U.S. patent number 3,873,017 [Application Number 05/348,660] was granted by the patent office on 1975-03-25 for corrugated polygonal container.
This patent grant is currently assigned to Franklin Container Corporation. Invention is credited to David H. Blatt.
United States Patent |
3,873,017 |
Blatt |
March 25, 1975 |
Corrugated polygonal container
Abstract
A polygonal shipping container, preferably hexagonal, formed of
die cut blanks of corrugated paper board superposed and glued one
upon another to provide a tubular type container having a side wall
of triple ply thickness, the several plies of corrugated board
being so respectively transversely scored and assembled as to
permit the container to be knocked down into a flattened condition
from which it may be easily erected into its expanded form for
receiving and shipping goods. The outer ply of the container is
provided at its opposite ends with end closure flaps which are
designed to be infolded from each of the side wall panels of the
container to provide a plurality of layered coplanar pairs of said
flaps having their meeting edges disposed in abutting relation.
Diametrically opposed corners of the container are fluted to permit
stress-free folding of the container into flattened condition and
provide hand hold ribs for rolling the container about its central
axis and for otherwise conveniently handling the container. The
corrugations of the inner plies extend orthogonally with respect to
those of the outer ply of the container to strengthen and rigidify
its side walls, the latter being internally shouldered at opposite
ends thereof to receive removable end pads which each underlie the
multi-layered end closure flaps. The container is provided with a
tear tape for partially or completely detaching one end closure
from its main body portion.
Inventors: |
Blatt; David H. (Elkins Park,
PA) |
Assignee: |
Franklin Container Corporation
(Philadelphia, PA)
|
Family
ID: |
23368989 |
Appl.
No.: |
05/348,660 |
Filed: |
April 6, 1973 |
Current U.S.
Class: |
229/108.1;
229/235; 229/122.33; 229/122.34; 229/110; 229/238; 229/930;
229/939 |
Current CPC
Class: |
B65D
5/0281 (20130101); Y10S 229/939 (20130101); Y10S
229/93 (20130101) |
Current International
Class: |
B65D
5/02 (20060101); B65d 005/36 () |
Field of
Search: |
;229/41C,41D,41R,14R,14C,14BE,14BW,14BL,43R,7 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Mautz; George F.
Attorney, Agent or Firm: Edelson and Udell
Claims
What is claimed as new and useful is:
1. A polygonal shipping container having a tubular main body
portion and integral top and bottom end closure flaps formed of
three die-cut blanks of corrugated paper board stock, said blanks
being respectively transversely scored along perimetrally spaced
parallel score lines and adhesively secured together in laminated
relation to provide said main body portion with a triple layered
substantially continuous polygonally shaped side wall opposite
halves of which each include at least three side wall panels, said
panels being relatively foldable in the regions of all of said
score lines for erecting said main body portion into polygonal
shape, the two outermost laminations of said sidewall each having a
single pair of diametrically spaced sets of closely adjoining score
lines for flat folding said opposite halves of the tubular main
body portion one against the other at two diametrically opposed
corners of said container, said diametrically spaced sets of score
lines in said two outermost laminations being respectively disposed
in nested relation about a fold line of the innermost lamination to
form at said diametrically opposed corners of said container
outwardly projecting triple-layered ribs or flutes which permit
unstressed flat folding of the opposite halves of the container as
aforesaid and serve as hand holds to facilitate rolling of the
containers about their central axes and vertical side-wise stacking
of the containers when erected into polygonal shape, the outermost
lamination of said side wall being perimetrally scored and
vertically slit to integrally provide the same with a plurality of
inwardly foldable end closure flaps respectively hinged to the top
and bottom edges of each of said side wall panels, said closure
flaps being each of a length substantially equal to one half the
distance between opposite side wall panels of the erected
container, the said pairs of said flaps being respectively adapted
to be inturned from opposite side wall panels of the erected
container toward the central axis thereof for coplanar disposition
with their free edges in abutting relation along angularly related
lines commonly intersecting said central axis of the container
whereby said inturned pairs of the end closure flaps conjointly
form a multi-layered closure at each end of the container.
