U.S. patent number 3,913,822 [Application Number 05/534,311] was granted by the patent office on 1975-10-21 for two component double thickness shipping containers.
This patent grant is currently assigned to Connelly Containers, Inc.. Invention is credited to Harry D. Heaps, Jr..
United States Patent |
3,913,822 |
Heaps, Jr. |
October 21, 1975 |
Two component double thickness shipping containers
Abstract
A shipping container of tubular form for shipping pipes and
tubes of great length, being made of two blanks secured together. A
first blank has five side-by-side panels each hinged to the
adjacent panel(s) and a second blank of equal length has three
side-by-side panels similarly hinged. The middle panels only are
adhered together and in erected condition, each of the four walls
of the container has the thickness of two panels. A method for
making a shipping container includes producing multi-ply paperboard
in indefinite lengths, cutting it into blanks of two different
widths, cutting four V-notches in the wider blank and two V-notches
in the narrower blank to produce a five panel and a three-panel
blank, and then securing the middle panels together with the
notches parallel and opening in the same direction.
Inventors: |
Heaps, Jr.; Harry D.
(Villanova, PA) |
Assignee: |
Connelly Containers, Inc. (Bala
Cynwyd, PA)
|
Family
ID: |
24129530 |
Appl.
No.: |
05/534,311 |
Filed: |
December 19, 1974 |
Current U.S.
Class: |
229/122.32;
229/919; 229/931; 229/939; 229/186 |
Current CPC
Class: |
B65D
5/32 (20130101); B65D 5/04 (20130101); Y10S
229/931 (20130101); Y10S 229/919 (20130101); Y10S
229/939 (20130101) |
Current International
Class: |
B65D
5/00 (20060101); B65D 5/02 (20060101); B65D
5/04 (20060101); B65D 5/32 (20060101); B65D
005/32 (); B65D 013/04 () |
Field of
Search: |
;229/14BA,14BL,14C,37R,23R,23C |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Moorhead; Davis T.
Attorney, Agent or Firm: Lavine; Irvin A.
Claims
I claim:
1. A shipping container made of two blanks of material
comprising:
a. a first blank comprising a first pair of spaced panels, a second
pair of spaced panels each inwardly of a panel of said first pair
and hingedly connected thereto by linearly extending hinge means,
and an interior panel between and hingedly connected by linearly
extending hinge means to said panels of said second pair of panels,
said hinge means being parallel,
b. a second blank comprising a pair of spaced panels and an
interior panel between and hingedly connected thereto by linearly
extending parallel hinge means,
c. means securing the interior panel of said second blank in
overlying relationship to the interior panel of said first blank
with the hinge means of said second blank parallel to and laterally
inwardly of the hinge means and said first blank interior
panel,
d. said spaced panels of said second blank being inwardly of and
substantially coextensive with said second pair of panels of said
first blank, and
e. said first pair of panels of said first blank being in adjacent
substantially coextensive overlapping relationship, parallel to
said interior panels and perpendicular to said panels of said
second pair.
2. The shipping container of claim 1, wherein said blanks are each
made of multi-ply corrugated paperboard.
3. The shipping container of claim 2, wherein the edge of each said
panel hingedly connected to another panel is beveled to permit
placement of contiguous panels substantially perpendicular to each
other.
4. The shipping container of claim 1, wherein the edge of each said
panel hingedly connected to another panel is beveled to permit
placement of contiguous panels substantially perpendicular to each
other.
5. The shipping container of claim 1, and further comprising means
for closing the ends thereof.
6. The shipping container of claim 1, wherein a first panel of the
first pair of said first blanks is narrower than the other panel of
said first pair.
7. The shipping container of claim 6, wherein the panel of said
second pair hingedly connected to the said first panel of the first
pair is narrower than the other panel of said second pair.
8. The shipping container of claim 1, wherein said first pair of
panels of said first blank are end panels.
9. The shipping container of claim 8, wherein said pair of panels
of said second blank are end panels.
10. The shipping container of claim 1, wherein said pair of panels
of said second blank are end panels.
11. The shipping container of claim 1, said first and second blanks
being rectangular when unfolded and of substantially the same
length.
Description
BACKGROUND OF THE INVENTION
The present invention pertains to shipping containers, and to a
method of making a composite blank from which a shipping container
may be erected.
Shipping containers or cartons are now widely used for the shipping
of goods from one place to another, as froma manufacturer to a
distributor or consumer, or from one manufacturer to another.
