Corner lock tray and blank therefor

Abstract

A container formed from a blank of sheet material includes a bottom panel, first end panel, and first side panel that together form a first corner of the container. The first corner is secured by a first corner locking member. The first corner locking member is struck in part from a first corner flap and in part from the first side panel. The first corner locking member is hingedly connected to the first corner flap along a first fold line. The first corner locking member is inserted through a slot formed through the first end panel and into a first corner aperture formed through the first side panel, wherein the first corner aperture is formed by folding the first corner locking member out of plane with the first side panel.

What is claimed is: 
     
         1 . A container formed from a blank of sheet material, the container comprising:
 a bottom panel forming a bottom wall of the container;   a first end panel extending upwardly from a first end edge of the bottom panel, the first end panel forming a first end wall of the container;   a first side panel extending upwardly from a first side edge of the bottom panel, the first side panel forming a first side wall of the container, the first end panel, first side panel, and bottom panel together forming a first corner of the container;   a first corner flap hingedly connected to the first side panel along a first end edge thereof, the first corner flap being disposed in face-contacting relationship with the first end panel;   a first corner locking member securing the first corner, the first corner locking member being struck in part from the first corner flap and in part from the first side panel, wherein the first corner locking member is hingedly connected to the first corner flap along a first fold line, wherein the first corner locking member is inserted through a slot formed through the first end panel and into a first corner aperture formed through the first side panel, wherein the first corner aperture is formed by folding the first corner locking member out of plane with the first side panel.   
     
     
         2 . The container according to  claim 1 , wherein the container further comprises second, third, and fourth corner locking members securing respective second, third, and fourth corners of the container. 
     
     
         3 . The container according to  claim 1 , wherein the first corner locking member comprises a bridge portion defined between the first fold line and a second fold line, wherein the bridge portion has a height that is at least about equal to a thickness of the blank of sheet material. 
     
     
         4 . The container according to  claim 1 , wherein the first corner locking member further comprises a generally-rectangular locking tab that is inserted into the first corner aperture. 
     
     
         5 . The container according to  claim 4 , wherein the first corner locking member further comprises an intermediate portion disposed between the bridge portion and the locking tab, wherein the intermediate portion is generally trapezoidal in shape, wherein the intermediate portion is disposed in face-contacting relationship with an interior surface of the first end panel. 
     
     
         6 . The container according to  claim 4 , wherein the first slot has a generally elongated rectangular shape, wherein the first slot has a width that is at least about equal to the thickness of the blank of sheet material, and wherein the first slot has a height that is at least about equal to a greatest width of the first corner locking member. 
     
     
         7 . A blank of sheet material for forming a container, the blank comprising:
 a bottom panel having first and second opposing end edges and first and second opposing side edges extending between the end edges, the bottom wall panel being configured to form a bottom wall in a set-up container;   a first end panel hingedly connected to the bottom panel along the first end edge, the first end panel being configured to form a first end wall in the set-up container;   a first side panel hingedly connected to the bottom panel along the first side edge, the first side panel being configured to form a first side wall in the set-up container, the first end wall, first side wall, and bottom wall together forming a first corner in the set-up container;   a first corner flap hingedly connected to the first side panel along a first end edge thereof, the first corner flap being configured to fold into face-contacting relationship with the first end panel in the set-up container;   a first corner locking member configured to secure the first corner in the set-up container, the first corner locking member being struck in part from the first corner flap and in part from the first side panel, wherein the first corner locking member is hingedly connected to the first corner flap along a first fold line, wherein, in the set-up container, the first corner locking member passes through a slot formed through the first end panel and into a first corner aperture formed through the first side panel, wherein the first corner aperture results from folding the first corner locking member out of plane with the first side panel.   
     
     
         8 . The blank according to  claim 7 , wherein the blank further comprises:
 a second end panel hingedly connected to the bottom panel along the second end edge, the second end panel being configured to form a second end wall in the set-up container;   a second side panel hingedly connected to the bottom panel along the second side edge, the second side panel being configured to form a second side wall in the set-up container;   a second corner flap hingedly connected to the first side panel along a second end edge thereof, the first corner flap being configured to fold into face-contacting relationship with the second end panel in the set-up container;   a third corner flap hingedly connected to the second side panel along a first end edge thereof, the third corner flap being configured to fold into face-contacting relationship with the first end panel in the set-up container;   a fourth corner flap hingedly connected to the second side panel along a second end edge thereof, the fourth corner flap being configured to fold into face-contacting relationship with the second end panel in the set-up container;   a second corner locking member configured to secure a second corner in the set-up container;   a third corner locking member configured to secure a third corner in the set-up container; and   a fourth corner locking member configured to secure a fourth corner in the set-up container.   
     
     
         9 . The blank according to  claim 7 , wherein the first corner locking member comprises a bridge portion defined between the first fold line and a second fold line, wherein the bridge portion has a height that is at least about equal to a thickness of the blank of sheet material. 
     
     
         10 . The blank according to  claim 7 , wherein the first corner locking member further comprises a generally-rectangular locking tab that is inserted into the first corner aperture in the set-up container. 
     
     
         11 . The blank according to  claim 10 , wherein the first corner locking member further comprises an intermediate portion disposed between the bridge portion and the locking tab, wherein the intermediate portion is generally trapezoidal in shape, wherein the intermediate portion is disposed in face-contacting relationship with an interior surface of the first end panel. 
     
     
         12 . The blank according to  claim 10 , wherein the first slot has a generally elongated rectangular shape, wherein the first slot has a width that is at least about equal to the thickness of the blank of sheet material, and wherein the slot has a height that is at least about equal to a greatest width of the first corner locking member.