U.S. patent application number 11/739967 was filed with the patent office on 2008-10-30 for folded and glued display container having integral shelf elements.
Invention is credited to Phil B. Sheffer.
Application Number | 20080265726 11/739967 |
Document ID | / |
Family ID | 39886092 |
Filed Date | 2008-10-30 |
United States Patent
Application |
20080265726 |
Kind Code |
A1 |
Sheffer; Phil B. |
October 30, 2008 |
FOLDED AND GLUED DISPLAY CONTAINER HAVING INTEGRAL SHELF
ELEMENTS
Abstract
A folded and glued container that quickly erects into a
container having multiple shelf structures is formed of a plurality
of panels defining a back panel, a front panel opposite the back
panel, two longitudinally opposite endwall panels joined to the
back panel and the front panel. The container further includes two
laterally opposite sidewalls joined to the front panel. The back
panel is integrally joined to one of the two endwall panels and
attached to the other of the two endwall panels. Inwardly folded
bellows panels extend between and integrally joined to the other of
the two endwall panels and the sidewalls. When the sidewalls are
folded upwardly from a knock-down-flat configuration of the
container, the sidewalls erect the two endwall panels and the back
panel into a rectilinear box in which multiple shelf panels cut out
from the front panel are erected in unison into their final
configuration.
Inventors: |
Sheffer; Phil B.; (Newtown,
PA) |
Correspondence
Address: |
DUANE MORRIS LLP - Philadelphia;IP DEPARTMENT
30 SOUTH 17TH STREET
PHILADELPHIA
PA
19103-4196
US
|
Family ID: |
39886092 |
Appl. No.: |
11/739967 |
Filed: |
April 25, 2007 |
Current U.S.
Class: |
312/259 ;
493/56 |
Current CPC
Class: |
A47B 47/06 20130101;
A47F 5/116 20130101 |
Class at
Publication: |
312/259 ;
493/56 |
International
Class: |
A47B 47/06 20060101
A47B047/06 |
Claims
1. An erectable container comprising: a plurality of panels
defining a back panel, a front panel opposite the back panel, two
longitudinally opposite endwall panels joined to the back panel and
the front panel, two laterally opposite sidewalls joined to the
front panel, the plurality of panels defining an internal space of
the container, the back panel being integrally joined to one of the
two endwall panels and attached to the other of the two endwall
panels; and at least one shelf panel cut out from the front panel
for forming a shelf, each said at least one shelf panel being
integrally joined to the front panel along one side and attached to
the back panel along an opposite side, wherein when the rectilinear
box is being erected from a knocked-down-flat configuration, the
shelf panel is erected in unison with erection into a final
configuration.
2. The container of claim 1, further comprising inwardly folded
bellows panels extending between and integrally joined between the
other of the two endwall panels and the sidewalls, such that
folding the sidewalls upwardly from the knocked-down-flat
configuration, draws the two endwall panels and the back panel into
a rectilinear box shape.
3. The container of claim 1, wherein the plurality of panels are
cut from a single sheet of stock material and integrally
joined.
4. The container of claim 1, wherein each of the shelf panels
comprises one or more tabs for attaching to the back panel and has
a depth defined as the distance between a first fold line joining
the shelf panel to the front panel, and a second fold line joining
the one or more tabs to the shelf panel, the depth being
substantially equal to the distance between the front panel and the
back panel.
5. A container comprising: a plurality of panels of an integral
sheet of stock material, wherein each of at least four of the
panels defining a front, back and two endwalls each abut two
adjacent ones of the panels along fold lines with at least
attachment strip joining ends of the integral sheet such that the
ate least four of the panels define a closed form that is can be
knocked down flat as a parallelogram in cross section and erected
from the parallelogram to a rectangular shape; at least one shelf
partially cut out from the front adjacent to a fold line between
the shelf and the front, wherein a strip of the shelf spaced from
the fold line is affixed to the back along a fold line, and wherein
the fold lines between the shelf and the front, between the shelf
and the back and at abutments of said panels are parallel, such
that the shelf remains parallel to the endwalls, wherein erection
of the closed form from the parallelogram to the rectangular shape
brings the shelf and the endwalls perpendicular to the panels
defining the front and back.
