Dividerless palletized packaging system with interlocking tray and corner posts

Patent metadata

Field	Value
Publication number	US-9428298-B2
Application number	US-201314072160-A
Country	US
Kind code	B2
Filing date	Nov 5, 2013
Priority date	Nov 5, 2013
Publication date	Aug 30, 2016
Grant date	Aug 30, 2016

Abstract

A modular packaging system for shipping and displaying palletized products is provided. The packaging system comprises a plurality of vertically stacked trays for holding the products and corner posts extending between vertically adjacent trays for spacing and supporting the trays. The corner posts and trays are locked together in a number of ways to strengthen and stabilize the system. The system is strong enough not only to support the weight of the products on the trays and withstand the vibration and impact forces that can occur during shipping, but to withstand the weight of one or more units stacked on top.

First claim

The invention claimed is:

1. A unitary folded blank for making a corner post, the folded blank comprising:
an outer half and an inner half foldably connected to each other along a bottom fold line;
the outer half comprising two substantially L-shaped outer panels foldably connected along an outer edge fold line, each L-shaped outer panel comprising an outer leg member adjacent the outer edge fold line and an outer foot member extending outwardly from the outer leg member away from the outer edge fold line and terminating at a free distal edge, and an outer reinforcing panel having an outer angled free edge extending between the outer leg member and the outer foot member, the outer leg member, outer foot member and outer reinforcing panel forming one contiguous, unitary structure lacking any fold or score lines; and
the inner half comprising two substantially L-shaped inner panels foldably connected along an inner edge fold line, the inner edge fold line being co-linear with the outer edge fold line, each L-shaped inner panel comprising an inner side panel adjacent the inner edge fold line, a narrow leg member hingedly attached to the inner side panel along a vertical fold line, an inner foot member extending outwardly from the narrow leg member and terminating at a free distal edge, and an inner reinforcing panel having an inner angled free edge extending between the narrow leg member and the inner foot member, the narrow leg member, inner reinforcing panel and inner foot member forming one contiguous substantially L-shaped structure lacking any fold or score lines.

2. The unitary folded blank of claim 1 wherein:
the inner half further comprises a flap cut out of each inner foot member and hingedly attached to the outer foot member along the bottom fold line.

3. The unitary folded blank of claim 1 wherein the inner half further comprises:
a top edge opposite and parallel to the bottom fold line;
locator tabs extending from the top edge; and
cut outs adjacent the bottom fold line, the cut outs being vertically aligned with the locator tabs.

4. A corner post made from a folded blank having an outer half and an inner half connected by a bottom fold, the corner post comprising:
a four-sided, substantially rectilinear tubular portion comprising two inner side panels formed from the inner half and hingedly connected along an inner edge fold line and two outer leg members formed from the outer half and hingedly connected along an outer edge fold line;
a top edge opposite and parallel to the bottom fold line;
locator tabs extending from the top edge;
cut outs adjacent the bottom fold line, the cut outs being vertically aligned with the locator tabs; and
a foot member extending laterally outward from each leg member.

5. The corner post of claim 4 further comprising:
a reinforcing panel having an angled free edge extending between the leg member and the foot member.

6. The corner post of claim 4 further comprising:
a flap cut out of each inner half and hingedly attached to the foot member along the bottom fold line.

7. The corner post of claim 4 wherein:
the inner half further comprises a narrow leg member hingedly attached to each inner side panel along a vertical fold line.

8. A packaging system for shipping and displaying products, the packaging system comprising:
a tray made from a first folded blank and having a bottom panel for supporting the products and having a perimeter, and two opposing side walls and two opposing end walls extending upward from the perimeter; and
a corner post made from a second folded blank having an outer half and an inner half foldably connected along a bottom fold line, the corner post comprising a four-sided, substantially rectilinear tubular portion comprising two inner side panels formed from the inner half and hingedly connected along an inner edge fold line and two leg members formed from the outer half and hingedly connected along an outer edge fold line, and a foot member extending laterally outward from each leg member and forming a corner therewith; wherein
one foot member is at least partially encapsulated within a side wall and the other foot member is at least partially encapsulated within an end wall.

9. The packaging system of claim 8 wherein:
the corner post further comprises a reinforcing panel disposed at the corner, the reinforcing panel having an angled free edge extending between a leg member and a foot member.

10. The packaging system of claim 9 wherein:
at least one of the side walls comprises an outer panel foldably connected to the bottom panel along a side fold line co-linear with the perimeter, an inner panel foldably connected to the outer panel along double fold lines parallel to the side fold line, a lip foldably connected to the inner panel along a lip fold line parallel to the side fold line, and an angled panel foldably connected to the outer panel along angled double fold lines, the angled double fold lines forming a non-right angle with the double fold lines; wherein
the angled panel at least partially encapsulates the reinforcing panel.

11. The packaging system of claim 10 wherein:
at least one of the inner side panels defines a vertical slot; and
the angled panel has a tab extending into the vertical slot.

12. The packaging system of claim 10 wherein:
the inner half further comprises a flap hingedly attached to the foot member along the bottom fold line, the flap defining a flap slot adjacent the bottom fold line; and wherein
a tab extending downward from the inner panel extends into the flap slot.

13. The packaging system of claim 10 wherein:
the inner half further comprises a flap hingedly attached to the foot member along the bottom fold line; and wherein
the lip abuts the flap.

Assignees

• Sonoco Dev Inc
• Frito Lay North America Inc

Inventors

• Bersamin Glen
• Tomaszewski Valentine
• Olmsted Jr John G
• Mathews Daniel Lee
• Nair Sunitha Ann

Classifications

• A47F5/116

  Shelving racks · CPC title

• A47F5/114

  in the form of trays with a base · CPC title

• B65D5/006 Primary

  Separate corner posts and like elements (B65D5/0065 takes precedence) · CPC title

• B65D5/445

  Reinforcements formed separately from the container · CPC title