US20070194095A1

US20070194095A1 - Container having reclosable end wall

Info

Publication number: US20070194095A1
Application number: US11/359,968
Authority: US
Inventors: David Brundage; Michael McLeod
Original assignee: Smurfit Stone Container Inc
Current assignee: Smurfit Stone Container Inc
Priority date: 2006-02-22
Filing date: 2006-02-22
Publication date: 2007-08-23

Abstract

A container for packaging a product includes a blank of sheet material having an interior surface and an opposing exterior surface. The container has a bottom panel, opposing side walls and opposing end walls constructed to define a cavity. At least one end wall is movable between an open configuration and a closed configuration.

Description

BACKGROUND OF THE INVENTION

This invention relates generally to containers and, more particularly, to a container, such as a display tray, having a reclosable end wall and a method for constructing the container.
At least some conventional display containers for transporting, storing and/or displaying product require manual assembly. Assembling the many display containers necessary for a product shipment is labor and/or time intensive. These conventional display containers include walls that are secured together to provide sufficient structural support to allow the stacking of the display containers. However, such construction provides limited access to a cavity defined within the display container through an opening formed in a top surface of the display container. In many conventional display containers, stacking shelves formed along the top edges of the display container further limit access to the cavity. Workers are required to pack product through the top surface opening and around the stacking shelves. As a result, fragile or delicate products, such as produce, are easily damaged during packing into conventional display containers.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, the present invention provides a container for packaging a product. The container includes a blank of sheet material having an interior surface and an opposing exterior surface. The blank forms the container having a bottom panel, opposing side walls and opposing end walls constructed to define a cavity. At least one end wall is movable between an open configuration and a closed configuration.
In another aspect, a container for packaging a product is provided. The container includes a blank of sheet material having an interior surface and an opposing exterior surface. The blank forms the container having a bottom panel, opposing side walls and opposing end walls constructed to define a cavity. At least one end wall is movable between an open configuration and a closed configuration. The open configuration facilitates loading the product into the cavity. The container further includes a locking handle system coupling the movable end wall to each side wall in the closed configuration.
In another aspect, the present invention provides a method for packaging a product. The method includes constructing a container having a bottom panel, opposing side walls and opposing end walls to define a cavity. A movable first end wall of the opposing end walls is configured in an open configuration. The product is loaded into the cavity through an opening formed by the movable first end wall configured in the open configuration. The movable first end wall is moved to a closed configuration. The movable first end wall is locked in the closed configuration.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of a blank of sheet material for constructing a container, according to one embodiment of this invention.
FIG. 2 is a perspective view of a container constructed from the blank shown in FIG. 1.
FIG. 3 is a perspective view of the container shown in FIG. 2 with an end wall in an open configuration and side panel flaps in an open position.
FIG. 4 is a perspective view of the container shown in FIG. 2 with an end wall in an open configuration and side panel flaps in a closed position.
FIG. 5 is a perspective side view of the container shown in FIG. 4.
FIG. 6 is a perspective view of the container shown in FIG. 2 with an end wall unlocked from the side walls.
FIG. 7 is an end view of a container having a locking system, according to one embodiment of this invention, in an unlocked configuration.
FIG. 8 is an end view of the container shown in FIG. 7 with the locking system in a partially locked configuration.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a stackable, collapsible and/or reclosable container, such as a display tray, and a method for constructing the container. In one embodiment, the container is constructed or erected using a machine. In a particular embodiment, the construction method utilizes a strategic gluing process such that at least one end wall of the container is partially formed but configured in an open configuration after being discharged from the forming machine to allow for end loading product into the container. The container is easily closed after loading the product and locked with a hand-articulated locking handle system.
The present invention is described below in reference to its application in connection with and operation of a display tray. However, it will be apparent to those skilled in the art and guided by the teachings herein provided that the invention is likewise applicable to any suitable storage and/or display container including, without limitation, a carton, a tray or a box.
