U.S. patent application number 14/643085 was filed with the patent office on 2015-09-10 for product container and reinforcement for a product container.
The applicant listed for this patent is PaperWorks Industries, Inc.. Invention is credited to Jean Manuel Gomes, Mahmood Shaikh.
Application Number | 20150251799 14/643085 |
Document ID | / |
Family ID | 54016637 |
Filed Date | 2015-09-10 |
United States Patent
Application |
20150251799 |
Kind Code |
A1 |
Gomes; Jean Manuel ; et
al. |
September 10, 2015 |
PRODUCT CONTAINER AND REINFORCEMENT FOR A PRODUCT CONTAINER
Abstract
A reinforcement member for a hollow structure includes a
plurality of generally planar panels. The panels can include a
plurality of outer support panels and at least one inner support
panel. The outer support panels can include a first panel, a second
panel extending generally perpendicular to the first panel, a third
panel extending generally perpendicular to the second panel, and a
fourth panel extending generally perpendicular to the first panel.
The at least one inner support panel can include a fifth panel
extending between the second panel and the third panel, the fifth
panel forming a first obtuse angle with the second panel and a
second obtuse angle with the third panel.
Inventors: |
Gomes; Jean Manuel;
(Acworth, GA) ; Shaikh; Mahmood; (Cincinnati,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PaperWorks Industries, Inc. |
Bala Cynwyd |
PA |
US |
|
|
Family ID: |
54016637 |
Appl. No.: |
14/643085 |
Filed: |
March 10, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61950360 |
Mar 10, 2014 |
|
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|
Current U.S.
Class: |
220/654 ;
229/199 |
Current CPC
Class: |
B65D 5/445 20130101;
B65D 5/58 20130101 |
International
Class: |
B65D 5/44 20060101
B65D005/44 |
Claims
1. A reinforcement member for a hollow structure, the reinforcement
member comprising a plurality of generally planar panels
comprising: A. a plurality of outer support panels, the outer
support panels comprising: i. a first panel; ii. a second panel
extending generally perpendicular to the first panel; iii. a third
panel extending generally perpendicular to the second panel; and
iv. a fourth panel extending generally perpendicular to the first
panel, and B. a plurality of inner support panels, the inner
support panels comprising: i. a fifth panel extending between the
second panel and the third panel; and ii. a sixth panel extending
between the first panel and the fourth panel, the fifth panel
forming a first obtuse angle with the second panel and a second
obtuse angle with the third panel, and the sixth panel forming a
third obtuse angle with the first panel and a fourth obtuse angle
with the fourth panel.
2. The reinforcement member of claim 1, wherein the first, second,
third and fourth panels are arranged with respect to one another
along a rectangular outline.
3. The reinforcement member of claim 1, wherein the first, second,
third and fourth panels are arranged with respect to one another
along a square outline.
4. The reinforcement member of claim 1, wherein the first, second,
third, fourth, fifth and sixth panels are arranged with respect to
one another along an irregular hexagonal outline.
5. The reinforcement member of claim 1, wherein at least one of the
outer support panels comprises a first panel section and a second
panel section, the first and second panel sections separated from
one another by a gap.
6. The reinforcement member of claim 1, wherein the sum of the
first obtuse angle, second obtuse angle, third obtuse angle and
fourth obtuse angle is approximately 540 degrees.
7. The reinforcement member of claim 1, wherein the outer and inner
support panels are collapsible to a generally flattened state in
which the second, third and fifth panels generally lie in a first
plane, and the first, fourth and sixth panels generally lie in a
second plane.
8. The reinforcement member of claim 1, wherein at least one of the
fifth panel and sixth panel comprises a first panel section and
second panel section, the first and second panel sections joined
together end to end.
9. The reinforcement member of claim 1, wherein at least one of the
outer support panels comprises a first panel section and a second
panel section, the first and second panel sections joined together
end to end.
10. The reinforcement member of claim 1, wherein at least one of
the outer support panels comprises a first panel section and a
second panel section, the first panel section comprising a first
end surface, and the second panel section comprising a second end
surface, the first end surface and second end surface facing each
other and in direct contact with one another.
11. The reinforcement member of claim 10, wherein the first end
surface and second end surface in direct contact with one another
form a support column.
