1. Field of the Invention
This invention relates to relatively large size merchandise trays having dimensions applicable conveniently for storage, transport of a selected large amount of merchandise as well as for displaying the merchandise at the sale location to facilitate easy selection of items to purchase from the tray by purchasers. More particularly, it relates to merchandise container trays made of cardboard or corrugated paperboard and having compatible dimensions suitable for being carried on common standard size pallets to utilize the support surface of the pallet fully and to facilitate transport of a selected large amount of merchandise as well as for ready display of the merchandise at the point of sale without requiring transfer of the merchandise to other display devices.
2. Background Art
This application is a divisional of U.S. patent application Ser. No. 12/661,266, filed Mar. 15, 2010, by the same applicant of this application.
Containers such as corrugated boxes are commonly used for storing and transporting merchandise from a manufacturing or distribution facility to a sale or retail location. However, the containers are not suitable for displaying the merchandise at the sale or retail location, since the merchandise is not readily accessible from the container by customers for selecting the items to purchase. Accordingly, the merchandise, after transported to the sale or retail location, must be unpacked from the containers and be transferred to display shelves, stands, or show cases in order that customers may select the items to purchase. This procedure is time consuming and labor intensive to carry out.
Also, a plurality of generally rectangular merchandise containers are normally placed on pallets for transportation. No provisions are made in the construction of the container to ensure the stability of the containers disposed on the pallet. Therefore, with a large number of containers stacked on top of one another on a pallet, often merchandise containers would fall off the stack during transport causing breakage, spoilage or spillage of the merchandise. Attempts have been made to incorporate interlocking means between stacked containers such as providing rectangular upstanding tabs at the middle at the top of their side panels and complementary openings formed at the middle of the side edge of the bottom panel of the container so that the complementary openings of a container stacked above another container located below it would engage with the tabs of the container below so as to hold the stacked containers together to reduce the relative movement between them for increasing the stability of the stacked containers during transport. However, such upstanding tabs are flimsy in construction and could easily be bent or crushed during handling of the containers and therefore rendering such provision ineffective. The drawback is further worsen by the fabrication of the containers with cardboard or corrugated board for reducing their weight and the cost and ease of their manufacture, because tabs made of cardboard or corrugated board are lacking the required rigidity and strength to withstand the inherent abuses they would be exposed to during the handling of the containers and they would readily be bent or mutilated.
Furthermore, in order to facilitate easy handling manually, merchandise containers are made in relatively small convenient sizes. Therefore for transporting a large quantity of required merchandise, it is necessary to place and to stack a large number of such relatively small convenient size containers on the pallet for their transportation. Since the size of the containers are commonly not designed to conform with the size of the load supporting top surface of the pallet, they could not normally be neatly arranged on the pallet; they may either not occupy the full usable top surface of the pallet so that the transport capability of the pallet is not fully utilized, or portions of some containers may extend outside of the top surface of the pallet in a hazardous manner thus making the load extremely unstable.
It is the principal object of the present invention to provide multiple use container trays which are applicable for transporting merchandise as well as be readily placed at a sale or retail location for displaying the merchandise therein for purchase by customers.
It is another object of the present invention to provide multiple use container trays having dimensions compatible with the supporting top surface of standard pallets such that the complete supporting top surface of the pallet can be efficiently utilized.
It is another object of the present invention to provide container trays having strong rigidity which can be readily fabricated with cardboard or corrugated paper board material
It is another object of the present invention to provide container trays having strong interlocking means such that a plurality of them may be disposed on a transport pallet with the trays coupled and/or stacked together securely and safely.
It is yet another object of the present invention to provide container trays having relatively large dimensions for carrying a large number of merchandise. The trays have reinforced supports therein for supporting the weight of the stack as well as the large amount merchandise disposed therein.
It is still another object of the present invention to provide container trays having various means for retaining the merchandise therein securely during transport as well as displaying for purchase at the retail location.