In one embodiment, the container is fabricated from a paperboard material. The container, however, may be fabricated using any suitable material, and therefore is not limited to a specific type of material. In alternative embodiments, the container is fabricated using cardboard, corrugated board, plastic and/or any suitable material known to those skilled in the art and guided by the teachings herein provided.
In a particular embodiment, the container includes a marking thereon including, without limitation, indicia that communicates the product, a manufacturer of the product and/or a seller of the product. For example, the marking may include printed text that indicates a product's name and briefly describes the product, logos and/or trademarks that indicate a manufacturer and/or seller of the product, and/or designs and/or ornamentation that attract attention. The container may have any suitable size, shape and/or configuration, i.e. number of sides, whether such sizes, shapes and/or configurations are described and/or illustrated herein. For example, in one embodiment, the container includes a shape that provides functionality, such as a shape that facilitates transporting the container and/or a shape that facilitates stacking and/or arrangement of a plurality of containers.
Referring now to the drawings, and more specifically to FIGS. 1 and 2, although as described above a display tray may have any suitable size, shape, and/or configuration, FIGS. 1 and 2 illustrate the construction or formation of one embodiment of a display tray. Specifically, FIG. 1 is a top plan view of one embodiment of a blank of sheet material 10. FIG. 2 is a perspective view of one embodiment of a display tray 300 formed from blank 10 shown in FIG. 1.
Referring to FIG. 1, blank 10 has an exterior surface 12 and an opposing interior surface 14. Further, blank 10 defines a leading edge 16 and an opposing trailing edge 18. Blank 10 has a corrugation direction from leading edge 16 to trailing edge 18. In one embodiment, blank 10 includes a bottom panel 22, opposing side panel 24 and side panel 26, and opposing end panel 28 and end panel 30. Side panel 24 and side panel 26 are coupled to bottom panel 22 by preformed, generally parallel, fold lines 32 and 34, respectively. Specifically, side panel 24 extends from bottom panel 22 along respective fold line 32 and side panel 26 extends from bottom panel 22 along respective fold line 34. As shown in FIG. 1, in one embodiment, fold line 32 and/or fold line 34 include a 0.5 inch×0.5 inch perforated score line.
Similarly, end panel 28 and end panel 30 are coupled to bottom panel 22 by preformed, generally parallel, fold lines 36 and 38, respectively. Specifically, end panel 28 extends from bottom panel 22 along respective fold line 36 and end panel 30 extends from bottom panel 22 along respective fold line 38. As shown in FIG. 1, in one embodiment, fold line 36 and/or fold line 38 include a 0.25 inch×0.25 inch perforated score line. It is apparent to those skilled in the art and guided by the teachings herein provided that fold lines 32, 34, 36 and/or 38, as well as other fold lines described herein, may include any suitable line of weakening known to those skilled in the art and guided by the teachings herein provided.
As shown in FIG. 1, bottom panel 22 defines a plurality of ventilation holes 40 to facilitate air flow through display tray 300, such as when display tray 300 is loaded with product and/or stacked with a plurality of display trays 300. Additionally or alternatively, side panel 24, side panel 26, end panel 28 and/or end panel 30 may include at least one ventilation hole or opening 41 to further facilitate air flow through display tray 300. Further, in one embodiment, at least one opening 42, 44, 46 and/or 47 is formed along a boundary line or area defined between bottom panel 22 and adjoining panels, including side panel 24, side panel 26, end panel 28 and/or end panel 30, to facilitate stacking of a plurality of display trays 300 during shipping, storing and/or displaying the product contained within display tray 300.
As shown in FIG. 1, two openings 42 are formed at a boundary line or area defined between bottom panel 22 and side panel 24 along fold line 32. In one embodiment, each opening 42 extends at least partially into bottom panel 22 and/or side panel 24. Similarly, two openings 44 are formed at a boundary line or area defined between bottom panel 22 and side panel 26 along fold line 34. In one embodiment, each opening 44 extends at least partially into bottom panel 22 and/or side panel 26 and is aligned with a corresponding opening 42. As shown in FIG. 1, at least one opening 46 is formed at a boundary line or area defined between bottom panel 22 and end panel 28 along fold line 36 and at least one opening 47 is formed at a boundary line or area defined between bottom panel 22 and end panel 30 along fold line 38. In one embodiment, each opening 46, 47 extends at least partially into bottom panel 22 and/or end panel 28, 30, respectively. As shown in FIG. 1, opening 46 is aligned with corresponding opening 47.
Referring further to FIG. 1, in one embodiment, side panel 24 defines at least one tab 48 along leading edge 16 to facilitate stacking of display trays 300, as described below. Further, in this embodiment, a projection 49 is defined by first side panel 24 along leading edge 16 to facilitate locking a movable end wall of display tray 300 in a closed configuration, as described below.
