Abstract:
A collapsible container assembly includes a folding container having at least two walls pivotable relative to each other at a corresponding corner disposed between the at least two walls, the folding container movable between a collapsed position wherein the at least two walls are disposed adjacent to one another and an extended position where in the at least two walls are spaced from each other, and an inside cellular structure attached to at least a portion of the at least two walls, the cellular structure comprising a plurality of panels forming a cellular structure, the cellular structure further comprising a plurality of cells in both an X and Y direction with respect to the cellular structure, each cell having four cell walls, when the folding container is positioned in the extended position, at least some of the plurality of cells having two connecting walls formed by one of plurality of panels and another two connecting walls formed by an adjacent one of the plurality of panels.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application Ser. No. 62/292,890 filed Feb. 9, 2016, which is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    Shipping and storage boxes are often provided with a divider that can be inserted into the box for separating individual items from one another. For example, breakable items, such as drinking glasses are often shipped in a box having a divider to prevent the drinking glasses from contacting each other. A divider can also facilitate packing and unpacking of the items within the box by maintaining the items within a defined position relative to one another. 
         [0003]    One example of a box and divider system is shown in U.S Publication No. 2008/0283535 to Westrate et al., which discloses a collapsible container assembly comprising a cell assembly that can be inserted into a box and attached to an interior wall of the box. The box with the cell assembly inside can be folded in a parallelogram motion into a collapsed position which is substantially flat. U.S. Pat. No. 145,137 to Wade discloses an egg carrier comprising a plurality of cells made from strips of pasteboard or thin veneers of wood, which can be used to carry eggs without a surrounding box or container, and which can be folded in a parallelogram motion to a substantially flat condition for transport and storage. 
       BRIEF SUMMARY 
       [0004]    In one aspect, the disclosure relates to a collapsible container assembly includes a folding container having at least two walls pivotable relative to each other at a corresponding corner disposed between the at least two walls, the folding container movable between a collapsed position wherein the at least two walls are disposed adjacent to one another and an extended position where in the at least two walls are spaced from each other, and an inside cellular structure attached to at least a portion of the at least two walls, the cellular structure comprising a plurality of panels forming a cellular structure, the cellular structure further comprising a plurality of cells in both an X and Y direction with respect to the cellular structure, each cell having four cell walls, when the folding container is positioned in the extended position, at least some of the plurality of cells having two connecting walls formed by one of plurality of panels and another two connecting walls formed by an adjacent one of the plurality of panels, each of the connecting walls having an attachment zone mechanically attached to an attachment zone of an adjacent one of the plurality of panels, and wherein corner cells located at opposite corners of the inside cellular structure have a reduced dimension representative of an aggregate size of the attachment zones making up the corresponding plurality of panels forming the corner cells. 
         [0005]    In another aspect, the disclosure relates to a collapsible container assembly includes a folding container having four walls movable between a collapsed position and an extended position, and an inside cellular structure comprising a plurality of cells in both an X and Y direction with respect to the inside cellular structure, a series of panels each mounted to one of the walls of the folding container and to an adjacent wall or an opposing wall of the folding container, each of the series of panels having an attachment portion that is mechanically fastened to an adjacent one of the series of panels or to one of the four walls of the folding container, whereby the plurality of cells each have four wall portions each formed either by a portion of the four walls of the folding container or by portions of the series of panels between adjacent attachment zones. 
         [0006]    In yet another aspect, a collapsible container assembly includes a folding container having four walls movable between a collapsed position and an extended position, and an inside cellular structure comprising a plurality of cells in both an X and Y direction with respect to the inside cellular structure, a series of panels having a first end and a second end, a first end of each panel mounted to a first wall of the folding container and a second end mounted to either an adjacent wall or an opposing wall of the folding container, each of the series of panels having at least one attachment zone at spaced intervals along the length of each panel, the attachment zone on each panel mounted by a mechanical fastener to an attachment zone on an adjacent panel to form corners of the cells. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    In the drawings: 
           [0008]      FIG. 1  is a prior art perspective view of a partially assembled container assembly according to an embodiment of the invention. 
           [0009]      FIG. 2  is a prior art diagram top-down view of the container assembly of  FIG. 1  in an assembled condition. 
           [0010]      FIGS. 3A-H  are a schematic illustration of a method of assembling a cell assembly according to a second embodiment of the invention. 
           [0011]      FIG. 4A  is a schematic illustration of a cell assembly in a partially collapsed condition according to a third embodiment of the invention. 
