US20200115098A1

US20200115098A1 - Shipping carton transformable into a shelf ready tray

Info

Publication number: US20200115098A1
Application number: US16/158,387
Authority: US
Inventors: Jeff T. Burks
Original assignee: WestRock Shared Services LLC
Current assignee: WestRock Shared Services LLC
Priority date: 2018-10-12
Filing date: 2018-10-12
Publication date: 2020-04-16
Also published as: GB201914722D0; CA3058113A1; GB2578826A; BR102019021420A2

Abstract

A shipping carton is disclosed that is transformable into a shelf ready tray, which includes an upper portion configured as an RSC type carton having a plurality of foldable closure flaps and a lower portion configured as a shelf ready tray that has a flat base panel, wherein the upper portion is separable from the bottom portion along a series of interconnected perforated cut lines, so as to transform the shipping carton into a shelf ready tray.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The subject invention is directed to packaging, and more particularly, to a shipping carton made from corrugated cardboard that is transformable into a shelf ready tray and also to a die cut blank for constructing a transformable shipping carton using a mandrel based tray former.

2. Description of Related Art

It is known to package and ship products for retail sale in a Regular Slotted Carton (RSC) constructed from a die cut corrugated cardboard blank. Once such a carton has reached its retail destination, the products packaged therein are removed and typically arranged on a shelf for display and subsequent purchase by a consumer. Over time, these products can become displaced or moved around on the shelf, resulting in a display that is no longer aesthetically pleasing to consumers, thus requiring time consuming reorganization.
It would be beneficial therefore to provide a shipping carton of the RSC type, that can be easily formed, loaded, closed, stacked and shipped in a conventional manner, without the need for slip sheets or master cases, and then subsequently transformed into a shelf ready display tray once it has reached its retail destination.
The subject invention provides such a shipping carton that is formed from a die cut blank using a mandrel based tray former and having a series of perforations provided therein that can be utilized to separate a lower portion of the shipping carton from an upper portion of the shipping carton, whereby the upper portion of the shipping carton is configured as an RSC type carton for convenient product loading and the lower portion of the shipping carton, once separated from the upper portion of the shipping carton, defines a shelf ready tray having a flat bottom for displaying products on a level base structure.

