Information
-
Patent Grant
-
6502698
-
Patent Number
6,502,698
-
Date Filed
Tuesday, October 9, 200122 years ago
-
Date Issued
Tuesday, January 7, 200321 years ago
-
Inventors
-
Original Assignees
-
Examiners
Agents
- Christensen O'Connor Johnson Kindness PLLC
-
CPC
-
US Classifications
Field of Search
US
- 229 178
- 229 915
- 229 919
- 229 918
- 206 509
- 206 511
- 206 512
-
International Classifications
-
Abstract
A tray-type container 10 is provided that includes a bottom wall 20, longitudinally-extending outer side walls 22, and laterally-extending end walls 24. The outer side walls 22 and the end walls 24 extend upwardly from the bottom wall 20 to form an inner cavity 26. As assembled, the outer side walls 22 include a plurality of spaced-apart stacking tabs 28. A plurality of tray-type containers 10 may be aggregated in a stacked configuration utilizing the stacking tabs 28, and placed upon a shipping pallet or slip sheet, or placed within a shipping container to facilitate shipping by large carriers.
Description
FIELD OF THE INVENTION
The present invention relates to shipping containers, and more particularly, to shipping containers having stacking tabs formed from a single blank.
BACKGROUND OF THE INVENTION
In the shipping container art there are many container designs that are manufactured for various end uses. One popular end use for a container is holding fresh fruits and produce during packing, shipping, for displaying at the retail level. Usually when packing produce such as tomatoes, peaches, mangos and the like there is a typical size requirement in that the container volume is sized to hold a certain amount of product. There is also a strength requirement given the weight of product packed and the shipping and handling requirements. Such containers are generally rectangular and have a variable height dimension ranging from three to twelve inches. Further, these containers are transported, stored, and displayed in a stacked configuration.
A well known single piece container design for holding produce is a single-piece tray type where a single piece of corrugated cardboard is cut and scored to form a flat blank. The blank has a bottom, two side walls hinged to the bottom and at least two end walls hinged to the bottom. To form the container, the walls of the blank are folded upwardly to be normal to the bottom and then connected to form the containment volume within the four walls. Variations are well known where top closure flaps are hinged to the top edges of the side walls, and for stacking strength, a second end wall can be hinged to the top edge of first end wall to then form a double layer of material thereby enhancing the stacking strength.
Typically, the tray-type containers are stacked on top of one another during shipping, storing, and displaying at the retail level, as was mentioned above. Accordingly, suitable stacking strength is one requirement of these type of containers so that the containers can be stacked as much as ten containers high. There have been improvements made to the trays by the addition of stacking tabs, which are insertable into another tray in the stacked position. With the advent of stacking tabs, it has been the desire of the container industry to develop a tray type-container with stacking tabs that is made from a single piece blank, and provides the necessary stacking strength, while reducing the amount of material used.
