BLANK FOR A FOLDABLE TRAY FOR FRESH PRODUCTS

Abstract

 The present disclosure relates to a blank (20) that has been cut and provided with folding indications (34, 54, 56) to be folded to a tray (10) for fresh products. The blank (20) has a substantially rectangular shape, defining a bottom plate (28) and first and second pairs of side wall flaps (30, 32) comprising first and second pairs of side wall portions (36, 38) configured to define first and second pairs of opposite side walls (40, 42) attached to the bottom plate (28) along respective bottom edge folding indications (34). Each side wall portion (36, 38) comprises a top edge (44) and two opposite side edges (46a, 46b). The side wall flaps (30, 32) comprise at least one spacer arrangement portion configured to define a spacer arrangement (24), said spacer arrangement portion comprising a connection flap (52) adapted for coupling of a first side wall (40) with a second adjacent sidewall (42) formed by said side wall portions (36, 38). The disclosure also relates to a tray (10) formed by folding a blank (20).

Description

Field of the invention

[0001] The present invention relates to a blank that has been cut and provided with folding indications to be folded to a tray for fresh products and to a fresh product tray formed by folding a blank.

Background

[0002] Open trays/boxes of a board material are widely used for transport, storage, and display of fresh products, especially for fruit and vegetables. Such products are relatively heavy, and the trays/boxes need to be stacked on top of each other to a reasonable height of for example from 5 to 15 boxes.

[0003] The size of the trays/boxes is targeted to contain a predetermined weight of a predetermined type of a fresh product is also dictated by the size of a pallet on which the trays/boxes are to be transported. Many different sizes of the tray/boxes are thus manufactured but the object is to fill substantially all the area of a pallet and substantially all the height of a container or transport vehicle. For example, the typical size of a tray for salad is 600 mm long, 400 mm wide and 180 mm high.

[0004] The trays are made of a sheet of a board material provided with folds and they are adapted to be erected manually or by a machine. To be able to carry a substantial portion of the weight of boxes stacked on top of another box, the trays/boxes need to have some kind of reinforcement in the corners.

[0005] US 2014/0312110 A1 describes a stackable open topped box made of folded fluted sheet material. The box has pillar formations in the corners to carry the weight of a stacked box. The box is erected by a machine and the parts are attached to each other with use of an adhesive.

Summary

[0006] It is an object of the present invention to provide a packaging for transport and storage of fresh products that can be stacked on top of another, similar packaging during transport and storage without collapsing and at the same time provide a packaging that has relatively low impact on the environment. To this end, there is provided a blank that has been cut and provided with folding indications to be folded to a tray for fresh products, said blank having a substantially rectangular shape, and defining a bottom plate, a first pair of side wall flaps comprising a first pair of side wall portion configured to define a first pair of opposite side walls attached to the bottom plate along respective bottom edge folding indications, and a second pair of side wall flaps comprising a second pair of side wall portions configured to define a second pair of opposite side walls attached to the bottom plate along respective bottom edge folding indications. Each side wall portion, when erected, comprises a top edge and two opposite side edges, and the side wall flaps further comprise at least one spacer arrangement portion configured to define a spacer arrangement adapted to keep a second, identical tray stacked on top at a distance from the top edge of the side wall. The at least one spacer arrangement portion comprises a connection flap adapted for coupling of a first side wall to a second, adjacent sidewall formed by said side wall portions.

[0007] Preferably at least one spacer arrangement is provided at each corner of a folded tray and each corner of the tray is held together by a respective connection flap of the respective corner. This assembly of trays requires no, or at least less, adhesives in form of for example of glue, or mechanical fasteners, to keep the parts of the tray together.

[0008] A spacer arrangement in trays for fresh products is used to protect the products within the trays when several trays are stacked on top of each other. The spacer arrangement will also provide ventilation for the products within the trays as well as the possibility to see the content within each tray when several trays have been stacked on top of each other. In prior art trays for fresh products, spacer arrangements can be plastic spacers arranged in the corners of the folded tray after the tray has been erected.

[0009] The spacer arrangement according to the present disclosure is an integral part of the blank formed by the spacer arrangement portion when folding the blank to a tray. The tray may therefore be cheaper to manufacture, has less impact on the environment, and weigh less compared to a tray with plastic spacer arrangements.

[0010] The blank can be transported to the field of the fresh products and be erected to a tray on site. The transport of a blank requires less space than a folded tray and thus more blanks than trays may be transported within the same vehicle; a flat blank therefore has less impact on the environment

[0011] In one embodiment, the spacer arrangement may comprise a support prism flap defined by a respective side wall flap. The support prism flap can be provided with at least two support prism flap folding indications arranged perpendicular to the bottom edge folding indication of the side wall flap, the support prism flap being arranged to form a support prism to extend inside the side walls when the support prism flap is folded at the support prism flap folding indications.

[0012] In one embodiment, the support prism flap can be arranged foldably connected at one of the side edges of the side wall portion of the respective side wall flap.

[0013] The support prism flap may extend, when folded at the support prism flap folding indications, inside the side walls of the folded tray. Preferably, the formed support prism will be arranged at a corner formed when the side walls flaps are erected. The formed support prism may reinforce the corners of the tray to give a higher vertical strength and a better loading capacity and thus increase the number of trays that can be stacked on top of each other compared to a tray without reinforcement of the corners.

