WO1994011269A1

WO1994011269A1 - Packaging system

Info

Publication number: WO1994011269A1
Application number: PCT/GB1993/002306
Authority: WO
Inventors: Christopher Peter Devereux
Original assignee: Elmpath Limited
Priority date: 1992-11-10
Filing date: 1993-11-09
Publication date: 1994-05-26
Also published as: GB2272683A; GB9319124D0; AU5428694A

Abstract

A packaging system for goods items comprises a plurality of trays (3) and a plurality of sleeve members (5) which, when the system is assembled, space the trays vertically from one another. Each tray (3) has in its upper surface means (4) for receiving goods items (2) and, in its upper and lower surfaces, means (6) for receiving the lower and upper edges (9, 8) of adjacent sleeve members. Each sleeve member (5) comprises a plurality of wall members (7) which, when the system is assembled, are inclined.

Description

Packaging System

The invention relates to a packaging system for packaging, storing and transporting goods items, and a tray for use in the packaging system. It is specifically intended for use in transporting goods and products for sale from the point of manufacture to the point of sale. In supermarkets and shops nowadays, many goods are not stacked on the shelves individually but are displayed in trays that are themselves placed on the shelves. These trays are known as "straight on" trays, because the same trays are used for transporting the goods and for displaying them on the shelves. The use of "straight on" trays is increasingly popular, as it reduces the time taken for shelf stacking and produces an attractive display.

When the goods are to be transported from the manufacturer or farmer, they are packed in the trays and the trays are then placed inside cardboard boxes. The cardboard boxes serve to protect the goods in the trays and allow them to be stacked for storage or transporta¬ tion. This is particularly important for goods which must not be crushed, for example, pot plants or fruit and vegetables. When the boxes arrive at the supermarket they are transferred onto a roll pallet and, when required, the trays are lifted out of the boxes and placed directly onto the shelves.

The problem with this system is that a lot of material is consumed in the manufacture of the boxes and the empty boxes create a great deal of bulky waste, which causes storage and disposal problems. The system is therefore costly and environmentally "unfriendly".

According to the present invention there is provided a packaging system for goods items, the system comprising a plurality of trays and a plurality of sleeve members which, when the system is assembled, space the trays vertically from one another, each tray having in its upper surface means for receiving goods items and, in its upper and lower surfaces, means for receiving the lower and upper edges, respectively, of adjacent sleeve members, each sleeve member comprising a plurality of wall members which, when the system is assembled, are inclined.

The packaging system allows trays containing goods for sale to be stacked for storage and for transportation from the producer to the point of sale. The sleeve member protects the goods in the tray from the environ- ment and spaces the trays from one another. The system therefore serves all the functions of the known box-based system. However, because the trays themselves form the tops and bottoms of each layer, there is a considerable saving in the amount of packaging material consumed, as compared with the known method in which the filled trays are placed in cardboard boxes. Typically, the amount of cardboard used is reduced by between 50% and 60%, and even greater savings may be achieved when packaging short items. Because the walls of the system are inclined, the assembled structure is very strong and stable, meaning that a large number of trays can be stacked. The system can be disassembled very easily, which enables the packaging trays to be placed on the supermarket shelves quickly and efficiently. Further, the used sleeve members can be stored flat, which reduces storage problems, and the whole system lends itself to recycling. The system can be used for packaging a large variety of goods, including processed and fresh foods, dry goods, pot plants, beverages, toiletries and household chemicals. Preferably, the means for receiving edges of the sleeve member extend around the periphery of the tray and one of said receiving means is located closer to the periphery of the tray than the other receiving means. This allows the edges of adjacent sleeve members to overlap one another, producing a stronger structure. Preferably, at least one of said receiving means comprises a groove formed in a surface of the tray. The tray may include a plurality of buttress members arranged to support a wall of the groove. The sleeve member may have a plurality of corresponding cut-out portions arranged to accommodate the buttress members. The cut¬ out portions also help to locate the tray correctly on the sleeve member.

At least one of said receiving means may comprise a ledge formed around the periphery of the tray. The ledge may have one or more protrusions extending from its surface.

Preferably, the tray includes means for retaining an edge of the sleeve member in the receiving means, in order to increase the structural strength of the as¬ sembled system..

The retaining means may comprise a comprise a plurality of deformations formed in a wall of the groove. Alternatively, the retaining means may comprise one or more areas of adhesive or high friction material applied to a surface of the groove and/or to an edge of the sleeve member. The retaining means may also comprise one or more detents provided at intervals along the groove, and one or more holes provided in the sleeve member which, when the system is assembled, are engaged by the detents.

