Self-locking Poultry Box

Abstract

This disclosure relates to a blank and a container or box formed therefrom particularly adapted for housing refrigerated (CO.sub.2 or ice) poultry, the blank being constructed from corrugated board having inner, intermediate and outer plies, a plurality of fold lines setting off a bottom panel, end panels joined to the bottom panel, side panels joined to the bottom panel, a reinforcing panel between adjacent edges of adjoining side and end panels and being joined to each side panel by an associated fold line, a locking panel joined to each end panel, each locking panel having a terminal locking tab formed from material at least in part robbed from the reinforcing panels, and each locking tab having an angular locking edge adapted for engagement with an angular locking cursh-score slit in the inner play of the side panels whereby in the set-up condition of the container the locking edges of each locking tab are in firm engagement with an associated locking slit.

Description

A primary object of this invention is to provide a novel container of the type heretofore mentioned whereby due to the unique and critical arrangements of the relative angles between the locking tabs and locking slits a quickly set-up and self-locking container is produced at a minimum loss of material and at high production speeds due to its capability of being manufactured on a rotary cutting die press.

Still another object of this invention is to provide a novel container of the type aforesaid wherein apart from minor offsetting to achieve accurate folding to various panels the overall external configuration of the container blank is virtually rectangular whereby the only material of any consequence lost during the manufacture of the blank is that removed to form two vent openings in the set-up condition of the container.

A final object of this invention is to provide a novel container of the type heretofore set forth wherein the locking panels are provided with inwardly converging lines of weakness to facilitate the setting up of the container and more particularly the engagement between the locking tabs and locking edges.

With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claimed subject matter, and the several views illustrated in the accompanying drawings.

In the drawings:

FIG. 1 is a top plan view of a novel blank constructed in accordance with this invention with the inside of the blank uppermost, and illustrates a pair of end panels to each of which is secured a locking panel having locking tabs whose angled edges interlock with crush-scores of side panels to provide a self-locking feature.

FIG. 2 is a perspective view of the container formed from the blank of FIG. 1, and illustrates the container in its set-up condition.

FIG. 3 is an enlarged fragmentary sectional view taken generally along line 3--3 of FIG. 2, and illustrates one of the interlocked locking tabs and slits.

FIG. 4 is an enlarged fragmentary sectional view taken generally along line 4--4 of FIG. 3, and illustrates the manner in which the slit is limited to a cutting and/or crushing of the inner and intermediate plies of the corrugated board in the absence of outer ply severance.

A novel container or box blank constructed in accordance with this invention is illustrated in FIG. 1 of the drawings, and is generally designated by the reference numeral 10. The blank 10 is constructed from a generally polygonal or rectangular piece of corrugated board defined by an inner planar ply 11, and intermediate corrugated ply 12 and an outermost planar ply 13.

A generally rectangular bottom panel 14 of the blank 10 is defined between a first pair of fold lines 15, 16 and a second pair of fold lines 17, 18.

A first side panel 20 is joined to the bottom panel 14 along the fold line 18, and is set off thereby along with a pair of fold lines 21, 22 and a side or upper edge 23.

A side panel 24 is joined to the bottom panel 14 by the fold line 17, and is set off by the fold line 17, a pair of spaced parallel fold lines 25, 26 and a side or top edge 27. The panels 20, 24 each include a pair of identical locking slits which are generally designated by the reference numeral 30 and include an angular portion 31 and a straight portion 32. The blank 10 is preferably formed on a rotary cutting die press and during the formation of each slit 30 only the inner ply 11 and the intermediate ply 12 are severed or, alternately, only the inner ply 11 is severed and the intermediate ply 12 is crushed, as is best illustrated in FIG. 4, to thereby maintain the outer ply 13 in the area of the slits 30 unapertured. The portions 31 of the slits 30 in the side panel 20 diverge away from each other in a direction away from the fold line 18, while the like portions 31 of the slits 30 in the side panel 24 diverge away from each other in a direction away from the fold line 17. However, all of the portions 32 of the slits 30 are generally in parallel relation to each other and by this construction the portions 31, 32 define an included angle whose apex (unnumbered) receives a terminal end of associated locking tabs, in a manner to be described more fully hereinafter. It is also to be noted that the shading associated with each slit 30 indicates that edge of the slit 30 which is crushed or indented which is in each case the edge of the slit most adjacent the fold lines 21, 22, 25 and 26.

