GB2518519A

GB2518519A - Corrugated pusher

Info

Publication number: GB2518519A
Application number: GB1414725.0A
Authority: GB
Inventors: James Mcdonald; Andrew Thompson; Gert De Smedt; Fredrik Jacobsson
Original assignee: DS Smith Packaging Ltd
Current assignee: DS Smith Packaging Ltd
Priority date: 2012-07-03
Filing date: 2012-07-03
Publication date: 2015-03-25
Also published as: CA2898395A1; DK2870073T3; UA123620C2; JP2015527105A; PT2870073T; RU2697543C2; HUE036032T2; SG10201702787PA; GB201300373D0; GB2527438A; GB2527438A8; GB2503677B; US10758061B2; RU2015103212A; SG10201702789WA; GB2503759A8; UA115065C2; SG11201408841TA; GB2503677A; GB201414725D0

Abstract

A method of forming a tray with a product pusher comprising feeding a resilient band across a face of a blank either before or after it has been formed into a tray and inserting products into the tray such that the web wraps partially around the products in a stretched state. A machine may be used to complete assembly of the tray and may employ means to feed the band across the front of the tray, a device to stretch the band to the back of the tray and hold it in tension, rods to hold the band in position and means to load the tray. Also disclosed are a tray with a product pusher formed from a single fabric or material which may be elastic. The tray may have a lid and be formed from a corrugated material.

Description

Product Pusher The present invention relates to product pusher, a product tray or box comprising such a product pusher, and a process for the assembly of said product tray or box comprising said product pusher, for assisting with the proper display of items on shelves in supermarkets and in other shops.

It is well known to provide products that are intended for sale in shops, such as in supermarkets, on trays or in boxes for displaying those products on the shelves within the shop. However, there is a developing trend to display the products in those trays or boxes in an aesthetic manner, such that they are stacked towards the front of the shelf so as to maximise the ease with which consumers can identify and collect their products -products recessed towards the back of the shelves are harder to see and harder to collect.

Much of the time, this forward-stacking is carried out by an in-store shelf stacker, i.e. an employee, who manually moves the front-most product, and any products behind it, forwards, i.e. either to or towards the front of the shelf. However, in addition to manual arrangements, there is an increasing occurrence of automated stacking, i.e. products that self-stack towards the front of the tray or box, ready for removal from the tray or box. Such products often rely upon gravity, such as by using angled racks or shelves -consider, for example, herb bottle dispensers, or by relying upon the biasing effect of a resilient biasing means coupled to a pusher that is located behind the products -see, for example, DE20316963 or EP1462034, and napkin holders or cup dispensers found in fast food outlets. These prior art arrangements, however, can significantly increase the production cost of the tray or box due to the reliance upon complex manufacturing processes.

It would be desirable, therefore, to provide a tray or box that can automate the front-stacking of products, but in a very low cost manner.

The present invention provides a product tray comprising a product pusher, wherein the product pusher is formed from just a single fabric or material, and is arranged to apply a resilient bias force to the rear surface of products contained within the tray.

The term pusher is used throughout the specification to describe devices that can apply a resilient bias force to the products. However the term pusher is also intended to encompass devices which apply a resilient bias force to products via a catapult motion or likewise via a pulling' motion. Thus a pusher can equally be described as a puller -the words being interchangeable in the present case's context.

The use of a single fabric or material simplifies the manufacturing process since the number of components made of different materials, used for assembling the pusher component, is reduced -no separate product pushing plate and no separate elastic bands or springs for driving it, are required to be connected or mounted together when assembling the pusher, whereby a reduced number of pieces of equipment are required in the assembly line.

The single fabric or material may be a length of resilient tape, such as a rubber, silicon or elastic strip. Preferably, the resilient tape is made of clear elastic or shirring elastic, e.g. knitted shirring elastic.

The single fabric or material may be attached at or towards its ends to the product tray, for example on the sides of the tray -preferably not the internal sides of the tray.

The pads of the product tray to which the ends are attached may be folded flaps, and are preferably flaps that will ultimately be folded outwardly and backwards from the sides. However, the flaps may also be folded inwardly and backwards from the sides.

Preferably the single fabric or material is applied to surfaces of the tray that at the time of application are lying in a common plane. Thereafter the surfaces can be folded backwardly relative to and against the sidewalls of the tray. The surfaces are preferably flaps that are integral to the sidewalls of the tray.

Preferably the surfaces are attached to the sidewalls upon folding them backwardly to secure them in place against the sidewalls. They might be folded inwardly or outwardly.

The pads of the product tray to which the single fabric or material is attached may be concealed by concealing flaps. This can be to make the single fabric or material non visible to the consumer, i.e. when removing a product from the tray, e.g. from the front of the tray, and while product is contained within the tray.

The attachment of the surfaces, flaps and/or single fabric or material could be using an adhesive or one or more staple, and is preferably done using the same means of attachment as used for holding other flaps of the tray, i.e. when folding/assembling the blank from which the tray is assembled. Alternatively, the flaps and/or single fabric or material could be secured by the use of a toggle such as a treasury tag or loop.

The flaps of the product tray to which the single fabric or material is attached may be folded back and held in position by a lid without the need for them to be adhered to the body of the tray.

The single fabric or material may be supplied from a roll.

The single fabric or material may be a length of elastically stretchable fabric or material, arranged to wrap behind and to the sides of products contained within the tray to apply the resilient bias force to the rear surface of those products.

Preferably it is applied to the tray by an automated tape feeding machine. The tape feeding machine can be located in line within a blank folding/tray erecting machine.

Preferably, the elastically stretchable fabric or material would have a backing material to act as a means of transfer to enable said material to be driven through a tape feeding machine without subjecting the tape to tensional forces.

In an alternative arrangement, the attachment of the pusher to the tray or box might be simply achieved by having clips on the ends of a length of elastic webbing, or some other such stretchy fabric or material. This would then facilitate for example a manual attachment by a customer, thus allowing a set of blanks and a set of pushers to be provided and assembled easily by the customer.

In another embodiment, the pusher may comprise two inter-engaged webs, each web comprising two hinge lines and three inter-engagement slots, the two hinge lines being oppositely bent and the three inter-engagement slots interlinking with the opposing inter-engagement slots on the other web. This pusher is preferably not attached to the tray, but instead simply sits within the tray.

Preferably the elasticity of the material or structure of the webs provides the resilient bias of the pusher.

Preferably the inter-engagement of the slots is provided with an interference fit upon compression of the pusher in a concertina fashion, whereupon the fit and material structure provides a resilient bias for the pusher.

Preferably the hinge lines provide a resilient bias.

No additional, separate, resiliently biasing means is provided -such as rubber bands or springs: due to the provision of two hinge lines on each web, rather than just one, and due to the bias provided by the inter-engagement of the inter-engaging slots, the material of the webs, and the structure of the webs, a sufficiently high biasing force is generated purely from the folded webs, to provide a product stacking effect as products are removed from the tray by a consumer, especially if the shop mounts the tray, on the shelf within the shop, with a raised back, such that gravity can also assist with the stacking effect. The additional biasing means of the prior art therefore becomes unnecessary.

Preferably the webs include folded sides so as to double the thickness of parts of the webs. This can improve the resilience of the webs.

Preferably one side that is folded extends the full length of the web. Preferably that side is the side spaced from the inter-engagement slots.

Preferably the side featuring the inter-engagement slots has folded portions between the slots, but no folded portions outside the outermost slots. The folded portions can provide additional resilience to the hinge lines, whereupon an additional biasing force can be provided to products within a box by the pusher.