SUMMARY OF THE DISCLOSURE

The subject invention is directed to a new and useful shipping carton that is made from corrugated cardboard and is transformable into a shelf ready tray for displaying the contents of the carton in a manner for easy access. In accordance with certain embodiments of the subject invention, the shipping carton is formed from a die cut blank that includes a flat rectangular bottom panel having opposed front and rear edges and opposed first and second side edges, wherein the bottom panel is common to the carton and the tray formed therefrom.
The die cut blank further includes a front panel that is foldably connected to the front edge of the bottom panel along a front crease and includes a front perforated cut line running parallel to the front crease for forming a front wall of the tray from the front panel. The blank also includes a rear panel that is foldably connected to the rear edge of the bottom panel along a rear crease and includes a rear perforated cut line running parallel to the rear crease for forming a rear wall of the tray from the rear panel.
The blank further includes opposed first and second main outer side panels that are foldably connected to the opposed first and second side edges of the bottom panel along respective first and second side creases to define outer opposed side walls of the tray. In certain embodiments of the subject invention, the opposed first and second side panels each includes a side perforated cut line for forming the outer opposed side walls of the tray from the opposed first and second side panels.
Preferably, the front panel has opposed first and second front side flaps that are foldably associated therewith and the front perforated cut line extends through the opposed first and second front side flaps for forming opposed front inner side wall portions of the tray from the opposed first and second front side flaps. In addition, the rear panel has opposed first and second rear side flaps that are foldably associated therewith and the rear perforated cut line extends through the opposed first and second rear side flaps for forming opposed rear inner side wall portions of the tray from the opposed first and second rear side flaps.
Preferably, the opposed front inner side wall portions of the tray are configured to align with the outer opposed side walls of the tray, and the opposed rear inner side wall portions of the tray are configured to align with the outer opposed side walls of the tray. In addition, the front panel includes a front perforated fold line extending parallel to the front perforated cut line to define an upper front flap of the carton, and the front perforated fold line extends through the opposed first and second front side flaps to define opposed first and second upper front side flaps of the carton.
Preferably, the opposed first and second rear side flaps each have a rear perforated fold line that extends therethrough to define opposed first and second upper rear side flaps of the carton. In certain embodiments of the subject invention, the rear perforated fold lines of the opposed first and second rear side flaps are co-extensively aligned with the rear perforated cut line of the rear panel. In other embodiments of the subject invention, the rear perforated fold lines of the opposed first and second rear side flaps are not aligned with the rear perforated cut line of the rear panel.
The subject invention is also directed to a die cut blank for a shipping carton transformable into a shelf ready tray that includes a rectangular bottom panel including opposed front and rear edges and opposed first and second side edges, wherein the bottom panel is common to the carton and the tray formed therefrom, a front panel that is foldably connected to the front edge of the bottom panel along a front crease to form an outer front wall of the tray, a rear panel that is foldably connected to the rear edge of the bottom panel along a rear crease to form an outer rear wall of the tray, and opposed first and second side panels that are foldably connected to the opposed first and second side edges of the bottom panel along respective first and second side creases, wherein each side panel includes a non-linear side perforated cut line for forming a side wall of the tray therefrom.
Preferably, the front panel includes a front perforated cut line that runs parallel to the front crease for forming a front wall of the tray from the front panel. Each of the opposed side panels includes a front side panel portion and a rear side panel portion that are foldably associated therewith and the respective side perforated cut line extends through the front and rear side panel portions to define opposed inner front and rear wall portions of the tray.
Each of the front side panel portions includes a front flap portion that is foldably associated therewith to define opposed first and second upper front flaps of the carton. Each of the rear side panel portions includes a rear flap portion that is foldably associated therewith to define opposed first and second upper rear flaps of the carton. Each of the opposed first and second side panels includes a side flap portion that is foldably associated therewith to define opposed first and second upper side flaps of the carton.
In sum, the subject invention is directed to a shipping carton made from corrugated cardboard that is transformable into a shelf ready tray, wherein the shipping carton has an upper portion that is configured as an RSC type carton having a plurality of foldable closure flaps, and a lower portion that has a flat base panel, wherein the upper portion of the shipping carton is separable from the lower portion of the shipping carton along a series of interconnected perforated cut lines, so as to transform the shipping carton into a shelf ready tray for displaying products on a level surface. Preferably, the upper and lower portions of the shipping carton are erected from a die cut blank using a mandrel based tray former.
These and other features of the transformable shipping carton of the subject invention will become more readily apparent to those having ordinary skill in the art to which the subject invention appertains from the detailed description of the preferred embodiments taken in conjunction with the following brief description of the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those skilled in the art will readily understand how to make and use the transformable shipping carton of the subject invention without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to the figures wherein:

FIG. 1 is an illustration of a die cut blank for a transformable shipping carton in accordance with a first embodiment of the subject invention;

FIG. 2 is a perspective view of a transformable shipping carton erected from the blank shown in FIG. 1, with the top portion of the carton in an open condition;

FIG. 3 is a perspective view of the transformable shipping carton shown in FIG. 2, with the top portion of the carton in a closed condition;

FIG. 4 is a perspective view of the tray formed from the shipping carton illustrated in FIG. 3;

FIG. 5 is an illustration of a die cut blank for a transformable shipping carton in accordance with a second embodiment of the subject invention;

FIG. 6 is a perspective view of a transformable shipping carton erected from the blank shown in FIG. 5, with the top portion of the carton in an open condition;

FIG. 7 is a perspective view of the transformable shipping carton shown in FIG. 6, with the top portion of the carton in a closed condition;

FIG. 8 is a perspective view of the tray formed from the shipping carton illustrated in FIG. 7;

FIG. 9 is an illustration of a die cut blank for a transformable shipping carton in accordance with a third embodiment of the subject invention;

FIG. 10 is a perspective view of a transformable shipping carton erected from the blank shown in FIG. 9, with the top portion of the carton in an open condition;

FIG. 11 is a perspective view of the transformable shipping carton shown in FIG. 10, with the top portion of the carton in a closed condition;

FIG. 12 is a perspective view of the tray formed from the shipping carton illustrated in FIG. 11;

FIG. 13 is an illustration of a die cut blank for a transformable shipping carton in accordance with a fourth embodiment of the subject invention;

FIG. 14 is an illustration of a die cut blank for a transformable shipping carton in accordance with a fifth embodiment of the subject invention, which is a modification of the die cut blank shown in FIG. 13.