6. The container of claim 5, further comprising two side walls,
each joined along a fold line on a lateral side of the container to
at least one of said panels defining the front and back, wherein
each of said side walls is affixable to a respective other of said
panels defining the front and the back at an edge opposite from the
fold, thereby fixing the container in the rectangular shape when
erected.
7. The container of claim 6, wherein the edge opposite from the
fold comprises a tab and slot structure complementary with the
respective other of said panels defining the front and the
back.
8. The container of claim 6, further comprising a bellows fold
between at least one of the side walls and at least one of the
endwalls, wherein the bellows fold comprises a triangular portion
configured upon hinging of said at least one of the side walls to
hinge said one of the endwalls relative to one of the front and the
back.
9. A container production method, comprising: cutting from an
integral flat blank of sheet stock material and providing
preferential folds defining a plurality of panels, wherein each of
at least four said panels define, in order, a front, a first
endwall, a back and a second endwall, abutting one another along
fold lines such that the at least four of the panels define a
closed form that is knocked down as a flat parallelogram in cross
section; further cutting from the integral flat blank a plurality
of shelf panels, wherein each of said shelf panels is separated
from the front at a fold line and has an attachment edge opposite
from the fold line, wherein the attachment edge, the fold lines of
the shelf panels and the fold lines of the front, endwalls and back
are parallel to one another; attaching said at least four of the
panels in the closed form by affixing at least one attachment strip
at least along one line crossing the closed form, and attaching the
attachment edge of each of the shelf panels to the back; and,
erecting the closed form from the flat parallelogram to a
rectangular shape, thereby bringing the shelves and the endwalls
perpendicular to the front and back.
10. The method of claim 9, further comprising providing side walls
extending laterally from the closed form along at least one of the
front and the back, and fixing the rectangular shape by attaching
the sidewalls between the front and the back after said erecting
step.
11. The method of claim 9, further comprising providing side walls
extending laterally along a fold line from the closed form along at
least one of the front and the back, and forming a bellows fold
between the side walls and the endwalls such that hinging the side
walls from parallel to perpendicular to the front and the back,
hinges the endwalls relative to the front and the back orthogonally
to the side walls.
12. The method of claim 11, further comprising hinging said
sidewalls to erect the closed form and affixing the closed form in
a rectilinear shape by attaching the sidewalls between the front
and back at a point spaced from the fold line.
Description
FIELD OF THE INVENTION
[0001] The invention relates to the structure and production of
corrugated paperboard and similar containers using fold-and-glue
production line techniques. The containers are produced from
strategically placed folds and adhered panel surfaces of an
integral die-cut blank. During container erection, panels coupled
by fold and glue connections are hinged on axes at folds, for
opening the container from a knocked-down flat state to an open
state having shelves.
BACKGROUND OF THE INVENTION
[0002] Corrugated craft and paperboard containers are made from one
or more pieces of flat stock that are typically die cut into shapes
that define various panels. The panels define the container top and
bottom panels, side walls, front and back, and any internal
reinforcements, partitions and other structural members that are
needed to form the particular container structure.
[0003] Preferably, the container consists essentially of the
minimum number of discrete pieces that are necessary to provide the
walls and other structural members that make up the container.
Ideally, a container might consist of a single integral flat sheet
wherein all the structural members are panel areas defined between
spaced folds in the sheet or adjacent to edges at which tabs
mechanically or adhesively join the respective panels to other
panels. Preferably, a container is erected or assembled with a
minimum number of manual or mechanical motions.
[0004] Typically, containers comprise one or more sheets where
structural panels exist between spaced folds. An overlapping strip
or panel is typically glued, taped, or affixed by a fastener to an
adjacent panel. Alternatively, a tab might be inserted into a slot
or otherwise captured to affix panels in a shape defining the
container. The panels form a closed perimeter around a space within
the container, and may include partitions, reinforcements, doubled
thicknesses and the like at different places. The various panels
typically include side walls, a top and/or bottom, etc., at least
partly bounding a volume as a full or partial enclosure when in
place.
