Two-piece, paperboard container construction

Abstract

Container construction, for cut-up meat and the like, formed from: a generally rectangular, leak resistant tray, which includes a hand hole in each end panel; and a telescoping lid, which includes depending side panels, overlying and adhesively bonded to the side panels of the tray, and depending end panels, overlying and adhesively bonded to only minor, upper portions of the end panels of the tray, the bottom edge of each depending end panel of the lid including a cut-out which is aligned with and conforms to the upper edge of the hand hole in the underlying end panel of the tray. The container also includes a label on a side panel of the tray and a cut-out in a side panel of the lid, overlying the label.

Description

BACKGROUND OF THE INVENTION

This invention relates to two-piece paperboard container constructions for cup-up meat, such as red meat, poultry and fish. This invention particularly relates to containers for relatively large quantities of meat, i.e., about 40 to 150 pounds. This invention is quite particularly concerned with containers for use in centralized meat-cutting operations.

Two-piece, generally rectangular, paperboard container constructions for packaging a wide variety of products, such as meat, are well known. See, for example, U.S. Pats. Nos. 2,912,152, 3,399,819, and 3,721,381. The tray members in such containers typically have been provided with a hand hole in each end panel, through which a hand can be inserted for lifting the container. The tray members also have been provided with waterproof, inner liners and with strong, corrugated, paperboard walls. The trays usually have been formed from a single blank, having score lines defining a plurality of panels, and have often included a gusset construction between panels in the area of the corners of the tray. See, for example, U.S. Pat. No. 3,399,819. By comparison with the tray members, the lid members in such containers generally have been relatively simple. The lid members usually have been nothing more than telescoping covers for the tray members, consisting essentially of a top wall and depending side and end walls completely covering the side and end walls of the tray members. Where the lid and tray members have had to be securely fastened together, the use of additional, external devices, such as the metal straps of U.S. Pat. No. 3,721,381, or additional, container structures, such as the interfolded flap extensions and tongues of U.S. Pats. Nos. 2,912,152 and 3,721,381, has been considered necessary.

However, problems have arisen in the design and use of such containers in centralized meat-cutting operations. The mechanized cutting, packaging and shipping of large quantities of fresh meat have required heavy-duty containers that can be easily and cheaply formed, filled without hindrance, and securely closed on automatic machinery. Such operations also have required containers that are suitable for handling by machines as well as by workmen, at any time such containers are to be moved or placed in storage between the time the containers are filled and closed at a centralized plant and the time the containers are opened by a retail butcher. In addition, the containers have had to be adapted to be filled at relatively high speeds with a quantity of meat on the order of about 40 to 150 pounds of red meat, fish or poultry. Furthermore, the containers have had to be strong enough to withstand abuse during the handling or mishandling of the containers and to withstand the effects of being stacked. The containers further have had to be designed so that labels, applied to them, cannot become detached or unreadably marred or obliterated.

Meeting all these requirements, at a minimum cost, has been an especially severe problem with heretofore available container constructions. For example, in many containers, the ends have been found to be somewhat weak, with the result that the inevitable pulling upon the ends of the containers by workmen has ripped the containers in the area of their handles, thereby rendering the containers unsatisfactory for further use. Likewise, in many containers, the connection between the lid and tray members has been found to be too weak, causing the lid and tray members to becomee pulled apart and separated when lifting or pulling the filled containers. Similarly, with the use of many containers, labels have become separated from the containers or unreadably scuffed by the rubbing of such containers together when the containers have been on conveyor belts, on pallets, in a stack or in trucks.

The problems with heretofore available containers for heavy loads of meat have been greatly aggravated by the inevitable tendency of such non-rigid containers to twist when moved and to bulge outwardly at their sides, due to the weight of their contents. The twisting and bulging of such containers have tended to render such containers even more prone to rip when pulled or lifted by the hand holes in their ends and to have their labels lost or obliterated.

SUMMARY OF THE INVENTION

In accordance with this invention, in a container construction for cut-up meat, formed from a generally rectangular, leak resistant tray, which includes a hand hole in each end panel, and a telescoping lid, which includes depending side panels overlying the side panels of the tray and depending end panels overlying the end panels of the tray, the improvement which comprises: each of the end panels of the lid having a cut-out in the bottom edge thereof aligned with and conforming to the upper, edge portion of the hand hole in each of the end panels of the tray; each of the lid side panels being adhesively bonded to substantially an entire tray side panel; and each of the lid end panels being adhesively bonded only to a minor, upper portion of each tray end panel, which upper portion constitutes substantially the entire area of the tray end panel outside of the hand hole and above the center of the hand hole. In accordance with another aspect of this invention, the container construction includes a label on a side panel of the tray and a cut-out in a side panel of the lid, overlying the label.

