GB2389354A

GB2389354A - A tray construction

Info

Publication number: GB2389354A
Application number: GB0212997A
Authority: GB
Inventors: Jeff Jones
Original assignee: Field Group PLC
Current assignee: Field Group PLC
Priority date: 2002-06-06
Filing date: 2002-06-06
Publication date: 2003-12-10
Also published as: GB0212997D0; EP1394053A1

Abstract

A tray comprises a first base member 4, a second base member 5 and a wall member 6 including an upstanding portion and a flange 9 arranged inwardly thereof, wherein the flange 9 which comprises a series of spaced tabs 10, is disposed between the first and second base members 4,5 and adhesively joined thereto. The first and second base members 4,5 are preferably different sizes so that one of the base members 4,5 extends beyond the wall 6 to define a rim. The first and second base members 4,5 may also include apertures which preferably contain a transparent patch, thus forming windows 16. While a single tray may be used to package a product if an open-top container is required, two trays may be used to define the lid and base of a box. The method and apparatus for forming the tray are also disclosed.

Description

1- 2389354

TRAY The present invention relates to trays, or more 5 particularly to trays made from paperboard, cardboard or other foldable sheet materials, and a method and apparatus for manufacturing such trays.

Trays are commonly used in the packaging of consumer products, such as cosmetics or confectionery. Such 10 trays typically comprise a first base member, a second base member and an upstanding wall member. The wall member is attached to the base members by means of a continuous flange, arranged inwardly of the upstanding portion, and which is sandwiched between opposed 15 surfaces of the two base members.

While a single tray may be used to package a product, for- exan-,ple if an open container is required, more commonly the packaging will comprise more than one tray of this basic construction. For example two trays 20 may define respectively the lid and base of a box.

Often the trays are shaped to provide the packaging with enhanced visual appeal and distinctiveness.

The present invention seeks to provide a new tray construction, and a method and apparatus for making such 25 a tray.

According to a first aspect of the present invention, there is provided a tray comprising: a first base member, a second base member, 30 and a wall member comprising an upstanding portion and a flange arranged inwardly thereof, the flange being disposed between said first and second base members and comprising or being formed as a plurality of spaced apart tabs, the base members and flange being adhesively 35 joined to one another.

From a second aspect of the invention there is provided a method for assembling a tray; the method

l - 2 comprising: providing a first base member, a second base member and a wall member; the wall member having a flange provided with or formed by a plurality of spaced apart 5 tabs; assembling the first base member, second base member and wall member such that the flange of the wall member is disposed between said first and second base members, the flange thereby defining a first interface 10 with the first base member and a second interface with the second base member; wherein the method further comprises the steps of; applying adhesive at a said interface; and applying pressure to adhesively join the base 15 members and the flange together.

From a third aspect there is further provided an apparatus for asserllng tray; the apparatus comprising: means for providing a first base member, a second 20 base member and a wall member; the wall member having a flange provided with or formed as a plurality ofspaced apart tabs; means for assembling the first base member, second base member and wall member such that the flange of the 25 wall member is disposed between said first and second base members, the flange thereby defining a first interface with the first base member and a second interface with the second base member; wherein the apparatus further comprises; 30 means for applying adhesive at a said interface;, and means for applying pressure to adhesively join the base members and the flange together.

Thus in accordance with the invention, adhesive is provided at an interface defined between a base member 35 and a tabbed flange of the wall member. Adhesive may be applied to a surface of the flange and/or to an interfacing surface of one or both of the base members

i.e. to any of the surfaces defining the interface.

Preferably, however, adhesive is applied to a surface of just one of the base members. This is advantageous in that it is simpler to effect, while at the same time S allowing for the bonding of all three components together using a single application of adhesive.

In this regard, the adhesive is preferably applied in a substantially continuous pattern in the region of the interface so that when the wall flange and second 10 base member are assembled, adhesive will be exposed between the tabs of the flange so allowing the first and second base members to bond together when pressure is applied to the assembled components. Furthermore, excess adhesive from between the first base member and 15 the tabs will flow into the spaces between the tabs, providing more adhesive for this purpose.

The tray of the prevail 11IVOnlOn allay Le formed from any suitable material, but preferably is a paper or cardboard tray. The size and shape of the tray will 20 depend upon the intended use of the tray. For example, the tray may be oval or circular, or, in certain contexts a more complicated form might be appropriate.

For example, if the tray is to contain a seasonal or novelty product, the tray could be shaped to resemble an 25 object such as a Christmas tree.

The first and second base members may be of identical or different shape and size. Preferably the first and second base members are of different sizes and one of the base members extends beyond the wall to 30 define a rim. Preferably the wall is of the same shape as the rim.