It is still another further object of the present invention to provide container trays which can be fabricated with a single piece of cardboard or corrugated paper board.
Other objects of the invention will become apparent in the following description and appended claims, reference being made to the accompanying drawings forming a part of the specification.
With reference to the drawings in which like reference numerals designate corresponding parts in the different views, the container tray 10 of the present invention includes a rectangular tray 11. The tray 11 may be conveniently fabricated with a configuration 12 as best shown in
A first U-shaped side panel 53 extends outwards from the side edge 14 of the bottom panel 13. The first U-shaped side panel 53 has an elongated rectangular middle panel and two vertical side panels 54 and 55 extending in a perpendicular manner from the two end portions of the middle panel. The width of the middle panel is much shorter than the length of the side edge 28 of the first end panel 25, and the length of the vertical side panels 54 and 55 is longer in length than the length of the side edge 28 of the first end panel 25. A first reinforced end panel 56 extends sideways from the outer edge 57 of the vertical side panel 53. The length of the both the vertical side panel 54 and the first reinforced end panel 56 are longer than the side edge 28 of the first end panel 25. A first foldable tab 58 extends outwards from the lower middle portion of the outer edge 59 of the first reinforced end panel 56. The first foldable tab 58 has a retaining tab 60 formed at its outer edge and a retaining slot 61 is formed on the edge portion of the edge 57 of the vertical side panel 54 and located directly opposite to the retaining tab 60. The width of the first foldable tab 58 is equal to the length of the slot 26 in the first end panel 25, and the length of the first foldable tab 58 is equal to the distance between the slot 26 to the side edge 28 of the first end panel 25. A second foldable tab 62 extends inwards from the inner edge 63 of the vertical side panel 54, and the distance between its upper edge 64 and the edge 14 of the base panel 13 is equal to the length of the side edge 28 of the first end panel 25. A retaining tab 65 is formed at the middle of the inner edge 66 of the second foldable tab 62.
Three foldable reinforce side panels 67, 68, and 69 extends upwards from the upper edge 70 of the elongated middle panel of the U-shaped side panel 53, and retaining tabs are formed at the outer edge of these reinforce side panels 67, 68 and 69. These foldable side panels 67, 68 and 69 are foldable inwards and downward towards the base panel 13 with their retaining tabs engaging with the slot openings 18 to secure in place in a folded position lying against the inner surface of the elongated middle panel of the side panel 53. A first vertical slot 71 is formed between the foldable side panels 67 and 68, and a second vertical slot 72 is formed between the foldable side panels 68 and 69.
Similarly, a second U-shaped side panel 73 equal in shape and dimensions to the first U-shaped side panel 53, extends outwards from the side edge 15 of the base panel 13. The U-shaped side panel 73 has two vertical side panels 74 and 75 extending upward from two end portions of the elongated middle panel. A second reinforced end panel 76 extends sideways from the outer edge 77 of the vertical side panel 74. The length of the vertical side panel 74 and the second reinforced end panel 76 is longer than the length of the side edge 29 of the first end panel 25. A second foldable tab 78 extends outward from the middle upper portion of the outer edge 79 of the second reinforced end panel 76. The second foldable tab 78 has a retaining tab 80 formed at its free edge and a mounting slot 81 is formed at the outer edge 77 of the vertical side panel 74 and located directly opposite to the retaining tab 80. A third foldable tab 82 extends sideway from the inner edge 83 of the vertical side panel 74, and a retaining tab 84 extends inward from the inner edge of the third foldable tab 82. The distance between the lower edge 85 and the edge 15 is equal to the length of the edge 29 of the first end panel 25. Three foldable reinforce side panels 86, 87 and 88 are formed along the outer edge 89 of the elongated middle panel of the side panel 73. The foldable reinforce side panels 86, 87 and 88 are foldable along the outer edge 89 inwardly and downwardly to lie juxtaposed to the inside surface of the elongated middle panel of the side panel 73 with the tabs formed at their outer free edge engaging with the slots 19 formed along the edge 15. A first vertical slot 90 is formed between the foldable reinforce side panels 86 and 87, and a second vertical slot 91 is formed between the foldable reinforce side panels 87 and 88. The vertical slot 90 is located directly opposite to the first vertical slot 71 formed between the foldable reinforce side panels 67 and 68, and the second vertical slot 91 is located directly opposite to the slot 72 formed between the foldable reinforce side panels 68 and 69.
