Pallet Case

Abstract

Pallet case for cartons or bottles has a bottom panel, upright side panels, rectangular end panels and cover panels hinged by scoring to the end panels, all formed from a single sheet of suitably scored and cut fiberboard. The end panels along each side edge have integral corner column members extending upright between the bottom and cover panels and lying against the interior surface of the side panels. Corner flaps depending from each side edge of the cover panels lie exterior of said column members and terminate at or just above the upper edge of the side panels.

Parent Case Text

This application is a continuation-in-part of my application Ser. No. 770,179, filed Oct. 24, 1968, now abandoned abandoned.

Description

This invention relates generally to a fiberboard container and more specifically to a pallet case particularly adapted for handling paperboard milk cartons or other like containers or bottles which do no exhibit great structural strength when subjected to vertical compression.

It has recently become common practice to distribute milk and similar products in relatively square-sectioned, treated paper cartons having a fin seal and a gable top. Such cartons are available in various sizes, such as quart, two quart and gallon, all of which have generally similar heights and are capable of uniform arrangement in refrigerated display and storage cabinets. In order to transport a group of such containers from a diary to the retail outlets, it has been the practice to arrange a plurality of the cartons in plastic, wood or metal wire baskets. Because the fin top seal and slanted covers render it difficult to stack such cartons in layers, each wire basket has a depth slightly greater than the height of the cartons to receive the requisite number of cartons which will constitute one layer and the baskets are adapted to be stacked without placing any load on the milk cartons. Such baskets are expensive and for economy must be reused, requiring that they be returned to the dairy and cleaned.

The present invention is directed to a low cost fiberboard pallet case for cartons or bottles of this general class, which pallet case can be used once and discarded. The cartons of milk or other product may be placed in the fiberboard pallet cases, stacked, delivered to the destination, restacked, and placed in the refrigerated display cabinets for sale, the pallet cases being thereafter discarded. Thus, the nuisance and expense of returning wire baskets to the dairy and cleaning them is eliminated. In addition, the pallet cases are light in weight compared to metal wire baskets, and a supply of the pallet cases in blank form can be stacked in the dairy without occupying a substantial amount of space.

The present invention is more particularly directed to an open-type boxlike construction having reinforced load bearing corner columns. The boxlike pallet case is constructed from a single blank of sheet material, such as corrugated board, which has been suitably scored, and cut, as by slitting or slotting or by some other cutting operation. Such a pallet case can accommodate quarts, half- and one-gallon milk cartons with equal efficiency and may easily be sized to accommodate blow-molded thermoplastic bottles or the like.

The above and other novel features of the invention will appear more fully hereinafter from the following detailed description when read in conjunction with the accompanying drawings. It is expressly understood that the drawings are employed for purposes of illustration only and are not designed as a definition of the limits of the invention, reference being had for this purpose to the appended claims.

In the drawings, wherein like reference characters indicate like parts:

FIG. 1 is a composite perspective view of two pallet cases oriented for stacking and of a group of paperboard cartons for which the cases are suited;

FIG. 2 is a horizontal sectional view taken generally along the line 2-2 of FIG. 1;

FIG. 2A is a fragmentary view of a modification of the pallet case shown in FIG. 2;

FIG. 2B is a fragmentary view of another modification of the pallet case shown in FIG. 2;

FIG. 3 is a plan view of a rectangular blank, scored and cut in the manner to form the pallet case shown in FIG. 1; and

FIG. 4 is a plan view of the blank shown in FIG. 3 with the waste removed and with portions doubled over.

FIG. 1 shows two fiberboard pallet cases in exploded, vertically spaced relation to illustrate the stacking practice to be employed and to illustrate the manner of filling the pallet case. Also illustrated in broken lines are the partial covers in the position in which they might reside after the pallet case is filled and before the covers are closed to provide a stacking platform for an additional pallet case to be disposed thereatop.

Each pallet case or container is formed from a single rectangular blank 20 of corrugated fiberboard; however, other suitable fiberboard or sheet material may also be used, as for instance a sandwich of expanded polystyrene between two sheets of linerboard. As an example, for a pallet case designed to accommodate four one-gallon milk cartons, the blank 20 may be about 24 by 36 or 37 inches, and the corrugating media flutes preferably run lengthwise of the blank as shown. However, for other applications, it may be desirable to have the corrugating media flutes running transversely, instead of lengthwise of the blank.

