WO1999051132A1

WO1999051132A1 - A tray container and blank

Info

Publication number: WO1999051132A1
Application number: PCT/US1999/007697
Authority: WO
Inventors: Oriol Renart Manent
Original assignee: The Mead Corporation
Priority date: 1998-04-08
Filing date: 1999-04-08
Publication date: 1999-10-14
Also published as: GB9807501D0; AU3481299A

Abstract

A tray and a blank (20) for holding foodstuff which tray is formed from paperboard or like foldable sheet material and can be erected from a flat collapsed condition into a position of use. A hinged lid (18) of the tray can be manipulated from a first position in which it closes the open top of the erected tray to a second position alongside the erected tray in which second position the lid can be set up to provide a support structure adapted to receive and hold a beverage container in an upright attitude.

Description

1

A TRAY CONTAINER AND BLANK

The invention relates to a carton (or tray) for accommodating an article for example a pizza or the like and more particularly to a self fastening carton being formed from a unitary blank of paperboard material or similar foldable sheet material..

Trays for accommodating an article formed from paperboard are well known. One example is shown in US 2,924,372 which illustrates a lap tray container comprising a pair of tubular structures formed from a unitary blank to define a compartment for receiving and supporting an article, for example a can and a second compartment for receiving a dish or the like. A separate top panel is required to close the tray.

A problem associated with the prior art is the amount of paperboard required to form a carton (or tray) and/or the complexity of a blank to form a tray container.

The present invention and its preferred embodiment seeks to overcome or at least mitigate the problems of the prior art.

A first aspect of the invention provides a tray for holding foodstuff which tray is formed from paperboard or like foldable sheet material and can be erected from a flat collapsed condition into a position of use and in which a hinged lid of the tray can be manipulated from a first position in which it closes the open top of the erected tray to a second position alongside the erected tray in which second position the lid can be set up to provide a support structure adapted to receive and hold a beverage container in an upright attitude. One advantage of this arrangement, is that the amount of paperboard required to form a blank is reduced. Further, the top panel can be used to protect an article contained in the carton and can, in use, also provide a support structure for receiving and retaining a beverage container.

According to an optional feature of this aspect of the invention, the support structure may comprise a plurality of panel portions foldably connected together to define a tubular structure. According to an optional feature of this aspect of the invention, the support structure may comprise a plurality of flexible tabs displaceable from the top panel, which tabs are adapted to frictionally engage the beverage container received in an aperture formed by displacing said tabs.

According to a second aspect of the invention it is a carton for accommodating a pizza or the like comprising a top, a base panel, a pair of oppositely disposed side panels interconnecting said top and said base to provide a flat tubular structure and an end closure arrangement to close opposite ends of the carton including end panels hinged to said base characterised in that the top panel comprises a plurality of panel portions and securing means adapted to form in use a second tubular structure adjacent said flat tubular structure to be secured thereto by the securing means, which second tubular structure comprises means to receive and retain an article to be held in the carton.

According to an optional feature of this aspect of the invention the top panel may be displaced outwardly of said flat tubular structure to define a second tubular structure.

According to another optional feature of this aspect of the invention the securing means may comprise a tab struck from an end portion of the top panel adapted to be received and secured by corresponding aperture formed from an adjacent side wall of said flat tubular structure.

Preferably, the means for receiving an article may comprise a plurality of flexible tabs displaced from said top panel, which tabs are adapted to frictionally engage an article received in an aperture formed by said displaced tabs.

A third aspect of the invention provides a blank for forming a tray comprising a top panel, a base panel, a pair of oppositely disposed side panels interconnecting said top panel and said base panel and an end closure arrangement including end panels hinged to said base panel wherein the top panel comprises a plurality of panel portions and securing means adapted to form, in use, a tubular structure adjacent the tray to be secured thereto by the securing means.

According to an optional feature of this aspect of the invention, the securing means may comprise a tab struck from an end portion of the top panel adapted to be received and secured by a corresponding aperture formed from an adjacent side panel.

According to another optional feature of this aspect of the invention, the top panel may further comprise a plurality of flexible tabs displaceable from the top panel, which tabs are adapted to frictionally engage the beverage container received in an aperture formed by displacing said tabs.

An embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

FIGURE 1 is a plan view of a blank for forming a carton according to a preferred embodiment of the invention;

FIGURE 2 is an isometric illustration of a carton formed from the blank of Figure 1 fully closed and sealed;

FIGURE 3 illustrates a carton of Figure 2 with the second tubular or support structure being formed; and

FIGURES 4a and 4b are isometric illustrations viewed from above and below respectively of the carton of Figure 2 ready for use as a tray.

Referring first to Figure 1 there is illustrated a blank 10 for forming a collapsible tray or carton made from a unitary blank of paperboard or similar foldable sheet material for holding one or more articles of foodstuff, for example a pizza.. The blank comprises a plurality of panels for forming a base, a top and opposed side and end walls. In this embodiment, the blank 10 comprises first outer side panel 12, a base panel 14, second outer side panel 16, a top panel 18 and an inner side panel 20 hingably connected along foldlines 22, 24, 26 and 28 respectively.

