GB2267697A - Packaging tray - Google Patents

Abstract

A packaging tray for marketing potato crisps and for storing on supermarket shelves has a rectangular base 1 and upstanding side 3, 5 and end walls or edges, at least the front end wall of which is preferably of two-layer thickness with one layer 23 folded into back-to-back relationship relative to the other 21 so as to upstand from the base 1 by a less amount than the remaining walls. A stacking pillar 37 is provided at each corner of the tray, the pillar being formed from a stacking panel fold ably connected to an end portion of a respective side wall 3, 5 and means 43 being provided to hold the stacking panel in position and latch ably connect it to the side wall 3, 5. <IMAGE>

Description

PACKAGING TRAY This invention relates to a packaging tray, and more particularly a tray for potato crisps and the like, and to a blank for erection into the tray.

Nowadays, packets of potato crisps are packed and stored in fibreboard boxes, which are converted at the point of sale by tearing one or more panels of the box along lines of weakness (and either folding it/them back or removing it/them) into display/dispensing trays. These are normally stacked on a shelf, and they have an open front, thus allowing one or more packets of potato crisps to be taken from the tray. These known boxes convertible into trays suffer from the disadvantage that they are very unstable when stacked, and it is not unusual for the stacks to collapse and for the packets of potato crisps to fall onto the floor.

In an attempt to overcome this problem, one box manufacturer has designed a stackable box which converts into a tray, and which has corner stacking pillars.

However, these pillars are provided by diagonal corner flaps provided by extensions of the box side walls, which have to be secured by adhesive to the side walls. While the box performs very satisfactorily, it is expensive to make since a machine has to be provided to apply the adhesive to the box and to erect it. It has therefore not been accepted by the potato crisp manufacturers.

We therefore decided there was a need for a handerected tray which possessed suitable stacking strength.

Traditional hand erected trays have separate corner pillars, e.g. of folded fibreboard, moulded plastics, or wood. One piece trays with integral corner pillars of fibreboard are known, but because of the need to use board material in the vicinity of the corner to sandwich between two layers of end wall to lock together the side and end walls at the corner, this has resulted, in all previous constructions, in there being no vertically continuous panel extending diagonally across the corner to provide vertical stacking strength.

A further problem which arises particularly during the loading of packets of potato crisps is that the packaging tray is tilted during the loading process so that packets tend to fall out of the tray either during loading by a packer or after loading when the tray is removed from support given by the packer's body. There is therefore a need for additional support to prevent loss of packets during or after loading, whilst maintaining the open front configuration for display and access purposes.

The present invention seeks to solve these problems.

According to the present invention, we provide a packaging tray comprising a rectangular base; a pair of side walls upstanding from a first opposite pair of sides of the base; first and second end ledges upstanding from a second pair of opposite sides of the base; a stacking pillar at each corner, each pillar comprising a stacking panel foldably connected to one end portion of a side wall and means to hold the stacking panel in position and latchably to connect it to the side wall; and co-operable detent means at-each corner for connecting each pillar to its respective end ledge; in which each stacking panel has one edge resting on the tray base and its opposite edge at the desired stacking height.

Preferably, the stacking panels are foldably connected to short substantially full height end wall panels each forming part of a stacking pillar and foldably connected to an end of a side wall and extend diagonally across the respective corners of the tray.

Preferably, a locking tab projects from an end edge of each stacking panel which engages within a slot formed in each side wall. The slot may comprise a flap formed in the side wall, which is folded inwardly to receive the edge of the stacking panel behind it, or an aperture in the side wall.

The side walls may project upwardly beyond the stacking panels to provide locating rails for the underside of another tray.

Suitable stacking strength is provided by this construction, but it is preferred that the first end ledge is deeper than the second end ledge so that support is given to the tray contents during packing or loading.

One or both end ledges may be of two layer thickness, with an inner layer folded into back to back relationship with an outer layer and held in place by at least one projecting tab on its free edge engaging in a corresponding slot in the end of the base. Alternatively, the or both end ledge(s) may be of single thickness. Alternatively, one end ledge may be of single thickness and the other of two layer thickness.

