RELATED APPLICATIONS

This patent application claims the benefit of U.S. Provisional Application No. 61/604,908, filed on Feb. 29, 2012, entitled, â€œReusable, Collapsible Tray,â€ the contents and teachings of which are hereby incorporated by reference in their entirety.

BACKGROUND

Container devices, such as corrugated containers, can be used for packing a variety of objects. For example, in the envelope manufacturing area, corrugated envelope container devices are configured to hold stacks of envelopes and to allow for easy delivery to customers. Accordingly, envelope container devices should be relatively sturdy to withstand stacking and to protect the envelopes from deformation.

SUMMARY

Container devices, such as envelope container devices, suffer from a variety of deficiencies. For example, in their assembled state, conventional container devices such as corrugated envelope container devices, can take up a relatively large volume of space, thereby requiring a facility to provide a storage area for the unused in the area of the envelope and inserter machinery. Additionally, conventional corrugated paper container devices are relatively expensive as a one-use type of product, but are commonly utilized in today's trade. Furthermore, conventional corrugated envelope container devices are not easily disassembled to allow for easy storage. For example, certain conventional containers are held together with adhesives or fasteners, which cannot be removed without damaging the container.

By contrast to conventional container devices, embodiments of the present innovation relate to a container that includes a base, a first sidewall extending along a first direction from the base, and a second sidewall extending along the first direction from the base, the first sidewall opposing the second sidewall. The container includes a first end wall extending along the first direction from the base and a second end wall extending along the first direction from the base, the first end wall opposing the second end wall and each of the first end wall and the second end wall disposed between the first sidewall and the second sidewall. Each of the first end wall and the second end wall include a first end wall panel coupled to the base and defining an opening and a second end wall panel hingedly coupled to the first end wall panel, the second ends wall panel defining a set of tabs configured to engage a set of slots defined by the base and further defining a panel flexion portion extending at least partially along a length of the second end wall panel, the panel flexion portion substantially aligned with the opening defined by the first end wall panel. The second end wall panel is configured to flex about the panel flexion portion in response to a load applied to the panel flexion portion through the opening defined by the first end wall panel.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, features and advantages will be apparent from the following description of particular embodiments of the innovation, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of various embodiments of the innovation.

FIG. 1 illustrates a blank used to create a storage tray, according to one arrangement.

FIG. 2 illustrates a partial perspective view of the blank of FIG. 1 during assembly, according to one arrangement

FIG. 3 illustrates a side sectional view of a portion of the blank of FIG. 1 where an end wall panel engages a base of the blank, according to one arrangement.

FIG. 4 illustrates a perspective view of the blank of FIG. 1 formed into a storage tray, according to one arrangement.

FIG. 5 illustrates a side sectional view of a portion on the blank of FIG. 1 where an end wall panel disengages engages a base of the blank, according to one arrangement.

DETAILED DESCRIPTION

Embodiments of the present innovation relate to a collapsible container, such as is configured to hold envelopes, tubes, or injected molded bottles, for example. The container is assembled from a pre-cut and scored sheet of corrugated material, such as a container form or blank. In one arrangement, the container is configured to allow for ease of disassembly. For example, a base of the container includes a pair of opposing end walls. Each end wall includes an outer end wall panel coupled to the base and an inner end wall panel coupled to the outer end wall panel. The inner wall panel includes set of tabs that engage corresponding openings defined by the base and a flexion portion, such as a score line, that allows the inner wall panel to flex relative to the base. The outer wall panel defines an opening that is substantially aligned with the score line. To disassemble the container, a user accesses the inner wall panel through the opening defined by the outer wall and applies a load against flexion portion. The load causes the inner wall panel to fold or buckle relative to the flexion portion, thereby shortening the length of the inner wall panel and releasing the tabs from the corresponding openings. In the case where the container is manufactured from a relatively stiff material, such as corrugated plastic or paper, this configuration of the container allows the user to easily disassemble tray and store in a substantially flat arrangement

FIG. 1 illustrates an arrangement of a unitary blank of material or container form 10, used to create a container, such as an envelope storage tray. In one arrangement, the container form 10 is die cut and scored from a flat sheet of material. The container form 10 can be constructed from a variety of relatively strong, durable, and lightweight materials. For example, the container form 10 can be manufactured from a single thickness corrugated material, such as corrugated paper or corrugated plastic, having two layers of linerboard separated by a single layer of fluted material. As indicated in FIG. 1, the set of corrugations 11 of the corrugated material define a longitudinal axis that extends along axis 13 of the container form 10 between a first end wall 51 and a second end wall 61.

