U.S. patent application number 14/996428 was filed with the patent office on 2016-07-21 for container with tabs and box blank.
This patent application is currently assigned to Georgia-Pacific Corrugated LLC. The applicant listed for this patent is Georgia-Pacific Corrugated LLC. Invention is credited to William Walter Letson, Michael Joseph Paiva, Ernest Barfield Widner.
Application Number | 20160207660 14/996428 |
Document ID | / |
Family ID | 56407258 |
Filed Date | 2016-07-21 |
United States Patent
Application |
20160207660 |
Kind Code |
A1 |
Paiva; Michael Joseph ; et
al. |
July 21, 2016 |
CONTAINER WITH TABS AND BOX BLANK
Abstract
A container has a folded configuration and an unfolded
configuration. The container may include a top, a bottom, and a
plurality of sides to form an interior when in the folded
configuration. The top may be formed of one or more panels and may
include one or more tabs. The tabs may be positioned on the top at
a location spaced from lateral edges of the top and/or lateral
edges of the sides adjacent the top. The tabs may extend from or be
formed from one or more panels forming the top, may be folded over
an edge connected to the top, and engaged with a panel of the top.
The container may include one or more openings in and/or through
the bottom of the container, where the openings may be configured
to receive tabs when containers are stacked to create stability in
stacks of the containers.
Inventors: |
Paiva; Michael Joseph; (San
Ramon, CA) ; Widner; Ernest Barfield; (Flowery
Branch, GA) ; Letson; William Walter; (Dunwoody,
GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Georgia-Pacific Corrugated LLC |
Atlanta |
GA |
US |
|
|
Assignee: |
Georgia-Pacific Corrugated
LLC
Atlanta
GA
|
Family ID: |
56407258 |
Appl. No.: |
14/996428 |
Filed: |
January 15, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62104581 |
Jan 16, 2015 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 5/0015 20130101;
B65D 5/4295 20130101; B65D 5/001 20130101; B65D 5/18 20130101 |
International
Class: |
B65D 5/00 20060101
B65D005/00; B65D 5/42 20060101 B65D005/42; B65D 5/18 20060101
B65D005/18 |
Claims
1. A container having an unfolded configuration and a folded
configuration, the container comprising: a bottom; a first side at
least partially adjacent to the bottom; a second side at least
partially adjacent to the bottom; a third side at least partially
adjacent to the bottom; a fourth side at least partially adjacent
to the bottom; and a top at least partially extending from one of
the sides, the top including one or more tabs laterally spaced from
the first side, the second side, the third side, and the fourth
side.
2. The container of claim 1, further comprising an opening
extending through the bottom.
3. The container of claim 2, wherein the opening is formed in a
panel of the bottom and the opening is spaced from all exterior
edges of the panel of the bottom.
4. The container of claim 2, wherein the opening extending through
the bottom is laterally spaced from first side, the second side,
the third side, and the fourth side.
5. The container of claim 1, wherein the first side at least
partially extends from the bottom and the second side at least
partially extends from the bottom.
6. The container of claim 1, wherein the one or more tabs of the
top include a first tab and a second tab.
7. The container of claim 1, wherein the top comprises a first top
panel extending from the second side and a second top panel
extending from the fourth side.
8. The container of claim 7, wherein the first top panel and the
second top panel have substantially the same dimensions.
9. The container of claim 7, wherein when the container is in a
folded configuration, the first top panel has an exterior surface
with a first surface area and the second top panel has an exterior
surface with a second surface area different in size than the first
surface area.
10. The container of claim 7, wherein: the first top panel includes
a first tab of the one or more tabs; and the second top panel
includes a second tab of the one or more tabs.
11. The container of claim 7, wherein: the first top panel has a
first edge at a lateral edge of the second side and a second edge
non-adjacently spaced from the first edge; and the first top panel
has one or more of the tabs extending from the second edge and in a
direction away from the first edge.
12. The container of claim 7, wherein: the first top panel has a
first edge at a lateral edge of the second side and a second edge
non-adjacently spaced from the first edge; and the first top panel
has one or more of the tabs extending from a position between the
first edge and the second edge and terminating at about the second
edge.
13. The container of claim 7, wherein: the first top panel has a
first edge at a lateral edge of the second side and a second edge
non-adjacently spaced from the first edge of the first top panel;
the second top panel has a first edge at a lateral edge of the
fourth side and a second edge non-adjacently spaced from the first
edge of the second top panel; and the second edge of the first top
panel and the second edge of the second top panel are spaced from
one another by a gap at least substantially along an entirety
thereof when the container is in a folded configuration.
14. The container of claim 1, wherein in an unfolded configuration:
a panel of the second side extends from the bottom in a direction
substantially perpendicular to a direction a panel of the first
side extends from the bottom; a panel of the third side extends
from the bottom in a direction substantially perpendicular to the
direction the panel of the second side extends from the bottom; and
a panel of the fourth side extends from the bottom in a direction
substantially perpendicular to the direction the panel of the third
side extends from the bottom.
15. A box blank for forming a container, comprising: a bottom panel
having one or more openings spaced from lateral edges of the bottom
panel; a first side panel extending from a first lateral edge of
the bottom panel; a second side panel extending from a second
lateral edge of the bottom panel; a top panel extending from one of
the first side panel and the second side panel; and a tab in the
top panel, the tab being spaced from all side panels of the box
blank.
16. The box blank of claim 15, wherein the top panel has a
plurality of outer edges defining the top panel and the tab is
spaced inward from each of the outer edges of the top panel.
17. The box blank of claim 15, wherein: the top panel has a first
edge at a lateral edge of one of the first side panel and the
second side panel from which it extends; the top panel has a second
edge non-adjacently spaced from the first edge; and wherein the tab
extends from the second edge of the top panel and extends away from
the first edge.
18. The box blank of claim 15, wherein: the top panel includes a
first top piece having a first edge extending along a lateral edge
of the first side panel and a second edge non-adjacently spaced
from the first edge; and the top panel includes a second top piece
having a first edge extending along a lateral edge of the second
side panel and a second edge non-adjacently spaced from the first
edge.
19. The box blank of claim 18, wherein the tab in the top panel has
a lateral edge formed from a lateral edge of the second edge of one
of the first top piece and the second top piece.