SUMMARY OF THE INVENTION
The present invention is directed to a tray-type container having stacking tabs. In accordance with the present invention, a single piece containerboard blank is provided for forming a tray-type container having an inner cavity and at least one stacking tab extending upwardly from the top of the container. The blank includes a bottom wall panel, and an outer side wall panel having an outer edge and hingedly connected to the bottom wall panel by a fold line. An inner side wall panel is provided having an outer edge and hingedly connected to the outer wall panel remote from the bottom wall panel by a two spaced-apart fold lines. The spaced-apart fold lines are interrupted by first and second cut lines. The container blank further includes at least one stacking tab positioned within and formed substantially from the inner side wall panel by the first and second cut lines. The stacking tab includes a base section connected to the outer side wall panel and partially defined by the interrupted spaced-apart fold lines, and a top section hingedly connected to the base section by a fold line and terminating at a position remote from the outer edge of the inner side wall panel. When the container black is erected, the inner side wall panel is folded about the two spaced-apart fold lines to overlay the outer side walls such that the stacking tab extends outwardly away from the top edge of the container formed by the spaced-apart fold lines.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1
is a perspective view of a tray-type container having stacking tabs formed in accordance with the present invention;
FIG. 2
is a plan view of a blank from which the tray-type container of
FIG. 1
is formed;
FIG. 3
is a partial plan view of the blank of
FIG. 2
; and
FIG. 4
is a perspective view of a plurality of tray-type containers of
FIG. 1
in a stacked configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described with reference to the accompanying drawings where like numerals correspond to like elements. The present invention is directed to a tray-type container that utilizes stacking tabs on opposing side walls to create a modular stackable container. One suitable embodiment of a tray-type container, generally designated
10
, constructed in accordance with aspects of the present invention is illustrated in
FIGS. 1 and 2
. Referring now to
FIG. 1
, the tray-type container
10
includes a bottom wall
20
, longitudinally-extending outer side walls
22
, and laterally-extending end walls
24
, the outer side walls
22
and the end walls
24
extending upwardly from the bottom wall
20
to form an inner cavity
26
. As assembled, the outer side walls
22
include a plurality of spaced-apart stacking tabs
28
. A plurality of tray-type containers
10
may be aggregated in a stacked configuration utilizing the stacking tabs
28
, and placed upon a shipping pallet or slip sheet, or placed within a shipping container to facilitate shipping by large carriers.
The tray-type container
10
shown in
FIG. 1
is made from any suitable material used in shipping, such as cardboard, pasteboard, fiberboard, corrugated cardboard, plastic, or a combination thereof. As best shown in
FIG. 2
, a blank
18
is stamped out of any of these suitable materials and assembled in a manner which can be seen in FIG.
1
.
With continued reference to
FIG. 2
, the blank
18
includes a bottom wall panel
20
A of generally rectangular shape having four edges. Unless otherwise apparent, the term “edges” refers generally to a zone or line of weakness along which a part can be folded, such as a score line, or a cut line. Opposing outer side wall panels
22
A are hingedly connected to opposing side edges of the bottom panel
20
A along interrupted fold lines
30
. The blank
18
further includes opposing end wall panels
24
A, which are hingedly connected to the remaining two opposing edges of the bottom panel
20
along fold lines
32
. The outer side wall panels
22
include end flaps
34
, which are hingedly connected to opposed ends of outer side wall panels
22
along fold lines
36
. The fold lines
36
are substantially perpendicular to the fold line
30
. When erected, as will be described in more detail below, the bottom wall panel
20
A, the outer wall panels
22
A, and the end wall panels
24
A form the bottom wall
20
, the outer side walls
22
, and the end walls
24
, respectively, as shown in FIG.
1
.
Referring now to
FIG. 2
, opposed inner side wall panels
40
are hingedly connected to outer side wall panels
22
via fold lines
42
and
44
. The respective fold lines
42
and
44
are provided so a two-ply layer of the blank material will be accommodated between the outer side walls
22
A and the inner side wall panels
40
when they are folded up to lay juxtaposed against one another, i.e., fold lines
42
and
44
are double-wide score lines to accommodate the two-ply thickness. The inner end walls
40
are constructed with a suitable height dimension such that outer edge portions
46
will abut against the corresponding portion of bottom panel
20
A, thereby creating a standard double-ply side panel. In this folded position, the double fold lines
42
and
44
creates a rolled shoulder that forms the top edge of the side walls of the erected container. In the embodiment shown, located centrally and opposed laterally within bottom panel
20
A are slots
50
. Cooperating locking tabs
52
depend outwardly from the outer edge
46
of each inner side wall
40
. Such tabs are not necessary to the present invention but do provide additional strength and rigidity if desired. The inner side wall panels
40
include end flaps
60
, which are hingedly connected to opposed ends of side wall panels
40
along fold lines
62
, the fold lines
62
being perpendicular to fold lines
30
.