Preferably, at least one of the co-operable detent means comprises a first tab, foldably connected to an upper region of its respective end ledge and a complementary locking tab on or aperture in an upper region of the side wall end portion. The first tab may include one or more locking projections foldably connected to the tab, the foldable connections between the tab and end ledge and between the locking projection and tab being substantially perpendicular.

The upper region of the end ledge may be a wing portion extending upwardly from the end ledge. This is particularly appropriate for connection of a two layer thickness end ledge.

Alternatively, the two layer thickness end ledge may be connected by co-operable detent means comprising a locking flap sandwiched between the two layers of the end ledge and foldably connected to a lower region of its respective stacking panel. Preferably, the locking flap is reverse folded for sandwiching between the two layers.

Also according to the present invention, we provide in one construction a blank for a packaging tray, the blank comprising a rectangular base panel, a pair of side wall panels foldably connected to the base panel about a first pair of parallel spaced fold lines defining the sides of the base panel, a second pair of spaced parallel fold lines at right angles to the first pair defining the ends of the base panel, a pair of ledge or end wall panels foldably connected to the base panel about respective ones of said second pair of fold lines, each of said ledge or end panels being divided into inner and outer portions by a tram line double score line parallel to the second pair of fold lines, at least one projecting tab extending from the free edge of each inner portion engageable in a corresponding slot in the end of the base panel, and, at each end of each side wall panel, at least a pair of spaced further fold lines extending parallel to said second pair of spaced fold lines, and defining a full height stacking panel and including a locking flap connected along a fold line in line with one of said further fold lines to each said stacking panel, and means associated with the stacking panel for holding and locking it in position in the erected tray.

Preferably, one of said further fold lines is substantially in line with one of the fold lines of the second pair of fold lines at the end of the base panel, and a short end wall panel is foldably attached by said one further fold line to the respective end of the side wall panel, with the stacking panel being foldably connected by the other one of the fold lines of the further pair of fold lines to the short end wall panel.

Preferably, the means associated with the stacking panel comprises a projecting locking tab on its free edge which engages in the erected tray in a slot in the side wall from which the stacking panel projects.

According to an alternative construction of the present invention, we provide a blank for a packaging tray comprising a rectangular base panel, a pair of side wall panels foldably connected to the base panel about a first pair of parallel spaced fold lines defining the sides of the base panel, a second pair of spaced parallel fold lines at right angles to the first pair defining the ends of the base panel, first and second ledge or end wall panels foldably connected to the base panel about respective ones of said second pair of fold lines, the first of said ledge or end panels being divided into inner and outer portions by a tram line double score line parallel to the second pair of fold lines, at least one projecting tab extending from the free edge of the inner portion engageable in a corresponding slot in the end of the base panel, and the second ledge or end panel having a tab at each side of the panel, the tabs being foldably connected to the panel along at least one fold line and being engageable with complementary locking means for holding the panel in position in the erected tray, and, at each end of each side wall panel, at least a pair of spaced further fold lines extending parallel to said second pair of spaced fold lines, and defining a full height stacking panel and means associated with the stacking panel for holding and locking it in position in the erected tray.

The first ledge or end panel may have wing portions extending outwardly from each end of its outer portion, and include a tab foldably connected along at least one fold line to an outer edge of each wing portion for engagement with complementary locking means for holding the panel in position in the erected tray.

The complementary locking means may comprise a locking flap formed in the side wall. The locking flap usually comprises a rectangular flap defined on three sides by cuts in the side wall and foldably connected to the side wall on its fourth side, the fourth side being parallel to the second pair of fold lines so that the locking tab may be folded about the fold line towards the centre of the side wall in which it is formed.

Preferably, however, the flap is replaced by a rectangular aperture of the same dimensions.

The tab usually includes one or more locking projections foldably connected to the tab and extending perpendicularly therefrom.

Preferred embodiments of packaging tray are now described by way of example with reference to the accompanying drawings, in which: FIGURE 1 is a plan view of a blank for a first embodiment of tray; FIGURE 2 is a plan view of one corner of a tray partly erected from the blank of Figure 1; FIGURE 3 is a plan view of the same corner of the fully erected tray; FIGURE 4 is a perspective view of the fully erected tray; FIGURE 5 is a plan view of a blank for a second embodiment of tray; FIGURE 6 is a perspective view of the second embodiment of tray, fully erected; FIGURE 7 is an enlarged perspective view of one corner of the fully erected tray of figure 6; FIGURE 8 is a plan view of a blank for a third embodiment of tray;; FIGURE 9 is a perspective view qf the third embodiment of tray, fully erected, and FIGURE 10 is a plan view of a modified and preferred version of the blank shown in figure 8.

