SE2050613A1 - Foldable tray for fresh products - Google Patents

Abstract

The present disclosure related to a blank (20) that has been cut and provided with folding indications (34, 54, 56) to be folded to a tray (10) for fresh products. The blank (20) has a substantially rectangular shape, and defining a bottom plate (28), a first pair of side wall flaps (30) comprising a first pair of side wall portions ((36) configured to define a first pair of opposite side walls (40) attached to the bottom plate (28) along respective bottom edge folding indications (34), and a second pair of side wall flaps (32) comprising a second pair of side wall portions (38) configured to define a second pair of opposite side walls (42) attached to the bottom plate (28) along respective bottom edge folding indications (34). Each side wall portion (36, 38), when erected, comprises a top edge (44) and two opposite side edges (46a, 46b). The side wall flaps (30, 32) further comprise at least one spacer arrangement portion configured to define a spacer arrangement (24) adapted to keep a second, identical tray (10) stacked on top at a distance from the top edge (44) of the side wall (40, 42), and the at least one spacer arrangement portion comprises a connection flap (52) adapted for coupling of a first side wall (40) with to second adjacent sidewall (42) formed by said side wall portions (36, 38). The disclosure also relates to a tray (10) formed by folding a blank (20) at folding indications (34, 54, 56) to define an inner storage volume (25) between the first pair and second pair of side walls (40, 42).

Description

FOLDABLE TRAY FOR FRESH PRODUCTS Field of the invention The present invention relates to a blank that has been cut and provided withfolding indications to be folded to a tray for fresh products and to a fresh product trayformed by folding a blank.

BackgroundOpen trays/boxes of a board material are widely used for transport, storage, and display of fresh products, especially for fruit and vegetables. Such products arerelatively heavy, and the trays/boxes need to be stacked on top of each other to areasonable height of for example from 5 to 15 boxes.

The size of the trays/boxes is targeted to contain a predetermined weight of apredetermined type of a fresh product is also dictated by the size of a pallet on whichthe trays/boxes are to be transported. Many different sizes of the tray/boxes are thusmanufactured but the object is to fill substantially all the area of a pallet andsubstantially all the height of a container or transport vehicle. For example, the typicalsize of a tray for salad is 600 mm long, 400 mm wide and 180 mm high.

The trays are made of a sheet of a board material provided with folds and theyare adapted to be erected manually or by a machine. To be able to carry asubstantial portion of the weight of boxes stacked on top of another box, thetrays/boxes need to have some kind of reinforcement in the corners.

US 2014/0312110 A1 describes a stackable open topped box made of foldedfluted sheet material. The box has pillar formations in the corners to carry the weightof a stacked box. The box is erected by a machine and the parts are attached to each other with use of an adhesive.

Summafllt is an object of the present invention to provide a packaging for transport and storage of fresh products that can be stacked on top of another, similar packagingduring transport and storage without collapsing and at the same time provide apackaging that has relatively low impact on the environment. To this end, there is provided a blank that has been cut and provided with folding indications to be folded to a tray for fresh products, said blank having a substantially rectangular shape, anddefining a bottom plate, a first pair of side wall flaps comprising a first pair of side wallportion configured to define a first pair of opposite side walls attached to the bottomplate along respective bottom edge folding indications, and a second pair of side wallflaps comprising a second pair of side wall portions configured to define a secondpair of opposite side walls attached to the bottom plate along respective bottom edgefolding indications. Each side wall portion, when erected, comprises a top edge andtwo opposite side edges, and the side wall flaps further comprise at least one spacerarrangement portion configured to define a spacer arrangement adapted to keep asecond, identical tray stacked on top at a distance from the top edge of the side wall.The at least one spacer arrangement portion comprises a connection flap adapted forcoupling of a first side wall to a second, adjacent sidewall formed by said side wallportions.

Preferably at least one spacer arrangement is provided at each corner of afolded tray and each corner of the tray is held together by a respective connectionflap of the respective corner. This assembly of trays requires no, or at least less,adhesives in form of for example of glue, or mechanical fasteners, to keep the partsof the tray together.

A spacer arrangement in trays for fresh products is used to protect theproducts within the trays when several trays are stacked on top of each other. Thespacer arrangement will also provide ventilation for the products within the trays aswell as the possibility to see the content within each tray when several trays havebeen stacked on top of each other. ln prior art trays for fresh products, spacerarrangements can be plastic spacers arranged in the corners of the folded tray afterthe tray has been erected.

The spacer arrangement according to the present disclosure is an integral partof the blank formed by the spacer arrangement portion when folding the blank to atray. The tray may therefore be cheaper to manufacture, has less impact on theenvironment, and weigh less compared to a tray with plastic spacer arrangements.

The blank can be transported to the field of the fresh products and be erectedto a tray on site. The transport of a blank requires less space than a folded tray andthus more blanks than trays may be transported within the same vehicle; a flat blanktherefore has less impact on the environment ln one embodiment, the spacer arrangement may comprise a support prismflap defined by a respective side wall flap. The support prism flap can be providedwith at least two support prism flap folding indications arranged perpendicular to thebottom edge folding indication of the side wall flap, the support prism flap beingarranged to form a support prism to extend inside the side walls when the supportprism flap is fo|ded at the support prism flap folding indications. ln one embodiment, the support prism flap can be arranged foldablyconnected at one of the side edges of the side wall portion of the respective side wallflap.

