Abstract:
A carton, fabricated preferably from corrugated paperboard material, including a bottom panel, two side panels, two end panels, a pair of top panels for closing the carton, locking flaps extending from the ends of the top panels and having tabs receivable in the end panels, and further including a plurality of corner support structures, formed from panels emanating from end edges of the end panels.

Description:
[0001]     This application claims the benefit of U.S. Provisional Application No. 60/519,918, filed Nov. 14, 2003. 
     
    
     BACKGROUND OF THE DISCLOSURE  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates in general to containers and cartons formed at least in part from corrugated paperboard material, and in particular to such containers and cartons that are provided with interior support structures for enhanced stacking strength and/or protection from impact.  
         [0004]     2. Background Art  
         [0005]     Shipping containers fabricated from corrugated paperboard material are known. Various methods have been provided in the prior art to impart to such containers enhanced stacking strength and protection from impact.  
         [0006]     Typically such methods employ the provision of stacking corner support structures and/or buffer structures that are formed from discrete, separate pieces of corrugated paperboard and/or fiberboard and/or polystyrene block or the like, which are attached to the container blanks during formation of the carton, or are inserted into the carton after it has been erected. Such additional components may be less than optimal because of the additional material cost and/or because, being formed from separate components, they can complicate the formation and assembly process.  
         [0007]     It would be desirable to provide a carton fabricated from corrugated paperboard material that is provided with enhanced stacking strength, without requiring the provision of separate stacking support structures.  
         [0008]     It would be further desirable to provide a carton that is fabricated from corrugated paperboard that is provided with enhanced impact protection for its contents, without the requiring the provision of discrete, separate buffer structures.  
         [0009]     It would also be desirable to provide a carton that is fabricated from corrugated paperboard that is easy to set up and capable of being sealed by automatic taping equipment, if desired, while being provided with enhanced stacking strength and impact protection.  
         [0010]     These and other desirable characteristics of the present invention will become apparent in view of the present specification, including claims, and drawings.  
       SUMMARY OF THE INVENTION  
       [0011]     The present invention comprises a container for storage and shipment of goods. The container comprises a bottom panel; opposing side panels emanating from side edges of the bottom panel; and end panels emanating from opposing end edges of the bottom panel. Top panels emanate from top edges of the opposing side panels, and are configured to be folded to positions spaced apart from and parallel to the bottom panel.  
         [0012]     A locking flap, having a locking tab extending from a free end thereof, emanates from at least one end of each of the top panels. Each locking flap is configured to be folded into an overlying parallel position relative to a corresponding one of the end panels. A slot is formed in each corresponding one of the end panels, for insertingly receiving a respective locking tab, when a respective locking flap is folded over its corresponding end panel.  
         [0013]     At least one corner post support structure is operably associated with each end panel, for providing enhanced stacking strength and end shock protection. Each corner post support structure includes a succession of panels, emanating successively from an end edge of each end panel. The succession of panels terminates in a panel disposed in juxtaposed relation to and affixed to, an inside surface of the respective end panel.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]      FIG. 1  is a plan view of a blank for forming a carton according to a preferred embodiment of the invention.  
         [0015]      FIG. 2  is a perspective view of a carton, according to the embodiment of  FIG. 1 , in partially erected configuration.  
         [0016]      FIG. 3  is perspective view of a carton, according to the embodiment of  FIGS. 1 and 2 , in fully erected configuration.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0017]     While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail, a preferred embodiment with the understanding that the present disclosure should be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiment so illustrated.  
         [0018]     In the figures, unless otherwise noted, the usual convention for illustration of blanks for cartons fabricated from paper, paperboard, corrugated paperboard and like materials is observed, in that solid lines on the interior of a figure represent cuts, edges or points of inflection (like a ridge, crease or inwardly or outwardly projecting gusset), and broken or dashed lines indicate fold lines, score lines or other lines of weakness.  
         [0019]      FIG. 1  illustrates blank  10  for a carton according to a preferred embodiment of the invention. Blank  10  is preferably fabricated from corrugated paperboard material, although in alternative embodiments of the invention, other materials having like performance characteristics may be employed, such as fiberboard or folding carton paperboard material. The direction of the flutes of the corrugated paperboard material is indicated in  FIG. 1  by the arrows.  
         [0020]     Blank  10  includes bottom panel  12 ; side panels  14 ,  16  emanating along fold lines  18 ,  20  along the side edges of bottom panel  12 ; top panels  22 ,  24  emanating along fold lines  26 ,  28  along the top edges of side panels  14 ,  16 ; and locking flaps  30 ,  32 ,  34 ,  36 , having locking tabs  38 ,  40 ,  42  and  44 .  
