U.S. patent application number 12/247473 was filed with the patent office on 2010-04-08 for materials for and method for manufacturing container with stacking shoulders and resulting container.
This patent application is currently assigned to YORK CONTAINER COMPANY. Invention is credited to Troy LITTLE.
Application Number | 20100083618 12/247473 |
Document ID | / |
Family ID | 42074673 |
Filed Date | 2010-04-08 |
United States Patent
Application |
20100083618 |
Kind Code |
A1 |
LITTLE; Troy |
April 8, 2010 |
MATERIALS FOR AND METHOD FOR MANUFACTURING CONTAINER WITH STACKING
SHOULDERS AND RESULTING CONTAINER
Abstract
In accordance with the invention, a method of manufacturing
containers such as shipping, display and display ready packaging,
for example, and resulting containers and associated preassemblies
and blanks are provided, which, when utilized, result in
preassemblies that are more easily and quickly assembled into fully
assembled containers.
Inventors: |
LITTLE; Troy; (Thomasville,
PA) |
Correspondence
Address: |
BARNES & THORNBURG LLP
750-17TH STREET NW, SUITE 900
WASHINGTON
DC
20006-4675
US
|
Assignee: |
YORK CONTAINER COMPANY
York
PA
|
Family ID: |
42074673 |
Appl. No.: |
12/247473 |
Filed: |
October 8, 2008 |
Current U.S.
Class: |
53/450 ; 206/784;
229/122.32 |
Current CPC
Class: |
B31B 2110/00 20170801;
B65D 5/4608 20130101; B31B 2120/30 20170801; B31B 2105/00 20170801;
B65D 5/0075 20130101; B31B 2100/00 20170801; B31B 50/804 20170801;
B31B 2120/10 20170801; B65B 43/265 20130101; B31B 50/81
20170801 |
Class at
Publication: |
53/450 ;
229/122.32; 206/784 |
International
Class: |
B65B 9/00 20060101
B65B009/00; B65D 3/22 20060101 B65D003/22; B65D 75/00 20060101
B65D075/00 |
Claims
1. A method of manufacturing a container, the method comprising:
cutting a primary blank including a plurality of side panels and
end panels configured to provide an exterior of the container;
cutting a plurality of supplementary blanks each including a major
panel and a plurality of end panels; and affixing an end panel of
each supplementary blank and a panel of the primary blank such
that, as the container is assembled, an exterior of the container
is formed by the plurality of side panels and end panels of the
primary blank, wherein a plurality of stacking shoulders are formed
by the supplementary blanks at opposing ends of an interior of the
container, and the plurality of stacking shoulders are formed as
part of the final assembly of the primary blank as the exterior of
the container.
2. The method of claim 1, wherein the plurality of side and end
panels of the primary blank include first and second front end
panels, at least one side panel and first and second back end
panels.
3. The method of claim 2, wherein the plurality of supplementary
blank end panels are affixed to either the first front end panel or
the first back end panel.
4. The method of claim 1, wherein the plurality of side and end
panels of the primary blank include a front end panel, major and
minor side panels, a back end panel and minor panels.
5. The method of claim 1, wherein the primary blank is affixed to
the supplementary blank via application of an adhesive.
6. The method of claim 1, wherein each supplementary blank includes
at least one slot configured and located to receive a corresponding
tab included in the primary blank.
7. A container preassembly comprising: a primary blank including a
plurality of side panels and end panels configured to provide an
exterior of the container; a plurality of supplementary blanks each
including a major panel and a plurality of end panels, wherein an
end panel of each supplementary blank and a panel of the primary
blank are affixed such that, as the container is assembled, an
exterior of the container is formed by the plurality of side panels
and end panels of the primary blank, wherein a plurality of
stacking shoulders are formed by the supplementary blanks at
opposing ends of an interior of the container, and the plurality of
stacking shoulders are formed as part of the final assembly of the
primary blank as the exterior of the container.
8. The preassembly of claim 7, wherein the container is a
display.
9. The preassembly of claim 7, wherein the plurality of side and
end panels of the primary blank include a first and second front
end panels, at least one side panel and first and second back end
panels.
10. The preassembly of claim 9, wherein the plurality of
supplementary blank end panels are affixed to either the first
front end panel or the first back end panel.
11. The preassembly of claim 7, wherein the plurality of side and
end panels of the primary blank include a front end panel, major
and minor side panels, a back end panel and minor panels.
12. The preassembly of claim 7, wherein the primary blank is
affixed to the supplementary blank via application of an
adhesive.
13. The preassembly of claim 7, wherein each supplementary blank
includes at least one slot configured and located to receive a
corresponding tab included in the primary blank.