Preferably, the sleeve member is made of cardboard or a plastics material. The tray may be moulded from a plastics material, and is preferably thermo-formed from a plastics sheet or injection moulded.

The wall members may be substantially planar and, advantageously, are substantially trapezoidal.

Preferably, the sleeve member is made from a flat strip of material divided by non-parallel fold lines into trapezoidal wall members. The sleeve member may be assembled for use by folding along the fold lines and joining the ends of the strip. The packaging system may include means for joining the ends of the strip, the joining means advantageously comprises a flap formed at one end of the strip, the flap being provided on a surface thereof with an adhesive. Alternatively, the joining means comprises a tab formed at one end of the strip and a slot formed at the other end of the strip for receiving the tab.

When the sleeve member is in the form of a flat strip of material, it can be kept flat and easily stored until it is needed.

The sleeve member may include one or more flap members formed along its upper edge, which may be folded over to form a lid. The system may include a plurality of secondary trays that are supported, when the system is assembled, by the first-mentioned trays, each secondary tray having in its upper surface means for receiving goods items. The system may include means, provided on the secondary and/or the first-mentioned trays, for support¬ ing the secondary trays.

The secondary trays may be smaller than the first- mentioned trays, to fit inside the sleeve members of the assembled system. The present invention further provides a packaging tray for use in a packaging system as described above, wherein the tray has in its upper surface means for receiving goods items and, in its upper and lower surfaces, means for receiving the lower and upper edges, respectively, of adjacent sleeve members, the means for receiving the edges of a sleeve members extend around the periphery of the tray, and the receiving means in one surface of the tray is located closer to the periphery of the tray than the other receiving means. By way of example, embodiments of the present invention will now be described with reference to the accompanying drawings, where:

Fig. 1 is a side view, in cross section, of a system for packaging pot plants;

Fig. 2 is a view from above of one of the trays of the system of Fig. 1;

Fig. 3 is a cross section on line III-III of the tray shown in Fig. 2;

Fig. 4 is a view of a cardboard sleeve member before folding; Fig. 5 is a view of a second form of sleeve member,

Fig. 6 is a view of a third form of sleeve member;

Fig. 7 is a view, from above, of a second form of tray, for packaging packets of coffee;

Fig. 8 is a detail, in cross section, of a third form of tray;

Fig. 9 is a detail, in cross section, of a fourth form of tray;

Fig. 10 is a side view, in cross section, of a packaging system for avocados; Fig. 11 is a side view, in cross section, of a packaging system for bottles;

Fig. 12 is a side view, in cross section, of a system for peaches;

Fig. 13 is a view from above of a tray used in the system shown in Fig. 12;

Figs. 14 and 15 are cross sections taken along lines A-A and B-B of Fig. 13, and

Figs. 16 and 17 are views of a fifth form of sleeve member, before and after assembly. Fig. 1 shows an assembled system 1 for packaging pot plants, including the packaged plants 2. The system includes a plurality of trays 3 having recesses 4 for receiving the plant pots, and a plurality of sleeves 5 that space the trays 3 from one another and protect their contents. The sleeves 5 engage grooves 6 formed around the periphery of each tray 3, the walls 7 of the sleeves being inclined so that the upper and lower edges 8,9 of adjacent sleeves overlap one another.

Figs. 2 and 3 show the tray 3 in more detail. The tray is rectangular and has a substantially flat upper surface 10 in which are formed four rows of three recesses 4 for receiving plant pots. Each recess 4 is frusto-conical with a circular cross section and a circular base 11. A drain hole 12 and two concentric circular reinforcing ribs 13 are formed in the base 11. Four vertical ribs 14, which grip a plant pot placed in the recess 4, are formed in the recess wall 15. A raised strengthening formation 16 is provided in the upper surface 10 of the tray, in the gaps between the recesses 4. The walls 15 of the recesses 4 and the walls 17,19 of the groove 6 are inclined to allow the tray 3 to nest with similar trays.

