U.S. patent application number 11/025541 was filed with the patent office on 2006-06-29 for stackable container with air cell corner assembly and associated container blank.
Invention is credited to Walter D. JR. Keefe, Nicholas A. Philips.
Application Number | 20060138205 11/025541 |
Document ID | / |
Family ID | 36610236 |
Filed Date | 2006-06-29 |
United States Patent
Application |
20060138205 |
Kind Code |
A1 |
Keefe; Walter D. JR. ; et
al. |
June 29, 2006 |
Stackable container with air cell corner assembly and associated
container blank
Abstract
A tray-type container includes a bottom wall,
longitudinally-extending outer side walls, and laterally-extending
end walls, the outer side walls and the end walls extending
upwardly from the bottom wall to form an inner cavity. The
container includes a corner assembly configured to increase the
container stability. The corner assembly includes an arrangement of
corner panels configured to form air cells that extend across the
end of the container and serve to provide added stability to the
container. The containers may be used singularly, or a plurality of
tray-type containers may be unitized in several stacked
configurations. Typically, the plurality of unitized containers are
placed upon a shipping pallet or slip sheet, or placed within a
shipping container to facilitate shipping by large carriers.
Inventors: |
Keefe; Walter D. JR.; (Carol
Stream, IL) ; Philips; Nicholas A.; (Sugar Grove,
IL) |
Correspondence
Address: |
WEYERHAEUSER COMPANY;INTELLECTUAL PROPERTY DEPT., CH 1J27
P.O. BOX 9777
FEDERAL WAY
WA
98063
US
|
Family ID: |
36610236 |
Appl. No.: |
11/025541 |
Filed: |
December 28, 2004 |
Current U.S.
Class: |
229/179 ;
229/177; 229/178; 229/918; 229/919 |
Current CPC
Class: |
B65D 5/0035
20130101 |
Class at
Publication: |
229/179 ;
229/177; 229/178; 229/918; 229/919 |
International
Class: |
B65D 5/00 20060101
B65D005/00 |
Claims
1. A blank for a container comprising: a single sheet of foldable
material cut and scored to define a bottom panel, said bottom panel
having a side edge and an end edge; a sidewall panel hingedly
attached to said bottom panel along said side edge, said sidewall
panel having a front edge, a first corner panel hingedly attached
to said side panel along said front edge; a second corner panel
hingedly attached to said first corner panel, opposite said side
panel; an third corner panel hingedly attached to said second
corner panel, opposite said first corner panel; a forth corner
panel hingedly attached to said third corner panel, opposite said
second corner panel, an end panel hingedly attached to said bottom
panel along said end edge; and end panel flap hingedly attached to
said end panel along a spaced apart hinge line, opposite said
bottom panel, wherein the first corner panel and the third corner
panel are substantially equally sized.
2. The blank of claim 1 wherein the blank is formed from at least
one of a paperboard, containerboard, cardboard, pasteboard,
fiberboard, corrugated containerboard, corrugated paperboard,
single wall corrugated containerboard, and multiwall corrugated
containerboard.
3. The blank of claim 1 further comprising an inner sidewall panel
hingedly attached to said outer sidewall panel, opposite said
bottom panel.
4. The blank of claim 1 further comprising first a hinge flap notch
formed in an outer edge of said first corner panel.
5. The blank of claim 1, wherein said forth corner panel further
comprises a locking tab slot.
6. A container comprising: a bottom panel, a side panel extending
upwardly from said bottom panel; an end panel extending upwardly
from said bottom panel to form, along with said side panel, an
inner cavity; a first corner panel adjacent the end panel; a second
corner panel positioned perpendicular to the first corner panel; a
third corner panel positioned parallel to the first corner panel,
and spaced apart from the first corner panel by the second corner
panel; a forth corner panel extending connected with the third
corner panel, the for the corner panel positioned parallel the side
panel. and, an end panel flap positioned adjacent the third corner
panel.
7. The container of claim 6 wherein the container is formed from at
least one of a paperboard, containerboard, cardboard, pasteboard,
fiberboard, corrugated containerboard, corrugated paperboard,
single wall corrugated containerboard, and multiwall corrugated
containerboard.
8. The container of claim 6, wherein said forth corner panel
further comprises a locking tab slot.
Description
FIELD OF THE INVENTION
[0001] This invention relates generally to shipping and display
type containers having angled corner panels.