2. A shipping container as defined in claim 1 wherein the two
innermost laminations of said side wall have their top and bottom
edges equally spaced inwardly of said end flap hinge lines to
provide said side wall of said container at each end thereof with a
continuously extending shoulder or seat for a removable rigid end
pad having a perimetral outline corresponding to the polygonal
shape of the erected container.
3. A shipping container as defined in claim 2 wherein a rigidifying
end pad is seated in said shoulder formed at each end of the
container in close underlying relation to the multilayered assembly
of said end closure flaps.
4. A shipping container as defined in claim 1 wherein the two inner
blanks of corrugated board constitute a laminated inner core of the
container side wall about which the outermost lamination is wrapped
and wherein the corrugations of said inner core laminations extend
orthogonally with respect to the corrugations of the outermost
laminations.
5. A shipping container as defined in claim 4 wherein the
corrugations of the inner core laminations extend along lines
normal to the central axis of the container while those of the
outermost lamination extend along lines parallel to said central
axis.
6. A shipping container as defined in claim 1 wherein the container
is provided with a tear tape extending continuously about the
perimeter of the tubular body portion of the container along a line
spaced inwardly from and in parallel relation to at least one of
said hinge lines for said end closure flaps.
Description
This invention relates generally to shipping containers made of
corrugated paper board and more particularly to a knockdown
construction of a polygonally shaped container having its multiple
side walls formed of three laminated die cut blanks of the
corrugated board which are respectively so die cut and scored as to
permit the container to be folded into flattened condition and yet
be adapted to be instantly set up and erected as a shipping
container for relatively heavy articles.
Among the principal objects of the present invention is to provide
an exceedingly rigid corrugated board shipping container which may
be rolled about its central axis in its fully loaded condition,
which may be stacked upon its side and which may withstand rough
handling thereof in both its knocked-down and erected
condition.
A further object is to provide the container, preferably of
hexagonal shape, wherein its side walls are formed of triple ply
corrugated board with the outer ply having integrally formed end
closure flaps at opposite ends thereof which serve not only to seal
the ends of the erected container closed but also to rigidify the
same as a whole.
Still another object of the invention is to provide an hexagonally
shaped shipping container having its side walls formed of three
laminated blanks of corrugated board which are each so die cut and
relatively scored as to provide the container at diametrically
opposite corners thereof with outwardly projecting vertically
extending flutes or ribs which serve as hand-holds for effectively
rolling the container about its central axis as aforesaid and which
permit compact creasing of said opposite corners of the container
for folding the same into a knocked-down condition for space-saving
shipment and storage of the containers in the form of easily
erectable substantially flat units.
A still further object is to provide shoulders or seats for
reception of reinforcing end pads at opposite ends of the
container, which pads are removably disposed interiorly of the
aforesaid layered end closure flaps and act in concert with said
end flaps to rigidify, strengthen and hold the container in its
erected hexagonal shape.
Still another object of the present invention is to die cut the
blanks which form the side walls of the carton so that certain of
the same, preferably those forming a two-ply inner-core thereof,
have their corrugationss running orthogonally with respect to the
corrugations of the third or outermost ply to thereby further
strengthen and rigidify the laminated side walls of the container
against any tendency to be distorted when the containers are rolled
about their central axes or are stacked on their sides one upon
another.
Other objects and advantages of the present invention will appear
more fully hereinafter, it being understood that the invention
consists in the combination, construction, location and relative
arrangement of parts as described more particularly in the
following specification, as shown in the accompanying drawings and
as finally pointed out in the appended claims.