           [0012]      FIG. 4B  is a schematic illustration of the cell assembly of  FIG. 4A  in a fully expanded condition. 
           [0013]      FIG. 5A  is a schematic illustration of a cell assembly in a partially collapsed condition according to a fourth embodiment of the invention. 
           [0014]      FIG. 5B  is a schematic illustration of the cell assembly of  FIG. 5A  in a fully expanded condition. 
           [0015]      FIG. 5C  is a schematic illustration of the exploded panels of the cell assembly of  FIG. 5A . 
           [0016]      FIG. 5D  is a schematic illustration of the various wall lengths and cell configurations of the cell assembly of  FIG. 5A . 
           [0017]      FIG. 6A-C  is a schematic illustration of a method of assembling a partially assembled container assembly having a cell assembly therein according to a fourth embodiment of the invention. 
           [0018]      FIG. 7  is a top-down view of the assembled container assembly having the cell assembly, of  FIGS. 6A-C , in a fully expanded condition 
           [0019]      FIG. 8  illustrates a process flowchart for forming the container assembly 
       
    
    
     DETAILED DESCRIPTION 
       [0020]      FIGS. 1-2  illustrate a container assembly  10  including a container  12  and a cell assembly  14 . The container  12  includes four side walls  16   a - d , four bottom panels  18   a - d  and four cover panels  20   a - d . While the container assembly  10  is illustrated as a box having a generally square shape, it will be understood that the container assembly  10  can have any desired geometric shape, having any desired dimensions, depending on the intended use of the container assembly  10 . It is also within the scope of the invention for the container  12  to include fewer bottom and/or top panels  18   a - d  and  20 - a - d , respectively. 
         [0021]    The container  12  can be made out of any suitable rigid or semi-rigid material such as paperboard, cardboard, wood, chipboard, corrugated paper or plastic. 
         [0022]    The cell assembly  14  of the container assembly  10  can comprise an interior cellular structure comprising a plurality of cells  30 . An example of an interior cellular structure suitable for use according to an embodiment of the invention is the cellular structures disclosed in U.S. Pub. No. 20080283535 to Westrate et al., filed May 15, 2007, which is hereby incorporated by reference in its entirety. 
         [0023]    As illustrated in  FIGS. 3A-H  and discussed in detail in U.S. Pub. No. 20080283535 to Westrate et al., the cell assembly  14  is formed from a plurality of panels  32 . Each panel  32  is connected with adjacent panels  32  at a joint  34  using an adhesive or weld, for example, to form cells  30 . Each panel  32  is superimposed with the other panels  32  forming the cell assembly  14  and does not intersect with the other panels  32  forming the cell assembly  14 . The length and number of panels  32  and the number and spacing of joints  34  between adjacent panels  32  can be varied to provide a cell assembly  14  having any desired number of cells  30 . All of the cells  30  can have the same dimensions, as illustrated. Alternatively, the cell assembly  14  can have cells  30  having different dimensions. 
         [0024]    As illustrated schematically in  FIGS. 4A-B , the stack of superimposed panels  32  forming the cell assembly  14  can be expanded from a partially collapsed condition, illustrated in  FIG. 4A , by drawing end panel  32 A away from end panel  32 B, as illustrated by arrows  40 A, to the expanded condition illustrated in  FIG. 4B . As the cell assembly  14  is expanded, the superimposed panels  32  form the cells  30 , such that each cell  30  has four cell walls, with each cell wall formed from a portion of a single panel  32 . As can be seen in  FIG. 4B , in the expanded condition, the cell assembly  14  and each cell  30  has a generally rectangular perimeter. The cell assembly  14  can be collapsed in a parallelogram motion to the collapsed condition illustrated in  FIG. 4A , by moving panels  32 A and  32 B towards each other, as illustrated by arrows  40 B in  FIG. 4B . 
         [0025]    Referring now to  FIGS. 5A-B , an alternative embodiment of the disclosure can include a cell assembly  114  having a stack of superimposed panels  132 , wherein the total length  180  of each span of superimposed panel  132 ,  132 A-D is longer than the embodiment shown in  FIGS. 4A-B  (wherein  132 A-D are the outer or exterior panels and  132  are the inner panels). In this sense, each length (illustrated as “L”) of the panel  132 ,  132 A-D is longer by a predetermined dimension (illustrated as “X”). Stated another way, the length  182  of each span of superimposed panels  132 ,  132 A,  132 B is equal to L plus X. When in the collapsed condition, the total length  180  of the cell assembly  114  is longer by two times X (2L plus 2X), since the total length  180  includes two superimposed panels  132  in series, and each panel  132  includes an extra length X. 