The opposed end walls are formed by an end panel 30 is hingably connected to a side edge of base panel 14, along foldline 32 and a second end panel 34 is hingably connected to the opposing side edge of base panel 14 along foldline 36. Suitable end closure arrangements are provided for securing the side and end walls in a set up condition. For example, the first side panel 12 comprises a pair of oppositely disposed securing tabs 54, 56 struck from opposed side edges of side panel 12 along foldlines 58 and 60 respectively and, likewise, second side panel 16 comprises opposed securing tabs 62, 64 foldably connected to second side panel 16 along foldlines 66 and 68.

In those embodiments that are required to collapse, end panel 30 may further comprise a pair of oppositely disposed triangular gusset panels 38, 40 struck from end panel 30 and connected thereto by foldlines 42, 44. Similarly, second end panel 34 may also comprise a pair of triangular gusset panels 46, 48 struck from opposite ends of end panel 34 along foldlines 50 and 52.

The triangular gusset panels are adapted to be folded about their respective fold lines to allow the side and end panels 16, 12, 30, 32 to be folded into a flat collapsed condition in face contacting relationship with base panel 14.

As shown in Figures 4a and 4b, the top panel 18 includes a support structure 19 which in this embodiment is defined by one or more spaced and substantially parallel foldlines 70, 72 intermediate foldlines 26 and 28 to define a plurality of panel portions. Figure 1 shows three panel portions 74, 76 and 78.

The support structure may include means 79 to receive and retain an article to be held in the carton. In this embodiment the article receiving and retaining means 79 includes at least one container receiving aperture 80 being defined in part by a plurality of flexible tabs 82 arranged radially and connected to panel portion 74 along circular foldline 84. Each tab 82 is separated from the next adjacent tab by cut line 83. Optionally, a second aperture 81 is provided being substantially identical to the first aperture, but of a larger diameter to the first aperture 80, so that it can receive a different size of article.

There may also comprise means for securing the support structure 19 to the tray. The securing means preferably secures the inner side panel 20 to first side panel 12 and/or the inner side panel 20 to second side panel 16. In this embodiment, the means for securing inner side panel 20 to second side panel 16 comprises a tab 90 foldably connected to an end portion of top panel 18 along foldline 28 and separated from inner side panel 20 by cut lines 92, 94. A corresponding aperture 100 (shown in Figure 4a) is provided to received tab 90. The aperture is formed by cut line 96 which interconnects interrupted foldline 24.

Turning to the construction of the carrier, illustrated in Figures 2 to 4b, side panels 12 and 16 are folded about foldlines 22, 24 and into a substantially perpendicular relationship with base panel 14 and securing flaps 54, 56 and 62, 64 are folded about foldlines 58, 60 and 62, 64 respectively and into a substantially perpendicular relationship with side panels 12 and 16. Thereafter, end panels 30 and 32 are folded about foldlines 34 and 36 respectively and into a substantially perpendicular relationship with base panel 14. End panels 30, 32 are secured to the corresponding securing flaps 54, 62; 56, 64 by glue or other means known in the art thereby forming a tray. In one class of embodiments the tray is in a collapsed form, whereby end panels 30, 34 are folded inwards about fold lines 32 and 36 and gusset panels 38, 40 and 46, 48 are folded about fold lines 42, 44 and 50, 52 respectively and into face contacting relationship with respective end panels. A collapsed carton can then be erected by a user to provide a tray which is then loaded and top panel can be folded as hereinafter described to provide a lid to the tray.

In another class of embodiments an article, such as a pizza, is loaded into the partly- erected carton (or tray) from above and the top panel 18 and inner side panel 20 are folded about fold lines 26 and 28 such that inner and outer side panels come into face to face relationship and are secured together along at least part of the aforesaid panels by glue or other means known in the art. Thus, a flat tubular structure is formed substantially corresponding to the carton illustrated in Figure 2.

It is envisaged that the carton of the present invention could be formed by a series of sequential folding and gluing operations which can be formed in a straight line machine so that the carton is not required to be rotated or inverted to complete its construction. The folding process is not limited to that described above and can be altered according to particular manufacturing requirements. For example, in another class of embodiments a flat tubular structure is first formed by folding side panels 12, 16, 22 and base and top panels 14, 18 along their respective fold lines such that inner and outer side panels 20, 12 are placed into a face contacting relationship and are secured together by known means. Thereafter, an article is loaded through one of the ends of the carton and the end panels are closed by the folding process hereinbefore described.

In use, or optionally during the carton manufacturing process, top panel can be detached from side panel 12 and folded outwards in the direction marked 'X', shown in Figure 3 about foldline 26. In addition, second panel portion 76 and third panel portion 78 are folded out of alignment with first and second panel portions 74, 76 respectively to define a second tubular structure 98 as shown in Figures 4a and b.