BACKGROUND OF THE INVENTION
[0002] Cartons or containers formed from folded corrugated
paperboard or similar flat sheet stock material are often stacked
on one another during shipping and storage of products. In high
volume retail stores, product is not only stored in stacked
cartons, but frequently is presented to consumers in that form,
e.g., with the stacked cartons disposed on pallets. Stacking is
obviously efficient as to the use of space and pallets enable a
number of cartons to be handled as a unit.
[0003] Containers in stacks are subjected to various forces, not
limited to vertical compression due to the weight of containers
over them in a stack. Such forces (as well as vertical compressive
forces) are aggravated by handling, for example transport of a
stack on a pallet, manual handling of one or more containers in a
stack, etc. Tension and/or compression applied in various
directions to the container walls can be sufficient to wholly or
partly collapse a container or laterally to deflect, bend or fold
the vertically oriented walls of the container. The result is a
reduction of structural integrity, and may include crushing or
other damage to the container contents. In addition, when the walls
of one or more containers in a stack are crushed, wholly or partly
collapsed, or otherwise deformed, the deformed container may no
longer provide a stable horizontal support for containers stacked
over it. The overlying stack may then tip laterally. A leaning
"tower" of containers may fall, and even if there is no injury to
persons, the contents of the containers may spill or be
damaged.
[0004] Apart from instability due to partial collapse of the walls
of one or more containers in a stack, instability leading to spills
and possible collapse of a stack may be caused by containers being
shifted horizontally relative to underlying containers. Customer
access and traffic in retail/warehouse stores makes it likely that
containers will be shifted horizontally.
[0005] It often is necessary for stock clerks at the warehouse
retailer to rearrange containers on a pallet as certain containers
are emptied, for example to consolidate product from a number of
nearly empty open cartons into one, to restack or reposition the
cartons for neatness, etc. It is advantageous if such rearrangement
can be accomplished easily and quickly, especially because stock
clerk staffing at warehouse retailers is preferably minimal.
Containers stacked on a pallet, however, may be difficult to
maneuver easily or quickly, may be stacked in close proximity to
each other and may be bulky and cumbersome when filled with
merchandise. If containers are stacked on open containers, which is
sometimes desirable, the stack may have inadequate support.
SUMMARY OF THE INVENTION
[0006] In accordance with aspects of the present invention, a
single piece blank for forming a container with improved stacking
stability is provided. The blank includes a bottom panel, and an
end panel hingedly connected to the bottom panel by a first fold
line. The blank also includes an outer side panel having an outer
edge and hingedly connected to the bottom panel by a second fold
line. An inner side wall panel is hingedly connected to the outer
panel. The blank further includes and air cell shaped corner
assembly including a first corner panel, a second corner panel, a
third corner panel and a forth corner panel. Still further, an end
panel flap is connected with the end panel via an interrupted and
spaced apart number of hinge flaps.
[0007] In accordance with another aspect of the present invention,
a container includes a bottom panel, and outer side panels that
extend upwardly from the bottom panel. The container also includes
end panels that extend upwardly from the bottom wall to form, along
with the side panels, an inner cavity. The container further
includes a corner assembly configured to form air cells that extend
across an end of the container. The corner assembly includes a
first corner panel and a third corner panel positioned parallel the
end panel, but separated by the second corner panel. Additionally,
the corner assembly includes a forth corner panel positioned
parallel to and affixed to the outer side panel. An end panel flap
is also positioned substantially parallel to and engaging with the
first corner panel and second corner panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The preferred and alternative embodiments of the present
invention are described in detail below with reference to the
following drawings.
[0009] FIG. 1 is a perspective view of a container blank formed in
accordance with the present invention;
[0010] FIG. 2 is a perspective view of a partially erected
container formed from the blank of FIG. 1;
[0011] FIG. 3 is another perspective view of a partially erected
container formed from the blank of FIG. 1;
[0012] FIG. 4 is yet another perspective view of a partially
erected container formed from the blank of FIG. 1; and,
[0013] FIG. 5 is a perspective view of a container made from the
blank of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The present invention includes a single sheet of foldable
material cut and scored to form a blank formable into a container
having angled corner walls. By way of overview and with reference
to FIGS. 1-5, an embodiment of the present invention includes a
single piece blank 20 arranged to form a stackable container 50.
Specific details of the blank 20 and container 50 are described
with more particularity below.
[0015] The present invention will now be described with reference
to the accompanying FIGS. 1-5 where like numerals correspond to
like elements. In all FIGURES, cut lines are shown as solid lines,
score lines or lines of weakness are shown as broken lines. The
present invention is directed to a tray-type container that
utilizes a corner assembly having an angled corner panel coupled
with other corner panels to create a modular stackable container.