In the accompanying drawings:
FIG. 1 is a perspective view showing a completed and closed form of
the triple-ply carton as constructed in accordance with the
principles of the present invention, the outer ply only of the
carton being shown in section;
FIG. 2 is a plan view showing in expanded flattened form the
die-cut blank of corrugated board which constitutes the outerply of
the carton and the end flaps for closing the top and bottom ends of
the carton;
FIG. 3 is a plan view of the intermediate die-cut corrugated blank
of the triple-ply carton of the present invention;
FIG. 4 is a plan view of the innermost die-cut corrugated blank of
the carton;
FIG. 5 is a plan view of one of the hexagonal die cut end pads
which are respectively disposed at opposite ends of the carton to
rigidify and hold the same in its expanded form as shown in FIG.
1;
FIG. 6 is a perspective view of an intermediate portion of the
expanded carton as viewed from the line 6--6 of FIG. 1, the several
laminated plies thereof being sectioned as shown;
FIG. 7 is an elevational view of one end portion of the carton as
it appears when it is folded from its expanded condition shown in
FIG. 6 about the line 7--7 of FIG. 6 into a flattened compact unit
to facilitate shipment and storage of the containers;
FIG. 8 is a horizontal cross-sectional view of the flat-folded unit
as taken along the line 8--8 of FIG. 7;
FIG. 9 is an end elevational view of an end portion of the
flattened carton when the same is viewed in its horizontally
disposed section with its end flaps extending to the right;
FIG. 10 is an enlarged horizontal cross-sectional view of one of
the diametrically opposed pair of the corners of the carton
inscribed within the dotted circle of FIG. 6;
FIG. 11 is a vertical cross-sectional view through a portion of the
top and one side wall portion of the expanded and closed carton as
taken along the line 11--11 of FIG. 1 showing the closure flaps
sealed over the end pad seated upon the shoulder formed between the
outer side wall ply and the two inner side wall plies of the
carton.
Referring now more particularly to the drawings, it will be
observed that the carton 10 of the present invention, in its fully
expanded and erected form as shown in FIG. 1, is of hexagonal shape
having its opposite ends adapted to be closed by end flaps which
respectively extend from and are folded inwardly from the top and
bottom ends of each side of the carton. These side walls of the
carton are formed of three double-faced corrugated paper board
blanks which are die-cut, slit and scored as separate units and
assembled to provide the carton with a triple ply, laminated side
wall construction as hereinafter described.
The three blanks of which the side walls and ends of the carton are
formed are respectively shown in FIGS. 2, 3 and 4. Thus, the blank
11 forming the outermost side wall ply is die cut and scored as in
FIG. 2; the blank 12 forming the intermediate ply is die cut and
scored as in FIG. 3; and the blank 13 forming the innermost ply is
die cut and scored as in FIG. 4. Since it is an important
desideratum that the carton of the present invention is adapted to
be flat-folded into a knocked-down condition from which it may be
instantly erected into its expanded form as shown in FIG. 1, the
several blanks which form the side walls of the carton are of
different dimensions and respectively have their scorings
differently spaced for reasons which will be apparent hereinafter.
In this connection, it will be noted also that the end closure
flaps of the carton are formed as integral extensions of only that
blank which forms the outermost side wall ply of the carton and
that the blanks which form the two inner side wall plies of the
carton each have their corrugations extending orthogonally with
respect to those of the outermost ply. Preferably, the outer ply
corrugations extend vertically of the carton, i.e., in parallel
relation to the central axis thereof.