The rectangular second end panel 92 and all associated parts attached thereto are identical in construction to the rectangular first end panel 25 and the associated parts 26 to 81 described above.
The tray 11 may be fabricated by first folding the U-shaped side panels 53 and 73 upwards along the foldable edges 14 and 15 respectively until they are perpendicular to the bottom panel 13. The foldable reinforce side panels 68 and 87 may then be folded inwardly and downwardly to lie juxtaposed to the inner surface of the elongated middle panel of the side panels 53 and 73 with the mounting tab at their free edges engaging with the associated slot openings 18 and 19 respectively formed along the edges 14 and 15 of the bottom panel 13 so as to maintain the side panels 53 and 73 securely mounted in the vertical position perpendicular to the bottom panel 13 to form rugged side panels for the tray 10. As best shown in
The first edge panel 41 and the second edge panel 42 are folded upwards along fold lines 38 and 40 respectively until they are perpendicular to the interior panel 32. The first foldable rectangular panel 43 and the second foldable rectangular panel 45 are the folded along fold lines 44 and 46 respectively toward one another and are mounted to one another by slidably engaging the open slot 47 and 48 with one another so that they form a combined panel equal in shape and dimension to the interior panel 32 and spaced therefrom of a distance equal to the width of the edge panels 41 and 42. The interior panel 32 is then folded along the line 33 until the interior panel 32, the combined panel, the edge panels 41 and 42 and the support panel 30 together form a rectangular case 93 as best shown in
Similarly, as shown in
Since the bottom panel 13 of the container tray 10 of the present invention has dimensions of 24 inches by 48 inches, it is compatible with the dimension of a standard 24 by 48 pallet such that it may be securely placed on the standard 24 by 48 pallet to utilize the usable support surface of the pallet fully as shown in
As best shown in
A plurality of container trays 10 with the transverse dividers mounted therein may be stacked together as shown in
Alternatively, an elongated longitudinal rectangular divider board or case 108 may be mounted in the tray 11 as shown in
As shown in
A selected number of the merchandise tray 10 with the longitudinal divider and slidable transverse dividers mounted therein may be stacked together and placed on a standard supporting pallet as shown in
In use, a selected number of the container trays may be stacked and placed on a standard transport pallet having a load supporting surface same as the bottom dimensions of the tray, at the merchandise manufacturing facility or at a distribution facility with the required merchandise placed into the trays. The stack of trays together with the pallet may then be covered with an outer protective wrap and be transferred to the transport vehicle by a forklift engaging the pallet in the common manner for delivery to the retail location. At the retail location the tray stack is unloaded from the transporting vehicle again with a forklift engaging the pallet in the common manner and placed at a desired floor area in the retail location. The desired area commonly is an aisle in the shop floor of the retail location. The outer wrap is then removed such that the merchandise is readily visible and available for purchase by customers walking through the aisle. The low height of the side panels of the tray 11 renders the merchandise clearly visible and easy access of the merchandise by the customers. When two stacks of the trays are located back to back on a 48 by 48 pallet, the merchandise are available to customers walking through both sides of the aisle. Therefore, the container tray of the present invention, greatly reduces the labor cost and time commonly required for having to pack the merchandise in transporting containers, stacking the containers in an inefficient manner on pallets, and then unloading the containers in the retail location, and unpacking the merchandise from the containers and rearranging them in or on other display devices.
While the preferred embodiments of the invention have been described above. It will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention.
Number | Date | Country | |
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Parent | 12661266 | Mar 2010 | US |
Child | 12932492 | US |