A groove 6 for receiving the lower edge 9 of the sleeve 5 is formed in the upper surface 10 of the tray and extends around its periphery. The groove 6 includes an inner wall 17, a base portion 18 and an outer wall 19. The inner wall 17 extends downwardly from the upper surface 10 of the tray at a small angle to the vertical. The base 18 of the groove is parallel to the upper surface 10 of the tray and is wide enough to accommodate a wall 7 of the sleeve 5. The base 18 is formed at a level above the base 11 of the plant pot receiving recess 4. The outer wall 19 extends upwardly from the oase 18 at a small angle to the vertical and ends in a small outwardly-extending rim 20. The recesses 4 for holding the plant pots are spaced inwardly from the outer edge of the upper surface 10 of the tray 3 so that, on the underside of the tray, a gap 21 is provided between the inner wall 17 of the groove 6 and the walls 15 of the recesses 4. The gap 21 is of sufficient width to accommodate a wall 7 of the sleeve 5. Around the edge of the upper surface 10 of the tray 3 there are formed ten downwardly-extending moulded buttresses 22, which interrupt and support the inner wall 17 of the peripheral groove 6. The buttresses 22 have the shape of truncated rectangular pyramids. The moulded tray 3 may be thermo-formed from a sheet of plastics material or, alternatively, it can be injection moulded.

Fig. 4 shows the sleeve 5 before assembly. The sleeve is cut from a sheet of 3mm cardboard and is divided by fold lines 23 into four areas 24a,b,c,d that, when the sleeve is assembled, form the four walls 7 of the sleeve, and a fifth area 24e that forms a tab 25 for joining the ends of the sleeve. The fold lines 23 are convergent, which results in the walls 7 of the assembled sleeve being inclined. A strip of adhesive tape (not shown) is provided on one side of the tab 25, for fixing it to the wall at the opposite end of the sleeve. Along the upper and lower edges of the sleeve there are a number of cut out portions 26,27 that accommodate the buttresses 22 when the system is assembled and provide thumb holes for carrying the trays.

An alternative form of the sleeve is shown in Fig. 5, in which one of the walls is divided into two parts 28a,b, which are provided at opposite ends of the un- assembled sleeve. One of those parts 28a is provided with a tab 29 and the other part 28b has a slot 30 which, when the sleeve is assembled, is engaged by the tab 29. A further form of sleeve is shown in Fig. 6. This sleeve 5 is narrower, and is intended for packaging items of small height, such as yoghurt cartons. Other forms of sleeve are possible and the sleeve may be solid or perforated for aeration, and made of materials other than cardboard, for example plastics sheet. A separate cardboard or plastic support, similar to the sleeve 5 shown in Fig. 6, may be provided underneath the edge of the bottom tray, to support the weight of the stack. The system preferably includes means for retaining the sleeve walls 7 in the peripheral groove 6 of a tray. For example, the inner surface of the groove 6 and/or the edge of the sleeve 5 can be coated with an adhesive or a material with a high coefficient of friction, such as latex. Alternatively, as shown in Fig. 7, the inner and outer walls 17,19 of the groove may include deformations 31a,b at intervals along their length, to grip the sleeve edge. In another method, shown in Fig. 8, a number of detents 32 are formed on the inner wall 17 of the peripheral groove 6, which engage corresponding holes 33 in the walls of the sleeve 5. The slight flexibility of the groove wall 17 allows the detents 32 to disengage the holes 33 when the sleeve is removed. The means for receiving the edge of the sleeve may take different forms. For example, the peripheral groove 6 may be discontinuous. Alternatively, the tray may be formed with a ledge around its perimeter, on which the sleeve rests. A number of upright abutments may be provided to prevent the sleeve slipping off the ledge. In another form, shown in Fig. 9, grooves 34,35 are formed in both the upper and lower surfaces of the tray 3, to receive the sleeve edges. In this example, the groove 34 in the upper surface is closer to the centre of the tray than the groove 35 on the lower surface, and the sleeve walls 7 are inclined outwards.

In use, the trays 3 are filled with goods items and the lower edge 4 of a sleeve is then slotted into the groove 6 in the upper surface of a first, base, tray 3. A second filled tray is then placed on top of the sleeve 5, with the upper edge of the sleeve fitting into the gap 21 around the edge of the underside of the second tray. The cut out portions 27 along the top edge of the sleeve engage the buttresses 22 on the underside of the second tray and so help to ensure correct alignment.

Successive layers are built up in the same way, each tray 3 being spaced from the next by a sleeve 5. Finally, an empty tray 3 is placed on top of the last sleeve 5, to form a protective lid for the goods in the tray below. Using this system, trays containing goods for sale can be stacked for transportation from the producer to the point of sale. The sleeves 5 protect the goods from damage and from contamination. As the trays 3 themselves form the tops and bottoms of each layer, there is a considerable saving in the amount of packaging material consumed, as compared with a method in which the filled trays are placed in cardboard boxes. Typically, the amount of cardboard used is reduced by between 50% and 60%, and even greater savings may be achieved when packaging short items. Because the supporting walls 7 are inclined, the structure is particularly strong and stable.