[0005] Advantageously, empty containers are supplied in a collapsed
or flattened parallelogram state (known as knocked-down-flat or
"KDF"), for efficient storage, handling and shipping. Before
packing with contents, the containers are opened out into a hollow
form wherein the panels are folded to reside in orthogonal planes.
Parallel panels are generally spaced from one another.
[0006] Such containers can be more or less complicated, and the
challenge to design a container with only one or a few integral
sheet pieces is increasingly greater for structures that require
more structural members. For complicated container structures,
multiple integral pieces are often needed and/or a large number of
assembly operations. A very simple container known, for example,
might consist of four integrally connected side walls, each of
which has a top and bottom flap. More complicated containers may
have doubled-over panels, reinforcing folded parts, inter-engaging
tabs and slots, volume partitions and other features.
[0007] Paperboard and corrugated containers advantageously are
produced by fold-and-glue production line techniques. A blank is
oriented and cut into a pattern that includes adjacent panel areas.
Preferential fold lines are formed between panels by perforations,
slits or crimp lines. The integral die cut sheets are fed through a
fold-and-glue production line, such as those available from Bobst
Group, Inc. of Roseland, N.J. As the blanks are advanced, adhesive
is applied to limited areas where surfaces are to be adhered.
Guides and rollers hold and fold-over certain panels in a designed
order so that the panels are adhered where necessary. The
containers that emerge are in a knocked down flat (KDF) state for
shipping or storage, and are ready to be erected into their final
configuration prior to being loaded with contents. Erection
comprises applying pressure manually or using a machine that causes
parallel panels in KDF state to become displaced, and panels
abutting one another at folds to hinge around the axis of the fold,
thereby articulating the panels into a final shape where typically
certain panels are spaced and parallel and other panels are
adjacent and perpendicular.
[0008] A simple regular slotted carton (RSC) version of such a
container might comprise a blank of four rectangular panels
serially abutting one another at folds, wherein the panels are to
be front/rear and side walls of the container, and oppositely
protruding flaps are to overlap to form the top and bottom. The
fold-and-glue line affixes the free ends of the first and last
serially abutting panels at a glued strip, while folding the blank
in half. Pressing inwardly from diagonally opposite corners opens
the container from a flattened parallelogram into a rectilinear
box, whereupon folding the flaps inwardly by 90.degree. from their
adjoined panels completes the erection. In relatively more
complicated full or partial containers, various panels may need to
be folded in appropriate directions in appropriate order. Various
tabs may need to be inserted into respective slots and so
forth.
[0009] Containers as described can be used for displaying items or
goods for the consumers at the point-of-sale location. Minimizing
the effort and complication required to erect and set up the
containers is an important factor for the viability and success of
the particular container design. Thus, the number of parts required
to erect or assemble the containers from their KDF configuration is
an important element in the acceptability of the container
design.
[0010] Generally, a container design is most efficient if most or
all of its parts are integral parts and extensions a single flat
blank, i.e., integral parts of the same sheet of material. A
container that comprises multiple discrete parts may still be
relatively efficient if the parts are adhered or otherwise captured
in one anther. However, separate parts such as separate lids, loose
partitions, shelves, reinforcing inserts and the like require
attention to inventory, manual assembly steps and other
complications during the production, erection and set up of the
container. Such separate parts are not desirable. However it is
difficult to design a complex container in one piece. It is
particularly difficult to do so if the container has structural
complications such as tiered shelves or if the container is
expected to have movable functional elements such as self erecting
parts.
[0011] In a container that has multiple discrete pieces, it is
possible to exploit relative movement between the pieces. In
commonly owned U.S. patent application Ser. No. 11/623,395, filed
Jan. 16, 2007, a container is disclosed wherein tiered shelves are
provided, cut partly from a front panel along fold lines, and
attached at the back to a discrete separate panel that is carried
within the container. The separate panel is movable in a direction
perpendicular to the longitudinal extension of the shelf fold, to
cause the tiered shelves to erect into a horizontal orientation.
The container can be produced with a fold and glue production line,
but two distinct integral parts must be provided and handled for
alignment, gluing, etc. This general sort of tiered shelf
container, known in the trade as a "wing," is useful as a
merchandise display. It would be advantageous to provide a wing
container that has similar functional advantages but does not
require multiple discrete parts.