FIG. 15 is a perspective view of a transformable shipping carton erected from the blank shown in FIG. 13, with the top portion of the carton in an open condition;

FIG. 16 is a perspective view of the transformable shipping carton shown in FIG. 15, with the top portion of the carton in a closed condition; and

FIG. 17 is a perspective view of the tray formed from the shipping carton illustrated in FIG. 16.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, wherein like reference numerals identify similar structural elements of the various embodiments of the subject invention, there is illustrated in FIGS. 1-4 a first embodiment of a transformable shipping carton constructed in accordance with the subject invention that is formed from a die cut corrugated cardboard blank configured to be erected into a Regular Slotted Carton (RSC) and subsequently transformed into a shelf ready tray for product display.
More particularly, as explained in detail below, the transformable shipping carton of the subject invention is formed from a die cut blank 10 shown in FIG. 1. The die cut blank 10 is adapted to be erected using a conventional mandrel based tray former into shipping carton 100 that has an upper portion configured as an RSC type carton for convenient product loading and a lower portion configured as shelf ready tray having a flat base for displaying products on a level surface, as shown in FIG. 2.
In the opened condition shown in FIG. 2, the carton 100 can be top-loaded with products in a conventional manner, as with any RSC type carton. The carton 100 is configured to be closed in a conventional manner utilizing existing closure methods such as a taper, hand tape, or gluer, as shown in FIG. 3. In this closed condition, the carton 100 can be stacked and shipped in a conventional manner, without the need for slip sheets or master cases. As explained in detail below, once the carton 100 has reached its retail destination, a series of die cut perforations formed in the blank 10 enable the carton 100 to be transformed into a shelf ready tray 200, which is shown in FIG. 4.
Referring now to FIG. 1, as noted above, the carton 100 is erected with a mandrel based tray former and glue from a die cut blank 10, which includes a flat rectangular bottom panel 12 having opposed front and rear edges 14 and 16, and opposed first and second side edges 18 and 20. The bottom or base panel 12 is common to the carton 100, which is shown in FIG. 2, and to the tray 200 that is formed therefrom, which is shown in FIG. 4.
With continuing reference to FIG. 1, the die cut blank 10 further includes a front panel 22 that is foldably connected to the front edge 14 of the bottom panel 12 along a front crease 24. The front panel 22 includes a front perforated cut line 26 running parallel to the front crease 24 that divides the front panel 22 into a lower front panel portion 25 that will form the front wall of the tray 200 and an upper front panel portion 27 that will be separated from the front wall of the tray 200. A handle 29 is defined within the upper front panel portion 27 by perforations for carrying the carton 100. In addition, the front panel 22 includes a front perforated fold line 62 that extends parallel to the front perforated cut line 26 to define an upper front flap 64 of the carton 100.
The die cut blank 10 also includes a rear panel 32 that is foldably connected to the rear edge 16 of the bottom panel 12 along a rear crease 34. The rear panel 32 includes a rear perforated cut line 36 running parallel to the rear crease 34 to separate and define the lower rear panel portion 35 that will form the rear wall of the tray 200 and an upper rear flap 78 of the carton 100. A handle 39 is defined within the rear panel 35 by perforations, and a semi-circular perforated punch 37 is formed therein to provide a starting point for engaging the perforation that define handle 39.
The die cut blank 10 further includes opposed first and second main or outer side panels 40 and 42 that are foldably connected to the opposed first and second side edges 18 and 20 of the bottom panel 12 along respective first and second side creases 44 and 46. The main side panels 40 and 42 each have a respective curvilinear upper edge 43 and 45, and these panels 40 and 42 will define the outer opposed side walls 55 and 65 of the tray 200, as best seen in FIG. 4. When the carton 100 is erected using a conventional tray former, glue is placed on the inner surfaces of the outer side panels 40 and 42, before they are folded into an upright position shown in FIG. 2.
