IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
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출원번호 |
US-0243404
(2011-09-23)
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등록번호 |
US-8763888
(2014-07-01)
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발명자
/ 주소 |
- Willman, James John
- Minsky, Craig Frederick
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출원인 / 주소 |
- Rock-Tenn Shared Services, LLC
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대리인 / 주소 |
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인용정보 |
피인용 횟수 :
4 인용 특허 :
22 |
초록
▼
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
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.
대표청구항
▼
1. A blank assembly for forming a reinforced tray container, the blank assembly comprising: a tray blank comprising: a first end panel assembly, a first side panel assembly, a second end panel assembly, and a second side panel assembly in series, wherein each panel assembly comprises a removable pad
1. A blank assembly for forming a reinforced tray container, the blank assembly comprising: a tray blank comprising: a first end panel assembly, a first side panel assembly, a second end panel assembly, and a second side panel assembly in series, wherein each panel assembly comprises a removable pad panel, and each side panel assembly further comprises a side panel and an inner side panel extending from the side panel along a hinge line; anda bottom panel extending from each panel assembly at a fold line;a first side insert blank configured to couple to the first side panel assembly, the first side insert blank comprising a removable pad panel configured to at least partially align with the removable pad panel of the first side panel assembly; anda second side insert blank configured to couple to the second side panel assembly, the second side insert blank comprising a removable pad panel configured to at least partially align with the removable pad panel of the second side panel assembly, wherein each inner side panel is configured to fold over a bottom portion of a respective side insert blank when the container is formed from the blank assembly. 2. A blank assembly in accordance with claim 1 further comprising: a first end insert blank configured to be positioned adjacent the first end panel assembly, the first end insert blank comprising a removable pad panel configured to at least partially align with the removable pad panel of the first end panel assembly; anda second end insert blank configured to be positioned adjacent the second end panel assembly, the second end insert blank comprising a removable pad panel configured to at least partially align with the removable pad panel of the second end panel assembly. 3. A blank assembly in accordance with claim 2, wherein each of the first and second end insert blanks comprises a first reinforcing end assembly and a second reinforcing end assembly connected to each other at a fold line. 4. A blank assembly in accordance with claim 3, wherein each of the first and second reinforcing end assemblies comprises: a reinforcing end panel configured to at least partially align with an end panel of a respective 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 an inner end panel of a respective end panel assembly; andthe removable pad panel removable from the reinforcing end panel at a pair of tear lines. 5. A blank assembly in accordance with claim 4, wherein the stacking flaps are configured to form a portion of a ledge when the container is formed from the blank assembly, the ledge configured to support an upper container stacked on the container. 6. A blank assembly in accordance with claim 1, wherein the removable pad panel of each side panel assembly is removable from the side panel at a pair of tear lines and from the inner side panel at a perforated line. 7. A blank assembly in accordance with claim 1, wherein each end panel assembly comprises: an end panel;an inner end panel extending from the end panel along a hinge line, wherein each inner end panel is configured to fold over a bottom portion of a respective end insert blank when the container is formed from the blank assembly; andthe removable pad panel removable from the end panel at a pair of tear lines and from the inner end panel at a perforated line. 8. A blank assembly in accordance with claim 1, wherein each panel assembly comprises a top edge having a first length and a bottom fold line having a second length shorter than the first length, and wherein a longitudinal axis of at least one panel assembly is orthogonal to a longitudinal axis of the tray blank. 9. A blank assembly in accordance with claim 1, wherein the bottom panels comprise: a first bottom end panel assembly extending from the first end panel assembly;a first bottom side panel extending from the first side panel assembly;a second bottom end panel extending from the second end panel assembly; anda second bottom side panel assembly extending from the second side panel assembly. 10. A blank assembly in accordance with claim 9, wherein: the first bottom end panel assembly comprises a first bottom end panel and a coupling panel extending from the first bottom end panel along a fold line, the coupling panel configured to couple to the first bottom side panel when the container is formed from the blank assembly; andthe second bottom side panel assembly comprises a second bottom side panel and a coupling panel extending from the second bottom side panel along a fold line, the coupling panel configured to couple to the second bottom end panel when the container is formed from the blank assembly. 