U.S. patent application number 11/514430 was filed with the patent office on 2008-03-06 for methods for creating multi-walled containers and articles produced there from.
Invention is credited to Giles Greenfield.
Application Number | 20080054060 11/514430 |
Document ID | / |
Family ID | 39136626 |
Filed Date | 2008-03-06 |
United States Patent
Application |
20080054060 |
Kind Code |
A1 |
Greenfield; Giles |
March 6, 2008 |
Methods for creating multi-walled containers and articles produced
there from
Abstract
Methods for making multi-walled containers from a single blank,
preferably using a continuous process approach, and the resulting
containers are disclosed. Various embodiments of the invention
include, alone or in combination, intermediate panels formed from
flap precursors that are in- or out-folded such that their distal
ends are in proximate relationship to each other; outer flaps sized
to overlap exposed edges of a container formed from the blank;
stress relief features a joint corners to reduce stresses thereat.
Methods for making select containers of the invention include
folding and adhering the flap precursors to an inner panel,
up-folding the inner panel/intermediate panel combination about a
mandrel, and continuing to up-fold the outer panel until a
container having a "use" position as a resting position is
formed.
Inventors: |
Greenfield; Giles; (Tacoma,
WA) |
Correspondence
Address: |
GRAYBEAL, JACKSON, HALEY LLP
155 - 108TH AVENUE NE, SUITE 350
BELLEVUE
WA
98004-5973
US
|
Family ID: |
39136626 |
Appl. No.: |
11/514430 |
Filed: |
August 31, 2006 |
Current U.S.
Class: |
229/185.1 ;
229/939 |
Current CPC
Class: |
B65D 5/0281 20130101;
B31B 50/322 20170801; B31B 2120/50 20170801; B31B 2105/00 20170801;
B31B 2110/35 20170801 |
Class at
Publication: |
229/185.1 ;
229/939 |
International
Class: |
B65D 5/02 20060101
B65D005/02 |
Claims
1. A single blank for forming a multiple sidewall container, the
blank defining a longitudinal direction from a first end to a
second end, with the blank comprising: an inner panel forming inner
sidewalls of the container when assembled, wherein the inner panel
comprises a plurality of inner panel portions, each inner panel
portion being contiguous with any adjacent inner panel portion and
each inner panel portion comprising one inner sidewall of the
container when assembled; at least one pair of opposing middle
flaps extending from the inner panel to a distal edge, wherein the
sum of the lateral length of the pair of middle flaps from their
intersection with the inner panel to the distal edge is equal to or
less than the lateral length of the inner panel from the
intersection of a first opposing middle flap to the intersection of
a second opposing middle flap, and wherein each middle flap
comprises a plurality of flap portions, each flap portion being
contiguous with any adjacent flap portion and each opposing pair of
flap portions comprising one middle sidewall of the container when
assembled; and an outer panel extending from the inner panel
forming outer sidewalls of the container when assembled, wherein
the outer panel comprises a plurality of outer panel portions, each
outer panel portion being contiguous with any adjacent outer panel
portion and each outer panel portion comprising an outer sidewall
of the container when assembled, wherein the at least one pair of
opposing middle flaps are involuted to bring their respective
distal edges into proximity with each other and with the inner
panel, thereby forming intermediate sidewalls when the blank is
assembled into the container.
2. The blank of claim 1 further comprising a glue tab at the first
end of the blank and a glue tab at the second end of the blank
wherein the first glue tab is adherable to the inner panel when the
container is assembled and the second glue tab is adherable to the
outer panel when the container is assembled.
3. The blank of claim 1 wherein the distal edges of the middle
flaps are not linear.
4. The blank of claim 3 wherein the distal edges of the middle
flaps are one of a repeating rectilinear, curvilinear, or a
combination rectilinear and curvilinear design.
5. The blank of claim 1 wherein the distal edges of the middle
flaps are complementary such that upon involution, the distal edge
of one middle flap will substantially abut the distal edge of the
opposing middle flap.
