Octagon shaped tray and corresponding blank

Abstract

The present invention includes and blank and container formed from cellulose based material configured to form an octagon shaped tray. The tray includes a roll-over side wall that provides structural rigidity as well as simple and fast container set-up. The octagon shape provides a relatively strong tray for the storage of products within. The tray may have solid walls, a single first side panel flap, or a pair of opposed first side panel flaps. The side panel flaps allow a user to see or access the contents of the tray as well as providing ventilation. Corner gussets provide additional structural integrity.

Description

FIELD OF THE INVENTION

This invention relates generally to blanks and their resulting containers, and more specifically to the blanks and containers forming octagonal-shaped trays with rolled side panels.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present invention are described in detail below with reference to the following drawings.

FIG. 1 is a plan view of a single piece container blank formed in accordance with the present invention;

FIG. 2 is a perspective view of a partially assembled container according to the present invention;

FIG. 3 is another perspective view of a partially assembled container according to the present invention;

FIG. 4 is yet another perspective view of yet another partially assembled container according to an aspect of the invention;

FIG. 5 is yet another perspective view of a partially assembled container made in accordance with the present invention; and

FIG. 6 is a perspective view of an assembled container according to various aspects of the present invention depicted in FIG. 1.

DETAILED DESCRIPTION

The present invention will now be described with reference to the accompanying drawings. The present invention is directed to a blank 20 and a container 50 that utilizes an octagonal shape to impart strength and stability. One suitable embodiment of the blank 20 and container 50 constructed in accordance with aspects of the present invention is illustrated in FIGS. 1 through 6. Specific details of the blank 20 and the resulting container 50 are described in more particularity below.

FIG. 1 depicts a blank 20 used to form the container 50. The blank 20 is typically constructed from a single piece of formable material such as, without limitation, sheets of cellulose-based materials formed from cellulose materials such as wood pulp, straw, cotton, bagasse or the like. Cellulose-based materials used in the present invention come in many forms, such as fiberboard, containerboard, corrugated containerboard and paperboard. The blank 20 is cut and scored, perforated or otherwise formed into a plurality of panels that when assembled form container 50. In all FIGURES, like numbers indicate like parts. Additionally, cut lines are shown as solid lines, score lines as dashed lines, and lines of perforation as broken lines. For the purposes of further description herein, the downward direction is defined as the direction perpendicular to the first bottom panel 30 that corresponds to the outer surface of the first bottom panel 30 when the container 50 has been erected. The upward direction is defined as the direction perpendicular to the first bottom panel 30 that corresponds to the inner surface of the bottom panel when the container 50 has been erected.

Referring now to FIG. 1, the blank 20 includes a first side panel 22. Attached to the first side panel 22 along a fold line 23 is a second bottom panel 30. The second bottom panel 30 is substantially trapezoidal in shape and has a length measured in a direction parallel to a fold line 23 that is greater than the length of the first side panel 22 measured along the same fold line. The first side panel 22 is also attached with a first angled corner panel 26 along a fold line 21. The plurality of first angled corner panels 26 are substantially rectangular in shape.

Attached to the first angled corner panel 26, opposite the first side panel 22, is a second side panel 24. The second side panel 24 is substantially rectangular in shape. The second side panel 24 is also attached with another first angled corner panel 26 opposite the first angled corner panel 26 that lies between the first side panel 22 and the second side panel 24. The second side panel 24 is also attached with a first bottom panel 28 along a fold line 37. The first bottom panel 28 is substantially rectangular in shape. Disposed through the first bottom panel 28 are slot(s) 44.

Attached to the second side panel 24, opposite the first bottom panel 28, are a pair of spaced-apart fold lines indicated by fold lines 31. These spaced-apart fold lines 31 form a rolled corner panel 36 there between. Attached with the rolled corner panel 36 opposite the second side panel 24 is a second side panel flap 38. The second side panel flap 38 has substantially the same geometry and size as the second side panel 24. On an edge opposite the rolled corner panel 36, the second side panel flap 38 has at least one locking tab 42 extending there from. The position and size of the locking tab 42 is configured to match the position and size of the slot 44 in the first bottom panel 28.

Disposed upon opposing ends of the second side panel flap 38 are second angled corner panels 40. The second angled corner panels 40 are connected with the second side panel flap 38 along fold lines 33. The second angled corner panels 40 are substantially rectangular in shape and sized similarly to the first angled corner panels 26.

One of the features of the present invention shall now be discussed. Specifically, the first side panels 22 may or may not include a first side panel flap 34 formed within the first side panel 22. As depicted in the FIGURES, only one of the first side panels 22 includes the first side panel flap 34. However, it will be understood that none of the first side panels 22 may include the first side panel flap 34 (not shown). Alternatively, both first side panels may include first side panel flaps 34 (not shown).

