Abstract:
A cardboard container which can be easily opened without tools and which, when opened, collapses and lies flat without further handling to permit ready access to the container contents and which facilitates the recycling or disposal of the container.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to cardboard containers. More particularly the invention is directed to a unique cardboard container which can be easily opened without tools and which, when opened, collapses and lies flat without further handling to permit ready access to the container contents. Besides providing easy and complete access to its contents, the motivation to provide a collapsible container further resides in the desirability of a flat container configuration which can be easily recycled or readily disposed of after its contents have been removed without taking up unnecessary space in a solid waste receptacle. Although the container of the present invention has many different applications, it is described herein primarily as used for the containment of vinyl floor tiles. 
     2. Description of the Related Art 
     U.S. Pat. No. 5,671,883 to Philips dated Sep. 30, 1997 discloses a paperboard container that has high stacking strength but also has structural elements incorporated therein in order to permit collapsing of the container, after use, to a flat configuration for subsequent retrieval and recycling. More particularly the container disclosed by Philips incorporates weakened lines in two of its opposing endwalls. This feature permits a portion of the endwalls, upon the application of an outward force by the customer, to be disengaged from the rest of the assembled container and then, upon further handling by the customer, to cause the container to lie flat. Unlike the container disclosed by Philips, the present invention does not utilize adhesively-secured bottom or top corners. As a result, upon the opening of the top of the container along lines of weakness displaced therein, the remainder of the container of the present invention readily collapses into a flat configuration without the need for further handling or cutting of any sort. 
     U.S. Pat. No. 3,355,089 to Champlin dated Nov. 28, 1967 discloses a box construction formed from a fibrous material and capable of having the top panel thereof readily opened to facilitate access to the contents of the box. The top panel is provided with a plurality of sections which are separated from one another by a plurality of tear scores radiating from near the center of the top of the box to the top corners thereof. In this manner the top of the box can be easily opened; however, unlike the box of the present invention, it cannot be quickly and readily collapsed into a flat configuration due to its design and the use of adhesive to secure the side panels and bottom of the container together. 
     The invention of Whitney (U.S. Pat. No. 3,447,735) dated Jun. 3, 1969 also discloses an easy-opening container. Like the invention of Champlin, the disclosure of Whitney uses lines of weakness in the top panel of the container. These perforated lines emanate from near the center of the top panel and extend outwards to each of the top four comers of the container. Further like the box of Champlin, but unlike the present invention, the design of the container of Whitney does not permit the container, after use, to be readily collapsed into a flat configuration, in part due to the presence of glued flaps which form and secure the corners of the container. 
     U.S. Pat. No. 3,542,569 to Farquhar dated Nov. 24, 1970 discloses a carton for holding and displaying a food product. Upon unfastening the top wall and removing the food product the walls of the carton are permitted to fall outwardly and the resulting structure defines a serving tray for the food product. The carton of Farquhar requires that the contents of the carton be removed before it can be unfolded and lay flat. This is due to the presence of overlapped panels in the structure of the carton which engage the food product within the carton. Such food product thus holds the overlapped panels in place and the overlapped panels, secured in such a manner, aid in defining the corners of the carton. In contrast, in the present invention, the container readily collapses without the contents of the container having to be removed first. 
     Accordingly, the present invention discloses an easy-opening collapsible container of a kind not known in the prior art. 