By this improved, container construction, an inexpensive container for relatively heavy loads of meat is provided which is strong, resists moisture, insulates, is sanitary, stacks well and is easy to handle at every step of a meat distribution system involving a centralized, meat-cutting operation.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a blank which can be formed into a tray for a container in accordance with this invention.

FIG. 2 is a perspective view of a partially formed tray, constructed from the blank of FIG. 1.

FIG. 3 is a plan view of a blank for a lid of a container in accordance with this application.

FIG. 4 is an exploded, perspective view of the container, formed from the blank for a lid of FIG. 3 and the blank for a tray of FIG. 1.

FIG. 5 is a perspective view of the container of this application, with the lid being attached to the tray.

DETAILED DESCRIPTION OF THE INVENTION

Shown in FIG. 1 is a blank, generally 10, adapted to be formed into a generally rectangular tray 11, which is shown in FIGS. 2 and 4. The tray blank 10 is provided with a bottom panel 12, a pair of side panels 13 and a pair of end panels 14. The side panels 13 and the end panels 14 are foldably connected to the bottom panel 12 along score lines in the blank 10 between the bottom panel 12 and the side panels 13 and end panels 14. The tray blank 10 also includes end flaps 15 foldably connected to the side panels 13 along score lines between the side panels 13 and end flaps 15. The tray blank 10 further includes triangular gusset panels 16 foldably connected to the end flaps 15 and to the end panels 14 along score lines in the blank 10. The tray blank 10 still further includes end flap segments 17 foldably connected to the end flaps 15 along score lines therebetween. The end flap segments 17 are adapted to fold in the same direction as the side panels 13.

The tray blank 10 also includes hand holes 18, cut out of the tray end panels 14. The hand holes 18 are preferably located adjacent to, e.g., about 2 inches away from, the edges 14a of the tray end panels 14 remote from the bottom panel 12. The portion of the edge 18a of each hand hole 18 remote from the bottom panel 12, i.e., adjacent tray end panel edge 14a, is preferably defined by a smooth curve, suitable for comfortably pressing a hand against.

As shown in FIG. 1, a portion 14b of each tray end panel 14 is preferably not cut away completely from the area defining the hand hole 18. As a result, each hand hole edge 18a is not continuous in the area adjacent to the tray end panel edges 14a. However, this discontinuity in the hand hole edges 18a is of a sufficiently short distance so that each tray end panel portion 14b can fold inwardly of the tray 11, along the discontinuity in edge 18a, and out of the hand hole area 18. When a hand is pressed against the tray end panel portion 14b, reaching through the hand hole 18, such folding of the tray end panel portion 14b, inwardly of the tray, can occur. Hence, for purposes of this Description of the Invention, the hand hole edge 18a of each hand hole 18 can be considered as continuous and including the fold line along which the end panel portion 14b folds inwardly of tray 11. Likewise, in this Description, the hand hole 18 can be considered as a continuous hole, having the end panel portion 14b completely folded out of the area of the hand hole 18.

The tray blank 10 can be suitably constructed from any paperboard material conventionally utilized in forming containers for heavy loads of red meat, poultry or fish. Among the materials which can be employed in the construction of the tray blank 10 are the materials described in U.S. Pat. No. 3,399,819. The preferred material for the tray blank 10 is a conventional, corrugated board having a wet strength characteristic of about 50 to 90 pounds, preferably about 60 to 70 pounds.

The surface of the tray blank 10, not shown in FIG. 1, intended to form the interior surface of the tray 11, is preferably provided with a layer of a barrier material which will render the tray 11 moisture resistant. For this purpose, any conventional material which is a barrier to water can be utilized. Among the barrier materials which can be suitably utilized are films of polyethylene, polypropylene or saran.

The surface of the tray blank 10, shown in FIG. 1, which is intended to form the exterior of the tray 11, is provided with a first adhesive pattern 19 on the end flaps 15 and the triangular gusset panels 16. The first adhesive pattern 19 is adapted to bond the end flaps 15, the gusset panels 16 and the end panels 14 to form the assembled tray 11. The first adhesive pattern 19 can be formed from any adhesive conventionally utilized to bond paperboard panels. For example, the adhesive pattern 19 can be formed from a cold set resin adhesive, such as polyvinyl acetate. Preferably, the adhesive pattern 19 is a hot melt adhesive pattern, applied to the tray blank 10 when the tray blank is formed into the tray 11. For this purpose, any conventional hot melt adhesive can be utilized.