The front panel 22 of blank 10 further includes opposed first and second front side panels 47 and 48 that are foldably connected to the front panel 22 along respective opposed front side crease lines 76 and 78. The first front side panel 46 includes an angled perforated cut line 90 that defines and separates a front inner side wall portion 50 of the tray 200 from a front inner side wall portion 94 of the carton 100. In addition, the first front side panel 47 includes a crease line 95 that defines and separates an upper front side flap portion 66 from the front inner side wall portion 94.
The second front side panel 48 includes an angled perforated cut line 92 that defines and separates a front inner side wall portion 52 of the tray 200 from a front inner side wall portion 96 of the carton 100. In addition, the second front side panel 48 includes a crease line 97 that defines and separates an upper front side flap portion 68 from the front inner side wall portion 96.
The rear panel 32 of blank 10 further includes opposed first and second rear side panels 54 and 56 that are foldably connected to the rear panel 32 along respective opposed rear side crease lines 86 and 88. The first rear side panel 54 includes a curvilinear perforated cut line 80 that defines and separates a rear inner side wall portion 58 of the tray 200 from a rear inner side wall portion 85 of the carton 100. In addition, the first rear side panel 54 includes a crease line 70 that is aligned with rear cut line 36 and defines and separates an upper rear side flap portion 74 from the rear inner side wall portion 85.
The second rear side panel 56 includes a curvilinear perforated cut line 82 that defines and separates a rear inner side wall portion 60 of the tray 200 from a rear inner side wall portion 87 of the carton 100. In addition, the second rear side panel 56 includes a crease line 72 that is aligned with rear cut line 36 and defines and separates an upper rear side flap portion 76 from the rear inner side wall portion 87.
When the carton 100 is transformed into the tray 200, the front inner side wall portion 50 and rear inner side wall portion 58 align or otherwise register with the main or outer side panel 40 of the tray 200, and the front inner side wall portion 52 and rear inner side wall portion 60 align or otherwise register with the main or outer side panel 42 of the tray 200, as best seen in FIG. 4. In this condition, the height of the rear wall 35 of the tray 200 is greater than the height of the front wall 25 of the tray 200.
Referring now to FIGS. 5-8, there is illustrated a second embodiment of the transformable shipping carton of the subject invention that is constructed from a die cut blank 110 shown in FIG. 5. The die cut blank 110 is adapted to be erected using a conventional tray former and glue into a shipping carton 300 having an upper portion constructed as an RSC type carton with closure flaps and a lower portion constructed as a mandrel formed tray having a flat base, as shown in FIG. 6.
The carton 300 is configured to be closed in a conventional manner utilizing existing closure methods such as a taper, hand tape, or gluer, as shown in FIG. 7. In this closed condition, the carton 300 can be stacked and shipped in a conventional manner without the need for slip sheets or master cases. Once the carton 300 has reached its retail destination, a series of die cut perforations formed in the blank 110 enable the carton 300 to be transformed into a shelf ready tray 400, which is shown in FIG. 8.
Referring now to FIG. 5, the die cut blank 110 includes a rectangular bottom panel 112 having opposed front and rear edges 114 and 116, and opposed first and second side edges 118 and 120. The blank 110 further includes a front panel 122 that is foldably connected to the bottom panel 112 along a front crease 124 and a rear panel 132 that is foldably connected to the rear edge 116 of the bottom panel 112 along a rear crease 134.
The front panel 122 includes a front perforated cut line 126 that divides the front panel 122 into a lower front panel portion 125 that will form the front wall of the tray 400 and an upper front panel portion 127 that will be separated from the front wall of the tray 400. A handle 129 is defined within the upper front panel portion 127 by perforations. In addition, the front panel 122 includes a front perforated fold line 162 that defines an upper front flap 164 of the carton 300.
The rear panel 132 includes a rear perforated cut line 136 that separates and defines the lower rear panel portion 135 that will form the rear wall of the tray 400 and an upper rear flap 178 of the carton 300. A handle 139 is defined within the rear panel 132 with a semi-circular perforated punch 137.
The blank 110 further includes opposed first and second outer side panels 140 and 142 that are foldably connected to the opposed first and second side edges 118 and 120 of the bottom panel 112 along respective first and second side creases 144 and 146. Here, the die cut blank 110 differs from the die cut blank 10, in that the first and second outer side panels 140 and 142 have respective curvilinear perforated cut lines 143 and 145.
