GB2443313A

GB2443313A - Blanks for tray-type packages

Info

Publication number: GB2443313A
Application number: GB0720659A
Authority: GB
Inventors: Roger Joseph Wonnacott
Original assignee: DS Smith Packaging Ltd
Current assignee: DS Smith Packaging Ltd
Priority date: 2006-10-24
Filing date: 2007-10-22
Publication date: 2008-04-30
Anticipated expiration: 2027-10-22
Also published as: GB0720659D0; GB2443313B; GB0621162D0

Abstract

A paperboard blank comprises a rectangular base panel (302) and first and second pairs of tapered side panels (304, 306). Corner gussets (380) are each connected to two of the side panels and foldable against one of the side panels (306). Side panels (306) of one of the pairs each have a side panel (360) formed therein. Each side panel (304) of the other pair has flaps (370) extending from opposed edges thereof, one or both of the flaps (370) having a flap hand-hold aperture (362) arranged to come into registration with one of the side panel hand-hold apertures (360) when the tray is erected and the flaps (370) are folded against the side panels (306) of said one of the pairs. The apertures (360, 362) may be clipped together to form the tray. An alternative tray (Figs. 1-5) is foldable into a small area, and another tray (Figs. 7-10) has self-erecting dividing walls.

Description

BLANKS FOR TRAY-TYPE PACKAGES

1]This invention relates to blanks and sets of blanks for forming packaging cartons or trays and cartons or trays formed from the blanks.

[OOD2JIt is an aim of the invention to provide trays of paperboard material useful in transporting goods from a store to a purchaser's home, in transporting recyclable waste materials, e.g. to a recycling point and capable of being recycled themselves.

3]From one aspect the invention provides a blank of stiff but foldable paperboard material for forming a tray, the blank comprising a rectangular base panel, first and second pairs of side panels each pair connected at base fold lines to opposite sides of the base panel and folded towards the base panel, corner gussets each connected to two of the side panels at fold lines, and foldable against one of the side panels, wherein ouiei portionG of the side panlc of one pair are folded against the remainder of said side panels of said one pair, and flaps extending from the other of the side panels of the other pair are attached to said outer portions of said side panels of said one pair.

4] In particular, there may be two outer portions in each of the side panels of said one pair. These outer portions may each be defined by an outer portion fold line running from point on an edge of the side panel at or near the corner gusset directly to an end point on the free edge of the panel opposite the edge defined by the base fold line. Said end point may be located at the centre of said free edge so that it is the end point of both outer portion fold lines.

[0005) From a second aspect the invention provides a set of blanks comprising a tray blank as described above and at least one divider blank for forming a divider for inserting into the erected tray to form compartments therein.

6] From a third aspect the invention provides a blank of stiff but foldable paperboard material for forming a tray, the blank comprising side panels joined in a series for forming sides of the tray when ends of said series are mutually connected, base sections each extending from one of said side panels for forming portions of a base of the tray, and divider portions each extending at a fold line from one of said base sections to form a wall of a compartment in said tray. For ease of use, the divider portions preferably lack any slots through which other such portions are to extend. Formation of the tray from the blank can be facilitated if one or more of the base sections is provided with a part folded against the remainder of the section and attached, e.g. by gluing, to another base section to bring both base sections substantially to right angles to the side panels.

The base sections may have different sizes or shapes to form compartments, e.g. substantially parallelepiped compartments, of different sizes in the tray. The base sections may be formed to partially overlap in the erected tray. The base sections and divider portions may be shaped to form compartment walls in the form of a letter "H" when viewed from above, two such divider portions being arranged to substantially coincide to form the central bar of the H and another two forming the verticals of the H when viewed as an H. Each of the two divider portions arranged to substantially coincide may have a flap arranged to lie against one of said other two divider portions, and optionally attached thereto e.g. by gluing.

7] The blanks for forming trays of the first and third aspects are preferably folded essentially flat with all panels coplanar. The attachment of the panels described above (as an option in the case of the third aspect) causes erection of the blank when the side panels of one pair are folded away from each other.