An end panel 33 is joined to the bottom panel 14 along the fold line 15 and is defined or set off by the fold line 15, parallel side edges 34, 35 outboard of the fold lines 17, 18 and joined thereto by short edge portions 36, 37. A fold line 38 defines the uppermost edge of the end panel 33, and the distance between the fold lines 15, 38 is equal to the distance between the fold lines 17, 18 and the respective edges 27, 23 of the respective side panels 24, 20. Material is bodily removed from the end panel 33 to form a hand-receiving opening 40 and a circular vent 41.

Another end panel 42 is joined to the bottom panel 14 along the fold line 16, and is defined by the fold line 16, a fold line 43 parallel thereto, parallel side edges 44, 45 outboard of the fold lines 17, 18, and joined thereto by respective short cut portions 46, 47, respectively. Material of the end panel 42 is removed to form a hand-receiving opening 48 and a circular vent opening 50. The distance between the fold lines 16, 43 corresponds to the distance between the fold lines 15, 38 to thereby achieve alignment between the edges 23, 27 and the fold lines 38, 43 in the set-up condition of the container which is best illustrated in FIG. 2.

Four reinforcing panels 51 through 54 are joined by the fold lines 25, 22, 21 and 23 to the respective side panels 24, 20, 20, 24.

The reinforcing panel 52 is identical to the panel 54 and is in generally diametric relationship thereto, while the panels 51, 53 are likewise of identical construction and are in diametrically disposed relationship.

The reinforcing panel 51 is set off by the side edge 34, the short angular portion 36 thereof, the fold line 25, a side or top edge 55, slightly offset inboard of and parallel to the top edge 27, an edge 56, a cut-out 57, and locking edges 58, 59. A generally U-shaped cut line 61 defines a flap 62 hinged to the reinforcing panel 51 by a fold line 63.

In view of the identical construction of the reinforcing panel 53, the same has been provided with identical reference characters except being primed.

The reinforcing panel 52 is likewise set off by the side edge 35, the short angular portion 37 thereof, the fold line 22, a side or top edge 64 which is parallel to but offset inboard of the top edge 23, an edge 65, a cutout 66, and locking edges 67, 68. A hand-receiving opening 69 is in part closed by a deflectable flap 70.

In view of the identical construction of the reinforcing panel 54, the same is not described but like primed reference numerals have been applied thereto.

A narrow rectangular panel 71 is set off by the fold line 38, a fold line 72 spaced therefrom, and portions of the edges 34, 35. The narrow panel 71 overlies the edges 55, 64 of the respective reinforcing panels 51, 52 in the set-up condition of the container.

A like narrow panel 73 is set off by the fold line 43, a fold line 74 in spaced parallel relationship thereto, and portions of the edges 44, 45.

A locking panel 75 is joined to the panel 71 along the fold line 72 and is set off thereby and by the edges 58, 59, 67, 68, and a terminal free edge 76. Each locking panel 75 includes locking tabs or ears 77, 78 with respective weakening or folding lines 79, 80 facilitating the folding of the locking tabs in a manner to be described more fully hereafter.

Centrally of the panel 75 is a weakening or fold line 81 normal to the fold line 72, and a pair of fold lines 82, 83 converging toward each other in a direction toward the fold line 72. The fold lines 81 through 83 facilitate the folding of the locking panel 85 incident to the automatic locking of the locking tabs 77, 78 and more specifically the edges 58, 59, and 67, 68 respectively, most closely adjacent the respective fold lines 25, 22.