[0014] Preferably, the support prism flap may be configured to form a triangular support prism when folded at the support prism flap folding indications. While reinforcements of the corners are desirable, the reinforcements should not interfere to much with the storage capacity within the tray. A support prism with triangular shape can give a reinforcement of the corners of the tray without excessively interfering with the storage space within the tray compared to a support prism with for example four or more side walls.

[0015] Preferably, the folded support prism can extend along the entire height of the side wall, from the bottom plate folding indication of the respective side wall flap to the top of the spacer arrangement. While the folded support prism reinforces the corner of the tray it also forms a part of the spacer arrangement, since the height of the support prism extends beyond the top edge of the side wall portion.

[0016] In one embodiment, the connection flap may be foldably connected to a wall of the support prism. The connection flap can be elongate and extend in a direction parallel with the respective bottom edge folding indication. It may extend from the wall of the support prism towards the centre of the same side wall portion to which the support prism flap is foldably connected.

[0017] In one embodiment, the spacer arrangement may comprise a rigid corner tab, The corner tab can be rigidly connected to a side wall portion and may extend in a plane of the side wall, when the side wall flap is erected, and wherein the corner tab may protrude in a direction perpendicular to the bottom edge folding indication of the side wall flap. The corner tab is a rigid tab arranged at least at one of the side wall edges. The corner tab extends above the top edge of the side wall portion and forms a part of the spacer arrangement.

[0018] In one embodiment, the corner tab may be arranged at a first side wall portion and the support prism flap may be arranged at a second side wall portion to form first and second side walls meeting each other to form an outer tray corner when the side wall flaps are erected. When the side wall flaps are erected, the corner tab will be arranged at the side edge of a first side wall, and a wall of the folded support prism will be defined by a portion of the second side wall of the two side walls meeting each other and forming an outer tray corner, where the other walls of the folded support prism will be arranged on the inside of the tray for reinforcement of the corner.

[0019] In one embodiment, the connection flap may be provided with at least two connection flap folding indications arranged perpendicular to the bottom edge folding indication of the side wall flap, and wherein the connection flap is adapted to be folded around the corner tab and the support prism for coupling of said first side wall with said second side wall meeting each other to form an outer tray corner when the side wall flaps are erected. The connection flap is arranged for coupling of a first side wall with a second side wall where the side walls meet each other and forms an outer tray corner. Thus, there is no need for any glue or mechanical fasteners for connection of the two side walls with each other.

[0020] Preferably, a width of the connection flap, perpendicular to the bottom folding indication, may correspond to the height of the corner tab above the top edge of the side wall. Since the connection flap extends above the top edge of the side wall, it will also form a part of the spacer arrangement.

[0021] Preferably, the corner tab can have a width, perpendicular to the respective bottom folding indication, adapted to the width of the support prism. The corner tab can be arranged both for formation of the corner and as to reinforce the folded support prism and thereby the corner of the tray. The corner tab reaches to the same height as the folded support prism.

[0022] In one embodiment, the connection flap may be arranged at the upper edge of a side wall portion, along the top edge of the respective side wall, when the side wall portion is erected. The connection flap is preferably cut out from the side wall portion and forms an integral part of the blank. Alternatively, the connection flap may be arranged at a lower portion of the side wall portion but will not then be a part of the spacer arrangement.

[0023] Preferably, the connection flap may comprise four segments separated by three connection flap folding indications. The length of each segment is adapted to the width of each support prism walls. The connection flap may be folded at least one lap around the outer corner of the tray, along and about the corner tab and the support prism side walls. The spacer arrangement will thereby only protrude the thickness of the blank from the outer face of the corner of the tray, which makes it possible to arrange two adjacent rows of trays close together.

[0024] In one embodiment, the spacer arrangement may comprise a connection flap locking arrangement, wherein said connection flap locking arrangement may comprise a female interface and a male interface. If a locking arrangement for the connection flap can be integrated within the blank, may be cheaper and have less impact on the environment compared to an external locking arrangement or adhesive.

[0025] In one embodiment, the female interface can at least be provided in the support prism flap, and the male interface can be provided at a free end of the connection flap.

[0026] Preferably, the male interface may be adapted to connect to the female interface when the connection flap has been folded at the connection flap folding indications around the corner tab and the support prism. The male interface can be provided with at least one barb. The male interface can be formed in one piece with the connection flap. The female interface can be a cut-out with a shape adapted to receive the male interface. The cut out can be arranged at an upper part of the folded support prism, in at least one of the support prism walls. Depending on the length of the connection flap, a further female interface can be arranged within the connection flap. This second female interface can be arranged close to the side wall portion for connection of the support prism flap. When the connection flap is folded at the connection flap folding indications around the corner tab and the support prism, the two female interfaces will end in register with each other and the male interface will connect through the two female interfaces at the same time.

[0027] Preferably, a coupling interface between the female and the male interfaces may be arranged on the inside of the folded prism. By placing the coupling interface on the inside of the formed prism, external impacts on the interface may be reduced, reducing the risk that the coupling interface may open unintentionally.

[0028] In one embodiment, the folding indications may be formed as creases. The folding indications may also be formed as perforations, but creases are preferred since it provides a more stable folding of the parts of the tray compared to perforations, especially if they are folded several times.