Blank 10 includes a first side panel flap 50 that extends from an end portion 52 of side panel 24 along a fold line 54. First side panel flap 50 is foldable with respect to side panel 24 about fold line 54 to facilitate construction of display tray 300 (shown in FIG. 2). In one embodiment, first side panel flap 50 includes a second fold line 55 generally parallel to fold line 54 that extends along a height of first side panel flap 50 to form a first flap portion 56 and a second flap portion 58. In this embodiment, a cutout portion 60 is defined along a periphery of second flap portion 58 to facilitate construction of display tray 300. In a particular embodiment, at least one ventilation opening 62 is defined by second flap portion 58 to facilitate ventilating a cavity defined within display tray 300.
A second side panel flap 70 extends from an end portion 72 of side panel 24 along a fold line 74. Second side panel flap 70 is movable between an open position, as shown in FIG. 3, to facilitate loading display tray 300 with product and a closed position, as shown in FIGS. 4 and 5, to facilitate construction of display tray 300. In one embodiment, second side panel flap 70 includes a second fold line 75 generally parallel to fold line 74 that extends along a height of second side panel flap 70 to form a first flap portion 76 and a second flap portion 78 of second side panel flap 70. In this embodiment, a handle opening 80 is defined within second flap portion 78 to facilitate construction of a locking handle system 400 (shown in FIGS. 7 and 8) of display tray 300, as described below. In a particular embodiment, at least one ventilation opening 82 is defined by second flap portion 78 to facilitate ventilating the cavity defined within display tray 300. As shown in FIG. 1, second flap portion 78 defines a tab 84 along leading edge 16 and a tab 86 defined along an opposing and generally parallel second edge 87 of second side panel flap 70. Opening 47 is configured to receive tab 86. For example, during construction of display tray 300, tab 86 is positioned within corresponding opening 47 formed along fold line 38 to maintain second side panel flap 70 in a closed position with respect to side panel 24 and/or bottom panel 22, for example with display tray 300 in a closed configuration.
Second side panel 26 includes a fold line 90 that extends along at least a portion of a width of second side panel 26 generally parallel to fold line 34. A first line of separation 92, such as a die cut and/or other suitable line of separation, extends from a first end 93 of fold line 90 to trailing edge 18 of blank 10. Similarly, a second line of separation 94 extends from a second end 95 of fold line 90 to trailing edge 18. Fold line 90, first line of separation 92 and second line of separation 94 define a first side panel portion 96 and a second side panel portion 98 of second side panel 26, as shown in FIG. 1. Second side panel portion 98 is foldable along fold line 90 and/or generally parallel fold line 99 with respect to first side panel portion 96 during construction of display tray 300. Second side panel portion 98 defines at least one tab 100 along trailing edge 18. With second side panel portion 98 folded with respect to first side panel portion 96, each tab 100 is positioned within a corresponding opening 44 formed along fold line 34 to maintain second side panel portion 98 folded with respect to first side panel portion 96. Further, in this embodiment, a projection 102 is defined by side panel 26 along trailing edge 18 to facilitate locking the movable end wall with respect to side panel 26 with display tray 300 in the closed configuration.
Blank 10 includes a third side panel flap 110 that extends from an end portion 112 of side panel 26 along a fold line 114. Third side panel flap 110 is foldable with respect to side panel 26 about fold line 114 to facilitate construction of display tray 300. As shown in FIG. 1, in one embodiment, third side panel flap 110 includes a second fold line 115 generally parallel to fold line 114 that extends along a height of third side panel flap 110 to form a first flap portion 116 and a second flap portion 118. In this embodiment, a cutout portion 120 is defined along a periphery of second flap portion 118 to facilitate construction of display tray 300. In a particular embodiment, at least one ventilation opening 122 is defined by second flap portion 118 to facilitate ventilating the cavity defined within display tray 300.
Referring further to FIG. 1, a fourth side panel flap 130 extends from an end portion 132 of side panel 26 along a fold line 134. Fourth side panel flap 130 is movable between an open position, as shown in FIG. 3, to facilitate loading display tray 300 with product and a closed position, as shown in FIGS. 4 and 5, to facilitate construction of display tray 300. As shown in FIG. 1, in one embodiment, fourth side panel flap 130 includes a second fold line 135 generally parallel to fold line 134 that extends along a height of fourth side panel flap 130 to form a first flap portion 136 and a second flap portion 138 of fourth side panel flap 130. In this embodiment, a handle opening 140 is defined within second flap portion 138 to facilitate construction of locking handle system 400, as described below. In a particular embodiment, at least one ventilation opening 142 is defined by second flap portion 138 to facilitate ventilating the cavity defined within display tray 300. As shown in FIG. 1, second flap portion 138 defines a tab 144 along trailing edge 18 and a tab 146 defined along an opposing and generally parallel second edge 147 of fourth side panel flap 130. During construction of display tray 300, tab 146 is positioned within corresponding opening 47 formed along fold line 38 to maintain fourth side panel flap 130 in a closed position with respect to side panel 26 and/or bottom panel 22, for example with display tray 300 in the closed configuration. With second side panel flap 70 and fourth side panel flap 130 in the closed position, handle opening 80 is aligned with handle opening 140.