Preferably the folded portions are adhered down although that is optional.

Preferably the pusher is formed from just two blanks. Preferably the two blanks are cut from a single sheet.

Preferably the pusher is formed from cardboard.

Preferably the pusher is formed from a corrugated material.

In a preferred configuration, the corrugations are oriented such that they run with their parallel axes extending perpendicular to the hinge lines. This configuration allows the corrugations to offer a sufficient bending stiffness for the pusher to this increase the bias-force provided thereby.

Preferably the tray is formed from one or more corrugated sheet of material. Preferably it comprises card, i.e. cardboard. It might alternatively be formed of plastic, corrugated plastic, non corrugated cardboard or metal.

The tray may comprise a lid or top, which lid or top may be a separate component, and thus readily removable therefrom, or integral to the tray but perforated relative thereto for simple removal, or partial removal, therefrom.

A divider -a division -may be provided for the tray to divide the product area into more than one chamber. A separate pusher may be provided for each chamber, although a single resilient strip may bridge both chambers, thereby requiring no additional strip-end attachments compared to a non-divided tray arrangement.

The divider may be a separate component. Preferably it is inserted before the pusher is applied to the tray.

The present invention also provides a corrugated pusher as defined above, rather than specifically a tray or a box comprising such a pusher, and also a blank or a pair or blanks for forming the above corrugated pusher, and also a method of self stacking of products comprising the provision of a tray or box as defined above, loaded with products.

The present invention also provides a product tray comprising a product pusher, wherein the product pusher is formed from a length of elastically stretchable fabric or material, and is arranged to wrap behind and to the sides of products contained within the tray to apply a resilient bias force to the rear surface of those products contained within the tray.

This tray can additionally comprise other features as described above.

The present invention also provides a method of assembling a tray having a product pusher, comprising: folding a blank to form at least part of a tray, feeding a resilient web across a face thereof, and inserting products into the tray such that the web wraps partially around the products in a stretched state.

After applying the web, the blank may then be further folded to complete the forming of the tray, assuming that the initial folds did not already do so, and/or additional pads can be applied to complete the tray, or to add a lid or an outer wrapping therefor. This might occur either before or after inserting the products, the timing generally being dependent upon the design thereof.

Preferably the face is a front face. In another embodiment it is preferably a top face.

The face is typically one for receiving or removing products therethrough. For example it can be an open face, or it may be partially open, or it may even be a closed face, e.g. with a removable section. Alternatively it may define a barrier for products, whereby products are resisted from further advancement upon being biased thereagainst.

Products may then be inserted or removed through a different face.

Preferably the web is applied to the face of the tray in a minimally tensioned, or non-tensioned condition, such that it gets put into the stretched state by the insertion of the products.

Preferably the web is applied to the face of the tray via one or more foldable tab.

Preferably the one or more foldable tab holds the web during insertion of the products.

The present invention also provides a method of assembling a tray having a product pusher, comprising: providing a blank for forming at least part of a tray, feeding a resilient web across a face thereof, folding the blank to form at least part of the tray; and inserting products into the tray such that the web wraps partially around the products in a stretched state.

After folding the blank, the blank may then be further folded to complete the forming of the tray, assuming that the initial folds did not already do so, and/or additional parts can be applied to complete the tray, or to add a lid or an outer wrapping therefor. This might occur either before or after inserting the products, the timing generally being dependent upon the design thereof.

A folding step may also occur prior to the feeding of the web across the face of the blank, e.g. to displace a tab out of the plane of the blank. The folded part may present the face ready for receiving the web.

Preferably the web is applied to the face of the blank in a stretched condition.

Preferably this arrangement is such that it gets relaxed at least to a certain degree upon folding the blank to form at least part of the tray.

Preferably the web is attached to the blank via one or more foldable tab. Preferably the one or more foldable tab holds the web during the folding of the blank so as to cause the web to remain in a stretched condition after folding the blank to form at least part of the tray. This second stretched condition is likely to be slightly relaxed compared to the initial stretched condition.

In either method, one or more glue bead may be applied to the blank before feeding the web. The glue bead or beads may be for securing the web, or for securing folded parts of the blank.

Preferably the web, in the stretched state, wraps behind the products. In another embodiment in the stretched state it wraps under the products.

Preferably the products are generally cuboid, i.e. each having a front, a back, a top, a bottom, a left side and a right side, i.e. six sides, or the products have a section having four sides. Preferably that section is generally square, generally rectangular or generally trapezoidal. Products with other sections, e.g. triangular or round or multi-sided, e.g. with more than four sides to its sectional shape, or with non-consistent or non regular sectional shapes, are also anticipated to be useable with the present invention.

Preferably the web wraps around three sides of the product.

Preferably the or each product has between one and four sides in a section defined by the approximated line followed by the wrapped web. The sides need not be flat, i.e. they may be curved.

Preferably a length of resilient web is drawn from a roll mounted on a motorised shaft by a pair of mechanical grippers.

Preferably, the length of resilient web is attached to the front of the tray, or to the blank, by means of a transfer device.

Preferably, prior to inserting the products into the tray, the resilient web is stretched around the inside (e.g. left and right sides, and the back wall) of the tray with a tension guide. Preferably, the tension guide is withdrawn from the loaded tray after inserting one or more product.

Preferably, the products are side loaded into the tray. Alternatively they might be top or bottom loaded into the tray.

Preferably, a lid or top is fitted to the tray. The lid or top may be an integral part of the blank, or it may be formed separately. If formed separately, it might be glued to the blank. Depending upon the design, that could occur either before or after the folding, or at some point mid way through the tray (or box) forming process.

Preferably the lid or top is separable from the tray or box, e.g. by having severable glue attachments (e.g. small glue beads) or simply through a friction fit, or via severable perforations in the material of the blank or lid (or top).

Preferably removal or separation of the top or lid from the tray or box releases at least one tab, thus releasing the web to allow it to resiliently bias towards a more relaxed condition, thus applying a biasing force against one or more of the products.

Preferably the blank is folded to form a front for the tray after the products are inserted.

These and other features of the present invention will now be described in further detail, purely by way of example, with reference to the accompanying drawings, in which: Figure 1 shows in plan view two blanks for forming the two webs of the pusher of the present invention; Figure 2 shows the two blanks after folding edges thereon; Figure 3 shows the two webs bent at their hinge lines ready for inter-engagement; Figure 4 shows the commencement of the inter-engagement of the respective slots on the two webs; Figure 5 shows the assembled arrangement in an expanded configuration; Figures 6 to 8 show the pusher being compressed into a collapsed configuration -the configuration it will adopt when located within a tray or box during transportation of products to a retail outlet; Figures 9 to 11 show the pusher of the present invention in use, pushing products forwards within a product delivery box; Figure 12 shows a cut and crease layout for forming the two webs of the present invention from a single sheet of material; Figures 13 to 21 show a further embodiment of the present invention in which the pusher takes the form of an elasticated tape and the products are side-loaded into the tray; Figures 22 to 29 show a variant of the embodiment over Figures l3to 21, but in which a divider has been inserted into the tray; Figures 30 and 31 show a variant of the embodiment over Figures 22 to 29 in which a lid covers the product box and conceals the side flaps and resilient tape, similar to the box in Figure 11; Figures 32 to 39 the same embodiment of the product tray shown in Figures 13 to 21, but in which pusher tension is established prior to product loading; Figures 40 to 50 show another embodiment of the present invention in which the pusher tape is retained by a holding clamp, the holding clamp being released by removal of a tear off portion in the back wall of the tray, and in which the tray has a removable lid, connected by a line of perforation; Figures 51 to 63 show a variant of the embodiment over Figures 40 to 50 in which the removable lid is separate to the tray; Figures 64 to 76 show a method of assembling a product box/tray comprising a product pusher which takes the form of an elasticated tape wherein products are side-loaded into the box; Figures 77 to 79 show a variant of the embodiment over Figures 64 to 76, but in which the products are top loaded into the box/tray; Figures 80 to 85 show a variant of the embodiment over Figures 64 to 76 which prevents the upward movement of tape upon removal of a tension guide insert; Figures 86 to 88 show a variant of the embodiment over Figures 80 to 85, but in which the products are top loaded; Figures 89 to 100 show a variant of the embodiment over Figures 40 to 50, using a U shaped device to expand a pusher tape or web; and Figures 101 to 113 show a variant of the embodiment over Figures 40 to 50, or 89 to 100, in which a lid is formed from a separate blank, and integrated into the folding/loading process.