SUMMARY OF THE INVENTION
[0012] It is an object of this disclosure to provide ways to make
and structure a complex container in a tiered shelf arrangement
that is self erecting, wherein the shelf and shelf erecting
elements preferably are parts of a single integral die cut piece of
paperboard, corrugated paper or the like. The product is produced
using a fold and glue production technique where the container
exterior walls and the shelves are glued in place during
manufacturing the shelves are erected in the same movement by which
the container is erected.
[0013] It is another object to improve on known tiered shelf wing
container structures by exploiting the linear displacement or
translation that occurs between opposite sides of a parallelogram
when the parallelogram is erected from a flat to rectilinear shape.
For this purpose, a fold and glue container structure is provided
wherein plural panels of an integral sheet abut one another along
parallel fold lines, and define (in order) a first endwall, the
front, a second endwall and the back. One or preferably several
shelves are affixed between the front and the back at folds that
are likewise parallel to the fold lines of the integral sheet. In
this way, opening out or erecting the container from a knocked down
flat state to a rectilinear box shape moves the shelves into
position. Moreover, by providing bellows or gusset folds at certain
corners joined to lateral sidewalls, simply hinging the lateral
sidewalls perpendicular to the plane of the front and/or back
erects the container and the shelves in one motion.
[0014] The container has a rectilinear shape along its outer
surfaces when erected (parallel opposite top and bottom, front and
back and opposite lateral sides) and erects from a flattened
parallelogram in section (viewed from either lateral side) into a
rectangle. The axes of the parallelogram on which the outer panels
hinge to erect the container (namely the four folds where the front
and back panels joint the top and bottom panels) are parallel to
axes at which each of the shelves folds relative to the front and
rear panels. The shelves are attached to the front and rear at
folds and glued fold flaps. Whereas the hinging axes are all
parallel, erecting the parallelogram of the outer panels also
erects the smaller parallelograms defined by the shelves and the
portions of the front and rear panels between the shelves.
[0015] The container does not have any particular fixed or required
orientation. Nevertheless, in order to distinguish the panels and
parts relative to one another, in this description the "front" is
used to refer to the panel where openings are provided between the
shelves. The "rear" is the panel behind the shelves and may be a
solid wall. The lateral sidewalls extend between the front and rear
on the opposite sides, generally at the ends of the shelves. The
top and bottom are referred to as endwalls, because the container
might be placed with either of its ends facing up, and still has a
substantially similar arrangement of vertically tiered shelves that
are open to the front and hinged to the back.
[0016] Therefore, a folded and glued container disclosed herein
comprises a plurality of panels defining a back panel, a front
panel opposite the back panel, and two longitudinally opposite
endwall panels (which can be deemed the top and bottom) joined to
the back panel and the front panel. The plurality of panels further
comprises two laterally opposite sidewalls joined to one of the
front and back panels, and removably coupled to the other of the
front and back panels. When the container is erected, the plurality
of panels define an internal space of the container.
[0017] The one of the front and back panel preferably is integrally
joined at a fold line with to a first one of the two endwall panels
and the other of the front and back panels is attached to the
second of the two endwall panels by an glued strip, also adjacent
to a fold line. In this way, the front, back and endwalls form a
parallelogram in cross section. The parallelogram is flat when the
container is in a KDF state and is opened into a rectangle when the
container is erected. Diagonally inwardly folded bellows panels can
be provided, extending between and integrally joined to one endwall
panel and its adjacent opposite sidewalls. Thus when the sidewalls
are hinged or pivoted over into a position covering the lateral
sides of the container, the bellows panels pull said endwall into
an orientation perpendicular to the front and back panels. The
container is thereby erected from the KDF state to the erected
rectangular state. In the erected state, the free edges of the
sidewalls can be captured by tab and slot couplings to one of the
front and back panels.