11. A blank assembly in accordance with claim 9, wherein the first bottom side panel comprises a cutout configured to allow the blank assembly to be formed into an assembled blank by a machine. 12. A reinforced tray container comprising: a pair of opposing side walls each comprising a side panel, a reinforcing side panel, and a side pad panel assembly connected to the side panel and the reinforcing side panel, wherein the side pad panel assembly is configured to be separated from the side panel and the reinforcing side panel for removal from a respective side wall;a pair of opposing end walls each comprising an end panel and an end pad panel connected to the end panel, wherein the pad panel is configured to be separated from the end panel for removal from a respective end wall; anda bottom wall connected to the pair of side walls and the pair of end walls, the bottom wall configured to fold into a cavity of the container to transition the container from an erect configuration to a knocked-down flat configuration, whereina first window is defined in a first side wall of the pair of side walls by folding a first inner side panel over a bottom portion of a first reinforcing side panel; anda second window is defined in a second side wall of the pair of side walls by folding a second inner side panel over a bottom portion of a second reinforcing side panel. 13. A tray container in accordance with claim 12, wherein each end wall of the pair of end walls comprises an end insert positioned adjacent a respective end panel. 14. A tray container in accordance with claim 13, wherein each 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 end pad panel of an adjacent end panel; anda cutout defined between the pad panel and the reinforcing end panel, the cutout configured to receive an inner end panel of a respective end wall therethrough to form an end lip of a respective end wall. 15. A tray container in accordance with claim 14, wherein the stacking flaps are positioned between the reinforcing end panel and an adjacent end panel to space a top edge of the reinforcing end panel and pad panel a distance from the adjacent end panel. 16. A tray container in accordance with claim 15, wherein the reinforcing end panel and pad panel are substantially perpendicular to the bottom wall and the adjacent end panel is at an obtuse angle to the bottom wall. 17. A tray container in accordance with claim 15 wherein the top edge of the reinforcing end panel and pad panel is lower than a top edge of the adjacent end panel to facilitate nesting of an upper container in the tray container. 18. A tray container in accordance with claim 12, wherein: a third window is defined in a first end wall of the pair of end walls by folding a first inner end panel over a bottom portion of a first end insert, the first inner end panel and the bottom portion of the first end insert forming a first end lip;the first inner side panel and the bottom portion of the first reinforcing side panel form a first side lip;a fourth window is defined in a second end wall of the pair of end walls by folding a second inner end panel over a bottom portion of a second end insert, the second inner end panel and the bottom portion of the second end insert forming a second end lip; andthe second inner side panel and the bottom portion of the second reinforcing side panel form a second side lip. 19. A tray container in accordance with claim 18, wherein when the pad panels are removed from a respective wall, the tray container comprises four corner columns, wherein the first end lip extends between a first corner column and a second corner column, the first side lip extends between the second corner column and a third corner column, the second end lip extends between the third corner column and a fourth corner column, and the second side lip extends between the fourth corner column and the first corner column. 20. A tray container in accordance with claim 12, wherein the bottom wall comprises a first bottom end panel assembly extending from the first end panel assembly, a first bottom side panel extending from the first side panel assembly, a second bottom end panel extending from the second end panel assembly, and a second bottom side panel assembly extending from the second side panel assembly, wherein: the first bottom end panel assembly comprises a first bottom end panel and a coupling panel extending from the first bottom end panel along a fold line, the coupling panel configured to couple to the first bottom side panel when the container is formed from the blank assembly; andthe second bottom side panel assembly comprises a second bottom side panel and a coupling panel extending from the second bottom side panel along a fold line, the coupling panel configured to couple to the second bottom end panel when the container is formed from the blank assembly. 