Universal Tray Cover

The present disclosure relates to tray covers and more particularly to universal tray covers.

Distribution centers are beginning to automate operations, including automating the depalletizing, sorting, and repalletizing of goods. Current packaging and tray technology, in particular for produce, soft goods, or open top trays, may not be compatible with the new requirements brought about by the incorporation of automated depalletizing and repalletizing processes. However, redesigning product trays to be compatible with new warehouse machines is not a suitable solution to quickly adapt to the rapid automation of distribution centers, nor is requiring all open top containers to be distributed through traditional hand pick warehouses.

There remains a need in the art for a universal solution for certain containers (e.g., open top trays, produce trays, and the like) to be compliant with automated distribution center machines, without requiring a complete change in the tray itself. This disclosure provides a solution for this need.

Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, an illustrative view of an embodiment of a container blank in accordance with the disclosure is shown inand is designated generally by reference character. Other embodiments and/or aspects of this disclosure are shown in. Certain embodiments described herein can be used to improve container handling in automated distribution centers.

In an automated distribution center, in particular automated refrigerated/freezer distribution centers, the typical chain of events begins with an order of common goods arriving on large pallets. Each pallet contains a number of packaged boxed of the same or similar items. At the distribution center, these items must first be removed from the original pallet, then counted, sorted, and stored based on any number of desired parameters, e.g., heights, weights, destination, etc. The automated sorting process begins with removing the containers from the original pallet using a depalletizer machine. Certain depalletizers use a combination of suction and radial compression to grab an entire layer of packages from the original pallet at a time and transfer them to a conveyer. On the conveyer the containers can then be weighed, measured, indexed, and sorted using automated means. After sorting, when a retailer places an order, the containers for that order then need to be removed from the selves, and repalletized on a mixed pallet with all containers going to the retailer. On the mixed pallets, packages need to be able to be stacked atop one another for efficient shipping. Accordingly, the containers holding the product must be able to withstand the suction and compression of the depalletizer vacuum and must be able to allow stacking on the mixed pallet for shipping to retailers.

Certain containers coming into the distribution centers may be open top container (e.g., having no lid), or may have lids that cannot withstand the suction of the depalletizer. In these cases, the depalletizing process may suck product out of the container or may cause product to be shifted within the container so that the height or weight measurements may become distorted, leading to downstream errors in sorting and shipping to retailers. Some containers are particularly susceptible to these errors, including open top containers holding produce such as plastic clamshell packaging, or produce held in bags, for example. Conventionally, these open top containers having sensitive product would be sent to a hand pick warehouse, where the depalletizing, sorting, and repalletizing would be done by hand, using human workers. However, as distribution centers move towards automation, there is a particular need for all containers to be compliant with the automated machinery to avoid having to send containers to hand pick warehouses. The container and lid as described hereinbelow provides a solution to the problems currently faced with these open top containers and provides a compliant container and lid set suitable for use with automated distribution center machinery.

In accordance with at least one aspect of this disclosure, as shown in, a blank set for forming a container and a lid for the container is provided, the blank set comprising a container blankand a lid blank. In, the container blank comprises a bottom paneland a plurality of panels each extending from the bottom panel.

The plurality of panels can include a first side panelfoldably connected to the bottom panelat a first fold line(e.g., configured to form a first side wallin a set up container), a second side paneldisposed opposite the first side paneland foldably connected to the bottom panelat a second fold line(e.g., configured to form a second side wallin the set up container), a first end panelfoldably connected to the bottom panelat a third fold line(e.g., configured to form a first end wallin the set up container), and a second end paneldisposed opposite the first end paneland foldably connected to the bottom panelat a fourth fold line(e.g., configured to form a second end wallin the set up container). In the set-up container, each of the bottom panel, the first and second side panels,, and the first and second end panels,are configured to partially define an interior spaceto hold product therein. In the example shown in, the product held within the interior space can include product clamshell packaging.

