Double-bottom, One-piece Beverage Case

Abstract

A wrap-around or end-loading style container, adapted to be formed in a typical rectangular, tubular configuration, but with a double thickness cushion bottom, a blank for making same, and a method for folding the blank into the container as disclosed. The design of this invention is unique in that a double thickness bottom with cushioning characteristics is obtained using a blank no larger than a standard blank, thereby giving minimal additional costs. To a typical rectangular container blank with four adjacent top, bottom, and side panels are added end closure flaps at each opposite end of the respective panels. The side panel closure flaps are inwardly folded after the four panels are rectangularly arranged and attached by way of a manufacturer's flap or joint. The top closure flap is glued and folded inwardly and down against these side panel flaps. The bottom panel closure flap is formed with two sections, each foldable along the line connecting the flap to the bottom panel. One of these sections, resembling a manufacturer's tab, is glued and folded inwardly to contact the first-folded side panel flaps, while the second section is glued and reversibly folded to contact the bottom of said container, thereby giving, in conjunction with the similarly folded flap at the opposite end of said bottom panel, a double thickness over a substantial portion of the surface of the bottom of the container for cushioning properties.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to fiberboard containers, blanks for making same, and methods of folding same, and, more particularly, to a container with a common rectangular, tubular configuration with an end closure which has one outer flap connecting the bottom panel formed in two foldable sections, the first section resembling a foldable tab which is inwardly folded to constitute a portion of the end closure, and the seccond section reversibly folded to be attached to the bottom of the container which, with the corresponding section from the flap at the opposite end of the panel, form a double thickness over a substantial portion of the bottom of the container.

2. Description of the Prior Art OF THE PRIOR ART

Modern automatic glass container handling equipment and carton handling techniques have resulted in a need for cartons having cushioning properties to resist breakage during handling and in transit. Initially, spaced inserts and partitions were used to prevent contact between the containers, arranging the containers into columns and rows. In time the concept of bulk packaging evolved wherein it was found that if sufficient cushioning could be provided for in the containers these partitions could be deleted. Early attempts to produce such a container were expensive in the utilization of additional sheets inserted into the bottom of the container. The invention in this case provides a unique design requiring no additional surface area of paperboard to obtain the cushioning properties, and at the same time is one which can easily be automated for folding.

SUMMARY OF THE INVENTION

A rectangularly arranged tubular container made from corrugated paperboard or the like is provided by this invention, wherein two side panel closure flaps are folded inwardly to cover an open end of said tubular container, an outer top closure flap is folded down and glued to said side panel closure flaps, a fourth outer flap hingedly attached to the panel designated as the bottom panel is formed with two sections, the first said section being a foldable tab inwardly folded and glued to said side panel closure flaps, thereby giving the end closure structure, and the remaining section being reversibly folded and glued to the bottom panel of said container, thereby giving a double thickness over a portion of the area of the bottom of the container.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a corrugated paperboard blank adapted to be foldable into the container disclosed in this invention.

FIG. 2 is a perspective view of the blank of FIG. 1 partly folded into rectangular, tubular configuration.

FIG. 3 is a perspective view of the blank in FIG. 2 folded in tubular configuration, with one end closure only partly folded.

FIG. 4 is a perspective view of the container in FIG. 3, with the end closure folded, and before final folding of the double bottom.

FIG. 5 is a perspective view of the container completely folded, showing the double thickness bottom.

FIG. 6 is a perspective schematic view of an apparatus suitable for automatically folding a portion of the end closure of the container.

DETAILED DESCRIPTION OF A PREFRRED EMBODIMENT

As can be seen generally in the drawings, a container and blank are disclosed including a top panel 10, two sidewall panels 11 and 12, and a bottom panel 13 connected along parallel fold lines 14. A manufacturer's glue flap 15 is attached to top panel 10 along fold line 16 and when attached to panel 12 holds the panels 10, 11, 12 and 13 in a tubular configuration. Each panel has flaps extending from the ends thereof defined by two parallel fold lines 17 arranged perpendicularly to fold lines 14 and 16. Top end closure flaps 18 and 19 extend from either end of top panel 10, connected along fold lines 17. Each flap 18 and 19 has an oval line-cut hand hole 20 formed therein spaced a distance from fold line 17. Side end closure flaps 21 and 22 extend from either end of side panel 11, connected along fold line 17. Each flap 21 and 22 has formed therein a slot or cut out portion 23 equivalent to one-half of the hand hole 20 as cut in flaps 18 and 19. Each of the slots 23 has as its center line (shown as dashed line 24) a line spaced from the edge of panel 10 adjacent panel 11 a distance equal to that spacing of the center line of oval line-cut hand hole 20 from the fold line 17. Such spacing allows for overlapping alignment of the hand hole 20 and the slot 23 when in the final folded position.