20. A method of using a box blank, the method comprising: folding
each of two side panels extending from a bottom panel of the box
blank, such that the two side panels are folded to a position
substantially perpendicular to the bottom panel; folding a top
panel extending from one or more of the two side panels to a
position substantially perpendicular to one or more side panels
from which the top panel extends to form an interior space at least
partially defined between the bottom panel, the two side panels,
and the top panel; and folding a tab of the top panel away from the
interior space, wherein the tab of the top panel is spaced from
lateral edges of the top panel.
21. The method of claim 20, wherein the tab has a lateral edge
formed at about a medial edge of the top panel, the medial edge of
the top panel is located substantially parallel to a first lateral
edge of the top panel and extends between a second lateral edge and
a third lateral edge of the top panel.
22. The method of claim 20, wherein the top panel includes a first
tab and a second tab both spaced from lateral edges of the top
panel, the method further comprising folding each of the first tab
and the second tab away from the interior space.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to design patent Application
Ser. No. 29/514,888 entitled BOX BLANK, having an attorney docket
number of 1385.1001101, and filed on Jan. 16, 2015, the entire
disclosure of which is incorporated herein by reference for all
purposes. This application is related to design patent Application
Ser. No. 29/514,892 entitled BOX BLANK, having an attorney docket
number of 1385.1002101, and filed on Jan. 16, 2015, the entire
disclosure of which is incorporated herein by reference for all
purposes. This application is related to design patent Application
Ser. No. 29/514,898 entitled BOX BLANK, having an attorney docket
number of 1385.1003101, and filed on Jan. 16, 2015, the entire
disclosure of which is incorporated herein by reference for all
purposes.
TECHNICAL FIELD
[0002] The disclosure is directed to containers for holding items.
More particularly, the disclosure is directed to containers in
unfolded and folded configurations with features configured to
facilitate alignment containers in a stack of containers and/or
promote stability in a stack of containers when the containers are
stacked upon one another.
BACKGROUND
[0003] A wide variety of containers have been developed for storing
items, along with methods for forming and using such containers.
Some containers may include stacking tabs extending upward from a
top edge of container sidewalls to provide stability when stacking
such containers. When stacking similar containers on top of one
another, the stacking tabs of the containers may fit into
corresponding notches cut into adjacent containers to secure the
stack. Of the known containers and methods of forming and using
thereof, each has certain advantages and disadvantages.
SUMMARY
[0004] The disclosure is directed to several alternative designs,
materials and methods of assembling containers for holding
items.
[0005] Accordingly, one illustrative embodiment is a container
having an unfolded configuration and a folded configuration. The
container may include a bottom, a first side, a second side, a
third side, a fourth side, and a top. The first side, the second
side, the third side, and the fourth side may at least partially
extend from the bottom. The top may at least partially extend from
one of the sides. In some cases, the top may include one or more
tabs, where the tabs may be laterally spaced from the first side,
the second side, the third side, and the fourth side.
[0006] In another illustrative embodiment, a box blank may be
configured to form a container. The box blank may include a bottom
panel, a first side panel, a second side panel, and a top panel.
The bottom panel may include one or more openings spaced from
lateral edges of the bottom panel. The first side panel may extend
from a first lateral edge of the bottom panel and the second side
panel may extend from a second lateral edge of the bottom panel.
The top panel may extend from one of the first side panel and the
second side panel. In some cases, the box blank may include a tab
in the top panel, where the tab may be spaced from all side panels
of the box blank.
[0007] Another illustrative embodiment is a method of using a box
blank. The method may include folding each of four side panels
extending from a bottom panel of the box blank. The four side
panels of the box blank may be folded to a position substantially
perpendicular to the bottom panel. Illustratively, the method may
include folding a top panel extending from one or more of the four
side panels to a position substantially perpendicular to one or
more of the side panels from which the top panel may extend.
Folding the top panel may form an interior space at least partially
defined between the bottom panel, the four side panels, and the top
panel. In some cases, the method may include folding a tab of the
top panel away from the interior space. The tab of the top panel
may be spaced from lateral edges of the four side panels adjacent
the top panel.
[0008] The above summary of some example embodiments is not
intended to describe each disclosed embodiment or every
implementation of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention may be more completely understood in
consideration of the following detailed description of various
embodiments in connection with the accompanying drawings, in
which:
[0010] FIG. 1 is a schematic perspective view of an illustrative
container in a folded configuration;
[0011] FIG. 2 is a schematic top plan view of the illustrative
container of FIG. 1;
[0012] FIG. 3 is a schematic bottom plan view of the illustrative
container of FIG. 1;
[0013] FIG. 4A is a schematic perspective view of two containers
illustratively stacked on top of one another;
[0014] FIG. 4B is a schematic cross-section view of the two
containers illustratively stacked on top of one another of FIG. 4A,
taken along line 4B-4B;
[0015] FIG. 5 is a schematic plan view of the illustrative
container of FIG. 1 in an unfolded configuration;
[0016] FIGS. 6-9 depict an illustrative flow of folding the
illustrative container of FIG. 1;
[0017] FIG. 10 is a schematic perspective view of an illustrative
container in a folded configuration;
[0018] FIG. 11 is a schematic top plan view of the illustrative
container of FIG. 10;
[0019] FIG. 12 is a schematic bottom plan view of the illustrative
container of FIG. 10;
[0020] FIG. 13 is a schematic plan view of the illustrative
container of FIG. 10 in an unfolded configuration;
[0021] FIG. 14 is a schematic perspective view of an illustrative
container in a folded configuration;
[0022] FIG. 15 is a schematic front view of the illustrative
container of FIG. 14;
[0023] FIG. 16 is a schematic cross-section view of the
illustrative container of FIG. 14, taken along line 16-16 in FIG.
15;
[0024] FIG. 17 is a schematic plan view of the illustrative
container of FIG. 14 in an unfolded configuration;
[0025] FIG. 18 is a schematic perspective view of an illustrative
container in a folded configuration;
[0026] FIG. 19 is a schematic front view of the illustrative
container of FIG. 18;
[0027] FIG. 20 is a schematic cross-section view of the
illustrative container of FIG. 18, taken along line 20-20 in FIG.
19;
[0028] FIG. 21 is a schematic plan view of the illustrative
container of FIG. 18 in an unfolded configuration;
[0029] FIGS. 22-25 are schematic perspective views of containers
having various illustrative dimensions.
