U.S. patent number 3,910,484 [Application Number 05/445,350] was granted by the patent office on 1975-10-07 for carton with exterior ledge.
This patent grant is currently assigned to International Paper Company. Invention is credited to Roger M. Wozniacki.
United States Patent |
3,910,484 |
Wozniacki |
October 7, 1975 |
Carton with exterior ledge
Abstract
A single piece, self-locking carton having excellent corner
strength and durable integral exterior ledges is described. The
carton has bottom, side and end wall panels. Ledge panels foldably
attached to the top edge of the end wall panels overlie the outer
face of the end wall panels. The ledge panels are shorter than the
end wall panels and form a protruding ledge at the top of each end
of the carton. The thickness and strength of the ledges is varied
by additional panels located between the ledge panels and end wall
panels. To provide corner strength, there are two sets of corner
connector panels, one set foldably attached to the end wall panels,
the other set to the ledge panels. The corner connector panels abut
the inner face of the side wall panels. Locking panels foldably
attached to the side wall panels overlie the inner face of the side
wall panels and sandwich the corner connector panels between them
and the side wall panels to maintain the structural integrity of
the carton.
Inventors: |
Wozniacki; Roger M. (Brea,
CA) |
Assignee: |
International Paper Company
(New York, NY)
|
Family
ID: |
23768571 |
Appl.
No.: |
05/445,350 |
Filed: |
February 25, 1974 |
Current U.S.
Class: |
229/174; 229/171;
229/178 |
Current CPC
Class: |
B65D
5/46072 (20130101); B65D 5/22 (20130101); B65D
5/2047 (20130101) |
Current International
Class: |
B65D
5/20 (20060101); B65D 5/46 (20060101); B65D
5/22 (20060101); B65D 005/22 () |
Field of
Search: |
;229/33,34,30 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Moorhead; Davis T.
Attorney, Agent or Firm: Flynn; Lawrence W.
Claims
What is claimed is:
1. A carton comprising:
a bottom panel with foldably attached side and end wall panels,
said bottom panel containing peripheral apertures;
outer ledge panels of a smaller height dimension than the end wall
panels foldably attached to the top edge of the end wall panels and
overlying the outer face of the end wall panels;
inner ledge panels of a smaller height dimension than the end wall
panels attached to that edge of the outer ledge panels opposite
that which attaches the outer ledge panels to the end wall panels,
the inner ledge panels located between the outer ledge panels and
the end wall panels, the outer and inner ledge panels cooperating
to form at the top of each end of the carton a ledge on the carton
exterior;
first corner connector panels foldably attached to opposite side
edges of the end wall panels and overlying the inner face of the
side wall panels;
second corner connector panels foldably attached to opposite side
edges of the outer ledge panels and overlying the inner face of the
side wall panels, the second corner connector panels located
between the first corner connector panels and the side wall panels
and having tabs which fit in the apertures of the bottom panel;
locking panels foldably attached to the top edge of the side wall
panels and overlying the inner face of the side wall panels, the
first and second corner connector panels located between the side
wall panels and the locking panels, the locking panels having tabs
at the bottom edge which fit in the apertures of the bottom panels
to hold the locking panels in position.
2. The carton of claim 1 further including an additional panel of a
smaller height dimension than the end wall panels foldably attached
to that edge of the inner ledge panels which attaches the inner
ledge panels to the outer ledge panels, said panel located between
the inner and outer ledge panels to further thicken the ledges on
the carton exterior.
3. A single unit blank comprising:
a bottom panel with foldably attached side and end wall panels,
said bottom panel having peripheral apertures;
outer ledge panels of a smaller height dimension than the end wall
panels foldably attached to the top edge of the end wall panels by
an intermediate shoulder panel;
inner ledge panels of a smaller height dimension than the end wall
panels foldably attached by an intermediate shoulder panel to that
edge of the outer ledge panels opposite that which attaches the
outer ledge panels to the end wall panels;
first corner connector panels foldably attached to opposite side
edges of the end wall panels;
second corner connector panels foldably attached to opposite side
edges of the outer ledge panels; and
locking panels foldably attached to the top edge of the side wall
panels by an intermediate shoulder panel, the locking panels having
tabs along the edge opposite that which connects the locking panels
to the side wall panels which are adapted to fit in the apertures
of the bottom panel in the assembled blank.