As shown in FIG. 3, the blank 20 is scored lengthwise long lines 22 and 24, which extend the length of the blank but which are preferably offset inwardly from otherwise straight alignment at sections 22a and 24a for a purpose explained hereinafter. The offset is by an amount at least about equal to the thickness of the corrugated fiberboard and may be offset by an amount 1 and 1/2 times the thickness. However, the lines 22 and 24 may be completely straight with crowding in the corners being relied upon to complete the setup and squaring of the pallet case. Transverse score lines 26 and 28 cross score lines 22 and 24 to provide a rectangular bottom panel 30, which in the illustrated embodiment is a 12-inch square base. Additional transverse score lines 70 and 72 define cover panels 48 and 50 which are hinged therealong to the upper edges of the end panels 44 and 46, and which are sized to only partially cover the top of the container.

The blank 20 is cut, slit or slotted inwardly from the longitudinal marginal edges to the score lines 22 and 24 at locations 32, 34, 36 and 38, and at locations 33, 35, 37 and 39, thereby defining side panels 40 and 42, end panels 44 and 46, cover flaps 52 and 54 which are hinged in flanking relationship to cover panels 48 and 50, and rectangular panels 56, 58, 60 and 62. The rectangular panels 56, 58, 60, and 62 are suitably partially cut or slit at one surface or creased along lines 57, 59, 61 and 63, respectively, to create two hinged column-forming portions 56a and b, 58a and b, 60a and b, and 62a and b. These hinged portions are adapted to be bent back on each other into surface-to-surface contact to form the columns shown in FIG. 2.

In addition, the portions of the score lines 22 and 24 and the transverse score lines 70 and 72 defining the cover panels 48 and 50 may be serrated or perforated to permit easy tear-out of the panels 48 and 50 after the pallet case has reached its shipping destination, to facilitate materials handling, pricing, and display. However, instead of serrating the score lines, it may be preferable to locate the serrations alongside the score lines to guard against inadvertent tearing. The blank 20, shown in FIG. 3, which has been suitably cut and scored and serrated, if desired, as above described, may be economically shipped in quantity to a dairy where the pallet cases can be quickly erected and filled in a simple operation.

Either prior to, or as an integral part of, the erection of the pallet case, the column members are folded over into surface-to-surface contact along the lines 57, 59, 61 and 63 which in double-face corrugated fiberboard may slit one liner and the corrugating medium to provide a single liner hinge. Such folding creates a column, as shown in FIGS. 2 and 4, which in combination with the overlying covers provides additional structural strength in the corners of the pallet cases to permit stacking without relying upon the milk cartons to supply vertical strength. The respective two column-forming portions may be glued or stitched or otherwise secured together. Preferably, the portions are adhesively joined over a major part of their adjacent surfaces to achieve a mutual reinforcement effect. If the columns are not to be formed as a part of an overall filling and closing operation, it might be desirable to form the columns prior to shipping the blanks 20 to the dairy.

Upon arrival at the dairy, the blank 20 is erected by forming the columns from the column-forming panels 56, 58, 60 and 62, folding the columns through 90.degree. so they are disposed at right angles to the end panels 44 and 46 and folding the end panels 44 and 46 upwardly to form the ends. Thereafter, the side panels 40 and 42 are folded upwardly and glued or stapled or otherwise secured to the outer surfaces of the column members 56a 58a, 60a and 62a. Because the score lines 22a and 24a are offset from the score lines 22 and 24 which form the hinge between the bottom panel 30 and the flanking side panels 40 and 42, there is no interference between the vertical columns and the vertical alignment of the side panels 40 and 42 in the assembled configuration.

The pallet case may be loaded after it has been erected to this configuration with the covers 48 and 50 left open, as shown at 48' and 50' in FIG. 1. Alternatively, it may be desirable to load the milk cartons (or whatever contents the pallet case is being used to carry) onto the bottom panel 30 before the side panels 40 and 42 are joined to the columns. In such an instance, the pallet case is erected by wrapping the panels of the blank 20 generally around the milk cartons and sealing the panels, with adhesive or other means, with the contents in place.