More particularly, the perforated cut line 143 of the first outer side panel 140 separates and defines an upper side panel portion 153 from a lower side panel portion 155, and the perforated cut line 145 of the second outer side panel 142 separates and defines an upper side panel portion 163 from a lower side panel portion 165. In addition, the opposed first and second outer side panels 140 and 142 include respective semi-circular perforated punches 157 and 167 for engaging the perforated cut lines 143 and 145, respectively.
The front panel 122 of blank 110 further includes opposed first and second front side panels 147 and 148 that are foldably connected to the front panel 122 along respective opposed front side crease lines 176 and 178. The first front side panel 147 includes an angled perforated cut line 190 that defines and separates a front inner side wall portion 150 of the tray 400 from a front inner side wall portion 194 of the carton 300. In addition, the first front side panel 147 includes a crease line 195 that defines and separates an upper front side flap portion 166 from the front inner side wall portion 194.
The second front side panel 148 includes an angled perforated cut line 192 that defines and separates a front inner side wall portion 152 of the tray 400 from a front inner side wall portion 196 of the carton 300. In addition, the second front side panel 148 includes a crease line 197 that defines and separates an upper front side flap portion 168 from the front inner side wall portion 196.
The rear panel 132 of blank 110 further includes opposed first and second rear side panels 154 and 156 that are foldably connected to the rear panel 132 along respective opposed rear side crease lines 186 and 188. The first rear side panel 154 includes a curvilinear perforated cut line 180 that defines and separates a rear inner side wall portion 158 of the tray 400 from a rear inner side wall portion 185 of the carton 300. In addition, the first rear side panel 154 includes a crease line 170 that is aligned with rear cut line 136 and defines and separates an upper rear side flap portion 174 from the rear inner side wall portion 185.
The second rear side panel 156 includes a curvilinear perforated cut line 182 that defines and separates a rear inner side wall portion 160 of the tray 400 from a rear inner side wall portion 187 of the carton 300. In addition, the second rear side panel 156 includes a crease line 172 that is aligned with rear cut line 136 and defines and separates an upper rear side flap portion 176 from the rear inner side wall portion 187.
When the carton 300 is transformed into the tray 400, the front inner side wall portion 150 and rear inner side wall portion 158 align or otherwise register with the main or outer side panel 140 of the tray 400, and the front inner side wall portion 152 and rear inner side wall portion 160 align or otherwise register with the main or outer side panel 142 of the tray 400, as best seen in FIG. 8. In this condition, the height of the rear wall 135 of the tray 400 is greater than the height of the front wall 125 of the tray 400.
Referring now to FIGS. 9-12, there is illustrated a third embodiment of the transformable shipping carton of the subject invention that is constructed from a die cut blank 210 shown in FIG. 9. The die cut blank 210 is adapted to be erected using a conventional tray former and glue into a shipping carton 300 having an upper portion constructed as an RSC type carton with closure flaps and a lower portion constructed as a mandrel formed tray having a flat base, as shown in FIG. 10.
The carton 500 is configured to be closed in a conventional manner utilizing existing closure methods such as a taper, hand tape, or gluer, as shown in FIG. 11. In this closed condition, the carton 500 can be stacked and shipped in a conventional manner without the need for slip sheets or master cases. Once the carton 500 has reached its retail destination, a series of die cut perforations formed in the blank 210 enable the carton 500 to be transformed into a shelf ready tray 600, which is shown in FIG. 12.
Referring now to FIG. 9, the die cut blank 210 includes a rectangular bottom panel 212 having opposed front and rear edges 214 and 216, and opposed first and second side edges 218 and 220. The blank 210 further includes a front panel 222 that is foldably connected to the bottom panel 212 along a front crease 224 and a rear panel 232 that is foldably connected to the rear edge 216 of the bottom panel 212 along a rear crease 234.