Referring first of all to Figures 1 to 12, this first embodiment of the present invention relates to a corrugated pusher for insertion into a product tray such as that shown in Figures 9 to 11. Other forms of box or tray will also be suitable for accommodating the pusher.

The tray 20 is sized to accommodate numerous products 22, in this case chocolate bars. The products 22 are arranged within the tray in an edgewise veitical orientation such that they stack backwardly towards a corrugated pusher 10 located behind them and within the tray 20. The pusher 10 thus is able to push the products 22 towards the front 24 of the tray 20.

Towards the front 24 of the tray 20, an opening 26 is provided. This opening is provided by means of a rip-off part of the lid (not shown since it has been removed) which was perforated along its edge for simplified removal from the tray 20. That perforation is evidenced by the remaining tags 28 on the leading edge of the top 30 of the box or tray 20. See Figure 11.

Referring again to Figure 1, two blanks for forming the corrugated pusher 10 are shown. These blanks are a first blank 32 and a second blank 34, which blanks are mirror copies of each other.

Each blank comprises two hinge lines 14, three inter-engagement slots 16 and various fold lines 36 by means of which the finally folded portions 18 can be folded over the webs 12 to double the thickness of the receiving parts of the webs 12.

Along one edge of the two webs 12, the folded portions 18 extend along the full length of the webs, whereas along the other edges of the webs, the folded portions 18 extend only partway along the length of the webs 12.

Figure 2 shows the two webs 12 in their initial folded condition -with the two folded portions 18 now folded over the central length of the webs 12. The two webs 12 are still mirror versions of each other.

Figure 3 then shows the two webs 12 upon folding them about their hinge lines, again in a mirror like fashion such that the inter-engagement slots 16 of each web 12 can intermesh as shown in Figure 4 to foirn a concertina arrangement. Figure 4 also clearly shows the corrugation of the material from which the webs 12 are made -look within the inter-engagement slots 16. This corrugated structure of the webs is helpful for providing resilience to the corrugated pusher 10 upon completion of the assembly thereof as shown in Figures 5, 6, 7 and 8, and to achieve the best effect, the direction of the corrugation should be perpendicular to the inter-engagement slots, as shown in Figure 12 by the cutaway triangle 38.

Figure 12 also shows preferred sizes for the corrugated pusher 10 in mm, although other sizes would of course be possible, for example where longer or smaller pushers are wanted. Even longer pushers can be provided by providing a longer web, and additional inter-engagement slots and hinge lines -such longer webs may be more preferred to scaling up the relevant dimensions.

For a pusher with an at least 20% longer effective reach, the corrugated pusher might comprise four inter-engagement slots on each web and three hinge lines, and more such inter-engagement slots and hinge lines can be provided to make the pusher even longer, although the thickness of the compressed pusher will correspondingly increase too. Nevertheless, the additional concertinas resulting therefrom will increase the effective resiliently biasing reach.

From the above, it will be appreciated that there is one less hinge line than inter-engagement slots on each web. Further, the pusher should not have fewer than two hinge lines and three inter-engagement slots so as to ensure an effective resilient bias can be provided for the intended reach of the pusher.

Referring next to Figures 13 to 21, a further embodiment of the present invention is shown. In this embodiment, again a tray 20 is provided and in Figure 13 it is shown to be already partially assembled, with the side walls and back wall already folded upright and glued at their jointing tabs 40. For that purpose it is usual that a hot-melt glue is used for the attachment. However, other adhesives or joining means, such as staples, are also able to be used.

The front of the tray 40 is not yet assembled, and although the tray is not fully assembled, flaps 42 arranged near the front of the tray 20 are shown part folded so as to lay in a common plane with respect to one another.

The flaps 42 provide forward facing surfaces onto which the pusher of this second embodiment can be mounted. This pusher 44 of this embodiment takes the form of a web of resilient material, such as a silicon strip or an elastic ribbon, and preferably it is a band, strip or web of very stretchy fabric that has been cut from a reel 46 thereof, e.g. shirring elastic.

For achieving the mounting of the pusher, the tape or web or the like is fed across and glued or otherwise attached to the flaps 42, e.g. by an automated arm on the assembly machine. As with the first embodiment, no other components are required for forming the pusher -it just consists of the tape or web. Preferably, the tape is of an appropriate or predetermined length chosen so that once affixed to the tray there is minimal slack or droop in the tape. However, it may be envisaged that for product trays of a significant depth, thus requiring a significant degree of stretch or length in the web to allow the web to fully extend into the back of the tray, or when the product may itself be relatively deep, thus requiring less web travel from its rearmost location to push a rearmost product to the front of the tray, the tape might be affixed to the tray with a certain degree of slackness. This then assists in ensuring that the web will stretch adequately around the inserted products, even if a less stretchy material is used -i.e. one that can stretch only to a lesser percentage of its initial relaxed length, many of which materials can provide a greater elastic return force per unit percentile extension.

The end of the tape or web is then cut and the flaps are folded backwards and are attached to the sides of the tray, such as again by gluing. See Figure 15.

Other adhesives, staples, treasury tags and the like are also able to be used instead.

By folding the flaps backwards, some of the tensional force is taken by the body (around the crease) of the tray rather than purely by the adhesive holding the tape to the flap. This can improve reliability from breakage of the bond between the tray and the tape.

Products 22, in this case six boxed items, are then pushed into the tray 20 so as to stretch the resilient, highly elastic tape that forms the pusher 44. The tape or web extends around the back of, including around the left and right sides of, the products 22 so as to assume the condition of Figure 17. The front flaps 48 are then folded up relative to the base of the tray so as to retain the products 22 within the tray 20, as shown in Figure 18.

Sides 50 of the front flaps 48 are then folded back and attached to the flaps 42, and also to the ends of the pusher 44 that are attached thereto, preferably again by gluing.

That then conceals the ends of the pusher 44, as shown in Figure 19. This presents a tidy finish to the assembled tray.

From this completely assembled tray, a front product 22 can be removed as shown in Figure 20 which results in the more rearward products being advanced by means of the tension in the elastic of the pusher 44. Figure 21 shows the condition arrived at after three products have been removed.

In this embodiment, the side walls 52 of the tray 20 have cut-out front top corners 54, as shown in Figure 21. This is to facilitate the grasping of a front most product 22 by a consumer. It is similar to the removed corners of the first embodiment, but is prefabricated in this second embodiment, rather than the result of ripping off a pad of the top.