By reason of its shape, the pallet case will accommodate four one-gallon cartons or nine half-gallon cartons or 16 quart cartons. After loading, the cover panels 48 and 50 are folded over and the cover flaps 52 and 54 are stapled, or otherwise secured as by adhesive, to the outer surface of the column members 56a, 58a, 60 a and 62a. If desired, the cover flaps 52 and 54 may extend below the top edge of the side panels 40 and 42 and be affixed to the side members as well. Staples, if employed, may be disposed vertically or horizontally as indicated at 53 (FIG. 1) and may overlap the flap 52 and the side panel 42.

Preferably, the sum of the height of the cover flaps 52 and 54 (x, FIG. 4) and height of the side panels 40 and 42 (y, FIG. 4) is slightly less than or equal to the height of the column members 56, 58, 60 and 62 (z, FIG. 4). When the sum is slightly less than the column height (x + y < z ) a slight gap is provided as illustrated in FIG. 1. By providing such a slight gap, for example, about one-eighth inch, sealing of the loaded cases on mechanical equipment is facilitated, and, when the loaded pallet cases are stacked, there is room for some slight deflection before the bottom edges of the corner flaps 52 and 54 abut the top edges of the side panels 40 and 42.

To provide the desired stacking strength, it is considered preferable that the width of the cover panels 48 and 50 and the cover flaps 52 and 54 be at least equal to the column width. However, the cover panels 48 and 50 may be made wider, if desired, for example to provide a complete cover. Similarly, although the column-forming members are preferably of equal width, as illustrated, the width of the free portions, 56b for example, could be made leas less than the intermediate portion 56a by positioning the line 57 at a location past the midpoint of the flap 56.

As soon as the cover panels are secured, the pallet case is complete and ready for stacking, shipping and even ultimate placement in a refrigerated display compartment. To facilitate access to the cartons within each pallet case, serrations, as previously mentioned, are located along the lines defining the cover panels 48 and 50. If desired, serrations may only be located along the sides of the cover panels 48 and 50 to facilitate separation from the flaps 52 and 54 and allow the panels to be folded upward. When the pallet case has served its purpose and its contents have been removed, it is anticipated that it will be discarded and destroyed.

It will be seen that the pallet case also affords some thermal insulation for the milk cartons therewithin inasmuch as the sidewalls 40 and 42 extend substantially to the shoulder at the gable top of the milk cartons. Gallon cartons measure about 55/8 inch square, half-gallon cartons measure about 33/4 inch square, and quart cartons measure about 23/4 inch square. Because all have about the same overall height, the pallet case readily accommodates four, nine or 16 cartons respectively and protects the cartons during shipment from dairy to the market, while assisting in insulating the cartons, which are usually prechilled before delivery. Another advantage of the illustrated pallet case lies in the fact that all six of its exterior surfaces are smooth, insofar as there are no portions projecting out of the surface plane. This feature facilitates handling, stacking and palletizing by mechanical equipment because pallet cases can be moved past one another in surface-to-surface contact inasmuch as there are no projections which would likely cause jams or blockages to occur.

Because the pallet case occupies little space, it may be placed in the refrigerated display cases at the retail market without removing the cartons therefrom, access to the individual cartons being readily afforded by tearing away the cover panels 48 and 50. Inasmuch as tests show a pallet case constructed of double-face corrugated fiberboard using the column-cover arrangement illustrated can support over a half ton, any number of pallet cases filled with milk cartons can be stacked as high as manual handling permits because the weight of each filled pallet case scarcely exceeds 32 pounds. A pallet case of milk cartons weighing 32 pounds can also be readily handled by market personnel.

It should be appreciated that the free portions 56b, 58b, 60b and 62b of the column-forming members may be disposed either interior of the intermediate portion 56a, 58a, 60a and 62a, as shown in FIG. 2, or between them and the interior surfaces of the side panels 40 and 42 as is FIG. 2A wherein the column 56' is constructed by folding the portion 56' b to lie sandwiched between the portion 56' a and the side panel 40. Alternatively, as shown in FIG. 2B, a third section 56" c can be provided in each of the column-forming members that would be folded at right angles to lie against the interior surface of the end panel 44. In such an instance, the width of the individual column-forming members might be reduced to preserve the overall rectangular configuration of the blank. Furthermore, if the pallet case is designed for bottles or the like having a rounded cross section, the sections 56" b and 56" c might not extend all the way into the corner. Instead, the sections might be disposed so that the section 56" b only partially lies in surface-to-surface contact with the section 56" a and then extends obliquely across the corner.