The container form 10 includes a base 12, opposing first and second sidewalls 18, 20 hingedly coupled to the base 12 via score or fold lines 171, 172, and opposing first and second end walls 50, 60 hingedly coupled to the base 12 between first and second sidewalls 18, 20 via fold lines 133, 132.

The base 12 is configured to form the bottom of a container or tray, following assembly. In one arrangement, the base 12 defines one or more openings 14 and 16 configured to allow air to pass through base 12 to help release envelopes from the base 12. The openings 14, 16 are also sized to allow the container form 10 to be stacked over corresponding supports or poles. With such a configuration, multiple container forms 10 can be stacked in a substantially flat, unassembled state in a secure manner, thereby minimizing the space needed for storage of the forms 10.

The first and second sidewalls 18, 20 each include respective first end flaps 30, 32 hingedly coupled to a first end of the sidewall 18, 20, and respective second end flaps 31, 33 hingedly coupled to a second end of the of the sidewall 18, 20. For example, the end flaps 30, 31 are connected to the sidewall 18 by hinges or fold lines 173, 174 and the end flaps 32, 33 are connected to the sidewall 20 by hinges or fold lines 175, 176. In one arrangement, cuts or openings 41, 43 separate the end flaps 30, 31 from the first and second end walls 50, 60 and cuts or openings 42, 44 separate the end flaps 32, 33 from the first and second end walls 50, 60. For example, panels 52 and 62 can be die cut such that the end flaps 32-33 can be separated from the adjacent panels of the end walls 50, 60.

The end flaps 30, 31, 32, 33 include tabs configured to secure the sidewalls 18, 20 to the base 12. For example, first end flaps 30, 32 include tabs 35, 36 that are configured to be inserted within openings 101, 102 defined by the base 12. Additionally, second end flaps 31, 33 include tabs 37, 38 configured to be inserted within openings 201, 202 defined by the base 12. As will be described below, as part of the assembly process, the first and second end flaps 30, 32 are configured to be further secured to the base 12 by the first end wall 50 and the first and second end flaps 31, 33 are configured to be further secured to the base 12 by the second end wall 60.

Each of the first and second end walls 50, 60 are disposed between the first and second sidewalls 18, 20 and include a first end wall panel 52, 62 and a second end wall panel 51, 61, respectively, separated by respective fold lines 130 and 131, such as a double fold mechanism. Each of the first end wall panels 52, 62 are coupled to the base 12 and define corresponding openings 56, 66. Additionally, each of the second panels 51, 61 are hingedly connected to the corresponding first end wall panels 52, 62 and define corresponding sets of tabs 54, 55 and 64, 65 engage a set of corresponding slots 101, 102 and 201, 202 defined by the base 12.

Each of the second end wall panels 51, 61 also define corresponding panel flexion portions 53, 63 extending at least partially along a length of the second end wall panels 51, 61 and along a direction that is substantially perpendicular to the longitudinal axis 13 of the corrugations 11. As will be described in detail below, the panel flexion portions 53, 63 are configured as weakening in the second end wall panels 51, 61 to allow the wall panels 51, 61 to flex in response to a load applied to the panel flexion portions 53, 63 to allow the tabs 54, 55, 64, and 65 to either engage or disengage corresponding slots 101, 102, 201 and 202.

The panel flexion portions 53, 63 can be configured in a variety of ways. For example, the panel flexion portions 53, 63 can be configured as a weakening in the second end wall panels 51, 61, such as substantially continuous score lines or as substantially perforated score lines extending at least partially along the length of the second end wall panel. Alternately, the panel flexion portions 53, 63 can be configured as a living hinge disposed between an upper second end wall panel portion and a lower second end wall panel portion. The panel flexion portions 53, 63 can extend either the full width of the end wall panels 51, 61 or partially across the panels 51, 61. The purpose of these lines lying across the corrugation direction is to allow the panels to flex just enough to engage and disengage tabs 54, 55, 64 and 65 from slots 101, 102, 201 and 202.