6. The blank of claim 1 wherein each middle flap portion is
separated from an adjacent middle flap portion by a score.
7. The blank of claim 1 wherein each middle flap portion is
separated from an adjacent middle flap portion by a slit, a slot or
a gap.
8. The blank of claim 1 wherein each inner panel portion is
separated from an adjacent inner panel portion by a score.
9. The blank of claim 1 constructed from a double liner corrugated
material.
10. The blank of claim 1 wherein the lateral dimension of any inner
panel portion is less than the lateral dimension of any outer panel
portion.
11. The blank of claim 1 further comprising at least one pair of
opposing end flaps extending from at least some outer panel
portions wherein each end flap is separated from any adjacent end
flap by one of a slot, a slit or a gap.
12. The blank of claim 11 wherein pairs of opposing end flaps
extend laterally from each outer panel portion.
13. The blank of claim 11 further comprising a stress relief
feature at an interface between an end flap and an outer panel
portion.
14. The blank of claim 12 further comprising a stress relief
feature at an interface between each end flap and each outer panel
portion.
15. The blank of claim 11 wherein the longitudinal length of each
end flap is one of greater or less than the longitudinal length of
a corresponding outer panel portion from which it extends.
16. The blank of claim 1 wherein the resting position of a
container formed from the blank is the same as the use position of
a container formed from the blank.
17. The blank of claim 1 wherein the blank is derived from a web of
double liner corrugated material.
18. The blank of claim 1 wherein the blank is derived from a
continuous process beginning with a corrugator.
19. The blank of claim 13 wherein the stress relief feature
comprises a hole defined at least in part by two adjacent end flaps
and the outer panel.
20. The blank of claim 1 wherein one inner panel portion has a
longitudinal length longer than any other inner panel portion.
Description
BACKGROUND OF THE INVENTION
[0001] Large format containers, generally referred to as "bins",
are used to hold a variety of materials, usually for transport but
also for retail display. Because more than 95% of all products in
the US are shipped in corrugated boxes, and because of the cost
advantages associated with this form of packaging, most bins are
constructed from corrugated paperboard. But while about 90% of all
corrugated paperboard is single wall, the relatively large
dimensions of bins in conjunction with the nature of the goods
being placed in the bins require the additional strength provided
by multiple wall construction.
[0002] The prior art is replete with various methods for
establishing a desired level of sidewall burst strength, bottom
crush resistance and vertical load capacity for bins. Some
solutions employ the use of double or triple wall corrugated
paperboard as the starting material, while others rely upon
layering walls or nesting boxes. Each of these approaches, however,
includes advantages as well as disadvantages. Exemplary
disadvantages include high manufacturing costs due to material
handling, use of adhesives, or fabrication equipment, etc.;
handling difficulties (both prior to box converting such as when
handling large area blanks as well as afterwards such as when
attempting to prepare the bins for shipping), and generation of
waste material, all of which are well known to the skilled
practitioner.
[0003] In view of these disadvantages, an improved bin would be
constructed from easy-to-create single wall corrugated material,
would use limited amounts of adhesive during the converting
process, would require little human effort during the converting
process, would generate little waste, and would require minimal
handling, among other advantages. While such a need exists,
heretofore, such need has not been met.
SUMMARY OF THE INVENTION
[0004] Embodiments of the invention in one respect are directed to
methods for creating a multi-walled container (and resulting
articles) from a corrugated material with minimal intentional
waste, wherein the container is formed from a single sheet or
preferably a continuous web of corrugated material, such as single
wall corrugated board, or double wall corrugated board. Because
embodiments of the invention create a multi-walled container from a
single sheet or web of material (as opposed to using inserts or a
box-within-a-box design), it is possible, as well as desirable, to
create the container in a single operation, which advantageously
lends itself to a continuous process. Moreover, a continuous
process will usually dispense with the need to manage container
blanks. Additionally, multi-walled containers are usually large,
e.g., from approximately 40'' in width/side. At this scale,
conventional container blanks would be very large, approaching 30
feet in length. If embodiments of the invention were formed using
traditional construction methodologies, e.g., one apparatus
manufactures the blanks, the blanks are then moved to storage, and
then moved to a box making machine, storage, transport and handling
of such large format blanks would present a formidable challenge.