The blank 11 (FIG. 2) is transversely scored along the
longitudinally spaced, parallel score lines 14 to provide six
panels 15a to 15f, one relatively narrow end flap 15g, and a pair
of intermediate longitudinally spaced relatively narrow panels
designated 15h each bounded by a pair of closely adjoining score
lines 14. In addition, the blank is longitudinally scored along the
parallel lines 16 and slitted, as at 17, to respectively provide
the panels 15a to 15f with oppositely projecting end flaps 18a to
18f. It will be noted that the closely adjoining score lines 14
which define therebetween the narrow panels 15h are disposed in
spaced relation beyond the side edges of the slits 17 which
separate the end flaps 18b and 18e from their adjoining end flaps
18c and 18f, while the remaining score lines 14 are respectively
centered between the remaining slits 17. It will be noted further
that the blank 11 is so die cut that the corrugations 19 of the
corrugated board extend parallel to the score lines 14, i.e.,
vertically of the carbon when it is erected into its expanded
condition shown in FIG. 1. The blank 11 is completed by adhesively
securing to its inner face a tear tape 20 of adequate tensile
strength to tear through the blank, which tape extends along the
full length of the blank along a line spaced within and paralleling
either one of the longitudinally extending score lines 16, said
tape being provided at one end thereof with a freely accessible tab
21 for tearing out the tape to thus partially or completely
separate the end flap portion of the blank 11 from its main body
portion.
FIG. 3 shows the blank 12 which forms the central or intermediate
side wall ply of the carton, which blank is transversely scored
along the vertically extending, parallel lines 22 to provide six
panels 23a to 23f and a pair of longitudinally spaced narrow panels
23g similar to those of the blank 11. However, the blank 12 is of
shorter length than that of the blank 11 to provide a series of
panels which are respectively somewhat narrower than their
corresponding panels of the blank 11 and is of a width equal to the
dimension A-2B wherein A is the dimension indicated in FIG. 2 and B
is the dimension indicated in FIG. 1, which latter dimension is
just slightly greater than the thickness of the corrugated board of
which the carton is formed. It will be noted that the blank 12 is
free of end flaps and that its corrugations, designated 24, extend
lengthwise of the blank, i.e., horizontally of the carton when it
is erected into its expanded form shown in FIG. 1.
The innermost side wall ply or lamination of the carton is formed
of the blank 13 shown in FIG. 4, which blank 13 is of further
reduced length relatively to that of the blanks 11 and 12 and is
transversely scored, as along the lines 25, to provide a series of
six panels 26a to 26f. This blank 13, the corrugations 27 of which
run in the same direction as those of the blank 12, is of exactly
the same width as that of the blank 12, namely, the dimension A-2B
as above set forth.
The carton of the present invention is formed in its entirety of
the three blanks 11, 12 and 13 above described and a pair of
hexagonally shaped end pads, one of which designated 28 is shown in
FIG. 5. These end pads 28 are die cut out of the same stock as that
of the side wall blanks.
It will be noted that when the three blanks 11, 12 and 13 are
superimposed one upon the other in their flat conditions, the
corresponding score lines 12 of the blank 11, 22 of the blank 12
and 25 of the blank 13 are so relatively offset that when the
blanks are adhesively secured to one another in angularly oriented
relation as hereinafter described to form the triple ply laminated
side walls of the container, their said corresponding side wall
panels are brought into substantial registry, thereby permitting
the laminated assembly to be folded into a compact, flattened
condition for shipment and storage thereof as substantially flat
units adapted respectively to be readily set up or erected into
their expanded polygonal shape as shown in FIGS. 1 and 6 for use as
shipping containers.
The carton of the present invention is preferably made up in the
following manner. First, the upper face of the blank 12 as viewed
in FIG. 3 and the bottom face of the blank 13 as viewed in FIG. 4
are each coated with glue, following which the glue face of the
panel 26a of the blank 13 is laid onto the glue face of the panel
23a of the blank 12 with the opposite longitudinal edges of the two
blanks being respectively in rectilinear alinement so that the
blank 13 constitutes an extension of the blank 12. Thereafter the
several panels 26a to 26f are angularly related into hexagonal
shape, following which the blank 12 is wrapped around the
hexagonally shaped blank 13 to form a two-ply hollow body of
hexagonal shape with the fold lines of the two blanks in
substantial coincidence and the panel 23f of the blank 12
overlapping the panel 26b of the blank 13, as see FIGS. 6 and
8.