In one embodiment, end panel 28 includes a fold line 150 generally parallel to fold line 36 that extends along at least a portion of a width of end panel 28 to form a first end panel portion 152 and a second end panel portion 154 of end panel 28. In this embodiment, a line of separation 156, such as a die cut, defines a tab 158 that extends outwardly from an end portion 160 of end panel 28 with second end panel portion 154 folded along fold line 150 with respect to first end panel portion 152. Further, first end panel portion 152 at least partially defines a handle opening 162 and a reinforcement flap 164 that is foldable along a fold line 166 and a generally parallel fold line 168 to facilitate construction of locking handle system 400. Reinforcement flap 164 reinforces an access hole defined by locking handle system 400 and prevents a handler from picking up display tray 300 against a raw corrugated edge.
As shown in FIG. 1, in one embodiment, blank 10 includes a first end panel flap 170 coupled to a first edge 172 of second end panel portion 154 along a fold line 174. In this embodiment, first end panel flap 170 includes a fold line 176 generally parallel to fold line 150 that extends along a width of first end panel flap 170 to form a first flap portion 178 and a second flap portion 180 of first end panel flap 170. A third flap portion 182 is coupled to second flap portion 180 along a fold line 184 at an edge 186 of second flap portion 180 for facilitating running blank 10. In one embodiment, third flap portion 182 is removed, e.g., decoupled from second flap portion 180, before display tray 300 is constructed.
Blank 10 further includes an opposing second end panel flap 190 coupled to a second edge 192 of second end panel portion 154 along a fold line 194. In this embodiment, second end panel flap 190 includes a fold line 196 generally parallel to fold line 150 that extends along a width of second end panel flap 190 to form a first flap portion 198 and a second flap portion 200 of second end panel flap 190.
In one embodiment, end panel 30 includes a fold line 210 generally parallel to fold line 38 that extends along at least a portion of a width of end panel 30 to form a first end panel portion 212 and a second end panel portion 214 of end panel 30. In this embodiment, a line of separation 216, such as a die cut, defines a tab 218 that extends outwardly from an end portion 220 of end panel 30 with second end panel portion 214 folded along fold line 210 with respect to first end panel portion 212. Further, first end panel portion 212 at least partially defines a handle opening 222 and a reinforcement flap 224 that is foldable along a fold line 226 and a generally parallel fold line 228 to facilitate construction of locking handle system 400. Reinforcement flap 224 reinforces an access hole defined by locking handle system 400 and prevents a handler from picking up display tray 300 against a raw corrugated edge.
As shown in FIG. 1, in one embodiment, blank 10 includes a third end panel flap 230 coupled to a first edge 232 of second end panel portion 214 along a fold line 233. A line of separation 234 intersects fold line 233 and defines a slot 235. In this embodiment, third end panel flap 230 includes a fold line 236 generally parallel to fold line 150 that extends along a width of third end panel flap 230 to form a first flap portion 238 and a second flap portion 240 of third end panel flap 230. Similarly, blank 10 includes an opposing fourth end panel flap 250 coupled to a second edge 252 of second end panel portion 214 along a fold line 253. A line of separation 254 intersects fold line 253 and defines a slot 255. In this embodiment, fourth end panel flap 250 includes a fold line 256 generally parallel to fold line 150 that extends along a width of fourth end panel flap 250 to form a first flap portion 258 and a second flap portion 260 of fourth end panel flap 250.