FIGS. 2-6 depict various stages of the container 50 being erected from the blank 20. Specifically, the various first side panels 22, second side panels 24, first bottom panels 28, second bottom panels 30, and first angled side panels 26 are folded over one another such that the two, singularly attached, first angled side panels 26 lay juxtaposed one another. At this time the first angled corner panels 26 that are juxtaposed to one another may be fastened together. Suitable nonlimited examples of methods of fastening the respective first angled corner panels 26 include mechanical and chemical binders. Suitable, nonlimiting examples of chemical binders include adhesives, glues, or tapes. Alternatively, suitable, nonlimiting examples of mechanical binders includes staples, brads and tacks. As best seen in FIG. 3, the panels, attached only at the respective first angled corner panels 26, may be pushed relative to one another to form the general outline the erect container 50.

With specific reference to FIGS. 4 and 5, the continued formation of the container 50 is shown. Specifically, the first bottom panels 28 may be folded inwardly approximately 90 degrees along fold lines 37. Likewise, the second bottom panels 30 may be folded inwardly approximately 90 degrees along a fold line 21. The status of the container formation with respect to this stage of formation is best depicted in FIG. 4. As can be seen, the bottom is substantially sealed off with the respective first bottom panels 28 and second bottom panels 30. Also the footprint of the container 50 is substantially formed at this stage.

With specific reference to FIG. 5, the final formation of the container 50 is depicted. Specifically, the second side panel flap 38 may be folded inwardly approximately 180 degrees along the two spaced-apart fold lines 31. In this fashion, the rolled corner panel 36 lies in a substantially horizontal orientation along the top end of the container 50. Upon folding the second side panel flap 38 inwardly approximately 180 degrees, the locking tabs 42 may be inserted into the slots 44 in the second side panels 28. This will substantially lock the container in place. It will be noted that by folding the second side panel flap in such a manner that the second angled corner panels 40 now lie substantially traverse the corners of the container 50, forming a substantially triangular shaped corner defined by the second angled corner panels 40, the first angled corner panels 26 and that portion of the rolled corner panel 36.

At this point, depending upon the box design, this box is substantially formed. However, where the container 50 includes a first side panel flap 34, the container 50 is not quite formed. Specifically, the first side panel flaps 34 may be folded downward inwardly approximately 180 degrees along a fold line 43. The locking tabs 42 that are located on the outermost edge of the first side panel flap 34 may then be inserted into respective slots 44 in the second bottom panel 30. It will be appreciated that, as discussed earlier, the first side panels 22 may not include a first side panel flaps 34 (not shown). Alternatively, both first side panels 22 may include a first side panel flap 34. It will be appreciated that any necessary respective tabs 42 and slots 44 associated with the presence or absence of the first side panel flap(s) 34 will be included or omitted as necessary without departing from the spirit and scope of this invention.

FIG. 6 depicts the formed container 50. It will be appreciated that the cut-outs formed by the first side panel flap 34 allow for ventilation as well as viewing the product contained therein. Likewise the rolled corners on the end of the panels on the second side panels 24 provide stability to the container 50 and a self-locking feature for locking tabs 42 into slots 44. Finally, the gusseted corners created by the first angled side panels 26 and the second angled side panels 40 provide for lateral stability as well as increase the overall stacking strength of the container 50.

While various embodiments of the invention have been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the various embodiments; instead the invention should be determined entirely by reference to the claims that follow.

Claims

1. A single sheet of foldable material cut and scored to define a container blank, comprising:

a first side panel;

a first angled corner panel connected with said first side panel;

a second side panel connected with the first angled corner panel, opposite the first side panel;

a second side panel flap connected with said second side panel by a pair of spaced apart fold lines; and,

a second angled corner panel connected with said second side panel flap;

wherein said first angled corner panel is substantially the same size and shape as the second angled corner panel.

2. The container of claim 1, wherein the single sheet of foldable material is formed from a cellulose-based material.

3. The container of claim 2, wherein the cellulose based material is formed from at least one of a wood pulp, straw, cotton, and bagasse.

4. The container of claim 2, wherein the cellulose based material is in the form of at least one of a fiberboard, containerboard, corrugated containerboard and paperboard.

5. The container of claim 1, further comprising a first bottom panel connected with the first side panel.

6. A single sheet of foldable material cut and scored to define a container, comprising:

a first side panel;

a first angled corner panel connected with said first side panel;

a second side panel connected with the first angled corner panel, opposite the first side panel;

a second side panel flap adjacent the second side panel;

a second angled corner panel extending between the second side panel flap and the first side panel,

wherein the second angled corner panel and the first angled corner panel lie in intersecting planes.