U.S. patent application number 11/025542 was filed with the patent office on 2006-06-29 for stackable container and container blank (l corner).
Invention is credited to Walter D. JR. Keefe, Nicholas A. Philips.
Application Number | 20060138206 11/025542 |
Document ID | / |
Family ID | 36610237 |
Filed Date | 2006-06-29 |
United States Patent
Application |
20060138206 |
Kind Code |
A1 |
Keefe; Walter D. JR. ; et
al. |
June 29, 2006 |
Stackable container and container blank (L corner)
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. 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: |
36610237 |
Appl. No.: |
11/025542 |
Filed: |
December 28, 2004 |
Current U.S.
Class: |
229/179 ;
229/177; 229/178; 229/918; 229/919 |
Current CPC
Class: |
B65D 5/003 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; an outer 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 bottom panel along said front edge; a second
corner panel hingedly attached to said first corner panel, opposite
said outer sidewall panel; a third corner panel hingedly attached
to said second corner panel, opposite said first 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.
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 third corner panel further
comprises a locking tab slot.
6. A container comprising: a bottom panel, an outer 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 positioned parallel to
the end panel; a second corner panel adjacent the first corner
panel; a third corner panel adjacent the outer wall panel; and, an
end panel flap positioned parallel to the end 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 further comprising an inner sidewall
panel adjacent said outer sidewall panel.
9. The container of claim 6, wherein said third corner panel
further comprises a locking tab slot.
Description
FIELD OF THE INVENTION
[0001] This invention relates generally to shipping and display
type containers.
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 having an inner cavity
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 "L" shaped corner assembly including a
first corner panel, a second corner panel and a third 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 and "L" shaped corner assembly associated with the outer
side panels and end panels. The corner assembly includes a first
corner panel and a second corner panel positioned parallel the end
panel. Additionally, the corner assembly includes a third corner
panel positioned parallel the outer side panel. And 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 tray-type container 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.
By way of overview and with reference to FIGS. 1-5, an embodiment
of the present invention includes a single piece blank 10 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 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 10 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 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 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 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. 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 44. The locking tab
slot 44 is generally formed in the third corner panel 34, adjacent
or along fold line 31.
[0021] 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. 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. dead
[0022] 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. The first step
begins 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
and the third corner panel 34 are folded inwardly, about fold line
29, approximately 180.degree. such that the second corner panel 32
and the third corner panel 34 lie adjacent the first corner panel
30 and a portion of the outer side wall 26. FIG. 2, best represents
the container at this stage of formation.
[0023] With specific reference to FIGS. 3 and 4, additional stages
of container formation are depicted. Specifically, the first corner
panel 30 and the second corner panel 32 are folded upwardly
approximately 90.degree., about fold lines 27 and 31, respectively.
In this manner, the first corner panel 30 and the second corner
panel 32 lie adjacent one another and lie in a plane that is
substantially perpendicular to the third corner panel 34 and outer
side wall 26. Then 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.
[0024] 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.
[0025] 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.
[0026] 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.
[0027] 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.
* * * * *