     SUMMARY OF THE INVENTION 
     The cardboard or paperboard containers of the prior art are generally not designed to permit the user to easily collapse the container once the top of the container is opened. The reasons for this are varied. In some instances this was not a desirable feature because the container itself was relied upon to hold or secure the contents of the container when the top was opened. In other instances the container was intended to function as a means for displaying the contents of the container such as in a retail store environment. In those few instances where a collapsible container was desired, the collapsible feature was designed not to function unless and until the contents of the container were removed first. In contrast, the container of the present invention collapses without the contents having to be removed. Thus in the present invention, the top wall of the container is readily opened by hand by means of a fingerhole from which lines of weakness, such as perforations, emanate radially to each of the four comers of the top wall. Upon disassociating each of the four triangular sections which make-up the top wall from each other, the container freely collapses into a flat configuration without any further handling by the user. No cutting instruments of any kind are required to open the top wall of the container. This is of particular importance when opening a container of vinyl floor covering whose surface can be easily marred or scratched by a sharp instrument. Neither is a cutting instrument needed to cut the remnants of the opened container in any fashion in order to cause the remnants of the container to lay flat when opened. This is a significant advantage over other prior art containers. When the contents of a container are heavy and tightly packed together with little room between the contents and the vertical walls of the container, such as in the case of vinyl floor covering tiles, removing the tiles from a prior art container whose top is opened but whose side, front and rear walls remain upright and intact is cumbersome and difficult. With the container of the present invention this problem is solved in that the front, rear and side walls of the container collapse upon the opening of the top wall thus affording ready access to the floor tiles without having to lift them out of the container. Another advantage of the present invention is that the container, when opened, lies flat and is therefore amenable to recycling or disposal in a solid waste receptacle without taking up a significant volume of apace within the receptacle. 
     Thus, it is one of the objects of this invention to provide a container which is not beset with the aforementioned shortcomings associated with the prior art containers. 
     It is a further object of the present invention to provide a cardboard or paperboard container which is easily collapsible into a flat configuration when its top wall is opened without the need for cutting or any further handling by the user. 
     It is a still further object of the present invention to provide a container which can be easily opened without the need for a sharp instrument or a cutting tool. 
     It is yet another object of the present invention to provide a container which can be easily collapsed into a flat configuration while the contents of the container remain in the container. 
     In accordance with the foregoing objects, a new container is disclosed. Briefly stated, the invention is practiced by forming the container from a blank of fibrous sheet material such as corrugated cardboard, paperboard, fiberboard or similar material. The container when formed has a top wall, a bottom wall, two side walls, a front wall and a rear wall. The front wall, rear wall and the two sidewalls are foldably connected to the bottom wall. The top wall is foldably connected to the rear wall. Two side extension flaps and one front extension flap are foldably connected to the top wall. These three extension flaps are adhesively secured to the two side walls and the front wall when the container is constructed. Importantly, this is the only adhesive or other securing means used in the construction of the container. A plurality of lines of weakness are provided within the top wall of the container. In the preferred embodiment, four lines of weakness are provided, each line of weakness extending diagonally from a fingerhole located in or near the center of the top wall to each of the four comers of the top wall. The lines of weakness serve as severance lines when an upward force is exerted on the top wall. when such a force is applied the top wall disassociates into four triangular sections which then, along with the side, front and rear walls to which they are attached, are permitted to freely fall outwards and away from the contents of the container. Thus, the contents of the container can be easily accessed and the container itself is now in a flat configuration lending itself to ready recycling or other form of disposal once the contents of the container have been consumed. 
     Further objects and advantages will be readily apparent to those skilled in the art and a better understanding of the present invention may be had by reference to the following detailed description taken in connection with the following drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a plan view of the blank for the container of the present invention. 
     FIG. 2 is a top perspective view of the container formed from the blank of FIG.  1  and shown in a condition for shipment. 
     FIG. 3 is a plan view of the of the top wall of the formed container. 
     FIG. 4 is a bottom perspective view of the formed container. 
     FIG. 5 is a perspective view of the formed container being opened. 
     FIG. 6 is a perspective view of the formed container, containing vinyl floor tiles, being collapsed so as to allow it to lie flat. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings and more particularly to FIG. 1, there is shown a flat body blank  10  formed of corrugated cardboard, paperboard, fiberboard or similar material, the gauge and selection thereof depending upon the type and weight of the product to be accommodated within the container. When the product is vinyl floor covering tile  11 , the blank  10  is preferably corrugated cardboard. The overall shape of the blank is substantially rectangular and may be readily formed by conventional high speed equipment. The blank  10  is a single piece construction which is suitably cut and scored and adapted to be assembled to define the resulting container  8  of the invention. The blank  10  may be printed with suitable indicia to identify the contents of container  8 . 