By using a continuous process wherein a web or constant source of
material is fed into a box making machine, all material handling
requirements that would otherwise be associated with conventional
blank-based box making procedures can be eliminated.
[0005] While the foregoing description of preferred methods
emphasizes the benefits of using a continuous process approach to
making containers according to the invention, the invention is not
limited to such approaches. Moreover, even in a continuous process,
container blanks will be formed prior to makeup of the container.
Thus, the term "blank" as used herein includes both conventional
container blanks not derived from a continuous process as well as
those that are so derived. In the event that a distinction is to be
made, and it is otherwise not clear from the context of usage, the
term "conventional blanks" or similar wording will refer to blanks
not derived from a continuous process.
[0006] Embodiments of the invention pertaining to articles
resulting from the practice of methods according to the invention
utilize in- or out-folded intermediate panels to establish a wall
in between an outer wall and an inner wall of a produced container.
In certain preferred embodiments of the invention, flap precursors
of a blank used to create the container are dimensioned to either
individually, or in combination, create an intermediate wall. Thus,
in one series of embodiments, opposing flap precursor are folded
toward each other, and attached, such as by adhesives, to the panel
from which they extended. Once folded and adhered, these flap
precursors collectively form an additional sidewall of the
container. By employing this method for producing the general
equivalent of triple wall containers where the flap precursors
constitute middle flaps, it is possible to construct such a
container with virtually no planned waste.
[0007] Embodiments of the invention in yet another respect are
directed to methods for creating a multi-walled container (and
resulting articles) that has a generally unstressed vertical fold
at all corner edges. By forming the container about a mandrel
having the desired shape of the container (at least side walls
thereof, the resultant container's relaxed state is that of its
in-use form. As a result, each vertical corner of a four-sided
container is less susceptible to tearing and breakage during use,
as is common in the prior art. The same applies to both 6 and 8
corner styles. Moreover, handling and storage of the resulting
containers is enhanced since no vertical corner in the four sided
configuration, for example, undergoes substantially greater than a
90.degree. bend from its "use" geometry to its "knocked down"
geometry.
[0008] Within the context of the invention, articles resulting from
the practice of the various method embodiments comprise a single
blank for forming a multiple sidewall container, as well as the
resulting container. The blank defines a longitudinal direction
from a first end to a second end, and comprises an inner panel
forming inner sidewalls of the container when assembled, wherein
the inner panel has a plurality of inner panel portions, each inner
panel portion being contiguous with any adjacent inner panel
portion and each inner panel portion making up one inner sidewall
of the container when assembled.
[0009] The blank further comprises at least one pair of flap
precursors, alternatively referred to as opposing middle flaps,
extending from the inner panel to a distal edge, wherein the sum of
the average lateral lengths of the pair of middle flaps from their
intersection with the inner panel to the distal edge is equal to or
less than the lateral length of the inner panel from the
intersection of a first opposing middle flap to the intersection of
a second opposing middle flap. Furthermore, each middle flap has a
plurality of flap portions, each flap portion being contiguous with
any adjacent flap portion and each opposing pair of flap portions
making up one middle sidewall of the container when assembled.
[0010] In addition, the blank comprises, in three sidewall
embodiments, an outer panel extending from the inner panel forming
outer sidewalls of the container when assembled, wherein the outer
panel has a plurality of outer panel portions, each outer panel
portion being contiguous with any adjacent outer panel portion and
each outer panel portion making up an outer sidewall of the
container when assembled. If additional intermediate sidewalls are
desired, then the outer panel will extend from the last
intermediate panel. In the described three sidewall embodiment,
such (an) intermediate panel(s) is/are located longitudinally
between the inner panel and the outer panel.