[0029] In one embodiment, the blank may further be provided with at least one alignment arrangement adapted to align a tray formed by the blank with a second, identical tray when the two trays are stacked on top of each other. When several trays are stacked on top of each other, it is preferred that the trays are aligned in relation to each other to get an even distribution of the weight at each space arrangement. Thus, the load on each corner can be aligned straight along the corners so that the corner does not bend resulting in damage to the product within the folded tray.

[0030] Preferably, the alignment arrangement may comprise at least one alignment tab provided at an upper edge of the spacer arrangement, when the side wall flaps are erected, and adapted to be connected to an alignment aperture provided in a corresponding corner of the bottom plate of a second identical tray stacked on top of the first tray. The alignment tab may be arranged on the upper edge of the same support prism wall as the female interface. Depending on the length of the connection flap, a further alignment tab can be arranged at the connection flap. This second alignment tab can be positioned such that when the connection flap is folded at the connection flap folding indications around the corner tab and the support prism, the two alignment tabs will end up in register with each other, and thus gives a reinforcement of the alignment. The alignment aperture may have the shape of a circle. The size of the aperture is so customized that the alignment tab can pass through. The alignment aperture may also be used for drainage of moisture from the fresh products stored within a folded tray.

[0031] Preferably, the at least one alignment tab may have an upwards tapering shape; by way of example, it can have the shape of a trapezoid. By providing the alignment tab with inclined side walls, the alignment tab has a more stable connection in the alignment aperture in a corresponding tray compared to straight side walls and provides a better alignment of the stacked trays. Since the alignment tab is arranged at the top edge of the spacer arrangement, the tab will protrude from the blank. Material costs in relation to a stable alignment of two identical trays stacked on top of each other must be considered when deciding the height of the alignment tab.

[0032] Preferably, the spacer arrangement may comprise an alignment notch, wherein said alignment notch may be arranged at a bottom edge of the folded support prism, opposite to the alignment tab. The alignment notch is arranged in the same support prism wall as the alignment tab. The notch is placed just above the aperture of the alignment arrangement so that the alignment tab/tabs of a first tray can be fitted through the aperture into the second identical tray when two identical trays are stacked on top of each other.

[0033] In one embodiment, the first pair of side wall flaps and/or the second pair of side walls flaps may be provided with at least one cut-out for a hand adapted to be used as a handle for a tray folded from a blank. To be able to handle and lift a tray more easily, especially when it is filled with fresh products, the tray may be provided with handles. The handles are preferably provided in each of the first pair of side wall flaps.

[0034] In one embodiment, the first pair of side walls portions may define short sides and said second pair of side walls portions may define long sides of the tray. The tray may have a rectangular bottom plate. The side wall flaps comprising the corner tab may comprise the side wall portions that define the short sides of the folded tray. The side wall flaps comprising the support prism flap and the connection flap may comprise the side wall portions that define the long sides of the folded tray.

[0035] In one embodiment, the blank can be cut in one piece from a solid board sheet, for example paperboard. The solid board can comprise at least two layers of a core material paper and two layers of a material paper coated with a thermoplastic, each arranged on each side of the core layers. All layers may be glued together forming a solid board. The first layer of coated material paper can form an outside of a tray folded from the blank and the second layer of coated material paper can form an inside of the tray. Since both the inside and the outside of the tray can be exposed to moisture, these layers may be provided with a barrier to prevent moisture from entering the core. The layers forming the inside and the outside of the folded tray may also be provided by a material paper without coating of a thermoplastic material. The choice of material for the layers within the board should be chose to provide a board with a flexibility to resist both pressure without curving or collapse due to load and at the same time have reduced density in order to save material costs. A board with a density of between 800 - 1100 g/m2 is preferred.

[0036] It may also be possible to cut out the blank in one piece from another sheet of paper material, for example corrugated paper, but a sheet of solid board is preferred.

[0037] In one embodiment, the blank can be configured to be folded back to a blank after having been folded to a tray. Since the parts of the tray may be connected to each other only by the folded connection flap, and with any connection flap locking arrangement as the case may be, it may be possible to fold back the tray into a blank after the tray has been used. The blank may then be transported to a new place, folded to a tray again and reused for storage and transport of fresh products.

[0038] According to a second aspect, parts or all of the above mentioned problems are solved, or at least mitigated, by a fresh product tray formed by folding a blank as defined above at folding indications to define an inner storage volume between the first pair and second pair of side walls. This tray can be used for storage and transport of fresh products. In prior art trays for fresh products, spacer arrangements are often plastic spacers arranged in the corners of the folded tray after the tray has been erected. These plastic spacers are comparatively expensive. The above defined tray may also have less impact on the environment since no adhesives or mechanical fasteners are needed to keep the parts of the tray together. The blank may be transported unfolded to the site of use. A blank requires less space than a folded tray and makes it possible to transport more blanks within the same transport vehicle. The folded tray may weigh less than a tray with plastic spacers.

[0039] It is noted that embodiments of the invention may be embodied by all possible combinations of features recited in the claims. Further, it will be appreciated that the various embodiments described for the device are all combinable with the method as defined in accordance with the second aspect of the present invention, and vice versa.