         [0026]    As used herein, the embodiments of the disclosure according to  FIGS. 5A-B  are “longer” in the sense that they are purposely elongated such that without modification, they would be unable to fit within the container  12 , as described below in  FIGS. 6A-C . Thus, modification of the cell assembly  114  can be included, such that the alternative cell assembly  114  matches the configuration of the container  12 . An X-length portion  183  of the cell assembly  114  can be cut or removed from, for example, each end of the assembly  114 , which, in turn, results in a total length  180  of the assembly configured to match the configuration of the container  12 . This results in a cell assembly  114  wherein the total length  182  of the outer panels  132 A-D have a length L, but the interior panels  132  still have a length of L plus X. 
         [0027]    While the portion  183  of the cell assembly  114  is described as cut or removed from, embodiments of the disclosure can include manufacturing, forming, or otherwise configuring the cell assembly  114  described herein, wherein the inner superimposed panels  132  include the length of L plus X, but the exterior or outer panels  132 A-D have a length of L. 
         [0028]      FIG. 5B  illustrates an example of the cell assembly  114  of  FIG. 5A  in the expanded condition. The panel  132 A-D ends  186  where the X-length portion  183  was removed can be coupled to each other, for example, by tape or adhesive, to create an enclosed corner. While the cell assembly  114  illustrated is shown to include the inner superimposed panels  132  in a straight configuration, embodiments of the disclosure are included wherein the inner superimposed panels  132  are not straight between opposing outer panels (for example, between outer panels  132 B and  132 D, or panels  132 A and  132  C; See  FIG. 7 ). 
         [0029]      FIG. 5C  illustrates the cell assembly  114  of  FIG. 5B  and cut ends or cut portions  184 , wherein the assembly  114  is deconstructed to illustrate the series of adjacent panels, similar to  FIG. 3H . 
         [0030]      FIG. 5D  illustrates the set of cell dimensions of the resulting cell assembly  114  in the expanded condition, according to embodiments of the disclosure. The cell assembly  114  can include a set of inner cells  130 , each having a set of walls of a first length  190 . A first set of opposing corner cells  192  can have a first set of walls of a second length  194  and a second set of walls of a third length  196 . A second set of opposing corner cells  198  can have a first set of walls parallel with and matching the second length  194 , and a second set of walls having a fourth length  200 . As shown, the cell assembly can include a perimeter set of cells  202 , which do not include the aforementioned corner cells  192 ,  198 , wherein each of the set of perimeter cells  202  can have a first set of opposing walls parallel with and matching the first length  190 , and a second set of opposing walls parallel with and matching the second length  194 . 
         [0031]    Generally, the second length  194  will be greater than the first length  190 , which is greater than the fourth length  200 . The third length  196  can, for example, be equal with the second length  194 , however, alternative embodiments or alternative sizes of the third length  196  can be included, if not limited by the cell assembly  114  configuration or the container  12 . While a four by four cell assembly  114  is illustrated, additional cell assembly configurations can be included (e.g. three by three, five by five, six by six, etc.) wherein the inner cells  130 , opposing corner cells  192 ,  198 , and perimeter cells  202  adhere with the sizing examples or wall lengths of the first, second, third, and fourth walls  190 ,  194 ,  196 ,  200 . Stated another way, any sizing of a cell assembly can include the opposing corner cells  192 ,  198 , and the perimeter cells  202  (any other outer boundary cells that are not the corner cells  192 ,  198 ). Additionally, any cells that are not the corner cells  192 ,  198  or perimeter cells  202  are located internal to the cell assembly  114  structure, and are inner cells  130 . 