The front panel 222 includes a front perforated cut line 226 that divides the front panel 222 into a lower front panel portion 225 that will form the front wall of the tray 600 and an upper front panel portion 227 that will be separated from the front wall of the tray 600. A handle 229 is defined within the upper front panel portion 227 by perforations. In addition, the front panel 222 includes a front perforated fold line 262 that defines an upper front flap 264 of the carton 500.
The rear panel 232 includes a rear perforated cut line 236 that separates and defines the lower rear panel portion 235 that will form the rear wall of the tray 600 and an upper rear flap 278 of the carton 500. A handle 239 is defined within the rear panel 232 with a semi-circular perforated punch 237.
The blank 210 further includes opposed first and second outer side panels 240 and 242 that are foldably connected to the opposed first and second side edges 218 and 220 of the bottom panel 212 along respective first and second side creases 244 and 246. Here, the die cut blank 210 is similar to the die cut blank 10, in that the first and second outer side panels 240 and 242 do not include any perforated cut lines. However, the upper edges 243 and 245 of outer side panels 240 and 242 of blank 210, which will define the outer opposed side walls 155 and 165 of the tray 600, are shaped differently from the upper edges 143 and 145 of outer side panels 40 and 42 of blank 10.
The front panel 222 of blank 210 further includes opposed first and second front side panels 247 and 248 that are foldably connected to the front panel 222 along respective opposed front side crease lines 276 and 278. The first front side panel 247 includes an curvilinear perforated cut line 290 that defines and separates a front inner side wall portion 250 of the tray 600 from a front inner side wall portion 294 of the carton 500. In addition, the first front side panel 247 includes a crease line 295 that defines and separates an upper front side flap portion 266 from the front inner side wall portion 294.
The second front side panel 248 includes an curvilinear perforated cut line 292 that defines and separates a front inner side wall portion 252 of the tray 600 from a front inner side wall portion 296 of the carton 500. In addition, the second front side panel 248 includes a crease line 297 that defines and separates an upper front side flap portion 268 from the front inner side wall portion 296.
The rear panel 232 of blank 210 further includes opposed first and second rear side panels 254 and 256 that are foldably connected to the rear panel 232 along respective opposed rear side crease lines 286 and 288. The first rear side panel 254 includes a perforated cut line 280 aligned with rear cut line 236 that defines and separates a rear inner side wall portion 258 of the tray 600 from an upper rear side flap portion 274, and the second rear side panel 256 includes a perforated cut line 282 aligned with tear cut line 236 that defines and separates a rear inner side wall portion 260 of the tray 600 from an upper rear side flap portion 276.
When the carton 500 is transformed into the tray 600, the front inner side wall portion 250 and rear inner side wall portion 258 align or otherwise register with the main or outer side panel 240 of the tray 600, and the front inner side wall portion 252 and rear inner side wall portion 260 align or otherwise register with the main or outer side panel 242 of the tray 600, as best seen in FIG. 12. In this condition, the height of the rear wall 235 of the tray 600 is greater than the height of the front wall 225 of the tray 600.
Referring now to FIGS. 13-17, there is illustrated a fourth embodiment of the transformable shipping carton of the subject invention that is constructed from a die cut blank 310 shown in FIG. 13, or from a slightly modified blank 410 shown in FIG. 14. In either case, the die cut blank 310, 410 is adapted to be erected using a conventional tray former and glue into a shipping carton 700 having an upper portion constructed as an RSC type carton with closure flaps and a lower portion constructed as a mandrel formed tray having a flat base, as shown in FIG. 15.
The carton 700 is configured to be closed in a conventional manner utilizing existing closure methods such as a taper, hand tape, or gluer, as shown in FIG. 16. In this closed condition, the carton 700 can be stacked and shipped in a conventional manner without the need for slip sheets or master cases. Once the carton 700 has reached its retail destination, a series of die cut perforations formed in the blank 310, 410 enable the carton 700 to be transformed into a shelf ready tray 800, which is shown in FIG. 17.
Referring now to FIG. 13, the die cut blank 310 includes a rectangular bottom panel 312 having opposed front and rear edges 314 and 316, and opposed first and second side edges 318 and 320. The blank 310 further includes a front panel 322 that is foldably connected to the bottom panel 312 along a front crease 324 and a rear panel 332 that is foldably connected to the rear edge 316 of the bottom panel 312 along a rear crease 334.
