CLUB TRAY

Abstract

A blank, package and method for producing a package comprising: a blank of sheet material folded along a longitudinal length to form a front wall, a bottom wall, a back wall, a first side wall and opposing second side wall, the package defining a cavity; the front wall defining a display opening for displaying product contained within the cavity; and where the first and second side walls each comprise spaced inner and outer side panels; including reinforcing spacing portions.

Description

FIELD OF INVENTION

This invention relates to packaging for shipping and displaying product, and in particular relates to blanks, trays and method of producing trays for shipping product and displaying the product.

BACKGROUND OF THE INVENTION

Retailers, such as big box stores, supermarkets, and warehouse clubs sell large amounts of fast moving product. Many of these retailers require product shipped from their distribution centers to the stores in bulk boxes that can be stacked without handling the contents in the bulk boxes.

The goal of such retailers is to have corrugated cardboard shipping containers put directly onto the shelves without individually handling the contents; in other words they require products to come in shelf ready containers or packages to reduce stocking costs by reducing labour costs.

Shelf ready packaging is also known as retail ready packaging or club trays; and refers to packaging of product so that it is delivered to a retailer in packaging designed for efficient stocking and sale.

These club trays need to be strong and durable as well as being easy to construct and handle.

Many of the club trays are constructed from cardboard sheets that are die cut into a pattern that start out as a flat sheet that is folded to produce a desired package. During the die cut process handles can be formed into the cardboard blank and sometimes an adhesive or glue can be used. During the folding process there can be intermediate steps to produce intermediate preform packages that can be further folded to produce the final container or club tray.

There have been many attempts in the past to produce product trays.

For example Canadian patent application 3154945 shows a retail ready package for shipping and displaying product which has a front and rear panel being spaced apart from one another along a longitudinal axis of the package when the package is in a shipping condition, where the front and rear panels each have a perforation line that facilitates a conversion of the package into an open top product display having a generally hexagonal shaped cross section which extends in a plane that is transverse to the longitudinal axis of the package.

US 2023/0139409 relates to an article and a blank for forming a carrier where the package comprises a carrier having a base wall, opposite side walls and opposed end walls to define an interior where the carrier may take the form of an open topped tray.

US 2009/011789 shows a blank of sheet material having an interior surface and opposing exterior surface where the blank forms the container having a front wall, a bottom wall a back wall and top wall a first side wall and a second opposing side wall the container defining a cavity and at least the front wall defining a display area for facilitating displaying product contained in the comtainer.

U.S. Pat. No. 9,216,837 illustrates a food tray.

Other attangements are shown in 2023/0075478, 2023/007547 and Canadian patents 2590385, 2283877, and 2378193.

It is an object of this invention to produce an improved club tray which is duable and easy to manufacture.

SUMMARY OF THE INVENTION

It is an aspect of this invention to provide a package comprising: a blank of sheet material folded along a longitudinal length to form a front wall, a bottom wall, a back wall, a first side wall and opposing second side wall, the package defining a cavity; the front wall defining a display opening for displaying product contained within the cavity; where the first and second side walls each comprise spaced inner and outer side panels.

In one embodiment the front wall, bottom wall and first and second side walls are foldably connected. In another embodiment the outer side panel is foldably connected to the inner side panel along said longitudinal length, the inner side panel including a connecting reinforcing flap foldably connected to said outer side panel and remote from said outer side panel, and an adhesive for connecting said connecting flap of said inner side panel to said bottom wall when said blank is folded along said longitudinal length.

In another embodiment the package comprises cardboard and the adhesive comprises glue.

In further embodiments the front wall comprises an outer front panel foldably connected to an inner front panel along the longitudinal length and wherein the adhesive connects the outer front panel to said inner front panel when said blank is folded along the longitudinal length. The back wall comprises an outer back panel foldably connected to an inner back panel along sthe longitudinal length and wherein the adhesive connects the outer back panel to the inner back panel when the blank is folded along the longitudinal length.