         [0032]    For ease of understanding, a first example of the cell assembly  114  configuration described in  FIGS. 5A-D  can include the following dimensions: 
         [0033]    A container  12  frame has a perimeter lengths of 10″ (L) by 10″ (L), and the cell assembly  114  is configured to include 4 cells by 4 cells. Each of the panels  132 ,  132 A-D can be sized to include an extra dimensional length (X) of 0.125″. The accumulated total lay flat length  180  is 0.25″ (2 times X) longer than the perimeter length. Only the 2 outer corner cells  198  can be shortened to fit into the container  12  frame or fixed perimeter length, so removing 0.125″ from each end  184  will permit the partition to fit into the frame but will make the opposing outer corner cells  198  smaller than is desired, but often workable. In this example, the set of cells  130 ,  192 ,  198 ,  202  can include configurations wherein the resulting first length  190  is 2.5″ (L/4 cells), the second length  194  is 2.625″ (L/4 cells+X; 2.5″+0.125″), the third length  196  is 2.625″ (L/4 cells+X; 2.5″+0.125″), and the fourth length  200  is 2.375″ (L/4 cells−X; 2.5″−0.125″). The total length of an outer perimeter panel  132 A-D is 10″ (2.375″+2.5″+2.5″+2.625″), while the total length of an inner panel  132  is 10.25″ (L+2X; 2.625″+2.5″+2.5″+2.625). A middle panel  32  illustrated in  FIG. 5C  will have a total length (after cut or removal) of 20″ (2.375″+2.625″+2.5″+2.5″+2.5″+2.5″+2.625″+2.375″). This configuration generally results in a cell assembly  114  wherein the inner cells  130 , perimeter cells  202 , and the first set of opposing corner cells  192  are of a generally uniform size, while the second set of opposing corner cells  198  (e.g. the cut ends  184 ) are slightly smaller. 
         [0034]    Additional examples of the cell assembly  114  configuration described in  FIGS. 5A-D  can be configured wherein, for example, the extra dimension (X) can be alternatively spread across the first, second, third, and fourth lengths  190 ,  194 ,  196 ,  200  for example, to create cells that are more uniformly sized across the container  12 , or wherein at least one of the sets of opposing corner cells  192 ,  198 , or the perimeter cells  202  can be larger than an inner cell  130 . 
         [0035]    Referring now to  FIGS. 6A-C , assembling the container assembly  10  includes providing an unassembled container  12  in the form of a container blank  40 , as is known in the art. Adhesive can be applied to the side walls  16   a - d  and a collapsed, unexpanded cell assembly  14  can be placed on top of the adhesive on the middle sidewalls  16   a  and  16   b , as illustrated in  FIG. 5B . Each side wall  16   a - d  can be configured to include a length L, as described above. As illustrated in  FIG. 5C , the outer sidewalls  16   c  and  16   d  (total length 2L) can be folded over the cell assembly  114  (having a total length 2L after removing portions, as described above) and adhered to the cell assembly  114 . Distal ends of the side walls  16   c  and  16   d  can be coupled, such as with additional adhesive or a weld to form a ready to assemble container assembly  10  comprising a partially assembled container  12  and a cell assembly  114 . The bottom and/or cover panels  18   a - d  and  20 - a - d  can be folded over and secured in a closed position, using adhesive, tape or weld, as is known in the art, to fill, ship and store the container assembly  10 . While cover panels  18   a - d  and  20   a - d  are shown, embodiments of the disclosure are envisioned wherein only a first set of cover panels (e.g. either  18   a - d  or  20   a - d ) are utilized, or no cover panels are utilized. 
         [0036]      FIG. 7  illustrates a top-down view of an assembled container assembly  10  having the cell assembly  114  and blank  40  of  FIGS. 6A-6C . As shown, the cell assembly  114  can include at least a partial length  210  of the panels  32  where the joints  34  are formed wherein the partial length  210  is a curved or straight portion, and thus, does not form a sharp corner. In this sense, each of the joints  34  require an additional small length of panel  32  to account for the “rounding” as shown. This additional length of panel is provided for or accounted for by the extra dimensional length X, as described above. As the extra length X is utilized over the set of joints, resulting in a longer panel  132  length than a perimeter panel  132 A length, as described herein. 
         [0037]    Referring now to  FIG. 8 , a process  400  for forming the container assembly  10  is illustrated. While the process  400  is described in the context of the container assembly  10 , it will be understood that the process  400  may be used to form any container assembly  10  in a similar manner. The sequence of steps depicted for this process is for illustrative purposes only, and is not meant to limit the process in any way as it is understood that the steps may proceed in a different logical order or additional or intervening steps may be included without detracting from the invention. 
         [0038]    As shown in  FIG. 8 , the process begins with step  401  with the production of a container blank, which is a sheet of container material, roughly cut into the dimensions required for the container  12 . In the following step  402 , the container blank is cut, stamped, or trimmed to remove portions of the blank to define the bottom and cover panels  18   a - d ,  20   a - d , as needed. Next, a first forming process can be performed at step  404 , in which the container blank is run through one or more machines which form inward-folding creases for each crease between adjacent sidewalls  16   a - d , between the sidewalls  16   a - d  and their respective bottom panels  18   a - d , and between the sidewalls  16   a - d  and their respective cover panels  20   a - d , as needed. Emblematic crease-forming machine embodiments will comprise of a rolling edge along the container blank, or alternatively a straight or curved edge die pressed into the blank. 