Referring next to Figures 22 to 27, a very similar arrangement to that of Figures 13 to 21 is shown, but before the elasticated tape is applied across the front of the tray 20, a divider 56 is inserted into the tray. The divider 56 comprises a folded blank of material, again preferably corrugated cardboard, like the tray. It is folded so as to have two base surfaces having a total size and shape corresponding to the size and shape of the inner product-receiving base of the tray 20, and an upstanding central wall 58 for providing a division of the product space of the tray 20. In this case, the division is a central division, although other dividers are also possible, including multiple wall dividers, or unequal divisions, subject to the width of the tray being suitable for such arrangements for the multiple divisions, given the elasticity (or stretchability) of the material used for the pusher -the pusher needs to be able to elastically stretch back and around the products in each product-receiving slot as the products are pushed into the tray, and without damaging the products or the web.

Once the divider is located within the partially assembled tray, as shown in Figure 24, the elastic or stretchy tape can then be mounted across the front of that divided tray, as shown in Figure 25. Product can then be inserted into the tray, either by hand or machine, as shown in Figure 27, before folding up the front wall ready for distribution, as shown in Figure 29.

In the embodiment shown in Figure 29, the front wall 60 of the tray would be taped into its upright, product restraining, position since retention flaps are not provided for gluing it in an upright position. Flaps may instead be provided.

In the further modified embodiment of Figures 30 and 31, a lid or casing 62 is additionally provided. It has front flaps 64 and an upper letterbox opening -possibly one formed using a rip-off portion defined by perforations. As shown in Figures 30 and 31, the front wall 60 could be maintained in its upright position simply by the flaps 64 of the lid, i.e. without the need for its own securement flaps or taping.

Still referring to Figures 30 and 31, the covering lid 62 could be used to partially enclose the product tray so that only one product unit from each product row is on display to the consumer.

The illustrated covering lid is of a shape and size which complements the shape and size of the product tray to ensure a close fit. A semi-circular indent 66 at the front edge of the top face of the covering lid 62 facilitates the grasping of the front most product by a consumer, and is an extension of the letterbox opening.

Figure 30 shows the partially constructed covering lid 62 placed over the product box with the hinged front flaps 64 in an open position. The lid can be just as seen, with no base under the tray. However, the lid may be a covering, i.e. a box, with a base under the tray, such that the tray is slotted into the box, rather than adapted just to receive the lid over the top of it.

As shown in Figure 31, after putting the lid over the tray the front flaps are then folded and stuck to the front wall 60 of the tray to secure the covering lid 62 in position.

In embodiments where the tray possesses a covering lid, the flaps 42 to which the pusher 44 is adhered might not be glued or otherwise attached to the body of the tray as they could be held in place by the side walls of the lid.

Referring next to Figures 32 to 39 a very similar arrangement to that of Figures 13 to 21 is shown. In this embodiment, products, in this case six boxed items 22, are top-loaded into the tray 20.

Once the pusher or tape or web 44 has been applied to the front of the tray it is pushed or stretched to the back of the tray under tension with the aid of a tension guide device 68. As shown in figure 35, the guide device 68 is a plate with a total width corresponding to the size of the back wall 70 of the tray 20. It might be replaced with two fingers for stretching the web back to the back corners of the tray, or by some other guide device for moving the web back to that displaced location. The front flaps 48 are then folded up relative to the base of the tray and sides 50 of the front flaps 48 are then folded back and attached to the flaps 42, and also to the ends of the pusher 44 that are attached thereto, preferably again by gluing. The order of these steps is not critical.

Products 22 can then be top-loaded into the tray, either by hand or by machine, so that the pusher 44 sits around the back of the products 22. The tension guide device 68 is then removed, i.e. once the products have been loaded, for example by lifting it upwards. However, holes or slots can be provided in the tray to allow the guide device to function through other directional movements, especially if provided in the form of two fingers.

The tension guide is not shown in Figures 36 to 38 to allow the web to be seen.

Figures 40 to 50 show another embodiment of the invention. In this embodiment, the pusher is applied prior to forming the tray, i.e. it is applied to a blank prior to folding it into the shape of a tray.

The tray has a lid which can be torn off, along a line of perforations, to reveal the encased products. Further, the pusher tape is retained behind a holding clamp in the form of a tab 124, the holding clamp being released by removal of a tear off portion 128 in the back wall of the tray.

Figure 40 shows a magazine of cardboard blanks 100 that form the product trays of this embodiment. Referring to Figure 40, each cardboard blank comprises four walls 102, 104a, 104b, and 106, four hinge lines 108, various fold lines 110, eight flaps 112, 114, 116 and 118, and a jointing tab 120. Walls 104a and 104b correspond to the side walls and are mirror images, wall 106 is the back wall, wall 102 is the front wall, flaps 112 and 114 form the base of the tray and flaps 116 and 118 form the top of the lid.

Two tabs (lateral clamps) 122a and 122b are located in walls 104a and 104b, respectively, towards edges distal to wall 106. A tab (back clamp) 124 is centrally located along the width of wall 106. These clamps are cut into the plane of the blank and are hingedly attached to the blank at hinge lines 126.

Adjacently below tab 124 is the tear-off tab (back clamp glue zone) 128.

A line of perforation 130 transects the blank along its length to define the line of attachment between the lid and the tray.

As shown in Figure 41, a length of pusher tape is unravelled from a reel 132 without stretching the tape, e.g. by an automated tape feeding device, and a length of that pusher tape 134 is cut. Preferably, the tape may have a backing layer to prevent stretching during the unwinding/cutting process.

Prior to mounting of the pusher onto the blank, beads of glue 136 are deposited, for example by a glue gun (not shown), adjacently below hinge lines 126 of lateral clamps 122a and 122b and to back clamp glue zone 128 (Figure 42).

To achieve mounting of the pusher 134, the tape is first stretched under tension to a suitable length. This may be done using a pair of grippers. Upon stretching it to the desired length, its ends can be adhered to the beads of glue 136 beneath hinge lines 126 of the lateral clamps 122a and 122b.

The centre of the pusher tape is arranged in this embodiment to run through a channel 138 residing between the hinge 136 of back clamp 124 and the back clamp glue zone 128 (Figure 43). This channel is absent of perforations, and as such is able to offer a reasonable degree of resistance to breakage -sufficient to restrain the pusher in a stretched condition towards the back of the folded tray, once assembled.

Referring now to Figure 44, the two lateral clamps 122a and 122b and the back clamp 124 are then folded downwardly to lay flat over the material of the stretched pusher, with the central back clamp extending over to the tear off tab 128. There they overlie the applied glue 136 so that they adhere to their respective glued area to assist in securing the tape/web/pusher in place.

As shown in Figure 45, the box or tray is then partially assembled by folding the blank about hinge lines 108, e.g. around a hollow mandrel. Jointing tab 120 is adhered to the inner surface of wall 104b, such as by gluing to hold the four sides in their rectangular-sectioned arrangement and length flaps 112 are folded inwardly followed by width flaps 114, which are adhered to flaps 112, such as again by gluing, to form the base of the box or tray.

At this stage the partially assembled case 142 may be ejected from an automated assembly line and introduced to an automated tray filling machine. As shown in Figure 46, for that purpose the box may be rotated to put the open end uppermost.

Products, in this case five rectangular boxes 144, may then be inserted into the tray via the opening in the top of the tray. See Figure 47.

In an alternative arrangement, this filling process may be side-loading instead of top-loading, or it might even be bottom loading, e.g. with the box itself being pushed down onto product.

As shown in Figure 48, the top of the case is then sealed by folding flaps 118 inwardly followed by flaps 116, which are adhered by glue. The box is thus then a loaded box ready for delivery to the shop shelves.

Figure 49 next shows a process for the removal of the lid 146 from the tray of the box.