The container includes an arrangement of panels, which are adapted
to provide suitable container stability.
[0016] One suitable embodiment of the blank 20, constructed in
accordance with the present invention is illustrated in FIGS. 1 and
5. The blank 20 and container 50 include a bottom panel 20,
longitudinally-extending outer side walls 26, and
laterally-extending end walls 24. A plurality of tray-type
containers 50 may be placed upon a shipping pallet or slip sheet
(not shown), or placed within a shipping container (not shown) to
facilitate shipping or displaying at a retail location.
[0017] For the purpose of further description herein, the downward
direction is defined as the direction perpendicular to bottom panel
22 that corresponds to the outer surface of the bottom panel when
the container 50 has been erected, and the upward direction is
defined as the direction perpendicular to the bottom panel that
corresponds to the inner surface of the bottom panel when the
container 50 has been erected.
[0018] The blank 20 and resulting container 50 is typically made
from any suitable material used in the shipping, storing or
displaying of goods. Suitable, nonlimiting examples of such
materials include paperboard, containerboard, cardboard,
pasteboard, fiberboard, corrugated containerboard, corrugated
paperboard, single wall corrugated containerboard, multiwall
corrugated containerboard or a combination thereof. As best shown
in FIG. 1, a blank 20 is stamped out of any of these suitable
materials and assembled in a manner which can be seen in FIGS.
1-5.
[0019] With continued reference to FIG. 1, the blank 20 includes a
bottom panel 22 of generally rectangular shape having multiple
edges. It will be appreciated, however, that the bottom panel 22
may also be of other geometries, such as, without limitation,
square. Unless otherwise apparent, the term "edges" refers
generally to a zone or line of weakness along which a part can be
folded, such as a score line, or a cut line. Opposite outer side
wall panels 26 are hingedly connected to opposite side edges of the
bottom panel 22 along fold lines 21. The blank 20 further includes
end panels 24, which are hingedly connected to the remaining two
opposite edges of the bottom panel 22 along fold lines 23. The
outer side panels 26 include inner side panels 28, which are
hingedly connected to the outer side panels 26, along a fold line
33, opposite the bottom panel 22.
[0020] Further, the outer side panels 26 include air cell corner
assemblies 46 located at opposite ends of outer side wall panels
26, and are hingedly connected to the outer side panels 26 along
fold lines 27. The fold lines 27 are substantially perpendicular to
fold lines 21. The corner assemblies 46 include a first corner
panel 30 connected with the outer side panel 26 along fold line 27.
A second corner panel 32 is connected with the first corner panel
30 along fold line 29, opposite fold line 27. A third corner panel
34 is connected with the second corner panel 32 along fold line 31,
opposite fold line 29. Still further, a third corner panel 48 is
connected with the third corner panel 34 along a fold line 33. The
first corner panel 30 and the second corner panel 32 each include a
hinge flap notch 38. The hinge flap notch 38 is typically formed in
an edge that lies substantially perpendicular to fold lines 27, 29,
and 31. Additionally, the third corner panel 34 includes a locking
tab slot 40. The locking tab slot 40 is generally formed in the
third corner panel 34, adjacent or along fold line 31. Those
skilled in the art will appreciate the locking tab slot 40 is
designed to work in tandem with the locking tabs 44 (discussed
below) in order to help hold the container 50 in an erect
state.
[0021] With regards to relative size, the first corner panel 30 and
the third corner panel 34 are substantially equal is geometry and
size. Also, the second corner panel 32 and the forth corner panel
36 are substantially equal is geometry and size. However, the
second corner panel 32 and the forth corner panel 36 are sized
smaller than the first corner panel 30 and the third corner panel
34. The ratio of size of the second corner panel 32 and the forth
corner panel 36 relative to the first corner panel 30 and the third
corner panel 34 is variable, and is within the skill of those in
the art to determine. Such factors that may affect the ratio size
includes the nature of product (not shown) placed within the
container 50, or the desired air cell size.