[0018] Preferably, all the foregoing panels are cut out from a
single flat blank and are processed by fold-and-glue steps, in
manner a described in detail below. However it would also be
possible to provide a structure that is integral before erection by
virtue of the fact that the respective non-integral panels or parts
thereof have been fixed permanently to one another by gluing them
into one affixed body. In any case, the result is that when the
sidewalls are hinged perpendicular to their knocked-down-flat KDF
configuration to cover the sidewalls of the container, the
sidewalls erect the two endwall panels and the back panel into a
rectilinear box.
[0019] Spaced between the endwall panels, at least one and
preferably plural shelf panels are provided. Each shelf panel is
cut out from the front panel except along a fold line parallel to
the top or bottom endwall. At the fold line, the shelf meets the
front panel at a right angle in the erected state. The edge of the
shelf opposite from the fold line has a glue strip, also making a
right angle in the erected state, and the glue strip is affixed to
the back panel at the same height as the fold line at the front
panel. Each of the shelf panels and the endwalls remain parallel in
parallelogram cross section. When the container is erected, the
flattened parallelogram defined by the front, back and endwall in
the KDF container, open into a rectangular cross, and likewise draw
the shelves into a position perpendicular to the front and back
panels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] A number of additional objects and aspects are apparent from
the appended description and the associated illustrations of
preferred embodiments, wherein:
[0021] FIG. 1 is a perspective view of an erected container
according to an exemplary embodiment;
[0022] FIG. 2 is a plan view of the die-cut blank for the container
of FIG. 1;
[0023] FIG. 3 is a plan view of an interim configuration of the
die-cut blank of FIG. 2 that is being folded and glued into a KDF
container blank;
[0024] FIG. 4 is a plan view of a KDF container blank made from the
die-cut blank of FIG. 2 by a fold and glue machine;
[0025] FIG. 5 is a perspective view of the KDF container blank of
FIG. 4; and
[0026] FIGS. 6-9 are sequential perspective views of the KDF
container blank of FIG. 5 in the process of being erected in to the
container of FIG. 1.
[0027] All drawings are schematic and not to scale. Like structures
are shown in like reference numbers.
DETAILED DESCRIPTION
[0028] As will be appreciated, terms such as "horizontal,"
"vertical," "left," "right," "up," "down," "top," "bottom," "front"
and "back," (etc.), used as nouns, adjectives or adverbs (e.g.
"horizontally," "rightward," "upwardly," "downwardly," etc.) that
appear in this description refer to the orientation of the
structure of the invention as the container of the invention
happens to be oriented in the particular drawing figure under
consideration, with that figure facing the reader. Such terms are
not intended to require or limit the invention to a particular
orientation. Similarly, the terms "longitudinal" and "lateral"
generally refer to the orientation of surfaces or other structures
relative to an axis of elongation or axis of rotation, as
appropriate.
[0029] The terms "connected" and "interconnected", when used to
describe the relationship between two or more structures, denote
that the structures are secured or attached either directly or
indirectly through intervening structures and include movable
connections such as pivoting connections. The terms "integral",
"integrally connected" or "integrally joined" when used to describe
the relationship between two or more structures generally means
that the structures are comprised of a single piece of material.
Often, however, two adhered or otherwise permanently affixed
elements function in the same way as an integral single piece. The
term "operatively" means that the foregoing direct or indirect
connections between such structures allow the structures to operate
as described and intended by virtue of such connection.
[0030] Lines representing fold lines are shown in the drawings by
broken and solid lines that represent lines along which the
material can be weakened or caused preferentially to fold by any of
various means. For example, corrugated or other material can be
compressed along a thin line defining a fold, or can be cut part
way through along the line, or cut all or part way through the line
at spaced intervals. Each of these and similar techniques form
lines along which the material is folded or made readily foldable,
in the knocked-down flat ("KDF") container blank and/or in the
erected container.
[0031] In the drawings, portions of joints in which glued surfaces
are exposed to view and discussed in this description are sometimes
shown in the relevant figures by "XXX" patterns, representing an
area to which adhesive has been or will be applied. Areas where the
glue on a rear face of a respective panel is relevant are at times
shown in broken line "XXX" patterns, indicating an adhering surface
on a side opposite from the side shown (i.e., the backside).
[0032] Referring to FIG. 1, a folded and glued container 100
according to an embodiment is shown in an erected configuration.
