walls either by an adhesive or by fasteners such as staples.

The blanks in accordance with thc invention and at least the side walls of the tray in accordance with the invention may be made of conventional fibreboard, but they are preferably made of plastic laminated fibreboard, of paper sheets laminated to a foamed plastic core, or of double-walled plastics sheeting, the two walls of which are connected to each other by closely spaced webs which are formed integrally with the walls.

These three materials are more durable than conventional fibreboard and so enable the trays to be re-used a greater number of times. The double-walled plastics sheeting in particular is impermeable to moisture and owing to its impermeability, it is easily cleaned and is therefore particularly suitable for making trays for packaging and transporting horticultural produce such as fruit.

So that the ledges which are formed when the portions of the side walls bounded by the ledge-forming fold-lines and the ledgeforming slits have top edges which are parallel to the base of the tray, each ledgeforming slit preferably has two straight portions which join each other at the corner fold-line and form an obtuse angle between them such that the angle between each portion of the ledge-forming slit and the adjacent ledge-forming fold-line is a right angle. Thus the portion of the side wall and of the adjacent flap bounded by a pair of ledge-forming fold-lines and a ledge-forming slit is kite-shaped.

An example of a blank in accordance with the invention and of a tray in accordance with the invention formed from the blank will now be described with reference to the accompanying drawings, in which: Figure 1 is a plan view of the blank; Figure 2 is a perspective view of the tray with the ledge-forming portions of the side walls snapped inwards; Figure 3 is an inside perspective view to a larger scale of one corner of the tray with the ledge-forming portions of the side walls snapped inwards to form a ledge; and, Figure 4 is a perspective view similar to Figure 3, but showing the ledge-forming portions of the side walls snapped outwards to remove the ledge for nesting purposes.

The blank shown in Figure 1 comprises a sheet 1 of foldable material which is rectangular except for chamfers 2, one at each corner. The sheet 1 is made of foldable material, which is preferably plastics sheeting as described above if the tray which is formed from the blank is required to be impermeable, but which may alternatively be of plastic laminated fibreboard or paper laminated to a foamed plastic core.

The sheet 1 has four base fold-lines 3 bounding a rectangular base portion 4. At each corner of the sheet 1 there is a corner slit 5 and a corner fold-line 6. At each corner there are also a pair of ledge-forming fold-lines 7 arranged symmetrically one on each side of the corner fold-lines 6. The lines 6 and 7 all radiate from the junction between two base fold-lines 3. The foldlines 3, 6 and 7 are all formed by scoring or creasing according to the nature of the material of which the sheet 1 is made. The outer ends of each pair of ledge-forming fold-lines are joined by a ledge-forming slit 8 which has two portions forming an obtuse angle between them. Each portion of the slit 8 lies at right angles to the adjacent ledgeforming fold-line 7 so that each ledgeforming portion 9 bounded by a pair of fold-lines 7 and a slit 8 is kite-shaped.The portion of the sheet lying between each corner slit 5 and the adjacent corner foldline 6 forms a corner flap 10.

To form a tray as shown in Figure 2 from the blank shown in Figure 1, the four corner flaps 10 are first bent upwards about the corner fold-lines 6 and then portions 11 of the sheet lying between the edges of the sheet and the base fold-lines 3 are bent upwards to form the side walls of the tray. The portions 11 are bent upwards so that they have an outward inclination from the vertical and each of the flaps 10 lies flush against the inside face of the adjacent end of one of the portions 11 with the chamber 2 in alignment with the edge of the portion 11 which forms the top edge of the side wall.

The flaps 10 are then fixed to the portions 11 by staples 12 as shown most clearly in Figures 3 and 4. Alternatively the flaps 10 may be stuck to the portions 11 by an adhesive.

This completes the formation of the tray, but at this stage the ledge-forming portions 9 lie in the planes of the side wall portions 11 as shown in Figure 4. Under these conditions, a number of identical trays can be nested one inside the other.

To enable a number of trays to be stacked with the lower portion of each upper tray inside the upper portion of the tray below, the ledge-forming portions 9 are pressed manually inwards so that they snap from the position shown in Figure 4 to that shown in Figure 3. When the portion 9 has been snapped inwards in this way, its upper edge forms a ledge 13 and when a number of trays are stacked, the bottom corners of one tray sit on the four ledges 13 of the tray below.

When it is required to nest the trays again, the portions 9 can very easily be snapped back into the position shown in Figure 4 of the drawings.

WHAT WE CLAIM IS: 1. A tray comprising a rectangular base and side walls which extend upwards from the base with an outward inclination, at least the side walls being made of foldable sheet material which is folded at each corner of the tray about a corner fold-line which extends upwards from the corner of the base to the top edge of the side walls at the corner, wherein a pair of ledgeforming fold-lines are provided in the side walls at each corner of the tray, the ledgeforming fold-lines extending upwards from the corner of the base one on each side of the corner fold-line and the upper ends of each pair of ledge-forming fold-lines being joined by a ledge-forming slit extending across the corner fold-line, whereby the portion of the side walls bounded by the ledgeforming fold-lines and the ledge-forming slit can be snapped inwards to form a ledge so that a number of identical trays so formed can be stacked one on top of the other with each tray supported on the ledges at the corners of the tray below.