14. A plurality of blanks for a container preassembly, the
plurality of blanks comprising: a primary blank including a
plurality of side panels and end panels configured to provide an
exterior of the container; a plurality of supplementary blanks each
including a major panel and a plurality of end panels, wherein the
primary blank is configured to mate with and be affixed with the
supplementary blanks so that an end panel of each supplementary
blank is affixed with an end panel of the primary blank such that,
as the container is assembled, an exterior of the container is
formed by the plurality of side panels and end panels of the
primary blank, wherein a plurality of stacking shoulders are formed
by the supplementary blanks at opposing ends of an interior of the
container, and the plurality of stacking shoulders are formed as
part of the final assembly of the primary blank as the exterior of
the container.
15. The plurality of blanks of claim 14, wherein the container is a
display.
16. The plurality of blanks of claim 14, wherein the plurality of
side and end panels of the primary blank include a first and second
front end panels, at least one side panel and first and second back
end panels.
17. The plurality of blanks of claim 16, wherein the plurality of
supplementary blank end panels are affixed to either the first
front end panel or the first back end panel.
18. The plurality of blanks of claim 14, wherein the plurality of
side and end panels of the primary blank include a front end panel,
major and minor side panels, a back end panel and minor panels.
19. The plurality of blanks of claim 14, wherein the primary blank
is affixed to the supplementary blank via application of an
adhesive.
20. The plurality of blanks of claim 14, wherein each supplementary
blank includes at least one slot configured and located to receive
a corresponding tab included in the primary blank.
Description
[0001] The invention relates in general to the manufacture of
containers that may be readily used to ship and/or display contents
following delivery of the container, as specified in the
independent claims.
BACKGROUND OF THE INVENTION
[0002] Various containers are conventionally provided as packaging
for shipping or for display of product in a retail environment to
prospective customers. As is conventionally known in the industry,
such containers can be transported to manufacturing and/or retail
environments for use in shipping or display in knock-down form,
i.e., flattened but otherwise being glued, stapled or otherwise
secured together, such that they are already substantially
pre-assembled; such knock-down form containers are also referred to
as preassemblies. In such a "knockdown" state (i.e., knocked down
or not set-up), personnel assembling the product container need
only open the sides and or ends of the container and affix the
package bottom wall into its assembled condition. As a result, such
containers assembly may be performed such that the product can be
placed into a resulting assembled container for shipping or as
display package for ready display.
[0003] Conventionally, it has been deemed advantageous at times to
stack a plurality of such containers, one on top of the other for
the purposes of transport to a retail environment or during display
in the retail environment. In this use, it is necessary that the
containers stacked above the bottom-most package are amply
supported also that a stack of a number of such containers, when
filled with product, will not collapse.
SUMMARY
[0004] The following presents a simplified summary in order to
provide a basic understanding of some aspects of various invention
embodiments. The summary is not an extensive overview of the
invention. It is neither intended to identify key or critical
elements of the invention nor to delineate the scope of the
invention. The following summary merely presents some concepts of
the invention in a simplified form as a prelude to the more
detailed description below.
[0005] In accordance with illustrated embodiments, a method of
manufacturing containers and resulting containers and associated
preassemblies and blanks, which, when utilized, result in
containers having an interior formed by a primary blank serving as
an exterior of the container, the interior including a plurality of
stacking shoulders formed by an supplementary blank at opposing
ends of the container interior, wherein the plurality of stacking
shoulders are formed as part of the set up or final assembly of
exterior of the container.
[0006] Additionally, in accordance with illustrated embodiments,
the plurality of stacking shoulders is formed by coupling of the
primary and supplementary blanks at a side panel of the primary
blank. Alternatively, or in addition, the plurality of stacking
shoulders is formed by coupling of the primary and supplementary
blanks at a back panel of the primary blank.
[0007] The illustrated embodiments of the invention have particular
utility when used for the manufacture of preassemblies and
associated containers that are flat bottomed tray type
containers.
[0008] These illustrated embodiments are achieved by a combination
of features recited in the independent claim. Accordingly,
dependent claims prescribe further detailed implementations of the
present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Various embodiments are described herein, by way of example
only, with reference to the accompanying drawings. With specific
reference now to the drawings, it should be understood that the
particulars shown are by way of example and for purposes of
discussion of illustrated embodiments only, and are presented in
order to provide what is believed to be a useful and readily
understood description of the principles and concepts of the
invention. In this regard, no attempt is made to show structural
details of the invention in more detail than is necessary for a
fundamental understanding of the invention, the description taken
with the drawings making apparent to those skilled in the art how
the several forms of the invention may be embodied in practice.