The lid can be torn off from the tray 148 by perforating the joint along the line of perforations 130. Once the lid is so removed, this allows the consumer to gain access to the products 144 contained therewithin -see Figure 50.

In addition to removing the lid, the pusher tape 134 will want to be released from its restraint. To achieve that, the back clamp glue zone tab 128 is removed (see Figure 49) by tearing it off along its perforated border. The tape or web 134 that forms the pusher is thus no longer held in restraint by the back clamp 124 and thus the pusher is free to apply a resilient bias force to the rear surface of products contained within the tray. The pusher will thus cause the products to front load automatically as a front product is removed therefrom. See Figure 50.

Figures 51 to 63 show a further embodiment, similar to that of Figures 40 to 50, but wherein the tray and lid are not integrally constructed from a single blank. The tray and the lid are still interconnected, for example by slotting together, and potentially by way of glue as well (e.g. small dabs thereof, but this embodiment differs from the former embodiment either way by the lid not being connected to the tray by a line of perforations.

Figure 51 shows a magazine of cardboard blanks 200 for forming the product tray.

Referring to Figures 51 and 53, each cardboard blank comprises, four walls, 202, 204a, 204b, 206, four hinge lines 208, various fold lines 210, four flaps 212 and 214, and a jointing tab 216. Walls 204a and 204b correspond to the left and right side walls and are mirror images of one another. Wall 206 forms the back wall. Wall 202 forms the front wall. Flaps 212a, 212b, 214a and 214b form the base of the tray. Flaps 214a and 214b are mirror images of one another.

Two tabs (lateral clamps) 218a and 218b are located in flaps 214a and 214b, respectively, near edges distal to flap 212b. A tab (back clamp) 220 is centrally located along the width of flap 212b. The clamps 218a, 218b and 220, as before, are formed to lie in the plane of the blank 200 and are hingedly attached to the blank at hinge lines 222, which correspond to fold lines 210.

Flap 212a contains a trapezoidal cut-out section 224, the base of trapezoid corresponding to fold line 210. Other shapes are possible too. However, the shape is ideally designed to correspond with an element in the top, as will be described later.

This, however, is not essential.

Figure 51 does not show the clamps and cut-out sections to simplify the drawings.

Adjacently above the hinge 222 of tab 220, located centrally in wall 206, is a tear-off tab (back clamp glue zone) 226. This is much like the previous embodiment as well.

Figure 52 shows the tape dispenser, again much like in the previous embodiment.

Referring to Figures 54 and 55, a cut length of pusher tape 228 is applied to the blank as in the previous embodiment for forming the element that will be the pusher.

Once again, prior to mounting the pusher, beads of glue 230 are deposited on the surface of walls 204a and 204b, adjacently above the hinge 222 of lateral clamps 218a and 218b and to back clamp glue zone 226. Lateral clamps 218a and 218b and back clamp 220 are then folded, upwardly in this illustration, to adhere to their respective glued area.

Figure 56 shows a magazine of blanks 232 corresponding to the removable lid. They are for applying to respective blanks for the trays, i.e. one per each tray blank.

Each of these cardboard blanks for the lids comprises four walls, 234, 236a, 236b, 238, four hinge lines 240, various fold lines 242, four flaps 244 and 246, and a jointing tab 248. Walls 236a and 236b, corresponding to the side walls of the lid, are mirror images.

Wall 238 corresponds to the back wall. Wall 234 corresponds to the front wall. Flaps 244 and 244 form the top of the lid.

A pair of trapezoidal cut-out sections 250a and 25Db are located at the base of walls 236a and 236b, respectively, at edges distal to back wall 238. Further, a trapezoidal cut-out section 252 lies at the centre of the base of wall 238. The areas of these cut-out sections 250a, 25Db and 252 correspond to the areas of the lateral clamps 218a and 218b and the back clamp 220, respectively, of the blank for the tray. As a result, the blank for the lid can overlay the blank for the tray in a locating fashion, and without unnecessarily stacking to a third thickness of blank material (i.e. the folded parts of the blank for the tray are not sandwiched between the two blanks, but are instead accommodated into the plane of the overlying blank by virtue of the corresponding cut-outs therein.

Two further tabs 254, located in flaps 244, lie in the plane of the blank 232 and are hingedly attached to that blank 232 at hinge lines 256, which are coaxial to fold lines 242.

Referring next to Figure 57, an uppermost lid blank 232 has been removed from the magazine of said lid blanks and has been placed on top of the tray blank 200 so that the cut-out sections 250a, 250b, and 252 align with the folded over clamps 218a, 218b and 220, respectively. The pusher tape 228 is now sandwiched between both blanks.

Like in the previous embodiments, the resulting assembly (here overlapped blanks, rather than the integral lid and tray) is folded about hinge lines 208 and 240 around a mandrel -e.g. a hollow one -and the length flaps 214a and 214b and then the width flaps 212a and 212b are folded inwardly to effect closure of the tray base (see Figure 58).

Jointing tab 216 is adhered to the inner surface of wall 234 and jointing tab 248 is adhered to the inner surface of wall 236b, such as by gluing, to hold this assembled shape together. The removable lid 260 thus now appears to be slotted into the tray 258.

Referring next to Figures 59 and 60, the products 262 are loaded into the case as per the previous embodiment.

To close the top of the lid, firstly width flaps 244 are folded inwardly. Hinged tabs 254 are then pulled upwardly by at least 90° to allow length flaps 246 to be folded inwardly on top of flaps 244. Flaps 246 need not be adhered to flaps 244. Lastly, tabs 254 are folded inwardly and adhered, for example with glue, to the top surface of flaps 246 so as to hold down the top of the lid, resulting in the fully assembled product case 262 (see Figure 61).

The tabs 254 are slightly raised above the surface of the top of the lid formed by flaps 246, which allows the cases 262 to be stacked centrally, one on top of another, as these raised portions can interlock with the corresponding depressions 255 on the base of the tray (see Figure 58), formed by the trapezoidal cut-out sections 224 on flaps 212a and 212b. Other shapes for these inter-engaging elements are possible, but the trapezoidal shape conveniently provides an interlock with a tendency to increasingly resist lateral sliding, e.g. in the event that such lateral sliding is likely to occurs.

Unless the lid and the tray are glued together, the lid 260 can then be simply lifted off the tray to display the products contained therewithin (Figures 62 and 63).

Unlike the previous embodiment of Figure 40 to 50, which may have a tendency for the lid or tray to be damaged as the perforations are broken, the lid and tray of this further embodiment is more readily reusable since damage is less likely. Further, the lid can easily be placed back over the tray if so desired.

As before, the back clamp glue zone 226 is broken off along the lines of perforation to release and activate the pusher. See Figure 62.

Referring next to Figures 64 to 76, there is shown a preferred embodiment of the present invention relating to a method of assembling a product tray containing products, such as chocolate bars.

As shown in Figure 64, which is at the start of the process, an automated transfer device 302 having a transfer block 304, extracts the uppermost cardboard blank 306 from a stack 308 of said blanks and feeds that blank to a processing conveyor. The base of the transfer block can have a surface area corresponding to the surface area of the base of the product tray blank, as shown. Blank 306 is the same as used to make product trays shown in Figures 13 to 39. The blank 306, once transferred to and positioned on a conveyer belt 310 (Figure 65), is further processed. At this stage the joining surfaces of the blank 306 may be coated with an adhesive substance, such as hot-melt glue. The joining surfaces may instead be already pre-coated with an adhesive substance, e.g. a two-part touch activated adhesive.