While a single embodiment of the invention has generally been illustrated and described, it is to be understood that the invention is not limited thereto. Because various changes in the construction and arrangement may be made without departing from the spirit of the invention, as will be apparent to those skilled in the art, reference will be had to the appended claims for a definition of the limits of the invention.

Claims

I claim:

1. A fiberboard container made from a blank of sheet material, which container comprises a rectangular bottom panel and a pair of flanking rectangular end panels, said two rectangular end panels being each hinged along the bottom edge thereof to an end edge of said bottom panel, two flanking side panels being each hinged at the bottom edge thereof to one of the side edges of said bottom panel, a pair of cover panels hinged respectively to upper edges of said end panels, four rectangular flaps hinged respectively to side edges of said end panels, each of said rectangular flaps containing means dividing said flap into vertical column members, said column members of each rectangular flap being doubled back on each other to lie at least partially in surface-to-surface contact and form a double thickness column, and a pair of corner flaps flanking each of said cover panels and being hinged thereto along the side edges of said cover panels, said columns being disposed adjacent the inner surface of said respective side panels and the inner surface of said corner flaps.

2. A container in accordance with claim 1 wherein the sum of the height of one of said side panels and the height of one of said corner flaps is slightly less than the height of said column members to provide a slight gap between the bottom edge of said corner flap and the upper edge of said side panel.

3. A container in accordance with claim 1 wherein said rectangular flaps are each divided into a pair of vertical column members of substantially equal width.

4. A container in accordance with claim 1 wherein said vertical column members are secured adhesively in surface-to-surface contact with each other over a major portion of the adjacent surface area.

5. A container in accordance with claim 1 wherein the width of said cover panels and said corner flaps is at least about equal to the width of said column.

6. A container according to claim 1 wherein serration means are provided along the sides of said top panels to permit the top panels to be torn from said corner flaps.

7. A container in accordance with claim 1 which is made from double-faced corrugated fiberboard in which the flutes of the corrugating medium extend vertically in said column-defining members.

8. A container in accordance with claim 1 wherein the lines along which said rectangular flaps are hinged to said end panels are offset inwardly from the lines along which said side panels are hinged to said bottom panel.

9. A substantially rectangular blank of fiberboard sheet material being suitably cut and scored to define a rectangular bottom panel and a pair of flanking rectangular end panels, said bottom panel being defined at the side edges thereof by a pair of score lines extending longitudinally of the blank and being defined at the end edges thereof by first and second transverse score lines extending between said pair of longitudinal score lines, said first and second transverse score lines respectively each defining one end edge of said bottom panel and the bottom edge of one of said two rectangular end panels, cover panels hingedly attached to upper edges of each of said end panels, respectively, along third and fourth transverse score lines which are parallel to and spaced from said first and second transverse score lines, said blank being cut inward from each of its longitudinal marginal edges in general alignment with said four transverse score lines to define two side panels integral with and hinged to the side edges of said bottom panel and to define four rectangular flaps hinged respectively to said end panels and to also define a pair of corner flaps flanking each of said cover panels which are hinged thereto along score lines substantially aligned with said pair of longitudinal score lines, said rectangular flaps being hinged to said end panels along score lines offset slightly inward from said longitudinal score lines and parallel thereto, and each of said rectangular flaps having means parallel with its hinge attachment dividing said flap into vertical column members whereby said column members of each rectangular flap may be doubled back on each other to at least partially lie in surface-to-surface contact and form a double thickness column, whereby when said blank is erected into a container with said columns disposed at about 90.degree. to said end panels, said columns lie adjacent the interior surfaces of said side panels and said corner flaps.

10. A blank in accordance with claim 9 made of double-faced corrugated fiberboard wherein the flutes of said corrugating medium run longitudinally of said blank.

11. A blank in accordance with claim 9 wherein the sum of the height of one of said side panels and the height of one of said corner flaps is slightly less than the height of said column members.

12. A blank according to claim 9 wherein said column-forming portions of each rectangular flap are adhesively secured in surface-to-surface contact with each other over a major portion of the adjacent surface area thereof.

13. A blank according to claim 9 wherein serration means is provided along the side edges of said cover panels to permit said cover panels to be torn from said corner flaps.