One of the outer side panels is foldably connected to a side connecting flap panel, where the adhesive connects the side connecting flap to the outer back panel to form: the package in a first flattened position; and a second preform position where said package is open.

In another embodiment the bottom wall comprises: first and second bottom side panels foldably connected to the first and second side panels respectively; front and back bottom panels foldably connected to the front outer panel and back outer panel respectively; where the first and second bottom side panels, and front and back bottom panels; move in the open position to produce the bottom wall.

In another embodiment the outer front panel and said inner front panel include an outer front opening and an inner front opening that register when said blank is folded along said longitudinal axis to form said display opening to display said product.

The inner side panels include reinforcing spacing flaps to space said outer side panel from said inner side panel.

Another aspect of this invents relates to a blank for forming a package comprising: sheet material foldable along a longitudinal length to form: an outer front panel foldably connected at a top front edge to an inner front panel along a first longitudinal fold line; an outer back wall foldably connected at a top back edge to an inner back panel along said first longitudinal fold line; a first outer side panel foldably connected at a first side edge of said outer front panel and where said first outer side panel foldably connected at a top first outer side edge to a first inner side panel along said first longitudinal fold line; a second outer side panel having a first side edge foldably connected to a second side edge of said outer front panel, and said second outer side panel foldably connected at a top side edge to a second inner side panel along said first longitudinal fold line; said outer back panel foldably connected at a first outer back edge to a second edge of said second outer side panel; said first side panel having a bottom edge foldably connected along a second longitudinal fold line, to a first bottom side panel; said second side panel having a bottom edge foldably connected along a second longitudinal fold line, to a second bottom side panel; said outer front panel foldably connected at a bottom front edge to a bottom front panel along said second longitudinal fold line; said outer back panel foldably connected at a bottom back edge to a bottom back panel along said second longitudinal axis; a flap presented by another edge of said first and second inner side panels remote from said first and second outer side panels; a side flap foldably connected to a second side edge of said first outer side panel to connect to a second side edge of said outer back panel; and said first and second inner side panels include reinforcement spacing portions. In one embodiment the inner front panel is glued to the outer front panel; the inner back panel is glued to said outer back wall; and where the flap is glued to the first and second bottom side panels respectively.

The sheet material in another embodiment comprises cardboard, and the adhesive comprises glue and the connecting meanscan comprises staples, clamps.

Another aspect of this invention relates to a method of forming a package by forming a blank having: an outer front panel foldably connected at a top front edge to an inner front panel along a first longitudinal fold line; an outer back wall foldably connected at a top back edge to an inner back panel along said first longitudinal fold line; a first outer side panel foldably connected at a first side edge of said outer front panel and where said first outer side panel foldably connected at a top first outer side edge to a first inner side panel along said first longitudinal fold line; a second outer side panel having a first side edge foldably connected to a second side edge of the outer front panel, and the second outer side panel foldably connected at a top side edge to a second inner side panel along the first longitudinal fold line; the outer back panel foldably connected at a first outer back edge to a second edge of said second outer side panel; the first side panel having a bottom edge foldably connected along a second longitudinal fold line, to a first bottom side panel; the second side panel having a bottom edge foldably connected along a second longitudinal fold line, to a second bottom side panel; the outer front panel foldably connected at a bottom front edge to a bottom front panel along said second longitudinal fold line; the outer back panel foldably connected at a bottom back edge to a bottom back panel along the second longitudinal axis; a flap presented by another edge of said first and second inner side panels remote from said first and second outer side panels; a side flap foldably connected to a second side edge of the first outer side panel to connect to a second side edge of said outer back panel; gluing one side of said inner front display panel; folding the inner front panel along the first longitunal length to contact and glue the inner front panel to the outer front panel; gluing one side of the inner back panel; folding the inner back panel along the first longitudinal length, to contact and glue the inner back panel to the outer back panel; gluing the flap of each of the first and second inner side panels to the first and second bottom side panels; gluing the side flap to the second side edge of the outer back panel to form a flattened preform package; moving the: first and second bottom side panels, and front bottom panel and back bottom panel, to form a bottom wall.

