US20250376290A1
PACKAGING ASSEMBLY
Publication
Application
Classifications
IPC Classifications
CPC Classifications
Applicants
Pratt Corrugated Holdings, Inc.
Inventors
Connor Cheney, Ryan Richmond, C. Samuel Simich
Abstract
A tray formed from a blank includes a bottom panel, a first side panel connected to the bottom panel, a second side panel connected to the bottom panel, at least one support connected to the first side panel, at least one support assembly connected to the second side panel, at least one end panel connected to the bottom panel, and each end panel secured to two support assemblies.
Figures
Description
TECHNICAL FIELD
[0001]This disclosure relates to packaging. More specifically, this disclosure relates to packaging for large and heavy items.
BACKGROUND
[0002]Packaging elements can be designed for a variety of applications and purposes. Various packaging elements need to be loaded from the top, side, or bottom in various applications. In some cases, access locations can be different from loading locations. Such requirements can cause challenges if the packaged elements are particularly heavy. Additionally, stacking of such packaging elements can require additional structural elements that can require additional parts and assembly.
SUMMARY
[0003]It is to be understood that this summary is not an extensive overview of the disclosure. This summary is exemplary and not restrictive and is intended to neither identify key or critical elements of the disclosure nor delineate the scope thereof. The sole purpose of this summary is to explain and exemplify certain concepts of the disclosure as an introduction to the following complete and extensive detailed description.
[0004]Disclosed is a blank formable into a tray that can include a bottom panel, the bottom panel can be rectangular in shape; a first side panel can be connected to the bottom panel by a first side panel line; at least one support assembly panel can be connected to the first side panel by a first support assembly line; a second side panel can be connected to the bottom panel by a second side panel line; at least one support assembly panel can be connected to the second side panel by a second support assembly line; and, at least one end panel can be connected to the bottom panel by an end panel line.
[0005]Also disclosed is a packaging assembly that can include a tray, the tray can be formed from a blank and can include a bottom panel; a first side panel can be connected to the bottom panel; a second side panel can be connected to the bottom panel; at least one support assembly can be releasably connected to the first side panel; at least one support assembly can be releasably connected to the second side panel; at least one end panel can be releasably connected to the bottom panel; and each end panel can be secured to two support assemblies, wherein the tray can define an opening between the first side panel, the second side panel, and each end panel; and a sleeve that can be sized to shroud the tray, the sleeve can thereby covering the opening.
[0006]Also disclosed is a method of forming a tray that can include obtaining a blank that can be formable into a tray, the blank can include a bottom panel, the bottom panel can be rectangular in shape; a first side panel can be connected to the bottom panel by a first side panel line; at least one support assembly panel can be connected to the first side panel by a first support assembly line; a second side panel can be connected to the bottom panel by a second side panel line; at least one support assembly panel can be connected to the second side panel by a second support assembly line; and, at least one end panel can be connected to the bottom panel by an end panel line; wherein each end panel can include at least one snap, and wherein each support assembly panel can define at least one snap receiver; each support assembly panel can be bent to form a support assembly from each support assembly panel; each side panel can be bent with respect to the bottom panel along each side panel line such that each side panel can be arranged orthogonally with respect to the bottom panel; each end panel can be bent with respect to the bottom along each end panel line such that each end panel can be arranged orthogonally with respect to the bottom panel and in contact with at least two support assemblies; each end panel can be secured to at least two support assemblies by connected at least one snap into each snap receiver.
[0007]Various implementations described in the present disclosure may comprise additional systems, methods, features, and advantages, which may not necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims. The features and advantages of such implementations may be realized and obtained by means of the systems, methods, features particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims or may be learned by the practice of such exemplary implementations as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008]The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several aspects of the disclosure and, together with the description, explain various principles of the disclosure. The drawings are not necessarily drawn to scale. Corresponding features and components throughout the figures may be designated by matching reference characters for the sake of consistency and clarity.
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[0020]
DETAILED DESCRIPTION
[0021]The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.