The wall member may extend around only a part of the base of the assembled tray, but preferably the wall member extends around the entire base to define a closed 35 wall. Preferably the ends of the wall member thus overlap and are adhesively joined together. In this way the wall member may, for example define a continuous

- 4 - curved wall without any corners. Preferably the wall component comprises a relatively flexible substrate for ease of shaping.

The tabs preferably extend substantially along the 5 entire length of the wall member. The distribution, shape and size of the tabs may be selected as desired provided that sufficient adhesive may be exposed or flow between the tabs to ensure adhesive joining of the components. Preferably the tabs are rectangular or 10 square in shape.

In some embodiments, the first and second base members are apertured so that the contents of the tray may be viewed. Preferably a transparent window is applied to the aperture to prevent access to the 15 contents of the tray.

=1, - MA '''I ad À T - d;, - _h F crew w e of I vie y I.. TV just one of the base members.

The base members and wall member may be provided in any suitable manner. Preferably the respective members 20 are stored in a storage stations, for example in respective magazines, and delivered to an assembly station. The apparatus thus preferably further comprises means for storing a first base member, a second base member and a wall member, and means for 25 delivering the members to an assembly station. Although assembly may be conducted at more than one station, it is preferably effected at a single station.

The members may be delivered to the assembly station in any suitable manner. However, preferably the 30 apparatus further comprises transfer means for; delivering the base members and wall member from their storage to the assembly stations.

Preferably the apparatus comprises separate transfer means for delivering the wall member to the 35 assembly station and transfer means for delivering the base members to the assembly station.

It will be understood that the transfer means may

be used to deliver the members to other parts of the apparatus as required during the process, e.g. for adhesive application. Preferably the transfer means is thus indexable between storage, assembly and adhesive 5 application stations. In a particularly preferred embodiment the transfer means comprises a movable arm, most preferably a rotatable arm.

The transfer means should be capable of picking up, retaining and releasing a component as required, and 10 thus further comprises retaining means, most preferably suction means. Most preferably the transfer means comprises a plurality of retaining means to allow transfer of more than one member simultaneously. Where the transfer means is a rotatable arm, the arm 15 preferably comprises retaining means at each end of the arm. Preferably the retaining means is movable relative to the transfer means. The movement may be rotary or linear, or more preferably both. For example, the 20 retaining means may be expendable relative to the transfer means to allow compression of a retained component against a surface, in order for example to provide a force during adhesion.

In a particularly preferred embodiment the 25 retaining means is rotatable through around 90 degrees from a generally vertical to a generally horizontal position. This will allow a retained component to be presented, for example, to the surface of an applicator for adhesive application.

30 Preferably the wall member is formed as a planar member with the tabbed flange formed along one edge, and the method of the present invention further comprises the step of deflecting the flange into its assembly position, typically at 90 from the wall member body.

35 Preferably the flange is deflected during delivery of the wall member from its storage station to the assembly station, and the wall member transfer means

6 - thus preferably comprises means for so deflecting the flange. For example, the wall member may be brought into contact with means, such as a bar, for deflecting the flange relative to the remainder of the wall member 5 as it is transferred to the assembly station.

Preferably the wall member transfer means comprises a plurality of rotatable vacuum arms.

As stated above the tray may be assembled at a number of stations. Preferably, however, the components 10 of the tray are assembled at a forming station. I In this embodiment the components are thus preferably mounted sequentially to the forming station, i.e. the method preferably comprises delivering the first base member to the forming station, mounting the 15 wall member to the first base member such that the flange of the way l member overlies the first base member, and mounting the secou bare fueler 6o tile 1rst base member and wall member such that the flange of the wall member is trapped between the first and second base 20 members. The forming station preferably further comprises a form and means for retaining the components on the surface of the form as they are assembled together. In a preferred embodiment the retaining means comprises 25 suction means. The assembled tray may then simply be released, for example on to a conveyor belt, by switching off the suction means.

Preferably the forming station comprises a form and I a base plate, the form mounted to, and projecting from 30 the base plate to define a front face and sidewalls. I In this embodiment the form may thus act as a "mould'' for the tray, and its shape should thus be chosen to correspond to the desired shape of the finished tray. The wall member is then mounted around 35 the sidewalls of the form to give the wall the desired shape. Thus the wall member may be folded around the walls of the form, and the apparatus further comprises

means for so folding the wall member, for example pivotally mounted forming arms which engage the wall member and fold it around the form, with the flange then being arranged to extend inwardly over the form.