In another embodiment the inner and outer side panels are further spaced by reinforcement spacing portion. The first and second bottom side panels and the front bottom panel and back bottom panel are folded substantially 90 degrees to form a bottom wall.

In another embodiment the package easily forms spaced first and second side walls. The outer and inner front panels include aligned holes to display product in said package. The spaced first and second walls strengthen the package.

These and other features of the invention shall now be described in relation to the following drawings and description.

SUMMARY OF DRAWINGS

FIG. 1 is a top plan view of a cut blank showing the inner view of the various panels and includes an enlarged portion showing reinforcing spacing portions or panels.

FIG. 2 is a front elevation view of FIG. 1 where the blank has been folded and flattened along a longitudinal length of the blank showing how the side panels are connected.

FIG. 3 is a front elevation view of FIG. 2 where the sides are fully glued.

FIG. 4 is a back view of the flat layout.

FIG. 5 is a front perspective view of the tray of FIG. 2 opened in an intermediary stage or preform resting on a flat surface.

FIG. 6 is a front perspective view with the bottom side walls raised showing the reinforced spaced side walls with the handle portions.

FIG. 7 is a front perspective fully assembled club tray.

DETAILED DESCRIPTION OF THE INVENTION

Like parts are given the same number throughout the drawings.

FIG. 1 generally illustrates a blank 10 formed of sheet material such as cardboard to produce a desired pattern which will be described herein. The blank 10 will be used to form a package, or package for shipping and displaying or club tray 100.

The blank 10 is foldable along a longitudinal length about a first longitudinal fold line 12.

The blank 10 includes an outer front panel 14 foldably connected at a top front edge 16 to an inner front panel 18 along a first longitudinal fold line 12. The blank 10 also includes an outer back panel 20 foldably connected at a top back edge 22 to an inner back panel 24 along said first longitudinal fold line 12;

FIG. 1 also shows a first outer side panel 30 foldably connected at a first side edge 32 of said outer front panel 14 and where said first outer side panel 30 is foldably connected at a top first outer side edge 34 to a first inner side panel 36 along said first longitudinal fold line 12.

There is a second outer side panel 40 having a first side edge 42 that is foldably connected to a second side edge 44 of said outer front panel 14, and said second outer side panel 40 is foldably connected at a top side edge 48 to a second inner side panel 46 along said first longitudinal fold line 12.

The blank 10 also shows the outer back panel 20 is foldably connected at a first outer back side edge 26 to a second edge 49 of said second outer side panel 40.

The first outer side panel 30 has a bottom edge 38 foldably connected along a second longitudinal fold line 60, to a first bottom side panel 70;

The second side panel 40 has a bottom edge 45 foldably connected along a second longitudinal fold line 60, to a second bottom side panel 72.

The outer front panel 14 is foldably connected at a bottom front edge 17 to a bottom front panel 74 along said second longitudinal fold line 60.

The outer back panel 20 is foldably connected at a bottom back edge 28 to a bottom back panel 76 along said second longitudinal fold line 60.

There is a flap 80 presented by another edge 35 of said first and second inner side panels 36 and 46 respectively that is remote from said first and second outer side panels 30 and 40 as shown.

There is also a side flap 90 the outer side panels 30 foldably connected to a second side edge 92 of said first outer side panel 30 to connect to a second side edge 94 of said outer back panel 20 as shown by the dotted lines in FIG. 1.

The inner front panel 18 is folded over the first longitudinal fold line 12 so as to contact and connect to the outer front panel 14 and thus rigidify and strengthen the front display panel as shown in FIG. 1. This can be accomplished by applying an adhesive (shown by hatching marks) to the inner front panel 18 to glue the inner front panel 18 to the outer front panel 14. In other words by viewing FIG. 1 the inner front panel 18 is folded towards the viewer about first fold line 12 and then downward to adhere to the backside of the front outer display panel 14 as shown by arrow Y.