In one embodiment, display tray 300 is constructed from blank 10 for packaging a product, such as produce, perishable products and/or fragile or delicate products. Display tray 300 is formed from blank 10 by folding blank 10 about the fold lines. In one embodiment, an adhesive is applied to portions of blank 10 to secure selected portions of display tray 300 together. Display tray 300 includes a bottom panel 302, a first side wall 304, a second side wall 306 opposing first side wall 304, a first end wall 308 and a second end wall 310 opposing first end wall 308. Display tray 300 is constructed to define a cavity 312. In a particular embodiment, display tray 300 is constructed using a machine (not shown) and is initially configured in a fully constructed configuration, as shown in FIG. 2. The constructed display tray 300 is manually opened for end loading of the product, as shown in FIG. 3, and then closed. In an alternative embodiment, display tray 300 is constructed using a machine (not shown) and is initially configured in an open configuration, as shown in FIG. 3, to facilitate end loading the product into cavity 312. In this embodiment, the machine is configured to apply a suitable adhesive material, such as a suitable glue material, to selected or desired portions of blank 10 to secure selected components of display tray 300 together. For example, an adhesive material may be applied to end wall 308, side wall 304 and/or side wall 306 to secure end wall 308 to side wall 304 and/or side wall 306. More specifically, in one embodiment, a suitable adhesive material is applied to an outer surface of flap portion 180 and/or flap portion 200 and/or a corresponding inner surface of first end panel portion 152 to form end wall 308. Additionally, or alternatively, an adhesive is applied to an inner surface of flap portion 178 and/or flap portion 198 and/or an outer surface of corresponding side panel 24 and/or side panel 26 to secure end wall 308 to side wall 304 and/or side wall 306.
At least one end wall is movable between an open configuration and a closed configuration. In one embodiment, end wall 310 is movable between an open configuration (as shown in FIG. 3) and a closed configuration (as shown in FIG. 2). In this embodiment, display tray 300 is initially constructed with end wall 310 in an open configuration to facilitate end loading the product into cavity 312. First end wall 308 is then movable to the closed configuration and locked in the closed configuration to store, transport and/or display the product contained within display tray 300. As shown in FIG. 2, bottom panel 302 at least partially defines at least one opening 320 to facilitate stacking a plurality of display trays 300 while storing, transporting and/or displaying the product. At least one opening 320 is formed along a boundary line defined between bottom panel 302 and side wall 304, side wall 306, end wall 308 and/or end wall 310.
Referring further to FIGS. 1-6, end wall 310 includes end panel 30 coupled to bottom panel 302 along fold line 38. End panel 30 is movable about fold line 38 with respect to bottom panel 302. End panel 30 also includes a second fold line 210 extending along at least a portion of a width of end panel 30 and defining first end panel portion 212 and second end panel portion 214. Line of separation 216 intersects fold line 210 and defines a tab 218. Second end panel portion 214 is foldable along fold line 210 with respect to first end panel portion 212 to form a top portion 330 of end wall 310, as shown in FIG. 2. With second end panel portion 214 folded along fold line 210, tab 218 extends outwardly from top portion 330.
In one embodiment, a first side portion 332 of end wall 310 includes first flap portion 238 coupled to top portion 330 along fold line 233 and second flap portion 240 coupled to end panel 30. Line of separation 234 intersects fold line 233 and defines slot 235. Opposing second side portion 334 includes a first flap portion 258 coupled to top portion 330 along fold line 253 and second flap portion 260 coupled to end panel 30. Line of separation 254 intersects fold line 253 and defines a slot 255. With end wall 310 in the closed configuration, projection 49 formed on side panel 24 of side wall 304 is positioned within slot 235 defined along line of separation 234, and projection 102 formed on side panel 26 of side wall 306 is positioned within slot 255 defined along line of separation 254 to facilitate locking end wall 308 side wall 304 and side wall 306, respectively.
Referring further to FIGS. 3-5, in one embodiment, second side panel flap 70 is coupled to end portion 72 of first side panel 24 along fold line 74. Second side panel flap 70 forms first tab 84 along leading edge 16 of second side panel flap 70 and second tab 86 along second side edge 87 opposing leading edge 16. Second side panel flap 70 is movable between an open configuration (as shown in FIG. 3) to facilitate end loading the product into cavity 312 and a closed configuration (as shown in FIGS. 4 and 5). In the closed configuration, first tab 84 is positioned within a slot 217 defined by line of separation 216 formed on top portion 330 and second tab 86 is positioned within opening 320 formed along a boundary line or area defined between bottom panel 302 and end wall 310.
Similarly, fourth side panel flap 130 is coupled to end portion 132 of second side panel 26 along fold line 134. Fourth side panel flap 130 forms third tab 144 along trailing edge 18 of fourth side panel flap 130 and fourth tab 146 along second side edge 147 opposing trailing edge 18. Fourth side panel flap 130 is movable between an open configuration (as shown in FIG. 3) to facilitate end loading the product into cavity 312 and a closed configuration (as shown in FIGS. 4 and 5). In the closed configuration, third tab 144 is positioned within slot 217 defined by line of separation 216 formed on top portion 330 and fourth tab 146 is positioned within opening 320.