The exterior surface of the tray blank 10, shown in FIG. 1, also is provided with a second adhesive pattern 20 on the tray side panels 13. The second adhesive pattern 20 is adapted to bond the tray side panels 13 to overlying side panels of a lid member. For this purpose, the second adhesive pattern 20 also can be any conventional adhesive utilized to bond paperboard panels. Preferably, the second adhesive pattern 20 also is formed from a hot melt adhesive, applied in such a manner as to cover substantially the entire, exterior surface of each tray side panel 13 when bonded to the side panels of the lid member.

Shown in FIG. 2 is a partially assembled tray 11, formed from the tray blank 10 of FIG. 1. As seen in FIG. 2, the upstanding side panels 13 and end panels 14 define a generally rectangular tray 11. One end of the tray 11 in FIG. 2 is completely formed. At the formed end of the tray 11, the end panels 14 are adhesively bonded to the end flaps 15 by means of the first adhesive pattern 19, with the end flap segments 17 covering the hand hole 18.

The cooperation of the end flaps 15, triangular gusset panels 16 and end panels 14 is seen at the other, partially formed end of the tray 11 in FIG. 2. At the partially formed end, the gusset panels 16 are partially folded about the score lines between the gusset panels 16 and the end flaps 15. Thereby, the adhesive covered surfaces of the gusset panels 16 and of the end flaps 15, shown in FIG. 1, are approaching an abutting relationship. At the same time, the gusset panels 16 are partially folded about the score lines between the gusset panels 16 and the end panels 14. Thereby, the adhesive-free surfaces of the gusset panels 16 and of the end panels 14, not shown in FIG. 1, are approaching an abutting relationship. When the tray 11 is formed, the triangular gusset panels 16 are sandwiched between the end panels 14 and the end flaps 15 at both ends of the tray.

In the blank 10 and tray 11 of this application, the form and construction of the individual elements are conventional. However, it is considered that the cooperation of the tray 11 with the lid 22, hereinafter described, provides new and unexpected properties in a two-piece container for relatively heavy weights of meat and the like.

Shown in FIG. 3 is a blank, generally 21, adapted to be formed into a lid 22, shown in FIG. 4. The lid blank 21 is provided with a top panel 23, centrally located in the lid blank 21, a pair of side panels 24 and a pair of end panels 25. The side panels 24 and end panels 25 of the lid blank 21 are foldably attached to the top panel 23 along score lines in the lid blank 21 between the respective panels. A cut-out 26 is provided in one or both of the side panels 24, and a cut-out 27 is provided in the edge 25a of each lid end panel 25, remote from the top panel 23.

The shape and location of the cut-out 27 in each end panel 25 is considered very important in accordance with this invention. The edge of cut-out 27 should substantially conform to the shape of the upper, edge portion of the hand hole 18, i.e., the portion of the hand hole edge 18a, in each end panel 14 of assembled tray 11, closest to tray end panel edge 14a. The edge of cut-out 27 should also be spaced from the top panel 23 by about the same distance that the upper, edge portion of the hand hole 18 is spaced from the tray end panel edge 14a. Preferably, the shape of the cut-out 27 and its spacing from the top panel 23 substantially correspond with the shape and spacing from tray end panel edge 14a of the edge of the upper half of hand hole 18 in assembled tray 11, i.e., the half of the hand hole edge 18a which is closest to tray end panel edge 14a. It is particularly preferred that both the edge of the upper half of hand hole 18 and the edge of cut-out 27, which conforms to and is aligned with the edge of the upper half of hand hole 18, are substantially arcuate.

The shape and location of each lid end panel edge 25a, outside of cut-out 27, is also considered very important in accordance with this invention. The lid end panel edge 25a, except for the arcuate cut-out 27, should be spaced from the top panel 23 a distance about equal to or greater than, preferably a distance equal to, the distance separating the center of the hand hole 18 and the tray end panel edge 14a.

The surface of the lid blank 21, shown in FIG. 3, which is intended to form the interior surface of the lid 22, is preferably provided with a layer of a barrier material. In the lid blank 21, any conventional material adapted to provide a barrier against water can be utilized. Among the barrier materials which can be utilized are the materials utilized in the layer of barrier material for the inner surface of the tray 11.