In the drawings, score lines are represented by broken lines, perforations by short-broken lines, and cuts by ordinary heavy lines.

Referring to Figure 1, the tray blank is divided into a base panel 1, and a pair df side wall panels 3, 5 by a first pair of spaced parallel fold lines 7 and 9. A second pair of parallel spaced fold lines 11 and 13 extending normal to the fold lines 7, 9 connect respective ones of a pair of ledge or end wall panels 15, 17 to the end edges of the base panel 1. Each end wall panel 15, 17 is divided by a tram line pair of score lines 19 into an outer ledge panel 21 and an inner ledge panel 23, there being a pair of projecting tabs 25 on the free edge of each panel 23 which engage in appropriate slots 27 provided in the ends of the base panel 1. It will be noted that the inner ledge panels 23 are shorter than the outer ones 21, due to cut-away areas 29.

At each end of each side wall panel, a further pair of spaced parallel fold lines 31, 33 is provided, defining a short substantially full height end panel 35 and a stacking panel 37. Each stacking panel has a locking tab 39 projecting from its free edge 41, which, in the erected tray, engages in a slot in a respective side wall panel 3, 5 provided by folding a flap 43 formed therein out of the plane of the panel.

Foldably connected to a lower inner portion of each stacking panel 37 about a fold line 45 formed as an extension of the fold line 33, is a locking flap 47. These flaps 47 extend partially into the side wall panels 3, 5.

It will be noted that the fold lines 31 do not extend into the flaps 47.

To erect a tray from the blank of Figure 1, the short end wall panels 35 are first folded about the fold line 31 to extend normal to side wall panels 3, 5 respectively, taking care not to crease flaps 47, and the stacking panels 37 are at the same time folded about their fold lines 33 towards respective side walls 3, 5 and the flaps 43 are lifted and locking tabs 39 are locked into the slots provided behind the flaps 43.

The side wall panels 3, 5 are then folded upwardly about the fold lines 7, 9 so as to lie normal to the base panel 1, whereupon the four locking flaps 47 are then reverse folded about the fold lines 45 connecting them to the stacking panels 37, so that they overlie the fold lines 11, 13 respectively. Then the end wall panels 15, 17 are folded upwardly about their respective fold lines 11, 13 so as to abut the flaps 47 and extend normal to the base panel 1, and the inner ledge panels 23 are then folded through 1800 about the score lines 19, and the locking tabs 25 are engaged in the respective slots 27 to provide a double layer end ledge, with the locking flaps 47 sandwiched between the two layers. Thus, both the side walls and the end ledge are locked in position at right angles to the base panel.

Instead of connecting the stacking panels 37 by fold lines 33 to the short end panels 35 which are connected to the ends of the side wall panels 3, 5 about fold lines 31, a "reverse" arrangement could be provided. In this arrangement, fold lines extending normal to fold lines 7, 9 would be provided in end portions of the panels 3, 5 in the vicinity of flaps 43, 45 by means of which the stacking panels would be connected to the panels 3, 5. A short end panel would then be foldably connected to an edge of each stacking panel about a fold line parallel to and spaced from the fold line connecting the stacking panel to its side wall. This short end panel would then have a short side wall panel foldably connected to it about a further fold line spaced from and parallel to the fold line connecting the short end panel to the stacking panel.The free edge of each short side panel would then have a projecting locking flap which would engage in a slot in the side wall panel which would be provided in line with the fold line connecting each stacking panel to the side wall panel.

In this alternative construction, the tray would be erected in a similar manner to the illustrated tray, except that the stacking panels would first be folded through about 300 about the fold lines connecting them to the side wall end portions, whereupon the short end wall panels would be reverse folded about their fold lines connecting them to the stacking panels through about 600, and the short side wall panels would then be reverse folded through 900 about the fold line connecting them to their respective short end wall panel. The short side wall panels will then be in line with the side walls, thus allowing their locking flaps to be engaged in the slots provided.