Currently, containers made of corrugated paperboard are widely
used, and over the years containers of heavier construction have
been introduced, supplanting containers made of other materials. In
particular, containers made of multi-ply corrugated paperboard have
supplanted in a number of instances containers made of wood.
One product which is still being predominantly shipped in wooden
containers is tubes or rods of relatively great length, such as 20
feet or 24 feet in length. Such tubes and rods are in many
instances very expensive, and therefore must be protected against
damage during shipment and storage. These products may be fragile,
or they may be of extremely heavy construction, with lesser
fragility. In either case, the shipping container must have
characteristics which will protect the fragile rod and tube
products, and also enable the heavier rod and tube products to be
transported and handled as necessary, without the products
themselves breaking open the containers in which they are
shipped.
The prior art has failed to provide containers of suitable
construction and characteristics for such tubular products. One
suggestion has been to use a plurality of lengths of U-shaped
channel members, made of hard board or particle board, the channel
members being arranged in end-to-end, abutting relationship, and
the channel members being covered by another series of inverted,
U-shaped channel members, with the abutting ends of the covering
channel members being in staggered relationship to the abutting
ends of the first mentioned U-shaped members. Another suggestion is
the provision of two or more channels in side-by-side relationship,
each made of U-shaped members of hard board or particle board, and
placed in side-by-side arrangement. Each of the U-shaped channel
members is made up of three panels hingedly connected together, and
a flat cover member extends over the several adjacent U-shaped
panels; U-shaped channels are abutted together, end-to-end, with
the abutting joints in staggered relationship. With these
constructions, relatively expensive hard board or particle board is
required, and it is known that material of this type is seldom
longer than 16 feet. Hence, the construction is expensive where
lengths greater than 16 feet are required.
In addition to the above, various suggestions have been made in the
prior art for shipping containers having walls of multiple
thicknesses. In one prior art container a blank for a regular
slotted carton was provided, and there was adhered to it a liner
blank which comprised four panels, each of which was secured by
adhesive to a corresponding panel of the blank of the regular
slotted carton. A special rupturable attachment region was provided
in the liner blank, so that when the box or container was set up,
these regions automatically ruptured. This construction, therefore,
required very special construction of blanks in order to provide
the double thickness of the container walls.
Yet another suggestion in the prior art provided a multi-ply
container which comprised a half slotted carton blank which had
applied or laminated to it two sets of L-shaped pads, the resulting
container having walls of triple thickness, but a feature of the
container was that at each of the corners, there was only provided
a double thickness of the material, in order to enable the
container to be formed as a tube by the manufacturer, and then
shipped flat.
Another suggestion in the prior art for a heavy duty container
provided two blanks each made up of five panels or partial panels.
In some instances, there were provided three full panels and two
partial panels, or four full panels and one partial panel. When
erected, the panels were all adhered to each other to thereby
provide a tubular container having double thickness in three walls,
and with the fourth wall having double thickness for most of its
length, but having triple thickness for a portion of its
length.
Yet another disclosure in the prior art provides a multi-ply
container made from three separate four-panel blanks which are
adhesively attached to one another. Two of the blanks are provided
with blind slots, instead of fold lines, between panels, to thereby
reduce the material at a corner, in order to permit folding for
shipping in flattened condition, such blank thereby requiring
special configuration at the corner, where stresses are apt to be
concentrated, and where, therefore, the carton would appear to be
weakest.
Among the objects of the present invention are the provision of a
container which is of strong construction, and may be made of
great, almost indeterminate length, in order to accommodate rods,
tubes and similar products of great length.
Yet another object of the present invention is the provision of a
container made of conventional corrugated paperboard material,
comprising two blanks of such material secured together, and
capable of being shipped in flat condition.
Yet another object of the present invention is to provide a
container for shipping material of great length which can be
readily erected by the user without special equipment, other than
conventional equipment, such as steel banding devices, which are
conventionally found in the shipping room of a manufacturer.
Yet another object of the present invention is to provide a tubular
container having the walls thereof of double thickness of material,
and without any deficiency in the construction of the corners which
would reduce the strength thereof.
A still further object of the present invention is to provide a
container which is made up of blanks which may be readily
constructed on conventional or readily obtainable equipment found
in corrugated container producing plants.
Still another object of the present invention is to provide a
method for making containers of corrugated paperboard material,
which containers will be strong and of indefinite length, and which
method is economical and does not require a substantial amount of
non-conventional equipment.
Other objects will be readily understood from a detailed
consideration of the following description, drawings, and
claims.