12. A reinforcement member for a hollow structure, the
reinforcement member comprising a plurality of generally planar
panels comprising: A. a plurality of outer support panels, the
outer support panels comprising: i. a first panel; ii. a second
panel extending generally perpendicular to the first panel; iii. a
third panel extending generally perpendicular to the second panel;
and iv. a fourth panel extending generally perpendicular to the
first panel, and B. at least one inner support panel, the inner
support panel comprising a fifth panel extending between the second
panel and the third panel, the fifth panel forming a first obtuse
angle with the second panel and a second obtuse angle with the
third panel.
13. The reinforcement member of claim 12, wherein the outer support
panels and at least one inner support panel are arranged with
respect to one another along an irregular polygonal outline.
14. The reinforcement member of claim 13, wherein the outer support
panels and at least one inner support panel are arranged with
respect to one another along an irregular pentagon outline.
15. The reinforcement member of claim 12, wherein the first,
second, third and fourth panels are arranged with respect to one
another along a rectangular outline.
16. The reinforcement member of claim 12, wherein the first,
second, third and fourth panels are arranged with respect to one
another along a square outline.
17. The reinforcement member of claim 12, wherein at least one of
the outer support panels comprises a first panel section and a
second panel section, the first and second panel sections separated
from one another by a gap.
18. The reinforcement member of claim 12, wherein the sum of the
first obtuse angle, second obtuse angle, third obtuse angle and
fourth obtuse angle is approximately 540 degrees.
19. The reinforcement member of claim 12, wherein the outer support
panels and at least one inner support panel are collapsible to a
generally flattened state in which the at least one inner panel and
some of the outer panels generally lie in a first plane, and the
other outer panels generally lie in a second plane generally
parallel to the first plane.
20. A reinforced hollow structure comprising: A. an outer structure
comprising a first side wall, a second side wall extending
generally parallel to the first side wall, a third side wall
extending generally perpendicular to the second side wall, and a
fourth side wall extending generally perpendicular to the first
side wall; and B. a reinforcement member for the outer structure,
the reinforcement member comprising a plurality of generally planar
panels, the generally planar panels comprising: i. a plurality of
outer support panels, the outer support panels comprising: a. a
first panel; b. a second panel extending generally perpendicular to
the first panel; c. a third panel extending generally perpendicular
to the second panel; and d. a fourth panel extending generally
perpendicular to the first panel, and ii. at least one inner
support panel, the at least one inner support panel comprising a
fifth panel extending between the second panel and the third panel,
the fifth panel forming a first obtuse angle with the second panel
and a second obtuse angle with the third panel.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of priority of U.S.
provisional application No. 61/950,360, filed Mar. 10, 2014, the
contents of which is incorporated by reference herein in its
entirety.
FIELD
[0002] The present invention relates generally to reinforced hollow
structures, and more specifically to reinforced product containers
and reinforcement members that can be used in product containers to
prevent the containers from buckling, collapsing or crushing under
compressive load.
BACKGROUND
[0003] Cartons, boxes and other forms of packaging are frequently
manufactured from heavy duty paper, such as paperboard or
corrugated fiber board. These materials are economical and
lightweight, but they are susceptible to buckling, collapsing, or
crushing if they are placed under heavy load. Any buckling,
collapsing, or crushing of packaging can result in product loss due
to spillage, or damage to products inside the packaging. Therefore,
packaging manufacturers often place a reinforcement, sometimes
referred to as a "liner", inside the carton or box. The liner is
typically a sheet or strip of fiber board, or other material, that
is bonded to the interior sidewalls of the box, with the sheet or
strip following the full perimeter of the box to add thickness and
rigidity to the sides of the box. Such a liner is relatively easy
to manufacture, as it requires only four fold lines in the strip of
material to conform to the four corner edges of the box. Bonding
such a liner to the inner sidewalls of the box, along the perimeter
of the box, is viewed as beneficial because it minimizes the amount
of storage volume lost to the liner.