8] From a fourth aspect the invention provides a blank of stiff but foldable paperboard material for forming a tray, the blank comprising a rectangular base panel, first and second pairs of side panels each pair connected at fold lines to opposite sides of the base panel, corner gussets each connected to two of the side panels, and foldable against one of the side panels, the side panels of one of the pairs each having a side panel hand-hold aperture formed therein, and the side panels of the other pair having flaps extending from opposed edges thereof that are perpendicular to the base panel fold lines, one or both of the flaps having a flap hand-hold aperture arranged to come into registration with one of the side panel hand-hold apertures when the tray is erected and the flaps are folded against the side panels of said one of the pairs.

9] In one embodiment, the blank may be provided with a clip for retaining each side panel hand-hold aperture together with its respective flap hand-hold aperture(s). This can be a means of retaining the finished tray erect.

0] The side panels are preferably of tapering shape for forming a nestable tray.

1]From a fifth aspect the invention provides a set of blanks comprising a tray blank as described above and at least one divider blank for forming a divider for inserting into the erected tray to form compartments therein. The divider blank may be Iormed with d di.iideI base panal and four divider side panels connected to the divider base panel at fold lines. The divider blank may have corner gussets. These may be formed with engaging means such as notches or tabs for engaging features of the tray such as the flaps.

2]From a sixth aspect the invention provides a tray formed from any of the blanks or sets of blanks described above.

3] Particular embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which: [0014]Figure I shows a blank in initial form for forming a tray according to a first embodiment; [0015] Figure 2 shows the tray blank of Figure 1 in a step of folding the blank; [0016] Figure 3 shows the tray blank of Figure 1 in a folded state; [0017] Figure 4 shows the tray blank of Figure 1 in a partially unfolded state; [001 8]Figure 5 shows a tray formed from the tray blank of Figure 1; [0019] Figure 6 shows the initial form of a divider blank for use with the tray of Figure 5; [0020] Figure 7 shows a blank in initial form according to a second embodiment; [0021]Figure 8 shows the blank of Figure 7 in a folded state; [0022] Figure 9 shows the blank of Figure 7 in a partially unfolded state;

] Figure 10 shows a tray formed from the blank of Figure 7, (0024] Figure 11 shows a blank according to a third embodiment; [0025] Figure 12 shows a tray formed from the blank of Figure 11; [0026] Figure 13 shows a clip for use with the tray of Figure 11; and [0027] Figure 14 shows the initial form of a divider blank for forming a divider for use with the tray of Figure 11; [OO2RFigire 15 is a fraernentarv view of the blank of Figure 14 in place in the tray of Figure 12; and [0029]Figure 16 is a fragmentary view of a divider erected from the blank of Figure 14 in place in the tray of Figure 12.

(0030]Blanks according to the invention are cut from foldable board material such as double-faced corrugated paperboard along the lines shown as solid in the drawings of the initial forms and creased along the dotted lines.

1]Figure I shows a tray blank 100 having a rectangular base panel 102 from which side panels 104 and end panels 106 extend. Each end panel has two flaps 108 extending laterally from the panel, the flaps having tab parts 110 at the edges of the flaps furthest from the end panels 106 extending towards the side panels 104. The end panels have hand hold apertures 140 formed by curved cuts 142 and creases 144.

2]Gussets 112 are provided at each corner of the base panel. The gussets have a triangular side panel parts 114 formed as parts of the side panels 104, a side of the parts 114 almost parallel to the free edge of the side panel 104 being formed as a cut, and triangular flap parts 116 formed as parts of the flaps 108 between tab parts 110 and end panels 106.

3] Diagonal crease lines 118 run from the corners of the base panel 102 to the centres of the free edges of the side panels 104 thus dividing each side panel into three parts other than gusset parts 114 -namely an isosceles triangle with its base as one side of the base panel 102 and two outer parts 120.

4] In order to form a folded blank from the initial blank of Figure 1, a first one of the side panels 104 and its adjacent end flaps 108 are folded substantially flush against the base panel 102 and end panels 106 respectively. The outer parts of that flap are folded along crease lines 118 against the remainder of their side panel 104. The second side panel 104 is then folded against the first, folded side panel, which it overlaps in the centre of base panel 102 in this example, the final end flaps 108 also being folded against their end panels 106, and the outer portions 120 of the second side panel 104 are folded thereagainst. The partially folded blank is shown in Figure 2. The folding operations can be carried out in a different order to that just described or simultaneously, particularly if a machine is used.