SUMMARY OF THE INVENTION
The present invention provides a shipping container of so-called
tubular form, which may be of great, indefinite length. The
shipping container is made up of two blanks which are secured
together, a first blank having five panels in side-by-side
relationship, the panels being hingedly connected together along
linearly extending, parallel hinge lines. A second blank is
preferably of the same length as the first blank, but has three
side-by-side panels which are similarly hinged. In the first blank,
of five panels, an end panel and an adjacent panel are narrower
than the other end panel and the other adjacent panel,
respectively. Each blank is of relatively thick corrugated
paperboard material, and the panels are routed at their adjacent
edges, so as to form V-notches between adjacent panels when the
blanks are flat, before the erection of the container. The middle
panels of the two blanks are adhered together, the other panels not
being adhered. All of the V-notches of the two blanks are parallel,
and open or face in the same direction. The composite blank, made
up of the two adhered blanks, is shipped, usually in flat
condition, and the user then erects the container by folding
upwardly the two end panels of the first blank so that they are
perpendicular to the middle panel. Then the panels adjacent the end
panels are folded up, so that they are substantially outwardly of,
coextensive with and adjacent the end panels of the first blank.
The end panels of the first blank are then placed in overlapping
relationship to each other, so that they are substantially adjacent
and coextensive, and are parallel to the middle panels. The rods or
tubes may be placed in the container either by inserting them
through the top of the shipping container before the end panels of
the five panel blank are placed in their final position, or
afterwards, by being inserted into the open ends of the shipping
container. Thereafter, end closure plates or plugs are positioned
in or on the container and secured in position, as by nailing.
The method of making a shipping container includes the step of
producing multi-ply corrugated paperboard, such as triple wall,
seven-component paper board of known construction, on standard
paperboard machinery, known as a combiner, thereby producing such
paperboard in indeterminate lengths. The paperboard is cut to the
desired length, and also to the desired width, to provide two
blanks of substantially the same length, but of differing width.
The wider blank is passed through a machine which cuts four spaced,
parallel V-notches therein, the notches extending almost but not
quite through the paperboard material, passing through perhaps four
to six of the paper components where the paperboard material is of
seven components. The narrower width blank is provided with two
V-shaped parallel notches, to thereby provide a blank with three
hingedly connected panels. The middle panels of the two blanks,
only, are then adhered to each other, with all of the V-notches
parallel and facing in the same direction.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a composite blank in accordance
with the present invention, shown broken away.
FIG. 2 is an end view of a container made from the composite blank
of FIG. 1, and with tubular or rod-like products therein.
FIG. 3 is a cross sectional view taken on the line 3--3 of FIG.
2.
FIG. 4 is a diagrammatic view illustrating the method of making a
container in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, wherein like or corresponding
reference numerals are used to designate like or corresponding
parts throughout the several views, there is shown in FIG. 1 a
perspective view of a composite blank 10, which may be of any
desired length, and which is shown broken away. For example, the
composite blank 10 may be in the range of twenty feet to
twenty-four feet, or even longer. The composite blank 10 is shown
made of two blanks or triple wall corrugated paperboard, a
commercially available product made by conventional
corrugator-combiner equipment, and including three corrugated paper
mediums interposed and adhesively secured to four paper liner
sheets.
Forming a part of the composite blank 10 is a first blank 12 which
is made up of five hingedly joined panels in series. Thus, the
first blank 12 comprises a first pair of spaced panels 14 and 16,
which are end panels, inwardly of which are a second pair of spaced
panels 18 and 20, which are adjacent to the end panels 14 and 16,
respectively, and which are hingedly connected to them. These
adjacent or intermediate panels 18 and 20 have between them a panel
22, which is the middle or mid-panel of the five panel first blank
12.
Provided between each two adjacent panels is a V-notch, there being
four such V-notches designated 24, 26, 28 and 30. Each of these
V-notches has side walls defined by the boundaries of the adjacent
panels, and each of the V-notches extends through, in the preferred
embodiment, five or six of the paper layers forming a part of the
first blank 12. That is, the V-notches leave intact the lower liner
sheet of the triple wall board forming the first blank 12, and may
also leave intact the lowermost corrugated medium. The V-notches
24, 26, 28 and 30 thereby provide an absence of material in order
to enable each panel to assume a position at right angles to the
panel or panels adjacent to it, the remaining material of the
corrugated board at the several V-notches providing a linearly
extending hinge, and as is apparent, all of the hinges are parallel
to each other.