Referring now to, the lid blankof the blank set can include a top panel, a first lid side flapfoldably connected to the top panelat a first top panel fold line, and a second lid side flapfoldably connected to the top panel, opposite the first side, at a second top panel fold line. When the containeris erected into the set up container, the first lid side flapand second lid side flapcan be folded downwards to be inserted into the interior spaceof the containersuch that the first lid side flapabuts the first side walland the second lid side flapabuts the second side wall. The first and second lid side flaps,are of a height H′ that is at least as tall as a height H of the first and second side walls,of the container. This allows additional containers to be stacked atop the lid panel(e.g., in the packed set up container shipping to and from the distribution center) without crushing the product within the interior spaceof the set up container. In certain embodiments, the lid panel can include one or more ventilation holesdefined in the top panel, e.g., as shown infor example. In certain embodiments, the lidcan be placed over the container, e.g., such that the first lid side flapabuts an outer surface of the first side walland the second lid side flapabuts an outer surface of the second side wall.

The lid blankcan also include one or more features configured to interact with the container to resist upward movement exerted onto the lid by a depalletizer vacuum to prevent the lid from being removed from the container by depalletizer. For example, as shown in, in certain embodiments, the container blankcan include a hole,defined in each of the first and second side panels,and the lid blankcan include a hole,defined in each of the first and second lid side flaps,. With the lidinserted into the container, the holedefined in the first lid side flapwill align with the holedefined in the first side wallof the container, and the same will be true for the second side of the container, where the holedefined in flapwill align with the holedefined in wall(e.g., as shown in). A fasteneris then provided and can be passed through the holes in both the lid flaps and the container side walls to secure the lid to the container (e.g., as shown in).shows one example of a fastener, e.g., a Christmas tree fastener or clip. Insertion of the fastenerinto the container and lid can be done at the time the container is packaged (e.g., in the field) and before shipped to the distribution center.

Still with reference to, as shown, the lid blankfurther includes a perforation or slit,extending from the hole,defined in the respective lid side flaps,to an outer edge,of the respective lid side flap,. The perforation/slit,will allow a user to remove the lidby pulling the lidupwards (e.g., using finger holes,) such that the fastenerrips through the perforation or slides through the slit. Here, the perforation,is configured and adapted to withstand the suction of the depalletizer to prevent the lidfrom being removed by depalletizer but is not so strong that a user cannot easily remove the lidto unpack the product once received by the retailer.

In certain embodiments, the containercan include double paneled side walls, wherein the first side panelincludes a first inner side paneland the container blankfurther includes a first outer side panelfoldably connected to the first inner side panelby a first side panel fold line, wherein the holeis defined in the first inner side paneland a perforation, or score, is defined in the first outer panel, aligned with the holein the first inner panel. The perforation or scoreensures that when the fasteneris inserted into the container, it is held tightly, and does not allow much lid play when the containeris moved using the depalletizer. The second side of the container can be the same, where the second side panel includes a second inner paneland second outer panelfoldably connected to the second inner panelby a second side panel fold line, wherein the second inner panelincludes the holeand the second outer panelincludes the perforation or score. With the fastenerinserted into the assembled container, each fastenerwill pass through three layers of board: the first and second outer panels,of the container, the first and second inner panels,of the container, and the first and second lid side flaps,of the lid, respectively.

As shown in, in certain embodiments, the holes,defined in the first and second lid side flaps,can be centrally located along a length of the side flap, and similarly holes,defined in the container side panels,can be defined at central location along a length of the first and second side flaps,. Also as shown, in certain embodiments, the holes,defined in the first and second lid side flaps,can be defined closer to the fold lines,than to the outer edges of the respective lid side flaps,.

In, a progression of installing the lidonto the containeris shown. In, the containeris shown packed with plastic produce clamshell packaging, with no lid over the container. In, the lidis shown being inserted into the container, over top of the product packaging, wherein the lid side flaps,abut the container side walls,. In, the lidis fully installed into the container, and a user is inserting the fastenerinto the containerand lid, e.g., inserting the fastenerfrom the first outer side panel, through the first inner side panel, and ultimately through the first lid side flap.shows the fastenerfully installed into the container, e.g., in the second side wall, and lid. This is an example of how the containerwould arrive at the distribution center, ready to be lifted by the depalletizer without risk of also removing the clamshells therein, and further allow for additional containers to be stacked atop the lid without crushing the clamshellswithin the container.

shows a user removing the lidfrom the container using the finger holesprovided, wherein the perforationis now ripped due to the fastenerpassing through. When the lid is removed, the fastenerremains within the container side wall.shows the containerwith the lidremoved, but with the fastenerstill in the container side walls (e.g., shown in sidewall). This is an example of how the containerwould be disassembled by a retailer ready to stock a display.