5]It is then possible to fold the end panels 106 towards the folded side panels 104 and glue the folded end flaps 108 to the folded outer parts 120. In this example the end flaps just meet when folded together. The gussets 112 are also folded and glued. Preferably both triangular parts 114, 116 are attached together and the side panel parts 114 are further attached to the outside of side panel 104, but the attachment could alternatively be to the inside of the side panel and only some of these attachments could be performed.

6] The blank then appears in the compact flat folded state shown in Figure 3 in which state it is intended to be supplied to a user.

7] The user pulls the end panels 1106 upwardly, for example by means of the apertures 1140, which causes the flaps 108 to fold to a position perpendicular to the end panels, and pulls the side panels 104 into an erect unfolded position. The blank unfolds through the position shown in Figure 4 to form the tray of Figure 5.

8] Figure 6 shows a divider blank 150 of generally rectangular shape with a length approximately equal to the width of base panel 102 of tray blank 100.

Cut-outs 152 are provided on opposed sides of the blank. Wings 154 of the divider blank, each having one of the cut-outs, are folded upwardly and wing halves 156 are then folded towards each other across the centre of the blank. The wing halves 156 have tabs 158 which lodge in the cut-outs 152 to maintain the divider erect. One or more such divider blanks or dividers formed therefrom can be placed in the tray of Figure 5, optionally gluing it/them to the base panel 102.

The dividers can then be erected and collapsed together with the tray.

9] Figure 7 shows a blank 200 for forming an alternative tray. The blank has four panels, namely end panels 201, 203 and side panels 205, 207, joined in a series at fold lines, in a longitudinal direction of the blank, at least one of the panels (in this case a side panel 207) having a flange 209 at its free edge parallel to those fold lines. End panels 201, 203 have hand hold apertures 240 formed by curved cuts 242 and creases 244.

0] A first, relatively narrow, base panel 211 depends from end panel 201 and whilst generally rectangular has an edge 213 tapering away from the end panel.

A second base panel 215 depends from side panel 205 and has an angled edge 217 at its location nearest side 213 of first base panel 211, a shorter straight edge 219 transverse to the longitudinal direction of the blank, a longitudinal straight edge 221 and a convex curved edge 223 extending from longitudinal straight edge 221 to the junction of side panel 205 and end panel 203. A generally triangular tab 225 extends from angled edge 217.

1]A third base panel 227 depends from end panel 203 and is generally rectangular but has an edge 229 tapering away from the end panel. A fourth base panel 231 depends from side panel 207 and has a shape somewhat similar to that of second base panel 215 but without the shorter transverse edge. A generally triangular tab 233 extends from the angled edge of the fourth base panel 231.

2]Two divider panels 235, 237, called long divider panels in this example, extend from longitudinal free edges of first and third base panels 211, 227 respectively. The long divider panels are of the same size and shape in this example i.e. generally rectangular but widening slightly back to the length reduced by the tapering edges 213, 229 of the respective base panels.

3]Two further rectangular divider panels 239, 241, called short divider panels in this example, extend from the longitudinal edges of the second and fourth base panels 215, 231 respectively. All four divider panels 235, 237, 239, 241 have the same transverse dimension in this example although first long divider panel 211 is offset from the others. A divider flap 243, 245 extends from the transverse side of each short divider panel 239, 241 for about the same longitudinal extent as that of the respective tab 225, 233 of the second or fourth base panel 215, 231 respectively. The perimeter of divider flaps 243, 245 is arcuate nearest the tabs 215, 231.

4]To form a folded blank, the base panels 211, 215, 227, 231 and the divider panels 235, 239, 237, 241 are folded up against the series of panels 201, 205, 203, 207, without any relative folding of the divider panels relative to the base panels at this stage. Next triangular tabs 215, 231 are folded back against the second or fourth base panel 215, 231 respectively. Now end panel 201 is folded towards side panel 205, bringing first base panel 211 into contact with folded triangular tab 225, to which a part of first base panel 211 is glued. First base panel 211 is also in contact with second base panel 215 and long divider panel 235 is in contact with second base panel 215 and short divider panel 239.