The panels making up the blank 12 are not all of the same width,
width being measured from, example, the left margin of panel 14 to
the mid-point of the V-notch 24, the width of panel 16 being
similarly defined, measured to the mid-point of the V-notch 30. The
width of panels 18, 20 and 22 are measured between the mid-points
of the V-notches which bound them. In a typical shipping container,
the width of the various panels of the blank 12 are as follows:
Panel 14 6 and 5/8 inches Panel 18 6 and 1/2 inches Panel 22 7 and
1/8 inches Panel 20 7 and 1/8 inches Panel 16 7 inches
The second component of the composite blank 10 is a blank 32, which
is made up of the same triple wall board material as the first
blank 12, and is narrower than the blank 12, having only three
panels. Thus there are provided a pair of spaced end panels 34 and
36, and a middle panel 38, in the same side-by-side relationship as
the panels of the first blank 12, there being a 90.degree. V-notch
40 separating the panels 34 and 38, and a similar 90.degree.
V-notch 42 separating the panels 38 and 36. These V-notches,
similarly to those of the blank 12, enable the panels 34 and 36 to
be moved into positions in planes perpendicular to the middle panel
38, on longitudinally extending parallel hinge lines lying at the
bottoms of the V-notches 40 and 42.
In the typical container provided with the blank 12 having the
above noted dimensions, the dimensions of the panels of the blank
32 are as follows:
Panel 34 5 and 3/8inches Panel 38 6 inches Panel 36 5 and
3/8inches
The first blank 12 and the second blank 32 are secured together by
suitable means 44, this being specifically a layer of adhesive
between the upper surface of middle panel 22 of first blank 12 and
the lower surface of middle panel 38 of the second blank 32. All of
the V-notches of the blanks 12 and 32 are parallel with each other,
and all of the V-notches open or face in the same direction. A
plane perpendicular to the planes containing the blanks 12 and 32
would pass through the center lines of the middle panels 22 and 38,
so that these middle panels are centered laterally to each other.
Further, the two blanks 12 and 32 are of the same length, and are
co-terminal at their ends, in the preferred embodiment, so that
there is double thickness of the panels 22 and 38 in their
overlying co-extensive relationship throughout their lengths.
The composite blank 10 may be shipped in the condition shown to a
user, such as a producer of tubes or rods, who will be enabled to
erect a container from the composite blank 10. Referring now to
FIG. 2, there is shown the container, in which the middle or
interior panels 22 and 38 are shown at the bottom of the container,
in overlying relationship. Due to the thickness of the triple wall
corrugated board, which may be approximately 3/8 inches, the hinge
line at the edges of the middle or interior panel 38 are laterally
inwardly of the hinge lines at the edges of the middle or interior
panel 22. Further, the spaced panels 34 and 36 of the second blank
32 may be seen to be in perpendicular relationship to the panel 38,
and the second pair of panels 18 and 20 of the first blank 12 may
be seen to be perpendicular to the middle or interior panel 22. The
first pair of end panels 14 and 16 of the first blank 12 are in
adjacent, substantially co-extensive overlapping relationship,
being parallel to the bottom or interior panels 22 and 38 of the
blanks 12 and 32, and perpendicular to the panels of the second
pair of panels, 18 and 20. The under surface of end panel 14
substantially rests upon the ends of the first, end pair, of panels
34 and 36 of the second blank 32. The under surface of the end
panel 16 is in substantially co-extensive surface engagement with
the upper surface of the end panel 14. Thus, the container shown in
FIG. 2 is structurally sound, having essentially four walls and
each of double thickness of the corrugated paperboard. As above
noted, this is preferably triple wall corrugated board, but not
necessarily so. The panels providing the double thickness walls,
including top, bottom and sides, are in substantially co-extensive
engagement with each other, due to the dimensioning disclosed in
the exemplary embodiment of the shipping container erected from the
two component composite blank 10. As will be appreciated by those
skilled in the art, the dimensions are given with the precision
generally prevalent in the art, it being understood that in the
paperboard industry, greater preciseness is not commercially
feasible.
There is shown in the shipping container erected from the composite
blank 10, in FIG. 2, as well as in FIG. 3, linearly extending
products generally designated P, which may be pipes, tubes or rods
of considerable length, such as twenty to twenty-four feet. These
products may be fragile, or of great weight, and in either case,
the disclosed shipping container will protect them, and enable them
to be shipped and handled with safety and without damage.