The surface of the lid blank 21, which is intended to form the interior surface of the lid 22, also is provided on the lid end panels 25 with a third adhesive pattern 28. The third adhesive pattern 28 is adapted to bond the interior surface of each lid end panel 25 to the exterior surface of a tray end panel 14. For this purpose, any conventional adhesive utilized to bond paperboard panels can be utilized. Preferably, the third adhesive pattern 28 is formed from a hot melt adhesive, applied in such a manner as to substantially cover the entire interior surface of each lid end panel 25 when bonded to a tray end panel 14.

An improved, two-piece container 29 of this application can be formed by placing the lid 22 over the filled tray 11 and bonding the lid side panels 24 to the tray side panels 13 and bonding the lid end panels 25 to the tray end panels 14. For the purpose of bonding the lid side panels 24 to the tray side panels 13, the second adhesive pattern 20 is utilized. However, if desired, an adhesive pattern (not shown), corresponding to pattern 20, can be provided on the interior surfaces of the lid side panels 24, instead of on the exterior surfaces of the tray side panels 13, to bond these lid and tray side panels together. For bonding the lid end panels 25 to the tray end panels 14, the third adhesive pattern 28 is utilized. However, if desired, an adhesive pattern (not shown), corresponding to pattern 28, can be provided on the exterior surfaces of the tray end panels 14 instead of on the interior surfaces of the tray end panels 25, to bond these lid and tray end panels together. Preferably, these adhesive patterns for bonding the lid and tray, side and end panels are applied either just before or soon after the lid 22 is placed over the filled tray 11.

Before bonding the lid side panels 24 to the tray side panels 13, a label 30 is affixed, e.g., glued, to the tray side panels 13. The label is placed in a position at which it will be visible through the lid side panel cut-out 26 after the lid side panels 24 are adhesively bonded to the tray side panels 13.

As shown in FIG. 5, the container 29 formed from the lid 22 and tray 11 is a trim, compact, generally rectangular container for relatively heavy quantities of meat and the like. The lid side panels 24 are aligned in the resulting container 29 with the tray side panels 13 to reveal the label 30 through the lid side panel cut-out 26. The two lid side panels 24 are adhesively bonded to the two tray side panels 13 over substantially the whole length and width of the tray side panels. The adhesive bonds between these panels hold the tray side panels 13 inwardly, substantially resisting the bulging effects of the contents of the tray. Were the lid side panels 24 not bonded to the tray side panels 13 over substantially the whole length and width of the tray side panels 13, bulging of the tray side panels would result in a general weakening of the resulting container 29.

Also as shown in FIG. 5, in the formed container 29, each cut-out 27 in the lid end panels 25 is aligned with and conforms to an upper, edge portion of each hand hole 18. Preferably, this upper, edge portion of hand hole 18 includes at least the edge portion defined by the discontinuity in each hand hole edge 18a associated with tray end panel portion 14b. It is particularly preferred that each lid end panel cut-out 27 be aligned with and conform to the edge of the upper half of hand hole 18.

As also seen from FIG. 5, each lid end panel edge 25a, outside of the cut-out 27, extends downwardly at least to about the center of the hand hole 18 in each tray end panel 14, preferably to the center of the hand hole. Each lid end panel 25 is adhesively bonded to at least substantially the entire portion of the tray end panel 14 outside of the perimeter of the hand hole 18 and above the center of the hand hole, preferably to the entire portion of the panel 14 outside of and above the center of the hand hole.

As further shown in FIG. 5, the lid end panels 25 in the formed container 29 are relatively small, as compared with the tray end panels 14. In fact, the lid end panels overlie and are bonded to only a minor, upper portion of the tray end panels 14. Preferably, the lid end panels 25 overlie and are bonded to about 15 to 35% of the area of the tray end panels 14, especially about 20 to 25% of the area of the tray end panels 14.

In accordance with this invention, the lid end panels 25 are relatively small so that they are out of the way and cannot obstruct the hand holes 18 of the assembled container 29. Yet, despite their small size, the lid end panels suitably reinforce the ends of the container 29 against the bulging of the tray end panels 14 due to the weight of the contents of the container. The lid end panels also reinforce the container ends against the twisting of the container when uneven forces are applied to the container 29. The lid end panels 25 further reinforce the container 29 so that it can be lifted by the hand holes 18 or pulled lengthwise by the hand holes 18 without risk of tearing the tray end panels 14 or separating the lid 22 from the tray 11. It is considered that the reinforcement of the container 29 by means of only the relatively small and inexpensive lid end panels 25 of this invention provides the resulting container construction with superior flexibility for use in a centralized meat-cutting operation.