SUMMARY
[0004] Many reinforcement liners have been designed under the
assumption that one must increase the amount of liner used inside a
box to increase the compressive strength of the box. For example,
to increase the crush resistance of a box reinforced with a strip
of liner, it has been assumed that one must provide a longer strip
of liner inside the box to create more load bearing material. This
assumption leads to a further assumption that increased compressive
strength adds more cost to produce the reinforced box.
[0005] Applicants have discovered that these conventional
assumptions about liners are not correct. While an increase in the
amount of liner material can result in greater compressive strength
and higher costs, this is not always true. Other factors play a
role in determining the compressive strength of a liner and box. In
particular, Applicants have discovered that the geometrical
arrangement of liners inside boxes can have a substantial impact on
the liner's ability to reinforce the box that is much more
significant than the amount of material used. For example,
Applicants have found that a strip of liner of a given length that
follows the perimeter of a box will provide much less crush
resistance to a box than a liner of the same length that does not
follow the perimeter. Moving a small section of a liner inwardly
toward the center of the box at a specific location can
dramatically increase the compressive strength of the liner and
box.
[0006] The thought of moving a liner inwardly from the perimeter of
the box contravenes traditional liner design in at least two
respects. First, moving a liner away from the perimeter of the box
is often considered unfavorable because it sacrifices interior
space and reduces the volume or size of product than can be
packaged in a box of a given size. Nevertheless, the amount of
volume that is lost by moving a small section of liner away from
the perimeter is extremely small, and is substantially outweighed
by the increased reinforcement.
[0007] Another misconception is that moving a liner away from the
perimeter requires a change in geometry and a longer length of
liner, adding material cost. However, Applicants actually propose
to use less liner material for a given box size, as will be
explained.
[0008] In one embodiment, a reinforcement member for a hollow
structure includes a plurality of generally planar panels. The
panels can include a plurality of outer support panels and at least
one inner support panel. The outer support panels can include a
first panel, a second panel extending generally perpendicular to
the first panel, a third panel extending generally perpendicular to
the second panel, and a fourth panel extending generally
perpendicular to the first panel. The at least one inner support
panel can include a fifth panel extending between the second panel
and the third panel, the fifth panel forming a first obtuse angle
with the second panel and a second obtuse angle with the third
panel.
[0009] The at least one inner support panel can include a plurality
of inner support panels. The plurality of inner support panels can
include at least a fifth panel and a sixth panel. The fifth panel
can extend between the second panel and the third panel. The sixth
panel can extend between the first panel and the fourth panel. The
fifth panel can form a first obtuse angle with the second panel and
a second obtuse angle with the third panel. The sixth panel can
form a third obtuse angle with the first panel and a fourth obtuse
angle with the fourth panel.
[0010] The sum of the first obtuse angle, second obtuse angle,
third obtuse angle and fourth obtuse angle can be approximately 540
degrees.
[0011] The outer support panels can be arranged with respect to one
another along a regular or irregular polygonal outline, such as a
rectangular outline, a square outline, or other geometrical
outline.
[0012] The outer support panels and inner support panel(s) can also
be arranged with respect to one another along a regular or
irregular polygonal outline. For example, the outer support panels
and inner support panel(s) can be arranged with respect to one
another along a pentagonal outline, a hexagonal outline or other
geometrical outline.
[0013] One of the outer support panels can include a first panel
section and a second panel section, the first and second panel
sections separated from one another by a gap.
[0014] The outer support panels and inner support panel(s) can be
collapsible to a generally flattened state in which the second,
third and fifth panels generally lie in a first plane, and the
first and fourth panels generally lie in a second plane.
[0015] The at least one inner support panel can include a first
panel section and second panel section, the first and second panel
sections joined together end to end.
[0016] At least one of the outer support panels can include a first
panel section and a second panel section. The first and second
panel sections can be joined together end to end. In the
alternative, the first panel section can include a first end
surface, and the second panel section can include a second end
surface, the first end surface and second end surface facing each
other and in direct contact with one another in an overlapping
arrangement. The overlapping first and second end surfaces can form
a support column.