[0022]The following description is provided as an enabling teaching of the present devices, systems, and/or methods in their best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects described herein while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present disclosure are possible and can even be desirable in certain circumstances and are a part of the present disclosure. Thus, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.
[0023]As used throughout, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a quantity of one of a particular element can comprise two or more such elements unless the context indicates otherwise. In addition, any of the elements described herein can be a first such element, a second such element, and so forth (e.g., a first widget and a second widget, even if only a “widget” is referenced).
[0024]Ranges can be expressed herein as from “about” one particular value and/or to “about” another particular value. When such a range is expressed, another aspect comprises from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about” or “substantially,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint and independently of the other endpoint.
[0025]For purposes of the current disclosure, a material property or dimension measuring about X or substantially X on a particular measurement scale measures within a range between X plus an industry-standard upper tolerance for the specified measurement and X minus an industry-standard lower tolerance for the specified measurement. Because tolerances can vary between different materials, processes, and between different models, the tolerance for a particular measurement of a particular component can fall within a range of tolerances.
[0026]As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur and that the description comprises instances where said event or circumstance occurs and instances where it does not.
[0027]The word “or” as used herein means any one member of a particular list and also comprises any combination of members of that list. The phrase “at least one of A and B” as used herein means “only A, only B, or both A and B”; while the phrase “one of A and B” means “A or B.”
[0028]As used herein, unless the context clearly dictates otherwise, the term “monolithic” in the description of a component means that the component is formed as a singular component that constitutes a single material without joints or seams. Unless otherwise specified herein, any structure disclosed in the drawings or in the written description as being so formed can be monolithic whether or not such an explicit description of the structure is included herein.
[0029]To simplify the description of various elements disclosed herein, the conventions of “left,” “right,” “front,” “rear,” “top,” “bottom,” “upper,” “lower,” “inside,” “outside,” “inboard,” “outboard,” “horizontal,” and/or “vertical” may be referenced. Unless stated otherwise, “front” describes that end of a break check valve nearest to an outlet of the valve, and “rear” is the end of the break check valve which can be opposite or distal the front. “Horizontal” or “horizontal orientation” describes that which is in a plane extending from left to right and aligned with the horizon. “Vertical” or “vertical orientation” describes that which is in a plane which can be angled at 90 degrees to the horizontal.
[0030]Disclosed is a packaging assembly and associated methods, systems, devices, and various apparatus. The packaging assembly can be formed of various blanks. It would be understood by one of skill in the art that the disclosed packaging assembly is described in but a few exemplary embodiments among many. No particular terminology or description should be considered limiting on the disclosure or the scope of any claims issuing therefrom.
[0031]One embodiment of a blank 1000 is disclosed and described with reference to
[0032]The blank 1000 can comprise an assortment of panels. The blank 1000 can be formable into a tray in the current aspect. A bottom panel 100 can be seen at the center of the blank 1000. The bottom panel 100 can be rectangular in shape in various aspects. A side panel 200 can be connected to the bottom panel 100 by a line 102.
[0033]In various aspects, a “line” or a plurality of “lines” can refer to bends, perforations, cuts, creases, or combinations of bends, cuts, perforations, and creases. In various aspects, perforations can be ⅜ inches; in various aspects, perforations can be ¼ inches; in various aspects, cuts can be ½ inches; in various aspects, perforations and cuts can be of variant sizes. If not specified in the disclosure, one of skill in the art would understand that various lines described herein can be interchangeable between various aspects of the current disclosure, and one of skill in the art would not understand any particular embodiment of “line” or “lines” to be limiting on the scope of the disclosure.
[0034]A side panel 400 can be connected to the bottom panel 100 by a line 104. In various aspects, lines 102,104 can be bend lines. In various aspects, each side panel 200,400 can be rectangular in shape. In various aspects, each side panel 200,400 can be about the same size as the other side panel 400,200 and can be of a length that is about the same as the bottom panel 100.