A series of pistons 312 then partly assembles the product tray around the transfer block 304 -by being the same size, the transfer block can be the mandrel. Firstly, as depicted in Figure 66, the depth flaps 314 are folded upright to form the sides of the tray and the jointing tabs 316 are pushed inwardly. A pair of pushing members 318 then fold the flaps 320 outwardly so that they adhere to their respective depth flaps 314 (see Figures 67 and 69).

The back of the tray is formed by a piston upwardly pushing the back flap 322 into contact with the adhesive surface of the jointing tabs 316.

At this stage, the transfer block 304 is then withdrawn from the partly assembled tray (see Figure 70) and is free to collect another blank from the stack.

The partly assembled tray 324 is moved along by the conveyor belt 310 into a position to receive the pusher 326.

The pusher of this embodiment takes the form of a web of resilient material; preferably a tape made of clear elastic tape or knitted shirring elastic. Clear elastic may be elastic manufactured from polyurethane and may be capable of being stretched to 4 times its original length in a preferred embodiment. Furthermore, by being elastic in nature, it retains its original length after being subjected to tensional stresses.

The pusher tape is dispensed from an automated tape feeding device 328 as shown in Figure 65 to 70. The reel of tape 330 is mounted on a motorised shaft 332 through its central core -see Figure 68 for a more detailed view of this preferred arrangement. A pair of interconnected grippers 334a and 334b is located at the end of the tape. Figure shows the end of the tape sandwiched between two interconnected grippers. The tape is clamped between the side walls of the gripper 334b but not between the side walls of gripper 334a. To unravel a length of tape, the motorised shaft 332 rotates in an anti-clockwise direction (although a clockwise direction would also be suitable) and the gripper 334b moves tangentially away from the roll at a rate consistent with the rotational speed of the motorised shaft, thus unravelling the tape without subjecting it to significant tensional forces, until a desired length of pusher material is dispensed (Figure 66).

The pusher tape is then collected by a tape transfer device 336. Referring to Figure 68, the device according to this embodiment consists of a bar 338 with two clamps 340 positioned along its length and two end blocks 342, capable of generating a suction force, pivotally attached at either end of the bar 338. The tape transfer device aligns itself with the length of pusher tape and collects it using the clamps 340. The tape is then cut to release it from the gripper 334a and the terminal end of the tape is released from gripper 334b. The ends of the length of pusher tape are held to the end blocks 342, preferably by suction force. The mobile gripper 334b then moves back into interconnection with gripper 334a and its sides close together to grip the end of the reel of tape left exposed by cutting the length of pusher tape adjacent to gripper 334a.

To achieve mounting of the pusher, the tape transfer device 336 is brought into alignment with the partly assembled product tray at the height of the flaps 320 (compare Figure 69 with Figure 70). The end blocks 342 of the device 336 are then rotated inwardly approximately at right angles about their pivot so that the ends of the tape can be glued or otherwise attached to the flaps 320. Upwardly moveable support members 344 are also inseited into tray behind the position of the flap 320 to provide support to the sides of the tray to prevent them from buckling inwards (see Figure 70).

They are then lifted out again -see Figure 71.

The partly assembled tray with the pusher attached is then transported along the conveyor belt 346, in this case one that is perpendicular to the last, although this is optional (although it helps to avoid the need for a rotation of the tray in a compact assembly line).

At the next station therealong, a tension guide 348 having approximately the same width and depth dimensions as the internal width and depth dimensions of the tray is inserted into the tray to establish pushel tension (Figures 71 and 72). Further, usually prior to insertion of the tension guide 348, support blocks 350 are pressed against the flaps 320, at the ends of the pusher tape, to prevent the ends becoming detached upon establishment of pusher tension. They can be rotated upwardly into those supporting positions, or they may be otherwise so positioned (e.g. in the manner of the support members 344, and vice versa).

Products 352 to be loaded into the tray are meanwhile fed into a product holding bay 351 and are stacked up in a back-to-back fashion against a plate 354. The product units are then pushed foiwards into the tiay by the plate 354 as shown in Figure 79.

The support blocks 350 can then be retracted and the front flaps 356 are folded up relative to the base of the tray with the aid of a pushing rod 358. The side flaps 360 are folded backwards and attached to the flaps 320, and also to the ends of the pusher that are attached thereto, preferably again by gluing. That conceals the ends of the pusher tape, as shown in Figure 75.

The tension guide 348 and plate 354 are then retracted or lifted to leave the fully loaded tray 362, which tray is ready for removal from the conveyor belt 346 (Figure 76).

The process could also be envisaged to include additional steps which serve to attach a covering lid, of the type depicted in Figures 30 and 31, to the product tray. Further, the direction of the conveyor 346 can be different, and the direction of feeding of the products can likewise be different.

Figures 77 to 79 depict an alternative product loading method where the direction of feeding of the products is different -it is now a top-loading arrangement. This top-loading method is beneficial where the products are difficult to pack by the side-loading method of Figures 72 to 76. For example, ordered rows of glass bottles will not necessarily keep formation if pushed from their side, but they are readily grasped by cap-holders and moved vertically.

Referring to Figure 77, a tension guide 348 is again inserted into the partially assembled tray to establish pusher tension. A plate 354 is then again positioned at the frontward edge of the tray, but this time without pushing products therewith. Further the front flaps 356 are folded up relative to the base of the tray with the aid of a pushing rod 358. The products, in this case, 16 bottles in a 4 x 4 arrangement, are however instead lowered into the cavity created by the tension guide 348 and the front plate 354.

In this embodiment the side flaps 360 are then folded back and aftached to the flaps 320 as described for the side-loading method (Figure 78). The timing of these folds, however, is not critical. For example, it may have occurred prior to loading the bottles.

Then, referring to Figure 79, the plate and tension guide are lifted out of the tray.

Referring next to Figures 80 to 85, a further embodiment of the present invention is shown. The process is very similar to before. However, in this embodiment the product tray 366 has two slots 368 located in the back wall 370, positioned at a height just above that at which the pusher tape 326 is attached to the side flaps 320. Further, the tension guide 372 has two rectangular channels 372 rising upwards from the base of its back wall, each having a height that corresponds to the height from the base of the back wall 370 to the top edge of the slots 368. The heights are not important, so long as they are no less high than this.

As before, this tension guide is inserted into the tray to establish pusher tension.

However, these channels are positioned so that in this location they eclipse, either partially or totally, the slots 368 in the back wall 370 of the partially assembled product tray 366 (Figure 81).

Once products have been side-loaded into the tray and the front flaps 356 have been folded up relative to the base of the tray, (or before this), two rods 376 are moved from behind the tray such that they are inserted through each of the slots 364 so that their ends do (or will) apply a slight positive pressure to the rearmost product in the tray.

Thus the rods locate above the pusher. As a result, upon withdrawal of the tension guide 372, the rods 376 -due to their positioning directly above the pusher tape 326 -prevent the pusher tape from being dragged in an upwards direction by the tension guide, which could otherwise potentially twist or displace the tape of the pusher so as to prevent it from functioning as intended.

Figures 86 to 88 show an alternative arrangement to the embodiment shown in Figures 80 to 85 in which the products are top-loaded into the product tray, e.g. as per Figures 77 to 79.

Referring next to Figures 89 to 100, they show a variant of the embodiment of Figures to 50. The blanks are rotated 1800 with respect to that earlier embodiment since in this embodiment the top of the case is closed and the case is filled via the bottom with the products upside down. The clamps, perforations and flaps are otherwise as before.