The support prism flap may extend, when fo|ded at the support prism flapfolding indications, inside the side walls of the fo|ded tray. Preferably, the formedsupport prism will be arranged at a corner formed when the side walls flaps areerected. The formed support prism may reinforce the corners of the tray to give ahigher vertical strength and a better loading capacity and thus increase the numberof trays that can be stacked on top of each other compared to a tray withoutreinforcement of the corners.

Preferably, the support prism flap may be configured to form a triangularsupport prism when fo|ded at the support prism flap folding indications. Whilereinforcements of the corners are desirable, the reinforcements should not interfereto much with the storage capacity within the tray. A support prism with triangularshape can give a reinforcement of the corners of the tray without excessivelyinterfering with the storage space within the tray compared to a support prism with forexample four or more side walls.

Preferably, the fo|ded support prism can extend along the entire height of theside wall, from the bottom plate folding indication of the respective side wall flap tothe top of the spacer arrangement. While the fo|ded support prism reinforces thecorner of the tray it also forms a part of the spacer arrangement, since the height ofthe support prism extends beyond the top edge of the side wall portion. ln one embodiment, the connection flap may be foldably connected to a wall ofthe support prism. The connection flap can be elongate and extend in a directionparallel with the respective bottom edge folding indication. lt may extend from thewall of the support prism towards the centre of the same side wall portion to whichthe support prism flap is foldably connected. ln one embodiment, the spacer arrangement may comprise a rigid corner tab,The corner tab can be rigidly connected to a side wall portion and may extend in aplane of the side wall, when the side wall flap is erected, and wherein the corner tabmay protrude in a direction perpendicular to the bottom edge folding indication of theside wall flap. The corner tab is a rigid tab arranged at least at one of the side walledges. The corner tab extends above the top edge of the side wall portion and formsa part of the spacer arrangement. ln one embodiment, the corner tab may be arranged at a first side wall portionand the support prism flap may be arranged at a second side wall portion to formfirst and second side walls meeting each other to form an outer tray corner whenthe side wall f|aps are erected. When the side wall f|aps are erected, the corner tabwill be arranged at the side edge of a first side wall, and a wall of the folded supportprism will be defined by a portion of the second side wall of the two side wallsmeeting each other and forming an outer tray corner, where the other walls of thefolded support prism will be arranged on the inside of the tray for reinforcement ofthe corner. ln one embodiment, the connection flap may be provided with at least twoconnection flap folding indications arranged perpendicular to the bottom edgefolding indication of the side wall flap, and wherein the connection flap is adapted tobe folded around the corner tab and the support prism for coup|ing of said first sidewall with said second side wall meeting each other to form an outer tray cornerwhen the side wall flaps are erected. The connection flap is arranged for coup|ing ofa first side wall with a second side wall where the side walls meet each other andforms an outer tray corner. Thus, there is no need for any g|ue or mechanica|fasteners for connection of the two side walls with each other.

Preferably, a width of the connection flap, perpendicular to the bottom foldingindication, may correspond to the height of the corner tab above the top edge of theside wall. Since the connection flap extends above the top edge of the side wall, itwill also form a part of the spacer arrangement.

Preferably, the corner tab can have a width, perpendicular to the respectivebottom folding indication, adapted to the width of the support prism. The corner tabcan be arranged both for formation of the corner and as to reinforce the foldedsupport prism and thereby the corner of the tray. The corner tab reaches to the same height as the folded support prism. ln one embodiment, the connection flap may be arranged at the upper edge ofa side wall portion, along the top edge of the respective side wall, when the side wallportion is erected. The connection flap is preferably cut out from the side wall portionand forms an integra| part of the blank. Aiternatively, the connection flap may bearranged at a lower portion of the side wall portion but will not then be a part of thespacer arrangement.

Preferably, the connection flap may comprise four segments separated bythree connection flap folding indications. The length of each segment is adapted tothe width of each support prism walls. The connection flap may be folded at least onelap around the outer corner of the tray, along and about the corner tab and thesupport prism side walls. The spacer arrangement will thereby only protrude thethickness of the blank from the outer face of the corner of the tray, which makes itpossible to arrange two adjacent rows of trays close together. ln one embodiment, the spacer arrangement may comprise a connection flaplocking arrangement, wherein said connection flap locking arrangement maycomprise a female interface and a male interface. lf a locking arrangement for theconnection flap can be integrated within the blank, may be cheaper and have lessimpact on the environment compared to an external locking arrangement oradhesive. ln one embodiment, the female interface can at least be provided in thesupport prism flap, and the male interface can be provided at a free end of theconnection flap.

Preferably, the male interface may be adapted to connect to the femaleinterface when the connection flap has been folded at the connection flap foldingindications around the corner tab and the support prism. The male interface can beprovided with at least one barb. The male interface can be formed in one piece withthe connection flap. The female interface can be a cut-out with a shape adapted toreceive the male interface. The cut out can be arranged at an upper part of the foldedsupport prism, in at least one of the support prism walls. Depending on the length ofthe connection flap, a further female interface can be arranged within the connectionflap. This second female interface can be arranged close to the side wall portion forconnection of the support prism flap. When the connection flap is folded at the connection flap folding indications around the corner tab and the support prism, the two female interfaces will end in register with each other and the male interface willconnect through the two female interfaces at the same time.