Also in accordance with this invention, positioning the label 30 interiorly of the lid side panels 24 renders it resistant to scuffing, marring or removal from the container 29. It is considered that this relatively inexpensive and efficient means for protecting the label also renders the container of this invention superior.

That this container maintains its integrity when stacked, pulled, rubbed, scuffed or mishandled is especially surprising since certain features, provided in the container, would be expected to weaken the container and make it more likely to be damaged. Among such features are the end flap segments 17 which prevent the meat contents of the container from being contacted by hands inserted through the hand holes 18 for the purpose of lifting or pulling the container. Such end flap segments 17 fold inwardly of the container and serve as a shield against the undesirable touching of the meat through the hand holes. Because such end flap segments 27 are not adhesively bonded to the tray end panels 14, these segments 17 represent a weakened area in the ends of the container 29 which would be expected to render the tray end panels 14 prone to being ripped when the container is pulled or lifted. Likewise, the triangular gusset panels 16, which provide a one-piece, leak resistant tray 11, also represent sites in the tray 11 prone to being ripped when the container 29 is pulled or lifted and prone to being crushed when the container is stacked. Similarly, the shortnened lid end panels 25, while providing savings in paperboard as well as in the volume taken-up by the container 29, would be expected to weaken the container and render it more prone to bulging or being crushed during stacking or twisted during handling. Surprisingly, this is not the case. Bulging and twisting of the container is not substantial, and the integrity of the container is maintained even during rough handling and stacking.

An additional, important feature of the container 29 is that it can be formed merely by the steps of placing the lid 22 over the filled tray 11, applying the second and third adhesive patterns 20 and 28 to the tray side panels 13 and lid end panels 25, respectively, applying a label to the tray side panel 13, and pressing the lid side panels 24 and lid end panels 25 over the tray side panels 13 and tray end panels 14. No further manipulative steps are required to provide a closed carton which can be lifted or pulled by the hand holes 18 without danger of tearing the end panels 14 of the tray 11 or separating the lid 22 from the tray 11. Still another important feature of this container 29 is that its tray member 11 includes no flaps or other members that can interfere with a machine's filling the tray, applying the adhesive patterns 19, 20 and 28, or placing the lid 22 on the tray 11.

It is thought that the invention and many of its attendant advantages will be understood from the foregoing description and it will be apparent that various changes may be made in the form, construction and arrangement of the parts without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the form hereinbefore described being merely a preferred embodiment thereof.

Claims

I claim:

1. In a generally rectangular container for relatively heavy materials, formed from: a tray member, which comprises a bottom panel, a pair of tray side panels and a pair of tray end panels, a hand hole being provided in each tray end panel; and a telescoping lid member, which comprises a top panel, a pair of lid side panels overlying the tray side panels and a pair of lid end panels overlying the tray end panels, the improvement which comprises:

a cut-out in the lower edge of each lid end panel, aligned with and conforming to the upper, edge portion of the hand hole in each tray end panel;

each of the lid side panels overlying and being adhesively bonded to substantially an entire tray side panel; and

each of the lid end panels overlying and being adhesively bonded only to a minor, upper portion of each tray end panel, the minor portion constituting at least, substantially the entire area of the tray end panel outside of the hand hole and above the center of the hand hole in the tray end panel.

2. The container of claim 1 wherein the cut-out in each lid end panel is aligned with and conforms to the shape of the edge of the upper half of the hand hole in each tray end panel.

3. The container of claim 2 wherein the cut-out in each lid end panel and the edge of the upper half of the hand hole in each tray end panel are arcuate.

4. The container of claim 1 wherein the minor, upper portion of each tray end panel overlain and adhesively bonded to each lid end panel is about 15 to 35% of the area of the tray end panel.

5. The container of claim 4 wherein the minor, upper portion is about 20 to 20% of the tray end panel area.

6. The container of claim 1 wherein the lower edge of each lid end panel, outside of the cut-out in the lower edge, extends downwardly to the center of the hand hole in each tray end panel.

7. The container of claim 1 wherein a label is provided on an outer surface of a tray side panel and a cut-out is provided on a lid side panel, overlying the label.