4. A carton comprising:
a bottom panel with foldably attached side and end wall panels,
said bottom panel having peripheral apertures;
outer ledge panels of a smaller height dimension than the end wall
panels foldably attached to the top edge of the end wall panels by
an intermediate shoulder panel and overlying the outer face of the
end wall panels;
inner ledge panels of a smaller height dimension than the end wall
panels attached by an intermediate shoulder panel to that edge of
the outer ledge panels opposite that which attaches the outer ledge
panels to the end wall panels, the inner ledge panels located
between the outer ledge panels and the end wall panels, the outer
and inner ledge panels cooperating to form at the top of each end
of the carton a ledge on the carton exterior;
first corner connector panels foldably attached to opposite side
edges of the end wall panels and overlying the inner face of the
side wall panels;
second corner connector panels foldably attached to opposite side
edges of the outer ledge panels and overlying the inner face of the
side wall panels, the second corner connector panels located
between the first corner connector panels and the side wall
panels;
locking panels foldably attached to the top edge of the side wall
panels by an intermediate shoulder panel and overlying the inner
face of the side wall panels, the first and second corner connector
panels located between the side wall panels and the locking panels,
the locking panels having tabs at the bottom edge which fit in the
apertures of the bottom panels to hold the locking panels in
position.
5. A carton comprising:
a bottom panel with foldably attached side and end wall panels;
a ledge panel foldably attached to the end wall panels by an
intermediate shoulder panel and overlying the outer face of the end
wall panels;
first corner connector panels foldably attached to opposite edges
of the end wall panels and overlying the inner face of the side
wall panels;
second corner connector panels foldably attached to opposite edges
of the ledge panel and overlying the inner face of the side wall
panels;
locking panels foldably attached to the side wall panels by an
intermediate shoulder panel and overlying the inner face of the
side wall panels, the corner connector panels located between the
side wall panels and the locking panels, said intermediate shoulder
panels forming a broadened, flat peripheral rim around the top of
the carton; and
means maintaining the locking panel in said position.
6. A carton comprising:
a bottom panel with foldably attached side and end wall panels,
said bottom panel containing peripheral apertures;
a ledge panel foldably attached to the end wall panels and
overlying the outer face of the end wall panels;
first corner connector panels foldably attached to opposite edges
of the end wall panels and overlying the inner face of the side
wall panels;
second corner connector panels foldably attached to opposite edges
of the ledge panel and overlying the inner face of the side wall
panels, said second corner connector panels having tabs which fit
in the apertures of the bottom panel;
locking panels foldably attached to the side wall panels and
overlying the inner face of the side wall panels, the corner
connector panels located between the side wall panels and the
locking panels; and
means maintaining the locking panel in said position.
7. A single unit blank comprising:
a bottom panel with foldably attached side and end wall panels,
said bottom panel containing peripheral apertures;
outer ledge panels of a smaller height dimension than the end wall
panels foldably attached to the top edge of the end wall
panels;
inner ledge panels of a smaller height dimension than the end wall
panels foldably attached to that edge of the outer ledge panels
opposite that which attaches the outer ledge panels to the end wall
panels;
first corner connector panels foldably attached to opposite side
edges of the end wall panels;
second corner connector panels foldably attached to opposite side
edges of the outer ledge panels and having tabs which are adapted
to fit in the apertures of the bottom panel in the assembled blank;
and
locking panels foldably attached to the top edge of the side wall
panels, the locking panels having tabs along the edge opposite that
which connects the locking panels to the side wall panels which are
adapted to fit in the apertures of the bottom panel in the
assembled blank.
8. A single unit blank comprising:
a bottom panel with attached side and end wall panels;
a ledge panel attached to the end wall panels by an intermediate
shoulder panel;
first corner connector panels attached to the end wall panels;
second corner connector panels attached to the ledge panels;
and
locking panels attached to the side wall panels by an intermediate
shoulder panel which, in the erected blank, cooperates with the
intermediate shoulder panel which attaches the ledge panels to the
end wall panels to form a broadened, flat peripheral rim around the
top of the erected blank.