[0030] While the invention is amenable to various modifications and
alternative forms, specifics thereof have been shown by way of
example in the drawings and will be described in detail. It should
be understood, however, that the intention is not to limit aspects
of the invention to the particular embodiments described. On the
contrary, the intention is to cover all modifications, equivalents,
and alternatives falling within the spirit and scope of the
invention.
DETAILED DESCRIPTION
[0031] For the following defined terms, these definitions shall be
applied, unless a different definition is given in the claims or
elsewhere in this specification.
[0032] All numeric values are herein assumed to be modified by the
term "about", whether or not explicitly indicated. The term "about"
generally refers to a range of numbers that one of skill in the art
would consider equivalent to the recited value (i.e., having the
same function or result). In many instances, the term "about" may
be indicative as including numbers that are rounded to the nearest
significant figure. Additionally, "about" may refer to being near
or at an object (e.g., about an edge).
[0033] The recitation of numerical ranges by endpoints includes all
numbers within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75,
3, 3.80, 4, and 5).
[0034] Although some suitable dimensions, ranges, and/or values
pertaining to various components, features, and/or specifications
are disclosed, one of skill in the art, incited by the present
disclosure, would understand desired dimensions, ranges, and/or
values may deviate from those expressly disclosed.
[0035] As used in this specification and the appended claims, the
singular forms "a", "an", and "the" include plural referents unless
the content clearly dictates otherwise. As used in this
specification and the appended claims, the term "or" is generally
employed in its sense including "and/or" unless the content clearly
dictates otherwise.
[0036] Any numbers (e.g., first, second, third, fourth, etc.),
letters (e.g., a, b, c, etc.), directional referents (e.g., left,
right, top, bottom, up, down, front, back, corner etc.), or other
terms (e.g., sides) used to describe features relative to another
feature (e.g., a first side and a second side or side A and side B
or a left side and a right side) are used for clarity of
descriptiveness purposes and are not meant to limit the
interpretation or scope of such features.
[0037] The following detailed description should be read with
reference to the drawings in which similar elements in different
drawings are numbered the same. The detailed description and the
drawings, which are not necessarily to scale, depict illustrative
embodiments and are not intended to limit the scope of the
invention. The embodiments depicted are intended only as
illustrative. Selected features of any illustrative embodiment may
be incorporated into an additional embodiment unless clearly stated
to the contrary.
[0038] Although containers configured for stacking on top of one
another are known, there is an ongoing need to provide alternative
containers configured to be stacked on top of one another.
Additionally or alternatively, there is an ongoing need to provide
alternative methods of forming and using containers configured to
be stacked on top of one another.
[0039] Containers may begin as sheets of materials (e.g.,
corrugated cardboard, other paper materials, metal, plastic, and/or
other material). The sheets of material may be cut and/or
perforated to form a box blank or unfolded container having panels
of the container and fold lines for forming a top, bottom, and
sides of the container. The box blank or unfolded container may be
formed (e.g., folded, bent, etc.) into a partial folded
configuration or a folded configuration and one or more of the
panels thereof may be connected to another panel thereof (e.g.,
with an adhesive or other connection mechanism). A machine and/or
an operator may perform the forming of the box blank or unfolded
configuration into the folded configuration.
[0040] Once a container is formed, the container may be filled with
items for storing in the container. In some cases, one or more tabs
or panels may be secured to another panel (e.g., via an adhesive or
other connection mechanism) to secure therein the items filled into
the container.
[0041] Filled (or unfilled) containers may be stacked. In some
cases, the containers may be stacked by a machine and/or an
operator. As discussed below, a container may include a tab on a
top of the container and spaced (e.g., medially spaced) from
lateral edges of the top and an opening on a bottom of the
container, where the tab and opening facilitate positioning of
containers on top of one another and/or stability in stacks of
containers due to the opening on the bottom of the container being
configured to receive the tab on the top of an adjacent container
to limit general horizontal movement (e.g., movement in an
x-direction and/or a y-direction) of containers stacked on top of
one another.
[0042] An illustrative container 10 in a folded configuration is
shown in FIG. 1. In one example of a container 10, the container 10
may include a top 12, a bottom 14, a front side 16, a back side 18,
a left side 20, and a right side 22. In some instances, the
container 10 may include one or more tabs 24 (e.g., a first tab 24a
and a second tab 24b, or different number of tabs) in or at the top
12. As shown illustratively in the Figures, the container 10 may
include one or more corner sides 26 (e.g., a first corner side 26a,
a second corner side 26b, a third corner side 26c, and a fourth
corner side 26d).
[0043] Although the container 10 may be depicted in the Figures
with a certain number of sides, the container 10 may include any
suitable number of sides. For example, the container may include
four (4) sides, five (5) sides, six (6) sides, seven (7) sides,
eight (8) sides, nine (9) sides, ten (10) sides, fifteen (15)
sides, twenty (20) sides, or any other suitable number of sides.
Sides, as used herein, may be a relative term and a side may be a
portion of a container or other element that extends or partially
extends between a top and a bottom of that object.
[0044] The top, bottom and each side of the container may be formed
with or may include one or more panels and have any configuration.
In one example of a container 10 as shown throughout FIGS. 1-9, the
top 12 may include a first top piece or panel 12a and a second top
piece or panel 12b, the front side 16 may be a single panel, the
back side 18 may be a single panel, left side 20 may include a
first left panel 20a, a second left panel 20b, a third left panel
20c, a fourth left panel 20d, and a fifth left panel 20e, the right
side panel may include a first right panel 22a, a second right
panel 22b, a third right panel 22c, a fourth right panel 22d, and a
fifth right panel 22e, and each corner side 26 may include three
panels (e.g., first corner panel 26', a second corner panel 26'',
and a third corner panel 26''', as shown in FIG. 1).
[0045] Although the panels forming the various sides may form gaps
extending there between, this is not required. Between any two or
more panels forming a side or between panels forming adjacent
sides, there may be a gap of any suitable size, or even no gap at
all such that edges of the relevant panels may be touching.