However, Figure 92 shows the mandrel for forming the general box shape. Here it is not hollow, and it is ejected (removed or extracted) after folding the sides and top of the case, but not the bottom. In this arrangement, the pusher is V shaped in section, when viewed from the bottom (i.e. through the top as shown in Figure 95, which top will be the final bottom of the loaded tray. The box here is then transferred to a box filler.

The processes of this preferred box filler is illustrated in Figure 96. Step a) is where the open box is received. Step b) is where a U shaped device is used to expand the pusher tape or web by inserting it at the top of the V. The U shaped device then expands the pusher back towards the point of the V so as to form an open U shape in the pusher ready for receiving the products, as shown in step c). The products are then loaded or "stuffed" into the tray through the open bottom (top as shown in step d)) before the U shaped device is extracted in step e).

The loaded tray or box is then closed by folding the flaps at the bottom (top as shown) thereof. The flaps are glued down and the box is then rotated to put the bottom to the top as shown in Fig 97c ready for shipping -Figure 98. The box can be opened by perforating along the line between the tray and the lid, as shown in Figure 99, and the tab can be removed to release the pusher. The products can then be removed by a customer as shown in Figure 100, with the products automatically restacking towards the front of the tray -to the right in Figure 100.

Figures 101 to 113 then show a final variant of the embodiments of Figures 40 to 50, or 89 to 100, in which a lid is formed from a separate blank, and integrated into the folding/loading process, as per Figures 51 to 63. Different to that of Figures 51 to 63, this final embodiment has access pods 391, as shown in Figure 105, for breaking the glue bond between the top and the tray.

The assembled pair of blanks (including a lid blank and a tray blank) are again folded around a mandrel, and the flaps form the depressions in the base of the tray as before -for controlled stacking of the finished articles. See Figure 107 for the depressions.

This figure also shows that the ports 391 in the lid blank are aligned with the edge of the tray in this pad assembled condition (and later once fully assembled). This means that the port provides an easy means for grasping the edge of the tray relative to the side of the lid to allow any glue joint therebetween -provided for example by dabs of glue in the vicinity of those pods -to be readily broken. The glue may even be on the tabs, with the tabs being part cut and part perforated to allow them readily to be broken out of the wall of the lid, thus releasing the joint between the lid and the tray.

Preferred features of the present invention have therefore now been described above purely by way of example. Modifications in detail may be made to the invention within the scope of the claims appended hereto.