Preferably, a coupling interface between the female and the male interfacesmay be arranged on the inside of the folded prism. By placing the coupling interfaceon the inside of the formed prism, external impacts on the interface may be reduced,reducing the risk that the coupling interface may open unintentionally. ln one embodiment, the folding indications may be formed as creases. Thefolding indications may also be formed as perforations, but creases are preferredsince it provides a more stable folding of the parts of the tray compared toperforations, especially if they are folded several times. ln one embodiment, the blank may further be provided with at least onealignment arrangement adapted to align a tray formed by the blank with a second,identical tray when the two trays are stacked on top of each other. When severaltrays are stacked on top of each other, it is preferred that the trays are aligned inrelation to each other to get an even distribution of the weight at each spacearrangement. Thus, the load on each corner can be aligned straight along thecorners so that the corner does not bend resulting in damage to the product withinthe folded tray.

Preferably, the alignment arrangement may comprise at least one alignmenttab provided at an upper edge of the spacer arrangement, when the side wall flapsare erected, and adapted to be connected to an alignment aperture provided in acorresponding corner of the bottom plate of a second identical tray stacked on top ofthe first tray. The alignment tab may be arranged on the upper edge of the samesupport prism wall as the female interface. Depending on the length of theconnection flap, a further alignment tab can be arranged at the connection flap. Thissecond alignment tab can be positioned such that when the connection flap is foldedat the connection flap folding indications around the corner tab and the supportprism, the two alignment tabs will end up in register with each other, and thus gives areinforcement of the alignment. The alignment aperture may have the shape of acircle. The size of the aperture is so customized that the alignment tab can passthrough. The alignment aperture may also be used for drainage of moisture from thefresh products stored within a folded tray.

Preferably, the at least one alignment tab may have an upwards tapering shape; by way of example, it can have the shape of a trapezoid. By providing the alignment tab with inclined side walls, the alignment tab has a more stableconnection in the alignment aperture in a corresponding tray compared to straightside walls and provides a better alignment of the stacked trays. Since the alignmenttab is arranged at the top edge of the spacer arrangement, the tab will protrude fromthe blank. Material costs in relation to a stable alignment of two identical traysstacked on top of each other must be considered when deciding the height of thealignment tab.

Preferably, the spacer arrangement may comprise an alignment notch,wherein said alignment notch may be arranged at a bottom edge of the foldedsupport prism, opposite to the alignment tab. The alignment notch is arranged in thesame support prism wall as the alignment tab. The notch is placed just above theaperture of the alignment arrangement so that the alignment tab/tabs of a first traycan be fitted through the aperture into the second identical tray when two identicaltrays are stacked on top of each other. ln one embodiment, the first pair of side wall flaps and/or the second pair of side walls flaps may be provided with at least one cut-out for a hand adapted to beused as a handle for a tray folded from a blank. To be able to handle and lift a traymore easily, especially when it is filled with fresh products, the tray may be providedwith handles. The handles are preferably provided in each of the first pair of sidewall flaps. ln one embodiment, the first pair of side walls portions may define short sides and said second pair of side walls portions may define long sides of the tray. Thetray may have a rectangular bottom plate. The side wall flaps comprising the cornertab may comprise the side wall portions that define the short sides of the foldedtray. The side wall flaps comprising the support prism flap and the connection flapmay comprise the side wall portions that define the long sides of the folded tray. ln one embodiment, the blank can be cut in one piece from a solid boardsheet, for example paperboard. The solid board can comprise at least two layers of acore material paper and two layers of a material paper coated with a thermoplastic,each arranged on each side of the core layers. All layers may be glued togetherforming a solid board. The first layer of coated material paper can form an outside ofa tray folded from the blank and the second layer of coated material paper can forman inside of the tray. Since both the inside and the outside of the tray can be exposedto moisture, these layers may be provided with a barrier to prevent moisture from entering the core. The layers forming the inside and the outside of the folded traymay also be provided by a material paper without coating of a thermoplastic material.The choice of material for the layers within the board should be chose to provide aboard with a flexibility to resist both pressure without curving or collapse due to loadand at the same time have reduced density in order to save material costs. A boardwith a density of between 800 - 1100 g/m2 is preferred. lt may also be possible to cut out the blank in one piece from another sheet ofpaper material, for example corrugated paper, but a sheet of solid board is preferred. ln one embodiment, the blank can be configured to be folded back to a blankafter having been folded to a tray. Since the parts of the tray may be connected toeach other only by the folded connection flap, and with any connection flap lockingarrangement as the case may be, it may be possible to fold back the tray into a blankafter the tray has been used. The blank may then be transported to a new place,folded to a tray again and reused for storage and transport of fresh products.

According to a second aspect, parts or all of the above mentioned problemsare solved, or at least mitigated, by a fresh product tray formed by folding a blank asdefined above at folding indications to define an inner storage volume between thefirst pair and second pair of side walls. This tray can be used for storage andtransport of fresh products. ln prior art trays for fresh products, spacer arrangementsare often plastic spacers arranged in the corners of the folded tray after the tray hasbeen erected. These plastic spacers are comparatively expensive. The abovedefined tray may also have less impact on the environment since no adhesives ormechanical fasteners are needed to keep the parts of the tray together. The blankmay be transported unfolded to the site of use. A blank requires less space than afolded tray and makes it possible to transport more blanks within the same transportvehicle. The folded tray may weigh less than a tray with plastic spacers. lt is noted that embodiments of the invention may be embodied by all possiblecombinations of features recited in the claims. Further, it will be appreciated that thevarious embodiments described for the device are all combinable with the method asdefined in accordance with the second aspect of the present invention, and vice VGFSG.