21. A method for forming a reinforced tray container from a blank assembly, the blank assembly including 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, wherein each panel assembly comprises a removable pad panel, the tray blank further includes a first bottom end panel assembly extending from the first end panel assembly, a first bottom side panel extending from the first side panel assembly, a second bottom end panel extending from the second end panel assembly, and a second bottom side panel assembly extending from the second side panel assembly, the blank assembly further includes a first side insert blank having a removable pad panel, and a second side insert blank having a removable pad panel, the method comprising: coupling the first side insert blank to the first side panel assembly such that the pad panel of the first side insert blank is substantially aligned with the removable pad panel of the first side panel assembly;coupling the second side insert blank to the second side panel assembly such that the pad panel of the second side insert blank is substantially aligned with the removable pad panel of the second side panel assembly;coupling a coupling panel of the first bottom end panel assembly to the second bottom end panel;coupling a coupling panel of the second bottom side panel assembly to the second bottom end panel;folding a first inner side panel over a bottom portion of the first side insert blank to define a window in a first side wall of a pair of opposing side walls; andfolding a second inner side panel over a bottom portion of the second side insert blank to define a window in a second side wall of the pair of side walls. 22. A method in accordance with claim 21 further comprising: forcing opposing corners of the container toward each other to form a bottom wall of the container, the bottom wall generally perpendicular to the pair of opposing side walls and a pair of opposing end walls of the container, wherein the bottom wall, the pair of side walls, and the pair of end walls define a cavity of the container. 23. A method in accordance with claim 21, wherein: folding the first inner side panel over the bottom portion of the first side insert blank forms a first side lip; andfolding the second inner side panel over the bottom portion of the second side insert blank forms a second side lip. 24. A method in accordance with claim 21 further comprising: positioning a first end insert adjacent the first end panel assembly such that stacking flaps of the first end insert are positioned between a reinforcing end panel and an end panel of a first end wall of the pair of end walls, wherein the first end insert defines a ledge of the first end wall; andpositioning a second end insert adjacent the second end panel assembly such that stacking flaps of the second end insert are positioned between a reinforcing end panel and an end panel of a second end wall of the pair of end walls, wherein the second end insert defines a ledge of the second end wall. 25. A method in accordance with claim 24 further comprising: folding a first inner end panel over a bottom portion of the first end insert to define a window in the first end wall and to form a first end lip; andfolding a second inner end panel over a bottom portion of the second end insert to define a window in the second end wall and to form a second end lip. 26. A blank assembly for forming a reinforced tray container, the blank assembly comprising: a tray blank comprising: a first end panel assembly, a first side panel assembly, a second end panel assembly, and a second side panel assembly in series, wherein each panel assembly comprises a removable pad panel; anda bottom panel extending from each panel assembly at a fold line;a first side insert blank configured to couple to the first side panel assembly, the first side insert blank comprising 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 configured to couple to the second side panel assembly, the second side insert blank comprising a removable pad panel configured to at least partially align with the removable pad panel of the second side panel assembly;a first end insert blank configured to be positioned adjacent the first end panel assembly; anda second end insert blank configured to be positioned adjacent the second end panel assembly, wherein each of the first and second end insert blanks comprises a first reinforcing end assembly comprising: a reinforcing end panel configured to at least partially align with an end panel of a respective end panel assembly; anda stacking flap extending from each side edge of the reinforcing end panel, the stacking flaps configured to be positioned between the reinforcing end panel and an adjacent end panel to form a portion of a ledge when the container is formed from the blank assembly. 27. A blank assembly in accordance with claim 26, wherein each of the first and second end insert blanks further comprise a removable pad panel configured to at least partially align with the removable pad panel of a respective end panel assembly, and the first reinforcing end assembly further comprises: a cutout configured to at least partially align with an inner end panel of a respective end panel assembly; andthe removable pad panel removable from the reinforcing end panel at a pair of tear lines. 28. A blank assembly in accordance with claim 27 wherein each of the first and second end insert blanks further comprises a second reinforcing end assembly connected to a respective first reinforcing end assembly along a fold line, each reinforcing end assembly comprising: a reinforcing end panel configured to at least partially align with an end panel of a respective end panel assembly;a stacking flap extending from each side edge of the reinforcing end panel, the stacking flaps configured to be positioned between the reinforcing end panel and an adjacent end panel to form a portion of a ledge when the container is formed from the blank assembly;a cutout configured to at least partially align with an inner end panel of a respective end panel assembly; andthe removable pad panel removable from the reinforcing end panel at a pair of tear lines. 