[0035]An end panel 600 can be connected to the bottom panel 100 by a line 106. The end panel 600 can be about rectangular in shape and can be of about the same width as the bottom panel 100. An end panel 800 can be connected to the bottom panel 100 by a line 108. The end panel 800 can be about rectangular in shape and can be of about the same width as the bottom panel 100. In various aspects, each end panel 600,800 can be about the same size as the other side panel 800,600.
[0036]One of skill in the art would understand that the lines 106,108 can be of various compositions in various aspects of the current disclosure. In the current aspect, each of the lines 106,108 can be a perforated line. The perforated line can be arranged such that each end panel 600,800 can be separated from the bottom panel 100 by sufficient force applied as will be discussed in further depth elsewhere in this disclosure.
[0037]A support assembly panel 220 can be connected to the side 200 by a line 222. A support assembly panel 270 can be connected to the side 200 by a line 272. A support assembly panel 420 can be connected to the side 200 by a line 422. A support assembly panel 470 can be connected to the side 400 by a line 472. One of skill in the art would understand that the lines 222,272,422,472 can be of various compositions in various aspects of the current disclosure. In the current aspect, each of the lines 222,272,422,472 can be a perforated line. The perforated line can be arranged such that each end panel support assembly panel 220,270,420,470 can be separated from the sides 200,400 by sufficient force applied as will be discussed in further depth elsewhere in this disclosure.
[0038]The support assembly panel 220 can comprise a first snap panel 221, a first boxing panel 223, an internal panel 225, a second boxing panel 227, and a second snap panel 229. The first snap panel 221 can be connected to the first boxing panel 223 by a line 231. The first boxing panel 223 can be connected to the internal panel 225 by a line 233. The internal panel 225 can be connected to the second boxing panel 227 by a line 237. The second boxing panel 227 can be connected to the second snap panel 229 by a line 239. In the current aspect, the lines 231,233,237,239 can be bend lines. The first snap panel 221 can define a first snap receiver 232 and a second snap receiver 234. Each snap receiver 232,234 can be a void defined in the first snap panel 221. Similarly, the second snap panel 229 can define a first snap receiver 242 and a second snap receiver 244. Each snap receiver 242,244 can be a void defined in the second snap panel 229. In the current aspect, each snap receiver 232,234,242,244 can be rectangular in shape. In various aspects, various shapes can be utilized in accordance with knowledge of one of skill in the art.
[0039]The support assembly panel 270 can comprise a first snap panel 271, a first boxing panel 273, an internal panel 275, a second boxing panel 277, and a second snap panel 279. The first snap panel 271 can be connected to the first boxing panel by a line 281. The first boxing panel 273 can be connected to the internal panel 275 by a line 283. The internal panel 275 can be connected to the second boxing panel 277 by a line 287. The second boxing panel 277 can be connected to the second snap panel 279 by a line 289. In the current aspect, the lines 281,283,287,289 can be bend lines. The first snap panel 271 can define a first snap receiver 282 and a second snap receiver 284. Each snap receiver 282,284 can be a void defined in the first snap panel 271. Similarly, the second snap panel 279 can define a first snap receiver 292 and a second snap receiver 294. Each snap receiver 292,294 can be a void defined in the second snap panel 279. In the current aspect, each snap receiver 282,284,292,294 can be rectangular in shape. In various aspects, various shapes can be utilized in accordance with knowledge of one of skill in the art.
[0040]The support assembly panel 420 can comprise a first snap panel 421, a first boxing panel 423, an internal panel 425, a second boxing panel 427, and a second snap panel 429. The first snap panel 421 can be connected to the first boxing panel 423 by a line 431. The first boxing panel 423 can be connected to the internal panel 425 by a line 433. The internal panel 425 can be connected to the second boxing panel 427 by a line 437. The second boxing panel 427 can be connected to the second snap panel 429 by a line 439. In the current aspect, the lines 431,433,437,439 can be bend lines. The first snap panel 421 can define a first snap receiver 432 and a second snap receiver 434. Each snap receiver 432,434 can be a void defined in the first snap panel 421. Similarly, the second snap panel 429 can define a first snap receiver 442 and a second snap receiver 444. Each snap receiver 442,444 can be a void defined in the second snap panel 429. In the current aspect, each snap receiver 432,434,442,444 can be rectangular in shape. In various aspects, various shapes can be utilized in accordance with knowledge of one of skill in the art.