Brief description of the drawinqs The above, as well as additional objects, features and advantages of thepresent invention, will be better understood through the following illustrative and non-limiting detailed description of preferred embodiments of the present invention, withreference to the appended drawings, where the same reference numerals will beused for similar elements, wherein: Fig. 1 is a schematic view in perspective of a fresh product tray, Fig. 2 is a schematic view in perspective of a blank adapted to folded to a trayaccording to Fig. 1, Fig. 3 is a schematic plan view of the blank of Fig. 2 with dimensionsindicated.

Fig. 4 -9 are schematic views of a blank according the Fig. 2 being folded intoa tray according to Fig. 1 in steps.

All the figures are schematic, not necessarily to scale, and generally only showparts which are necessary to elucidate the embodiments, wherein other parts may be omitted.

Detailed description of the exemplarv embodiments Fig. 1 illustrates a tray 10 formed by folding a blank 20 (illustrated in Fig. 2) atfolding indications to define an inner storage volume 25 between a first pair and asecond pair of side walls 40, 42. The tray 10 is used for storage, transport, anddisplay of freshly harvested products.

The tray 10 is provided with cut-outs 22 for hands, the cut-outs 22 beingadapted to be used as handles for the tray 10 to facilitate lifting and moving of filledtrays 10.

Several trays 10 need to be stacked on top of each other during transport andstorage to save space. When the trays 10 are stacked on top of each other, the innerstorage volumes 25 cannot be placed too close on top of each other. ln order toprevent damage of the products within the trays 10, a spacer arrangement 24 can beprovided in each corner 26 of the tray 10 to provide at distance between the storagevolumes 25 of two trays 10 stacked on top of each other. The spacer arrangement 24also provides for visual contact with and ventilation of the products with the tray 10.

The spacer arrangement 24 can according to prior art be an external spacerthat's is connected to each corner 26 of the tray 10 after the tray 10 has been erected or the spacer arrangement 24 can be an integral part of the blank 20 that is folded toa spacer arrangement 24 when the tray 10 is erected.

The tray 10 can be erected by a machine or manually. When the tray 10 iserected by a machine, the side walls of the tray are preferably connected to eachother by an adhesive or a mechanical fastener. When the tray 10 is erectedmanually, the side walls of the tray 10 are preferably according to prior art connectedto each other by locking tabs that are manually locked in position with acorresponding aperture.

The size of the tray 10 is adapted to contain a certain amount or weight of acertain fresh product. The size of the tray 10 is also dependent on the size of thepallet, on which trays 10 are to be transported. The height of the tray 10 depends onwhich product that shall be stored within the tray 10, and the height of the vehicle orcontainer in which the trays 10 are to be transported. Thus, many different sizes oftrays 10 are manufactured.

Fig. 2 illustrates a blank 20 that has been cut and provided with foldingindications to be folded to a tray 10 for fresh products as shown in Fig.1.

The blank 20 is cut in one piece from a solid board sheet. The solid boardcomprises four layers of paper (not shown): Two core layers and two coated layers(not shown). The coated layers are coated with an environmentally friendly plastic,for example polythylene. The core layers are attached to each other, and the coatedlayers are each arranged on each side of the core layers. The layers are glued toeach other forming a solid board. One of the coated layers forms the outside of a tray10 folded from the blank 20 and the other coated layer forms an inside of the tray 10.Since both the inside and the outside of the tray 10 are exposed to moisture from theproduct within the tray 10 or from different weather conditions, the plastic coatingprevents the tray 10 from becoming wet and thus soft, which can cause the tray 10 tocollapse. The two coated layers can be provided with different colours to distinguishbetween the inside face and the outside face, and different trays may be givendifferent colours to distinguish between trays from different growers. The outside ofthe tray 10 can also be provided with the trademark of the grower. The choice ofmaterial for the layers within the solid board should be chosen to provide a boardwith a flexibility to resist both pressure without curving or collapse due to load and atthe same time have reduced density in order to save material costs. A solid board with a density of between 800-1100 g/m2 may be preferred. The solid board ispreferably made of recycled material.

The blank 20 has a substantially rectangular shape and defines a bottom plate28, a first pair of side wall flaps 30 and a second pair of side wall flaps 32, attachedto the bottom plate 28 along respective bottom edge folding indications 34. The firstpair of side walls flaps 30 comprises a first pair of side wall portions 36 configured todefine a first pair of opposite side walls 40 (Fig. 1) and the second pair or side wallflaps 32 comprise a second pair of side wall portions 38 configured to define asecond pair of side walls 42 (Fig.1) when the side wall flaps 30, 32 are erected.

When the side walls flaps 30, 32 are erected (Fig. 1), each side wall portion36, 38 will comprise a top edge 44 and two opposite side edges 46a, 46b. The firstpair of side wall portions 36 will define short sides 40 and the second pair of side wallportions 38 will define long sides 42 of the tray 10 (Fig. 1).

The side wall flaps 32, 34 further comprise at least one spacer arrangementportion configured to define a spacer arrangement 24, adapted to keep a second,identical tray 10 stacked on top at a distance from the top edge 44 of the respectiveside wall 40 or 42. Preferably, as illustrated in Fig. 1, a spacer arrangement 24 isarranged in each corner 26 of the tray 10.