29. A reinforced tray container comprising: a pair of opposing side walls each comprising a side panel, a reinforcing side panel, and a side pad panel assembly connected to the side panel and the reinforcing side panel, wherein the side pad panel assembly is configured to be separated from the side panel and the reinforcing side panel for removal from a respective side wall;a pair of opposing end walls each comprising an end panel, an end pad panel connected to the end panel, the end pad panel configured to be separated from the end panel for removal from a respective end wall, and an end insert positioned adjacent a respective end panel, each end insert comprising a first reinforcing end assembly comprising: a reinforcing end panel; anda stacking flap extending from each side edge of the reinforcing end panel, the stacking flaps positioned between the reinforcing end panel and an adjacent end panel, and configured to form at least a portion of a ledge; anda bottom wall connected to the pair of side walls and the pair of end walls, the bottom wall configured to fold into a cavity of the container to transition the container from an erect configuration to a knocked-down flat configuration. 30. A tray container in accordance with claim 29, wherein each first reinforcing end assembly further comprises: a pad panel connected to the reinforcing end panel at a pair of tear lines, the pad panel at least partially aligned with the end pad panel of an adjacent end panel; anda cutout defined between the pad panel and the reinforcing end panel, the cutout configured to receive an inner end panel of a respective end wall therethrough to form an end lip of a respective end wall. 31. A tray container in accordance with claim 30, wherein each end insert further comprises a second reinforcing end assembly connected to a respective first reinforcing end assembly 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 positioned between the reinforcing end panel and an adjacent end panel, and 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 end pad panel of an adjacent end panel; anda cutout defined between the pad panel and the reinforcing end panel, the cutout configured to receive an inner end panel of a respective end wall therethrough to form an end lip of a respective end wall. 32. A tray container in accordance with claim 30, wherein the reinforcing end panel and pad panel are substantially perpendicular to the bottom wall and the adjacent end panel is at an obtuse angle to the bottom wall. 33. A tray container in accordance with claim 30 wherein the top edge of the reinforcing end panel and pad panel is lower than a top edge of the adjacent end panel to facilitate nesting of an upper container in the tray container. 34. A method for forming a reinforced tray container from a blank assembly, the blank assembly including 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, wherein each panel assembly comprises a removable pad panel, the tray blank further includes a first bottom end panel assembly extending from the first end panel assembly, a first bottom side panel extending from the first side panel assembly, a second bottom end panel extending from the second end panel assembly, and a second bottom side panel assembly extending from the second side panel assembly, the blank assembly further includes a first side insert blank having a removable pad panel, and a second side insert blank having a removable pad panel, the method comprising: coupling the first side insert blank to the first side panel assembly such that the pad panel of the first side insert blank is substantially aligned with the removable pad panel of the first side panel assembly;coupling the second side insert blank to the second side panel assembly such that the pad panel of the second side insert blank is substantially aligned with the removable pad panel of the second side panel assembly;coupling a coupling panel of the first bottom end panel assembly to the second bottom end panel;coupling a coupling panel of the second bottom side panel assembly to the second bottom end panel;positioning a first end insert adjacent the first end panel assembly such that stacking flaps of the first end insert are positioned between a reinforcing end panel and an end panel of a first end wall of the pair of end walls, wherein the first end insert defines a ledge of the first end wall; andpositioning a second end insert adjacent the second end panel assembly such that stacking flaps of the second end insert are positioned between a reinforcing end panel and an end panel of a second end wall of the pair of end walls, wherein the second end insert defines a ledge of the second end wall. 35. A method in accordance with claim 34 further comprising: folding a first inner end panel over a bottom portion of the first end insert to define a window in the first end wall and to form a first end lip; andfolding a second inner end panel over a bottom portion of the second end insert to define a window in the second end wall and to form a second end lip.
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