[0046] The tabs 24 may extend from the top 12 and may include any
suitable number of edges and may take on any suitable shape. In one
example, as shown in the Figures, a tab 24 may include four edges,
where three edges 28 may be free, detached, and/or unconnected from
the panel(s) forming the top 12 and one edge 30 that may be
connected to and/or extend from a panel of the top 12 (e.g., a
hinge or hinge link connection). In another example, one or more
edges of the tab 24 may have a perforated connection or attachment
to a remainder of the top 12 such that when desired the
perforations on the tab 24 may be separated to allow the tab 24 to
be folded or removed.
[0047] Illustratively, the tab 24 may be configured to be folded or
bent about the edge 30 such that an exterior surface of the tab 24
opposite an interior surface thereof (when the container 10 is in a
folded configuration) is folded onto or adjacent an exterior
surface of a panel of the top 12. In some cases, the tab 24 may be
configured (e.g., elongated) to be folded back one or more times to
increase or decrease a thickness of the tab 24, as desired, or for
other purposes. For example, if the tab 24 is folded back once,
then the thickness of tab 24 may be the thickness of the material
of the container 10, and if the tab 24 is folded back twice, then
the thickness of the tab 24 may be twice the thickness of the
material of the container 10, and so on. The additional tab
thickness may reduce the likelihood of inadvertent dislodgement or
disengagement from an adjacent box in a stack.
[0048] Although the tab 24 is disclosed herein as a rectangle, the
tabs 24 may take on any suitable shape and have any suitable number
of edges. Additionally, in some instances, the tabs 24 may be sized
to promote strength in a container 10 and/or in a stack of
containers 10, to facilitate positioning a container 10 on top of
another container 10, and/or to resist twisting between containers
10 of a stack of containers. In one example, enlarging a tab 24
relative to a top 12 of a container 10 (e.g., to coordinate a size
of a tab with one or more dimensions of a container or for other
purposes) may increase stability of a stack of containers and/or
increase resistance to twisting of the stack.
[0049] Although the tabs 24 described herein have one or more edges
30 connected to or extending from a panel of the top 12, one or
more tabs may be configured in one or more other manners. In one
example, all of a tab's edges may be free from connection to the
panel(s) of the top 12, such that the tab may be set on a panel of
the top 12 and secured thereto rather than being folded onto the
panel of the top 12.
[0050] Tab 24 may be connected to a panel of the top 12 through one
or more affixing and/or connection techniques. For example, a tab
24 may be connected to a panel of the top 12 with an uncut edge
(e.g., edge 30), a bonding connection (e.g., an adhesive, weld,
etc.), an extension engaging an opening (e.g., extending an
extension through a slit or slot), and/or through one or more other
connection techniques.
[0051] FIG. 2 is a schematic top plan view of the container 10 with
one tab 24 extending from each panel 12a, 12b of the top 12 and
folded over edge 30 of the tab 24 (e.g., folded in a direction of
the front side 16 or the back side 18). When the tabs 24 are folded
over edge 30, the respective panel(s) of the top 12 may at least
partially define an opening 34 through the panels 12a, 12b of the
top side 12 into an interior space 44 of the container 10. In one
example as shown in FIG. 2, the opening 34 may be at least
partially defined by the associated panel 12a, 12b of the top 12
and the gap 32 between panels. Alternatively, the opening 34 may be
entirely defined by a panel of the top 12 (see e.g., opening 234 in
FIG. 14).
[0052] The top 12 may include lateral edges 36. The lateral edges
36 of the top 12 may be formed along and/or adjacent lateral edges
36 of one or more of the sides of the container 10. In one example,
the lateral edges of the top 12 may be formed along and/or adjacent
one or more of lateral edges 38 of the front side 16, the back side
18, the left side 20, the right side 22, and the corner sides
26.
[0053] The tabs 24 may be formed and/or positioned at any suitable
location on the top 12. In one example, the tabs 24 may be spaced
(e.g., medially and/or laterally spaced) from one or more of the
front side 16, the back side 18, the left side 20, the right side
22, and the corner sides 26. Illustratively, the tabs 24 may be
laterally spaced from lateral edges 36 of the top 12 adjacent to
and/or lateral edges 38 of the front side 16, the back side 18, the
left side 20, the right side 22, and the corner sides 26. In some
instances, the tabs 24 may be formed in the top side 12 such that
the tabs 24 may be spaced from all lateral edges 36 of panels
forming the top 12 and/or may include one or more edges that form
and/or run along a central edge 36' of a panel at least partially
forming the top 12. The central edge 36' may extend between two
lateral edges 36 of the top 10 and may otherwise be non-adjacently
spaced from the lateral edges 36 of the top 10.
[0054] The bottom 14 of the container 10 may be at least partially
defined by lateral edges 39 adjacent lateral edges 38 of the front
side 16, the back side 18, the left side 20, the right side 22,
and/or the corner sides 26. In some cases, the bottom 14 may
include one or more openings 40. The openings 40 may be at least
partially defined by edges 42, where one or more or all of the
edges 42 may be spaced laterally inward from lateral edges 39 of
the bottom 14, as shown in FIG. 3.
[0055] The openings 40 in the bottom 14 of a first container 10a
may be configured to receive tabs 24 of a second container 10b on
which the first container 10a may be stacked. As shown in FIGS. 4A
and 4B, when the first container 10a is stacked or positioned on a
top 12 of the second container 10b, each opening 40 may receive a
tab 24 (e.g., one or more tabs 24). Illustratively, the openings 40
for may be configured on the bottom 14 to align with tabs 24 and
receive the tabs 24 therein. The number of openings 40 on the
bottom 14 of the container 10b may correspond to the number of tabs
24 on the top of the container 10b, however, it may be appreciated
that the number of openings 40 on the bottom 14 of a container may
differ from the number of tabs on the container so as to allow
containers having a different number of tabs to be combined in a
stack.
[0056] FIG. 4B is a cross-section taken along line 4B-4B in FIG. 4A
and depicts a cross-section of a tab 24 received in or inserted
into the opening 40. In one example, the tab 24 may be inserted
into the opening 40 so as to limit side to side movement as the
edges 42 defining the opening 40 are configured to engage on a tab
24 received in the opening 40 to limit side-to-side movement of one
or both of the first container 10a and the second container 10b
relative to the other of the first container 10a and the second
container 10b.