Brief description of the drawings

[0040] The above, as well as additional objects, features and advantages of the present invention, will be better understood through the following illustrative and nonlimiting detailed description of preferred embodiments of the present invention, with reference to the appended drawings, where the same reference numerals will be used for similar elements, wherein:

Fig. 1 is a schematic view in perspective of a fresh product tray,

Fig. 2 is a schematic view in perspective of a blank adapted to folded to a tray according to Fig. 1,

Fig. 3 is a schematic plan view of the blank of Fig. 2 with dimensions indicated.

Fig. 4 -9 are schematic views of a blank according the Fig. 2 being folded into a tray according to Fig. 1 in steps.

[0041] All the figures are schematic, not necessarily to scale, and generally only show parts which are necessary to elucidate the embodiments, wherein other parts may be omitted.

Detailed description of the exemplary embodiments

[0042] Fig. 1 illustrates a tray 10 formed by folding a blank 20 (illustrated in Fig. 2) at folding indications to define an inner storage volume 25 between a first pair and a second pair of side walls 40, 42. The tray 10 is used for storage, transport, and display of freshly harvested products.

[0043] The tray 10 is provided with cut-outs 22 for hands, the cut-outs 22 being adapted to be used as handles for the tray 10 to facilitate lifting and moving of filled trays 10.

[0044] Several trays 10 need to be stacked on top of each other during transport and storage to save space. When the trays 10 are stacked on top of each other, the inner storage volumes 25 cannot be placed too close on top of each other. In order to prevent damage of the products within the trays 10, a spacer arrangement 24 can be provided in each corner 26 of the tray 10 to provide at distance between the storage volumes 25 of two trays 10 stacked on top of each other. The spacer arrangement 24 also provides for visual contact with and ventilation of the products with the tray 10.

[0045] The spacer arrangement 24 can according to prior art be an external spacer that's is connected to each corner 26 of the tray 10 after the tray 10 has been erected or the spacer arrangement 24 can be an integral part of the blank 20 that is folded to a spacer arrangement 24 when the tray 10 is erected.

[0046] The tray 10 can be erected by a machine or manually. When the tray 10 is erected by a machine, the side walls of the tray are preferably connected to each other by an adhesive or a mechanical fastener. When the tray 10 is erected manually, the side walls of the tray 10 are preferably according to prior art connected to each other by locking tabs that are manually locked in position with a corresponding aperture.

[0047] The size of the tray 10 is adapted to contain a certain amount or weight of a certain fresh product. The size of the tray 10 is also dependent on the size of the pallet, on which trays 10 are to be transported. The height of the tray 10 depends on which product that shall be stored within the tray 10, and the height of the vehicle or container in which the trays 10 are to be transported. Thus, many different sizes of trays 10 are manufactured.

[0048] Fig. 2 illustrates a blank 20 that has been cut and provided with folding indications to be folded to a tray 10 for fresh products as shown in Fig.1.

[0049] The blank 20 is cut in one piece from a solid board sheet. The solid board comprises four layers of paper (not shown): Two core layers and two coated layers (not shown). The coated layers are coated with an environmentally friendly plastic, for example polythylene. The core layers are attached to each other, and the coated layers are each arranged on each side of the core layers. The layers are glued to each other forming a solid board. One of the coated layers forms the outside of a tray 10 folded from the blank 20 and the other coated layer forms an inside of the tray 10. Since both the inside and the outside of the tray 10 are exposed to moisture from the product within the tray 10 or from different weather conditions, the plastic coating prevents the tray 10 from becoming wet and thus soft, which can cause the tray 10 to collapse. The two coated layers can be provided with different colours to distinguish between the inside face and the outside face, and different trays may be given different colours to distinguish between trays from different growers. The outside of the tray 10 can also be provided with the trademark of the grower. The choice of material for the layers within the solid board should be chosen to provide a board with a flexibility to resist both pressure without curving or collapse due to load and at the same time have reduced density in order to save material costs. A solid board with a density of between 800-1100 g/m2 may be preferred. The solid board is preferably made of recycled material.

[0050] The blank 20 has a substantially rectangular shape and defines a bottom plate 28, a first pair of side wall flaps 30 and a second pair of side wall flaps 32, attached to the bottom plate 28 along respective bottom edge folding indications 34. The first pair of side walls flaps 30 comprises a first pair of side wall portions 36 configured to define a first pair of opposite side walls 40 (Fig. 1) and the second pair or side wall flaps 32 comprise a second pair of side wall portions 38 configured to define a second pair of side walls 42 (Fig. 1) when the side wall flaps 30, 32 are erected.

[0051] When the side walls flaps 30, 32 are erected (Fig. 1), each side wall portion 36, 38 will comprise a top edge 44 and two opposite side edges 46a, 46b. The first pair of side wall portions 36 will define short sides 40 and the second pair of side wall portions 38 will define long sides 42 of the tray 10 (Fig. 1).

[0052] The side wall flaps 32, 34 further comprise at least one spacer arrangement portion configured to define a spacer arrangement 24, adapted to keep a second, identical tray 10 stacked on top at a distance from the top edge 44 of the respective side wall 40 or 42. Preferably, as illustrated in Fig. 1, a spacer arrangement 24 is arranged in each corner 26 of the tray 10.

[0053] Each spacer arrangement 24 comprises a support prism flap 48, a rigid corner tab 50, a connection flap 52 and a connection flap locking arrangement.