     The flat body blank  10  has a bottom wall  12  and two opposed side walls  14 ,  16  foldably connected thereto along side edge fold lines  24 ,  26  respectively. Sidewall  14 ,  16  are of approximately the same dimensions. Front wall  18  is foldably connected to bottom wall  12  along front edge fold line  28 . Opposed front wall panels  46 ,  48  are of approximately the same dimensions and are hinged to front wall  18  along fold lines  45 ,  47  respectively. Rear wall  20  is of approximately the same dimensions as front wall  18  and is foldably connected to bottom wall  12  along rear edge fold line  22 . Opposed rear wall panels  42 ,  44  are of approximately the same dimensions and are hinged to rear wall  20  along fold lines  41 ,  43  respectively. Top wall  30  is of approximately the same dimensions as bottom wall  12  and is foldably connected to rear wall  20  along fold line  31 . Opposed side extension flaps  34 ,  36  are of approximately the same dimensions and are connected to top wall  30  along fold lines  33 ,  37  respectively. Front extension flap  38  is connected to top wall  30  along fold line  35 . 
     Referring to FIGS. 2,  4  and  5 , side extension flaps  34 ,  36  extend outwardly from their associated fold lines  33 ,  37  a sufficient distance so that they may be adhesively secured to sidewalls  14 ,  16  respectively as further described below. Similarly, front extension flap  38  extends outwardly from fold line  35  a sufficient distance so that it may be adhesively secured to front wall  18 , also as further described below. 
     Referring now to FIG. 2, there is shown the container  8  of the invention after it has been formed from the flat body blank  10 . The size and shape of the container  8  may vary from that shown without departing from the scope of the invention. The illustrated container is a top loading type, that is to say, the products to be accommodated are spotted on the bottom wall  12  of the flat body blank  10  and the container  8  is then erected around the product in the manner hereinafter described. 
     Referring to FIG. 3, additional elements of top wall  30  include fingerhole  32 , which is located generally at or near the center of the top wall, and lines of weakness  40   a,b,c,d  extending diagonally outward from fingerhole  32  to comers  30   a,b,c,d  of top wall  30  thereby forming triangular sections  50 ,  52 ,  54 ,  56  within top wall  30 . 
     After spotting the product  11  on the bottom wall  12  of blank  10 , sidewalls  14 ,  16  and front wall  18  are folded upward to be at right angles to bottom wall  12  along side edge fold lines  24 ,  26  and front edge fold line  28 , respectively. Front wall panel  46  is then folded along fold line  45  and oriented in such a manner that front wall panel  46  is in contact with the inside surface of side wall  14 , that is, between side wall  14  and the spotted product. Similarly, front wall panel  48  is folded along fold line  47  and oriented to be in contact with the inside surface of side wall  16 , that is, between side wall  16  and the product. This relationship is illustrated in FIGS. 2 and 6. 
     Rear wall  20  is folded upward to be at a right angle to bottom wall  12  along rear edge fold line  22 . Rear wall panels  42 ,  44  are folded along fold lines  41 ,  43  respectively and oriented in such a manner that rear wall panel  42  is in contact with side wall  14  and rear wall panel  44  is in contact with side wall  16 . Importantly, no adhesive or other securing means is provided to attach any of rear wall panels  42 ,  44  to side walls  14 ,  16  nor is any adhesive or other securing means used to attach front wall panels  46 ,  48  to side walls  14 ,  16 . Thus, front wall panels  46 ,  48  and rear wall panels  42 ,  44  are not adhesively secured to or interlocked with any portion of the container  8 . 