[0057] In some instances, the container 10 may be formed from a
single piece of material (e.g., the material may be or may include
corrugated cardboard, cardboard, paper, metal, plastic, or other
material). FIG. 5 is a schematic plan view of a container 10 formed
from a single piece of material in an unfolded configuration (e.g.,
as a blank). Unfolded container 10 may be folded in one or more
manners. FIGS. 6-9 depict one illustrative method of folding panels
of the box blank or unfolded container 10 to form a folded
container 10, as shown in FIG. 1.
[0058] Although FIGS. 6-9 depict a method of folding the container
10, this illustrative method of folding is not meant to be limiting
and the blank or unfolded container 10 may be folded using one or
more additional or alternative steps (e.g., via wrapping the
unfolded container 10 around a mandrel, etc.) to achieve the
configuration of container 10 or one or more other container
configurations. One skilled in the art may appreciate that the
particular method of container assembly (e.g., an automated method
or a manual method) as well as particular equipment and/or
materials of a container may dictate timing and/or sequence of
folding the container 10, including the tabs 24 thereof.
Illustratively, the tabs 24 may be folded at any suitable time
during an assembly or folding of the container 10 including, but
not limited to, prior to any other folds, after all other folding
steps, or any time there between.
[0059] FIG. 6 depicts the container 10 of FIG. 5 with portions of
the left side 20, right side 22, and the corner sides 26 in a
folded configuration. For example, second corner panels 26'' of the
corner sides 26 which may extend from one of a panel of the front
side 16 and a panel of the back side 18 may be folded with respect
to panels forming the front side 16 and the back side 18 of the
container 10. Generally, second corner panels 26'' of the corner
sides 26 may be folded about forty-five (45) degrees with respect
to the respective panels of the front side 16 and the back side 18.
Alternatively, the second corner panels 26'' may be folded to any
other suitable angle with respect to the respective panels of the
front side 16 and/or the back side 18. Similarly, although other
panels of the container 10 may be discussed herein as being folded
to a particular angle or to about a particular angle with respect
to other panels or portions of container 10, these other panels may
be folded to any other suitable angle than the one specified.
[0060] In the example of FIG. 6, panels 20c, 20d, 22c, and 22d of
the left side 20 and right side 22 of the container 10 and
extending from the second corner panels 26'' of the corner sides 26
may be folded with respect to second corner panels 26'' of the
corner sides 26. Generally, each of the panels 20c, 20d, 22c, and
22d may be folded about forty-five (45) degrees with respect to the
respective second corner panels 26'' form which the panels 20c,
20d, 22c, and 22d extend.
[0061] FIG. 7 depicts the container of FIG. 6 with the back side 18
in a folded configuration. For example, a panel of the back side 18
which extends from a panel of the bottom 14 may be folded upward
until the back side 18 reaches a position about ninety (90) degrees
from the panel of the bottom 14. Such positioning of a panel of the
back side 18 at about ninety (90) degrees relative to a panel of
the bottom 14 may position folded second corner panels 26''
extending from the back side 18, folded third left panel 20c, and
folded third right panel 22c at positions approximately ninety (90)
degrees from the bottom 14. With folded second corner panels 26''
of the corner sides 26 extending from the back side 18, the folded
panels 20c and 22c of the left side 20 and the right side 22, and
the folded panel of the back side 18, the container 10 begins to
define an interior space 44.
[0062] FIG. 8 depicts the container of FIG. 7 with the front side
16, a portion of the top 12, and more portions of the left side 20
and the right side 22 in a folded configuration. For example, a
panel of the front side 16 which may extend from a panel of the
bottom 14 may be folded upward until the front side 16 reaches a
position about ninety (90) degrees from a panel of the bottom 14.
Such positioning of a panel of the front side 16 at about ninety
(90) degrees relative to a panel of the bottom 14 may position
second corner panels 26'' extending from the front side 16, folded
left side panel 20d, and folded right side panel 22d at a position
approximately ninety (90) degrees from the bottom 14. With all of
the folded second corner panels 26'' of the corner sides 26, the
folded panels 20c, 20d. 22c, 22d, of the left side 20 and the right
side 22, and the folded panels of the front side 16 and the back
side 18 in a folded position, the container 10 may further define
an interior space 44.
[0063] In the illustrative method of folding the blank or unfolded
container 10, the panels 20e, 22e of the left and right side may be
folded upward until the panels 20e, 22e reach a position about
ninety (90) degrees from a panel of the bottom 14. Such positioning
of the panels 20e, 22e at about ninety (90) degrees relative to a
panel of the bottom 14 may position first corner panels 26' at a
position approximately ninety (90) degrees from the bottom 14.
[0064] As illustrated, the first corner panels 26' may be folded
inward until the corner panels reach about forty-five (45) degrees
with respect to either panel 20e, 22e from which it extends. When
the panels 20e, 22e are folded to a position about ninety (90)
degrees from the bottom 14 and the container 10 is in a folded
configuration, the first corner panels 26' may wrap or extend
around or about (e.g., underlay or overlay) the second corner
panels 26''. As an alternative to positioning the first corner
panels 26' at a position about forty-five (45) degrees from the
bottom 14, the first corner panels 26' may be folded to any other
suitable angle with respect to a panel of the bottom 14.
[0065] As shown in FIG. 8, a panel of the top 12 (e.g., first top
panel 12a) may be folded inward until the first top panel 12a
reaches a position about ninety (90) degrees from the front side 16
from which the first top panel 12a may extend, for example. As an
alternative to positioning the first top panel 12a at a position
about ninety (90) degrees from the front side 16, the first top
panel 12a may be folded to any other suitable angle with respect to
a panel of the front side 16. With the first top panel 12a in a
folded position in conjunction with other folded panels of the
container 10, the container 10 may further define an interior space
44. Although the Figures depict the top panel 12a and the top panel
12b being folded at separate times, these panels 12a, 12b, along
with other panels, may be folded in other orders, including but not
limited to at the same time.
[0066] The second panels 20b, 22b of the left and right side 20, 22
that may extend from the first top panel 12a may be folded inward
until the panels 20b, 22b reach a position about ninety (90)
degrees from the first top panel 12a. When the first top panel 12a
is in a folded position, the panels 20b, 22b with respect to the
first top panel 12a may underlay or overlay the fourth panels 20d,
22d of the left and right sides 20, 22. As an alternative to
positioning the panels 20b, 22b at about ninety (90) degrees from
the first top panel 12a when in a folded position, the panels 20b,
22b may be folded to any other angle with respect to the first top
panel 12a.