With continued reference to FIG. 1, FIGS. 2-4 illustrate an example of an assembly process for folding the container blank 10 into a three dimensional container or tray 300.

To assemble form 10 into the three dimensional container, an assembler rotates sidewalls 18, 20 about score or fold lines 171, 172 and relative to the base 12 until the sidewalls 18, 20 extend from the base 12 along direction 302. In one arrangement, with such rotation, the sidewalls 18, 20 are disposed at an orientation that is substantially orthogonal to the base 12. The assembler then rotates or folds end flaps 30-33 about respective hinges or fold lines 173-176 relative to the sidewalls 18, 20 such that the end flaps 30-33 are disposed at an orientation that is substantially orthogonal to the sidewalls 18, 20. Next, the assembler inserts the tabs 35-38 of the end flaps 30-33 into corresponding slots 101, 102, 201, and 202 to secure the sidewalls 18, to the base 12. With such insertion, as indicated in FIG. 2, the end flaps 30-33 are disposed at an orientation that is substantially orthogonal to the base 12. Additionally, as indicated in FIGS. 1 and 2, cutout portions 81-84, such as semicircular cutouts, meet at about the center of the base 12 to form a cut out relief that allows a user to access panel flexion portions 53 and 63 from the outside of the tray through openings 56, 66, respectively, as described below.

Next, the assembler folds the first end wall panels 52, 62 relative to the base 12 and about respective fold lines 132, 133 to dispose the first end wall panels 52, 62 at an orientation that is substantially orthogonal to the base 12. Such positioning substantially aligns the openings 56, 66 defined by the first end wall panels 52, 62 with the corresponding cutout portions 81-84 defined by the end flaps 30-33, as indicated in FIG. 2.

The assembler then folds the second end wall panels 51, 61 about respective fold lines 130, 131 to capture the respective end walls 30-33 there between and to dispose the second end wall panels 51, 61 at an orientation as illustrated in FIG. 3. With continued reference to FIG. 3, the assembler applies a load 304 to a lower second end wall panel portion 306 of the second end wall panel 51 to cause the lower second end wall panel portion 306 to rotate about the panel flexion portions 53 relative to an upper second end wall panel portion 308. Such rotation causes tabs 54 and 55 to be inserted within openings 101, 102. The assembler can repeat the process with respect to the second end wall panel 61 to insert tabs 64, 65 into slots 201, 202, respectively.

As a result of the assembly process, the assembler generates a container 300 as illustrated in FIG. 4. The container 300 can be used to hold envelopes stacked vertically on the long edge. However, this is not a limitation of the disclosure as the container can be used to hold, contain, or carry other objects.

In one arrangement, when the box is formed, tabs 57, 67 project upwardly from the first and second end walls 50, 60, respectively. These tabs 57, 67 are configured to insert into corresponding slots 103, 203, such as indicated in FIG. 1 of a substantially identical container located on top of the subject container 300. This allows containers 300 to be stacked with some registration between them such that the sidewalls 18, 20 and end walls 50, 60 of the subject container 300 support a container above it. Multiple containers, such as trays filled with envelopes, can thus be stacked in a footprint area equal to that of only one tray.

In order to store the container 300 when not in use, the container can be disassembled to the substantially flat container form 10 illustrated in FIG. 1.

With reference to FIGS. 4 and 5, once assembled, the panel flexion portions 53, 63 are configured to substantially align with the openings 56, 66 defined by the corresponding first end wall panels 51, 61 and with the cutouts 81-84 defined be corresponding end flaps 30-33. With such a configuration, and with reference to FIG. 5, to disassemble the container 300 an end user applies a load 310 to the panel flexion portion 53 of the first end wall panel 51. This loading causes the lower second end wall panel portion 306 and the upper second end wall panel portion 308 to buckle or rotate about the panel flexion portions 53. Such rotation causes the tabs 54 and 55 to slide relative to the base and to be extracted from the openings 101, 102. The assembler can repeat the process with respect to the second end wall panel 61 to disengage the tabs 64, 65 from the 201, 202, respectively. This allows the container 300 to be disassembled back into the flat form 10 shown in FIG. 1.

While various embodiments of the innovation have been particularly shown and described, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the innovation as defined by the appended claims.