It will be seen that the first portion 74 forms the upper panel, second portion 76 forms a side panel and third portion forms a lower panel of the second tubular structure.

In order to maintain the second tubular structure in a set up condition, suitable securing means is used to detachably connect the second tubular structure to the flat tubular structure. It will be seen from Figure 4, that in this embodiment the securing means comprises a retaining aperture 100 formed by cut line 96 and by folding side panel 16 about foldline 24. Tab 90 is folded out of alignment from inner side panel 20 and is inserted through the aperture 100 to be retained in that position by the engagement of the side edges 102 of aperture 100 with edges 104 of tab 90 shown in Figure 4a.. The remaining portions 106 of inner side panel 20 shown in Figure 3 can be folded into face-contacting relationship with side panel 16. Alternatively, portions 106 can be secured to base panel 14 to produce a more rigid structure. It is envisaged that other known detachable connection means can be used to secure the support structure to the tray, without departing from the scope of the invention.

Thus, a tray 130 for holding foodstuff shown in Figures 4a and 4b is formed, from paperboard or like foldable sheet material which can be erected from a flat collapsed condition into a position of use and in which a hinged lid 132 of the tray can be manipulated from a first position, shown in Figure 2, in which it closes the open top of the erected tray to a second position shown in Figures 4a and 4b in which second position the lid can be set up to provide a support structure 19 adapted to receive and hold a beverage container (not shown) in an upright attitude. It is envisaged that the term "beverage container" is a container for, but not necessarily containing, a beverage and encompasses a cup, pot, can, bottle or jar.

More particularly, apertures 80, 81 illustrated in Figure 4a are formed by folding flexible tabs 82 inwardly along fold line 84 by the introduction of a beverage container to the apertures such that the tabs frictionally engage the container. Preferably a portion of the container abuts the edge of aperture 80, 81 defined by fold line 84.

The present invention in its preferred embodiment relates to an article carrier which is shaped to provide a satisfactory rigidity to hold items such as a pizza securely but with a degree of flexibility. The shape of the blank minimises the amount of paperboard required for the carton. The items can be applied to the carrier by hand or by automatic machinery. It is anticipated that the invention can be applied to a variety of carriers and not limited to those of the flat tubular sort. For example, the flat tubular structure could be replaced by a structure with longer side and end panels to receive a dish or other articles without departing from the scope of invention.

Claims

8CLAIMS

1. A tray for holding foodstuff which tray is formed from paperboard or like foldable sheet material and can be erected from a flat collapsed condition into a position of use and in which a hinged lid of the tray can be manipulated from a first position in which it closes the open top of the erected tray to a second position alongside the erected tray in which second position the lid can be set up to provide a support structure adapted to receive and hold a beverage container in an upright attitude.

2. A collapsible tray according to claim 1 wherein the support structure comprises a plurality of panel portions foldably connected together to define a tubular structure.

3. A collapsible tray according to claim 1 or claim 2 wherein the support structure comprises a plurality of flexible tabs displaceable from the top panel, which tabs are adapted to frictionally engage the beverage container received in an aperture formed by displacing said tabs.

4. A carton for accommodating a pizza or the like, comprising a top, a base panel, a pair of oppositely disposed side panels interconnecting said top and said base to provide a flat tubular structure and an end closure arrangement to close opposite ends of the carton including end panels hinged to said base characterised in that the top panel comprises a plurality of panel portions and securing means adapted to form in use a second tubular structure adjacent said flat tubular structure to be secured thereto by the securing means, which second tubular structure comprises means to receive and retain an article to be held in the carton.

5. A carton according to claim 4 characterised in that the top panel is displaced outwardly of said flat tubular structure to define said second tubular structure.

6. A carton according to claim 4 or claim 5 wherein the securing means comprising a tab struck from an end portion of the top panel adapted to be received and secured by a corresponding aperture formed from an adjacent side wall of said flat tubular structure.

7. A carton according to any of claims 4 to 6 wherein the means for receiving an article comprises a plurality of flexible tabs displaced from said top panel, which tabs are adapted to frictionally engage an article received in an aperture formed by said displaced tabs.

8. A carton according to claim 4 or claim 5 wherein the securing means comprising a tab struck from an end portion of the top panel adapted to be received and secured by a corresponding aperture formed from an adjacent side panel.

9. A blank for forming a tray comprising a top panel, a base panel, a pair of oppositely disposed side panels interconnecting said top panel and said base panel and an end closure arrangement including end panels hinged to said base panel wherein the top panel comprises a plurality of panel portions and securing means adapted to form, in use, a tubular structure adjacent the tray to be secured thereto by the securing means.

10. A blank according to claim 9 wherein the top panel further comprises a plurality of flexible tabs displaceable from the top panel, which tabs are adapted to frictionally engage the beverage container received in an aperture formed by displacing said tabs.