         [0039]    Next, in step  404  the cell assembly  114  can be formed by layering and adhering the panels  32 , as shown in  FIGS. 3A-H . Following the forming of the cell assembly  114 , the opposing ends of the assembly  114  can be cut or removed in step  406 , as described herein, and illustrated in  FIG. 5A . Next, in step  408 , adhesive required for the securing the cell assembly  114  to the container sidewalls  16   a - d  and/or adhesive for securing the open ends of the container blank to form the unexpanded container can be applied. In one example, the adhesive is applied in or about the creases at any or all of the intersections of sidewalls  16   a - d . In another example, the adhesive is applied on any of all of the sidewalls  16   a - d . Alternatively, adhesive is applied to the surface of the collapsed cell assembly  114 . The adhesive may further be applied in any combination including the creases, sidewalls  16   a - d , or collapsed cell assembly  114 . The applying of the adhesive may be formed by depositing adhesive on a surface in parallel or perpendicular lines, as beads, dots, or by depositing the adhesive over a partial or complete surface of the sidewalls  16   a - d  or cell assembly  114 . The adhesive for securing the cell assembly  114  and the open ends of the container blank may be the same or different adhesive and may be applied as part of the same step or as different steps in the process  400 . 
         [0040]    In the next step  410 , a collapsed, unexpanded cell assembly  114  can be placed on top of the middle sidewalls  16   a  and  16   b . Next, in step  412 , the outer sidewalls  16   c  and  16   d  can be folded over the cell assembly  114  and adhered to the cell assembly  114  using adhesive that has been applied to the cell assembly  114 , creases, and/or the outer sidewalls  16   a - d.    
         [0041]    In step  414 , distal ends of the side walls  16   c  and  16   d  can be coupled, such as with additional adhesive or a weld to form a ready to assemble container assembly  10  comprising a partially assembled container  12  and a cell assembly  114 . The thus partially assembled, collapsed container  12  can then be expanded and the bottom and/or cover panels  18   a - d  and  20 - a - d  can be folded over and secured in a closed position (if needed), using further adhesive, tape or a weld, for example, to fill, ship and store the container assembly  10  in manner similar to that described above for container assembly  10 . 
         [0042]    The steps in the process of creating the container  12  may be performed in a multitude of different operations, in any order, by a single or multiple processes. 
         [0043]    Various materials known in the art can be used to form the cell assembly  114 . Commonly used material, such as Kraft paper, is fairly rigid and has minimal or no stretch. Thus, when the cell assembly  114  is made from Kraft paper and connected with the container  12  as described above, as the cell assembly  114  expands, the non-stretching Kraft paper cannot accommodate for the decreased length in the panels  32  between the joints as a result of the curvature of the expanding panels and the width of the joints  34  as the cell assembly  114  is expanded. The extra dimension X, and configuration of the cell assembly  114 , as described herein, allows for the expansion of the cell assembly  114  while providing sufficient or adequate slack on the panels  132  to prevent the drawing of the side walls  16   a - d  of the container  12  inward during expansion. This prevents deformation or uncontrolled collapse of the side walls of the container  12 . 
         [0044]    Several factors affect the amount of stress applied to the container  12  as the cell assembly  114  expands. Non-limiting examples of these factors include the dimensions of the container, the dimensions of the cells, the type of material the panels are made from, the width of the joint, and the number of joints/number of cells. Increase in the rigidity of the panel material, decrease in the stretch of the panel material, increasing number of cells, and increase in the width of the joint can all increase the amount of stress applied to the container and thus may require different lengths of the dimension X, as well as different lengths of cut or removed portions  184 , in order to accommodate the stress. 
         [0045]    To the extent not already described, the different features and structures of the various embodiments may be used in combination with each other as desired. That one feature may not be illustrated in all of the embodiments is not meant to be construed that it cannot be, but is done for brevity of description. Thus, the various features of the different embodiments may be mixed and matched as desired to form new embodiments, whether or not the new embodiments are expressly described. 
         [0046]    While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible within the scope of the forgoing disclosure and drawings without departing from the spirit of the invention which is defined in the appended claims.