[0067] As illustrated, the third corner panels 26''' that may
extend from the panels 20b, 22b may be folded inward until the
third corner panels 26''' reach a position about forty-five (45)
degrees from the panels 20b, 22b. When the second corner panels
26'', the first top panel 12a, and the panels 20b, 22b are in
folded positions, the third corner panels 26''' may wrap or extend
around or about (e.g., underlay or overlay) the second corner
panels 26''. As an alternative to positioning the third corner
panels 26'' extending from panels 20b, 22b at about forty-five (45)
degrees from the panels 20b, 22b, the third corner panels 26'
extending from panels 20b, 22b may be folded to any other suitable
angle with respect to the panels 20b, 22b.
[0068] As shown in FIG. 9, a panel of the top 12 (e.g., second top
panel 12b) may be folded inward until the second top panel 12b
reaches a position about ninety (90) degrees from the back side 18
from which the second top panel 12b may extend, for example. As an
alternative to positioning the second top panel 12b at a position
about ninety (90) degrees from the back side 18, the second top
panel 12b may be folded to any other suitable angle with respect to
a panel of the back side 18. With the second top panel 12b in a
folded position in conjunction with other folded panels of the
container 10, the container 10 may further define an interior space
44.
[0069] The first panels 20a, 22a of the left and right side 20, 22
that may extend from the second top panel 12b may be folded inward
until the panels 20a, 22a reach a position about ninety (90)
degrees from the second top panel 12b. When the second top panel
12b is in a folded position and the panels 20a, 22a are folded with
respect to the second top panel 12b, the panels 20a, 22a may
underlay or overlay the third panels 20c, 22c of the left and right
sides 20, 22. As an alternative to positioning the panels 20a, 22a
at about ninety (90) degrees from the second top panel 12b when in
a folded position, the panels 20a, 22a may be folded to any other
suitable angle with respect to the second top panel 12b.
[0070] The third corner panels 26''' that may extend from the
panels 20a, 22a may be folded inward until the third corner panels
26' reach a position about forty-five (45) degrees from the panels
20a, 22a. When the second corner panels 26'', the second top panel
12b, and the panels 20a, 22a are in folded positions, the third
corner panels 26''' may wrap or extend around or about (e.g.,
underlay or overlay) the second corner panels 26''. As an
alternative to positioning the third corner panels 26''' extending
from panels 20a, 22a at about forty-five (45) degrees from the
panels 20a, 22a, the third corner panels 26''' extending from
panels 20a, 22a may be folded to any other suitable angle with
respect to panels 20a, 22a.
[0071] As shown in FIG. 9, the tabs 24 cut, formed, and/or
extending from the top 12 of the container 10 may be folded over
edge 30 of the tab 24. Tab 24 may be folded over edge 30 such that
an interior surface 48 of the container 10 on tab 24 faces outward
from the container and an exterior surface 46 of the container 10
on tab 24 may rest on the exterior surface 46 of the container 10
on the top 12.
[0072] The tabs 24 may have consistency in size and configuration
due to being only folded over a single edge 30. In such instances,
the tabs 24 may extend at least a thickness of the material of the
container 10 above the exterior surface 46 of the container 10 on
the top 12. Alternatively, or in addition, other positioning of the
tab 24 with respect to the top 12 may be utilized such that that
the tab 24 may be elevated above an exterior surface 46 of the
container 10 on the top 12 so as to be received in an opening 40 of
a container 10 stacked thereon. For example, as discussed above,
the tab 24 may be folded over multiple times to adjust a thickness
of the tab 24.
[0073] Although the Figures may depict the tabs on a top of a
container as being mirrored about one or more edges (e.g., edge
36') or about the top, the tabs may be non-mirrored (e.g.
non-uniformly configured). In another example, a first tab on a top
may have a first surface area and a second tab on the top may have
a second surface area larger than the first surface area. In some
cases, a top of a container may have one larger tab and two or more
smaller tabs, or other combinations of tabs have various sizes. In
still other embodiments, the tabs on the container may be unevenly
distributed about the top of the container.
[0074] In some cases, a portion of the top 12 may be removed from
around any cut edges of tab 24 so as to create space between the
cut edges of the tab and a panel of the top 12, where the space may
facilitate engaging the tab for folding the tab or having one or
more other purposes. The space around cut edges of tab 24 is not
required.
[0075] The tabs 24 may have any suitable dimension and any suitable
size. For example, the tabs 24 may be at least generally square,
rectangular, triangular, circular, and/or have any suitable number
of sides or edges. Examples sizes of the tabs may include tabs 24
having a height or thickness (e.g., in a Z-direction) of about a
caliper (e.g., a thickness of the material from which the container
is formed) and measurements of dimensions in a horizontal or X-Y
direction with an X-direction dimension of between 0.125''-12'',
1''-10'', 1''-5'', 1''-3'', or greater and a Y-direction dimension
of between 0.125''-12'', 1''-10'', 1''-5'', 1''-3'' or greater. The
height, thickness or Z-direction dimensions may be configured to be
received in opening 40 of an adjacent container, but not extend
substantially into the interior space 44 of the container 10. In
some cases a material thickness of the container 10 may be
0.0125'', 0.125'', 0.25'', 0.375'', 0.5'', 0.75'', 1'', a thickness
there between, or other thickness.
[0076] As discussed above, the tabs 24 positioned on the top 12 on
an exterior surface 46 of the container 10 may facilitate or
promote stability in a stack of containers 10 stacked on top of one
another. Openings 40 in the bottom 14 of the container 10 may be
configured to receive the tabs 24 therein and as a result, the
edges 42 of the openings 40 may engage the edges 28, 30 of the tabs
24 as one or more stacked containers 10 may be urged in a
horizontal direction (e.g., an X-direction or Y-direction).
[0077] The openings 40 may be sized equal to or larger than a
surface area of the tabs, and/or may have any suitable dimensions.