9. A single unit blank comprising:
a bottom panel with attached side and end wall panels, said bottom
panel containing peripheral apertures;
a ledge panel attached to the end wall panels;
first corner connector panels attached to the end wall panels;
second corner connector panels attached to the ledge panels and
having tabs which are adapted to fit in the apertures of the bottom
panel in the assembled blank; and
locking panels attached to the side wall panels.
Description
BACKGROUND OF THE INVENTION
This invention relates to a rugged single piece carton having high
corner strength and durable integral ledges on the carton exterior.
The carton is preferably made of corrugated paperboard and has
self-locking features.
Although the carton has many uses, it is particularly useful as a
tray for storing, handling and transporting items such as
envelopes, letters, stationeary, mail, and the like. It finds
particular utility as a stationery, for use in conjunction with
wheeled tray carrying racks of the type commonly used by the United
States Postal Service. One such rack is described in U.S. Pat. No.
2,928,681. Such racks are designed to accommodate a large number of
individual trays of mail in a multi-layered arrangement. The racks
have metal guide runners which cooperate with ledges formed on the
exterior of the tray to support the trays in the rack. The ledges
normally rest on the runner so that virtually the entire weight of
the tray is supported by the ledges. Heretofore, such trays were
often made of plastic and were sufficiently expensive that they
were not considered "disposable" items. As will become apparent,
the present invention provides a disposable alternate to such
plastic trays which can be inexpensively fabricated from corrugated
paperboard. Although corrugated paperboard is used, the cartons of
the invention, because of their unique construction, have
exceptionally strong and durable exterior ledges and excellent
corner strength.
SUMMARY OF THE INVENTION
The carton of the present invention has a bottom panel to which end
wall and side wall panels are foldably attached. To provide the
exterior ledges, ledge panels are foldably attached to the top edge
of the end wall panels. These ledge panels are generally of a
smaller height dimension than the end wall panels and overlie the
outer face of the end wall panel to form an exterior ledge at the
top of each end of the carton. The thickness and strength of the
ledge can be increased by placing additional panels between the
ledge panels and the wall panels. To provide corner strength two
sets of corner connector panels are used, one set foldably attached
to the side edges of the end wall panels and the other foldably
attached to the side edges of the ledge panels. These corner
connector panels overlie the inner face of the side wall panels
with the first corner connector panels located interiorly of the
second corner connector panels. The structural integrity of the
carton is maintained by locking panels foldably attached to the
upper edge of the side wall panels which overlie the inner face of
the side wall panels and sandwich the first and second corner
connector panels between them.
The invention is described more specifically below in conjunction
with preferred embodiments and the accompanying drawings
illustrating these embodiments.
BRIEF DESCRIPTION OF THE DRAWNGS
FIG. 1 is a single piece blank from which a preferred embodiment of
the carton is formed.
FIGS. 2-5 are perspective views showing the assembly of the blank
of FIG. 1 into a completed carton, with the completed carton shown
in FIG. 5.
FIG. 6A is a sectional view taken along the line 6A--6A in FIG.
5.
FIGS. 6B-6C are sectional views similar to FIG. 6A showing other
embodiments of the ledge structure of the carton.
FIG. 7 is a sectional view taken along the line 7--7 in FIG. 5.
FIG. 8 is a partial front sectional view illustrating the use of
the carton in conjunction with a carrying rack for the carton.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 depicts a pre-scored single piece blank 10 from which a
preferred embodiment of the carton can be prepared. The blank
comprises a rectangular bottom panel 11 containing a plurality of
spaced apertures or slots 12 along its side edges. A pair of
generally rectangular side wall panels 13 are foldably attached to
opposite edges of panel 12 by score lines 14. Similarly, a pair of
generally rectangular but slightly tapered end wall panels 15 are
foldably attached to opposite edges of panel 12 by score lines 16.
The purpose of the taper is to provide a carton whose walls slope
slightly inwardly instead of being completely erect.
The exterior ledges of the carton are formed from the three panels
17, 18, 19 which are foldably interconnected in series, with end
panel 19 of the series being foldably attached to the top edge of
end wall panel 15. When the blank is assembled, panel 19 becomes an
outer ledge panel while panels 17, 18 become inner ledge panels.