5 In this embodiment, the base plate conveniently acts a datum for locating one end of the wall member.

Preferably the depth of the sidewalls is variable to accommodate different heights of wall members and thus different depths of tray. This may be achieved most 10 conveniently by mounting the form to the base plate such I that the position of the form may be varied relative to the base plate. Variation of the depth of the sidewalls may then be achieved by movement of the base plate or the form. For example, in a preferred embodiment the 15 form is mounted within an aperture provided in the base plate, and the depth of the walls of the form may then be altered by varying the ntoullL by wiicr1 e form projects from the base plate. In this way, trays having walls of differing height may be produced without the 20 need to replace the form.

It is believed that such an arrangement is advantageous in its own right, and thus from a further aspect the present invention provides apparatus for forming a tray from a foldable sheet material, the 25 apparatus comprising a forming station for receiving a wall member of the tray, said forming station comprising a base plate and a form mounted therein; the form projecting from a surface of said base plate to define a I front surface and sidewalls; 30 wherein the position of the form relative to the I base plate may be varied to alter the depth of said projecting sidewalls.

As stated above, the tray components are assembled together with pressure to ensure an intimate contact 35 between the members and the ensure that adhesive is applied to the appropriate surfaces. Pressure may be applied to the assembled tray in any suitable manner.

- 8 - The pressure should be applied at least in the region of the interface to which adhesive is applied.

Advantageously the pressure is applied as part of the step of assembling the members to form the tray. For S example, the necessary pressure may be exerted by pressing the second base member against the first base member and flange as it is delivered to the assembly station. Alternatively, the pressure may be supplied in a separate step.

10 The adhesive may be applied to a surface of either I of the first or the second base member and/or to a surface of the flange of the wall member, and preferably to a surface of only one member most preferably to one of the base members. For ease of assembly, the adhesive 15 is preferably applied only to the second base member.

Adhesive may be applied to the relevant member or members at the assembly station. However, more preferably adhesive is applied to the members during delivery to the assembly station at an adhesive 20 application station. In the preferred embodiment, therefore, the second base member is transferred from its storage station to the assembly station via an adhesive application station.

In those embodiments where one of the base members 25 further comprises a window patch, adhesive should also be applied to the base member for attaching the window patch. Preferably adhesive for attaching the window patch is applied in the same operation as the I application of adhesive for holding the base members and 30 wall member together. Preferably therefore first and I second patterns of adhesive are applied to the base member. The adhesive may be of any suitable type and consistency to allow bonding of the members in 35 accordance with the present invention. Preferably the adhesive is a hot melt adhesive, and preferably the adhesive is applied in the form of a continuous bead.

The adhesive may be applied in any suitable manner, for example; by. srying or using a roller. In a particularly preferred embodiment, however, the adhesive is applied using an applicator having a profiled surface 5 for retaining a pattern of adhesive. The profiled surface preferably comprises a channel of a shape corresponding to the desired pattern of adhesive to be transferred to a surface. The quantity of adhesive transferred will depend upon the depth of the channel.

10 In the preferred embodiment therefore, the adhesive applicator comprises radially inner and outer channels.

Preferably the outer channel for bonding the members together is deeper than the second channel for bonding the window, as less adhesive is generally required for 15 this purpose.

In these embodiments, the retained adhesive is transferred to a surface by compressing the surface against the applicator. In a particularly preferred embodiment, the applicator is movable from a first 20 position in which it is dipped in adhesive, for example an adhesive bath, to receive adhesive to a second position where it is brought into contact with the base member. Preferably the applicator thus further comprises an adhesive bath, and in the first position 25 the profiled surface is immersed in the glue bath.

It is believed that this method of adhesive application is advantageous in its own right, and from a further aspect the present invention thus provides a method for applying a pattern of adhesive to a 30 substrate, the method comprising:.

providing an applicator having a profiled surface for retaining a pattern of adhesive; immersing the profiled surface in adhesive; moving the profiled surface out of contact with 35 said adhesive; and bringing the profiled surface into contact with the substrate thereby transferring adhesive retained by

- 10 said profiled surface to the surface.

According to a further aspect of the invention there is provided apparatus for applying a pattern of adhesive to a substrate, the apparatus comprising an 5 applicator having a surface movable between a first position in which it is immersed in adhesive and a second exposed position; wherein the applicator comprises a profiled surface for retaining a pattern of adhesive as said applicator TO is moved from said first to said second position. I The ends of the wall member are preferably arranged to overlap to form a continuous wall. In such cases, adhesive is preferably applied between the overlapping ends of the upstanding portion of the wall member.

15 Preferably this is achieved by a separate, second, applicator such as a jet or spray. Preferably the adhesive in applied walls bile wall -erwer is belrly moved from its storage means to the forming station.