Each spacer arrangement 24 comprises a support prism flap 48, a rigid cornertab 50, a connection flap 52 and a connection flap locking arrangement.

A support prism flap 48 is foldably connected to at least one side edge 46a,46b of a side wall portion 36 or 38 of the respective side wall flap 30, 32. ln the blankillustrated in Fig. 2, a support prism flap 48 is connected to each of side edge 46a,46b of the side wall portions 38 that defines long sides 42 of the tray 10. The supportprism flap 48 is provided with three support prism flap folding indications 54 arrangedperpendicular to the bottom edge folding indication 34 of the second side wall flap 32.The support prism flap 48 is arranged to form a support prism 49, when the supportprism flap 48 is folded at the support prism flap folding indications 54.

A rigid corner tab 50 is rigidly connected to a side wall portion 36 or 38. ln theblank 20 according to Fig. 2 there are two rigid corner tabs 50 rigidly connected toeach respective side wall portion 36 that defines a respective short side 40 of the tray10. The corner tabs 50 extend in a plane of the respective side wall 40, when the firstside wall flaps 30 are erected. The rigid corner tabs 50 are arranged close to the sideedges 46a, 46b of the respective side wall portions 36 of the first pair of side wall portions, and protrude in a direction perpendicular to the bottom edge foldingindications 34 of the respective side wall flaps 30. The corner tabs 50 extend abovethe top edge 44 of the side wall portion 36.

Two connection flaps 52 are arranged at the top edge 44 of each side wallportion 38 of the second pair of side wall flaps 32. Each connection f|ap 52 isarranged above the top edge 44 of the respective side wall portion 38 and extendsalong the side wall portion 38, parallel to the bottom edge folding indication 34. Eachconnection f|ap 52 is foldably connected to a wall of the support prism 49, formedwhen the support prism f|ap 48 is fo|ded at the support prism f|ap folding indications54 in a manner which will be e|ucidated further below, and extends towards thecentre of the second side wall portion 38. Each connection f|ap 52 is provided with atleast two, and in the i||ustrated example, four connection f|ap folding indications 56arranged perpendicular to the bottom edge folding indication 34 of the respectiveside wall f|ap 32. ln the embodiment, i||ustrated in Fig 2, each connection f|ap 52comprises four segments 57 separated by three connection f|ap folding indications56.

Each connection f|ap locking arrangement comprises at least one femaleinterface 58 and a male interface 60, adapted to be the connected to each other. Themale interface 60 is provided at a free end of the connection f|ap 52, opposite to anattached end of the connection f|ap 52. A female interface 58 is arranged in a wall ofthe support prism 49 formed by the support prism f|ap 48 when fo|ded at the supportprism f|ap folding indications 54. As i||ustrated in Fig. 2, a further, second femaleinterface 58 can be arranged in the connection f|ap 52; this second female interface58 is arranged in a segment of the connection f|ap close to the attached end of theconnection f|ap 52. This second female interface 58 may also act as a male interface60 since the second female interface is formed when the male interface is pressingthe tab within the segment of the connection tab inwards and follows the maleinterface 60 through the first female interface 58 (as i||ustrated in Fig 9). ln the embodiment according to Fig. 2, the male interface 60 is provided withat least one barb and the female interface 58 is a cut-out with a shape to receive themale interface 60. Other shapes of the male interface 60 are possible wherein thefemale interface 58 is adapted to receive the shape of the male interface 60.

The blank 20 is further provided with at least one alignment arrangementadapted to align a tray 10 fo|ded by the blank 20 with a second identical tray 10 when two trays 10 are stacked on top of each other. The alignment arrangement comprisesalignment tabs 62, an alignment aperture 64, and an alignment notch 66.

An alignment tab 62 is provided in the support prism flap 48. The alignmenttab 62 is arranged on a top edge of the support prism 49 formed when the supportprism flap 48 is folded at the support prism flap folding indications 54, extending fromthe same support prism wall as the female interface 58 is formed in. As illustrated inFig. 2, a further, second alignment tab 62 is arranged at the connection flap 52. Thissecond alignment tab 62 is arranged in a segment of the connection flap close to theattached end of the connection flap 52. The alignment aperture 64 is provided inbottom plate 28, at a corner formed between the long side 42 and the short side 40when the side wall flaps 30, 32 are erected.

The alignment tabs 62 have the shape of trapezoids and the apertures 64have circular shape. The alignment tabs 62 of a first tray 10 are adapted to passthrough the apertures 64 of a second identically tray 10, when the second tray 10 isstacked on top of the first tray 10. The inclined side edges of the alignment tabs 62facilitate the alignment of the trays 10 in relation to each other and prevent the trays10 from moving sideways in relation to each other.

The alignment notch 66 is provided in the support prism flap 48. Thealignment notch 66 is arranged in the same wall of the support prism as the firstalignment tab 62 and the first female interface 58. The alignment notch 66 is adaptedto make room for the alignment tab 62 when the alignment tab 62 of a first tray 10 ispassed through the alignment aperture 64 of a second tray 10, stacked on top of thefirst tray 10.

Preferably, as illustrated in Fig. 2, a set of alignment tabs 62 and an alignmentnotch 66 are arranged at each support prism flap 48 and an alignment aperture 64 isarranged in each corner of the bottom plate 28 formed where the long sides 42meets the short sides 40.