[0010] Accordingly, a more complete understanding of the present
invention and the utility thereof may be acquired by referring to
the following description in consideration of the accompanying
drawings, in which like reference numbers indicate like features,
and wherein:
[0011] FIG. 1 illustrates a side perspective view of a container
manufactured in accordance with an illustrated embodiment.
[0012] FIG. 2 illustrates an example of a primary blank used in
manufacturing the container of the type illustrated in FIG. 1.
[0013] FIG. 3 illustrates an example of a supplementary blank used
in manufacturing the container of the type illustrated in FIG.
1.
[0014] FIG. 4 illustrates the interconnectedness of the primary and
supplementary blanks illustrated in FIGS. 2 and 3 to provide the
container illustrated in FIG. 1.
[0015] FIG. 5 illustrates a side perspective of the preassembly
manufactured from the blanks illustrated in FIG. 4.
[0016] FIG. 6 illustrates a side perspective of the preassembly
manufactured from the blanks illustrated in FIG. 4 during final
assembly.
[0017] FIG. 7 illustrates a side perspective of an alternative
embodiment of a preassembly manufactured in accordance with another
illustrated embodiment as shown during final assembly of the
container from the preassembly.
[0018] FIG. 8 illustrates an example of a primary blank in
combination with supplementary blanks used in manufacturing the
container of the type illustrated in FIG. 7.
[0019] FIG. 9 illustrates an example of a supplementary blank used
in manufacturing the container of the type illustrated in FIG.
7.
[0020] FIG. 10 illustrates the interconnectedness of the primary
and supplementary blanks illustrated in FIGS. 8 and 9 to provide
the container illustrated in FIG. 7.
[0021] FIG. 11 illustrates a side perspective of the preassembly
manufactured from the blanks illustrated in FIG. 10 at a first
stage of assembly.
[0022] FIG. 12 illustrates a side perspective of the preassembly
manufactured from the blanks illustrated in FIG. 11 at a second
stage of assembly.
[0023] FIG. 13 illustrates a functional block diagram used to
describe the manufacturing method of containers in accordance with
an illustrated embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0024] In the following description of various invention
embodiments, reference is made to the accompanying drawings, which
form a part hereof, and in which is shown, by way of illustration,
various embodiments in which the invention may be practiced. It is
to be understood that other embodiments may be utilized and
structural and functional modifications may be made without
departing from the scope and spirit of the present invention.
[0025] As explained above, it is useful to be able to stack a
plurality of containers one on top of the other for the purposes of
transport to a retail environment or during display in the retail
environment. This ability (also known as "stackability") requires
that containers stacked above the bottom-most package are amply
supported also that a stack of a number of such containers, when
filled with product, will not collapse.
[0026] Conventionally, there are various container designs that
provide increased stackability by including, for example, stacking
shoulders that utilize additional material and components to
increase the vertical stability of the container. However, the
skill level and time required for assembling such containers varies
depending on the number of touches required for assembling the
container. In fact, the time required for assembling conventional
containers including stacking shoulders of some sort or another may
be somewhat lengthy as assembly of a container may require a number
of separate actions to be performed by the final assembler of a
container. The number of such separate actions is conventionally
referred to as the number of "touches" required for assembly; thus,
a container requiring complex assembly requires a greater number of
touches than a container requiring relatively simple assembly.
[0027] Another problem with such stackable containers is the
increased height, length, width and weight of such containers due
to the added material provided for the stacking shoulders.
Therefore, although the use of such stackable containers is useful,
the increased time for final assembly and increased dimensions and
weight of the containers are deficiencies of conventional designs.
Thus, there is a need for a design for a stackable container (e.g.,
a shipping package, display or display ready package or
compartmentalized package so as to reduce fulfillment cost and
time) that includes stacking shoulders with less affect on the
overall dimensions and weight of the stackable container, while
reducing the amount of material used in the container and reduces
the number of touches required for final assembly of the
container.
[0028] With this understanding in mind, a description of various
invention embodiments is now provided.
[0029] According to as least one illustrated embodiment, there is
provided equipment configured to manufacture containers, e.g., for
shipment or display of product (as well as corresponding container
preassemblies and blanks) that result in containers having an
interior formed by a primary blank serving as an exterior of the
container, the interior including a plurality of stacking shoulders
formed by an supplementary blank at opposing ends of the container
interior, wherein the plurality of stacking shoulders are formed as
part of the set up or final assembly of exterior of the
container.
[0030] Understanding of the manufacturing of a container, blanks
and/or preassemblies in accordance with embodiments may best be
understood by first reviewing an illustration of a manufactured
container provided in accordance with one illustrated embodiment.