When the goods are to be displayed for sale, the stack is placed on a shelf, and the lid (the empty top tray 3) and the first sleeve 5 are removed to reveal the goods in the uppermost filled tray. When that tray is empty, it and the next sleeve are removed to reveal the goods in the next filled tray. Because the sleeves fold flat and the trays nest with one another, only a rela¬ tively small volume of waste material has to be removed. As illustrated by Figs. 10 and 11 , the system can be used for packaging a large variety of goods. Fig. 10 shows a system for packaging avocados, the tray 3 having recesses 36 shaped to accommodate the avocados. The sleeve walls 7 are shorter than those of the system for packaging pot plants.

Fig. 11 shows a system for packaging bottles. Each tray 3 is formed with six rows of four cylindrical reces¬ ses, each recess being shaped to receive the base of a bottle. The base 38 of each of the cylindrical recesses 37 is shaped to match the cavity formed in the base of the bottle 39. When the bottles 39 are packed in the trays 3 and trays are stacked, the top 40 of each bottle in the lower tray abuts the lower side of one of the recesses 37 of the tray above. Thus, each bottle directly supports the weight of the bottle above, which reduces the load carried by the sleeve walls 7. This feature gives the stack greater strength and stability. A further form of the packaging system is shown in Figs. 12 to 15. In this form, a plurality of secondary trays 41 are provided in addition to the trays of the embodiments described above (which trays will, in the following description, be referred to as primary trays 42). The secondary trays 41 are similar to the primary trays 42, but are not provided with a peripheral groove 43 for receiving an edge of the sleeve 44. The secondary trays 41 are designed to fit inside the sleeves 5, stacked on top of, and between, the primary trays 42. The primary and secondary trays 42,41 (which, in this case, are designed for packaging peaches), are each provided with a number of pyramid shaped hollow pillars 45 that extend upwardly from the upper surface 10 of the tray, and a corresponding number of moulded receiving members 46 formed on the lower side of the tray, for receiving the tops of the pillars 45. For each pillar 45 there is an associated receiving member 46 located at a position opposite to it, on a line through the central axis of the tray. The pillars 45 and the receiving members 46 are thereby arranged so that the trays nest when aligned, but are spaced from one another when one tray is rotated through 180° relative to one another. In the example shown in Fig. 12, two secondary trays 41 are stacked on each primary tray 42. The weight of the secondary trays 41 is borne by the primary tray 42, which may be made of more rigid material than the secondary trays 41. The sleeve 5 fits into the peripheral groove 6 of the primary tray 42 and is sufficiently tall that its top edge is higher than the tops of the peaches in the higher of the secondary trays 41. A second primary tray 42 fits on top of the sleeve 5, as in the previously described examples. Further layers are built up in the same way. The advantage of this form of the packaging system is that several trays of goods can be displayed at once, by removing a single sleeve member. This is particularly useful for goods that are sold quickly or in large numbers, for example fruit and vegetables. Figs. 16 and 17 show an alternative form of sleeve member, before assembly, that includes an integral lid 47. The basic shape of the sleeve 5 is similar to that of the sleeve member shown in Fig. 4, with two pairs of trapezoidal walls 48a,b,c,d. In addition, the sleeve 5 has four flaps 49ab,c,d, one flap being formed along the top edge of each of the sleeve walls. Each flap 49a,b,c,d is joined to the wall along fold lines 50 at the bottoms of rectangular cut out portions 51 formed in the top edge 52 of the wall. The sides of the cut out portions and top edge of the wall are cut through, to allow the flaps to be folded over along the fold lines 50.

The flaps 49a,c, that are joined to the two longer walls 48a,c each have two slots 53, one at either end, and the flaps 49b,d that are joined to the two shorter walls 48b,d each have two tabs 54 which fit into the slots 53 when the flaps are folded over. The flaps 49a,b,c,d can be folded over to enclose and protect the goods in the tray, and locked to one another by means of the tabs 54 and slots 53. Because the flaps 49a,b,c,d are joined to the walls along the bottoms of the rectangular cut out portions 51, the portions 55 of the wall between the cut out portions 51d stick up above the level of the lid 47 when the flaps are folded over. A further tray can therefore be placed on top of the sleeve 5 without interfering with the lid.