The flap 80 of each first and second inner side panels 36, 46 is moved in the direction of arrow Y and then attached or connected to the first and second bottom side panels 70 and 72 respectively in the zone marked 71 and 73 respectively. Adhesive, glue, staples or other means may be used to connect the flaps 80 to the first and second bottom side panels 70 and 72 (also shown in FIG. 6).

Once the package is moved from a preform position (where the flaps 80 are glued to the bottom side panels 70 and 72) to be described herein the inner side panels 36, 46 and outer side panels 30 and 40 will be spaced (by the distance X shown in FIG. 6) once folded over in the direction of arrow Y, about the first fold line 12. Once folded the side panels will present a top portion 93 a spaced distance of X as shown in FIG. 6, which rigidifies the structure.

The flap 90 is glued and then can be moved in the direction of arrow Z to be glued to the side edge 94 of back panel 20 as shown in FIG. 1.

FIG. 2 shows the blank when the panels are glued and folded over the first longitudinal fold line 12. In particular the invention describes a method of producing a package from the blank 10 by:

• • a) gluing one side of said inner front display panel 36, alternatively the back side of the outer front display panel 14 could be glued;
  • b) folding said inner front panel 36 along said first longitudinal fold line 12 to contact and glue said inner front panel 36 to said outer front panel 30;
  • d) gluing one side of said inner back panel 24, alternatively the back side of the outer side back 20 could be glued;
  • e) folding said inner back panel 24 along said first longitudinal fold line 12, to contact and glue said inner back panel 24 to said outer back panel 20;
  • f) gluing said flap 80 of each of said first and second inner side panels 36 and 46 to said first and second bottom side panels 70 and 72 respectively;
  • g) gluing said side flap 90 to said second side edge 94 of said outer back panel 20 to form a flattened preform package as shown in FIGS. 3 and 4;
  • h) moving said:
    • xii) first and second bottom side panels 70 and 72; and
    • xii) front bottom panel 74 and back bottom panel 76;
  • to form a bottom wall 110.

As described herein the method produces inner and outer side panels 36,46 and 30,40 that are spaced by X. The first and second bottom side panels 70 and 72 and the front bottom panel 74 and back bottom panel 76 are folded substantially 90 degrees to form a bottom wall 110.

The outer and inner front panels 14, 18 include aligned holes 120a and 120b to produce a hole or viewing area 120 when folded and glued to display product in said package 100.

The inner and outer side panels 30, 40 include hand holes 113 and 115 so that the package can be manually moved.

Furthermore each inner 36,46 side panel includes a spacing flap 130 that comprises a reinforcement spacing portion or spacing panel 132 and gluing portion or reinforcing flap 134. The gluing portion 134 doubles up the thickness of the outer side panels 30,40 when glued and adds to the reinforcing feature of this invention. The gluing portion or reinforcing portion 134 is glued as shown and then moved in the direction of arrow Y as previously described to zone 137 of outer side panels 30,40. The width of reinforcement spacing portion 132 is X the same distance as the shoulder of 93 so as to reinforce the spacing of inner side panel 36,46 from outer side panels 30,40 respectively. Also since the gluing portion 134 is disposed just below the handles 113 and 115 in the median area or region of the outer panels 30,40 such gluing portions 134 in combination with the part or shoulder 93 rigidify the package 100. In other words the gluing or reinforcing portion 134 reinforces the spacing of the inner panels 36,46 from the outer panels 30, 40 by X.

The Figures also show that the spacing flap 130 includes a spacing flap fold line 135a and that inner side panels 36,46 include shoulder fold lines 93a. When the side panels and bottom panels are moved as described from the intermediary pre form position shown in FIG. 5 to the final position shown in FIG. 7 the inner side panels 36,46 are spaced apart from the outer side panels 30,40 automatically since the shoulder portion 93 and side spacing panel 132 create a bridging feature between the inner and outer side panels; in an automatic way.