As illustrated in FIG. 1, one example of such a container 100 may
be a flat bottomed tray, which may include a main compartment
defined between a plurality of stacking shoulders formed by a
corresponding plurality of supplementary blanks 102 and included in
an interior space of a primary blank 101 following assembly. These
stacking shoulders may be formed by coupling the supplementary
blanks to locations on the primary blank 101. For example, a
plurality of tabs 104 (one provided on each end of the container
100 by the primary blank 101) may be inserted in corresponding
slots 103 provided on the supplementary blank 102. Additionally, as
part of preassembly manufacture for a preassembly for container
100, the supplementary blank 102 may be adhered to the primary
blank 101 as explained in connection with FIGS. 5-12 so in various
alternative configurations to provide for improved ease of final
assembly for the container 100.
[0031] Such a container 100 may be used for various purposes
including shipping and placement on a display floor along with
other such containers in a stack. However, it should be understood
that the manufactured container may be any type of container
including, for example, any carton, package, box, etc. of any
suitable type; accordingly, the actual configurations of the
primary blank 101 and the interrelationship with the supplementary
blank 102 may change without departing from the scope of the
embodiments.
[0032] Thus, in accordance with illustrated embodiments, a method
is provided of manufacturing containers and resulting containers
100 and associated preassemblies (the combination of 101, 102) and
blanks 101, 102, which, when utilized, result in containers 100
that include a supplementary blank 102 that provides a plurality of
stacking shoulders that serve as a mechanism for improving the
stackability of the container 100, whereby the container 100 may be
configured to bare larger amounts of force (e.g., weight) from a
top direction.
[0033] Based on the illustrated examples of container designs
provided with stacking shoulders as disclosed herein, it should be
appreciated that the incorporation of the stacking shoulders
increases stackability of the resulting containers without
requiring a lengthier time period for final assembly and without a
need for assemblers having superior skill. This is because, as
explained herein, the majority of manipulation of the preassembly
to form the stacking shoulders are already performed as part of the
assembly of the primary blank as the exterior of the container. As
a result, the additional touches needed to provide the stacking
shoulders is reduced relative to what is conventionally
required.
[0034] Further, the illustrated examples of containers designs
provide stacking shoulders but with significantly less material
than is conventionally required for stacking shoulders. For
example, the square footage of material incorporated in container
designs utilizing the inventive concept may be reduced on average
between 30%-35%. This reduction in material results in a reduction
in the container weight and resources expended to produce the
container, while still providing improved strength.
[0035] As will be appreciated from the remaining disclosure by one
of ordinary skill in the art, the container 100 may be used to ship
or display product therein in a retail environment. Thus,
subsequent to arrival at a retail environment or off-site
fulfillment or contract packaging facility, a knockdown version of
the container 100 (e.g., a preassembly) may be assembled and
product placed in the container 100 for transport and/or
display.
[0036] FIG. 2 illustrates an example of a primary blank 101, which
may be thought of as a conventional tray such as the one
illustrated in FIG. 1. The knockdown of the container 100 is
manufactured by joining the primary blank 101 with a supplementary
blank 102 (which may be thought of as a pad) illustrated in FIG. 3,
as explained herein. The primary blank 101 illustrated in FIG. 2
corresponds to an exterior of the container 100 illustrated in
FIGS. 1 and 4; therefore, the container 100 includes primary blank
101. Likewise, the container 100 also includes supplementary blank
102 illustrated separately in FIG. 3 and in conjunction with
primary blank 101 in FIGS. 4-5.
[0037] As used in FIG. 2, solid lines indicate edges of the blank
illustrated, whereas dashed lines indicate perforation, folding or
scoring lines provided as part of manufacturing to enable folding
of the blanks along the dashed lines.
[0038] As shown in FIG. 2, the primary blank 101 includes a first
front end panel 105, a side panel 106 and a first back end panel
107, along with a bottom panel 108 and a second front end panel 109
and a second back end panel 110. The primary blank 101 also
includes a plurality of minor panels 111 with included interlock
tabs that interact with corresponding minor side panel portions
113, 114 to provide an open side of the container illustrated in
FIG. 1. The primary blank 101 also includes minor panels 115 that
fold over as part of assembly and provide part of the exterior of
container 100 by interacting with panels 117, 118.
[0039] Thus, the total width 119 of the blank 101 includes the
width 120 of the side panel 106 as well as the width 121 of the
bottom panel 108 and the widths 122 (which is approximately the
same width as width 124 of the minor panels 111) and 123 of the
minor side panels 113, 114. Likewise, the total length 125 of the
blank 101 includes the length 126 of the first back end panel 107,
which is slightly larger than the length 127 of the second back end
panel 110, as well as the width 130 of the bottom panel 108. The
total length 125 also includes the widths 128, 129 of the panels
118, 117 respectively.
[0040] FIG. 3 illustrates an example of a supplementary blank 102
used in manufacturing the container of the type illustrated in FIG.