Side end closure flaps 25 and 26 extend from either end of side panel 12 and have formed therein a cutout or slot 27 similar to slot 23, centered along dashed line 28, spaced from the outer edge of panel 12 a distance equal to the spacing of the oval hand holes 20 from fold line 17 in flaps 18 and 19. The fractional cut hand holes 23 and 27 meet in end-abutting relation when the end closure is folded and, when the top end closure flap 18 or 19 is folded into position, the overlapping alignment gives a complete hand hole extending through the closure.

Bottom panel 13 has extending therefrom closure flaps 29 and 30. Each flap 29 and 30 has cut therein a smaller secondary glue tab 31 and 32, respectively. After the side end closure flaps and top closure flaps are in position, the glue tabs 31 and 32 are glued into place over the side end closure flaps 21 and 25, or 22 and 26. Tabs 31 and 32 hold the lower portion of the side end closure flaps in position and give a satisfactory end closure.

The closure flaps 29 and 30 are reversibly folded and glued to the bottom panel 13 to provide the necessary cushion. The shape of tabs 31 and 32 and the relative percentage of area used for the tabs can be varied depending on the weight of the contents of the container and the type of material used in fabricating the container, as well as the nature of the forces to be exerted on the end closure restrained in part by tabs 31 and 32.

In FIG. 6 a portion of an automatic folding apparatus is shown to be used in conjunction with other automatic folding equipment, that shown in FIG. 6 being particularly adapted for folding the bottom closure flaps 29 and 30 and secondary glue tabs 31 and 32. It is to be understood that a similar device would be located on the opposite side of the conveyor for folding the other end of the container.

A typical conveyor 33 is shown moving the partly folded containers in the direction as shown. At this stage, the containers are already loaded with glass bottles or whatever and are being sealed for shipment.

The container approaches the apparatus as shown in A, with the side closure flaps in place and the top closure flap (shown as 18) glued and in position. The line cut has been made in bottom closure flap 30 to form tab 32, but the two separately foldable portions of that flap 30 have not been broken apart. Glue has been applied to the inside surface of the tab 32 only, and the entire flap and tab 30 and 32 have been folded up into contact with the side closure flaps 22 and 26.

A vacuum head 34 is brought into contact with bottom closure flap 30 to break it loose from tab 32 which remains in position as part of the closure, the flap 30 not being adhesively attached. The vacuum head 34 pulls the flap 30 out a distance sufficient to allow engagement with a fixed guide rail 35, commonly referred to in the art as a fixed plow. The vacuum head 34 is disengaged from flap 30 as soon as engagement with guide rail 35 is accomplished. The movement of the container (as in B) past the guide rail 35 results in deflection and folding of the flap 30 according to the design of the guide rail 35. Adhesive is applied to the outer surface of flap 30 by a brush 36 or similar apparatus, and is usually done while the flap 30 is in contact with the guide rail 35 to prevent deflection of the flap 30 by the brush 36.

The guide rail 35 is arranged in a downward section of a helix or spiral to deflect and fold the flap 30 through nearly 270.degree. of arc into contact with the surface of the bottom of the container as can be seen at positions C and D. A roller 37, seen at position E, presses the flap 30 against the container to ensure adhesive contact after the flap 30 disengages from guide rail 35. This roller 37 may be heated to help set the glue.

Claims

We claim:

1. A container having a double-thickness area over a portion of its bottom panel and adapted to be formed from corrugated paperboard or similar foldable material, said container having top, bottom and opposed side panels arranged into a rectangular tubular configuration, and closure flaps hinged to the opposite edges of each of said top, bottom, and opposed side panels, said end closure flaps adapted to form end closures for said tubular configuration, and said end closure flaps attached to the opposite ends of said bottom panel including a reversibly foldable portion adapted to be reversibly folded into contact with said double thickness area over a portion of the panel of said container and a glue tab portion foldable into contact with the end closure flaps connected to reinforce the side walls.

2. A container having a double-thickness area over a portion of its bottom panel as set forth in claim 1 wherein the reversibly foldable portion of the end closure flap attached to the opposite ends of said bottom panel comprises the major portion of the area of said end closure flap attached to the ends of said bottom panel.