Also the package 100 includes perforations 116 to assist in folding. in other words the perforations provide for less resistance to folding.

FIG. 7 shows a completed package or club tray 100 having a blank of sheet material 10 folded along a longitudinal length to form a front wall 102, a bottom wall 110, a back wall 104 a first side wall 106 and opposing second side wall 108, the package defining a cavity; the front wall 102 defining a display opening 120 for displaying product contained within the cavity;

The invention herein describes a package 100 where one of said outer side panels 30,40 is foldably connected to a side connecting flap panel 90, where said adhesive connects said side connecting flap 90 to said outer back panel 20 to form:

• • a) said package 100 in a first flattened position shown in FIGS. 3 and 4; and
  • b) a second preform position shown in FIGS. 5 and 6 where said package 100 is open.

FIGS. 1 and 7 shows a package 100 where the first and second bottom side panels 70 and 72 are foldably connected to said first and second side panels 30,40 respectively, and front and back bottom panels 74 and 76 foldably connected to said front outer panel 14 and back outer panel 20 respectively. more particularly the first and second bottom side panels 70,72, and front and back bottom panels 74,76 move from said open position to produce a bottom wall 110.

The outer front panel 14 and the inner front panel 18 include an outer front opening 120a and an inner front opening 120b that register when the blank 10 is folded along said longitudinal first folding line 12 to form said display opening 120 and display said product.

Claims

1. A package comprising: a blank of sheet material folded along a longitudinal length to form a front wall, a bottom wall, a back wall, a first side wall and opposing second side wall, the package defining a cavity;said front wall defining a display opening for displaying product contained within the cavity;said first and second side walls each comprise spaced inner and outer side panels.

2. A package as claimed in claim 1 wherein said front wall, bottom wall and first and second side walls are foldably connected.

3. A package as claimed in claim 2 wherein said outer side panel is foldably connected to said inner side panel along said longitudinal length, said inner side panel including a connecting flap foldably connected to said outer side panel and remote from said outer side panel, and an adhesive for connecting said connecting flap of said inner side panel to said bottom wall when said blank is folded along said longitudinal length.

4. A package as claimed in claim 3 wherein said blank comprises cardboard and said adhesive comprises glue.

5. A package as claimed in claim 3 wherein said front wall comprises an outer front panel foldably connected to an inner front panel along said longitudinal length and wherein said adhesive connects said outer front panel to said inner front panel when said blank is folded along said longitudinal length.

6. A package as claimed in claim 3 wherein said back wall comprises an outer back panel foldably connected to an inner back panel along said longitudinal length and wherein said adhesive connects said outer back panel to said inner back panel when said blank is folded along said longitudinal length.

7. A package as claimed in claim 1 wherein one of said outer side panels is foldably connected to a side connecting flap panel, where said adhesive connects said side connecting flap to said outer back panel to form: a) said package in a first flattened position; andb) a second preform position where said package is open.

8. A package as claimed in claim 7 wherein said bottom wall comprises: a) first and second bottom side panels foldably connected to said first and second side panels respectively;b) front and back bottom panels foldably connected to said front outer panel and back outer panel respectively.

9. A package as claimed in claim 7 wherein said; a) first and second bottom side panels, andb) front and back bottom panels;

10. A package as claimed in claim wherein said outer front panel and said inner front panel include an outer front opening and an inner front opening that register when said blank is folded along said longitudinal axis to form said display opening to display said product.

11. A package as claimed in claim 10 wherein said inner side panels include reinforcing spacing flaps to space said outer side panel from said inner side panel.