The front panel 322 includes a front perforated cut line 326 that divides the front panel 322 into a lower front panel portion 325 that will form the front wall of the tray 800 and an upper front panel portion 327 that will be separated from the front wall of the tray 800. A perforated semicircular punch 329 is defined within the upper front panel portion 327 for engaging the cut line 326.
In contrast to this die cut blank 310, the die cut blank 410 shown in FIG. 14 has a front panel 422 that is foldably connected to the bottom panel 412 along a front crease 424 that only includes a front panel portion 325 that will form the front wall of the tray. Otherwise, blank 410 and 310 are identical in form and function.
With continuing reference to FIG. 13, the rear panel 332 of blank 310 will form, in and of itself, the rear wall 335 of the tray 800. The rear panel 332 further includes a pre-cut handle area 339, for carrying the carton 700. The blank 310 further includes opposed first and second outer side panels 340 and 342 that are foldably connected to the opposed first and second side edges 318 and 320 of the bottom panel 312 along respective first and second side creases 344 and 346.
The first outer side panel 340 includes a curvilinear perforated cut lines 343 that separates and defines an upper side panel portion 353 and a lower side panel portion 355. The lower side panel portion 355 will form the first side wall of the tray 800 once it is separated from the upper side panel portion 353. The first outer side panel 340 further includes an upper side flap 364 that is foldably connected to the upper side panel portion 353 along a perforated crease 367.
The first outer side panel 340 also includes opposed front and rear side panel portions 347 and 354 that are foldably connected to the outer side panel 340 along respective front and rear crease lines 376 and 386. The front side panel portion 347 includes a substantially linear perforated cut line 390 that defines and separates a front inner wall portion 350 of the tray 800 from front inner wall portion 394 of the carton 700. In addition, the front side panel 347 includes a crease line 395 that defines and separates an upper front flap portion 366 from the front inner wall portion 394.
The rear side panel portion 354 includes a generally L-shaped perforated cut line 380 that defines and separates a rear inner wall portion 358 of the tray 800 from rear inner wall portion 385 of the carton 700. In addition, the rear side panel portion 354 includes a crease line 370 that defines and separates an upper rear flap portion 374 from the rear inner wall portion 358.
The second outer side panel 342 includes a curvilinear perforated cut line 345 that separates and defines an upper side panel portion 363 and a lower side panel portion 365. The lower side panel portion 365 will form the second side wall of the tray 800 once it is separated from the upper side panel portion 363. The second outer side panel 342 further includes an upper side flap 378 that is foldably connected to the upper side panel portion 363 along a perforated crease 369.
The second outer side panel 342 also includes opposed front and rear side panel portions 348 and 356 that are foldably connected to the outer side panel 342 along respective front and rear crease lines 378 and 388. The front side panel portion 348 includes a substantially linear perforated cut line 392 that defines and separates a front inner wall portion 352 of the tray 800 from front inner wall portion 396 of the carton 700. In addition, the front side panel 348 includes a crease line 397 that defines and separates an upper front flap portion 368 from the front inner wall portion 396. The rear side panel portion 356 includes a generally L-shaped perforated cut line 382 that defines and separates a rear inner wall portion 360 of the tray 800 from rear inner wall portion 387 of the carton 700. In addition, the rear side panel 356 includes a crease line 372 that defines and separates an upper rear flap portion 376 from the rear inner wall portion 360.
When the carton 700 is transformed into the tray 800, the opposed front inner wall portions 350 and 352 align or otherwise register with the front outer wall portion 325 of the tray 800, and the opposed rear inner wall portions 358 and 360 align or otherwise register with the rear wall portion 335 of the tray 800, as best seen in FIG. 17. In this condition, the height of the rear wall 353 of the tray 800 is greater than the height of the front wall 325 of the tray 800.
While the subject disclosure has been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes or modifications may be made thereto without departing from the spirit or scope of the subject disclosure.