Claims

1. A packaging system for goods items, the system comprising a plurality of trays and a plurality of sleeve members which, when the system is assembled, space the trays vertically from one another, each tray having in its upper surface means for receiving goods items and, in its upper and lower surfaces, means for receiving the lower and upper edges, respectively, of adjacent sleeve members, each sleeve member comprising a plurality of wall members which, when the system is assembled, are inclined.

2. A packaging system as claimed in claim 1, in which the means for receiving edges of the sleeve members extend around the periphery of the tray, one of said receiving means being located closer to the periphery of the tray than the other receiving means.

3. A packaging system as claimed in claim 1 or claim 2, in which at least one of said receiving means comprises a groove formed in a surface of the tray.

4. A packaging system as claimed in claim 3, in which the tray includes a plurality of buttress members arranged to support a wall of the groove.

5. A system as claimed in claim 4, in which the sleeve member has a plurality of corresponding cut-out portions arranged to accommodate the buttress members.

6. A packaging system as claimed in any of claims 1 to 5, in which at least one of said receiving means comprises a ledge formed around the periphery of the tray.

7. A packaging system as claimed in claim 6, in which the ledge has one or more protrusions extending from its surface.

8. A packaging system as claimed in any one of claims 1 to 7, including means for retaining an edge of the sleeve member in the receiving means.

9. A packaging system as claimed in claim 8 when dependent on any one of claims 3 to 5, in which the retaining means comprises a plurality of deformations formed in a wall of the groove.

10. A packaging system as claimed in claim 8 when dependent on any one of claims 3 to 5, in which the retaining means comprises one or more areas of adhesive or high friction material applied to a surface of the groove and/or to an edge of the sleeve member.

11. A packaging system as claimed in claim 8 when dependent on any one of claims 3 to 5, in which the retaining means comprises one or more detents provided at intervals along the groove, and one or more holes provided in the sleeve member which, when the system is assembled, are engaged by the detents.

12. A packaging system as claimed in any of claims 1 to

11, in which the sleeve member is made of cardboard or of a plastics material.

13. A packaging system as claimed in any of claims 1 to

12, in which the tray is moulded from a plastics material.

14. A packaging system as claimed in claim 13, in which the tray is thermo-formed from a plastics sheet.

15. A packaging system as claimed in claim 13, in which the tray is injection-moulded.

16. A packaging system as claimed in any of claims 1 to 15, in which the wall members are substantially planar.

17. A packaging system as claimed in any one of claims 1 to 16, in which the wall members are substantially trapezoidal.

18. A packaging system as claimed in any one of claims 1 to 17, in which the sleeve member is made from a flat strip of material divided by non-parallel fold lines into trapezoidal wall members.

19. A packaging system as claimed in claim 18, in which the sleeve member is assembled for use by folding it along the fold lines and joining the ends of the strip.

20. A packaging system as claimed in claim 19, in which the sleeve member includes means for joining the ends of the strip.

21. A packaging system as claimed in claim 20, in which the joining means comprises a flap formed at one end of the strip, the flap being provided on a surface thereof with an adhesive.

22. A packaging system as claimed in claim 20, in which the joining means comprises a tab formed at one end of the strip and a slot formed at the other end of the strip for receiving the tab.

23. A packaging system as claimed in any one of the preceding claims, in which the sleeve member includes one or more flap members formed along its upper edge, which may be folded over to form a lid.

24. A packaging system as claimed in any one of claims 1 to 23, including a plurality of secondary trays that are supported, when the system is assembled, by the first- mentioned trays, each secondary tray having in its upper surface means for receiving goods items.

25. A packaging system as claimed in claim 24, including means, provided on the secondary and/or the first- mentioned trays, for supporting the secondary trays.

26. A packaging system as claimed in claim 23 or claim 25, in which the secondary trays are smaller than the first-mentioned trays, to fit inside the sleeve members of the assembled system.

27. A packaging tray for use in a packaging system according to any of claims 1 to 26, wherein the tray has in its upper surface means for receiving goods items and, in its upper and lower surfaces, means for receiving the lower and upper edges, respectively, of adjacent sleeve members, the means for receiving the edges of a sleeve members extend around the periphery of the tray, and the receiving means in one surface of the tray is located closer to the periphery of the tray than the other receiving means.

28. A packaging system substantially as hereinbefore described with reference to, and as shown in, Figs. 1 to 4, 5, 6, 7, 8, 9, 10, 11, 12 to 15 or 16 and 17 of the drawings.

29. A packaging tray substantially as hereinbefore described with reference to, and as shown in, Figs. 1 to 3, 7, 8, 9, 10, 11, or 12 to 15 of the drawings.