Panels 17, 18 are primarily intended to add thickness and strength
to the ledges. Panel 19 is foldably attached to panel 15 by an
intermediate thin shoulder panel 20 and the score lines 21 at
opposite edges of shoulder panel 20. In the same fashion, inner
ledge panel 18 is foldably attached to outer ledge panel 19 by a
thin shoulder panel 22 and the score lines 23 at opposite edges of
shoulder panel 22. The other inner ledge panel 17, for reasons
which become apparent when the assembly of the blank is described,
is foldably attached to adjoining panel 18 by a slit score line
24.
The end structure of the carton is connected to the side structure
by a first set of corner connector panels 25 which are foldably
attached to the side edges of the end wall panels 15 along score
lines 26, and by a second set of corner connector panels 27 which
are foldably attached to the side edges of the outer ledge panel 19
along score lines 28. Panels 27 have a small cut-out 29 so part of
panel 27 does not extend below the ledges in the assembled blank.
Panels 27 also contain a tab 30 which upon assembly of the blank
fits into the slots 12 of bottom panel 11 to assist in holding
panels 27 in place.
To maintain the structural integrity of the carton, there are
locking panels 31 foldably attached to the upper edges of side wall
panels 13. Panels 31 have at their bottom edge tabs 32 which upon
assembly of the blank fit into the slots 12 of panel 11 to assist
in holding panels 30 in place. Panels 31 are foldably attached to
panels 13 by a thin intermediate shoulder panel 33 and the score
lines 34 at opposite edges of panel 33. In cases where the fold
mechanism between adjoining panels includes a thin intermediate
shoulder panel between the adjoining panels, it will be seen that
additional panels are intended to be located between the two
foldable panels. The intermediate shoulder panel provides the space
required to accommodate these additional panels while at the same
time facilitating the foldability of the two adjoining panels.
While shoulder panels are preferred under such circumstances, it is
to be understood that they are in no way essential. It will also
become apparent that in the assembled carton, the shoulder panels
provide flat, smooth surfaces which are aesthetically pleasing and
functionally desirable.
The sequential assembly of the blank is shown in FIGS. 2-5.
Referring to FIG. 2, the end wall panels 15 are elevated along fold
lines 16 into an erected position. The outer ledge panel 19 are
then folded downwardly toward the outer face of end panel 15 but
not flush against panel 15. Inner ledge panels 17 are then folded
inwardly against inner ledge panels 18 along the slit score line 24
until panels 17 are in face to face relation with panels 18 as
shown in FIG. 2. For this reason, a slit score line is required
between panels 17 and 18. Panels 18 are then folded upwardly
against the outer ledge panels 15 to sandwich panel 17 between them
and panels 19, as shown in FIGS. 3 and 6A. In effect, the inner
ledge panels 17, 18 have been sequentially folded one on top of the
other to produce a stack in which the panels 17, 18 rest on top of
each other. This stack is then located between the outer ledge
panels 19 and the end wall panels 15 to add thickness and strength
to the ledges (see FIGS. 3 and 6A). Although only the two inner
edge panels 17, 18 are shown in the drawings, a plurality of such
panels could be used in place of panels 17, 18, with the panels
foldably attached to each other in series. An end panel of the
series could then be foldably attached to the outer ledge panel 19
in a manner similar to that by which panels 18 are shown to be
attached to panel 19. In such a case, these panels would be
sequentially folded one on top of the other to produce a stack of
the panels which would be located between the outer ledge panel 19
and the end wall panels. Similarly, in certain cases, panel 17, or
both panels 17 and 18, could be omitted having as the respective
ledge panels only panels 18 and 19, or 19 alone (see FIGS.
6B-6C).
Once inner ledge panels 17 and 18 are folded into place between
outer ledge panel 19 and the end wall panels 15, the corner
connector panels 25 and 27 are folded inwardly toward the bottom
panel 11 along score lines 26, 28, respectively, until they come
into approximate alignment with the scored side edges 14 of bottom
panel 11, as shown in FIGS. 3, 4 and 7. Panels 25 and 27 are in
face to face relation, with panel 25 located interiorly of panel
27. The tabs 30 on the bottom edge of panels 27 are then inserted
into the slots 12 in the bottom panel 11 to hold the corner
connector panels in place. The inclusion of tabs 30 on panels 27 is
an optional feature and an acceptable carton can be prepared
without tabs 30.