1. The supplementary blank 102 includes a major panel 131 as well
as a minor panel 132 and two end panels 133, 134. The major panel
131 includes two slots 103 located and configured to interact with
tab 104 of the primary blank 101 as part of final assembly of the
container 100. As will be become clear with reference to FIGS. 4-6,
the two locations for the slots 103 are provided because the
supplementary blank may be used on either the front end or back end
of the container 100. As such, the supplementary blank 102 needs to
be flipped horizontally depending on the end on which the blank 102
is to be located.
[0041] The total length 135 of the supplementary blank 102 includes
the length 136 of the major panel 131, as well as the lengths 137,
138 of the two end panels 133, 134 respectively and the length 139
of the minor panel 132. The total width 140 of the blank 102 may be
uniform across the major panel 131, minor panel 132 and end panels
133, 134.
[0042] As explained above, illustrated embodiments may provide
improved assembly of containers for shipping and/or display ready
packaging that have increased stackability as a result of stacking
shoulders formed by the interaction of the supplementary blank 102
with the primary blank 101 through at least one of adhering a
plurality of parts of the supplementary and primary blanks to one
another.
[0043] FIG. 4 illustrates the interconnectedness of the primary and
secondary blanks illustrated in FIGS. 2 and 3 to provide the
container illustrated in FIG. 1. Accordingly, as illustrated in
FIG. 4, the primary and supplementary blanks 101, 102 may be
configured so as to interact in a manner that enables the stacking
shoulders to be formed easily and quickly as part of the final
assembly of the container 100. Accordingly, the total length and
width dimensions for the blanks 101, 102 and their constituent
panels, walls and sections may be selected so as to facilitate the
positioning of the supplementary blanks 102 with respect to the
interior of the assembled primary blank 101.
[0044] In one potential implementation, one or more portions of the
primary and supplementary blanks 101, 102 may be adhered to one
another via, for example, adhesive such as glue, staples, tape,
etc. so as to produce a preassembly (e.g., a knockdown or
preassembly for the container illustrated in FIG. 1.), wherein the
positioning of supplementary blank 102 in cooperation with primary
blank 101 is controlled. For example, the primary and supplementary
blanks 101, 102 may be adhered to each other on their mating faces
(e.g., the bottom face of supplementary blank 102 and the top face
of the primary blank 101. More specifically, adhesive may be
applied to end panels 133, 134 of each of the supplementary blanks
102; subsequently, the end panels may be placed in contact with
corresponding portions of the end panels of the primary blank 101
during preassembly manufacture.
[0045] More specifically, an end panel 134 of a first supplementary
blank 102 may be adhered to the first front end panel 105 and the
corresponding end panel 133 of the first supplementary blank 102
may be adhered to the side panel 106. Similarly, the end panel 134
of the second supplementary blank 102 may be adhered to first back
end panel 107 and the corresponding end panel 133 may be adhered to
side panel 106. Accordingly, adhesive may be applied on the top
surfaces of the panels of the primary blank 101 or on bottom
surfaces of the end panels 133, 134 of the supplementary blanks
102. Following application of adhesive, the supplementary blanks
102 may be placed in contact with the primary blank 101 to provide
adherence between primary and supplementary blanks 101, 102.
[0046] As a result of such a process, a preassembly may be provided
that which, when utilized, results in a container having an
interior formed by a primary blank serving as an exterior of the
container, the interior including a plurality of stacking shoulders
formed by the supplementary blank at opposing ends of the container
interior, wherein the plurality of stacking shoulders are formed as
part of the set up or final assembly of exterior of the
container.
[0047] It should be appreciated that, as a first operation in
manufacturing the preassembly for the container 100, the faces of
the primary and supplementary blanks 101, 102 are affixed together
at various locations. Thus, although not shown, a preassembly may
be provided wherein the primary and supplementary blanks 101, 102
are adhered to one another via adhesive but the panels, walls, etc.
are not configured for final assembly. As a result, such a
preassembly may be delivered to a location for final assembly and
placement of product; such a preassembly may be effectively and
easily stacked with other preassemblies because such preassemblies
are flat having not yet been built or assembled as shown in FIG. 1.
Accordingly, it should be understood that the faces of the blanks
101, 102 may be affixed in one or more suitable manners including,
for example but not limited to, application of adhesive on one or
both of the affixed faces, use of staples, tape, etc.
[0048] Thus, FIG. 5 illustrates a side perspective of the
preassembly manufactured from the blanks illustrated in FIG. 4. As
shown in FIG. 5, the supplementary blanks 102 are adhered to the
primary blank 101 and located such that two non-overlapping
sections 142, 143 are provided on the first front end panel 105 and
the first back end panel 107, respectively.