Referring to FIGS. 5, 7 and 8, in one embodiment, display tray 300 includes a locking handle system 400 coupling movable end wall 310 with respect to each side wall 304 and 306 in the closed configuration. Locking handle system 400 includes an access opening 402 defined by an alignment of opening 80 (shown in FIG. 1) defined by second side panel flap 70 with opening 140 (shown in FIG. 1) defined by fourth side panel flap 130, with second side panel flap 70 and fourth side panel flap 130 in the closed position (shown in FIG. 5). A locking tab 404 is formed by end wall 310. Locking tab 404 is positionable within opening 80 and opening 140 in the closed configuration to interfere with second side panel flap 70 and fourth side panel flap 130. As shown in FIG. 7, locking tab 404 is defined by a line of separation 406, such as a die cut or a perforated line, formed in end panel 30 of end wall 310. Voids 408 are cut from locking tab 404 to facilitate positioning locking tab 404 within access opening 402. With a hand articulation, a portion of locking tab 404 is decoupled from end panel 30. Locking tab 404 is foldable along fold line 226 and fold line 228 to position locking tab 404 through access opening 402 to construct locking handle system 400. With locking tab 404 positioned within access opening 402, an integrated handle 410 is formed in end wall 310. In one embodiment, locking handle system 400 includes a similar or identical integrated handle 410 formed in end wall 308. In an alternative embodiment, locking tab 404 is defined by line of separation 406 without forming or cutting a void, such as voids 408, from locking tab 404.
In one embodiment, a method for packaging a product, such as produce, perishable products and/or fragile or delicate products is provided. The method includes constructing a display tray having a bottom panel, opposing side walls and opposing end walls to define a cavity. A movable first end wall of the display tray is configured in an open configuration. The product is loaded into the cavity through an opening formed by the movable first end wall configured in the open configuration. The movable first end wall is then moved to a closed configuration and locked in the closed configuration with respect to each opposing side wall. In one embodiment, a first side panel flap coupled to a first side panel is moved from the open configuration to the closed configuration. In the closed configuration, a tab formed along a first side edge of the first side panel flap is positioned within a line of separation defined on the top portion. A tab formed along a second side edge of the first side panel flap opposing the first side edge is positioned within an opening formed along a boundary line or area defined between the bottom panel and the movable first end wall. A locking tab formed within the movable first end wall is positioned within a first access opening formed in the first side panel flap in the closed configuration to interfere with the first side panel flap. In one embodiment, a projection formed on a side edge of each side wall is positioned within a corresponding slot defined within the top portion to facilitate locking the end wall in the closed configuration.
The first end wall is movable from the closed configuration to the open configuration to remove the product from the display tray, if desired. Thus, the display tray is reclosable. Further, the display tray is further configured to facilitate stacking of display trays. In one embodiment, at least one opening is at least partially formed or defined within the bottom panel to facilitate stacking of display trays. Additionally, at least one tab is formed or defined with respect to a top surface of the display tray, such as on the top portion of each end wall. Each tab extends outwardly from the top surface and cooperates with a corresponding opening formed or defined on the bottom panel of an adjacent display tray to facilitate stacking of display trays.
The above-described display tray is constructed by a forming machine using a strategic gluing process, wherein specific areas of the display tray are not glued such that at least one end wall of the display tray is partially formed and configured in an open configuration after being discharged from the forming machine. With the end wall in the open configuration, a user is able to end load products into the display tray without obstructions, which may damage the products. Once loading is complete, the display tray is easily closed by moving the end wall to a closed configuration. In one embodiment, the end wall is locked in the closed configuration using a hand-articulated locking handle system. The locking handle system includes a handle opening defined within aligned side panel flaps and a locking tab that is configured to be inserted through an access hole formed by the handle openings. The locking tab is movable such that the locking tab couples the movable end wall with respect to the side walls of the display tray.
Exemplary embodiments of a stackable, collapsible and/or reclosable display tray and a method for constructing the display tray are described above in detail. The display tray and method are not limited to the specific embodiments described herein, but rather, components of the display tray and/or steps of the method may be utilized independently and separately from other components and/or steps described herein. Further, the described display tray components and/or method steps can also be defined in, or used in combination with, other apparatus and/or methods, and are not limited to practice with only the display tray and method as described herein.
While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.