In accordance with the present invention, stacking tabs
28
are provided with the tray-type container
10
and are utilized to extend into similarly constructed tray-type containers
10
when properly aligned in a stacked configuration. Looking now to the intersection of the bottom panel
20
A and the outer side wall panels
22
A of
FIGS. 2 and 3
, the fold lines
30
are interrupted by a cut-out portion
70
. In the embodiment shown, pairs of spaced apart cut-out
70
are positioned to interrupt fold lines
30
. The fold lines
30
will form a part of the bottom edge of the erected container in its erected condition and thus the cutout portions will form receptacle portions along the bottom edges of the outer side panel
22
A, as best shown in FIG.
1
. Each cut-out portion
70
is suitably dimensioned to accept an upwardly extending stacking tab from another similar container which is positioned beneath the container
10
. Provided along the outer edge
46
of inner side wall panels
40
are pairs of opposed generally rectangular cutouts
72
that are in substantial longitudinal alignment with cut-out parts
70
. Likewise, the cutouts
72
are suitably dimensioned to accept an upwardly extending stacking tab when like containers are stacked one atop another.
The stacking tabs
28
that are insertable into cut-out portions
70
and cutouts
72
will now be described in detail. Referring to
FIGS. 2 and 3
, the stacking tabs
28
are formed at the intersection of the outer side wall panels
22
A and inner side wall panels
40
of the blank
18
. As was described above, the double fold lines
42
and
44
separating the inner side wall panels
40
from the outer side wall panels
22
A does not extend the full length of the bottom panels
20
A. Rather, the double fold line is comprised of two separate sections separated by an unscored portion of material that, in the erected position, becomes the base of the stacking tab
28
, generally denoted
80
. The unscored portion or base
80
is formed by two spaced apart cut lines
82
and
84
, the distance between the cut lines defining the width of the stacking tab
28
.
As best shown in
FIGS. 2 and 3
, the cut lines
82
and
84
continue to extend from the beginning of the base at line
44
, into the inner side wall panels
40
to form the remaining portion of the stacking tabs
28
. The remaining portion of the stacking tabs
28
include opposing projection portions
86
formed by a generally C-shaped cut line that intersects the cut lines
82
and
84
. These projection portions
86
are utilized to secure the top of the stacking tabs
28
between the inner side wall panel
40
and the outer side wall panel
22
A when in the erected position, as will be described in detail below. The stacking tabs
28
further include a fold line
88
substantially parallel with the folds lines
30
separating the stacking tabs into two sections, a top section
90
and a base section
92
that includes the base
80
. The distance between the fold lines
88
and the fold lines
44
, which defines the base of the stacking tabs
28
, forms the height of the stacking tab
28
in its erected position.
To enhance the ability for the container
10
to be stacked one upon another, the side walls tilt or lean inwardly into the cavity
26
of the container
10
so that the stacking tabs
28
on the tilted side walls are in alignment with the slots disposed in the bottom wall panel
20
A. To achieve the tilting side walls, the opposed edges
96
and
98
of the end flaps
36
are tapered so that end flaps
36
form a parallelogram. Similarly, opposed edges
100
and
102
of the end wall panel
24
A are inwardly tapered as the edges
100
and
102
extend from the fold lines
32
to its outer edge. At the approximate intersection of fold lines
30
and fold lines
32
, the flap edges
96
of the end flaps
36
and the respective edges
100
or
102
end wall panel
24
A taper in the opposite direction. Thus, when erected, the outer side wall panel
22
A engages the tapered edges
100
and
102
of the end wall panel
24
A, while the edges
96
of the end flaps meets with the fold lines
32
.
Referring now to
FIGS. 1-4
, one method of constructing the tray-type container
10
from the blank
18
will be described. The first step begins with the outer side wall panels
22
A and end wall panels
24
A being each folded upright approximately 90° with respect to the bottom wall panel
20
A, with the end flaps
34
of the outer side wall panels
22
A folded inwardly 90° so that they are juxtaposed against the outer surface of end wall panels
24
A. The flaps
34
are secured to the outer surface of end wall panels
24
via any conventional manner, such as being stitched or glued, to form corners, the resulting erected container forming the bottom wall
20
, to outer side walls
22
, and the end walls
22
. As was described above, the end panels
34
and the end edges panel
102
of the end wall panel
24
A are formed with a slight taper, such that when secured together, the outer side wall
22
A slant slightly inward toward the middle of the container
10
.