[0011] As noted above, the combined average lateral widths of the
middle flaps is equal to or less than the lateral width of the
inner panel. This relationship permits the at least one pair of
opposing middle flaps to be involuted, thereby bringing their
respective distal edges into proximity with each other and with the
inner panel. The resulting structure can then function as
intermediate sidewalls when the blank is assembled into the
container. The skilled practitioner will of course realize that as
the geometries of the distal edges vary, so may the lateral length
determinations. Thus, while the combined lengths are described in
terms of "average", it is within the scope of the invention to
include any geometry that will not result in an overlapping
condition when the opposing flaps are involuted and brought into
relative proximity with one another.
[0012] In certain embodiments, an interlocking or inter-meshing
pair of middle flap edges is established. In these embodiments,
stresses at what would otherwise be localized at a butt joint after
involution and formation of the container are dispersed over a
larger area of the container when in use. This is especially
important when maximizing burst and vertical compression strength
values.
[0013] Still other embodiments of the invention employ a corner
stress relief feature at the intersection of a flap joint and a
panel joint, preferably on the outermost panels and flaps. Because
this intersection would otherwise undergo bidirectional
manipulation, select removal of material from this intersection
permits a greater degree of articulation and delocalizes stresses
that would otherwise occur at a single, small location.
[0014] And yet other embodiments of the invention provide for the
slit separating two flaps to be off set from a score to facilitate
bending of two adjacent panels. The offset, which preferably occurs
with respect to the outer panels and flaps, is preferably
approximately equal to the thickness dimension of the material used
to construct the container. When implemented, each flap will have a
width dimension that is different (longer or shorter) than the
width dimension of the panel width from which it extends. When the
container is assembled into its final configuration, the wider
outer flaps will extend to the outer edge of the container, and the
inner flaps will fully extend over the intermediate and inner
layer, thereby providing additional stacking strength and making
full use of, and contact with, the outer panel(s) of the container.
Those persons skilled in the art will appreciate that this
configuration is more easily achieved when used in conjunction with
the previously described stress relief feature.
[0015] While practice of the invention can be made in a continuous
process environment, benefits of the invention can also be realized
in a batch process, whereby conventional container blanks are used.
Because the continuous process methods do create discrete
containers, at some point during practice of the method a "blank"
will be established and the resultant container formed there from.
Therefore, the term "blank" is used broadly herein to include both
conventional container blanks as well as the discrete sections of
material created in the continuous process environments. Unless
otherwise specified, the term "blank" or its plural comprises both
forms.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of a first embodiment of the
invention shown in a generally assembled state;
[0017] FIG. 2 is a detailed perspective view of a portion of the
double liner corrugated material used in the construction of the
first embodiment;
[0018] FIG. 3 is a plan view of the first embodiment with the upper
flaps shown in phantom to better illustrate the layering of the
corrugated material;
[0019] FIG. 3a is a detailed plan view of a corner of the
embodiment shown in FIG. 3;
[0020] FIG. 4 is a plan view of a "blank" used to form the first
embodiment of the invention;
[0021] FIG. 5 is a detailed plan view of a stress relief feature
and vertical crush resistance geometry feature of the first
embodiment of the invention;
[0022] FIG. 6 is a perspective view of a first step in forming a
multi-walled container using the "blank" of FIG. 4 where the middle
flaps are folded into close proximity to form a middle sidewall of
corrugated material;
[0023] FIG. 7 is a perspective view of a second step in forming a
multi-walled container using the "blank" of FIG. 4;
[0024] FIG. 8 is a perspective view of a third step in forming a
multi-walled container using the "blank" of FIG. 4 where the
combined inner panel and middle flaps are involuted;
[0025] FIG. 9 is a perspective view of a fourth step in forming a
multi-walled container using the "blank" of FIG. 4 where an inner
glue tab is attached to an inner panel, thereby forming a basic
container shape;
[0026] FIG. 10 is a perspective view of a fifth step in forming a
multi-walled container using the "blank" of FIG. 4 where the outer
panels are wrapped around the basic container of FIG. 9;
[0027] FIG. 11 is a perspective view of a sixth step in forming a
multi-walled container using the "blank" of FIG. 4 where an outer
glue tab is attached to an outer panel, completing formation of the
first embodiment; and
[0028] FIG. 12 is a detailed perspective view of a stress relief
feature shown in FIG. 5 when the "blank" of FIG. 4 is converted
into the container of FIG. 11, and the upper and lower flaps are
folded inward.