Claims

1. A container for packaging a product, the container comprising:

a blank of sheet material having an interior surface and an opposing exterior surface, the blank forming the container having a bottom panel, opposing side walls and opposing end walls constructed to define a cavity, at least one end wall of the opposing end walls movable between an open configuration and a closed configuration.

2. A container in accordance with claim 1 wherein the at least one end wall further comprises:

an end panel coupled to the bottom panel along a first fold line, the end panel movable about the first fold line with respect to the bottom panel between an open position and a closed position;

a second fold line extending along at least a portion of a width of the end panel and defining a first end panel portion and a second end panel portion; and

a line of separation intersecting the second fold line and defining a tab, the second end panel portion foldable along the second fold line with respect to the first end panel portion to form a top portion of the end wall.

3. A container in accordance with claim 2 wherein, with the second end panel portion folded along the second fold line, the tab extends outwardly from the top portion.

4. A container in accordance with claim 2 further comprising:

a first side portion comprising a first flap portion coupled to the top portion along a third fold line and a second flap portion coupled to the end panel; and

an opposing second side portion comprising a first flap portion coupled to the top portion along a fourth fold line and a second flap portion coupled to the end panel.

5. A container in accordance with claim 4 further comprising:

a projection defined on a first side edge of a first side wall of the opposing side walls; and

a slot defined on the top portion and configured to receive the projection in the closed configuration.

6. A container in accordance with claim 2 further comprising:

a first side panel flap coupled to an end portion of a first side panel of the opposing side panels along a third fold line, the first side panel flap defining a first tab along a first side edge of the first side panel flap and a second tab along a second side edge opposing the first side edge, the first side panel flap movable between an open position for facilitating loading the product into the cavity and a closed position, in the closed position the first tab positioned within a slot defined by the line of separation formed on the top portion and the second tab positioned within an opening formed along a boundary line defined between the bottom panel and the end wall.

7. A container in accordance with claim 6 further comprising:

a second side panel flap coupled to an end portion of a second side panel of the opposing side panels along a fourth fold line, the second side panel flap defining a third tab along a first side edge of the second side panel flap and a fourth tab along a second side edge opposing the first side edge, the second side panel flap movable between an open position for facilitating loading the product into the cavity and a closed position, in the closed position the third tab positioned within the slot and the fourth tab positioned within the opening.

8. A container in accordance with claim 1 further comprising a locking handle system comprising:

a first access opening defined by a first side panel flap coupled to a first side wall of the opposing side walls, the first side panel flap movable between an open position and a closed position;

a second access opening defined by a second side panel flap coupled to a second side wall of the opposing side walls, the second side panel flap movable between an open position and a closed position, in the closed position the second access opening aligned with the first access opening; and

a tab formed by a first end wall of the opposing end walls, the tab positionable within the first access opening and the second access opening in the closed configuration to couple the first side panel flap and the second side panel flap.