The side wall panels 13 are then folded upwardly along score lines
14 as shown in FIGS. 3-4 until panels 13 are in face to face
relation with the outer face of corner connector panels 27. The
locking panels 31 are then folded inwardly until they overlie the
inner face of side wall panels 13 and the corner connector panels
25, 27 as shown in FIGS. 4, 5 and 7. The tabs 32 at the bottom edge
of the locking panels are then inserted into the slots 12 in bottom
panel 11 to frictionally hold the locking panels 31 in place. Any
suitable means for holding the locking panels in place other than
tabs 32 and apertures 12 could be used. For example, panels 31
could be stapled, glued or otherwise attached to side wall panels
13 and/or corner connector panels 25, 27.
In the completed carton shown in FIG. 5, the corner connector
panels 25, 27 are sandwiched between the side wall and locking
panels as best shown in FIG. 7. This arrangement maintains the
structural integrity of the carton by holding the end wall panels
in an erect position. End wall panels 13 cannot collapse outwardly
because the top edges of corner connector panels 25, 27 would
strike the underside of shoulder panel 33 to prevent this. With the
stability of the end wall panels assured, the corner connector
panels then function, by their insertion between the side wall and
end wall panels, to prevent collapse of the side wall panels.
The use of two corner connector panels as shown in FIG. 7 provides
a strong corner structure for the carton. As pointed out above, the
thickness of the ledges can be varied by eliminating one or both of
the inner ledge panels 17, 18. These modifications are shown in
FIGS. 6B-6C, respectively. Of course, additional inner ledge panels
could also be used. In such case, the additional panels could be
foldably attached to the edge of panels 17 opposite that which
attaches panels 17 to panels 18. It would also be possible to use
as the inner ledge panels, panels which were not necessarily
attached to the blank at all. For example, a separate detached
panel or a separate detached stack of panels could be inserted
between outer ledge panels 19 and the end wall panels, and if
necessary, glued or otherwise attached to the carton structure to
thicken and strengthen the carton ledges.
In the assembled carton of FIG. 5, it is seen that the shoulder
panels 20 and 33 cooperate to form a broadened, smooth, flat
peripheral rim around the top of the carton. This rim imparts an
attractive, finished appearance to the carton. The shoulder panel
22 on the other hand provide a smooth underside for the ledge
structure as best shown in FIGS. 6A and 6B, which facilitates
manual handling of the carton, especially a loaded carton, since
the carton will ordinarily be grasped by the ledge with the fingers
in contact with the underside of the ledge.
The dimensions and shape of the carton, the blank and the various
panels of the carton can vary considerably without departing from
the scope of the invention. For example, although the embodiment
shown in the drawings has walls with a slight inward taper, the
walls could just as well be made upright without a taper by
modifying in known manner those score lines of the blank which are
responsible for the tapering.
The carton can be fabricated from any suitable material. Corrugated
paperboard is a preferred material because it is relatively
inexpensive and readily available. Different thickness of the
corrugated paperboard can be used and if a thicker variety of
paperboard, such as double-wall paperboard, is used, the ledge
structure may require only a single ledge panel, such as the outer
ledge panel 19, for the required thickness and strength.
Single-wall paperboard, as shown in the drawings, is a preferred
material for the carton and when single-wall paperboard is used, it
is preferable to use one or more inner ledge panels, such as panels
17, 18, to provide added thickness and strength for the ledges.
FIG. 8 illustrates the use of the carton in a tray-carrying rack.
Such racks usually comprise a frame structure consisting of a
number of braced vertical beams 40 which support a plurality of
horizontal guide runners 41 on which the trays are slidably mounted
within the rack. As shown in FIG. 8, the carton of this invention
is supported in the rack by the exterior ledges 42 of the carton
resting on the runners 41. This arrangement allows the cartons to
slide along the runners while at the same time they are guided to
move in a fixed direction.
The descriptive matter and other specific information presented
above was for purposes of illustration only, and such alterations
or modifications thereof as would be within the capabilities of
those skilled in the art are deemed to fall within the scope and
spirit of the invention, bearing in mind that the invention is
defined only by the following claims.
* * * * *