[0017] In another embodiment, a reinforced hollow structure, such
as a box or carton, can include an outer structure and a
reinforcement member. The outer structure can include a first side
wall, a second side wall extending generally parallel to the first
side wall, a third side wall extending generally perpendicular to
the second side wall, and a fourth side wall extending generally
perpendicular to the first side wall. The reinforcement member can
include a plurality of generally planar panels. The generally
planar panels can include a plurality of outer support panels. The
outer support panels can include a first panel, a second panel
extending generally perpendicular to the first panel, a third panel
extending generally perpendicular to the second panel, and a fourth
panel extending generally perpendicular to the first panel. The
generally planar panels can also include at least one inner support
panel. The at least one inner support panel can include a fifth
panel extending between the second panel and the third panel. The
fifth panel can include a first obtuse angle with the second panel
and a second obtuse angle with the third panel.
[0018] The at least one inner support panel can include a plurality
of inner support panels. The plurality of inner support panels can
include at least a fifth panel and a sixth panel. The fifth panel
can extend between the second panel and the third panel. The sixth
panel can extend between the first panel and the fourth panel. The
fifth panel can form a first obtuse angle with the second panel and
a second obtuse angle with the third panel. The sixth panel can
form a third obtuse angle with the first panel and a fourth obtuse
angle with the fourth panel.
[0019] The sum of the first obtuse angle, second obtuse angle,
third obtuse angle and fourth obtuse angle can be approximately 540
degrees.
[0020] The outer support panels can be arranged with respect to one
another along a regular or irregular polygonal outline, such as a
rectangular outline or a square outline.
[0021] The outer support panels and inner support panel(s) can also
be are arranged with respect to one another along a regular or
irregular polygonal outline. For example, the outer support panels
and inner support panel(s) can be are arranged with respect to one
another along a pentagonal outline, a hexagonal outline or other
geometrical outline.
[0022] One of the outer support panels can include a first panel
section and a second panel section, the first and second panel
sections separated from one another by a gap.
[0023] The outer structure and reinforcement structure can be
collapsible together to a generally flattened state. For example,
the outer structure, outer support panels, and inner support
panel(s) can be collapsible to a generally flattened state in which
the second, third and fifth panels generally lie in a first plane,
and the first and fourth panels generally lie in a second
plane.
[0024] The at least one inner support panel can include a first
panel section and second panel section, the first and second panel
sections joined together end to end.
[0025] At least one of the outer support panels can include a first
panel section and a second panel section. The first and second
panel sections can be joined together end to end. In the
alternative, the first panel section can include a first end
surface, and the second panel section can include a second end
surface, the first end surface and second end surface facing each
other and in direct contact with one another in an overlapping
arrangement. The overlapping first and second end surfaces can form
a support column.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The following description will be better appreciated in
conjunction with the following drawing figures, of which:
[0027] FIG. 1 is a perspective view of a reinforced product
container in accordance with one embodiment of the invention;
[0028] FIG. 2 is top view of the reinforced product container of
FIG. 1;
[0029] FIG. 3 is a side view of a reinforcement member used in the
reinforced product container of FIG. 1;
[0030] FIG. 4 is a top view of the reinforced product container of
FIG. 1, showing the container in a partially collapsed state;
[0031] FIG. 5 is a top view of the reinforced product container of
FIG. 1, showing the container in a flattened state;
[0032] FIG. 6 is a top view of a reinforcement member in accordance
with another embodiment of the invention;
[0033] FIG. 7 is a top view of a reinforcement member in accordance
with another embodiment of the invention;
[0034] FIG. 8 is a top view of a reinforcement member in accordance
with another embodiment of the invention;
[0035] FIG. 9 is a top view of a reinforcement member in accordance
with another embodiment of the invention;
[0036] FIG. 10 is a top view of a reinforcement member in
accordance with another embodiment of the invention; and
[0037] FIG. 11 is a top view of a reinforcement member in
accordance with another embodiment of the invention.
DETAILED DESCRIPTION
[0038] Although the invention is illustrated and described herein
with reference to specific embodiments, the invention is not
intended to be limited to the details shown. Rather, various
modifications may be made in the details within the scope and range
of equivalents of the claims and without departing from the
invention.
[0039] Applicants have developed an improved product package that
exhibits greater compressive strength than conventional packages of
comparable size and material, while using less material and
exhibiting less weight than conventional packages. The Applicants'
proposed "HT Package" (High Topload Package) is one example of the
invention. Although embodiments of the invention are described in
the form of boxes and liners used in the packaging industry, the
invention is not defined by or limited to packaging
applications.