Claims

1. A die cut blank for a shipping carton transformable into a shelf ready tray, comprising:

a) a rectangular bottom panel including opposed front and rear edges and opposed first and second side edges, wherein the bottom panel is common to the carton and the tray formed therefrom;

b) a front panel foldably connected to the front edge of the bottom panel along a front crease and including a front perforated cut line running parallel to the front crease for forming a front wall of the tray from the front panel;

c) a rear panel foldably connected to the rear edge of the bottom panel along a rear crease and including a rear perforated cut line running parallel to the rear crease for forming a rear wall of the tray from the rear panel; and

d) opposed first and second main outer side panels foldably connected to the opposed first and second side edges of the bottom panel along respective first and second side creases to define outer opposed side walls of the tray;

wherein the front panel has opposed first and second front side panels foldably associated therewith and the front perforated cut line extends through the opposed first and second front side panels for forming opposed front inner side wall portions of the tray from the opposed first and second front side panels;

wherein the front panel includes a front perforated fold line extending parallel to the front perforated cut line to define an upper front flap of the carton for forming at least part of a top wall of the shipping carton, the top wall being disposed opposite the bottom panel;

wherein the front perforated fold line extends through the opposed first and second front side flaps to define opposed first and second upper front side flaps of the carton for forming at least part of the top wall of the shipping carton.

2. (canceled)

3. A die cut blank as recited in claim 1, wherein the rear panel has opposed first and second rear side panels foldably associated therewith and the rear perforated cut line extends through the opposed first and second rear side panels for forming opposed rear inner side wall portions of the tray from the opposed first and second rear side panels.

4. A die cut blank as recited in claim 1, wherein the opposed front inner side wall portions of the tray are configured to align with the outer opposed side walls of the tray.

5. A die cut blank as recited in claim 3, wherein the opposed rear inner side wall portions of the tray are configured to align with the outer opposed side walls of the tray.

6. (canceled)

7. (canceled)

8. A die cut blank as recited in claim 3, wherein the opposed first and second rear side flaps each have a rear perforated fold line that extends therethrough to define opposed first and second upper rear side flaps of the carton for forming at least part of the top wall of the shipping carton.

9. A die cut blank as recited in claim 8, wherein the rear perforated fold lines of the opposed first and second rear side flaps are co-extensively aligned with the rear perforated cut line of the rear panel.

10. A die cut blank as recited in claim 8, wherein the rear perforated fold lines of the opposed first and second rear side flaps are not aligned with the rear perforated cut line of the rear panel.

11. A die cut blank as recited in claim 1, wherein the opposed first and second main outer side panels each includes a side perforated cut line for forming the outer opposed side walls of the tray from the opposed first and second main outer side panels.

12. A die cut blank as recited in claim 1, wherein a height of the rear wall of the tray formed from the rear panel is greater than a height of the front wall of the tray from the front panel.

13. A die cut blank for a shipping carton transformable into a shelf ready tray, comprising:

b) a front panel foldably connected to the front edge of the bottom panel along a front crease to form an outer front wall of the tray;

c) a rear panel foldably connected to the rear edge of the bottom panel along a rear crease to form an outer rear wall of the tray; and

d) opposed first and second side panels foldably connected to the opposed first and second side edges of the bottom panel along respective first and second side creases, each side panel including a non-linear side perforated cut line for forming a side wall of the tray therefrom;

14. (canceled)

15. A die cut blank as recited in claim 13, wherein each of the opposed side panels includes a front side panel portion and a rear side panel portion foldably associated therewith and the respective side perforated cut lines extend through the front and rear side panel portions to define opposed inner front and rear wall portions of the tray.

16. A die cut blank as recited in claim 15, wherein each of the front side panel portions includes a front flap portion foldably associated therewith to define opposed first and second upper front flaps of the carton.

17. A die cut blank as recited in claim 15, wherein each of the rear side panel portions includes a rear flap portion foldably associated therewith to define opposed first and second upper rear flaps of the carton.

18. A die cut blank as recited in claim 15, wherein each of the opposed first and second side panels includes a side flap portion foldably associated therewith to define opposed first and second upper side flaps of the carton.

19. A shipping carton transformable into a shelf ready tray, comprising:

a) an upper portion configured as an RSC type carton having a plurality of foldable closure flaps;

b) a lower portion configured as a shelf ready tray that has a unitary flat base panel that forms an entirety of a bottom wall of the shipping carton and the shelf ready display, wherein the upper portion is separable from the bottom portion along a series of interconnected perforated cut lines, so as to transform the shipping carton into a shelf ready tray.

20. A shipping carton as recited in claim 19, wherein the upper and lower portions are erected from a die cut blank using a mandrel based tray former.

21. A diet cut blank as recited in claim 1, wherein the rear perforated cut line defines a rear upper flap for forming at least part of the top wall of the shipping carton.