The container 100 is a generally rectilinear box container
comprised of six major panels defined by a back panel 10,
longitudinally opposite endwalls 20a, 20b, a front panel 40
opposite from the back panel 10 and two laterally opposite
sidewalls 30a, 30b.
[0033] The front panel 40 comprises a plurality of front face
panels 44a, 44b, 44c, and 44d, which are spaced by gaps
corresponding to locations at which the shelf panels 60 are folded
90 degrees relative to the front panel 40, and from the front to
the back to define useful areas within the volume of the container
for supporting items (not shown) to be displayed on the
shelves.
[0034] The front face panels 44a-44d are portions that are cut
along one line from a continuous length for the front panel in the
die-cut blank 100a, and fold relative the plane of the front panel
along a line spaced from the fold. This aspect is shown in FIG. 2.
The front face panels 44a-44d remain in the plane of the front
panel, attached by a fold to one edge of the respective shelf panel
60. The shelf panels are separated by die-cutting from the integral
sheet of the front panel 40 at the other edge.
[0035] The major panels 10, 20a, 20b, 30a, 30b, and 40
substantially define the internal space of the container, knocked
down flat when initially produced, and opened out when the
container is erected. As the container is erected from its KDF
state, the shelf panels 60 likewise hinge, remaining parallel to
the endwalls, to form shelves.
[0036] In the configuration and/or orientation illustrated in FIG.
1, the front face panels 44a-44d extend upwardly perpendicular to
the horizontal surface of their associated shelf panels 60. In this
embodiment, the fold joining the shelf to the associated front face
panel is at the lower edge of the front face panel. The face panels
44a-44d function as a front fence edge for each of the shelves and
prevent items displayed on the shelves from sliding off. It is also
possible to put the fold at the upper edge of the front face panel,
which leaves the upper surface of the shelf unobstructed at the
front.
[0037] FIG. 2 is a plan view of a die-cut blank 100a for the
container 100, according to a preferred embodiment wherein the
container is cut from a single integral flat blank sheet of stock
material. As discussed above, it is also possible to provide a
blank that comprises affixed integral portions of or two or more
smaller blanks.
[0038] The die-cut blank 100a can be cut, for example, from a sheet
of corrugated craft board, paperboard or other suitable sheet
material. A number of thicknesses can be die cut in a single step.
Preferably, the die-cut blank 100a is cut out individually so that
fold lines in the die-cut blank can be appropriately scored,
creased, compressed or perforated at the same time that the
perimeter of the die-cut blank is parted away from the blank sheet.
All fold lines in the die-cut blank 100a are appropriately scored,
creased, compressed or perforated to allow the two adjacent panels
that are joined along a particular fold line can be preferentially
folded in a desired direction.
[0039] The shelf panels 60 (advantageously two or more shelf panels
are provided) are cut out of the front panel and form shelves. In
this illustrated example, three shelf panels 60 are die-cut formed
from the front panel 40. Each of the shelf panels 60 is integrally
joined to the front face panels 44a-44d along a fold line 6f while
cut or detached from the front face panels 44a-44d along the
die-cut line 64. Each of the shelf panels 60 is provided with one
or more glue-tab portions 62 for attaching to the back panel 10
during the interim assembly into the KDF container blank. In the
illustrated example, the glue-tabs 62 are configured as a single
tab for each of the shelf panels 60 extending for the lateral
length of the shelf. However, the glue-tabs 62 can be configured as
more than one tab per shelf panel 60. Each of the shelf panels 60
has a depth defined as the distance between the fold line 6f
joining the shelf panel to the front panel and the second fold line
8f joining the one or more tabs to the shelf panel. This depth of
the shelf panel is substantially equal to the distance between the
front panel and the back panel when the container 100 is
erected.
[0040] Optionally, a portion of the sidewalls 30a, 30b adjacent to
each of the shelf panels 60 is removed during the die-cut process
leaving behind openings H. As shown in the fully assembled view of
FIG. 1, these openings H form decorative openings along the
sidewalls 30a, 30b and may be cut into any variety of desired
shapes.