In a particularly preferred embodiment the first 20 and second adhesive applicators share an adhesive supply, whereby the applicators may then be replenished as required from a common adhesive supply. This source may be arranged to be easily accessible to allow replenishing of the adhesive sources associated with the 25 first and second applicators without interfering with the assembly process. Preferably the common adhesive supply comprises the adhesive source associated with the second applicator. I Preferably the adhesive level of the first adhesive 30 applicator may be automatically replenished. Inthe I preferred embodiment this may be achieved by drawing adhesive from the adhesive source of the second applicator without the need to stop production in order to gain access to the adhesive source of the first 35 applicator. It is believed that this arrangement is advantageous in its own right, and thus from a further

aspect the present invention provides an adhesive application s'rstem. comprising: a first adhesive applicator having a store of adhesive and including means for sensing when the store 5 of adhesive in the first source of adhesive falls below a predetermined level, and a second adhesive applicator comprising a source of adhesive; wherein the store of adhesive for the first lO applicator is connected to the said source of adhesive; the apparatus further comprises means for delivering adhesive from said source to the said store when the level of adhesive of the store falls below the predetermined level.

15 A preferred embodiment of the present invention will now be described, by way of example only with reference to the accompanying drawings in which: Figure 1 illustrates a box comprising two trays in accordance with embodiments of the present invention; 20 Figure 2 is a schematic cut-away view illustrating in greater detail the interface between components of the lid in the circled region A of Figure 1; Figure 3 is a crosssectional view along the line 2-2 of Figure 2; 25 Figure 4 is a crosssectional view of the lid along the line 1-l of Figure 1; Figure 5 is the schematic plan view illustrating apparatus for assembling a tray in accordance with the present invention; 30 Figure 6 is a more detailed view of certain parts of the apparatus; Figure 7 is a more detailed view of the forming station of the apparatus of Figure 5; Figures 8 and 9 are top plan and cross-sectional 35 views of an adhesive application station of the apparatus; Figure 10 is a more detailed view of the moulded

- 12 surface of the adhesive applicator of Figures 8 and 9; Figure 11 is a cross sectional view alone the arrow 10-10 in Figure 10; Figure 12A is a more detailed view of a transfer 5 arm of the apparatus in a first position; Figure 12B is a cross-sectional view of the transfer arm in the first position along the line 12-12 of Fig. 12A.

Figure 13 is a more detailed view of the transfer 10 arm in a second position; and Figures 14 A-C are schematic end on views in the region of the wall member delivery means of the apparatus. Figure 1 shows a box 1 comprising two paperboard 15 trays embodying the invention. The trays define the lid 2 and base 2' of the box. The construction of the lid 2 will now be described ire none detail.

The lid 2 comprises a first windowed base member 4 a second windowed base member 5 and a wall member 6 The 20 caliper of the material used for the base and wall members 5, 6 is suitably in the range of 350 to 450 microns. The wall member 6 is in the form of a strip whose ends overlap to define a closed wall enclosing the first base member 4. An overlap of around 20mm is 25 typical.

The second base member 5 is similar in shape to the first base member 4, but is larger in size so that it extends beyond the wall 6 to define a rim 7.

A window 16 of a transparent plastics material is 30 adhesively joined to the lower surface of the second base member 5 by a bead of adhesive 18 and is sandwiched between the first and second base members, as shown in Figure 4.

As may be seen more clearly with reference to 35 Figures 2 to 4, the wall member 6 comprises an upstanding portion 8 and a flange 9 which is substantially perpendicular to, and arranged inwardly of

the upstanding portion 8. The flange 9 comprises a plurality of tabs 10 between which is defined a plurality of spaces ll. The tabs 10 extend between the first base member 4 (indicated by hashed lines in Figure 5 2) and the second base member 5. The flange 9 thus defines a first interface 12 with the first base member 4 and a second interface 13 with the second base member 5. The wall tabs are suitably square cut and of dimensions of 5mm x 12mm at lOmm pitch. However, the 10 most suitable dimensions will depend upon the shape of the walls.

A glue bead 14 extends along the surface of the first base member 4 in the region of the first interface 12. The flange 9 is thus joined to the first base 15 member 4 by means of the tabs 10 which contact the adhesive 14 at the first interface 12. The second base member b is adhesively joined to the first base member 4 by means of the adhesive exposed in the regions 11 defined between the tabs 10.

20 The base 2' is identical in construction to the lid 2, except that the first and second base members 4', 5' are not apertured, and no window is provided.