[0041]The support assembly panel 470 can comprise a first snap panel 471, a first boxing panel 473, an internal panel 475, a second boxing panel 477, and a second snap panel 479. The first snap panel 471 can be connected to the first boxing panel by a line 481. The first boxing panel 473 can be connected to the internal panel 475 by a line 483. The internal panel 475 can be connected to the second boxing panel 477 by a line 487. The second boxing panel 477 can be connected to the second snap panel 479 by a line 489. In the current aspect, the lines 481,483,487,489 can be bend lines. The first snap panel 471 can define a first snap receiver 482 and a second snap receiver 484. Each snap receiver 482,484 can be a void defined in the first snap panel 471. Similarly, the second snap panel 479 can define a first snap receiver 492 and a second snap receiver 494. Each snap receiver 492,494 can be a void defined in the second snap panel 479. In the current aspect, each snap receiver 482,484,492,494 can be rectangular in shape. In various aspects, various shapes can be utilized in accordance with knowledge of one of skill in the art.
[0042]In various aspects, the blank 1000 can be comprised of corrugated cardboard, as previously noted. In some aspects, the corrugation direction of the cardboard can be aligned with a particular direction to increase strength in that direction. As such, in various aspects, the corrugation direction can be aligned with lines 106, 108, 222, 272, 422, and 472, among others. Such arrangement need not be present in all aspects of the current disclosure.
[0043]Various dimensions can be utilized in various aspects of the current disclosure. The bottom panel 100 can be of a width 192 of about 47 and 11/16 inches. The bottom panel 100 can be of a length 193 of about 21 and 1/16 inches. Each end panel 600,800 can be of a width 194 of about 14 and ⅛ inches. An overall width 195 of the blank 1000 can be about 75 and 15/16 inches. An overall length 196 of the blank 1000 can be about 49 and 5/16 inches.
[0044]As previously mentioned, the corrugation direction can be aligned with the “length” direction, generally being parallel to length 196 and length 193. In assembly, such a corrugation direction can assist with structural integrity when stacking the resultant packaging.
[0045]The end panel 600 can comprise a plurality of snaps 610 (labeled as 610a, 610b, 610c, and 610d). The end panel 800 can comprise a plurality of snaps 810 (labeled as 810a, 810b, 810c, and 810d). A view of the snap 610 that is representative of all snaps 610,810 can be seen with reference to
[0046]The snap 610 of the current aspect can be designed to be inserted in the snap receivers (232,234,242,244,282,284,292,294,432,434,442,444,482,484,492,494). Each snap 610 can comprise a stub 612 connected to the end panel 600 by bend line 611. Cut lines 613,615 can be arranged on sides of the stub 612. The stub 612 can be connected to a central portion 622 by a bend line 614. The stub 612 can be rectangular in the current aspect and defined by bend lines 612,614 and cut lines 613,615. In various aspects, various shapes can be utilized as would be understood by one of skill in the art.
[0047]The central portion 622 of the snap 610 can be about triangular in shape. The central portion 622 can be connected to a first side portion 635 by a bend line 632. The central portion 622 can be connected to a second side portion 645 by a bend line 642. Each side portion 635,645 can be shaped and arranged extending away from the central portion 622 and outside of a width of the stub 612. A cut line 637 can extend around the perimeter of the first side portion 635 to define a separable border with the end panel 600. Similarly, a cut line 647 can extend around the perimeter of the first side portion 645 to define a separable border with the end panel 600.
[0048]Because of the triangular shape of the central portion 622, bend lines 632,642 can allow the side portions 635,645 to be bent inwardly toward the central portion 622 and stub 612. Shape memory in the material of the blank 1000 can bias the side portions 635,645 toward opening. As such, each snap 610 (and 810) of the current aspect can be utilized as a way of connecting the end panels 600,800 to the snap receivers (232,234,242,244,282,284,292,294, 432,434,442,444,482,484,492,494).
[0049]Assembly and use steps can be followed with reference to the following discussion. As seen with reference to
[0050]As seen with reference to
[0051]As seen with reference to
[0052]It should also be noted that the second snap panels 229,429,279,479 can be aligned with and in contact with the first snap panels 221,421,271,471. As such, the snap receivers 242,244 can be aligned with the snap receivers 232,234, respectively. The snap receivers 442,444 can be aligned with the snap receivers 432,434, respectively. The snap receivers 292,294 can be aligned with the snap receivers 282,284, respectively. The snap receivers 492,494 can be aligned with the snap receivers 482,484, respectively. As such, each of the snaps 610a,b,c,d and 810a,b,c,d can be aligned with two snap receivers (232,234,242, 244,282,284,292,294,432,434,442,444,482,484,492,494) at the same time.
[0053]As seen with reference to
[0054]As seen with reference to
[0055]In various aspects, the various panels 2100,2200,2300,2400,2500 can be of various sizes. One of skill in the art would understand that dimensions of various panels need not be particular lengths and that various lengths cited herein are provided for exemplary purposes only. In the current aspect, all of the panels 2100,2200,2300,2400,2500 can be of the same width 2125. In the current aspect, the width 2125 can be about 48 inches. An overall length 2127 can define the overall dimension of the sleeve blank 2000. In the current aspect, the overall length 2127 can be about 74 and 11/16 inches. Lengths of the various panels can be of various sizes. In the current aspect, similarity of size between the first side panel 2100 and the third side panel 2300 along with the similarity of size between the second side panel 2200 and the fourth side panel 2400 can lead to a roughly rectangular cross-sectional shape of the packaging element formed from the sleeve blank 2000. A length 2131 of the first side panel 2100 can be about 14 and one half inches. A length 2132 of the second side panel 2200 can be about 21 and 11/16 inches. A length 2133 of the third side panel 2300 can be about 14 and 11/16 inches. A length 2134 of the fourth side panel 2400 can be about 21 and 13/16 inches. A length 2135 of the connection panel 2500 can be about two inches. In the current aspect, the direction of the corrugations can be parallel to the direction in which lengths (such as overall length 2127) are measured. Having the corrugations pointed in the direction cited can aid in providing structural integrity for stacking when assembled.
[0056]As seen with reference to
[0057]The tray 1000′ can be arranged inside a sleeve 2000′. Together, the tray 1000′ and the
[0058]sleeve 2000′ can combine to form a packaging assembly 3000. The sleeve 2000′ can provide a cover to the tray 1000′ such that the opening 1250 can be covered.
[0059]As seen with reference to
[0060]In the current view, one tray 1000′ can be seen telescoping out of one sleeve 2000′ as part of the packaging assembly 3000. A feature that can be included as part of the packaging assembly 3000 can allow the tray 1000′ can be pulled away from the sleeve 2000′ as one would open a drawer.
[0061]In various aspects, the tray 1000′ can allow packing or unpacking through the opening 1250. In various aspects, however, the tray 1000′ can be utilized for top load and side unloading, as seen with reference to
[0062]As seen with specific reference to
[0063]Because of the support structure afforded by the design described herein, heavy elements can be top loaded into the trays 1000′. The trays 1000′ can then be arranged with the sleeves 2000′ to form packaging assemblies 3000. Because of support assemblies 220′,270′,420′,470′, multiple packaging assemblies 3000 can be stacked, even when the contents of the packaging assemblies 3000 are heavy. Additional support elements such as corner braces or wood brackets can be omitted entirely in various aspects—such as those shown and described herein—or can be minimized in other aspects. As such, the blank 1000 can be utilized to form a structurally secure packaging assembly 3000 without added fasteners or structural elements other than the sleeve 2000′. Such packaging assembly 3000 can be low production cost with minimal assembly steps and supplies while maintaining the structural integrity needed to stack heavy elements that can be contained within such packaging assembly 3000.
[0064]One should note that conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more particular embodiments or that one or more particular embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular embodiment.
[0065]It should be emphasized that the above-described embodiments are merely possible
[0066]examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Any process descriptions or blocks in flow diagrams should be understood as representing modules, segments, or portions of code which include one or more executable instructions for implementing specific logical functions or steps in the process, and alternate implementations are included in which functions may not be included or executed at all, may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art of the present disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. Further, the scope of the present disclosure is intended to cover any and all combinations and sub-combinations of all elements, features, and aspects discussed above. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure.
Claims
That which is claimed is:
1. A blank formable into a tray, the blank comprising:
a bottom panel, the bottom panel being rectangular in shape;
a first side panel connected to the bottom panel by a first side panel line;
at least one support assembly panel connected to the first side panel by a first support assembly line;
a second side panel connected to the bottom panel by a second side panel line;
at least one support assembly panel connected to the second side panel by a second support assembly line; and,
at least one end panel connected to the bottom panel by an end panel line,
wherein each end panel comprises at least one snap, and
wherein each support assembly panel defines at least one snap receiver.
2-3. (canceled)
4. The blank of
5. The blank of
6. The blank of
7. The blank of
8. The blank of
a first snap panel connected to one of the first side panel and the second side panel by one of the first support assembly line and the second support assembly line;
a first boxing panel connected to the first snap panel by a bend line;
an internal panel connected to the first boxing panel by a bend line;
a second boxing panel connected to the internal panel by a bend line; and,
a second snap panel connected to the second boxing panel by a bend line.
9. The blank of
10. The blank of
11. The blank of
12. The blank of
a stub connected to one end panel by a bend line;
a central portion connected to the stub by a bend line; and,
at least one side portion connected to the central portion by a bend line,
wherein each snap is sized to be inserted within one snap receiver.
13. The blank of
14. A packaging assembly comprising:
a tray, the tray being formed from a blank and comprising:
a bottom panel;
a first side panel connected to the bottom panel;
a second side panel connected to the bottom panel;
at least one support assembly releasably connected to the first side panel;
at least one support assembly releasably connected to the second side panel;
at least one end panel releasably connected to the bottom panel; and
each end panel secured to two support assemblies,
wherein the tray defines an opening between the first side panel, the second side panel, and each end panel; and,
a sleeve sized to shroud the tray, the sleeve thereby covering the opening,
wherein the connection between each end panel and the bottom panel is a perforated line,
wherein the connection between each support assembly and one side panel is a perforated line, and
wherein each end panel comprises at least two snaps, wherein each support assembly defines at least one snap receiver, and wherein each end panel is secured to two support assemblies by at least one snap connection for each support assembly, each snap connection being one snap inserted into at least one snap receiver.
15-17. (canceled)
18. The packaging assembly of claim 18, wherein each panel comprises four snaps, wherein each support assembly defines four snap receivers, and wherein each end panel is secured to two support assemblies by two snap connections for each support assembly, each snap connection being one snap inserted into two snap receivers.
19. The packaging assembly of
20. A method of forming a tray, the method comprising:
obtaining a blank formable into a tray, the blank comprising:
a bottom panel, the bottom panel being rectangular in shape;
a first side panel connected to the bottom panel by a first side panel line;
at least one support assembly panel connected to the first side panel by a first support assembly line;
a second side panel connected to the bottom panel by a second side panel line;
at least one support assembly panel connected to the second side panel by a second support assembly line; and,
at least one end panel connected to the bottom panel by an end panel line;
wherein each end panel comprises at least one snap, and
wherein each support assembly panel defines at least one snap receiver;
bending each support assembly panel to form a support assembly from each support assembly panel;
bending each side panel with respect to the bottom panel along each side panel line such that each side panel is arranged orthogonally with respect to the bottom panel;
bending each end panel with respect to the bottom along each end panel line such that each end panel is arranged orthogonally with respect to the bottom panel and in contact with at least two support assemblies;
securing each end panel to at least two support assemblies by connected at least one snap into each snap receiver.