[0041] The various panels of the container 100 described above can
be seen in the die-cut blank 100a. The die-cut blank 100a comprises
the back panel 10 that is integrally joined to a first endwall 20b
along a fold line 1f. The first endwall 20b is joined to the front
panel 40 along a fold line 5f. The front panel 40 is joined to a
second endwall 20a along a fold line 2f. The second endwall 20a has
a glue application region 23 to which glue is applied by the fold
and glue machine and attached to the tab 14 of the back wall 10
during the assembly into a KDF container blank 100b shown in FIG.
4. These fold lines define parallel hinging axes for the parts that
abut said fold lines.
[0042] Bellows panels or gusset fold joints 25 are provided,
extending between the second endwall 20a and the sidewalls 30a, 30b
so as to render the front/back and endwall panels self erecting
when the sidewalls 30a, 30b are hinged to 90 degrees from their
abutting major panel (in this example, the sidewalls abut at a fold
to the front panel). The bellows panels 25 are tab-like structures
extending between two orthogonally oriented panels near a corner of
a rectilinear container that enables automatic or coordinated
erection of the joined panels when one of the two joined panels are
raised. Each of the bellows panels 25 includes a diagonal fold line
7f that divides the bellows into two substantially triangular
portions. One triangular portion of each of the bellows panels 25
is integrally joined to the endwall 20a along a side edge defined
by fold lines 12f. This triangular portion is not glued. The second
triangular portions of the gusset fold joints 25, across the
diagonal fold line 7f, is adhered on a side that is folded under
and bears against the adjacent sidewalls 30a, 30b when the die-cut
blank 100 is glued and folded into the KDF container blank 100b.
Thus, the second triangular portions are noted with "XX" symbols
showing the areas that are glued.
[0043] The die-cut blank 100a is preliminarily assembled by
processing the blank 100a through a fold and glue machine to
accomplish successive steps wherein glue is applied and various
panels are folded over and compressed against other panels where
the glue surface adheres and sets. As the die-cut blank 100a
advances through the fold and glue machine, adhesive is applied by
roller, spray or other techniques to respective parts that need to
adhere. Panels, flaps or strips that need to be folded over are
urged by to advance in a feed direction by drive rollers, and pass
along ramp-like deflectors that turn and fold the necessary parts
around crease lines. Over and under rollers compress the folded
over panels. The container blanks are processed one after another
and stacked, which further compresses the adhered surfaces.
[0044] The fold-and-glue process as described may be carried out by
fold-and-glue machines, such as those available from Bobst Group,
Inc. of Roseland, N.J. Fold-and-glue machines apply adhesive to
pre-selected areas of the die-cut blank and preliminarily fold over
pre-selected panels, and are generally reconfigurable to run
containers of different sizes, different numbers of shelves and
other variations. The end result is an assembled but knocked down
flat KDF container blank 100b, shown in FIG. 4.
[0045] During the process of gluing and folding the die-cut blank
100a to produce the KDF container blank 100b, the glue-tab areas
62, 23 and the glue area portion of the bellows panels 25 are
glued. The back panel 10 is then folded along the fold line 1f and
attached to the glued-tab areas 62 of the shelf panels 60. This
interim stage is illustrated in FIG. 3. The glued-tab areas 62 are
shown in broken X lines under the folded over back panel 10. Next,
the endwall panel 20a is folded along the fold line 2f over onto
the back panel 10 such that the glued-tab 23 on the endwall panel
20a overlaps the tab 14 of the back panel 10 and is glued to the
tab 14. Because the bellows panels 25 on either side of the endwall
panel 20a are integrally joined to the endwall panel 20a, they also
get folded along the fold line 2f along with the endwall panel 20a.
Thus, the glued portions of the bellows panels 25 get attached to
the sidewalls 30a, 30b. The resulting configuration illustrated in
FIG. 4 is the KDF container blank 100b that can be shipped to the
end users who will erect the KDF container blank 100b into the
final container 100. All glued areas in the die-cut blank 100a are
at this point attached to the intended mating parts, and cured,
e.g., by cooling or chemical reaction. All glued areas are on the
back sides of the panels facing the viewer in FIG. 4, which is
shown by "XXX" symbols in broken lines.