Figures 5 to 11 illustrate an apparatus for constructing trays in accordance with the present 25 invention. With reference to Figure 5, the apparatus comprises a first base member magazine 20 a second base member magazine 22, a window patch magazine 24. The second base member magazine 22 and window patch magazine 24 form a double magazine linked by slider 42. Wall 30 member supply means 26 is situated above the apparatus in the hashed area denoted in Figure S. The apparatus further comprises a first adhesive application station 28, a second adhesive application station 30, a forming station 32 and a conveyor belt 34 (in the dotted region 35 shown in Figure 5).

A transfer arm 36 is rotatable in a horizontal plane about an axis 37 located at the centre of the

apparatus. The transfer arm comprises first retaining means 38 and End retaining means 40 at opposite ends of the arm.

Figure 6 shows the conveyor belt 34, the rear of 5 the forming station 32 and wall member supply means 26 in more detail. The wall member supply means 26 comprises a wall member magazine 27 and wall member.

transfer means 50 comprising a plurality of vacuum arms 51. The vacuum arms S1 are rotatable about an axis 52 10 to transfer the planar wall members from the wall member magazine 27 to the forming station 32. The vacuum arms 51 are also movable linearly in the direction of the arrow AA. The wall member magazine further comprises a deflecting bar (not shown) for deflecting the tabs 10 of 15 the wall member 6 to form a flange 9 as described in [GOOD= A=t 1 h1 I., 1 1 k VY.

The forming station 32 comprises a base place 5 and a form 56 mounted within an aperture 58 provided within the base plate 54. Form displacement means 60 20 are provided for moving the base plate 54 backwards and forwards relative to the form 56 in the direction of the arrow B-B.

A more detailed front view of the forming station 32 is shown in Figure 7. The forming station 32 25 comprises base plate 54, form 56, and means for wrapping the wall member around the side walls 58 of the form 56. The wrapping means comprise a pair of pivotally mounted folding arms 76, a top clamp 79 and a bottom clamp 78. The form 56 has a front face 70 and 30 side walls 58. The front face further comprises,a number of openings 74 which are connected to a vacuum source for retaining components on the face as will be described further below.

The first adhesive application station 28 is shown 35 in more detail in Figures 8 and 9. The station comprises a glue bath 90 and an applicator 92 having a profiled surface. The glue bath 90 comprises means for sensing

- 15 the level of adhesive within it. The profiled surface is provided with a plurality of channels 94. The station 28 further comprises means 96 for raising and lowering the applicator 92 in the direction of the arrow 5 C-C so as to immerse the surface 94 in or lift it from the adhesive in the bath 90.

The profiled surface of the applicator 92 is shown in more detail in Figures 10 and 11. The profiled surface comprises first and second rectangular section 10 channels 94, 94' for retaining adhesive when the surface is raised out of the adhesive bath 90. The first channel 94 is for adhesive for adhering the base members 4, 5 and wall member 6 together and is deeper than the second channel 94' which is for applying adhesive to 15 attach the window patch 16.

The second adhesive application station 30 comprises an adhesive Jet supplied from a supply container (not shown), and mounted to an easily accessible part of the apparatus The adhesive supply 20 is also connected to the adhesive bath So of the first adhesive application station 28. When the levelof adhesive in the bath 90 falls below a predetermined level, adhesive is drawn from the supply container to replenish the bath 90.

25 The transfer arm 36 is illustrated in more detail in Figures 12A and B and 13. The arm comprises first retaining means 38 comprising a vacuum head 100 and second retaining means 40 comprising a vacuum head 102.

The vacuum head 100 is reciprocable along a line E-E by 30 means of sliding mechanism 101. The vacuum head-102 is reciprocable in the direction of arrow F-F by means of a sliding mechanism 104. The head 102 is also rotatable through 90 about pivot point 103 by means of pneumatic activating cylinder 105 from a generally vertical 35 position (as shown in Figures 12A and B) to a generally horizontal position as shown in Figure 13. The actuating mechanism is shown in more detail in Figure

- 16 12B. Operation of the apparatus described above to produce the windowed lid 2 will now be described.

At the beginning of a cycle, the transfer arm 36 is 5 positioned located such that the first vacuum head 100 is in a vertical position opposite the first base member magazine 22 and the second vacuum head 102 is opposite the second base member magazine 20. The slider 42 is located such that first base members 4 are presented for 10 removal from the magazine 22 by the vacuum head 102.

The transfer arm 36 then removes a first base member 4 from the magazine 20 by advancing the vacuum head 100 and a second base member 5 from the magazine 22 by advancing the vacuum head 102. The base members 4,5 15 are held on the heads by vacuum.

The -a=f= =m than rotate thrnugt qn .. antlalockwlse to the position illustrated in Figure 5, whereby the vacuum head 100 of the first transfer means 38 presents the first base member 4 to the forming 20 station 32 andthe second base member 5 is presented to the first adhesive application station 28.