9. A container in accordance with claim 1 wherein one end wall of the opposing end walls is glued to each of the opposing side walls.

10. A container in accordance with claim 1 wherein the bottom panel at least partially defines at least one opening and at least one tab is formed on a top surface of the container, the at least one tab positionable within a corresponding opening formed in a bottom panel of a second container for facilitating stacking of a plurality of containers.

11. A container for packaging a product, the container comprising:

a blank of sheet material having an interior surface and an opposing exterior surface, the blank forming the container having a bottom panel, opposing side walls and opposing end walls constructed to define a cavity, at least one end wall of the opposing end walls movable between an open configuration and a closed configuration, the open configuration facilitates loading the product into the cavity; and

a locking handle system coupling the movable end wall to each side wall of the opposing side walls in the closed configuration.

12. A container in accordance with claim 11 further comprising:

a first side wall of the opposing side walls comprising a first side panel and a first side panel flap extending from an edge of the first side panel, the first side panel flap movable between an open position and a closed position and defining a first access opening;

a second side wall of the opposing side walls comprising a second side panel and a second side panel flap extending from an edge of the second side panel, the second side panel flap movable between an open position and a closed position and defining a second access opening, in the closed position the second access opening aligned with the first access opening; and

a first end wall of the opposing end walls defining a locking tab, the locking tab positionable within the first access opening and the second access opening in the closed configuration to interfere with the first side panel flap and the second side panel flap.

13. A container in accordance with claim 12 wherein the at least one end wall further comprises:

an end panel coupled to the bottom panel along a first fold line, the end panel movable about the first fold line with respect to the bottom panel;

14. A container in accordance with claim 13 further comprising:

15. A container in accordance with claim 14 further comprising:

a slot defined along the third fold line and configured to receive the projection in the closed configuration.

16. A container in accordance with claim 13 further comprising:

a first side panel flap coupled to an end portion of a first side panel of the opposing side panels along a third fold line, the first side panel flap forming a first tab along a first side edge of the first side panel flap and a second tab along a second side edge opposing the first side edge, the first side panel flap movable between an open position for facilitating loading the product into the cavity and a closed position, in the closed position the first tab positioned within a slot defined by the line of separation formed on the top portion and the second tab positioned within an opening defined along a boundary line defined between the bottom panel and the end wall; and

a second side panel flap coupled to an end portion of a second side panel of the opposing side panels along a fourth fold line, the second side panel flap forming a third tab along a first side edge of the second side panel flap and a fourth tab along a second side edge opposing the first side edge, the second side panel flap movable between an open position for facilitating loading the product into the cavity and a closed position, in the closed position the third tab positioned within the slot and the fourth tab positioned within the opening.

17. A method for packaging a product, the method comprising:

constructing a container having a bottom panel, opposing side walls and opposing end walls to define a cavity, and configuring a movable first end wall of the opposing end walls in an open configuration;

loading the product into the cavity through an opening formed by the movable first end wall configured in the open configuration;

moving the movable first end wall to a closed configuration; and

locking the movable first end wall in the closed configuration.

18. A method in accordance with claim 17 further comprising moving the movable first end wall from the closed configuration to the open configuration to remove the product from the container.

19. A method in accordance with claim 17 wherein locking the movable first end wall in the closed configuration further comprises positioning a projection defined on a first side edge of a first side wall of the opposing side walls within a slot defined within a top portion of the movable first end wall in the closed configuration.

20. A method in accordance with claim 17 wherein locking the movable first end wall in the closed configuration further comprises moving a first side panel flap from an open position for facilitating loading the product into the cavity and a closed position, in the closed position a first tab formed along a first side edge of the first side panel flap positioned within a slot defined on a top portion of the movable first end wall and a second tab formed along a second side edge of the first side panel flap opposing the first side edge positioned within an opening formed along a boundary line defined between the bottom panel and the movable first end wall.

21. A method in accordance with claim 20 wherein locking the movable first end wall in the closed configuration further comprises positioning a tab formed by the movable first end wall within a first access opening formed in the first side panel flap in the closed position to interfere with the first side panel flap.