Blank assembly for forming a reinforced, stackable tray container

Patent metadata

Field	Value
Publication number	US-9580201-B2
Application number	US-201414309426-A
Country	US
Kind code	B2
Filing date	Jun 19, 2014
Priority date	Sep 23, 2011
Publication date	Feb 28, 2017
Grant date	Feb 28, 2017

Abstract

A blank assembly includes a tray blank having a first end panel assembly, a first side panel assembly, a second end panel assembly, and a second side panel assembly in series. Each panel assembly includes a removable pad panel. The tray blank further includes a bottom panel extending from each panel assembly at a fold line. The blank assembly further includes a first side insert blank configured to couple to the first side panel assembly. The first side insert blank having a removable pad panel configured to at least partially align with the removable pad panel of the first side panel assembly. A second side insert blank is configured to couple to the second side panel assembly. The second side insert blank includes a removable pad panel configured to at least partially align with the removable pad panel of the second side panel assembly.

First claim

What is claimed is:

1. A blank assembly for forming a reinforced tray container, the blank assembly comprising: a tray blank comprising a plurality of panel assemblies coupled together in series, wherein a first end panel assembly of the plurality of panel assemblies comprises a removable pad panel, an end panel, and an inner end panel extending from the end panel along a hinge line; and a first end insert blank configured to be positioned adjacent the first end panel assembly, the first end insert blank comprising at least one removable pad panel configured to at least partially align with the removable pad panel of the first end panel assembly, wherein the inner end panel is configured to fold over a bottom portion of the first end insert blank when the container is formed from the blank assembly.

2. A blank assembly in accordance with claim 1 , wherein the first end insert blank comprises a first reinforcing end assembly and a second reinforcing end assembly connected to each other at a fold line.

3. A blank assembly in accordance with claim 2 , wherein the at least one removable pad panel of the first end insert blank is a pair of removable pad panels, each of the first and second reinforcing end assemblies comprises: a reinforcing end panel configured to at least partially align with the end panel of the first end panel assembly; a stacking flap extending from each side edge of the reinforcing end panel; a cutout configured to at least partially align with the inner end panel of the first end panel assembly; and a respective removable pad panel of the pair of removable pad panels, the respective removable pad panel is removable from the reinforcing end panel at a pair of tear lines.

4. A blank assembly in accordance with claim 3 , wherein the stacking flaps extending from each side edge of each respective reinforcing end panel are configured to form a portion of a ledge when the container is formed from the blank assembly.

5. A blank assembly in accordance with claim 1 , wherein a second end panel assembly of the plurality of panel assemblies comprises a removable pad panel, an end panel, and an inner end panel extending from the end panel along a hinge line, the blank assembly further comprising a second end insert blank configured to be positioned adjacent the second end panel assembly, the second end insert blank comprising at least one removable pad panel configured to at least partially align with the removable pad panel of the second end panel assembly.

6. A blank assembly in accordance with claim 5 , wherein the inner end panel of the second end panel assembly is configured to fold over a bottom portion of the second end insert blank when the container is formed from the blank assembly.

7. A blank assembly in accordance with claim 5 , wherein each of a first side panel assembly and a second side panel assembly of the plurality of panel assemblies comprises a removable pad panel, a side panel, and an inner side panel extending from the end panel along a hinge line, the blank assembly further comprising: a first side insert blank configured to be coupled to the first side panel assembly, the first side insert blank comprising at least one removable pad panel configured to at least partially align with the removable pad panel of the first side panel assembly; and a second side insert blank configured to be coupled to the second side panel assembly, the second side insert blank comprising at least one removable pad panel configured to at least partially align with the removable pad panel of the second side panel assembly.

8. A reinforced tray container comprising: a pair of opposing side walls; a pair of opposing end walls, a first end wall of the pair of opposing end walls comprises a first end insert positioned adjacent a first end panel assembly, the first end panel assembly comprises a first end panel and a first end pad panel connected to the first end panel, wherein the first end pad panel is configured to be separated from the first end panel for removal from the first end wall, and wherein a first end window is at least partially defined in the first end wall by a first inner end panel of the first end panel assembly folded over a bottom portion of the first end insert; and a bottom wall connected to the pair of side walls and the pair of end walls.

9. A tray container in accordance with claim 8 , wherein the first end insert comprises a first reinforcing end assembly and a second reinforcing end assembly connected along a fold line, each reinforcing end assembly comprising: a reinforcing end panel; a stacking flap extending from each side edge of the reinforcing end panel, the stacking flaps configured to form at least a portion of a ledge; a pad panel connected to the reinforcing end panel at a pair of tear lines, the pad panel at least partially aligned with the first end pad panel of the first end panel assembly; and a cutout defined between the pad panel and the reinforcing end panel, the cutout configured to receive the first inner end panel therethrough to at least partially define the first end window.

10. A tray container in accordance with claim 9 , wherein each reinforcing end panel and each pad panel of the first and second reinforcing end assemblies is substantially perpendicular to the bottom wall and the first end panel is at an obtuse angle to the bottom wall.

11. A tray container in accordance with claim 9 , wherein a top edge of each reinforcing end panel and each pad panel of the first and second reinforcing end assemblies is lower than a top edge of the first end panel to facilitate nesting of an upper container in the tray container.

12. A tray container in accordance with claim 8 , wherein a second end wall of the pair of opposing end walls comprises a second end insert positioned adjacent a second end panel assembly, the second end panel assembly comprises a second end panel and a second end pad panel connected to the second end panel, wherein the second end pad panel is configured to be separated from the second end panel for removal from the second end wall, and wherein a second end window is at least partially defined in the second end wall by a second inner end panel of the second end panel assembly folded over a bottom portion of the second end insert.

13. A tray container in accordance with claim 12 , wherein a first side wall of the pair of opposing side walls comprises a first side insert positioned adjacent a first side panel assembly, the first side panel assembly comprises a first side panel and a first side pad panel connected to the first side panel, wherein the first side pad panel is configured to be separated from the first side panel for removal from the first side wall, and wherein a first side window is at least partially defined in the first side wall by a first inner side panel of the first side panel assembly folded over a bottom portion of the first side insert.

14. A tray container in accordance with claim 13 , wherein a second side wall of the pair of opposing side walls comprises a second side insert positioned adjacent a second side panel assembly, the second side panel assembly comprises a second side panel and a second side pad panel connected to the second side panel, wherein the second side pad panel is configured to be separated from the second side panel for removal from the second side wall, and wherein a second side window is at least partially defined in the second side wall by a second inner side panel of the second side panel assembly folded over a bottom portion of the second side insert.

15. A method for forming a reinforced tray container from a blank assembly, the blan

Assignees

• Westrock Shared Services Llc

Inventors

• Willman James John
• Minsky Craig Frederick

Classifications

• B65D5/445

  Reinforcements formed separately from the container · CPC title

• B65D5/542

  the lines of weakness being provided in the container body · CPC title

• B65D5/10

  with end closures formed by inward-folding of self-locking flaps hinged to tubular body · CPC title

• B65D5/0015 Primary

  the container being formed by folding up portions connected to a central panel · CPC title

• B31B2105/00

  Rigid or semi-rigid containers made by assembling separate sheets, blanks or webs · CPC title