[0054] A support prism flap 48 is foldably connected to at least one side edge 46a, 46b of a side wall portion 36 or 38 of the respective side wall flap 30, 32. In the blank illustrated in Fig. 2, a support prism flap 48 is connected to each of side edge 46a, 46b of the side wall portions 38 that defines long sides 42 of the tray 10. The support prism flap 48 is provided with three support prism flap folding indications 54 arranged perpendicular to the bottom edge folding indication 34 of the second side wall flap 32. The support prism flap 48 is arranged to form a support prism 49, when the support prism flap 48 is folded at the support prism flap folding indications 54.

[0055] A rigid corner tab 50 is rigidly connected to a side wall portion 36 or 38. In the blank 20 according to Fig. 2 there are two rigid corner tabs 50 rigidly connected to each respective side wall portion 36 that defines a respective short side 40 of the tray 10. The corner tabs 50 extend in a plane of the respective side wall 40, when the first side wall flaps 30 are erected. The rigid corner tabs 50 are arranged close to the side edges 46a, 46b of the respective side wall portions 36 of the first pair of side wall portions, and protrude in a direction perpendicular to the bottom edge folding indications 34 of the respective side wall flaps 30. The corner tabs 50 extend above the top edge 44 of the side wall portion 36.

[0056] Two connection flaps 52 are arranged at the top edge 44 of each side wall portion 38 of the second pair of side wall flaps 32. Each connection flap 52 is arranged above the top edge 44 of the respective side wall portion 38 and extends along the side wall portion 38, parallel to the bottom edge folding indication 34. Each connection flap 52 is foldably connected to a wall of the support prism 49, formed when the support prism flap 48 is folded at the support prism flap folding indications 54 in a manner which will be elucidated further below, and extends towards the centre of the second side wall portion 38. Each connection flap 52 is provided with at least two, and in the illustrated example, four connection flap folding indications 56 arranged perpendicular to the bottom edge folding indication 34 of the respective side wall flap 32. In the embodiment, illustrated in Fig 2, each connection flap 52 comprises four segments 57 separated by three connection flap folding indications 56.

[0057] Each connection flap locking arrangement comprises at least one female interface 58 and a male interface 60, adapted to be the connected to each other. The male interface 60 is provided at a free end of the connection flap 52, opposite to an attached end of the connection flap 52. A female interface 58 is arranged in a wall of the support prism 49 formed by the support prism flap 48 when folded at the support prism flap folding indications 54. As illustrated in Fig. 2, a further, second female interface 58 can be arranged in the connection flap 52; this second female interface 58 is arranged in a segment of the connection flap close to the attached end of the connection flap 52. This second female interface 58 may also act as a male interface 60 since the second female interface is formed when the male interface is pressing the tab within the segment of the connection tab inwards and follows the male interface 60 through the first female interface 58 (as illustrated in Fig 9).

[0058] In the embodiment according to Fig. 2, the male interface 60 is provided with at least one barb and the female interface 58 is a cut-out with a shape to receive the male interface 60. Other shapes of the male interface 60 are possible wherein the female interface 58 is adapted to receive the shape of the male interface 60.

[0059] The blank 20 is further provided with at least one alignment arrangement adapted to align a tray 10 folded by the blank 20 with a second identical tray 10 when two trays 10 are stacked on top of each other. The alignment arrangement comprises alignment tabs 62, an alignment aperture 64, and an alignment notch 66.

[0060] An alignment tab 62 is provided in the support prism flap 48. The alignment tab 62 is arranged on a top edge of the support prism 49 formed when the support prism flap 48 is folded at the support prism flap folding indications 54, extending from the same support prism wall as the female interface 58 is formed in. As illustrated in Fig. 2, a further, second alignment tab 62 is arranged at the connection flap 52. This second alignment tab 62 is arranged in a segment of the connection flap close to the attached end of the connection flap 52. The alignment aperture 64 is provided in bottom plate 28, at a corner formed between the long side 42 and the short side 40 when the side wall flaps 30, 32 are erected.

[0061] The alignment tabs 62 have the shape of trapezoids and the apertures 64 have circular shape. The alignment tabs 62 of a first tray 10 are adapted to pass through the apertures 64 of a second identically tray 10, when the second tray 10 is stacked on top of the first tray 10. The inclined side edges of the alignment tabs 62 facilitate the alignment of the trays 10 in relation to each other and prevent the trays 10 from moving sideways in relation to each other.

[0062] The alignment notch 66 is provided in the support prism flap 48. The alignment notch 66 is arranged in the same wall of the support prism as the first alignment tab 62 and the first female interface 58. The alignment notch 66 is adapted to make room for the alignment tab 62 when the alignment tab 62 of a first tray 10 is passed through the alignment aperture 64 of a second tray 10, stacked on top of the first tray 10.

[0063] Preferably, as illustrated in Fig. 2, a set of alignment tabs 62 and an alignment notch 66 are arranged at each support prism flap 48 and an alignment aperture 64 is arranged in each corner of the bottom plate 28 formed where the long sides 42 meets the short sides 40.

[0064] The alignment apertures 64 can also be used for ventilation and drainage of the product within a tray 10 folded from a blank 20. To contribute to the ventilation and drainage, a further aperture can be provided in the middle of the bottom plate 28 as seen Fig. 2.