5]Side panel 207 is now folded towards end panel 203, bringing folded triangular tab 233 into contact with part of third base panel 227 to which the tab is glued. Fourth base panel 231 contacts third base panel 227 and short divider panel 241 and its divider flap 245 contact long divider panel 237, the flap 245 being glued to the long divider panel. Flange 209 is then glued to end panel 201.

and the blank then appears in the compact flat folded state shown in Figure 8 in which state it is intended to be supplied to a user.

6] To unfold the blank into a tray the user pulls the end panels 201, 203 by means of their apertures 240 into a position in which the series of panels 201, 205, 203, 207 forms a rectangle. Thus the blank passes through the position shown in Figure 9 and forms the tray of Figure 10. During this process the attachment of the triangular tabs 225, 233 to the first and third base panels 211, 227 respectively causes all four base panels 211, 215, 227, 231 to come to right angles to the end and side panels 201, 205, 203, 207 and form a base of the tray. The arcuate parts of second and fourth base panels 215, 231 slide under ends of the third and first base panels 227, 211 respectively. At the same time the divider panels 235, 237, 239, 241, and divider flaps 243 come to right angles with the base panels and form compartment walls in an H-shape, with short divider panels 239, 241 lying against each other in the centre of the tray and divider flap 243 lying against long divider panel 235.

7] The trays of Figures 5 and 10 can be collapsed back to the folded blanks of Figures 3 and 8 respectively for transit when empty or for recycling. It will be appreciated that the area of the collapsed blanks is no greater than the area of the bases of the trays.

8]Figure 11 shows a blank 300 for forming a non-parallelepiped nestable tray. The blank has a rectangular base panel 302 from which side panels 304 and end panels 306 extend. The side and end panels each have two parallel edges one forming the crease line with the base panel but the remaining edger not parallel, as the side and edge panels widen slightly in the direction away form the base panel 302. Each end panel has two end flaps 308 extending laterally from the panel. The end panels 306 have substantially rectangular end hand hold apertures 360.

9] Side flaps 370 extend from the non-parallel edges of side panels 304. The side flaps generally taper in the direction away from the side panels and in this example each side flap 370 has an edge touching one edge of one of the end flaps 308. Each side flap 370 has a substantially rectangular flap hand-hold aperture 362.

[00501 A triangular gusset part 380 is formed in the area between the end panel 306, end flap 308 and side flap 370, joined to the end panel 306 and side flap 370 at fold lines.

1]The blank of Figure 11 may be supplied in this state to a user who folds the blank into the tray shown in an almost-finished form in Figure 12. This is achieved by folding the side and end panels 304. 306 to an almost vertical position and folding the side flaps 370 and gusset parts 380 either outside (as shown) or inside the end panels 306 so that the flap hand hold apertures 362 register with the end hand hold apertures 360. End flaps 308 are folded inside side panels 304 if the side flaps 370 and gusset parts 380 are folded outside the end panels 306 and vice versa. The user is also supplied with two clips, for example of the known type shown in Figure 13. These have a tubular outer portion 402, wings 404 joined to the tubular portion by living hinges and a closure part 406 with an aperture therein, hinged to the tubular portion 402. The tubular portion 402 is placed through the registering apertures 360, 362 and when the closure part 406 is latched to the tubular portion it pushes wings 404 outwards to secure the clip in place, secure the panels 306 to the flaps 370 and maintain the tray erect. The clips are reusable in a new blank once a first blank is recycled.

2] In an alternative version the tray of Figure 12 is supplied erected -for example a large number of such trays can be nested in a stack. In this version the side flaps 370 and optionally the gusset parts 380 can be glued to the end panels 306 and the end flaps 308 can be glued to the side panels 304.

3]Figure 14 shows a blank for a divider for the tray of Figure 12. A rectangular divider base panel 390, with a length equal to or slightly less than the width of base panel 302, has divider end panels 391 extending from ends thereof and divider side panels 392 extending from its sides, Divider side panels 392 each have diagonal crease lines 393 extending from corners of the divider base panel 390 to recesses 397 in the centre of the free edge of the divider side panels.