Having so formed the two-ply hexagonal-shaped two-ply inner core of
the carton, there is now adhesively secured thereto the third ply
formed of the blank 11, which step consists in first glueing the
flap 15g of the blank 11 to the exposed outer face of the innermost
panels 26a and then consecutively glueing the panels 15f, 15e, 15d,
15c, 15b and 15a to the panels 23f, 23e, 23d, 23c, 23b and 23a
respectively. In this last-mentioned step, the two-ply inner core
of the assembly is so centrally disposed between the two
longitudinally extending score lines 16--16 of the external side
wall ply or lamination formed by the blank 11 as to provide a
shoulder 29, as see FIG. 11, at opposite ends of the carton upon
each of which is adapted to be seated one of the end pads 28 shown
in FIG. 5.
The closely spaced pairs of score lines forming the narrow panels
15h of the blank 11 and the narrow panels 23g of the blank 12
constitute an important feature of the present invention. These
paired score lines provide channeled ribs or flutes 30 at
diagonally opposite corners of the carton of sufficient capacity to
embrace and permit flat folding of the inner two-ply core of the
carton in the regions of such corners when the opposite laminated
side wall portions of the carton are pressed together about the
line 7--7 of FIG. 6 to flat-fold the carton into its condition as
shown in FIGS. 7 to 9, all without imposing any such undue strains
or stresses therein as might tend to break or otherwise destroy the
integrity of the carton side walls.
The end flaps 18a to 18f of the blank 11 serve to close off the
opposite ends of the carton when it is erected and expanded into
shape as shown in FIG. 1. It will be noted that the carton includes
at each end thereof three pairs of these flaps, each pair of which
is adapted to be infolded into coplanar relation with their free
ends in abutting engagement. The several pairs of the end flaps are
disposed in layered relation at each end of the carton and when
stitched, taped or otherwise secured in their closed position as
shown, they mutually act to reinforce and strengthen the ends of
the carton against buckling and collapse thereof.
The hexagonal end pads 28 which are inserted into opposite ends of
the carton as above described and as shown in FIG. 11, in
underlying relation to the infolded pairs of end closure flaps, add
strength and rigidity to the loaded carton. Also, the reversal in
direction of run of the corrugations as between those of the outer
lamination and those of the inner laminations so further
strengthens and reinforces the carton that it may be rolled and, if
desired, stacked on its side without any appreciable distortion and
buckling of the carton side walls. In this connection, the
diagonally opposed corner ribs or flutes 30 effectively serve as
hand holds for rolling the filled carton about its central
axis.
When it is desired to unload the filled carton, it is only
necessary to pull the tear tape 20 through the outer wall of the
carton in the region just above the top edge of its inner two-ply
core, thereby severing the sealed top from the carton to permit
removal of the end pad 28 and instantly render accessible the
carton contents. By so severing the carton top from all but one of
the side walls of the carton, the top may be held hinged to one
wall of the carton and thus be available to repeatedly open and
close the carton as frequently as may be required.
It will be understood of course that the procedure for assembly of
the three blanks to produce the triple-walled carton of the present
invention may be varied as desired. As an example of one such other
procedure, the several blanks 11, 12 and 13 may be superimposed one
upon the other in that order with wet glue coatings applied to
their contacting surfaces and then, while the glue is still wet,
flat fold three of the side wall panels of the assembly against the
remaining opposite three panels so that the folds which form the
aforesaid diametrically opposed corner flutes 30 of the carton are
at opposite ends of the flattened assembly and all of the score
lines which form the remaining corners of the carton are in
substantial registry. Upon setting of the glue, the carton is
complete in its flattened form for shipment and storage as flat,
compact units ready to be expanded into hexagonal shape for use as
shipping containers. It will be further understood that the present
invention is susceptible of various changes and modifications which
may be made from time to time without departing from the general
principles or real spirit thereof and that it is accordingly
intended to claims the same broadly, as well as specifically, as
indicated by the appended claims.
* * * * *