Normally, the tray would be stacked full of bags of potato crisps or the like, and then closed off by an inverted U-shaped cover, the top (i.e. base of the U) of which rests on the top edges of the stacking panels 37, with the lower ends of the depending arms of the U being tucked behind the end ledges of the tray. It can then be taped in position, and may then receive a final wrapping, e.g. of shrink wrap material. Preferably, the cover is of the construction described in our co-pending U.K. Patent Application No. 9210449.6.

It is preferred that the corrugations in the board material from which the tray is made extend vertically (as shown in Figure 4) in the stacking pillars 37.

It will thus be appreciated that a tray is provided which is hand erectable, and yet which has diagonally extending stacking panels at each corner which rest on the base and therefore have maximum stacking strength from the material of the tray. Further identical trays may be stacked on top of the trays with the stacking panels 37 taking the majority of the weight of superimposed trays. It will be noted that each side wall panel 3, 5 has a projecting central region 49. This provides a rail giving lateral location for stacking purposes, but is optional.

It has been found that the above described embodiment of a tray is difficult to fill, due to the low height of the end walls 21, 23 at each end of the tray. We have therefore developed two modified constructions which overcome this problem, which are now described with reference to Figures 5-9.

Figure 5 shows a tray blank divided in the same fashion as the tray blank of Figure 1 with like features sharing the same reference numerals.

The blank differs from that shown in figure 1 in that a high end wall panel 115 is foldably connected to the base panel 1 about the fold line 11. The panel 115 comprises a single panel with a locking tab 120 connected to the outer end of each side 117 of the end panel 115 by a first pair of tram line score lines 119. Each of the tabs 120 has two side projections 122 foldably connected to the tab about fold lines 123.

Apertures to receive the respective locking tabs 120 are provided in the end of each side wall panel 3, 5 by flaps 125 connected to side wall panels 3 and 5 along fold lines 129. The flaps 125 are rectangular and defined.on three sides by cuts in the side wall 3, 5, and foldably connected to the side wall on its fourth side along the fold lines 129. Spaces 127 between the ends of the flaps 125 and fold lines 31 are filled by the areas between tram lines 119 when the tray is erected.

To erect the tray from the blank of Figure 5, the stacking panels 37 are first folded and locked in position and the end wall 17 is also erected and locked in position as in the embodiment of Figure 4.

The end panel 115 is folded upwardly to abut the end panels 35 and is locked in position by folding tabs 120 through 900 about one of the score lines 119 around the corner of the tray as best seen in Figure 7, until they abut the locking flaps 125. Further inward pressure on the tabs 120 towards the centre of the tray will force the locking flaps 125 to fold inwardly about fold lines 129, and projections 122 connected to tabs 120 by fold lines 123 to fold outwardly about the fold lines 123. Eventually, the tabs 120 will be pushed beyond the locking flaps 125 at which point the tabs 120 and flaps 125 are released and, due to their resilient nature, snap back into the plane of the respective side walls 3, 5, with tabs 120 locating behind the locking flaps 125. The area between tram lines 119 then fills the space 127 between the locking flap 125 and fold line 31.

The tabs 120 are further locked in position by the projections 122 which spring back into the plane of the tabs 120 behind the respective side wall.

The alternative end wall locking arrangement of this second embodiment may also be used to lock a folded end wall 17 in position. In the blank shown in Figure 8 modified end walls panels 210, 230 are provided, the panel 230 having a single projecting tab 250 on its free edge which engages in a single slot 270 in one end of base panel 1 to hold the end wall 17 in its folded state.

In the embodiment of Figure 8, the end portions of panel 210 extend outward into wing portions 229 to which locking tabs 220 similar to tabs 120 are foldably connected.

Locking flaps 222 are formed in side wall panels 3, 5, which are of the same construction, and for the same purpose as the locking flaps 125 in Figure 5. The end wall 17 is locked in position in the erected tray by pushing the tabs 220 through apertures defined by the flaps 222, and locking them in position in the same manner as tabs 120 in the embodiment of Figures 5, 6 and 7.