[0046] In an alternate embodiment, the shelf panels 60 and the
bellows panels 25 may be attached to their respective mating parts,
the back panel 10 and the sidewalls 30a, 30b by use of fasteners
rather than glue. Suitable fasteners can be, for example, one or
more staples, clips, rivets, etc. In a container of sheet material
comprising thermoplastic or the like, the mating parts can be
welded.
[0047] FIG. 5 shows a perspective view of the KDF container blank
100b ready to be erected into the final container configuration.
The containers are compact when stacked flat and generally
containers 100 would be shipped to the end users in the KDF
container blank 100b configuration and erected by the end user into
the container 100. It is thus desirable that the erection be simple
and sure.
[0048] Referring to FIG. 6, the tuck tabs 12a, 12b on the back
panel 10 are first folded up along the fold lines 3f and then
folded in the opposite direction along the fold lines 4f. Referring
to FIG. 7, next the sidewalls 30a, 30b are folded upward along the
fold lines 11f. As the sidewalls 30a, 30b are folded upward, by
operation of the bellows panels 25 which will fold inwardly along
the fold the fold lines 7f, the endwall panel 20a are pushed up and
raised. Because the back panel 10 is now joined to both endwall
panels 20a, 20b, the back panel 10, endwall panels 20a, 20b and the
front panel 40 first form an interim structure whose longitudinal
cross-section is a parallelogram and then open into a rectilinear
box-like configuration so that the back panel 10 and the endwall
panels 20a, 20b are perpendicular to each other. The parallelogram
interim transient configuration is shown in FIG. 11. At the same
time, because the shelf panels 60 are attached to the interior
surface of the back panel 10, the shelf panels 60 are pulled up by
the back panel 10. The shelf panels 60 fold upward along the fold
lines 6f into the interior space of the container being formed and
raised in parallel formation with the endwall panels 20a, 20b. As
mentioned above, the fold lines 6f are appropriately scored or
creased to preferentially fold in the desired direction allowing
the shelf panels 60 to fold as described. The self-erecting
operation of the bellows panels 25 can be helped along by folding
up the endwall panel 20b along the fold line 5f if necessary. The
depth of the shelf panels 60 is generally preferred to be
substantially equal to the distance between the front panel 40 and
the back panel 10, defined by the width of the two endwall panels
30a, 30b, in the fully erect container 100. This allows the shelf
structures in the container 100 to be in perpendicular orientation
to the back panel 10 and the front panel 40.
[0049] Referring to FIG. 8, the rectilinear box-like configuration
is shown. The endwall panels 20a, 20b are in perpendicular
orientation to the back panel 10 and the front panel 40. Next, the
tabs 26 of the endwall panel 20b are folded inwardly along the fold
lines 10f. Then, the tabs 32a, 32b of the sidewalls 30a, 30b are
folded along the fold lines 11f toward the interior of the
container structure and the sidewalls 30a, 30b are folded into
their final perpendicular orientation as illustrated in FIG. 9.
Finally, the tuck tabs 12a, 12b are tucked into the slots 34a, 34b
that are provided along the fold line 11f of the sidewalls 30a,
30b, completing the erection of the container 100 and fixing the
container in a rectilinear shape. The slots 34a, 34b may be formed
by making appropriate cuts in the fold line 11f during the die-cut
operation from the stock sheet material. Referring back to FIG. 1,
the bottom-most shelf is actually formed by the endwall panel 20b
rather than by one of the shelf panels 60. And one of the shelf
panels 60 is integrally joined to the front face panel 44a and, in
the orientation of the container 100 shown in FIG. 1, does not
function as a shelf at all. However, it should be noted that the
container 100 may be flipped top to bottom from the orientation
shown in FIG. 1 if appropriate.
[0050] The invention having been disclosed in connection with the
foregoing variations and examples, additional variations will now
be apparent to persons skilled in the art. The invention is not
intended to be limited to the variations specifically mentioned,
and accordingly reference should be made to the appended claims
rather than the foregoing discussion of preferred examples, to
assess the scope of the invention in which exclusive rights are
claimed.
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