[0065] The folding indications 34, 54, 56 illustrated in the figure could be formed as perforations or creases but are preferably formed as creases, since a tray 10 formed from a blank 20 will be subject to heavy load and compression when several trays 10 are stacked on top of each other.

[0066] Fig. 3 illustrates a blank 20 with exemplary dimensions to be folded to a tray 10, whose size is such that four identical trays 10 can be placed close to each other, forming a first layer of trays 10 stacked on a pallet with the size 80 X 120 cm:

A length L1 of each side wall flap 30 of the first pair of side wall flaps, extending along the respective bottom plate folding indications 34, is approximately 350 - 400 mm,

a length L2 of each side wall flap 32 of the second pair of side wall flaps, extending along the respective bottom plate folding indications 34, is approximately 700-750 mm,

a height H1 of each side wall portion 36 of the first pair of side wall flaps 30, extending perpendicular to the respective bottom plate folding indications 34, from the bottom plate 28 to the top edge 44 of the side wall 40, is approximately 150-160 mm,

a height H2 of each side wall portion 38 of the second pair of side wall flaps 32, extending perpendicular to the bottom plate folding indication 34, from the bottom plate 28 to the top edge 44 of the side wall 42, is approximately 150-160 mm,

a height H3 of the corner tabs 50, extending above the top edge 44 of the first side wall 40, is approximately 25-35 mm,

a width W1 of the connection flap 52 is about 25-35 mm, and

a width W2 of the corner tab 50, extending above the top edge 44 of the first side wall 40, approximate 25-35 mm.

Figs. 4-9 illustrate how a blank 20 according to Figs. 2 or 3 is folded to a tray 10 according to Fig.1.

Figs. 4-5 illustrates the erection of the side wall flaps 30, 32 for forming the side walls 40, 42 of the tray 10.

[0067] In Fig. 4, the second pair of side wall flaps 32 are folded at the respective bottom edge folding indications 34 and erected in a direction perpendicular to the bottom plate 28 to define long sides 42 of the tray 10. Each long side 42 has a top edge 44, with the connection flaps 52 extending above this top edge 44. The support prism flaps 48 are each folded at support prism folding indications 54 to extend in a direction perpendicular to the long sides 42, thereby extending along the respective bottom edge folding indications 34 of the first side wall flap 30, providing two opposite side edges 46a, 46b of each long side 42.

[0068] In Fig. 5, the first pair of side wall flaps 30 are folded at the respective bottom plate folding indications 34 and erected in a direction perpendicular to the bottom plate 28 to define short sides 40 of the tray 10 and an inner storage volume 25 between the first pair and second pair of side walls 40, 42. Each short side 40 has a top edge 44, with the rigid corner tabs 50 extending in a plane of the side wall above the top edge 44 and protruding in a direction perpendicular to the bottom edge folding indication 34, and two side edges 46a, 46b. Outer corners 26 of the tray 10 are formed where each side edge 46a, 46b of the short sides 40 meets respective side edges 46a, 46b of the long sides 42. The support prism flaps 48 extend on the inside of the short sides 40, facing the inner storage volume 25 of the tray 10.

[0069] Figs. 6-9 illustrate the formation of a reinforced spacer arrangement 24 in each corner 26 of the tray 10 formed when the side walls flap 30, 32 were erected. Each spacer arrangement 24 comprises the support prism flap 48, the rigid corner tab 50, the connection tab 52, and the connection tab locking arrangement 58, 60.

[0070] In Fig. 6, each prism support flap 48 is folded at the prism support flap folding indications 54, to form a support prism 49 extending inside the side walls 40, 42 at each corner 26 of the tray 10. The illustrated prism support flap 48 contains three support prism flap folding indications 54 and a support prism 49 with triangular shape is formed when the support prism flap 48 is folded at the support prism flap folding indications 54. The folded support prism 49 extends along the entire height of the side walls 40, 42, from the bottom edge folding indications 34 of the respective side wall flaps 30, 32 to the top of the respective spacer arrangements 24 to be formed. The support prism wall containing the second female interface 58, the second alignment tab 62 and the alignment notch 66 face the inner storage volume 25 of the tray 10 when the support prism 49 is formed. The alignment notch 66 will be arranged in a bottom edge of the support prism wall and the alignment tab will be arranged in a top edge of the same support prism wall, while the female interface 58 is formed within the support prism wall below the alignment tab 62 but above the top edge 44 of the side wall 40, 42. The alignment notch 66 is arranged above the alignment aperture 64, and when a first tray 10 is stacked on top of a second identical tray 10, the alignment tab/tabs 62 will be inserted through the alignment aperture 64 of the second tray 10 and arranged within the alignment notch 66.

[0071] The rigid corner tab 50 forms a part of the spacer arrangement 24 and has a height H3 (Fig. 3) extending above the top edge 44 of the first side wall 40. The corner tab 50 has a width, parallel to the respective bottom edge folding indications 34, adapted to the width of the support prism 49.

[0072] The connection flap 52 is also a part of the spacer arrangement 24 and is adapted for, when folded at the connection flap folding indications 56, coupling of a first side wall 40 with an adjacent side wall 42 formed by the side wall portions 36, 38.

[0073] Figs. 7-9 illustrates the folding of the connection flaps 52 at the connection flap folding indications 54 for coupling of respective long sides 42 of the tray 10 with respective short side 40 of the tray 10.