[0049] FIG. 6 illustrates a side perspective of the preassembly
manufactured from the blanks illustrated in FIG. 4 during final
assembly. As shown in FIG. 6, the side panel 106 and first front
and back end panels 105, 107 are folded towards the remaining
components of the preassembly such that side panel 106 becomes a
major side panel of the container 100 and the first front and back
end panels 105, 107 form front and back ends of the container 100,
respectively.
[0050] Subsequently, the second front and back end panels 109, 111
are folded upward and the pairs of panels 117, 118 on each end are
folded over the respective end panels 105, 107 to enable the tabs
104 provided on each end to be inserted into the corresponding slot
103.
[0051] FIG. 7 illustrates a side perspective of an alternative
embodiment of a preassembly manufactured in accordance with another
illustrated embodiment, as shown during final assembly of the
container from the preassembly. As shown in FIG. 7, the stacking
shoulders are formed by supplementary blanks 702 adhered to
singular end panels of the primary blank 701. Thus, whereas the
embodiment illustrated in FIG. 1 has first and second end panels on
both the front and back ends of the container 700, the embodiment
illustrated in FIG. 7 has only a single front and back end panel as
part of the primary blank 701.
[0052] The knockdown of the container 700 is manufactured by
joining the primary blank 701 (illustrated in FIG. 8) with a
supplementary blank 702 which may be thought of as a pad
(illustrated in both FIGS. 8 and 9), as explained herein. The blank
701 illustrated in FIG. 8 corresponds to an exterior of the
container 700 illustrated in FIGS. 1 and 4; therefore, the
container 700 includes primary blank 701. Likewise, the container
700 also includes supplementary blank 702 illustrated in
combination with primary blank 701 in FIG. 8 and also separately in
FIG. 9.
[0053] FIG. 8 illustrates an example of a combination primary blank
701 and secondary blanks 702 provided together in a manner that may
be provided in a single die cut and scoring phase of manufacturing
the container of the type illustrated in FIG. 7. As used in FIG. 7,
solid lines indicate edges of the blanks illustrated, whereas
dashed lines indicate perforation, folding or scoring lines
provided as part of manufacturing to enable folding of the blanks
along the dashed lines.
[0054] As shown in FIG. 8, a substantial portion of the primary
blank 701 is configured similarly to the primary blank illustrated
in FIG. 2; accordingly, those panels that are similar are not
particularly referenced with new reference numbers. However, that
portion of the primary blank 701 that includes differing
components, structure or panels are separately numbered as
follows.
[0055] Minor panels 148 and 150 and a first major side panel 149
are provided along the panels that comprise the front end panel
109, bottom panel 108 and a back end panel 110. The minor panels
148, 150 and first major side panel 149 and a second major side
panel 156 are adjacent to the two supplementary blanks 702.
[0056] Thus, the width 156 of the second major side panel 146 is
smaller than the width of the first major side panel 149. The
length 157 of the first major side panel 149 is substantially equal
to the length of the second major side panel 146. Like the
embodiment of FIG. 2, however, the embodiment of FIG. 7 also
includes a bottom panel 108 that includes slots 116, two of which
most proximate to the first major side panel 149 interact with tabs
145 provided on the second major side panel 146.
[0057] As illustrated in FIG. 9, the secondary blanks 702 include a
major panel 158 and a plurality of end panels 153, 154 that are
hingedly connected. The total length 160 of the secondary blank 702
includes the length 161 of the major panel 158, and the lengths 162
of the end panels 153, 154. The width 163 of the secondary blank
702 is uniform among the plurality of panels 153, 154, 158.
[0058] It should be appreciated that, unlike the embodiment of FIG.
1, this embodiment's supplementary blank 702 includes only one slot
703. This is because there is no need to have alternative slot
locations even if supplementary blank 702 is used on either end of
the container 700; more specifically, there is no need to flip the
blank (as in blank 102 of the embodiment illustrated in FIG. 1)
because the blank 702 is symmetrical horizontally.
[0059] FIG. 10 illustrates the interconnectedness of the primary
and supplementary blanks illustrated in FIGS. 8 and 9 to provide
the container illustrated in FIG. 7. As shown in FIG. 10, the
blanks 702 are positioned over the end panels 109, 110 to provide a
preassembly as illustrated in FIG. 11. Accordingly, the end panels
154 of the secondary blanks 702 may overlap the minor side panels
111 of the primary blank 701.