The first base member 4 is transferred to the form 70 and held in place by the suction means 74. The vacuum head 102 then pivots down through 90 about pivot 25 point 103 by means of pneumatic actuating cylinder 105, to the horizontal position shown in Figure 13. At the same time the adhesive applicator 92 is raised out of the glue bath 90 to the position shown in Figure 9. In this way, the second base member 5 is brought into 30 contact with the profiled surface 92, adhesive being transferred to the member 5 from the channels 94, 94'.

The applicator is then lowered once more into the adhesive bath 90, and the vacuum head 102 pivoted upwardly once more.

35 At the same time as the first and second base members 4, 5 are being taken from the magazines by the transfer arm 36, a wall member blank 6 is being taken

- 17 from the wall member magazine 27 by wall member transfer means 50. The operation of the wall member transfer means 5G will now be described in more detail in relation to the end on views of Figures 14 A to 14 C. 5 The vacuum arms 51 engage the lower surface of the wall blank and then move a short distance vertically downwards in the direction of the arrow A in Figure 14 A to release the wall member 6 from the wall member magazine 27.

10 The wall members 6 are stored in the wall member magazine 27 with the tabbed part to the right of the magazine as shown in Figure 14A. As the wall member moves downwards, the tabbed edge engages the top surface 210 of a deflecting block 200, to provide an initial 15 pre-bending of the tabs. The vacuum arms 51 then move a short distance horizontally in the direction of the arrow B in Figure 14 forcing the tabbed edge below the surface 212 of the deflecting block 200 such that wall member 6 defines a flange 9 and overcreased portion 8.

20 The vacuum arms 51 then rotate through 180 about axis 52 in the direction of arrow C as shown in Figure 14C to present the wall member 6 (which is still planar at this stage) to the form 56 of forming station 32 and then moves forwardly so that its upstanding portion 8 25 overlies the apex of the sidewalls 58 of form 56 and the tabbed flange 9 overlies the first base member 4 which is already located on the front face 70 of the form. As the wall member 6 is being moved forward, a line of glue is sprayed onto one end of the wall member by the second 30 adhesive applicator 30.

Once the wall member 6 is so positioned, the central region of the wall member is held in place on the form wall 72 by means of the top clamp 79. The wall member is then wrapped around the side walls 72 of the 35 form 56 by rotating the folding arms 76 downwardly using the actuators 71. The overlapping ends of the wall

member 6 are clamped together by the bottom clamp 78, so bonding the ends together. After depositing the wall members on the form 56, the vacuum arms 51 return to their original position to pick up the next wall blank.

5 The transfer arm 36 then rotates anticlockwise through 90 to present the vacuum head 102 holding the base member 5 to the window magazine 24. The slicer, 42 moves so as to present a window patch 16 to the second base member 5 held on the vacuum head 102, and the head 10 102 moves forward to press the window patch 16 against the window, thereby picking up and adhesively joining it to the base member 5 using the adhesive transferred by the inner channel 94' of the first adhesive applicator 92. 15 The transfer arm 36 then rotates a further 90 anticlockwise to transfer urine second base member 5 with the window attached from the window patch magazine 24 to the forming station 32. The vacuum head 102 then extends towards the form 56 to compress the second base 20 member 5 against the wall member 6 and first base member already positioned on the form 56, thus forcing the adhesive applied to second base member between the tabs 10 of the flange 9 of the wall member 6 and into contact with the first base member 4.

25 The vacuum means 74 at the forming station is then released, and the vacuum head 102 retracted so as to move the assembled tray away from the form 56. The vacuum in the head 102 is then released allowing the assembled tray to drop onto the conveyor belt 34. The 30 transfer arm 36 then rotates a further 90 to its initial position to recommence the cycle.

The base 2' without a window is produced in the same manner as described above except that the profiled surface 92 of the first adhesive applicator only has an 35 outer channel 94. After presenting the second base member 5 to the first adhesive applicator, the transfer arm rotates through 180 degrees anticlockwise directly

- 19 to the forming station 32, without stopping at the window magazine 24. Although, the same piece of apparatus may be used to produce windowed and non windowed trays, preferably a separate machine is used 5 for each type of tray for speed of manufacture. The lids and bases may then be assembled, usually manually, to produce a finished box.

Although the components of the tray may generally be of any shape and size, it has been found that the 10 method is particularly suitable for forming a tray in which the base members of a size up to that of a rectangle of 375 mm high x 325 mm wide. Suitably the depth of the walls lies between 25mm and 75mm, and the wall length is between 300mm and llOOmm. The form 15 should is suitably of corresponding dimensions.