In one example, the openings 40 may have a tolerance of between
1/32'' and 1'' in one or more direction, between 1/16'' and 1'' in
one or more direction, between 1/8'' and 1'' in one or more
direction, between 1/4'' and 1'' in one or more direction, between
1/2'' and 1'' in one or more direction, or other tolerance in one
or more direction to facilitate receiving the tabs 24 while
maintaining X- and Y-direction stability in a stack of containers
10. Illustratively, if a tab 24 has dimensions of 1''.times.1'', an
opening 40 may have dimensions of 1.125''.times.1.125'' or
1.25''.times.1.25'', and if a tab 24 has dimensions of
3''.times.3'', an opening 40 may have dimensions of
3.125''.times.3.125'' or 3.25''.times.3.25''. In some instances of
the opening having a greater tolerance (e.g., 0.25'' or other
suitable tolerance) around a tab, the opening may be configured to
receive a tab for the purpose of aligning or positioning a
containers relative to one another in a stack. In some instances of
the opening having a lesser tolerance (e.g., 0.125'' or other
suitable tolerance) around a tab, the opening may be configured to
receive a tab for the purpose of promoting stability in a stack of
containers and/or for the purpose of resisting twisting of a stack
of containers.
[0078] In instances when a tab 24 may be positioned on an exterior
surface 46 the top 12 of the container 10, the tab 24 may be
connected to one or more panels of the top 12. In one example, the
tab 24 may be at least partially connected to the one or more
panels of the top 12 via an adhesive (e.g., resin, glue, or other
adhesive). Alternatively, or in addition, the tabs 24 and/or the
top 12 of the container 10 may include connectors (e.g., inserts
that may engage openings on either or both of the tabs 24 and the
top 12 of the container 10) configured to maintain a connection
between the tabs 24 and the tops 12 with or without an adhesive or
other connector.
[0079] Although the tabs 24 are shown and described in FIGS. 1-9 as
being cut from a top panel 12a, 12b, one or more tabs 124 may,
additionally or alternatively, extend from a center edge 136' and
away from a lateral edge 136 substantially opposite the center edge
136' of one or more panels of the top 112 of the container 110, as
shown for example in FIGS. 10-13. Some references numerals
represented on FIGS. 10-13 are not specifically discussed as,
unless expressly indicated otherwise, reference numerals shown in
FIGS. 10-13 having "100" added thereto indicate similar features as
the reference numerals without "100" added thereto in FIGS. 1-9. As
shown in FIG. 13, which is a schematic illustration of a blank or
the container 110 in an unfolded configuration, the tabs 124 may
extend from and away (e.g., outward) from a center edge 136' of the
top panels 112a, 112b and may include free or unconnected edges 128
and connected edge 130. Although the tabs 124 take a rectangular
form in the example of FIGS. 10-13, the tabs 124 of this example
may be any suitable shape and/or size, similar to as discussed with
respect to tabs 24. In some instances, as shown in FIGS. 10 and 11,
the tabs 124 may be folded over edge 130 of the tabs 124 at which
the tabs 124 may be connected or secured to one of the top panels
112a, 112b. In this instance, edges 130 of the tabs 124 may be
coincident with the center edge 136' of the top panels 112a,
112b.
[0080] As shown in FIGS. 12 and 13, the openings 140 in the bottom
114 may be positioned therein to receive the tabs 124 extending
from the center edge 136' of the top panels. When the dimensions of
the container 10 in the examples of FIGS. 1-9 and the container 110
of FIGS. 10-13 are generally the same, the openings 140 may be
positioned more central to an imaginary or real center line
dividing the bottom 114 into substantially equal parts than the
openings 40 configured to receive tabs 24 due to the positioning of
the tabs 124 more central on the top 112 relative to the
positioning of the tabs 24 on the top 12. However, this is not
required as tabs 124 may have varying dimensions and/or positioning
about the top 12.
[0081] Although the tabs 24, 124 are shown and described in the
examples of FIGS. 1-13 as being adjacent center edges 36', 136' of
the top 12, 112 of the containers 10, 110, one or more tabs 224
may, additionally or alternatively to one or more tabs 24, 124
being adjacent center edge 36', 136', may be positioned in a medial
portion 236' of one or more panels (e.g., a single panel 212a as
shown in the example of FIGS. 14-17 or multiple panels) of the top
212 of a container 210, as shown in example the container 210 of
FIGS. 14-17. Some references numerals represented on FIGS. 14-17
are not specifically discussed as, unless expressly indicated
otherwise, reference numerals shown in FIGS. 14-17 having "200"
added thereto indicate similar features as the reference numerals
without "200" added thereto in FIGS. 1-9.
[0082] In one example container 210, the medial portion 236' may be
a portion of the top 212 spaced from lateral edges 236 of the top
212 and/or spaced from lateral edges 238 of one or more of a panel
of a glue tab 250 (e.g., where a glue tab 250 may be utilized to
secure a top of the container in a closed position), a panel of a
back side 218, a panel of a left side 220, and/or a panel of a
right side 222. As depicted in FIG. 17, which is a schematic
illustration of a blank or the container 210 in an unfolded
configuration, the tabs 224 may be positioned in the medial portion
236' of the panel 212a of the top 212. Although the tabs 224 take a
rectangular form in the example of FIGS. 14-17, the tabs 224 of
this example may be any suitable shape and/or size (see discussion
regarding shape and size of tabs 24, 124 above).
[0083] The tabs 224 may be defined by free or unconnected edges 228
cut into the panel 212a and a fold edge or line 230 about which the
tabs 224 may be folded prior to being secured to an exterior
surface 246 of the top 212 of the container 210. In one instance,
space may be formed (e.g., material may be removed from the top
212) between the free or unconnected edges 228 and adjacent edges
of the panel 212a of the top 212. In some instances, as shown in
FIG. 14, the tabs 224 may be folded over edge 230 of the tabs 224
at which the tabs 224 may be connected to a top panel (e.g., one or
more top panels 212a).
[0084] As shown in FIGS. 16 and 17, the openings 240 in the bottom
214 may be positioned therein to receive the tabs 224 of an
adjacent container 210 extending from the center portion 236' of a
top panel (e.g., the top panel 212a). As discussed above with
respect to the examples of FIGS. 1-13, the openings 240 in the
bottom side may be configured to receive tabs 224 of containers 210
on which a container 210 may be stacked and may be configured so as
to be spaced, in some cases entirely, away from lateral edges 238
of the front side 216, the back side 218, the left side 220, and
the right side 222 of the container 210.