[0074] As illustrated in the Figs. 7, the connection flap 52 is foldably connected to a wall of the support prism 49 and extends above the top edge 44 of the side walls 40, 42. Each connection flap 52 has a width W1 (Fig. 3), perpendicular to bottom edge folding indication 34, that corresponds to the height H3 (Fig. 3) of the corner tab 50.

[0075] Each connection tab 52 is adapted, when folding at the connection tab folding indications 56, to be folded around the corner tab 50 and the support prism 49 for coupling of the side walls 40, 42.

[0076] The connection flap 52 according to the showed embodiment comprises four segments 57 and four connection tab folding indications 56. The connections flap 52 is first folded at the first folding indication 56 nearest the wall of the support prism 49, such that a first segment 57 of the connection flap 52 will thus be arranged on a top section of the support prism's 49 wall facing the inner storage volume 25 of the tray 10, along the entire width of the support prism's 49 wall. The female interface 58 arranged in the connection flap 52 will be arranged in register with the female interface 58 in the support prism's 49 wall, and the alignment tab 62 of the connection flap 56 will be arranged in register with the alignment tab 62 of the support prism's 49 wall, at a top edge of the spacer arrangement 24. The alignment tabs protrude approximate between 5-15 mm above the top edge of the spacer arrangement.

[0077] The connection flap 52 is then folded at a second connection flap folding indication 56, towards an outside face of the short side 40, where a second segment 57 of the connection flap 52 is arranged along the entire width W2 of the corner tab 50, as illustrated in Fig. 8.

[0078] The connection flap 52 is then folded at a third connection flap folding indication 56, towards an outside face of the long side 40, where a third segment 57 of the connection flap 52 is arranged along the entire width of the support prism 49 . The connection flap 52 is finally folded at a third connection flap folding indication 56, towards the inner storage volume 25 of the tray 10 again, where the male interface 60 of the connection flap locking arrangement is arranged in register with the two female interfaces 58, as illustrated in Fig. 9. The male interface 60 is then pressed through the female interfaces 58 to form a coupling interface on the inside of the folded support prism 49. The second female interface 58 may also act as a male interface 60 since the second female interface 58 is formed while the male interface 60 is pressing the tab within the segment of the connection tab 52 inwards and thus follows the male interface 60 through the first female interface 58 to form a connection interface on the inside of the folded support prism 49.

[0079] A reinforcement of the spacer arrangement 24 has now been finalized in each corner 26 of the tray 10 and a tray 10 has been folded from a blank 20 without the use of adhesive or mechanical fasteners for connection of the individual parts of the tray 10.

[0080] When the tray 10 has been used for transport and storage of fresh products, the blank 20 is configured to be folded back to a blank 20 again. Thus, it is possible to reuse the same blank 20 at several occasions.

[0081] The invention has mainly been described above with reference to a few embodiments. However, as is readily appreciated by a person skilled in the art, other embodiments than the ones disclosed above are equally possible within the scope of the invention, as defined by the appended patent claims.

[0082] For example, the support prism flaps and the connection flaps could be provided at the first pairs of side wall flaps instead of the second pairs of side wall flaps as illustrated in the embodiment according to the figures. This will result in that the connection flap comprises less segments and folding indications and will therefore not be arranged to be folded around all the prism walls as illustrated in Figs. 7-9 and that only one female interface is required.

[0083] The blank can also have a substantially square shape, resulting in that the first and the second side wall flaps and thereby the side walls provided when the side wall flaps are erected, are of the same length and thus it does not matter on which side wall flap, the support prism flap and the connection flap are provided.

[0084] In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality.

Claims

1. A blank (20) that has been cut and provided with folding indications (34, 54, 56) to be folded to a tray (10) for fresh products, said blank (20) having a substantially rectangular shape, and defining

a bottom plate (28), a first pair of side wall flaps (30) comprising a first pair of side wall portions (36) configured to define a first pair of opposite side walls (40) attached to the bottom plate (28) along respective bottom edge folding indications (34), and a second pair of side wall flaps (32) comprising a second pair of side wall portions (38) configured to define a second pair of opposite side walls (42) attached to the bottom plate (28) along respective bottom edge folding indications (34),

wherein each side wall portion (36, 38), when erected, comprises a top edge (44) and two opposite side edges (46a, 46b),

wherein said side wall flaps (30, 32) further comprise at least one spacer arrangement portion configured to define a spacer arrangement (24) adapted to keep a second, identical tray (10) stacked on top at a distance from the top edge (44) of the side wall (40, 42), and

wherein said at least one spacer arrangement portion comprises a connection flap (52) adapted for coupling of a first side wall (40) with a second adjacent side wall (42) formed by said side wall portions (36, 38).

2. A blank (20) according to claim 1, wherein said spacer arrangement (24) comprises a support prism flap (48), defined by a respective side wall flap (30, 32)
wherein said support prism flap (48) is provided with at least two support prism flap folding indications (54) arranged perpendicular to the bottom edge folding indication (34) of the side wall flap (30, 32), the support prism flap (48) being arranged to form a support prism (49) to extend inside the side walls (40, 42) when the support prism flap (48) is folded at the support prism flap folding indications (54).

3. A blank (20) according to claim 2, wherein said support prism flap (48) is arranged foldably connected at one of the side edges (46a, 46b) of the side wall portion (36, 38) of the respective side wall flap (30, 32).