Reinforced Product Container
[0040] Referring to FIGS. 1 and 2, a reinforced product container
100 in accordance with one embodiment of the invention is shown.
Reinforced product container 100 includes an outer box 120 and an
inner liner 150 affixed to the interior of the box. Container 100
can be assembled to form a generally rectangular enclosure, and can
also be collapsed to a flattened state, which is more efficient for
transporting empty containers in bulk.
[0041] Box 120 has a first side wall 122, a second side wall 124
extending generally perpendicular to the first side wall, a third
side wall 126 extending generally perpendicular to the second side
wall 124, and a fourth side wall 128 extending generally
perpendicular to the first side wall. The four sidewalls 122, 124,
126 and 128 define four vertices or corner edges 123, 125, 127 and
129 as shown. Liner 150 is a single unitary strip or sheet of
material 152 that is affixed to inner surfaces of the first,
second, third and fourth side walls 122, 124, 126 and 128 of box
120. The unitary sheet of material 152 is folded at a number of
locations to line the interior of box 120.
[0042] Referring now to FIG. 3, the liner 150 is shown in an
unfolded state. Liner 150 includes six fold lines 153-158 that
divide the liner into seven distinct sections. In particular, the
fold lines define seven liner sections 161, 162, 163, 164, 165, 166
and 167. When liner 150 is inserted inside box 120, the seven liner
sections form six support panels that reinforce the box. Each
support panel acts as a vertical column to absorb compressive load
placed on top of box 120. Four of the support panels are referred
to herein as "outer support panels" that are affixed to inner
surfaces of box 120. Two of the support panels are referred to
herein as "inner support panels" that extend inwardly from two
opposing corner edges of box 120.
[0043] Referring back to FIGS. 1 and 2, liner sections 161 and 167
abut one another and join end to end to form a first panel 171.
Liner section 162 forms a second panel 172, liner section 164 forms
a third panel 173 and liner section 165 forms a fourth panel 174.
First, second, third and fourth panels 171-174 are the outer
support panels that are affixed to inner surfaces of box 120. In
particular, first panel 171 is glued to an inner surface 131,
second panel 172 is glued to an inner surface 132, third panel 173
is glued to an inner surface 133, and fourth panel 174 is glued to
inner surface 134. It is assumed for simplicity that the sidewalls
of box 120 conform to a perfect rectangle. As such, the first,
second, third and fourth panels 171-174 are arranged with respect
to one another along a rectangular outline 180, and the first
through sixth panels are arranged with respect to one another along
an irregular hexagonal outline 190.
[0044] Liner section 163 forms a fifth panel 175, and liner section
166 forms a sixth panel 176. Fifth panel 175 and sixth panel 176
constitute the inner support panels that extend inwardly from
opposing corner edges of box 120. Fifth panel 175 extends between
second panel 172 and third panel 173, offset inwardly from corner
edge 125. Similarly, sixth panel 176 extends between first panel
171 and fourth panel 174, offset inwardly from corner edge 129.
Fifth panel 175 forms a first obtuse angle 182 with second panel
172, and forms a second obtuse angle 184 with third panel 173.
Similarly, sixth panel 176 forms a third obtuse angle 186 with
first panel 171 and a fourth obtuse angle 188 with fourth panel
174. Assuming again that box 120 has a perfectly rectangular shape,
the sum of the first, second, third and fourth obtuse angles 182,
184, 186 and 188 is approximately 540 degrees.
[0045] The fifth and sixth panels 175 and 176 are positioned closer
to the center of box 120, as compared to the panels 171-174, which
are positioned as far out as possible from the center of the box,
extending adjacent to the perimeter of the box, i.e. adjacent to
side walls 122, 124, 126 and 128 of box 120. By being located
closer to the center of box 120, fifth and sixth panels 175 and 176
absorb more of the compressive load exerted toward the center of
the box and thereby reinforce more area inside the perimeter of the
box.