     Top wall  30  is folded along fold line  31  and oriented so that top wall  30  is parallel to bottom wall  12  with the product thus being disposed between the top wall and the bottom wall. Thereupon front extension flap  38  is folded to be at a right angle to top wall  30  along fold line  35  and disposed in adhesively secured overlapping relation with the outer surface of front wall  18 . Side extension flaps  34 ,  36  are folded to be at right angles to top wall  30  along fold lines  33 ,  37  respectively, and disposed in adhesively secured overlapping relationship with the outer surface of side walls  14 ,  16  respectively. In such a manner container  8  is formed from flat body blank  10 . The product, now within container  8 , does not aid in securing the container in any of its intermediate or final forms. 
     Any suitable holding means or adhesive may be used to secure front extension flap  38  to front wall  18  and side extension flaps  34 ,  36  to side walls  14 ,  16  respectively, thereby holding the container together when it is fully assembled. In this example of the invention a quick drying adhesive is provided and shown as a granular presentation which is designated generally by reference numeral  60  in FIG.  1 . 
     FIG. 3 illustrates top wall  30 , lines of weakness  40   a,b,c,d  and comers  30   a,b,c,d . The lines of weakness provided in the top wall may be in the form of perforations, cut slits, or the like, and may be formed utilizing any suitable technique. Further illustrated is fingerhole  32  which serves a dual purpose. One function of the fingerhole is to permit access for a finger to enter the formed container, apply upward force to top panel  30 , and thus open the top panel along the lines of weakness. The fingerhole also permits the observation of the contents of the container, such as the color or texture of vinyl floor covering, without the need to open the container. 
     In FIG. 4, perforated knockout portions  58  are illustrated. These knockout portions can optionally be removed, thus enabling, for example, an identification number stamped on the bottom of vinyl floor covering tile to be observed without the need for opening the container. 
     FIGS. 5 and 6 illustrates clearly the manner in which triangular sections  50 ,  52 ,  54 ,  56  may be readily folded back independently of each other so as to cause the container to collapse to a flat configuration thus giving full exposure and access to the contents of the container  8 . To collapse the container  8 , a finger is inserted through fingerhole  32  and an upward force applied to cause the perforations, for example, forming the lines of weakness  40   a,b,c,d  to tear from fingerhole  32  to each of the four corners  30   a,b,c,d  of top wall  30  thus creating triangular sections  50 ,  52 ,  54 ,  56 . Triangular section  50 , front extension flap  38  and front panel  18 , to which front extension flap  38  is adhesively secured, are thus permitted to fall outward, away from the contents of the container, and lie flat in the same plane as bottom wall  12  while front panel  18  remains connected to bottom wall  12 . Similarly, triangular section  52 , side extension flap  36  and side panel  16 , to which side extension flap  36  is adhesively secured, are permitted to fall outward, away from the contents of the container, and lie flat in the same plane as bottom wall  12  while side wall  16  remains connected to bottom wall  12 . In like manner, triangular section  56 , side extension flap  34  and side wall  14 , to which side extension flap  34  is adhesively secured, are permitted to fall outward and lie flat in the same plane as bottom wall  12  while sidewall  14  remains connected to bottom wall  12 . Lastly, triangular section  54 , and rear wall  20  to which triangular section  54  is connected, are permitted to fall outward, away from the contents of the container, and lie flat in the same plane as bottom wall  12  while rear wall  20  remains connected to bottom wall  12 . That is, opening and/or tearing of the top wall  30  along lines of weakness  40   a,b,c,d  impairs the structural strength of the remainder of the container permitting it to be easily collapsed. 
     The shape, size and number of sections formed in top wall  30  may readily vary from that shown and still fall within the scope of the invention. 
     Thus, it is seen that an easy-opening collapsible container and blank therefor have been provided which readily avoid the problems and shortcomings associated with prior containers. A container which is easily opened without damage to its contents and which is fully collapsible has been described. The preferred embodiment has been illustrated and described. Further modifications and improvements may be made thereto as may occur to those skilled in the art and all such changes as fall within the true spirit and scope of this invention are to be included within the scope of the claims to follow.