The inner end wall or ledge panel 230 is separated from the wing portions 229 by cuts so that the inner panel 230 tapers down to the fold line 13 when erected, as can be seen from Figure 9.

A modified version of the blank shown in Figure 8, and which is more quickly and easily erected, is shown in Figure 10. Parts of the blank of Figure 10 which are identical to the parts in Figure 8 are identified by the same reference numerals as in Figure 8.

The blank of Figure 10 differs from that of Figure 8 in that the top free edges of the side wall panels 3, 5, do not project above the top of the stacking ledges defined by the edges of the panels 350, 370, which means that a flat tray is formed from the blank, without any upstanding stacking rails for locating a superimposed tray. Also, instead of providing flaps 222 and flaps 43 in the side walls 3, 5, cut-outs or apertures 322 and 430, respectively, are provided to receive the tabs 39 and tabs 220, respectively. Furthermore, instead of providing a single projecting locking tab 250 engaging in a single slot 270 in the respective end of the base panel 1, two spaced tabs 350 engage in respective spaced apertures 370. This provides a more satisfactory locking arrangement.

The erected trays of Figures 6 and 9 thus both include one end wall 115 which is deeper than the opposing end wall 13 so that the tray may be loaded without loss of its contents during or following loading. This deeper end panel will be placed at the back of a display at the point of sale so that loaded products may be viewed or removed from the tray over the lower end wall.

It will thus be appreciated that one of the end walls in the tray is of two layer thickness and may be locked in position either as described in the first two embodiments by sandwiching locking flaps between its two layers, or in the same manner as for the deeper panel configuration of Figures 6 and 9.

A number-of modifications may be made to the score or fold lines. For example, corner score lines 31 may be perforated to enable very square corners to be provided.

Similarly, central slits 231, 232 may be provided on the fold lines 129, 123 of locking flaps 125 and projections 122 respectively so as to ensure easy folding. These central slits are about one third of the length of the respective fold lines.

It will of course be understood that the present invention has been described above purely by way of example, and modifications of detail can be made within the scope of the invention.

Claims (32)

CLAIMS:

1. A packaging tray comprising a rectangular base; a pair of side walls upstanding from a first opposite pair of sides of the base; first and second end ledges upstanding from a second pair of opposite sides of the base; a stacking pillar at each corner, each pillar comprising a stacking panel foldably connected to one end portion of a side wall and means to hold the stacking panel in position and latchably to connect it to the side wall; and cooperable detent means at each corner for connecting each pillar to its respective end ledge; in which each stacking panel has one edge resting on the tray base and its opposite edge at the desired stacking height.

2. A packaging tray according to claim 1 wherein the stacking panels are foldably connected to short substantially full height end wall panels each forming part of a stacking pillar and foldably connected to an end of a side wall and extend diagonally across the respective corners of the tray.

3. A packaging tray according to claim 1 or 2 wherein a locking tab projects from the end edge of each stacking panel which engages within a slot formed in each side wall.

4. A packaging tray according to claim 3 wherein the slot is formed by a flap formed in the side wall, which is folded inwardly to receive the edge of the stacking panel behind it.

5. A packaging tray according to claim 3 wherein the slot is an aperture in the side wall.

6. A packaging tray according to any one of claims 1-5 wherein the side walls project upwardly beyond the stacking panels to provide locating rails for the underside of another tray.

7. A packaging tray according to any preceding claim wherein at least one end ledge is of two layer thickness, with an inner layer folded into back to back relationship with an outer layer and held in place by at least one projecting tab on its free edge engaging in a corresponding slot in the end of the base.

8. A packaging tray according to any one of claims 1-6 wherein the first end ledge is deeper than the second end ledge so that support is given to the tray contents during packing or loading.

9. A packaging tray according to claim 8 wherein the first end ledge is of single layer thickness, and the second end ledge is of two layer thickness.

10. A packaging tray according to any preceding claim wherein at least one of the co-operable detent means comprises a first tab, foldably connected to an upper region of its respective end ledge and a complementary locking tab on or aperture in an upper region of the side wall end portion.

11. A packaging tray according to claim 10 wherein the first tab includes one or more locking projections foldably connected to the tab, the foldable connections between the tab and end ledge and between the locking projection and tab being substantially perpendicular.