Top Load Testing
[0046] Applicants have discovered that inner support panels, like
fifth and sixth panels 175 and 176, provide a substantial increase
in compressive strength that is far greater than the compressive
strength provided by a conventional liner that only reinforces the
outer sidewalls of a box along the box perimeter. By moving
sections of the liner (i.e. the inner support panels) inwardly from
the corner edges of the box, even by a small distance, the total
compressive strength of the box can increase by 25 percent or
more.
[0047] To compare the compressive strength of conventionally
reinforced boxes with boxes reinforced with liners in accordance
with the invention, Applicants performed a series of top load
tests. In these tests, Applicants tested the compressive strength
of boxes formed with conventional liners that reinforced only the
perimeter of the boxes. Applicants also tested the same boxes
reinforced with liners having inner support panels similar to fifth
and sixth panels 175 and 176 of liner 150. In all samples that were
tested, the boxes were made of Clay Coated News Back (CCNB)
material and had dimensions of 11.625 in..times.5.187 in by 10.0
in. The liners were made of a B-flute corrugated liner.
[0048] The boxes with conventional liners supported loads of 642
pounds per square inch on average. The boxes with liners in
accordance with the invention supported loads of 910 pounds per
square inch on average. Therefore, the liners made in accordance
with the invention provided a 29 percent increase in compressive
strength over the conventional perimeter liners. In addition, the
liners made in accordance with the invention were made with less
material (i.e. shorter length) than the conventional perimeter
liners, which translated into a much higher contribution toward
compressive strength per unit length of material used to make the
liner.
[0049] Liner 150 has two inner support panels 175 and 176 that are
positioned inwardly from corner edges of box 120, as noted above.
Other embodiments of the invention may have fewer or more inner
support panels that are positioned inwardly from the corner edges
or other sections of their respective boxes. For example, an
embodiment of the invention may include only one inner support
panel positioned inwardly from the perimeter of a box. The inner
support panel can be positioned inwardly from a corner edge of the
box, as shown in FIG. 11. FIG. 11 shows a liner 750 with four outer
support panels 771, 772, 773 and 774, and only one inner support
panel 775. Inner support panel 775 is between outer support panels
772 and 773.
[0050] Embodiments of the invention can also include three, four or
more inner support panels positioned inwardly from corner edges of
a box. By increasing the number of sections that are moved inwardly
from the corners, a greater increase in compressive strength can be
obtained.
[0051] The inner support panel can be positioned inwardly from a
corner edge of the box, or a section of the box other than a corner
edge. For example, a liner can feature one or more inner support
panels positioned inwardly from a sidewall of the box. In such an
embodiment, the inner support panel(s) can be offset inwardly from
the center or midline of the side wall, or from a point or line on
the sidewall that is offset from the center or midline of the
sidewall. Inner support panel(s) that are offset from a sidewall,
as opposed to a corner edge, can have various geometric
configurations and arrangements as viewed from the top, including
but not limited to a V-shape, with the vertex of the "V" pointing
toward the center of the box, or a curved U-shape.
Liner Collapsibility
[0052] Applicants have found that two inner support panels located
at opposite corners of the box provides the benefit of increased
compressive strength in an arrangement that is easily collapsible
within a plane orthogonal to the direction of load. Liners with
fewer or more inner support panels in accordance with the invention
can also provide increased compressive strength and collapsibility.
The ability to collapse liner 150 is schematically illustrated in
FIGS. 4 and 5.
[0053] FIG. 4 shows box 120 and liner 150 in a partially collapsed
condition, relative to an erect state represented by the dashed
outline X, which represents the shape of the box before being
collapsed, as seen from the top. As box 120 is collapsed in
direction Y, liner 150 tends to collapse in the same direction.
That is, the fold lines 153-158 in liner 150 yield to the
surrounding box 120 as the box is collapsed. The orientation of
fifth and sixth panels 175 and 176 do not oppose or resist
collapse. As such, fifth and sixth panels 175 and 176 gradually
flatten out with respect to the respective adjacent panels. FIG. 5
shows box 120 and liner 150 in a completely collapsed or flattened
state, relative to the erect state represented by the dashed
outline X. In this state, the second, third and fifth panels 172,
173 and 175 generally lie in a first plane, and the first, fourth
and sixth panels 171, 174 and 176 generally lie in a second plane
more or less parallel to the first plane.