The alignment apertures 64 can also be used for ventilation and drainage ofthe product within a tray 10 folded from a blank 20. To contribute to the ventilationand drainage, a further aperture can be provided in the middle of the bottom plate 28as seen Fig. 2.

The folding indications 34, 54, 56 illustrated in the figure could be formed as perforations or creases but are preferably formed as creases, since a tray 10 formed from a blank 20 will be subject to heavy load and compression when several trays 10are stacked on top of each other.

Fig. 3 illustrates a blank 20 with exemplary dimensions to be folded to a tray10, whose size is such that four identical trays 10 can be placed close to each other,forming a first layer of trays 10 stacked on a pallet with the size 80 X 120 cm: A length L1 of each side wall flap 30 of the first pair of side wall flaps,extending along the respective bottom plate folding indications 34, is approximately350 - 400 mm, a length L2 of each side wall flap 32 of the second pair of side wall flaps,extending along the respective bottom plate folding indications 34, is approximately700-750 mm, a height H1 of each side wall portion 36 of the first pair of side wall flaps 30,extending perpendicular to the respective bottom plate folding indications 34, fromthe bottom plate 28 to the top edge 44 of the side wall 40, is approximately 150-160mm, a height H2 of each side wall portion 38 of the second pair of side wall flaps32, extending perpendicular to the bottom plate folding indication 34, from the bottomplate 28 to the top edge 44 of the side wall 42, is approximately 150-160 mm, a height H3 of the corner tabs 50, extending above the top edge 44 of the firstside wall 40, is approximately 25-35 mm, a width W1 of the connection flap 52 is about 25-35 mm, and a width W2 of the corner tab 50, extending above the top edge 44 of the firstside wall 40, approximate 25-35 mm.

Figs. 4-9 illustrate how a blank 20 according to Figs. 2 or 3 is folded to a tray10 according to Fig.1.

Figs. 4-5 illustrates the erection of the side wall flaps 30, 32 for forming theside walls 40,42 of the tray 10. ln Fig. 4, the second pair of side wall flaps 32 are folded at the respectivebottom edge folding indications 34 and erected in a direction perpendicular to thebottom plate 28 to define long sides 42 of the tray 10. Each long side 42 has a topedge 44, with the connection flaps 52 extending above this top edge 44. The supportprism flaps 48 are each folded at support prism folding indications 54 to extend in adirection perpendicular to the long sides 42, thereby extending along the respective bottom edge folding indications 34 of the first side wall flap 30, providing two oppositeside edges 46a, 46b of each long side 42. ln Fig. 5, the first pair of side wall flaps 30 are folded at the respective bottomplate folding indications 34 and erected in a direction perpendicular to the bottomplate 28 to define short sides 40 of the tray 10 and an inner storage volume 25between the first pair and second pair of side walls 40, 42. Each short side 40 has atop edge 44, with the rigid corner tabs 50 extending in a p|ane of the side wall abovethe top edge 44 and protruding in a direction perpendicular to the bottom edgefolding indication 34, and two side edges 46a, 46b. Outer corners 26 of the tray 10are formed where each side edge 46a, 46b of the short sides 40 meets respectiveside edges 46a, 46b of the long sides 42. The support prism flaps 48 extend on theinside of the short sides 40, facing the inner storage volume 25 of the tray 10.

Figs. 6-9 illustrate the formation of a reinforced spacer arrangement 24 ineach corner 26 of the tray 10 formed when the side walls flap 30, 32 were erected.Each spacer arrangement 24 comprises the support prism flap 48, the rigid cornertab 50, the connection tab 52, and the connection tab locking arrangement 58, 60. ln Fig. 6, each prism support flap 48 is folded at the prism support flap foldingindications 54, to form a support prism 49 extending inside the side walls 40, 42 ateach corner 26 of the tray 10. The illustrated prism support flap 48 contains threesupport prism flap folding indications 54 and a support prism 49 with triangular shapeis formed when the support prism flap 48 is folded at the support prism flap foldingindications 54. The folded support prism 49 extends along the entire height of theside walls 40, 42, from the bottom edge folding indications 34 of the respective sidewall flaps 30, 32 to the top of the respective spacer arrangements 24 to be formed.The support prism wall containing the second female interface 58, the secondalignment tab 62 and the alignment notch 66 face the inner storage volume 25 of thetray 10 when the support prism 49 is formed. The alignment notch 66 will bearranged in a bottom edge of the support prism wall and the alignment tab will bearranged in a top edge of the same support prism wall, while the female interface 58is formed within the support prism wall below the alignment tab 62 but above the topedge 44 of the side wall 40, 42. The alignment notch 66 is arranged above thealignment aperture 64, and when a first tray 10 is stacked on top of a secondidentical tray 10, the alignment tab/tabs 62 will be inserted through the alignmentaperture 64 of the second tray 10 and arranged within the alignment notch 66.

The rigid corner tab 50 forms a part of the spacer arrangement 24 and has aheight H3 (Fig. 3) extending above the top edge 44 of the first side wall 40. Thecorner tab 50 has a width, parallel to the respective bottom edge folding indications34, adapted to the width of the support prism 49.

The connection flap 52 is also a part of the spacer arrangement 24 and isadapted for, when fo|ded at the connection flap folding indications 56, coupling of afirst side wall 40 with an adjacent side wall 42 formed by the side wall portions 36,38.