The movement of the various components of the appa-at-us rna-y be effected In any suitable manner' but for ease of manufacture, this is most easily done pneumatically. 20 Although the invention has been described in terms of a paperboard or cardboard tray, it can also be applied to ether materials such as plastics.

Claims

- 20 CLAIMS:

1. A tray comprising: 5 a first base member, a second base member, and a wall member comprising an upstanding portion and a flange arranged inwardly thereof, the flange being disposed between said first and second base members and 10 comprising or being formed as a plurality of spaced apart tabs, the base members and flange being adhesively joined to one another.

2. The tray of claim 1 wherein the first and second 15 base members are of different sizes and one of the base members extends beyond the wall to define a rim.

3. The tray of claim 1 or 2 wherein the wall member extends around the entire base to define a closed wall.

4. The tray of claim 3 wherein the ends of the wall member overlap and are adhesively joined together.

5. The tray of any of claims 1 to 4 wherein the tabs 25 extend substantially along the entire length of the wall member. 6. The tray of any of claims 1 to 5 wherein the first and second base members are apertured.

7. The tray of claim 6 further comprising a transparent window patch applied to one of said apertured base members.

35 8. A method for assembling a tray; the method comprising: providing a first base member, a second base member

- 21 and a wall member; the wall member having a flange provided with or formed by a plurality of spaced apart tabs; assembling the first base member, second base 5 member and wall member such that the flange of the wall member is disposed between said first and second base members, the flange thereby defining a first interface with the first base member and a second interface with the second base member; 10 wherein the method further comprises the steps of; applying adhesive at a said interface; and applying pressure to adhesively join the base members and the flange together.

15 9. The method of claim 8 wherein adhesive is applied to a surface of only one member.

10. The method of claim 9 wherein said member is a base member. 11. The method of any of claims 8 to 10 wherein the step of providing said members comprises delivering the members from respective storage stations to an assembly station. 12. The method of claim ll further comprising deflecting the flange of the wall member during delivery of the wall member from its storage station to the assembly station.

13. The method of claim 11 or 12 further comprising applying adhesive to an end of the wall member as it is delivered to the assembly station.

35 14. The method of any of claims 8 to 13 wherein the tray is assembled by mounting the base and wall members sequentially to a forming station.

- 22 15. The method of claim 14 wherein said forming station comprises a form and further comprising mounting the recall member around the side- of the form to shape the wall member.

16. The method of any of claims 8 to 15 further comprising applying adhesive to one of the base members for attaching a window patch.

lo 17. The method of claim 16 wherein adhesive for attaching the window patch is applied in the same operation as the application of adhesive for holding the base members and wall member together.

18. The method of any of claims 8 to 17 wherein adhesive is applied in the form of a continuous bead.

19. The method of any of claims 8 to 18 wherein said step of applying adhesive to the interface comprises 20 providing an applicator having a profiled surface for retaining a pattern of adhesive; immersing the profiled surface in adhesive; moving the profiled surface out of contact with said adhesive; 25 and bringing the profiled surface into contact with a surface of one of the members defining the interface thereby transferring adhesive retained by said profiled surface to the surface of said member.

30 20. A method for applying a pattern of adhesive to a substrate, the method comprising: providing an applicator having a profiled surface for retaining a pattern of adhesive; immersing the profiled surface in adhesive; 35 moving the profiled surface out of contact with said adhesive; and bringing the profiled surface into contact with

the substrate thereby transferring adhesive retained by said profiled surface to the surface.

21. An apparatus for assembling a tray; the apparatus 5 comprising: means for providing a first base member, a second base member and a wall member; the wall member having a flange provided with or formed as a plurality of spaced apart tabs; 10 means for assembling the first base member, second base member and wall member such that the flange of the wall member is disposed between said first and second base members, the flange thereby defining a first interface with the first base member and a second 15 interface with the second base member; wherein the apparatus further comprises; means for applying adhesive at a said interface; and means for applying pressure to adhesively join the base members and the flange together.

22. The apparatus of claim 21 further comprising means for storing the first base member, a second base member and a wall member, and means for delivering the members to an assembly station.

23. The apparatus of claim 22 further comprising transfer means for delivering the base members and wall member from their storage stations to the assembly station. 24. The apparatus of claim 23 wherein the transfer means is movable between storage, assembly and adhesive application stations.

35 25. The apparatus of claim 23 or 24 wherein the transfer means comprises a rotatable arm.

- 24 26. The apparatus of claim 25 wherein said arm further comprises retaining means at each end of the arm for retaining meters to be transferred.