         [0021]     End panels  46 ,  48 , emanate along fold lines  50 ,  52  from end edges of bottom panel  12 . End panels  46 ,  48  include slots  54 ,  56 ;  58 ,  60 , respectively, the use of which is described elsewhere herein. End cover panels  62 ,  64  emanate along top edges of end panels  46 ,  48 . End closure flaps  66 ,  68  emanate from inside edges of end cover panels  62 ,  64 . End closure flaps  66 ,  68  include notches  70 ,  72 ;  74 ,  76 , respectively.  
         [0022]     Blank  10  also includes panels that when folded and glued, form corner support structures  120 - 126 , as shown in  FIG. 2 . Comer support  120  comprises outer depth panel  80 , foldably emanating from end panels  46 ; transverse panel  82  foldably emanating from outer depth panel  80 ; inner depth panel  84  foldably emanating from transverse panel  82 ; and glue panel  84  foldably emanating from inner depth panel  84 .  
         [0023]     Corner support  122  comprises outer depth panel  88 , foldably emanating from end panel  48 ; transverse panel  90  foldably emanating from outer depth panel  88 ; inner depth panel  92  foldably emanating from transverse panel  90 ; and glue panel  94  foldably emanating from inner depth panel  92 . Comer support  124  comprises outer depth panel  96 , foldably emanating from end panel  48 ; transverse panel  98  foldably emanating from outer depth panel  96 ; inner depth panel  100  foldably emanating from transverse panel  98 ; and glue panel  102  foldably emanating from inner depth panel  100 . Corner support  126  comprises outer depth panel  104 , foldably emanating from end panel  46 ; transverse panel  106  foldably emanating from outer depth panel  104 ; inner depth panel  108  foldably emanating from transverse panel  106 ; and glue panel  110  foldably emanating from inner depth panel  108 .  
         [0024]     Corner support structure  120  includes notch  130 ; corner support structure  122  includes notch  132 ; corner support structure  124  includes notch  134 ; and corner support structure  126  includes notch  136 .  
         [0025]     Making reference to  FIGS. 1-3 , blank  10  is first prepared for shipment to a customer/packer by folding and gluing the panels that form corner support structures  120 - 126 . Each of corner supports  120 - 126  are formed by successively folding the respective panels  86 - 80 ;  94 - 88 ;  102 - 96 ; and  110 - 104  inwardly at right angles to one another, beginning with the panels furthest from end panels  46 ,  48 , and adhesively affixing panels  86  and  110  to the inside surface of end panel  46 , and adhesively affixing panels  94  and  102  to the inside surface of end panel  48 . Panel  86  will be glued to panel  46  after being folded on the score between panel  80  and panel  82 . Likewise, panel  110  will be glued to panel  46  after being folded on the score between panel  104  and panel  106 . Likewise, panel  94  will be glued to panel  48  after being folded on the score between panel  88  and panel  90 . Panel  102  will be glued to panel  48  after being folded on the score between panel  96  and panel  98 .  
         [0026]     Thereafter, the blanks having the corner support structures formed can be transported to the customer who will erect and fill the cartons. Upon arrival at the customer who will be erecting and packing the cartons  200 , end panels  46 ,  48  are folded up perpendicular to bottom panel  12 . End cover panels  62 ,  64  are folded over the tops of corner support structures  120 ,  126 , and  122 ,  124 , respectively, with end closure flaps  66 ,  68  folded down, so that notches  70 ,  72 ,  74 ,  76  interdigitate with notches  130 ,  136 ,  132 ,  134 , respectively.  
         [0027]     Side panels  14 ,  16  are then folded up perpendicular to bottom panel  12 . Top panels  22 ,  24  are then folded up and over to be parallel to bottom panel  12  (as shown in  FIG. 3 ). Flaps  30 ,  32 ,  34 ,  36  are then folded down, over the outside surfaces of end panels  46 ,  48 , with locking tabs  38 ,  40 ,  42 ,  44  being inserted into slots  54 ,  58 ,  60 ,  56 , respectively. Thereafter, tape (not shown) may be applied to the top of carton  200 , along the adjacent free edges of top panels  22 ,  24 , and down the outer surfaces of end panels  46 ,  48 , if desired.  
         [0028]     The carton of the present invention is believed to be advantageous over prior art constructions, in that it provides excellent stacking strength through the corner post constructions, which also provide cells for absorbing endwise impacts. These results are achieved through structural elements that are integral to the carton blank, and are machine formable and erectable, thus providing for reduced cost and simplified formation. Further, upon cutting of the tape (if used), opening of the end closure flaps and end cover panels, carton  200  falls open completely, providing for ease of access in a retail environment, for rapid opening and shelving.  
         [0029]     The foregoing description and drawings merely explain and illustrate the invention, and the invention is not so limited as those skilled in the art who have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention.