U.S. patent application number 10/357736 was filed with the patent office on 2003-08-07 for stackable container having support flanges.
Invention is credited to Kanter, Allen, Tibbels, Brian J..
Application Number | 20030146126 10/357736 |
Document ID | / |
Family ID | 27663289 |
Filed Date | 2003-08-07 |
United States Patent
Application |
20030146126 |
Kind Code |
A1 |
Kanter, Allen ; et
al. |
August 7, 2003 |
Stackable container having support flanges
Abstract
Containers are disclosed having a plurality of interconnected
panels forming sidewalls surrounding a central space. Flaps extend
from lower sidewall edges and fold along fold lines to form a
bottom. Support flanges are arranged along upper sidewall edges on
oppositely facing sidewalls. The support flanges are oriented at
right angles to the sidewalls and provide a support surface
allowing the containers to be stacked one atop another without
collapsing or nesting within each other. Side flanges are attached
to each end of the support flanges and to sidewalls joined to the
sidewalls having the support flanges. The side flanges each have an
angularly oriented fold line which divides the side flanges into
facing portions and permits them to fold like a bellows or
accordion pleat. The facing portions are adhered together to hold
the support flanges in position.
Inventors: |
Kanter, Allen; (Malvern,
PA) ; Tibbels, Brian J.; (Levittown, PA) |
Correspondence
Address: |
SYNNESTVEDT & LECHNER, LLP
2600 ARAMARK TOWER
1101 MARKET STREET
PHILADELPHIA
PA
191072950
|
Family ID: |
27663289 |
Appl. No.: |
10/357736 |
Filed: |
February 4, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60354099 |
Feb 4, 2002 |
|
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|
Current U.S.
Class: |
206/503 |
Current CPC
Class: |
B65D 5/001 20130101;
B65D 5/48014 20130101; B65D 5/02 20130101; B65D 5/52 20130101 |
Class at
Publication: |
206/503 |
International
Class: |
B65D 021/00; B65D
085/62 |
Claims
What is claimed is:
1. A container upon which another container having similar
dimensions may be stacked without nesting in said container, said
container comprising: a plurality of panels attached to one another
along adjacent edges to form a plurality of sidewalls surrounding a
central space; a plurality of flaps extending from said sidewalls
to form a bottom; a first flange attached to a first of said
sidewalls along an edge thereof positioned opposite to said bottom;
and a second flange attached to a second of said sidewalls along an
edge thereof positioned opposite to said bottom, said second
sidewall being attached to said first sidewall, said second flange
being attached to said first flange along a common edge, said first
flange being oriented substantially parallel to said bottom and
extending inwardly toward said central space for supporting said
other container when stacked thereon, said second flange being
folded along a fold line oriented at an angle to said common edge,
said second flange being thereby divided into second overlying
flange portions, each of said second overlying flange portions
having an outer face, said outer faces being attached to one
another in face to face relationship thereby holding said first
flange in position substantially parallel to said bottom.
2. A container according to claim 1, wherein said first flange
extends across the length of said first sidewall.
3. A container according to claim 2, further comprising a third
flange attached to a third of said sidewalls along an edge thereof
opposite to said bottom, said third sidewall being attached to said
first sidewall in facing relationship opposite to said second
sidewall, said third flange being attached to said first flange
along a second common edge and being folded along a fold line
oriented at an angle to said second common edge, said third flange
being thereby divided into third overlying flange portions, each of
said third overlying flange portions having an outer face, said
outer faces of said third overlying flange portions being attached
to one another in face to face relationship thereby holding said
first flange in position substantially parallel to said bottom.
4. A container according to claim 3, further comprising: a fourth
flange attached to a fourth of said sidewalls along an edge thereof
positioned opposite to said bottom, said fourth sidewall being in
facing relationship opposite said first sidewall and attached to
said second and third sidewalls; and a fifth flange attached to one
of said second and third sidewalls along an edge thereof positioned
opposite to said bottom, said fifth flange being attached to said
fourth flange along a third common edge, said fourth flange being
oriented substantially parallel to said bottom and extending
inwardly toward said central space for supporting said other
container when stacked thereon, said fifth flange being folded
along a fold line oriented at an angle to said third common edge,
said fifth flange being thereby divided into fifth overlying flange
portions, each of said fifth overlying flange portions having an
outer face, said outer faces of said fifth overlying flange
portions being attached to one another in face to face relationship
thereby holding said fourth flange in position substantially
parallel to said bottom.
5. A container according to claim 4, wherein said fourth flange
extends across the length of said fourth sidewall.
6. A container according to claim 5, further comprising a sixth
flange attached to the other of said second and third sidewalls
along an edge thereof opposite to said bottom, said sixth flange
being attached to said fourth flange along a fourth common edge and
being folded along a fold line oriented at an angle to said fourth
common edge, said sixth flange being thereby divided into sixth
overlying flange portions, each of said sixth overlying flange
portions having an outer face, said outer faces of said sixth
overlying flange portions being attached to one another in face to
face relationship thereby holding said fourth flange in position
substantially parallel to said bottom.
7. A container according to claim 1, wherein said faces of said
overlying flange portions facing each other are adhesively bonded
together.
8. A container according to claim 6 and formable from a knockdown
having first and second knockdown walls attached to one another at
first and second knockdown corners to form a substantially flat
assembly, said first knockdown wall including said first and said
second sidewalls and said first, second and sixth flanges in a
substantially same first plane, said second knockdown wall
including said third and fourth sidewalls and said third, fourth
and fifth flanges in a second substantially same plane parallel to
said first plane.
9. A container according to claim 6, wherein said second, third,
fifth and sixth flanges are square in shape and said fold line on
each of said flanges extends diagonally thereacross.
10. A container according to claim 6, wherein said flanges, said
sidewalls and said flaps comprise corrugated paperboard.
11. A container according to claim 10, wherein said fold lines
dividing said flanges into said overlying flange portions are
defined by respective perforations of said flanges.
12. Support surfaces useable on containers to permit stacking of
said containers one atop another without nesting, said containers
comprising a plurality of interconnected panels forming sidewalls
surrounding a central space, said sidewalls having flaps extending
therefrom and foldable to form a bottom, a first and a second of
said sidewalls facing one another in opposing relationship, said
support surfaces comprising: first and second support flanges
respectively attached to said first and second sidewalls and
extending lengthwise along edges thereof in spaced relation to said
bottom, said support flanges each being oriented substantially at a
right angle to said first and second sidewalls and projecting
inwardly toward said central space; and side flanges attached to
each end of said first and second support flanges, each said side
flange also being attached to a respective sidewall adjacent to one
of said first and second sidewalls, said side flanges each being
folded along a respective fold line extending diagonally across
each said side flange, said fold line dividing each of said side
flanges into overlying flange portions, each of said overlying
flange portions having an outer face, said outer faces of overlying
flange portions being attached to one another in face to face
relationship.
13. Support surfaces according to claim 12, wherein said flanges,
said sidewalls and said flaps comprise corrugated paperboard.
14. Support surfaces according to claim 13, wherein said fold lines
dividing said side flanges into said overlying flange portions are
defined by respective perforations of said side flanges.
15. Support surfaces according to claim 13, wherein said first and
second support flanges are integrally formed with said first and
second sidewalls respectively, said first and second support
flanges being defined by perforated fold lines located between said
first and second sidewalls and said first and second flanges
respectively.
16. Support surfaces according to claim 13 wherein said faces of
said overlying flange portions are adhered together by an adhesive
positioned therebetween.
17. Support surfaces according to claim 13 wherein said containers
are formed from a knockdown having first and second knockdown walls
attached to one another at first and second knockdown corners to
form a substantially flat assembly, said first knockdown wall
including said first sidewall, said first support flange, one of
said adjacent sidewalls attached to said first sidewall, and two of
said side flanges attached to said one adjacent sidewall, all
located in a substantially same first plane, said second knockdown
wall including said second sidewall, said second support flange,
another of said adjacent sidewalls attached to said second
sidewall, and two of said side flanges attached to said other
adjacent sidewall, all located in a substantially same second plane
parallel to said first plane.
Description
RELATED APPLICATION
[0001] This application is based on and claims the benefit of U.S.
Provisional Application No. 60/354,099, filed Feb. 4, 2002.
FIELD OF THE INVENTION
[0002] The invention relates to containers used for packaging,
shipping and displaying goods. More particularly, the invention
relates to display containers such as corrugated paperboard boxes
having flanges to facilitate the stacking of such containers on top
of one another.
BACKGROUND OF THE INVENTION
[0003] Display containers, for example, boxes of corrugated
paperboard, are widely used for shipping and marketing products.
Such containers are especially popular in warehouse-type marketing
settings and supermarkets where many containers are stacked on top
of one another and have open tops and partially open sides to
display the food or merchandise held within them. Examples include
containers of packaged candy which may be decorated for display
purposes. The containers of candy are shipped to the store in
stacked form. Store personnel remove the tops of the containers
and, in many cases, fold down or remove a side display panel from
the container which exposes the candy within the container to view
and allows access thereto by the consumer. The containers are then
stacked one on top of another on the retail floor for display of
the candy to the consumer.
[0004] A major problem with stacked containers having open tops and
sides is that a container may partially fall into or "nest" within
the container beneath it. Another problem is the lack of strength
for stacking. All too often loaded containers near or at the bottom
of a stack collapse or become misshapen under the weight of the
containers above them. This impairs the aesthetic appearance of the
display sought by the seller, ruins the products within, and
requires clean up.
[0005] One known container, disclosed in U.S. Pat. No. 5,791,555,
and which is hereby incorporated by reference, provides a shelf
like flap to help support a container stacked on top and prevent
nesting. This container is configured to automatically pull the
shelf into position upon the assembly of the container. One end of
the shelf is connected to a side wall of the container to pull the
shelf down, the other end being free and typically resting on the
top of one of the side walls. While this container provides
advantages over other type containers, further improvements are
believed desirable. For example, many products, such as candy, are
drop loaded into the containers. If the shelf is already in place,
this can interfere with the loading process. Furthermore, it has
been found that in some uses the free end of the shelf can be
forced into the container, creating a nesting problem.
SUMMARY AND OBJECTS OF THE INVENTION
[0006] The invention concerns a container upon which another
container having similar dimensions may be stacked without nesting
in the container. The container comprises a plurality of panels
attached to one another along adjacent edges to form a plurality of
sidewalls surrounding a central space. A plurality of flaps extend
from the sidewalls inwardly toward the central space, the flaps
being positioned substantially co-planarly in one of overlapping
and adjacent positions relative to one another to form a bottom. A
first flange is attached to a first of the sidewalls along an edge
thereof positioned opposite to the bottom. A second flange is
attached to a second of the sidewalls along an edge thereof
positioned opposite to the bottom, the second sidewall being
attached to the first sidewall, the second flange being attached to
the first flange along a common edge. The first flange is oriented
substantially parallel to the bottom and extends inwardly toward
the central space for supporting the other container when stacked
thereon. The second flange is folded along a fold line oriented at
an angle to the common edge, the second flange being thereby
divided into overlying flange portions. Each of the overlying
flange portions has an outer face, the outer faces being attached
to one another in face to face relationship, thereby holding the
first flange in position substantially parallel to the bottom.
Attachment of the faces is preferably by adhesive.
[0007] The invention also concerns support surfaces useable on
containers to permit stacking of the containers one atop another
without nesting. The containers comprise a plurality of
interconnected panels forming sidewalls surrounding a central
space. The sidewalls have flaps extending therefrom which are
foldable to form a bottom. First and second support flanges are
respectively attached to first and second sidewalls which face one
another in opposing relationship. The support flanges extend
lengthwise along edges of the sidewalls in spaced relation to the
bottom. The support flanges are each oriented at a substantially
right angle to the first and second sidewalls and project inwardly
toward the central space. Side flanges are attached to each end of
the first and second flanges. Each side flange is also attached to
a respective sidewall adjacent to one of the first and second
sidewalls. The side flanges are folded along respective fold lines
extending diagonally across each side flange, the fold lines
dividing each of the side flanges into overlying flange portions
facing one other and extending inwardly toward the central space,
the overlying flange portions being adhered together, preferably by
adhesive.
[0008] Accordingly, one object of the present invention is to
provide a display-ready container with improved anti-nesting
capabilities.
[0009] Another object is to provide a container with anti-nesting
capabilities that can be assembled by machine.
[0010] Another object is to provide a display-ready container that
is economical to produce.
[0011] A further object of the present invention is to provide a
display-ready container that is easy to assemble and use.
[0012] Another object is to provide a display-ready container that
can be safely stacked during shipping and display.
[0013] Additional objects, advantages and novel features of the
invention will be set forth in part in the description which
follows, and in part will become apparent to those skilled in the
art upon examination of the following, or may be learned from
making and using the invention. The objects and advantages of the
invention may be realized and attained by means of the combinations
pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of a container according to the
invention stacked atop similar containers;
[0015] FIG. 2 is a plan view of a blank from which the container
shown in FIG. 1 is formed;
[0016] FIGS. 3A through 3C are perspective views of a container
being formed from a knockdown shown in 3A;
[0017] FIG. 4 is an alternate embodiment of a container according
to the invention;
[0018] FIG. 5 is a blank from which the container in FIG. 4 is
formed; and
[0019] FIG. 6 is a knockdown formed from the blank shown in FIG. 5
and transformable into the container shown in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] FIG. 1 shows a container 10 according to the invention.
Container 10 is preferably formed of a stiff, lightweight substrate
such as corrugated paperboard and comprises a plurality of panels
12 attached to one another along adjacent edges 14 to form a
plurality of sidewalls 16, 18, 20 and 22. The sidewalls define and
surround a central space 24 where merchandise is received for
storage, transport and display. Container 10 is depicted in a stack
of similar containers 10b and 10c (shown in phantom line) and
without a top as it might be seen in a display on a market floor.
Sidewall 18 is a partial panel and has a reinforcing fold-down
portion 26, the partial panel 18 providing an opening 28 in the
container 10 allowing display and access to the goods therein even
when the containers are stacked one atop another as shown.
[0021] Flaps 30, 32, 34 and 36 extend respectively from the lower
edge of each sidewall 16, 18, 20 and 22 and are folded inwardly
toward the central space 24 along respective fold lines (identified
in detail below) to form a bottom 38. Upon folding, the flaps 30,
32, 34 and 36 are positioned substantially co-planarly in
overlapping and adjacent positions relatively to one another. There
are several possible folding combinations used to form bottoms of
containers, such as the 1-2-3-4 bottom or the "crash" bottom, all
of which are known to those of skill in the art.
[0022] Generally the sidewalls, flaps, fold down portions and other
parts comprising the container 10 are joined together at adjacent
edges defined by fold lines formed in the substrate comprising the
container. For containers made of corrugated paperboard, the fold
lines may be formed in any of a number of ways, such as by cutting,
creasing or perforating the paperboard as is known in the art. For
economy of reference herein, when an edge of a part of the
container is defined by a fold line, both the fold line and the
edge are denoted by the same reference character. This does not
imply, however, that all edges are necessarily fold lines or that
all parts of the container need be joined at fold lines in the
substrate.
[0023] Containers 10 according to the invention have support
flanges 40 and 42 which form flat support surfaces 44 across the
tops of the containers upon which other containers sit when the
containers are stacked as illustrated in FIG. 1. The support
flanges 40 and 42 prevent nesting of the containers within one
another when stacked and also strengthen the container sidewalls
against collapse. Preferably, the support flanges 40 and 42 extend
across the entire width or length of the container and are
respectively positioned on opposing sidewalls such as 16 and 20.
Each support flange 40 and 42 is preferably integrally formed with
its respective sidewall 16 and 20 and extends from a respective
edge 74 and 92 located on each sidewall opposite to the bottom 38
of the container. The edges 74 and 92 are defined by respective
fold lines in the container substrate which preferably have
lengthwise perforations 46 along at least a portion of the span of
the support flange. The perforations provide increased flexibility
for folding the support flange without significantly compromising
the strength of the flange attachment to its respective sidewall.
Further details related to the construction of the support flanges
40 and 42 are provided below.
[0024] Container 10 is preferably formed from a unitary substrate
blank 48, shown in FIG. 2. The substrate blank 48 is preferably
die-cut from a sheet of corrugated paperboard during which the fold
lines defining the panel edges are formed, by creasing, perforating
and cutting operations as described above. Sidewalls 16, 18, 20 and
22 are shown as they would appear after the blank 48 is cut from
the paperboard sheet. The surfaces visible in FIG. 2 comprise the
outwardly facing surfaces of the container 10 in FIG. 1.
[0025] Beginning at the rightmost side of blank 48, there is a
portion of sidewall 22, denoted 22a, which is later attached to a
counterpart portion 22b (described below) to form the sidewall 22.
A portion of flap 36, denoted 36a, extends from a lower edge of the
sidewall portion 22a, that edge being defined by a fold line 50.
Sidewall portion 22a is joined to sidewall 16 at an edge defined by
a fold line 52. Flap 30 extends from a lower edge of sidewall 16,
that edge being defined by fold line 54. Sidewall 16 is joined to
sidewall 18 along an edge defined by a fold line 56. Flap 32
extends from a lower edge of sidewall 18, that edge being defined
by a fold line 58. Sidewall 18 has a large cut-out region defining
the display opening 28 in the sidewall for access to the
container's central space once assembled. Sidewall 18 also has a
fold down portion 26, shown before folding, which reinforces the
sidewall. When the blank 48 is formed, fold down portion 26 is
defined by two parallel cuts 60 and 62 respectively positioned at
either end of the fold down portion, and a fold line 64 which
extends lengthwise along the fold down portion between the cuts.
Cuts 60 and 62 extend through the entire thickness of the substrate
blank 48 to free the ends of the fold down portion 26 from the
sidewall 18 and allow it to be reverse folded inwardly to reinforce
the sidewall 18.
[0026] Sidewall 18 is joined to sidewall 20 along an edge defined
by a fold line 66. Flap 34 extends from a lower edge of sidewall
20, that edge being defined by a fold line 68. Sidewall 20 is
joined to sidewall portion 22b along an edge defined by a fold line
70. Sidewall portion 22b is the counterpart to sidewall portion
22a, and when joined together, the sidewall portions 22a and 22b
form sidewall 22. A portion of flap 36, denoted 36b, extends from a
lower edge of the sidewall portion 22b, that edge being defined by
a fold line 72. Joining of sidewalls 22a and 22b also effect the
joining of flaps 36a and 36b which form bottom flap 36.
[0027] Support flange 40 extends from an upper edge of sidewall 16,
that edge being defined by a fold line 74. Support flange 40
preferably runs along the entire length of sidewall 16, and each
end of the support flange is attached to a respective side flange
76 and 78. Side flange 76 extends from an upper edge of sidewall
portion 22a, that edge being defined by a fold line 80. Another
fold line, 82, defines the edge between support flange 40 and the
side flange 76. Yet another fold line, 84, extends across the side
flange 76 at an angle to the edge defined by fold line 82.
Similarly, side flange 78 extends from an upper edge of sidewall
18, that edge being defined by a fold line 86. Another fold line,
88, defines the edge between support flange 40 and the side flange
78. Yet another fold line, 90, extends across the side flange 78 at
an angle to the edge defined by fold line 88.
[0028] Similarly, support flange 42 extends from an upper edge of
sidewall 20, that edge being defined by a fold line 92. Support
flange 42 preferably runs along the entire length of sidewall 20,
and each end of the support flange is attached to a respective side
flange 94 and 96. Side flange 94 extends from an upper edge of
sidewall portion 22b, that edge being defined by a fold line 98.
Another fold line, 100, defines the edge between support flange 42
and the side flange 94. Yet another fold line, 102, extends across
the side flange 94 at an angle to the edge defined by fold line
100. Similarly, side flange 96 extends from an upper edge of
sidewall 18, that edge being defined by a fold line 104. Another
fold line, 106, defines the edge between support flange 42 and the
side flange 96. Yet another fold line, 108, extends across the side
flange 96 at an angle to the edge defined by fold line 106.
[0029] Preferably, the side flanges 76, 78, 94 and 96 are square in
shape and the fold lines 84, 90, 102 and 108 extend diagonally
across their respective side flanges. The reasons for these
preferences are explained below.
[0030] Blank 48 is next formed into a knockdown 110 shown in FIG.
3A. The knockdown is advantageous because it allows containers such
as container 10 to be shipped from the manufacturer in a flat
configuration, saving space and reducing shipping costs. The
knockdown is configured to be conveniently converted from the flat
configuration into the container 10 as depicted in FIG. 1 through a
series of simple steps (described below) performed by automated
machinery. Once the container is formed from the knockdown, it is
then loaded with merchandise, final actions are executed, and the
container with its contents is ready for shipment.
[0031] Knockdown 110 is formed by first reverse folding fold down
portion 26 along fold line 64 and into overlying relation with the
inwardly facing surface of sidewall 18. Next blank 48 is reverse
folded along fold lines 66 and 52 to bring sidewall portion 22b
into partial overlying relation with counterpart sidewall portion
22a. The two sidewall portions 22a and 22b are bonded together,
preferably with an adhesive 112 (see FIG. 1) to form sidewall 22,
and the knockdown 110 shown in FIG. 3A.
[0032] Knockdown 110 comprises a first knockdown wall 114 formed of
sidewalls 18 and 16 along with their respective flaps 32 and 30 as
well as flanges 96, 78 and 40 all aligned in a same first plane
when the knockdown is in its flat configuration. Edges 66 and 52
form the first and second knockdown corners which define the ends
of the first knockdown wall 114. A second knockdown wall 116 is
formed of sidewalls 20 and 22, their respective flaps 34 and 36,
and flanges 42, 94 and 76 all in a same second plane which is
parallel to the first plane. The second knockdown wall 116 is
joined to the first knockdown wall 114 at the first and second
knockdown corners defined by edges 66 and 52.
[0033] FIGS. 3A through 3C show a series of steps performed to
transform the knockdown 110 into the container 10. In the first
step, shown in FIG. 3A, the first and second knockdown walls 114
and 116 are separated from one another with the sidewalls 16, 18,
20 and 22 pivoting relatively to one another in the manner of a
four bar linkage about fold lines 52, 56, 66 and 70. As the
sidewalls comprising the respective knockdown walls 114 and 116
move outwardly they are no longer substantially in the same plane
and the knockdown 110 transforms into the configuration shown in
FIG. 3B wherein adjacent sidewalls are oriented at right angles to
one another.
[0034] Once the sidewalls 16, 18, 20 and 22 are moved into the
right angled configuration, the flaps 30, 32, 34 and 36 are folded
inwardly along respective fold lines 54, 58, 68, 72 and 50 to form
the bottom 38. In the example shown in FIGS. 3B and 3C, flaps 30
and 34 are first folded inwardly followed by flaps 32 and 36, the
latter two flaps being preferably adhesively bonded to the first
two to form a permanent bottom. Other bottom configurations are of
course feasible, as known in the art. Typically, an auxiliary panel
(not shown) will be installed within the central space 24 in
overlying relation with sidewall 18 to close off the opening 28.
The auxiliary panel is removed at the point of sale to display the
container contents in the stacked configuration as shown in FIG.
1.
[0035] With sidewalls 16, 18, 20 and 22 in right-angle relation, an
auxiliary panel in place, and bottom 38 formed, the container 10 is
now ready to be loaded with merchandise. It is advantageous to
perform the loading step before the support flanges 40 and 42 are
folded into the final configuration shown in FIG. 1. This allows
for a maximum sized opening in the container for receiving the
contents.
[0036] In the next step, shown in FIG. 3C, the support flanges 40
and 42 are folded inwardly about respective fold lines 74 and 92
toward the central space 24 to provide the support surfaces 44
which strengthen the sidewalls and support a container stacked on
top of the container 10 without allowing nesting of the containers.
Note that the side flange 78 is attached to both support flange 40
and sidewall 18, side flange 76 is attached to both support flange
40 and sidewall 22, and the side flanges 78 and 76 are at right
angles to support flange 40. This configuration will generally
prevent folding of support flange 40 about fold line 74. However,
fold lines 90 and 84 are positioned diagonally across side flanges
78 and 76 respectively. As shown in FIG. 2, the fold lines 90 and
84 divide their respective side flanges 78 and 76 into respective
overlying flange portions 78a, 78b, 76a and 76b. Each overlying
flange portion has an outer surface 78c, 78d, 76c and 76d also
shown in FIG. 2. The fold lines 90 and 84 allow the side flanges 78
and 76 to fold inwardly in the manner of a bellows or accordion
pleat to respectively bring their outer faces 78c, 78d, 76c and 76d
into face to face relationship as shown in FIG. 3C. This permits
support flange 40 to fold inwardly and be positioned at a right
angle to the sidewall 16, thus, forming one of the support surfaces
44. Flanges 42, 94 and 96 are similarly configured with fold lines
102 and 108, forming respective overlying flange portions 94a, 94b,
96a and 96b. Each overlying flange portion has an outer surface
94c, 94d, 96c and 96d as shown in FIG. 2. The fold lines 102 and
108 allow their respective side flanges 94 and 96 to fold inwardly,
permitting support flange 42 also to fold as described for support
flange 40. Adhesive 118 is applied between the outer facing
surfaces 78c, 78d, 76c, 76d, 94c, 94d, 96c and 96d to secure them
to one another in facing relationship and hold the support flanges
40 and 42 in the folded configuration. Adhering the faces together
also serves to strengthen the container 10, permitting deeper
stacking without nesting or collapse. Side flanges 78, 76, 94 and
96 are preferably square in shape so as to minimize their size and
yet provide a shape which will fold neatly within the perimeter of
the container. The square shape allows the fold lines 76, 78, 102
and 108 to naturally be oriented diagonally and thus maximize the
contact area when the flanges are folded to ensure good
adhesion.
[0037] Once loaded and with support flanges 40 and 42 folded, a top
(not shown) is placed on the container 10 and the container is
ready for shipping. It is clear that the steps involved in forming
the container from the knockdown, filling the container, folding
and adhering the support flanges 40 and 42 in place and placing a
top on the container are relatively simple steps occasioned by the
design of the knockdown 110 which allows these steps to be
performed rapidly and reliably by automated machinery.
[0038] FIG. 4 shows another embodiment 120 of a container according
to the invention. Container 120 has many of the same features as
container 10, and the same reference characters are used to
identify those parts common to both embodiments. Again, support
flanges 40 and 42 are formed along edges 74 and 92 of opposite
sidewalls 16 and 20 to strengthen the container 120 and provide
support surfaces 44 to prevent nesting of containers one within the
other when stacked. Container 120 has a divider panel 122 extending
from sidewall 22 to opposite sidewall 18. The divider panel 122
divides the central space 24 into separate regions 24a and 24b
allowing the container to hold two different types of merchandise
and keep them separated. Again, sidewall 18 is a partial panel and
has openings 28a and 28b providing access to each of the separate
regions 24a and 24b when the containers are stacked together.
Sidewall 18 has an upstanding middle extension 124 to which the
divider panel 122 is attached.
[0039] Container 120 is formed from a blank 126 shown in FIG. 5.
Blank 126 is preferably die-cut from corrugated paperboard
substrate and has fold lines defining the edges between sidewalls,
flaps and flanges substantially as described above for container
10. The panel surfaces visible in FIG. 5 are those which face
outwardly from the central space when the container 120 is formed.
Note that divider panel 122 extends from sidewall portion 22b, a
fold line 128 defining the edge between the sidewall 22b and the
divider panel 122. Divider panel 122 also has an attachment flap
130 positioned at its end opposite to sidewall portion 22b and
defined by a fold line 132. As shown in FIG. 4, the attachment flap
130 is folded along fold line 132 at a right angle to divider panel
122 and attached to middle extension 124 to effect the attachment
of divider panel 122 to the sidewall 18. Attachment of flap 130 is
preferably effected by adhesive.
[0040] The configuration of the divider panel 122 allows the
container 120 to be formed into a knockdown 134, shown in FIG. 6.
Knockdown 134 is shown in its flat configuration for shipping and
has a first knockdown wall 136 comprising sidewalls 18 and 16,
their respective flaps 32 and 30 as well as flanges 96, 78 and 40
in a substantially same first plane 138. Fold lines 66 and 52
define the first knockdown wall 136. A second knockdown wall 140 is
attached to the first knockdown wall 136 at the fold lines 66 and
52 and is positioned in a substantially same second plane 142
parallel to and behind the first plane 138. The second knockdown
wall 140 comprises sidewalls 20 and 22 (formed by attaching
sidewall portions 22a and 22b together) along with their flaps 34
and 36 and flanges 94, 42 and 76 all substantially in second plane
142, not all of which can be shown in FIG. 6. Knockdown 134 is
transformed into the container 120 using substantially the same
steps as described above for container 10. Note that the divider
panel 122 is sandwiched between the first and second knockdown
walls 136 and 140 when the knockdown is in the flat configuration
depicted in FIG. 6. When the knockdown walls 136 and 140 are
separated, the divider panel 122 pivots about its fold lines 128
and 132 similar to the way sidewalls 16 and 20 (to which it is
parallel) pivot about their respective fold lines in the manner of
a four-bar linkage to effect transformation from the knockdown to
the container configuration.
[0041] Containers according to the invention provide a convenient
and cost effective item for packaging, transporting and displaying
bulk items. Such containers are rugged and reliably stackable and
avoid the problems of nesting and collapse from which other
containers suffer.
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