Next, the end panels
60
are folded 90° about fold line
62
in the opposite direction as end panels
34
. The inner side wall panels
40
are then folded inwardly 180° along fold lines
42
and
44
so that inner side wall panels
40
are juxtaposed against outer side wall panels
22
, causing the now folded end panels
60
to be juxtaposed against the inner surface of the end walls
24
. As the inner side wall panels
40
are folded inwardly 180° along fold lines
42
and
44
, the optional locking tabs
52
may be inserted into slots
50
, thereby forming a rolled shoulder of two-ply thickness. As described above, the rolled shoulder forms the top edge of the erected container. The end flaps
60
may be secured to the inside surface of end walls
24
via any conventional manner, such as being stitched or glued.
At the same time the inner side wall panels
40
are folded inwardly 180° along fold lines
42
and
44
so that inner side wall panels
40
are juxtaposed against outer side wall panels
22
, the stacking tabs
20
are partially formed. Since the bases
80
of the stacking tabs
28
are unscored, it remains extending upwardly with the outer side wall
22
. To finish forming the stacking tabs
28
, the top sections
90
are folded inwardly 180° along fold lines
88
so that the top sections
90
are juxtaposed against the base sections
92
. To secure the top sections
90
of the stacking tabs
28
, the opposed projection portions
86
are inserted between the inner and outer side wall panels
40
and
24
. One skilled in the art will appreciate that the top section including projection portions may be crushed slightly to reduce the thickness of the material, thereby aiding in the insertion of the projection portion
86
between the inner and outer side wall
40
and
24
.
While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. For example, the blank may also include other features specified by the customer, such as hand holds, vent holes and the like. Additionally, while the blank described above and illustrated herein depict the end wall
24
sandwiched between the end flaps
36
of the outer side walls
22
and the end flaps
60
of the inner side walls
40
, it will be readily evident to those skilled in the art that the containers blank may be slightly modified so as to allow the bottom end flaps
36
and
60
to be attached to either the inner or outer surface of the end walls
24
.
Claims
- 1. A single piece containerboard blank for forming a tray-type container having an inner cavity and at least one stacking tab extending upwardly from the top of said container, comprising:a bottom wall panel; an end wall panel hingedly connected to said bottom wall panel by a first fold line; an outer side wall panel having an outer edge and being hingedly connected to said bottom wall panel by a second fold line; an inner side wall panel having an outer edge and being hingedly connected to said outer wall panel remote from said bottom wall panel by two spaced-apart fold lines, said spaced-apart fold lines interrupted by first and second cut lines, said inner side wall panel further includes end flaps hingedly connected thereto by end flap fold lines, wherein substantially the entire length of one of said end flaps extends parallel with said end wall panel when secured thereto in an erect condition; at least one stacking tab positioned within and formed substantially from said inner side wall panel by said first and second cut lines, said stacking tab including: a base section connected to the outer side wall panel and partially defined by said interrupted spaced-apart fold lines; and a top section hingedly connected to said base section by a fold line and terminating at a position remote from said outer edge of said inner side wall panel, said top section including opposed projection portions; wherein when the blank is erected to form said tray-type container, said inner side wall panel is folded about said two spaced-apart fold lines to overlay said outer side wall panel such that said stacking tab extends outwardly away from the top edge of said container formed by said spaced-apart fold lines, said stacking tab further being formed by folding said top section about said stacking tab fold line so that said top section is juxtaposed against said base section, wherein said projection portions of said top section are operable to secure said top section between said outer side wall panel and said inner side wall panel.