[0060] In one potential implementation, one or more portions of the
primary and supplementary blanks 701, 702 may be adhered to one
another via, for example, adhesive such as glue, staples, tape,
etc. so as to produce a preassembly (e.g., a knockdown or
preassembly for the container illustrated in FIGS. 10-12), wherein
the positioning of supplementary blanks 702 in cooperation with
primary blank 701 is controlled. For example, the primary and
supplementary blanks 701, 702 may be adhered to each other on one
or more mating faces. More specifically, adhesive may be applied to
end panels 153, 154 of each of the supplementary blanks 702;
subsequently, the end panels 153, 154 may be placed in contact with
corresponding portions of the primary blank 701 as shown in FIGS.
10-12 during preassembly manufacture.
[0061] More specifically, a top surface of the end panel 153 of a
first supplementary blank 702 may be adhered to a mating surface of
a primary blank minor side panel 148 (as explained below with
reference to FIG. 12) and a corresponding top surface of an end
panel 153 of a second supplementary blank 702 may be adhered to the
bottom surface of a primary blank minor side panel 150. Similarly,
the bottom surfaces of the end panels 154 of the supplementary
blanks 702 may be adhered to the top surfaces of minor panels 111
of the primary blanks 701. Accordingly, adhesive may be applied on
the top surfaces of the panels of the primary blank 101 or mating
surfaces of the end panels 153, 154 of the supplementary blanks
702. Following application of the adhesive, the supplementary
blanks 702 may be placed in contact with the primary blank 701 to
provide adherence between primary and supplementary blanks 701,
702.
[0062] Thus, as illustrated in FIG. 12 a final stage of preassembly
manufactured from the blanks illustrated in FIG. 10 involves the
folding of the minor panels 148, 150 towards the supplementary
blanks 702 located on the top surface of the end panels 109, 110
respectively. Subsequently, the minor panels 148, 150 and their
corresponding supplementary blanks 702 are adhered to one another,
e.g., end panels 153 for the supplementary blanks 702 illustrated
in FIG. 11 are adhered with the bottom surface of the minor panels
148, 150. Likewise, as explained above, the bottom surfaces of the
supplementary blank end panels 154 illustrated in FIG. 11 may be
adhered to the top surfaces of the minor panels 111 of the primary
blank 701.
[0063] As a result of such a process, a preassembly may be provided
which, when utilized, results in a container having an interior
formed by a primary blank serving as an exterior of the container;
the container interior includes a plurality of stacking shoulders
formed by the supplementary blanks at opposing ends of the
container interior, wherein the plurality of stacking shoulders are
formed as part of the set up or final assembly of exterior of the
container.
[0064] Accordingly, the inclusion of stacking shoulders is
implemented with minimal effort and deviation from the assembly
required for the exterior of the container. Thus, stacking
shoulders may be provided with improved ease and consistency as
part of final assembly of a container exterior.
[0065] FIG. 13 illustrates a functional block diagram used to
describe the manufacturing method of containers in accordance with
an illustrated embodiment. As alluded to in the background section,
and as conventionally known, the manner of manufacturing containers
such as the examples illustrated in FIGS. 1-12 may be conveniently
described in two phases: preassembly and final assembly/use.
[0066] Preassembly is normally performed at a container
manufacturing facility to produce a preassembly which may also be
thought of and referred to as a knockdown of the container. These
preassemblies may be shipped to a customer location such as a
product manufacturing facility or retail environment or third party
fulfillment contract packaging facility. At that destination, the
container customer may perform final assembly/use of the containers
by, for example, folding and assembling various panels of the
container to provide a container that is configured to hold
manufacture product, e.g., for shipping and/or display.
[0067] In such operations, the manufacturing of the container
preassemblies may be performed by the customer of the preassemblies
and/or as part of manufacture of the preassemblies as illustrated
in FIG. 13.
[0068] FIG. 13 illustrates various functional operations performed
as part of the manufacture of a preassembly by, for example, a
display, shipping or display ready packaging manufacturer. The
operations may begin, for example, with printing 1305 of container
material prior to the container material being die cut and/or
scored 1310 as part of an overall blank manufacturing operation
1315. The manufactured blanks 1330 may or may not be printed on one
or both sides of the blanks 1330 depending on customer
requirements. Accordingly, the printing operation 1305 may be
omitted.
[0069] Subsequent to blank manufacturing 1315, the manufactured
blanks may be affixed to one another as part of the joining of
multi-blank preassembly operations 1320. The operations performed
at 1320 may be performed in various suitable manners including by
hand or using various commercially available machines (for example,
those produced by Bahmueller Technologies, Inc. of Charlotte, N.C.,
USA or Bobst Group North America of Roseland, N.J., USA). Thus, the
operations performed at 1320 may produce preassemblies for
containers such as that illustrated in FIGS. 1 and 7.
[0070] Therefore, it should be appreciated that one or more of the
operations performed to produce blanks, preassemblies, knockdowns
and containers may be performed in whole or in part by machines and
or human personnel. Moreover, human personnel may utilize one or
more different types of machines and/or tools to perform assembly
operations performed either to manufacture preassemblies or finally
assembled containers.