Figs. 7-9 illustrates the folding of the connection f|aps 52 at the connection flapfolding indications 54 for coupling of respective long sides 42 of the tray 10 withrespective short side 40 of the tray 10.

As illustrated in the Figs. 7, the connection flap 52 is foldably connected to awall of the support prism 49 and extends above the top edge 44 of the side walls 40,42. Each connection flap 52 has a width W1 (Fig. 3), perpendicular to bottom edgefolding indication 34, that corresponds to the height H3 (Fig. 3) of the corner tab 50.

Each connection tab 52 is adapted, when folding at the connection tab foldingindications 56, to be fo|ded around the corner tab 50 and the support prism 49 forcoupling of the side walls 40,42.

The connection flap 52 according to the showed embodiment comprises foursegments 57 and four connection tab folding indications 56. The connections flap 52is first fo|ded at the first folding indication 56 nearest the wall of the support prism 49,such that a first segment 57 of the connection flap 52 will thus be arranged on a topsection of the support prism's 49 wall facing the inner storage volume 25 of the tray10, along the entire width of the support prism's 49 wall. The female interface 58arranged in the connection flap 52 will be arranged in register with the femaleinterface 58 in the support prism's 49 wall, and the alignment tab 62 of theconnection flap 56 will be arranged in register with the alignment tab 62 of thesupport prism's 49 wall, at a top edge of the spacer arrangement 24. The alignmenttabs protrude approximate between 5-15 mm above the top edge of the spacerarrangement.

The connection flap 52 is then fo|ded at a second connection flap foldingindication 56, towards an outside face of the short side 40, where a second segment57 of the connection flap 52 is arranged along the entire width W2 of the corner tab50, as illustrated in Fig. 8.

The connection flap 52 is then folded at a third connection flap foldingindication 56, towards an outside face of the long side 40, where a third segment 57of the connection flap 52 is arranged along the entire width of the support prism 49 _The connection flap 52 is finally folded at a third connection flap folding indication 56,towards the inner storage volume 25 of the tray 10 again, where the male interface60 of the connection flap locking arrangement is arranged in register with the twofemale interfaces 58, as illustrated in Fig. 9. The male interface 60 is then pressedthrough the female interfaces 58 to form a coupling interface on the inside of thefolded support prism 49. The second female interface 58 may also act as a maleinterface 60 since the second female interface 58 is formed while the male interface60 is pressing the tab within the segment of the connection tab 52 inwards and thusfollows the male interface 60 through the first female interface 58 to form aconnection interface on the inside of the folded support prism 49.

A reinforcement of the spacer arrangement 24 has now been finalized in eachcorner 26 of the tray 10 and a tray 10 has been folded from a blank 20 without theuse of adhesive or mechanical fasteners for connection of the individual parts of thetray 10.

When the tray 10 has been used for transport and storage of fresh products,the blank 20 is configured to be folded back to a blank 20 again. Thus, it is possibleto reuse the same blank 20 at several occasions.

The invention has mainly been described above with reference to a fewembodiments. However, as is readily appreciated by a person skilled in the art, otherembodiments than the ones disclosed above are equally possible within the scope ofthe invention, as defined by the appended patent claims.

For example, the support prism flaps and the connection flaps could beprovided at the first pairs of side wall flaps instead of the second pairs of side wallflaps as illustrated in the embodiment according to the figures. This will result in thatthe connection flap comprises less segments and folding indications and willtherefore not be arranged to be folded around all the prism walls as illustrated inFigs. 7-9 and that only one female interface is required.

The blank can also have a substantially square shape, resulting in that the firstand the second side wall flaps and thereby the side walls provided when the side wallflaps are erected, are of the same length and thus it does not matter on which side wall flap, the support prism flap and the connection flap are provided. ln the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality.

Claims (28)

Claims

1. A blank (20) that has been cut and provided with folding indications (34,54, 56) to be folded to a tray (10) for fresh products, said blank (20) having asubstantially rectanguiar shape, and defining a bottom plate (28), a first pair of side wall flaps (30) comprising a first pair ofside wall portions (36) configured to define a first pair of opposite side walls (40)attached to the bottom plate (28) along respective bottom edge folding indications(34), and a second pair of side wall flaps (32) comprising a second pair of side wallportions (38) configured to define a second pair of opposite side walls (42) attachedto the bottom plate (28) along respective bottom edge folding indications (34), wherein each side wall portion (36, 38), when erected, comprises a top edge(44) and two opposite side edges (46a, 46b), wherein said side wall flaps (30, 32) further comprise at least one spacerarrangement portion configured to define a spacer arrangement (24) adapted to keepa second, identical tray (10) stacked on top at a distance from the top edge (44) ofthe side wall (40, 42), and wherein said at least one spacer arrangement portion comprises a connectionflap (52) adapted for coupling of a first side wall (40) with a second adjacent side wall(42) formed by said side wall portions (36, 38).

2. A blank (20) according to claim 1, wherein said spacer arrangement (24)comprises a support prism flap (48), defined by a respective side wall flap (30, 32) wherein said support prism flap (48) is provided with at least two support prismflap folding indications (54) arranged perpendicular to the bottom edge foldingindication (34) of the side wall flap (30, 32), the support prism flap (48) beingarranged to form a support prism (49) to extend inside the side walls (40, 42) whenthe support prism flap (48) is folded at the support prism flap folding indications (54).

3. A blank (20) according to claim 2, wherein said support prism flap (48) isarranged foldably connected at one of the side edges (46a, 46b) of the side wall portion (36, 38) of the respective side wall flap (30, 32).