DESCRIPTION OF THE INVENTION EMBODIMENTS
[0029] The following discussion is presented to enable a person
skilled in the art to make and use the invention. Various
modifications to the embodiments shown herein will be readily
apparent to those skilled in the art, and the generic principles
herein may be applied to other embodiments and applications without
departing from the spirit and scope of the present invention, as
defined by the appended claims. Thus, the present invention is not
intended to be limited to the embodiments shown, but is to be
accorded the widest scope consistent with the principles and
features disclosed herein.
[0030] Turning then to the several Figures, where like numerals
indicate like parts, and more particularly to FIGS. 1-4, an
embodiment of the invention employing many of the features and
elements of the invention will now be described. Container 20
comprises "blank" 22, which is preferably constructed from a double
lined, single wall corrugated material such as 5/16'' L flute
corrugated board shown in FIG. 2. In the illustrated embodiment,
container 20 has dimensions of about 42'' H.times.48'' W.times.40''
D, while blank 22 has maximum dimensions of about 355''
L.times.83'' W. In the illustrated embodiment, container 20 has
triple sidewalls and single overlapping bottom and top flaps.
[0031] In order to form container 20, it is necessary to create
container blank 22 either prior to assembly or in line with the
assembly process. As is best shown in FIG. 4, container blank 22 is
a unitary piece of corrugated material, such as of the type shown
in FIG. 2, with the direction of corrugation running laterally.
From a single sheet, selected scores, cuts and perforations are
carried out, such as by rotary die cutter(s) or other means
appreciated by the skilled practitioner. Each container blank 22
then comprises inner panel 40, opposing middle flaps 50, outer
panel 60, and a plurality of end flaps 70. Container blank 22
preferably further comprises inner glue tab 30 and outer glue tab
80. For convention purposes, the observed sides of all panels and
flaps are as indicated, with the reverse side being numbered
similarly, but within the one hundred series. Thus, the reverse
side of inner panel 40, for example, is labeled as inner panel
140.
[0032] Inner panel 40 comprises inner panel portions 42, 44, 46 and
48, separated by scores 34a, 34b, and 34c. Inner glue tab 30
extends longitudinally from inner panel portion 42, and is
separated there from by score 32. Extending laterally outwardly
from inner panel portions 42, 44, 46 and 48, and defined in part by
slit-scores 43a/b, 45a/b, 47a/b and 49a/b, and by scores 34a, 34b,
and 34c (as well as edges 51a/b, and slits 73a and 73b), are
respective middle flaps 50, identified in this embodiment as middle
flap portions 52a/b, 54a/b, 56a/b and 58a/b. While those persons
skilled in the art will appreciate that other forms of scoring
(e.g., point-to-flat) as well as slitting or even slotting can be
used instead of those portions of scores 34a, 34b, and 34c that
partially define each middle flap portion pair 52a/b, 54a/b, 56a/b
and 58a/b, additional strength and handling advantages can be
realized by retaining robust physical linkage between adjacent
middle flap portions, as will be described below. Moreover, each
"flap" 50 may comprise physically discrete flap portions (as are
end flaps 70, discussed below), visually discrete flap portions as
illustrated herein, or may be wholly contiguous (no scoring).