[0085] The containers disclosed herein may take on one or more
configurations. The containers may include, for example, three
sides and a bottom; four sides and a bottom; four sides, a bottom,
and a top; five sides, a bottom, and a top; six sides, a bottom,
and a top; seven sides, a bottom, and a top; eight sides, a bottom,
and a top; and/or any other suitable combination of sides. In the
examples depicted in FIGS. 1-13, the containers 10, 110 may
generally have eight (8) sides (e.g., a front side, a back side, a
left side, a right side, and four corner sides), a top, and a
bottom, where panels extending from panels of the left side, the
right side, the front side, and/or the back side may be folded or
bent to form corner sides, as discussed above. In the examples of
FIGS. 14-21, the container may generally have eight (8) sides
(e.g., a front side, a back side, a left side, a right side, and
four corner sides), a top, and a bottom, where the ends of panels
extending from the top and bottom and forming the left and right
sides and extend out and over the corners sides formed from panels
extending from panels of the front side and back side, but do not
wrap around and form the corner sides.
[0086] A container 310 in a folded configuration is shown in FIG.
18. Some references numerals represented on FIGS. 18-21 are not
specifically discussed as, unless expressly indicated otherwise,
reference numerals shown in FIGS. 18-21 having "300" added thereto
indicate similar features as the reference numerals without 300
added thereto in FIGS. 1-9.
[0087] In one example of a container 310, the container 310 may
include a top 312, a bottom 314, a front side 316, a back side 318,
a left side 320, and a right side 322. In some instances, the
container 310 may include one or more tabs 324 (similar to or
different than the tabs 24, 124, 224 discussed above) in or at the
top 312. As shown illustratively in the Figures, the container 310
may include one or more corner sides 326 (e.g., a first corner side
326a, a second corner side 326b, a third corner side 326c, and a
fourth corner side 326d (see FIGS. 20 and 21)). Similar to as
discussed above with containers 10, 110, 210, the container 310 may
have any number of sides.
[0088] Each side of the container 310 may be formed with or may
include one or more panels. In one example as shown throughout
FIGS. 18-21, the top 312 may include a first top panel 312a and a
second top panel 312b, the front side 316 may be a single panel,
the back side 318 may be a single panel, the left side 320 may
include a first left panel 320a (e.g., extending from a second top
panel 312b), a second left panel 320b (e.g., extending from the
first top panel 312a), a third left panel 320c (e.g., extending
from the panel of the back side 318), a fourth left panel 320d
(e.g., extending from the panel of the front side 316), and a fifth
left panel 20e (e.g., extending from a panel of the bottom 314),
the panels of the right side 322 may include a first right panel
322a (e.g., extending from the second top panel 312b), a second
right panel 322b (e.g., extending from the first top panel 312a), a
third right panel 322c (e.g., extending from the panel of the back
side 318), a fourth right panel 322d (e.g., extending from the
panel of the front side 316), and a fifth right panel 322e (e.g.,
extending from a panel of the bottom 314), and each corner side 326
may include a single panel (e.g., extending from either the panel
of the front side 316 or extending from a panel of the back side
318).
[0089] As shown in the example of FIGS. 18-21, one or more panels
of the left side 320 and one or more panels of the right side 322
may overlap the corner sides 326. As shown, for example, in FIG.
20, a gap as depicted by dotted line G may be formed between a
panel of a corner side 326 and the second side panel 320b of the
left side 320 of the container 310. Similarly, one or more gaps may
formed between each corner side 326 and one or more panels of the
left side 320 and one or more panels of the rights side 322 (e.g.,
at the positioning of panels of the left side 320 and panels of the
right side 322 over the corner sides 326). In some instances, the
gap G between the corner sides 326 and panels of the left side 320
and panels of the right side 322 may facilitate carrying, moving,
forming, and/or breaking down of containers 310 by providing a
location to grip the container 310 at a portion of the left side
320 and/or the right side 322 overlaying the corner sides 326.
[0090] FIG. 21 depicts an illustrative box blank or unfolded
container 310. The openings 340 in the bottom 314 and the tabs 324
in the top 312 of the container 310 are similar to the openings 40
and tabs 24 described above with respect to the example container
10 of FIGS. 1-9. In the box blank or unfolded configuration of the
container 310, the container 310 may include panels having tapered
edges 352 along one or more edges of the panels forming the left
side 320 and/or the right side 322. The tapered edges 352 may be
angled at the same or different angle as one or more other tapered
edges 352. In one case, the tapered edges 352 of panels of the left
side 320 and the right side 322 may facilitate stacking containers
310 next to one another as the tapered edges 352 may prevent panels
of adjacent containers 310 from catching on one another.
Additionally, or alternatively, the tapered edges 352 may be
utilized for other purposes.
[0091] The containers described herein and the panels thereof may
have any suitable dimension, as measured in width, height, and
depth directions. As an example of containers with various
dimension, FIGS. 22-25 depict containers 410, 510, 610 having
various dimensions, where each of containers 410, 510, 610 may
include one or more feature of containers 10, 110, 210, and/or 310
described herein. FIG. 22 depicts container 410 having a
measurement of the width dimension that may be about two (2) times
a measurement of the height dimension or a measurement of the depth
dimension. FIG. 23 depicts container 510 having a measurement of
the width dimension and a measurement of a height dimension that
may both be about two (2) times a measurement of the depth
dimension. FIG. 24 depicts container 610 having a measurement of
the height dimension that may be about two (2) times a measurement
of the width dimension or a measurement of the depth dimension.
FIG. 25 depicts container 710 having a top 712 with two top panels
712a, 712b, where the top panels 712a, 712b have different
dimensions (e.g., interior and/or exterior surface areas of the top
panel 712a differs from the respective interior and/or exterior
surface areas of the top panel 712b). As discussed, although
specific relative dimensions may be provided with respect to
containers 10, 110, 210, 310, 410, 510, 610, 710, and features
thereof, the containers disclosed herein may have other dimensions,
as desired.
[0092] Those skilled in the art will recognize that the present
invention may be manifested in a variety of forms other than the
specific embodiments described and contemplated herein.
Accordingly, departure in form and detail may be made without
departing from the scope and spirit of the present invention as
described in the appended claims.
* * * * *