4. A blank (20) according to claim 2 or 3, wherein said support prism flap(48) is configured to form a triangular support prism (49) when folded at the support prism flap folding indications (54).

5. A blank (20) according to any of the claims, 2-4 wherein the foldedsupport prism (49) extends along the entire height of the side wall (40, 42), from thebottom edge folding indication (34) of the respective side wall flap (30, 32) to the top of the spacer arrangement (24).

6. A blank (20) according to any of the claims 2-5, wherein the connectionflap (52) is foldably connected to a wall of the support prism (49).

7. A blank according to any of the preceding claims, wherein the spacerarrangement (24) comprises a rigid corner tab (50), wherein said corner tab (50) is rigidly connected to a side wall portion (36, 38)and extends in a plane of the side wall (40, 42), when the side wall flap (30, 32) iserected, and wherein the corner tab (50) protrudes in a direction perpendicular to the bottom edge folding indication (34) of the side wall flap (30, 32).

8. A blank (20) according to claim 7 in combination with any of the claims 2-

9. A blank (20) according to claim 8 , wherein the corner tab (50) isarranged at a first side wall flap (30) and the support prism flap (48) is arranged at asecond side wall flap (32) to form first and second side walls (40, 42) meeting eachother to form an outer tray corner (26) when the side wall flaps (30, 32) are erected.

10. A blank (20) according to claim 9, wherein said connection flap (52) isprovided with at least two connection flap folding indications (56) arrangedperpendicular to the bottom edge folding indication (34) of the side wall flap (30, 32),and wherein the connection flap (52) is adapted to be folded around the corner tab(52) and the support prism (49) for coupling of said first side wall (40) with saidsecond side wall (42) meeting each other to form an outer tray corner (26) when theside wall flaps (30, 32) are erected.

11. A blank (20) according to claim 10, wherein a width (W1) of theconnection flap (52), perpendicular to the respective bottom edge folding indication(34), correspond to the height (H3) of the corner tab (50).

12. A blank (20) according to any of the claims 8-11, wherein the corner tab(50) has a width (W2), parallel to the respective bottom edge folding indication (34),adapted to the width of the support prism (49).

13. A blank (20) according to any of the preceding claims, wherein saidconnection flap (52) is arranged at the top edge (44) of a side wall portion (36, 38),when the side wall portion (36, 38) is erected.

14. A blank (20) according to any of the preceding claims, wherein theconnection flap (52) comprises four segments (57) separated by three connection flap folding indications (56).

15. A blank (20) according to any of the preceding claims, wherein saidspacer arrangement (24) comprises a connection flap locking arrangement (58, 60),wherein said connection flap locking arrangement (58, 60) comprises a femaleinterface (58) and a male interface (60).

16. A blank (20) according to claim 15 in combination with any of claims 2-6,wherein the female interface (58) is at least provided in the support prism flap (48),and the male interface (60) is provided at a free end of the connection flap (52).

17. A blank (20) according to any of the claims 15 and 16, wherein the maleinterface (60) is adapted to connect to the female interface (58) when the connectionflap (52) is folded at the connection flap folding indications (56) around the corner tab(50) and the support prism (49).

18. A blank (20) according to any of the claims 15-17, wherein a coupling interface between the female (58) and the male interface (60) is arranged on theinside of the folded support prism (49).

19. A blank (20) according to any of the preceding claims, wherein thefolding indications (34, 54, 56) are formed as creases.

20. A blank (20) according to any of the preceding claims, wherein saidblank (20) further is provided with at least one alignment arrangement (62, 64, 66)adapted to align a tray (10) formed by the blank (20) with a second, identical tray (10) when the two trays (10) are stacked on top of each other.

21. A blank (20) according to claim 20, wherein said alignment arrangement(62, 64, 66) comprises at least one alignment tab (62) provided at an upper edge ofthe spacer arrangement (24), when the side wall flaps (30, 32) are erected, andadapted to be connected to an alignment aperture (64) provided in a correspondingcorner of the bottom plate (28) of a second identically tray (10) stacked on top of thefirst tray (10).

22. A blank (20) according to claim 21, wherein said at least one alignmenttab (62) has the shape of a trapezoid.

23. A blank (20) according to 21 or 22 in combination of any of claims 2-6,wherein the spacer arrangement (24) comprises an alignment notch (66), whereinsaid alignment notch (66) is arranged at a bottom edge of the folded support prism(49), opposite to the alignment tab (62).

24. A blank (20) according to any of the preceding claims, wherein the firstpair of side wall flaps (30) and/or the second pair of side walls flaps (32) are providedwith at least one cut-out (22) for a hand adapted to be used as a handle for a tray(10) folded from a blank (20).

25. A blank (20) according to any of the preceding claims, wherein said firstpair of side walls portions (36) defines short sides (40) and said second pair of sidewalls portions (38) defines long sides (42) of the tray (10).

26. A blank (20) according to any of the preceding claims, wherein the blank(20) is cut in one piece from a solid board sheet.

27. A blank (20) according to any of the preceding claims, wherein the blank(20) is configured to be folded back to a blank (20) after having been folded to a tray(10).

28. A fresh product tray (10) formed by folding a blank (20) according to claims 1-27 at folding indications (34, 54, 56) to define an inner storage volume (25)between the first pair and second pairs of side walls (40, 42).