Because it is only necessary to form a wall or layer within
container 20, there is no intrinsic need to form physically
discrete flap portions as long as those portions of blank 22 that
fold to meet the opposing portions of blank 22 can result in the
creation of such wall or layer.
[0033] The distal ends of each middle flap portion are
characterized by chevron edges 53a/b, 55a/b, 57a/b and 59a/b, again
as shown best in FIG. 4. The inclusion of these chevron edges, or
any non-linear edge, will beneficially delocalize burst and column
compression stresses that may occur after assembly and use of
container 20, as will be described in later detail below. Thus,
curvilinear edges or rectilinear edges such as repeating square or
saw-tooth geometries are considered desirable. However, it is not
necessary to the operation or constitution of the embodiments of
the invention to incorporate such non-linear edges, and a linear
edge will provide benefits as herein described.
[0034] While inner panel 40 and middle flaps 50 both form sidewalls
of the container, only outer panel 60 forms sidewalls; end flaps 70
constitute single bottom and top sides of container 20 as shown in
FIG. 11. Outer panel 60 comprises outer panel portions 62, 64, 66
and 68, separated by scores 38a, 38b, and 38c; outer panel portion
62 is separated from inner panel portion 48 by score 36. Outer glue
tab 80 extends longitudinally from inner panel portion 42, and is
separated there from by score 82. Extending laterally outwardly
from outer panel portions 62, 64, 66 and 68, and defined in part by
point-to-point scores 63a/b, 65a/b, 67a/b and 69a/b, and by slits
73a/b, 75a/b, 77a/b and 79a/b (as well as edges 71a/b), are
respective end flaps 72a/b, 74a/b, 76a/b and 78a/b, as shown. Those
persons skilled in the art will appreciate that slots can be used
instead of slits 73a/b, 75a/b, 77a/b and 79a/b, although as will be
described in detail below, advantages can be achieved through the
use of slits with respect to stress relief feature 90.
[0035] It should be noted that the lateral width (or as assembled,
the height) of outer panel 60 is greater than that of inner panel
40. This increased dimension addresses the consequence of the
increased external dimensions as container 20 is formed (discussed
and shown below). Similarly, the longitudinal length (or as
assembled, the width and depth) of outer panel 60 is greater than
that of inner panel 40. Those persons skilled in the art will
appreciate that the increases are related to the number of walls
used to form the container, as well as the thickness of the
material comprising the walls.
[0036] FIG. 5 illustrates two features of the subject embodiment,
namely, stress relief feature 90, which is characterized as a hole
of approximately 0.375'' diameter, and flap offsets. It is well
known in the art that flaps on containers frequently tear at the
exposed edge interface between the flap and a sidewall panel. This
is due in part to the effect of the three edge corner present on
the underside of the flap: the three edge corner causes a crushing
of the flap at its edge, thereby compromising the structural
integrity of the flap and related structure. This consequence, in
conjunction with the inherent weakness of the material at this
position, often invites mechanical failure during repeated use or
operation of the flap. By establishing a hole, and preferably, but
not necessarily, a round or circular hole, the three edge corner
will not directly impinge upon the underside of the flap. Depending
upon the number of walls for any particular container, additional
stress relief features may be employed with respect to interior or
middle walls, as the case may be.
[0037] Also shown in FIG. 5 is an offset with respect to the slits
separating adjacent flaps 70 and the point-to-point scores
separating adjacent outer panel 60. Unlike the continuous scores
34a, 34b, and 34c of inner panel 40 (which create inner panel
portions 42, 44 and 46) and middle flaps 50 (which partially define
each middle flap portion pair 52a/b, 54a/b, 56a/b and 58a/b), and
which result in equally dimensioned walls, flaps 70 have differing
dimensions when compared to their companion panels. Because flaps
70 form end walls as opposed to sidewalls, there is no need for
such symmetry. Moreover, and as best shown in FIG. 3, because flaps
70 will be positioned orthogonal to the sidewalls comprising inner
panel 40, middle flaps 50 and outer panel 60, the dimensionally
larger flaps will extend over the entire exposed edges of outer
panels 60 when container 20 is in the assembled configuration. The
consequence of this arrangement is that all exposed vertical
sidewall edges can be "covered" by the end flaps, and that vertical
compression loads can be evenly distributed to the end flaps. See
also FIG. 11.