12. A blank for forming a package comprising: a) sheet material foldable along a longitudinal length to form: i) an outer front panel foldably connected at a top front edge to an inner front panel along a first longitudinal fold line;ii) an outer back wall foldably connected at a top back edge to an inner back panel along said first longitudinal fold line;iii) a first outer side panel foldably connected at a first side edge of said outer front panel and where said first outer side panel foldably connected at a top first outer side edge to a first inner side panel along said first longitudinal fold line;iv) a second outer side panel having a first side edge foldably connected to a second side edge of said outer front panel, and said second outer side panel foldably connected at a top side edge to a second inner side panel along said first longitudinal fold line;v) said outer back panel foldably connected at a first outer back edge to a second edge of said second outer side panel;vi) said first side panel having a bottom edge foldably connected along a second longitudinal fold line, to a first bottom side panel;vii) said second side panel having a bottom edge foldably connected along a second longitudinal fold line, to a second bottom side panel;viii) said outer front panel foldably connected at a bottom front edge to a bottom front panel along said second longitudinal fold line;ix) said outer back panel foldably connected at a bottom back edge to a bottom back panel along said second longitudinal axis;x) a flap presented by another edge of said first and second inner side panels remote from said first and second outer side panels;xi) a side flap foldably connected to a second side edge of said first outer side panel to connect to a second side edge of said outer back panel; andxii) said first and second inner side panels include reinforcement spacing portions

13. A blank as claimed in claim 12 wherein said inner front panel is glued to said outer front panel; said inner back panel is glued to said outer back wall; and wherein said flap is glued to said first and second bottom side panels respectively.

14. A blank as claimed in claim 13 wherein said sheet material comprises cardboard, said adhesive comprises glue and said connecting means comprises staples, clamps.

15. A method of forming a package by: a) forming a blank having i) an outer front panel foldably connected at a top front edge to an inner front panel along a first longitudinal fold line;ii) an outer back wall foldably connected at a top back edge to an inner back panel along said first longitudinal fold line;iii) a first outer side panel foldably connected at a first side edge of said outer front panel and where said first outer side panel foldably connected at a top first outer side edge to a first inner side panel along said first longitudinal fold line;iv) a second outer side panel having a first side edge foldably connected to a second side edge of said outer front panel, and said second outer side panel foldably connected at a top side edge to a second inner side panel along said first longitudinal fold line;v) said outer back panel foldably connected at a first outer back edge to a second edge of said second outer side panel;vi) said first side panel having a bottom edge foldably connected along a second longitudinal fold line, to a first bottom side panel;vii) said second side panel having a bottom edge foldably connected along a second longitudinal fold line, to a second bottom side panel;viii) said outer front panel foldably connected at a bottom front edge to a bottom front panel along said second longitudinal fold line;ix) said outer back panel foldably connected at a bottom back edge to a bottom back panel along said second longitudinal axis;x) a flap presented by another edge of said first and second inner side panels remote from said first and second outer side panels;xi) a side flap foldably connected to a second side edge of said first outer side panel to connect to a second side edge of said outer back panel;b) gluing one side of said inner front display panelc) folding said inner front panel along said first longitunal length to contact and glue said inner front panel to said outer front panel;d) gluing one side of said inner back panel;e) folding said inner back panel along said first longitudinal length, to contact and glue said inner back panel to said outer back panelf) gluing said flap of each of said first and second inner side panels to said first and second bottom side panels;g) gluing said side flap to said second side edge of said outer back panel to form a flattened preform package;h) moving said: xii) first and second bottom side panels; andxii) front bottom panel and back bottom panel;to form a bottom wall.

16. A method as claimed in claim 15 wherein said inner and outer side panels are further spaced by reinforcement spacing portion.

17. A method as claimed in claim 16 wherein said first and second bottom side panels and said front bottom panel and back bottom panel are folded substantially 90 degrees to form a bottom wall.

18. A method as claimed in claim 17 wherein said package automatically forms spaced first and second side walls.

19. A method as claimed in claim 18 wherein said outer and inner front panels include aligned holes to display product in said package.

20. A method as claimed in claim 19 wherein said spaced first and second walls strengthen said package.