12. A packaging tray according to any preceding claim wherein the end regions of the end ledge are wing portions extending upwardly from the end ledge.

13. A packaging tray according to claim 7 wherein the two layer thickness end ledge is connected to the side walls by co-operable detent means comprising a locking flap sandwiched between the two layers of the end ledge and foldably connected to a lower region of its respective stacking panel.

14. A packaging tray according to claim 13 wherein the locking flap is reverse folded for sandwiching between the two layers.

15. A packaging tray substantially as hereinbefore described with reference to Figures 1-4 of the accompanying drawings.

16. A packaging tray substantially as hereinbefore described with reference to Figures 5-7 of the accompanying drawings.

17. A packaging tray substantially as hereinbefore described with reference to Figures 8 and 9 of the accompanying drawings.

18. A packaging tray substantially as hereinbefore described with reference to Figures 8 and 9, as modified by Figure 10, of the accompanying drawings.

19. A blank for a packaging tray, the blank comprising a rectangular base panel, a pair of side wall panels foldably connected to the base panel about a first pair of parallel spaced fold lines defining the sides of the base panel, a second pair of spaced parallel fold lines at right angles to the first pair defining the ends of the base panel, a pair of ledge or end wall panels foldably connected to the base panel about respective ones of said second pair of fold lines, and, at each end of each side wall panel, at least a pair of spaced further fold lines extending parallel to said second pair of spaced fold lines, by means of which a full height stacking panel is foldably connected to each end of each side wall panel and including a locking flap connected along a fold line in line with one of said further fold lines to each said stacking panel, and means associated with the stacking panel for holding and locking it in position in the erected tray.

20. A blank according to claim 19 wherein one of said further fold lines is substantially in line with one of the fold lines of the second pair of fold lines at the end of the base panel, and a short end wall panel is foldably attached by said one further fold line to the respective end of the side wall panel, with the stacking panel being foldably connected by the other one of the fold lines of the further pair of fold lines to the short end wall panel.

21. A blank according to claim 19 or 20 wherein the means associated with the stacking panel comprises a projecting locking tab on its free edge which engages in the erected tray in a slot in the side wall from which the stacking panel projects.

22. A blank according to claim 19, 20 or 21 wherein each of said ledge or end panels is divided into inner and outer portions by a tram line double score line parallel to the second pair of fold lines, at least one projecting tab extending from the free edge of each inner portion engageable in a corresponding slot in the end of the base panel.

23. A blank according to claim 19, 20 or 21 wherein the first of said ledge or end panels is divided into inner and outer portions by a tram line double score line parallel to the second pair of fold lines, at least one projecting tab extending from the free edge of the inner portion engageable in a corresponding slot in the end of the base panel, and the second ledge or end panel having a tab at each side of the panel, the tabs being foldably connected to the panel along at least one fold line and being engageable with complementary locking means for holding the panel in position in the erected tray.

24. A blank according to claim 23 wherein the first ledge or end panel has wing portions extending outwardly from each end of its outer portion, and include a tab foldably connected along at least one fold line to an outer edge of each wing portion for engagement with complementary locking means for holding the panel in position in the erected tray.

25. A blank according to claim 24 wherein the complementary locking means comprises a locking flap formed in the side wall.

26. A blank according to claim 25 wherein the locking flap comprises a rectangular flap defined on three sides by cuts in the side wall and foldably connected to the side wall on its fourth side, the fourth side being parallel to the second pair of fold lines so that the flap may be folded out of the plane of its side wall so that the locking tab may be pushed through the aperture thus formed.

27. A blank according to claim 24 wherein the complementary locking means is an aperture in the side wall.

28. A blank according to any one of claims 24-27 wherein the tab includes one or more locking projections foldably connected to the tab and foldable perpendicularly thereto.

29. A blank for a packaging tray, substantially as hereinbefore described with reference to Figure 1 of the accompanying drawings.

30. A blank for a packaging tray, substantially as hereinbefore described with reference to Figure 5 of the accompanying drawings.

31. A blank for a packaging tray, substantially as hereinbefore described with reference to Figure 8 of the accompanying drawings.

32. A blank for a packaging tray, substantially as hereinbefore described with reference to Figure 10 of the accompanying drawings.