Claims

CLAIMS: 1. A method of assembling a tray having a product pusher, comprising: folding a blank to form at least part of a tray, feeding a resilient web across a face thereof, and inserting products into the tray such that the web wraps partially around the products in a stretched state.
2. A method of assembling a tray having a product pusher, comprising: providing a blank for forming at least part of a tray, feeding a resilient web across a face thereof, folding the blank to form at least part of the tray; and inserting products into the tray such that the web wraps partially around the products in a stretched state.
3. The method of claim 1 or claim 2, wherein the length of resilient web is fed across the tray front by a transfer device.
4. The method of any one of claims 1 to 3, comprising an additional step, prior to inserting the products, of pushing the length of resilient web towards the back and around the side walls of the tray.
5. The method of claim 4, wherein the length of resilient web is pushed back by a tension guide.
6. The method of claim 5, wherein the tension guide is withdrawn from the tray after insertion of the products.
7. The method of claim 6, wherein prior to the withdrawal of the tension guide, one or more rods are inserted through one or more slots in the back wall of the tray and corresponding channels in back wall of the tension guide in order to maintain the web in position upon withdrawal of the tension guide.
8. The method of any of claims 1 to 7 wherein the products are side-loaded into the tray.
9. The method of any of claims 1 to 7 wherein the products are top-loaded into the tray
10. The method of any one of claims ito 9 wherein a lid or top is added to the tray.
ii. The method of any one of claims ito 10, wherein the length of resilient web is drawn from a roll.
12. A product tray comprising a product pusher, wherein the product pusher is formed from just a single fabric or material, and is arranged to apply a resilient bias force to the rear suiface of products contained within the tray.
13. The tray of claim i2, wherein the single fabric or material is a length of resilient tape, such as a rubber, silicon or elastic strip, or shirring elastic, knitted or otherwise.
14. The tray of claim 12, wherein the single fabric or material is a plurality of lengths of a single type of resilient tape, such as a rubber, silicon or elastic strip.
15. The tray of claims 2 or 3 wherein the resilient tape is a length of shirring elastic or clear elastic.
16. The tray of any one of claims 12 to 15, wherein the single fabric or material is attached at or towards its ends to the product tray.
17. The tray of any one of claims 12 to 16, wherein the single fabric or material is attached at or towards its ends to the sides of the tray.
18. The tray of any one of claims 12 to 17, wherein the single fabric or material is attached at or towards its ends to folded flaps formed near the front of the tray.
19. The tray of any one of claims 12 to 18, wherein the single fabric or material is attached at or towards its ends to two surfaces that lying in a common plane at the time of attachment.
20. The tray of any one of claims 12 to 19, wherein parts of the product tray to which the single fabric or material is attached are concealed by concealing flaps.
21. The tray of any one of claims 12 to 20, wherein the single fabric or material is supplied from a roll.
22. The tray of any one of claims 12 to 21 wherein the single fabric or material is attached to the product tray at two or more sites of attachments along its length.
23. The tray of any one of claims 12 to 22, comprising a restraining member, wherein the single fabric or material is restrained by said restraining member.
24. The tray of claim 23, wherein the restraining member is a clamp.
25. The tray of claim 24, wherein the clamp is a tab folded over the pusher tape and wherein the uppermost portion of the tab is glued to a zone in the wall of the tray.
26. The tray of claim 25, wherein the zone is bordered by a line of perforation.
27. The tray of claims 23 to 26, wherein the restraining force exerted by the restraining member can be optionally relieved by user interference.
28. The tray of any one of claims 12 to 27, wherein the single fabric or material is one or more length of elastically stretchable fabric or material, arranged to wrap behind and to the sides of products contained within the tray to apply the resilient bias force to the rear surface of those products.
29. The tray of claim 12, wherein the pusher comprises two inter-engaged webs, each web comprising two hinge lines and three inter-engagement slots, the two hinge lines being oppositely bent and the three inter-engagement slots interlinking with the opposing inter-engagement slots on the other web.
30. The tray of claim 12 or claim 29, wherein the pusher is not attached to the tray, but instead simply sits within the tray.
31. The tray of claim 29, wherein the elasticity of the material or structure of the webs provide at least part of the resilient bias of the pusher.
32. The tray of claim 29, wherein the inter-engagement of the slots is provided with an interference fit upon compression of the pusher in a concertina fashion, whereupon the fit and material structure provides at least a part of the resilient bias of the pusher.
33. The tray of claim 29, wherein the hinge lines provide at least a part of the resilient bias of the pusher.
34. The tray of any one of claims 29 to 33, wherein the webs include folded sides so as to double the thickness of parts of the webs.
35. The tray of any one of claims 29 to 34, wherein the pusher is formed from just two blanks, cut from a single sheet.
36. The tray of any one of claims 29 to 35, wherein the pusher is formed just from cardboard and optionally glue.
37. The tray of any one of claims 29 to 36, wherein the pusher is formed just from a corrugated material and optionally glue.
38. The tray of claim 37, wherein the corrugations are oriented such that they run with their parallel axes extending perpendicular to the hinge lines.
39. The tray of any one of claims 12 to 38, wherein the tray, in use, is mounted on a shelf within a shop with a raised back, such that gravity can assist with the front-stacking effect.
40. The tray of any one of claims 12 to 39, wherein the tray is formed from one or more corrugated sheet of material.
41. The tray of any one of claims 12 to 40, wherein the tray additionally comprise a lid or top.
42. The tray of claim 41, wherein the lid or top may be a separate component to the tray.
43. The tray of claim 42, wherein the lid can be refitted onto the tray.
44. The tray of claim 41, wherein the lid or top is integral to the tray but perforated relative thereto for simple removal, or partial removal, therefrom.
45. The tray of any one of claims 12 to 44, wherein a divider is provided to divide the product receiving area of the tray into more than one chamber.
46. The tray of claim 45, wherein a separate pusher is provided for each chamber.
47. The tray of claim 45, wherein a single resilient strip bridges two or more chambers, thereby providing a pusher for both or each chamber.
48. A product tray comprising a product pusher, wherein the product pusher is formed from a length of elastically stretchable fabric or material arranged to wrap behind and to the sides of products contained within the tray to apply a resilient bias force to the rear surface of those products contained within the tray.
49. A box substantially as hereinbefore described with reference to any one or more of the accompanying drawings.
50. A tray substantially as hereinbefore described with reference to any one or more of the accompanying drawings.
51. A blank for forming a tray according to any one of claims 12 to 48.
52. A stack of blanks according to claim 51.CLAIMS: 1. A method of assembling a tray having a product pusher, comprising: folding a blank to form at least part of a tray, feeding a resilient web across a face thereof, and inserting products into the tray such that the web wraps partially around the products in a stretched state.2. A method of assembling a tray having a product pusher, comprising: providing a blank for forming at least part of a tray, feeding a resilient web across a face thereof, folding the blank to form at least part of the tray; and inserting products into the tray such that the web wraps partially around the products in a stretched state.3. The method of claim 1 or claim 2, wherein the length of resilient web is fed across the tray front by a transfer device.4. The method of any one of claims 1 to 3, comprising an additional step, prior to inserting the products, of pushing the length of resilient web towards the back and around the side walls of the tray.5. The method of claim 4, wherein the length of resilient web is pushed back by a tension guide.6. The method of claim 5, wherein the tension guide is withdrawn from the tray after insertion of the products.7. The method of claim 6, wherein prior to the withdrawal of the tension guide, one or more rods are inserted through one or more slots in the back wall of the tray and corresponding channels in back wall of the tension guide in order to maintain the web in position upon withdrawal of the tension guide.8. The method of any of claims 1 to 7 wherein the products are side-loaded into the tray.9. The method of any of claims 1 to 7 wherein the products are top-loaded into the tray 10. The method of any one of claims ito 9 wherein a lid or top is added to the tray.ii. The method of any one of claims ito 10, wherein the length of resilient web is drawn from a roll.12. A product tray comprising a product pusher, wherein the product pusher is formed from just a single fabric or material, and is arranged to apply a resilient bias force to the rear suiface of products contained within the tray.13. The tray of claim i2, wherein the single fabric or material is a length of resilient tape, such as a rubber, silicon or elastic strip, or shirring elastic, knitted or otherwise.14. The tray of claim 12, wherein the single fabric or material is a plurality of lengths of a single type of resilient tape, such as a rubber, silicon or elastic strip.15. The tray of claims 2 or 3 wherein the resilient tape is a length of shirring elastic or clear elastic.16. The tray of any one of claims 12 to 15, wherein the single fabric or material is attached at or towards its ends to the product tray.17. The tray of any one of claims 12 to 16, wherein the single fabric or material is attached at or towards its ends to the sides of the tray.18. The tray of any one of claims 12 to 17, wherein the single fabric or material is attached at or towards its ends to folded flaps formed near the front of the tray.19. The tray of any one of claims 12 to 18, wherein the single fabric or material is attached at or towards its ends to two surfaces that lying in a common plane at the time of attachment.20. The tray of any one of claims 12 to 19, wherein parts of the product tray to which the single fabric or material is attached are concealed by concealing flaps.21. The tray of any one of claims 12 to 20, wherein the single fabric or material is supplied from a roll.22. The tray of any one of claims 12 to 21 wherein the single fabric or material is attached to the product tray at two or more sites of attachments along its length.23. The tray of any one of claims 12 to 22, comprising a restraining member, wherein the single fabric or material is restrained by said restraining member.24. The tray of claim 23, wherein the restraining member is a clamp.25. The tray of claim 24, wherein the clamp is a tab folded over the pusher tape and wherein the uppermost portion of the tab is glued to a zone in the wall of the tray.26. The tray of claim 25, wherein the zone is bordered by a line of perforation.27. The tray of claims 23 to 26, wherein the restraining force exerted by the restraining member can be optionally relieved by user interference.28. The tray of any one of claims 12 to 27, wherein the single fabric or material is one or more length of elastically stretchable fabric or material, arranged to wrap behind and to the sides of products contained within the tray to apply the resilient bias force to the rear surface of those products.29. The tray of claim 12, wherein the pusher comprises two inter-engaged webs, each web comprising two hinge lines and three inter-engagement slots, the two hinge lines being oppositely bent and the three inter-engagement slots interlinking with the opposing inter-engagement slots on the other web.30. The tray of claim 12 or claim 29, wherein the pusher is not attached to the tray, but instead simply sits within the tray.31. The tray of claim 29, wherein the elasticity of the material or structure of the webs provide at least part of the resilient bias of the pusher.32. The tray of claim 29, wherein the inter-engagement of the slots is provided with an interference fit upon compression of the pusher in a concertina fashion, whereupon the fit and material structure provides at least a part of the resilient bias of the pusher.33. The tray of claim 29, wherein the hinge lines provide at least a part of the resilient bias of the pusher.34. The tray of any one of claims 29 to 33, wherein the webs include folded sides so as to double the thickness of parts of the webs.35. The tray of any one of claims 29 to 34, wherein the pusher is formed from just two blanks, cut from a single sheet.36. The tray of any one of claims 29 to 35, wherein the pusher is formed just from cardboard and optionally glue.37. The tray of any one of claims 29 to 36, wherein the pusher is formed just from a corrugated material and optionally glue.38. The tray of claim 37, wherein the corrugations are oriented such that they run with their parallel axes extending perpendicular to the hinge lines.39. The tray of any one of claims 12 to 38, wherein the tray, in use, is mounted on a shelf within a shop with a raised back, such that gravity can assist with the front-stacking effect.40. The tray of any one of claims 12 to 39, wherein the tray is formed from one or more corrugated sheet of material.41. The tray of any one of claims 12 to 40, wherein the tray additionally comprise a lid or top.42. The tray of claim 41, wherein the lid or top may be a separate component to the tray.43. The tray of claim 42, wherein the lid can be refitted onto the tray.44. The tray of claim 41, wherein the lid or top is integral to the tray but perforated relative thereto for simple removal, or partial removal, therefrom.45. The tray of any one of claims 12 to 44, wherein a divider is provided to divide the product receiving area of the tray into more than one chamber.46. The tray of claim 45, wherein a separate pusher is provided for each chamber.47. The tray of claim 45, wherein a single resilient strip bridges two or more chambers, thereby providing a pusher for both or each chamber.48. A product tray comprising a product pusher, wherein the product pusher is formed from a length of elastically stretchable fabric or material arranged to wrap behind and to the sides of products contained within the tray to apply a resilient bias o 20 force to the rear surface of those products contained within the tray.(0 49. A box substantially as hereinbefore described with reference to any one or more of the accompanying drawings.50. A tray substantially as hereinbefore described with reference to any one or more of the accompanying drawings.