4. A blank (20) according to claim 2 or 3, wherein said support prism flap (48) is configured to form a triangular support prism (49) when folded at the support prism flap folding indications (54).

5. A blank (20) according to any of the claims, 2-4 wherein the folded support prism (49) extends along the entire height of the side wall (40, 42), from the bottom edge folding indication (34) of the respective side wall flap (30, 32) to the top of the spacer arrangement (24).

6. A blank (20) according to any of the claims 2-5, wherein the connection flap (52) is foldably connected to a wall of the support prism (49).

7. A blank according to any of the preceding claims, wherein the spacer arrangement (24) comprises a rigid corner tab (50),
wherein said corner tab (50) is rigidly connected to a side wall portion (36, 38) and extends in a plane of the side wall (40, 42), when the side wall flap (30, 32) is erected, and wherein the corner tab (50) protrudes in a direction perpendicular to the bottom edge folding indication (34) of the side wall flap (30, 32).

8. A blank (20) according to claim 7 in combination with any of the claims 2-6.

9. A blank (20) according to claim 8 , wherein the corner tab (50) is arranged at a first side wall flap (30) and the support prism flap (48) is arranged at a second side wall flap (32) to form first and second side walls (40, 42) meeting each other to form an outer tray corner (26) when the side wall flaps (30, 32) are erected.

10. A blank (20) according to claim 9, wherein said connection flap (52) is provided with at least two connection flap folding indications (56) arranged perpendicular to the bottom edge folding indication (34) of the side wall flap (30, 32), and wherein the connection flap (52) is adapted to be folded around the corner tab (52) and the support prism (49) for coupling of said first side wall (40) with said second side wall (42) meeting each other to form an outer tray corner (26) when the side wall flaps (30, 32) are erected.

11. A blank (20) according to claim 10, wherein a width (W1) of the connection flap (52), perpendicular to the respective bottom edge folding indication (34), correspond to the height (H3) of the corner tab (50).

12. A blank (20) according to any of the claims 8-11, wherein the corner tab (50) has a width (W2), parallel to the respective bottom edge folding indication (34), adapted to the width of the support prism (49).

13. A blank (20) according to any of the preceding claims, wherein said connection flap (52) is arranged at the top edge (44) of a side wall portion (36, 38), when the side wall portion (36, 38) is erected.

14. A blank (20) according to any of the preceding claims, wherein the connection flap (52) comprises four segments (57) separated by three connection flap folding indications (56).

15. A blank (20) according to any of the preceding claims, wherein said spacer arrangement (24) comprises a connection flap locking arrangement (58, 60), wherein said connection flap locking arrangement (58, 60) comprises a female interface (58) and a male interface (60).

16. A blank (20) according to claim 15 in combination with any of claims 2-6, wherein the female interface (58) is at least provided in the support prism flap (48), and the male interface (60) is provided at a free end of the connection flap (52).

17. A blank (20) according to any of the claims 15 and 16, wherein the male interface (60) is adapted to connect to the female interface (58) when the connection flap (52) is folded at the connection flap folding indications (56) around the corner tab (50) and the support prism (49).

18. A blank (20) according to any of the claims 15-17, wherein a coupling interface between the female (58) and the male interface (60) is arranged on the inside of the folded support prism (49).

19. A blank (20) according to any of the preceding claims, wherein the folding indications (34, 54, 56) are formed as creases.

20. A blank (20) according to any of the preceding claims, wherein said blank (20) further is provided with at least one alignment arrangement (62, 64, 66) adapted to align a tray (10) formed by the blank (20) with a second, identical tray (10) when the two trays (10) are stacked on top of each other.

21. A blank (20) according to claim 20, wherein said alignment arrangement (62, 64, 66) comprises at least one alignment tab (62) provided at an upper edge of the spacer arrangement (24), when the side wall flaps (30, 32) are erected, and adapted to be connected to an alignment aperture (64) provided in a corresponding corner of the bottom plate (28) of a second identically tray (10) stacked on top of the first tray (10).

22. A blank (20) according to claim 21, wherein said at least one alignment tab (62) has the shape of a trapezoid.

23. A blank (20) according to 21 or 22 in combination of any of claims 2-6, wherein the spacer arrangement (24) comprises an alignment notch (66), wherein said alignment notch (66) is arranged at a bottom edge of the folded support prism (49), opposite to the alignment tab (62).

24. A blank (20) according to any of the preceding claims, wherein the first pair of side wall flaps (30) and/or the second pair of side walls flaps (32) are provided with at least one cut-out (22) for a hand adapted to be used as a handle for a tray (10) folded from a blank (20).

25. A blank (20) according to any of the preceding claims, wherein said first pair of side walls portions (36) defines short sides (40) and said second pair of side walls portions (38) defines long sides (42) of the tray (10).

26. A blank (20) according to any of the preceding claims, wherein the blank (20) is cut in one piece from a solid board sheet.

27. A blank (20) according to any of the preceding claims, wherein the blank (20) is configured to be folded back to a blank (20) after having been folded to a tray (10).

28. A fresh product tray (10) formed by folding a blank (20) according to claims 1-27 at folding indications (34, 54, 56) to define an inner storage volume (25) between the first pair and second pairs of side walls (40, 42).

Drawing