In certain embodiments, the lid and/or lid blankshown incan be a universal lid. For example, the lid need not have any particular interaction with the container other than the holes formed in the container. Forming the holes in the container blank is a simple retooling operation that can be done by the container manufacturer for little time and cost. The container blankdoes not need to be redesigned, nor the machines be reconfigured to accommodate this change. Accordingly, the lid provided inis a convenient and cost-effective solution for container manufacturers looking to quickly adapt to the increase in downstream automation.

With reference now to, another embodiment of a container blankand lidare shown. Here, the container and lid blanks,can be similar to the container and lid blanks,described above with respect to the blanks of. Like features already described above will not be repeated herein with respect to the blanks,of.

As shown in, the container blankcan also include a plurality of stacking flaps,,,extending from each of the first outer side panelthe second outer side panelconfigured to form a plurality of stacking tabs,,,in the set up container(e.g., as best seen in). These stacking tabs to allow an additional set up container formed from the same or a similar blank to be placed atop the stacking tabs and locked into place to prevent or limit horizontal movement of the containers. The container blankcan also include a plurality of stacking tab recesses,,,defined in the bottom panel, configured to accept a plurality of stacking tabs from an additional set up container stacked below the set up container.

As shown, the plurality of stacking flaps extend from the first and second outer panels at a folding tab fold line,,,above the first and second side panel fold lines,such that in the set up container, the stacking flaps fold over the folding tab fold lines and extend above a top edge,of the side walls,(e.g., as best seen in). Because of this, a gap is formed between a bottom edge of the stacking flaps,,,and the first and second fold lines,. This gap is best visualized in the blank by the distance G. G can be determined by determining the distance between the first fold line (e.g.,) and the side panel fold line (e.g.,) and subtracting from there, the sum of: the distance between the side panel fold line (e.g.) and the stacking flap fold line (e.g.,), plus the length of the stacking flap measured from the stacking flap fold line (e.g.,) to the bottom edge of the stacking tab fold line (e.g.,).

The plurality of stacking flaps can include a first and second stacking flap,extending from the first outer side paneland a third and fourth stacking flap,extending from the second outer side panel. As shown in, the lid blankcan further include a first and second locking flap,extending from the first lid side flapand a third and fourth locking flap,extending from second lid side flap. When the lidis inserted into the set up container, the first and second locking flaps,rest in the gaps G formed by the first and second stacking tabs,in the set up container, and the third and fourth locking flaps,rest in the gaps G formed by the third and fourth stacking tabs,in the set up container.

The plurality of locking tabs,,,are configured to fold in a reverse direction relative to the first and second lid side flaps,. Thus, when the lidis inserted into the set up container, the locking tabs,,,are configured to resist upward movement exerted onto the lidvia the depalletizer vacuum, by pushing against the stacking tabs, to prevent the lidfrom being removed by depalletizer. In this embodiment, no additional fasteners or other intrusive attachment means are required to hold the lid to the container, and no change needs to be made to the container blank from a conventional stacking tab container.

show a progression of folding the lid blankinto the lidand installing the lid into the container.shows the locking flaps,,,folded upwards relative to the folding table, whileshows folding the lid side flaps downwards and inwards,, towards the table.shows the insertion of the lidinto the container where the locking flaps,,,are pointing upwards, aligned with the stacking tabs,,,of the container. The slight spring bias of the locking flaps will urge the locking flaps into place, e.g., into the gaps of the stacking tabs, when the lidis pushed all of the way into the container interior space. As shown in, where the lid is fully inserted into the container, the locking flaps are no longer visible as they are beneath the stacking tabs. This arrangement will allow hold the lid in place when the container is moved by the depalletizer.again shows the fully assembled container with the lid installed in the container, which is an example of how the container would be shipped to and from the distribution center.shows a user removing the lid from the container using the provided finger holes,, e.g., when removing the product in the retail setting.

In certain embodiments, the lid and/or lid blank as described with respect tocan be universal to any containers having stacking tabs with gaps under the stacking tabs. This is a convenient and cost-effective solution for container manufacturers because the lid is designed for use with the existing container design, thus requiring no retooling or redesign of any container manufacturing processes.