- 2. The blank of claim 1, wherein when said inner side wall panel is folded about said two spaced-apart fold lines to overlay said outer side wall panel so that said stacking tab extends outwardly away from the top edge of said container formed by said spaced-apart fold lines, a void is created in said inner wall panel having a shape corresponding to the shape of the stacking tab, said void operable to accept said projection portions to secure said top section between said outer side wall panel and said inner said wall panel.
- 3. The blank of claim 1, further comprising as least one cut out positioned along said fold line between said bottom panel and said outer side wall panel and dimensioned to correspond with the dimensions of said stacking tab.
- 4. The blank of claim 3, wherein said inner side wall panel further includes at least one cut out portion disposed at said inner side wall outer edge, said inner side wall panel cut out portion in substantial alignment with said cut out positioned along said fold line between said bottom panel and said outer side wall panel and dimensioned to correspond with the dimensions of said stacking tab.
- 5. The blank of claim 1, wherein said side wall panel is constructed such that when erected, said top edge of said side wall panel extends partially into said container cavity.
- 6. In a container of the type formed from a single blank cut and scored and having a bottom wall, two-ply side walls extending upwardly from the bottom wall, and end walls extending upwardly from the bottom wall to form, along with the side walls, an inner cavity, the improvement comprising:wherein each said two-ply side wall includes: an outer side wall panel having an outer edge and being hingedly connected to said bottom wall by a fold line; an inner side wall panel having an outer edge and being hingedly connected to said outer wall panel remote from said bottom wall panel by two spaced-apart fold lines, said spaced-apart fold lines interrupted by first and second cut lines; said inner side wall panel further includes end flaps hingedly connected thereto by endflap fold lines, said end flaps being folded approximately 90 degrees about said end flap fold lines and secured to one of said end walls in a substantially parallel manner; at least one stacking tab positioned within and formed substantially from said inner side wall panel by said first and second cut lines, said stacking tab including: a base section connected to the outer side wall panel and formed partially from said interrupted cut lines; and a top section hingedly connected to said base section by a fold line and terminating at a position remote from said outer edge of said inner side wall panel, said top section including projection portions extending from opposite sides thereof; wherein said inner side wall panel is folded about said two spaced-apart fold lines to overlay said outer side wall panel so that said stacking tab extends outwardly away from the top edge of said container formed by said spaced-apart fold lines, said stacking tab further being formed by folding said top section about said stacking tab fold line so that said top section is juxtaposed to said base section, wherein said projection portions of said top section are operable to secure said top section between said outer side wall panel and said inner side wall panel.
- 7. A single piece containerboard blank for forming a tray-type container having an inner cavity and at least one stacking tab extending upwardly from the top of said container, comprising:a bottom wall panel; an end wall panel hingedly connected to said bottom wall panel by a first fold line; an outer side wall panel having an outer edge, said outer side wall hingedly connected to said bottom wall panel by a second fold line; an inner side wall panel having an outer edge, said inner side wall panel hingedly connected to said outer edge of said outer wall panel by two spaced-apart fold lines, said spacedapart fold lines interrupted by first and second cut lines, said inner side wall panel further includes end flaps hingedly connected thereto by end flap fold lines, wherein substantially the entire length of one of said end flaps extends parallel with said end wall panel when secured thereto in an erect condition; at least one stacking tab formed partially from said inner side wall panel by said first and second cut lines, said stacking tab including: a base section partially defined by said interrupted spaced-apart fold lines; and a top section hingedly connected to said base section by a fold line and terminating at a position remote from said outer edge of said inner side wall panel, said top section including opposed projection portions; wherein when the blank is erected to form said tray-type container, said inner side wall panel is folded about said two spaced-apart fold lines to overlay said outer side wall panel such that said stacking tab extends outwardly away from the top edge of said container formed by said spaced-apart fold lines, said stacking tab further being formed by folding said top section about said stacking tab fold line so that said top section is juxtaposed to said base section, wherein said projection portions of said top section are operable to secure said top section between said outer side wall panel and said inner side wall panel.
US Referenced Citations (10)
Foreign Referenced Citations (1)
Number |
Date |
Country |
2682936 |
Apr 1993 |
FR |