These products P may be placed in the container by lowering them
into it before the end panels 14 and 16 are folded to the positions
shown in FIG. 2, or alternatively, the container may be erected in
the tubular form shown in FIG. 2, and the products P inserted
linearly.
Referring now to FIG. 3, the two component composite blank 10 is
shown with the products P extending linearly within the tubular
form of the container. The products P are somewhat shorter than the
container, and the ends of the container are closed, in known
manner, by end walls in the form of plugs 52 and 54, which may be
of wood, corrugated paperboard or other products. Such an end plug
or end wall is shown in a tubular container in, for example,
Geisler U.S. Pat. No. 3,313,465, issued Apr. 11,1967. Such end
plugs or end walls 52, 54 may be secured in position by suitable
means, such as nails driven generally perpendicularly to the axis
of the container, penetrating through the double wall thickness
thereof and into the end walls or end plugs 52, 54. While FIG. 3
discloses the end plugs 52, 54 at the ends of the container, they
may be inwardly of the ends thereof, where the products P have a
somewhat lesser length than shown in FIG. 3. Thus, the plugs or end
walls 52, 54 may be a suitable distance within the ends of the
container such as 3 inches, 6 inches, etc. This enables the
utilization of relatively standard size containers, even where
there is some variation in the length of the specific products P to
be incorporated therein.
The container is maintained in closed condition in any suitable
manner, such as by conventional steel band straps S, applied to the
completed and filled container by conventional strapping
equipment.
Referring now to FIG. 4, there is shown in diagrammatic form a
method for making a container such as is shown in FIGS. 1-3. A
corrugator combiner 60 of known construction is provided, this
machine combining a plurality of paper webs, such as the seven
paper webs shown, into triple wall or seven-layer corrugated
paperboard 62. The corrugator combiner 60 corrugates three of the
mediums, applies adhesive to the tips of the corrugations, engages
the three corrugated mediums with and between the four liner
sheets, and then combines the seven elements under heat and
pressure, to produce the paperboard 62. The paperboard 62 is
discharged from the corrugator combiner 60 in an indefinite length,
such machines conventionally running at high speeds for hours or
even days at a time without stopping. The corrugated board 62 is
then led to a cutter 64 which cuts the board into suitable lengths,
such as 20 feet or 24 feet. Also, since the corrugated paperboard
62 is of relatively great width, which may be approximately eight
feet or nine feet, the cut lengths of the paperboard 62 are further
cut longitudinally, so as to provide blanks of the desired width.
Specifically, there are produced blanks of two different widths,
and of substantially the same length. The wider blank is processed
in a V-notching machine 66, wherein four spaced, parallel V-notches
are routed or cut partially through the said blank of greater width
in order to provide a component having five panels, each hingedly
connected to the panel or panels adjacent to it. The five panel
component produced from the V-notching machine 66 is indicated at
68, and as will be understood, this is the first blank 12 shown in
FIG. 1.
The panel of narrower width is also passed through the V-notching
machine which similarly cuts two spaced parallel V-notches partly
therethrough to provide a component of three panels, designated 70,
which will be understood to be the second blank 32 shown in FIG. 1.
Next, adhesive is applied to the upper surface of the
five-component panel 68 (12) and specifically to only the upper
surface of the middle of the five panels. Thereafter, the
three-component panel 70 (32) is placed on the five component panel
68 (12) in the manner hereinabove described in relation to FIG. 1,
so that the two components are thereby laminated to provide the
two-component composite blank made up of the components 68 (12) and
70 (32), shown specifically in FIG. 1.
There has been provided a shipping container construction
particularly suitable for the shipment of pipes, tubular articles
and rods of substantial length, such as 20 feet to 24 feet, which
shipping container may be produced on conventional or easily
obtainable equipment, and without involving any unusual techniques
or manufacturing methods. The shipping container herein provided is
extremely strong, providing for double wall thickness of the four
walls thereof. The herein disclosed shipping container may be
manufactured and shipped as a blank in flat condition, and then
readily erected and filled by the user of the container. The user
is not required to have any unusual equipment, and may rely upon
such simple completion equipment as nailing equipment and steel
strapping equipment, both conventional.
The herein disclosed method provides for the manufacture of such a
container by the use of relatively standard equipment, and without
involving unusual or complicated techniques, the method being
extremely simple and economical, and providing containers of
suitable length and of great strength.
It will be obvious to those skilled in the art that various changes
may be made without departing from the spirit of the invention and
therefore the invention is not limited to what is shown in the
drawings and described in the specification but only as indicated
in the appended claims.
* * * * *