In certain embodiments, for example as shown in, the lidcan be configured such that the lid flaps are defined on the ends of the lid panel, referred to as a first and second lid end flaps,. In such embodiments, the lidcan insert into or over the interior spaceof the containersuch that the first and second lid end flaps,abut the first and second end walls,of the container, respectively, as shown in. In, an embodiment is shown wherein the lid end flaps,are placed on an outside of the container, and can have holes,defined therein, and the container end panels,can have perforations or scores,configured to accept the fastener(e.g., as shown in), similar to that described above with respect to the embodiment of. In certain embodiments, the lid end flaps,can have perforations or slits,defined therein to allow the fastenerto tear through the end flaps when removing the lid in an upward motion using the finger holes. In certain embodiments, the perforation may not be included on the end flaps,and in order to remove the lid, the lid end flaps,can be pulled outward, away from the container, removing the fastenerwith the lid end flaps.

In certain embodiments, for example as shown in, the lidcan be configured to be placed over the interior spaceof the container, such that the lid side flaps,abut on the first and second outer side panels,, where inonly the first outer side panelis shown as the second outers side panelis obstructed. The lidcan also include stacking tab apertures,,,defined in the lid top panelconfigured to be placed over the stacking tabs,,,of the containerso that the lidcan lay flat on the edges of the container, e.g., as shown in. The holecan receive the apertureas shown insimilar to that described above with respect to.

Referring now to, an embodiment of a blank for forming a container with an integrated lid is shown, where blankis shown in, the containeris shown partially assembled in, and the containeris shown fully assembled in.

As shown, each of the first end paneland the second end panelfurther include a lid flap having first and second minor flaps. The first end panelcan include lid flaphaving first and second minor flaps,. The second end panelcan include lid flaphaving first and second minor flaps,. When erecting the container, the lid flaps,can be configured to fold over the respective end walls,to form a lid structure at respective ends of the containerpartially enclosing the interior space. In the container, e.g., as shown in, the first minor flaps,abut an inner surface of the first side walland the second minor flaps,abut an inner surface of the second side wall. In certain embodiments, e.g., as shown, the first and second side walls,can be double walled, each having an inner paneland an outer panel,, where stacking tabs,,,are defined in the outer panel,. In such embodiments, the first minor flaps,and second minor flaps,can each have locking flaps,,,configured to interact with the stacking tabs,,,to hold the lid panels,in place and to resist upward movement exerted onto the lid via the depalletizer vacuum to prevent the lid from being removed by the depalletizer. The minor flaps,,,can be of a length equal to or greater than a height of the side walls so that the lid panels,sit flat and allow for stacking additional containersatop the lid.

In accordance with at least one aspect of this disclosure, there is provided a set comprising a container and a lid for the container. The container and lid can be formed from the blanks described herein above. Embodiments of the lid and container set, and the container with integrated lid provided herein allow for complaint containers for use within an automated distribution center using suction based depalletizer and requiring stacking of containers on mixed pallets leaving the distribution center. Embodiments as described herein allow, in this particular example, produce growers, to continue using their same tray forming equipment to accommodate the addition of the lid, since the containers remain the same.

Those having ordinary skill in the art understand that any numerical values disclosed herein can be exact values or can be values within a range. Further, any terms of approximation (e.g., “about”, “approximately”, “around”) used in this disclosure can mean the stated value within a range. For example, in certain embodiments, the range can be within (plus or minus) 20%, or within 10%, or within 5%, or within 2%, or within any other suitable percentage or number as appreciated by those having ordinary skill in the art (e.g., for known tolerance limits or error ranges).

The articles “a”, “an”, and “the” as used herein and in the appended claims are used herein to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article unless the context clearly indicates otherwise. By way of example, “an element” means one element or more than one element.

The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.

As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e., “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.”

Any suitable combination(s) of any disclosed embodiments and/or any suitable portion(s) thereof are contemplated herein as appreciated by those having ordinary skill in the art in view of this disclosure.

The embodiments of the present disclosure, as described above and shown in the drawings, provide for improvement in the art to which they pertain. While the apparatus and methods of the subject disclosure have been shown and described, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.