Inasmuch as a locking panel 85 is identical to the locking panel 75, the locking panel 85 is not described but like primed reference characters have been applied thereto.

The blank 10 of FIG. 1 is set up to form the box or container 10 of FIG. 2 through 4 by first folding the side panels 20, 24 about the respective fold lines 18, 17 to a position normal to the bottom panel 14. Thereafter the reinforcing panels 51 through 54 are folded about the respective fold lines 25, 22, 21 and 26 to positions normal to the side panels 20, 24. As indicated in FIG. 2, it makes no difference which of the reinforcing panels 51, 52 or 53, 54 is innermost and therefore the panel 52 is shown innermost of the panel 51 whereas at the opposite end of the container 10 the panel 53 is shown inboard of the panel 54. Thus, irrespective of one's unfamiliarity with the blank 10, the container can be erected automatically without air irrespective of which of the reinforcing panels 51 through 54 is positioned innermost.

Thereafter the end panels 33, 42 are folded about the respective fold lines 15, 16 to a position normal to the bottom panel 14. Thereafter the locking panels 75, 84 are folded inwardly and downwardly about the fold lines 38, 72 and 43, 74, respectively, whereupon the edges 59, 58 and 59', 68' contact the associated side panels 20, 24 causing the locking tabs 77 to automatically progressively fold about the fold lines 79, 80, 79', 80'. At this same time the locking panels 75, 84 may deflect along the weakening lines 81 through 83 and 81' through 84'. This folding takes place until the edges 59, 58, 68, 67 of the locking panel 75 and the like primed edges of the locking panel 84 automatically drop into and bear against the respective portions 32, 31 of the associated slits 30. As was heretofore noted, due to the crushed intermediate ply 12 and the slit inner ply 11, as is best shown in FIG. 4, the edges 58, 59, 67, 68, and the like primed edges, interlockingly bear against and grip the slits resulting in an automatic locking which precludes the container 10 from collapsing until intentionally unlocked. The unlocking is accomplished by grasping the locking flaps 75, 84 in the area of the weakening lines 81 through 83 and 81' through 84' and applying thereto an inward force which permits the locking panels to deflect or bow inwardly resulting in pivoting of the flaps or tabs 77, 77', 78, 78', automatically about the associated fold lines to an unlocked position without tearing or severing of these locking tabs or the associated locking slits 30.

While preferred forms and arrangements of parts have been shown in illustrating the invention, it is to be clearly understood that various changes in details and arrangement of parts may be made without departing from the spirit and scope of this disclosure.

Claims

I claim:

1. A container blank comprising corrugated board having inner, intermediate and outer plies, first and second spaced pairs of fold lines setting off a bottom panel, end panels joined to said bottom panel by said first pair of fold lines, side panels joined to said bottom panel by said second pair of fold lines, a reinforcing panel between adjacent edges of adjoining side and end panels and being joined to each side panel by an associated fold line, a locking panel joined to each end panel along fold line means parallel to said first pair of fold lines, each locking panel having a terminal locking tab formed from material at least in part robbed from said reinforcing panels, each locking tab having an angular locking edge adapted for engagement with an angular locking slit in said inner ply of said side panels, said locking edges of each locking panel being in diverging relationship relative to each other in directions away from said first pair of fold lines, and said locking slits of each side panel being in diverging relationship relative to each other in directions away from said second pair of fold lines.

2. The container blank as defined in claim 1 wherein the slits of each side panel have portions in generally parallel relationship to each other and to said first pair of fold lines.

3. The container blank as defined in claim 1 wherein the intermediate ply of material is crushed along only one edge of said slits and each of said one edges is most adjacent an adjacent reinforcing panel than the remaining edge of each slit.

4. The container blank as defined in claim 1 wherein each locking tab is further defined by a fold line, and the last-mentioned fold lines of each locking panel converge toward each other in a direction away from the most adjacent fold line means.