[0022] The end panels 24 include end panel flaps 36, which are
hingedly attached to the end panel 24, opposite the bottom panel
22, by hinge flaps 42 along interrupted cut line 31. As depicted in
the FIGURES, only two hinge flaps 42 are used, however, it will be
appreciated that the present invention may include more or fewer
hinge flaps 42 without exceeding the spirit and scope of the
present invention. It will also be appreciated that as the hinge
flap notch 38 (discussed in more detail below) is configured to
receive the hinge flaps 42, if more or fewer hinge flaps 42 are
used, then the hinge flap notch configuration will need to change
accordingly. Positioned on an outer edge of the end panel flaps 36
are locking tabs 40. Those skilled in that art will appreciate that
the locking tabs 40 and the locking tab slot 44 are configured to
interact upon formation of the container 50 (discussed in more
detail below), to lock the container 50 in its assembled form.
[0023] Referring now to FIGS. 2-5, one method of constructing the
container 50 from the blank 20 will be described. In the ensuing
description, erecting one side of the containers will be described.
However, it will be appreciated that the other side of the
container is formed in substantially similar steps.
[0024] The first step may begin with the inner side panel 28 being
folded inwardly, about fold line 33, approximately 180.degree. such
that the inner side panel 28 and the outer side panel 26 lie
adjacent one another and in parallel planes. Additionally, both the
second corner panel 32, the third corner panel 34 and the forth
corner panel 48 are folded inwardly, about fold lines 29 and 31,
such that the third corner panel 32 and the first corner panel 30
lie in parallel planes, separated in distance from one another by
the second corner panel 32. Subsequently, the forth corner panel 48
is folded about fold line 33 to bring the forth corner panel
adjacent a portion of the outer side wall 26. At this point, the
outer side wall 26 and the forth corner panel 48 may be suitably
attached to one another, via, an adhesive, tape, or mechanical
fastener. Likewise, the first corner panel and the second corner
panel may also be attached to one another in a similar fashion. At
this stage, the corner assemblies 46 form air cells 52, defined by
the first corner panel 30, second corner panel 32, and third corner
panel 34. FIGS. 2 and 3, best represent the container at this stage
of formation.
[0025] With specific reference to FIGS. 3 and 4, additional stages
of container formation are depicted. Specifically, the entire wall
panel and corner assembly 46 is folded upwardly along fold line 21
such that the first corner panel 30 and the second corner panel 32
lie in a plane parallel to fold line 23. At this stage of
formation, the outer side wall 26, inner side wall 28 at in a plane
that is approximately 90.degree. relative to the bottom panel 22.
Likewise, the corner assemblies 46 are formed into air cells 52 and
extend across the ends of the container 50, between the respective
side outer side panels 26.
[0026] Further, end panels 24 are then folded upright, along fold
line 23, approximately 90.degree. with respect to the bottom wall
panel 22, as best shown in FIG. 4. In this position, the hinge flap
notches 38 are along an upper edge of the end walls of the
container 50 are spatially positioned to receive hinge flaps 42
when the end panel flap 36 if folded over the first corner panel 30
and the second corner panel 32 as depicted in FIG. 5. The locking
tabs 44 may then be inserted into the locking tab slots 40 to help
hold the container 50 in an erect position.
[0027] In use, container 50 may be filled with product (not shown)
and stacked with one or more other containers 50 on a pallet (not
shown) or display shelf (not shown). In one possible application, a
selected number of containers 50 filled with product (not shown)
are stacked on pallet (not shown), and pallet (not shown) may be
moved from receiving directly to the display floor of the retailer
(perhaps after removing an external common cover, strapping or
wrap), where end-user purchasers have access to the pallet of
containers. The individual containers 50 may not include covers,
tops or lids of corrugated material, instead being arranged such
that the upper containers engage over and cover the next lower one.
The containers 50 are accessed on the display floor and generate
less waste. Purchasers may select product (not shown) from one of
the open containers 50, generally from those containers at the top
of the stack. The increased strength of the containers allows the
containers to better resist vertical collapse or lateral deflection
caused by the forces of handling and the like. Handholds (not
shown) allow containers to be easily manipulated by stock personnel
or others, individually or in stacks of two or more.
[0028] As another alternative, the container of the invention may
also include a top or other means to cover the container. In
addition to the advantages apparent from the foregoing description,
the present invention improves the container's strength, especially
crushed in the vertical direction. A related advantage is that the
contents of such containers are less likely to be damaged.
[0029] While an embodiment of the invention has been illustrated
and described, as noted above, many changes can be made without
departing from the spirit and scope of the invention. For example,
the blank may also include other features specified by the
customer, such as hand holds, vent holes, grease or moisture
barriers and the like without exceeding the scope of the present
invention. Accordingly, the scope of the invention is not limited
by the disclosure of the preferred embodiment. Instead, the
invention should be determined entirely by reference to the claims
that follow.
* * * * *