Divider gussets 394 are formed in the corners of the divider blank between divider end panels 391 and divider side panels 392. In this example, each divider gusset is divided into three parts by crease lines radiating from the corner of the divider base panel 390. A notch 395 is formed in the corner of each gusset.

4]The divider blank cart be placed in the tray of Figure 12 as shown in Figure 15 -the tray being formed with side flaps 370 on its inside -transverse to the tray with the divider end panels 391 and gussets 395 folded approximately at right angles to the base panel 390 or at the same angle thereto as the angle between side panels 304 and base panel 302 of the tray. The free edge of divider side panel 392 cart abut the junction of tray base panel 302 and end panel 306.

Divider base panel 390 can be glued to tray base panel 302. To erect the divider, a user pulls recesses 397 upwardly and toward the centre of the tray and the divider is held erect in the position of Figure 16 with notches 395 engaging with side flaps 370. Apart from the interior of the divider, the tray is then divided into small and large compartments on either side of the divider.

5]The corner gussets of the trays of Figures 5 and 12 and in the divider of Figure 16 prevent or alleviate leaks in case of liquid spillages in the trays.

(00561 References to gluing in the foregoing description are made for brevity and should be interpreted to include attachment generally including by means such as stapling or the use of self-adhesive strips.

Claims

1. A blank of stiff but foldable paperboard material for forming a tray, the blank comprising a rectangular base panel, first and second pairs of side panels each pair connected at fold lines to opposite sides of the base panel, corner gussets each connected to two of the side panels, and foldable against one of the side panels, the side panels of one of the pairs each having a side panel hand-hold aperture formed therein, and each side panel of the other pair having flaps extending from opposed edges thereof that are substantially perpendicular to the base panel fold lines, one or both of the flaps having a flap hand-hold aperture arranged to come into registration with one of the side panel hand-hold apertures when the tray is erected and the flaps are folded against the side panels of said one of the pairs.

2. A blank according to claim 1, provided with a clip for retaining each side panel hand-hold aperture together with its respective flap hand-hold aperture(s).

3. A blank according to claim 2, wherein the clips are a means of retaining the finished tray erect.

4. A blank according to claim 1, 2 or 3, wherein the side panels are of tapering shape for forming a nestable tray.

5. A set of blanks comprising a tray blank according to any of the preceding claims and at least one divider blank for forming a divider for inserting into the erected tray to form compartments therein.

6. A set of blanks according to claim 5, wherein the divider blank is formed with a divider base panel and four divider side panels connected to the divider base panel at fold lines.

7. A set of blanks according to claim 5 or 6, wherein the divider blank has corner gussets.

8. A set of blanks according to claim 7, wherein the gussets are formed with engaging means such as notches or tabs for engaging features of the tray such as the flaps.

9 A blank of stiff but foldable paperboard material for forming a tray, the blank comprising a rectangular base panel, first and second pairs of side panels, each pair connected at base fold lines to opposite sides of the base panel and folded towards the base panel, corner gussets each connected to two of the side panels at fold lines, and foldable against one of the side panels, wherein outer portions of the side panels of one pair are folded against the remainder of said side panels of said one pair, and flaps extending from the other of the side panels of the other pair are attached to said outer portions of said side panels of said one pair.

10. A blank according to claim 9, having two outer portions in each of the side panels of said one pair.

11. A blank according to claim 10, wherein these outer portions are each defined by an outer portion fold line running from a point on an edge of the side panel at or near the corner gusset directly to an end point on the free edge of the panel opposite the edge defined by the base fold line.

12. A blank according to claim 11, wherein said end point is located at the centre of said free edge so that it is the end point of both outer portion fold lines.

13. A set of blanks comprising a tray blank according to claim 10, 11 or 12 and at least one divider blank for forming a divider for inserting into the erected tray to form compartments therein.

14. A blank of stiff but foldable paperboard material for forming a tray, substantially as described herein with respect to Figures 2 and 3, or Figure 7, or Figure 11 of the accompanying drawings.

15. A tray formed from a blank or set of blanks according to any preceding claim.

16. A blank of stiff but foldable paperboard material for forming a divider for inserting into a tray, substantially as described herein with reference to Figure 6 or Figure 14 of the accompanying drawings.