[0038] Turning then to FIGS. 6-12, the assemblage of container 20
is shown in detail. Completed blank 20, as described in FIG. 4,
emerges from a converting machine and enters a folding and gluing
section of the process. Using folding rails or paddles, co-joined
middle flap portions 52a, 54a, 56a and 58a, and 52b, 54b, 56b and
58b are down folded 180.degree., along slit-scores 43a, 45a, 47a
and 49a, and 43b, 45b, 47b and 49b to join in surface-to-surface
area contact with respective inner panel portions 42, 44, 46 and 48
as shown in FIG. 6. Prior to initiation or completion of the
180.degree. folding process, adhesive is applied to the contact
area surfaces using an extrusion or roller coating system. On
completion of the 180.degree. folding and gluing process, chevron
edges 53a/b, 55a/b, 57a/b and 59a/b meet about mid way of inner
panel portions 42, 44, 46 and 48. The `serrated` and intermeshing
nature of chevron edges 53a/b, 55a/b, 57a/b and 59a/b distribute
the joined line over a greater area than a pure straight cut and
now appear on the underside of the flat box blank.
[0039] Using a gripper mechanism, inner glue tab 30 is up-folded
90.degree. at score 32, inner panel portion 42 (with middle flap
pair 52a/b) is up-folded 90.degree. at score 34a, inner panel
portion 44 (with middle flap pair 54a/b) is up-folded 90.degree. at
score 34b, inner panel portion 46 (with middle flap pair 56a/b) is
up-folded 90.degree. at score 34c, and inner panel portion 48 (with
middle flap pair 58a/b) is up-folded 90.degree. at score 36, as is
shown in FIG. 8. All 90.degree. folds are `up` and therefore away
from the surface joint of chevron edges 53a/b, 55a/b, 57a/b and
59a/b. The resulting structure is best shown in FIG. 9.
[0040] Adhesive is applied to the intended mating surfaces of outer
panel portions 62, 64, 66 and 68, and the up-folding process
continues with outer panel portion 62 folding 90.degree. at score
38a, outer panel portion 64 folding 90.degree. at score 38b, outer
panel portion 66 folding 90.degree. at score 38c, and outer panel
portion 68 folding 90.degree. at score 82, with outer glue tab 80
completing the folding and gluing process. This process is best
shown in FIG. 10. As those persons skilled in the art will
appreciate, the up-folding process may be accomplished by use of a
forming mandrel or other aid.
[0041] The collective effect of the multiple-90 degree folding and
gluing process takes the original flat, rigid corrugated board
blank, comprising inner glue tab 30, inner panel 40, middle flaps
50, which form an intermediate panel, and outer panel 60, as well
as outer glue tab 80, all as shown in FIG. 4, and forms a
multi-walled, four sided, finished container/bin, with single wall
flaps top and bottom, that has no `manufacturers-joint`, as best
shown in FIG. 11. Because the relaxed state (manufacturer's resting
position) is the use state of the container, there is a natural
tendency of the container to return to its resting position if
collapsed. In single wall construction containers, this advantage
is of little consequence; however, in multi-walled containers the
force necessary to form the desired container shape can be
significant. Therefore, there is a significant labor advantage to
constructing a container to have a resting position the same as its
use position regarding multi-walled containers. Furthermore, by
incorporating panel scores at each edge, knockdown of the container
is made easier (the score lines further localize any resulting
crushing, thereby preserving the structural integrity of the
container at locations adjacent to the edges).
* * * * *