2. A tray according to claim 1, in which the base and the side walls are made of the shame sheet material.

3. A tray according to claim 2, in which the sheet material is plastic laminated fibreboard, paper sheets laminated to a foamed plastic core, or double-walled sheeting of plastics material, the two walls of which are connected to each other by closely spaced webs which are formed integrally with the walls.

4. A tray according to any one of the preceding claims, in which one of the side walls at each corner of the tray is provided with a corner flap which is connected to the one side wall along the corner foldline and is fixed to the other side wall at the corner by fasteners or an adhesive.

5. A blank for forming a tray, which has a rectangular base and side walls extending upwards from the base at an outward inclination, the blank comprising a substantially rectangular sheet of foldable material having four base fold-lines spaced inwards from the edges of the sheet to define the edges of the base, four corner slits extending inwards from the edges of the sheet one of the junction of the pair of base fold-lines at each corner of the base, four corner fold-lines extending inwards from the edges of the sheet one to each of the said junctions, each corner fold-line with the adjacent corner slit defining a corner flap, and a pair of ledge-forming fold-lines extending outwards from each of the said junctions, one on each side of the corner fold-line at the junction, the outer ends of each pair of ledge-forming fold-lines being joined by a ledge-forming slit extending across the corner fold-line, whereby, when the edges of the sheet are folded upwards along the base fold-lines to form the side walls and each corner flap is fixed to a side wall on the side of the corner slit remote from the flap, each portion of the side wall and the adjacent flap bounded by the ledge-forming fold-lines and the ledgeforming slit can be snapped inwards to form a ledge so that a number of identical trays so formed can be stacked one on top of the other with each tray supported on the ledges at the corners of the tray below.

6. A blank according to claim 5, in

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **. fold-lines are joined by a ledge-forming slit 8 which has two portions forming an obtuse angle between them. Each portion of the slit 8 lies at right angles to the adjacent ledgeforming fold-line 7 so that each ledgeforming portion 9 bounded by a pair of fold-lines 7 and a slit 8 is kite-shaped. The portion of the sheet lying between each corner slit 5 and the adjacent corner foldline 6 forms a corner flap 10. To form a tray as shown in Figure 2 from the blank shown in Figure 1, the four corner flaps 10 are first bent upwards about the corner fold-lines 6 and then portions 11 of the sheet lying between the edges of the sheet and the base fold-lines 3 are bent upwards to form the side walls of the tray. The portions 11 are bent upwards so that they have an outward inclination from the vertical and each of the flaps 10 lies flush against the inside face of the adjacent end of one of the portions 11 with the chamber 2 in alignment with the edge of the portion 11 which forms the top edge of the side wall. The flaps 10 are then fixed to the portions 11 by staples 12 as shown most clearly in Figures 3 and 4. Alternatively the flaps 10 may be stuck to the portions 11 by an adhesive. This completes the formation of the tray, but at this stage the ledge-forming portions 9 lie in the planes of the side wall portions 11 as shown in Figure 4. Under these conditions, a number of identical trays can be nested one inside the other. To enable a number of trays to be stacked with the lower portion of each upper tray inside the upper portion of the tray below, the ledge-forming portions 9 are pressed manually inwards so that they snap from the position shown in Figure 4 to that shown in Figure 3. When the portion 9 has been snapped inwards in this way, its upper edge forms a ledge 13 and when a number of trays are stacked, the bottom corners of one tray sit on the four ledges 13 of the tray below. When it is required to nest the trays again, the portions 9 can very easily be snapped back into the position shown in Figure 4 of the drawings. WHAT WE CLAIM IS:

1. A tray comprising a rectangular base and side walls which extend upwards from the base with an outward inclination, at least the side walls being made of foldable sheet material which is folded at each corner of the tray about a corner fold-line which extends upwards from the corner of the base to the top edge of the side walls at the corner, wherein a pair of ledgeforming fold-lines are provided in the side walls at each corner of the tray, the ledgeforming fold-lines extending upwards from the corner of the base one on each side of the corner fold-line and the upper ends of each pair of ledge-forming fold-lines being joined by a ledge-forming slit extending across the corner fold-line, whereby the portion of the side walls bounded by the ledgeforming fold-lines and the ledge-forming slit can be snapped inwards to form a ledge so that a number of identical trays so formed can be stacked one on top of the other with each tray supported on the ledges at the corners of the tray below.

6. A blank according to claim 5, in

which the sheet of foldable material is made of plastic laminated fibreboard, paper sheets laminated to a foamed plastic core, or double-walled sheeting of plastics material, the two walls of which are connected to each other by closely spaced webs which are formed integrally with the walls.

7. A blank according to claim 5 or claim 6, in which each ledge-forming slit has two straight portions which join each other at the corner fold-line and form an obtuse angle between them such that the angle between each portion of the ledge-forming slit and the adjacent ledge-forming foldline is a right angle, the portion of the side wall and of the adjacent flap bounded by a pair of ledge-forming fold-lines and the ledge-forming slit being kite-shaped.

8. A tray according to claim 1, substantially as described with reference to Figures 2 to 4 of the accompanying drawings.

9. A blank according to claim 5, substantially as described with reference to Figure 1 of the accompanying drawings.