5. The container blank as defined in claim 1 wherein each end panel includes a pair of side edges parallel to but outboard of said second pair of fold lines, and each locking edge is offset inboard of the most adjacent end panel side edge.

6. The container blank as defined in claim 1 wherein each locking panel includes a pair of weakening lines converging in a direction toward the most adjacent of said first pair of fold lines.

7. The container blank as defined in claim 2 wherein the intermediate ply of material is crushed along only one edge of said slits and each of said one edges is most adjacent an adjacent reinforcing panel than the remaining edge of each slit.

8. The container blank as defined in claim 2 wherein each locking tab is further defined by a fold line, and the last-mentioned fold lines of each locking panel converge toward each other in a direction away from the most adjacent fold line means.

9. The container blank as defined in claim 2 wherein each end panel includes a pair of side edges parallel to but outboard of said second pair of fold lines, and each locking edge is offset inboard of the most adjacent end panel side edge.

10. The container blank as defined in claim 2 wherein each locking panel includes a pair of weakening lines converging in a direction toward the most adjacent of said first pair of fold lines.

11. The container blank as defined in claim 3 wherein each locking tab is further defined by a fold line, and the last-mentioned fold lines of each locking panel converge toward each other in a direction away from the most adjacent fold line means.

12. The container blank as defined in claim 3 wherein each end panel includes a pair of side edges parallel to but outboard of said second pair of fold lines, and each locking edge is offset inboard of the most adjacent end panel side edge.

13. The container blank as defined in claim 3 wherein each locking panel includes a pair of weakening lines converging in a direction toward the most adjacent of said first pair of fold lines.

14. The container blank as defined in claim 4 wherein each end panel includes a pair of side edges parallel to but outboard of said second pair of fold lines, and each locking edge is offset inboard of the most adjacent end panel side edge.

15. The container blank as defined in claim 4 wherein each locking panel includes a pair of weakening lines converging in a direction toward the most adjacent of said first pair of fold lines.

16. A container blank comprising corrugated board having inner, intermediate and outer plies, first and second spaced pairs of fold lines setting off a bottom panel, end panels joined to said bottom panel by said first pair of fold lines, side panels joined to said bottom panel by said second pair of fold lines, a reinforcing panel between adjacent edges of adjoining side and end panels and being joined to each side panel by an associated fold line, a locking panel joined to each end panel along fold line means parallel to said first pair of fold lines, each locking panel having a terminal locking tab formed from material at least in part robbed from said reinforcing panels, each locking tab having an angular locking edge adapted for engagment with an angular locking slit in said inner ply of said side panels, said locking edges of each locking panel being in diverging relationship relative to each other in directions away from said first pair of fold lines, said locking slits of each side panel being in diverging relationship relative to each other in directions away from said second pair of fold lines, each locking panel and its most adjacent pair of reinforcing panels having generally aligned end edges, and each side panel and its most adjacent reinforcing panels having generally aligned side edges whereby said blank is constructed of a polygonal configuration with minimum scrap loss during the fabrication thereof.

17. A container blank comprising corrugated board having inner, intermediate and outer plies, first and second spaced pairs of fold lines setting off a bottom panel, end panels joined to said bottom panel by said first pair of fold lines, side panels joined to said bottom panel by said second pair of fold lines, a reinforcing panel between adjacent edges of adjoining side and end panels and being joined to each side panel by an associated fold line, a locking panel joined to each end panel along fold line means parallel to said first pair of fold lines, each locking panel having a terminal locking tab formed from material at least in part robbed from said reinforcing panels, each locking tab having an angular locking edge adapted for engagement with an angular locking slit in said inner ply of said side panels, said locking edges of each locking panel being in diverging relationship relative to each other in directions away from said first pair of fold lines, said locking slits of each side panel being in diverging relationship relative to each other in directions away from said second pair of fold lines, and each of said locking panels having means between the locking tabs thereof for bending the locking tabs transverse to their length causing a bowing thereof incident to an unlocking operation whereby damage to said locking tabs and locking slits is minimized.