Liner Configuration and Arrangement
[0054] Liners in accordance with the invention can have a regular
or irregular polygonal configuration having one or more panels
moved toward the center of the box. By moving sections of the liner
toward the center of the box, the total length of material used to
form the liner is reduced. In the case of liner 150, for example,
the liner "cuts two corners" of the rectangle, reducing the total
length of the unitary strip. Depending on how far inwardly the
inner panels extend, manufacturers can reduce the amount of
material by two percent or more. This reduces material cost and the
total weight of the packaging, while providing a disproportionate
increase in compressive strength per inch of liner material. Liners
having one or more panels moved toward the center of the box can be
inserted into existing rectangular box designs without the need to
modify manufacturing machinery.
[0055] FIGS. 6-9 illustrate other liner configurations in
accordance with the invention. The configurations in FIGS. 6-9
represent the shape of the liner as it would appear affixed in an
erected box, as viewed from the top.
[0056] FIG. 6 shows a liner 250 in accordance with the invention
with two liner sections 261 and 267 that form a first panel 271.
Unlike liner 150, the liner sections 261 and 267 are separated from
one another by a gap 280. As such, the configuration for liner 250
uses less material than the configuration for liner 150.
[0057] FIG. 7 shows another liner 350 in accordance with the
invention with two inner support panels 375 and 376 that comprise
additional folds. Panel 375 has a fold 377 that divides the panel
into two panel sections joined end to end. Similarly, panel 376 has
a fold 378 that divides the panel into two panel sections joined
end to end. The folds 377 and 378 allow panels 375 and 376,
respectively, to project further inwardly toward the center of the
box and provide more column support toward the center of a box.
[0058] FIG. 8 shows another liner 450 in accordance with the
invention with two inner support panels 475 and 476 that comprise
folds 477 and 478, respectively, similar to the folds in liner 350.
Folds 477 and 478 allow panels 475 and 476, respectively, to
project further outwardly toward the corners of the box.
[0059] FIG. 9 shows another liner 550 in accordance with the
invention. Liner 550 includes outer support panels 571-574 of equal
length, and arranged with respect to one another along a square
outline 580 for use in boxes having a square shape.
[0060] Liners in accordance with the invention can be affixed to
the interior of a box or other outer structure in various ways. For
example, each panel of a liner can be affixed to the interior of an
outer structure by an adhesive that bonds the panel to the inner
surface of the outer structure. The adhesive can be applied to the
entire surface of the panel that will contact the inner surface of
the outer structure. Alternatively, the adhesive can be applied to
some but not all of the surface of the panel that will contact the
inner surface of the outer structure. The adhesive can be applied
to each and every panel of a liner, or to some panels and not
others.
[0061] FIG. 10 shows another liner 650 in accordance with the
invention. Liner 650 has many of the same features of liner 150,
including two liner sections 661 and 667 that form a first panel
671. Instead of joining one another end to end, liner sections 661
and 667 overlap one another by a small distance. This area of
overlap defines a flap 680. Flap 680 is defined by an end surface
661A of liner section 661 that faces inwardly toward the center of
a box when liner 650 is erected inside the box. Flap 680 is also
defined by an end surface 667A of liner section 667 that faces
outwardly and away from the center of a box when liner 650 is
erected inside the box. End surface 661A overlaps and directly
contacts end surface 667A when liner 650 is erected inside a box. A
bead of glue can be applied to one or both end surfaces 661A and
667A to join the two end surfaces together. The joined end surfaces
661A and 667A form a short section of liner 650 that has twice the
thickness of other sections of the liner. This section of double
thickness provides a support column 682 that adds compressive
strength to liner 650 and the box reinforced by the liner. The
length of overlap can be very small, such as 3/4 inches or less.
Longer overlaps can also be used. The length of overlap can depend
on the desired size of the flap, the dimensions of the box and
other variables.
[0062] While preferred embodiments of the invention have been shown
and described herein, it will be understood that such embodiments
are provided by way of example only. Numerous variations, changes,
substitutions and combinations of features described herein,
including combinations of features described in different
embodiments herein, will occur to those skilled in the art without
departing from the scope of the invention. Accordingly, it is
intended that the appended claims cover all such variations as fall
within the scope of the invention.
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