[0071] Thus, at the beginning of such operations, raw material 1325
is used to produce blanks 1330. Such raw materials 1325 may include
but are not limited to various grades, types, configurations and
combinations of corrugated fiberboard and/or solid paperboard,
liner board, board of various fluting types and combinations as
well as various types of sealants, non-organic materials and inks
and dies of various suitable types.
[0072] It should be understood that implementation of the method
and system of the present invention involves performing or
completing certain selected tasks or steps manually, automatically,
or a combination thereof.
[0073] While this invention has been described in conjunction with
the specific embodiments outlined above, it is evident that many
alternatives, modifications and variations will be apparent to
those skilled in the art. Accordingly, the various embodiments of
the invention, as set forth above, are intended to be illustrative,
not limiting. Various changes may be made without departing from
the spirit and scope of the invention.
[0074] For example, various illustrated features of the preassembly
and resulting containers may be omitted. Furthermore, it should be
understood that invention embodiments are capable of variations
practiced or carried out in various ways. Therefore, it should be
appreciated that, in accordance with at least one embodiment of the
invention, any and all of the walls may be constructed of
corrugated cardboard. However, it should be understood that the
walls, panels, any tabs on various panels, etc., may be constructed
of various industry recognized appropriate materials that meet
various transporting and/or display criteria. As a result, it
should be understood that containers manufactured in accordance
with at least one embodiment of the invention may also be
considered "cartons," which may be considered packaging or display
containers, commonly made from cardstock or cardboard. Further, it
should be understood that cartons come in many different varieties
but most cartons can be folded and assembled from a flat form,
known as a carton blank. Thus, it should be understood that the
pattern for any blank, preassembly or container may be different
than those described herein.
[0075] Alternatively, or more specifically, the packaging and/or
display containers may be made using corrugated board, e.g.,
material made by a corrugator (a machine that produces corrugated
board by attaching fluting to liners) which is a structured board
formed by gluing one or more arched layers of corrugated medium to
one or more flat-facing linerboards.
[0076] Additionally, it should be appreciated that material used in
accordance with at least one embodiment of the invention may be
laminated to provide barrier properties. Further, other barrier
materials may be used including Ultra Violet (UV), moisture and gas
barriers. Additionally, though not discussed in detail herein, it
should be understood that any adhesive used to provide a bond
between materials used in containers provided in accordance with
the invention may include any substance that helps bond two
materials together, examples including but not limited to glue and
paste.
[0077] Further, it should be appreciated that the material used to
form the primary blank may be different, stronger, or weaker than
the blank used to form the supplementary blank. Thus, for example,
use of a supplementary blank that is of a heavier, more durable or
stronger material than the material used for primary blank, may
provide the increased ease of final assembly as well as increased
durability or strength to the resulting container while reducing
the amount of material in the container (something of interest for
environmental and cost issues).
[0078] It should also be appreciated that certain features of the
invention, which are, for clarity, described in the context of
separate embodiments, may also be provided in combination in a
single embodiment. Conversely, various features of the invention,
which are, for brevity, described in the context of a single
embodiment, may also be provided separately or in any suitable
sub-combination.
[0079] Although the invention has been described in conjunction
with specific embodiments thereof, it is evident that many
alternatives, modifications and variations will be apparent to
those skilled in the art. Accordingly, it is intended to embrace
all such alternatives, modifications and variations that fall
within the spirit and broad scope of the appended claims. All
publications, patents and patent applications mentioned in this
specification are herein incorporated in their entirety by
reference into the specification, to the same extent as if each
individual publication, patent or patent application was
specifically and individually indicated to be incorporated herein
by reference. In addition, citation or identification of any
reference in this application shall not be construed as an
admission that such reference is available as prior art to the
present invention.
[0080] Additionally, it should be understood that the functionality
described in connection with various described components of
various invention embodiments may be combined or separated from one
another in such a way that the structure of the invention is
somewhat different than what is expressly disclosed herein.
[0081] For example, although not discussed in detail, it should be
appreciated that the supplementary blank and/or resulting stacking
shoulders may be, for example, rectangular or trapezoidal or any
other configuration that provides the features to manufactured
containers discussed herein.
[0082] Moreover, it should be understood that, unless otherwise
specified, there is no essential requirement that methodology
operations be performed in the illustrated order; therefore, one of
ordinary skill in the art would recognize that some operations may
be performed in one or more alternative order and/or
simultaneously.
[0083] As a result, it will be apparent for those skilled in the
art that the illustrative embodiments described are only examples
and that various modifications can be made within the scope of the
invention as defined in the appended claims.
* * * * *