5 27. The apparatus of claim 26 wherein at least one said retaining means is movable relative to the transfer means. 28. The apparatus of claim 27 wherein the retaining 10 means is rotatably and linearly movable relative to the transfer means. -

29. The apparatus of claims 27 or 28 wherein the retaining means is rotatable through around 90 degrees 15 from a generally vertical to a generally horizontal position. 30. The apparatus of any of claims 23 to 29 wherein the apparatus comprises separate transfer means for 20 delivering the wall member to the assembly station and transfer means for delivering the base members to the assembly station.

31. The apparatus of claim 30 wherein the wall member 25 transfer means comprises means for deflecting the flange of the wall member.

32. The apparatus of claim 30 to 31 wherein the wall member transfer means comprises a plurality of rotatable 30 vacuum arms.

33. The apparatus of any of claims 23 to 32 wherein the means for assembling the members comprises a forming station. 34. The apparatus of claim 33 wherein said forming station comprises a form and means for retaining the

- 25 members on the surface of the form during assembly.

35. The apparatus of claim. 33 -' 34 wherein the forming station comprises a form and a base plate, the form 5 being mounted to, and projecting from the base plate to define a front face and sidewalls.

36. The apparatus of claim 35 further comprising means for folding the wall member around the side walls of the 10 form.

37. The apparatus of claim 35 or 36 wherein the depth of the sidewalls of the form is variable to accommodate different heights of wall members.

38. The apparatus of any of claims 35 to 37 wherein the form is mounted within an aperture provided in the base plate, whereby the depth of the walls of the form may be altered by varying the amount by which the form projects 20 from the base plate.

39. The apparatus of any of claims 21 to 38 wherein the means for applying adhesive to the interface comprises an adhesive applicator having a profiled 25 surface for retaining a pattern of adhesive whereby the retained adhesive may be transferred to a surface of a member defining the interface by compressing the surface of the member against the applicator.

30 40. The apparatus of claim 39 wherein the adhesive applicator comprises radially inner and outer channels for applying a first pattern of adhesive to a base member for holding the base members and wall members together and a second pattern for attaching a window 35 patch to the base member.

The apparatus of claim 40 wherein the outer channel

- 26 for applying adhesive to bond the members together is deeper than the second channel for attaching the window patch. 5 42. The apparatus of any of claims 39 to 41 wherein the applicator is movable from a first position for receiving adhesive to a second position for contacting a member. 10 43. The apparatus of any of claims 39 to 42 wherein the applicator further comprises an adhesive bath, and in the first position the profiled surface is immersed in the glue bath.

15 44. The apparatus of any of claims 21 to 43 further comprising means for applying adhesive between overlapping ends of the wall member.

45. The apparatus of claim 44, comprising first 20 adhesive applicator means for applying adhesive to said interface for holding the base and wall members together and second applicator means for applying adhesive to said wall member as the wall member is transferred from a storage location to the assembly station.

46. The apparatus of claim 45 wherein the first and second adhesive applicators share an adhesive supply, whereby the applicators may be replenished as required from a common adhesive supply.

47. The apparatus of claim 46 wherein the common adhesive supply comprises the adhesive source associated with the second adhesive applicator.

35 48. The apparatus of any of claims 45 to 47 comprising means for automatically supplying adhesive to replenish the first adhesive applicator.

- 27 49. An apparatus for forming a tray from a foldable sheet material, the apparatus comprising a forming station for receiving a '',all member of the tray, said forming station comprising a base plate and a form 5 mounted therein; the form projecting from a surface of said base plate to define a front surface and sidewalls; wherein the position of the form relative to the base plate may be varied to alter the depth of said projecting sidewalls.

50. An apparatus for applying a pattern of adhesive to a substrate, the apparatus comprising an applicator having a surface movable between a first position in which it is immersed in adhesive and a second exposed 15 position; wherein the applicator comprises a profiled surface for retaining a pattern of adhesive as said applicator is moved from said first to said second position.

20 51. An adhesive application system comprising: a first adhesive applicator having a store of adhesive and including means for sensing when the store of adhesive in the first source of adhesive falls below a predetermined level, 25 and a second adhesive applicator comprising a source of adhesive; wherein the store of adhesive for the first applicator is connected to the said source of adhesive; the apparatus further comprises means for 30 delivering adhesive from said source to the said store when the level of adhesive of the store falls below the predetermined level.

52. A method for assembling a tray substantially as 3S hereinbefore described with reference to any one of the accompanying drawings.

- 28 53. An apparatus for assembling a tray substantially as hereinbefore described with reference to any one of the accompanying drawings.

5 54. A tray substantially as hereinbefore described with reference to any one of the accompanying drawings.

55. The tray, method, apparatus or any preceding claim wherein the tray is a paper or cardboard tray.