Container having stackable shelf assembly

A container assembly is provided. The container has at least one bottom panel, and at least one side panel extending upwardly from the at least one bottom panel, to form an inner cavity. The bottom panel has at least one vent hole. A blank is provided having a substantially rectangular shape. The blank has flaps extending from corners of the blank. The flaps have tabs extending from an end. The flaps are folded substantially perpendicular to a plane defined by a body of the blank. At least one of the tabs are placed into at least one vent hole in the bottom panel.

FIELD OF THE INVENTION

This invention relates generally to shipping and display type containers.

BACKGROUND OF THE INVENTION

It is generally known to ship products. The shipment of certain kinds of products, such as, for example, hot tortilla shells can be problematic. In an example, the tortilla shells can tend to “block” together if under too much pressure. Accordingly, it would be beneficial to have multiple layers of product which are isolated from the weight of other layers above. Previously, only 2 layers of shells could be stacked in a box using a standard U-hoard for separation. Stackable-type shelves were not a good option; since the box ended up so deep they were too time consuming to install. Previous solutions also led to a lack of desirable “corner-blocking” to prevent the tortillas from shifting into a square corner and being subject to damage after freezing. Accordingly, a need exists for a container having a shelving system which allows efficient storage of products.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a container or box having a stackable shelf assembly. The shelf assembly serially supports an inner-pack shelf upon the shelf immediately below. This assembly can be used for transporting, for example, tortillas or similarly shaped products. The assembly has a container having at least one bottom panel, and at least one side panel extending upwardly from said at least one bottom panel, to form an inner cavity. The bottom panel has at least one vent hole. A blank is provided having a substantially rectangular shape. The blank has flaps extending from corners of the blank. The flaps have tabs extending from an end. The flaps are folded substantially perpendicular to a plane defined by a body of the blank. At least one of the tabs are placed into at least one vent hole in the bottom panel.

The present invention includes a single sheet of foldable material cut and scored to form a blank formable into a container. By way of overview and with reference toFIGS. 1-11, an embodiment of the present invention includes a single piece blank2arranged to form a container100. A blank20which forms a stackable shelf102is also provided. Specific details of the blanks2,20, shelf102and container100are described with more particularity below.

The present invention will now be described with reference to the accompanyingFIGS. 1-11where like numerals correspond to like elements. In all FIGURES, cut lines are shown as solid lines, score lines or lines of weakness are shown as broken lines. For the purpose of further description herein, the downward direction is defined as the direction perpendicular to bottom panels10a,10b,10c,10dthat corresponds to the outer surface of the bottom panels when the container has been erected, and the upward direction is defined as the direction perpendicular to the bottom panels that corresponds to the inner surfaces of the bottom panels when the container has been erected.

The blank2and resulting container100is typically made from any suitable material used in the shipping, storing or displaying of goods, as are the blank20and resulting shelf102. Suitable, nonlimiting examples of such materials include paperboard, containerboard, cardboard, pasteboard, fiberboard, corrugated containerboard, corrugated paperboard, single wall corrugated containerboard, multiwall corrugated containerboard or a combination thereof.

FIG. 1illustrates a blank2having panels4a,4b,4c,4d. Fold line3is provided between side panel4aand side panel4b. Fold line5is provided between side panel4band side panel4c. Fold line7is provided between side panel4cand side panel4d. Attached to side panel4dis glue tab panel6, which is opposite side panel4dalong fold line25. Attached to each of the side panels4a,4b,4c,4dare top panels8a,8b,8c,8d. Top panel8ais attached to side panel4aand is opposite side panel4aalong fold line9. Top panel8bis attached to side panel4band is opposite side panel4balong fold line11. Top panel8cis opposite side panel4calong fold line13. Top panel8dis opposite side panel4dalong fold line15.

Attached to each of the side panels4a,4b,4c,4dare bottom panels10a,10b,10c,10d. Bottom panel10ais opposite side panel4aalong fold line17. Bottom panel10bis opposite side panel4balong fold line19. Bottom panel10cis opposite side panel4calong fold line21. Bottom panel10dis opposite side panel4dalong fold line23. Top panels8a,8b,8c,8dmay have slits or vent holes12located adjacent to fold lines9,11,13,15, respectively. The vent holes12may be symmetrically positioned adjacent the fold lines and may be identical in shape. Similarly, bottom panels10a,10b,10c,10dmay have slits or vent holes14which are located on the bottom panels adjacent to fold lines17,19,21,23. The slits16may extend, in an embodiment, from the side panels4a,4cto top panels8a,8c, respectively, across each respective fold line9,13. Similarly, the slits16may extend, in an embodiment, from the side panels4a,4cto bottom panels10a,10crespectively, across each respective fold line17,21. Side panels4aand4cmay have identical widths. Side panels4band4dmay have identical widths as well. The width of side panel4amay be greater than the width of side panel4b. In addition, the dimensions selected for each of the panels4,8,10may be those which are contemplated by one of ordinary skill in the art for a given application.

FIG. 2illustrates a blank20which can be assembled into a stackable shelf102. The blank20has a center panel22which is attached to corner flaps24opposite fold lines27. The center panel22is substantially rectangular in shape. The corner flaps24have a tab26which extends from an end opposite the center panel22. Located adjacent to fold line27are diagonal fold lines29,31which meet at an apex. Located between fold lines29,31is score line33. Located at sides30,32of the center panel22are concave sections34which are formed within the body of the center panel22.

The blank2may be assembled in a manner similar to conventional four-sided boxes wherein side panels4a,4b,4c,4dare folded at fold lines3,5, and7. Next bottom panels10a,10b,10c,10dmay be folded towards the side panels4a,4b,4c,4dat fold lines17,19,21and23. Side panel4amay be positioned adjacent to side panel4dwherein tab6may be attached to the side panel4avia a fastener, such as glue or other adhesive, or mechanical fasteners, for example.

FIG. 3illustrates the blank20positioned above the assembled container100made from the blank2wherein the blank20is being prepared for assembly as a shelf102within the container100. The blank20is adjacent the bottom panels10,10b,10c,10d. The container100in this embodiment may be considered as being upside-down, with panels8a,8b,8c,8dbeing in a closed arrangement. As seen inFIG. 4, corner flaps24are folded towards the bottom flaps10a,10b,10c,10dof the container100as the blank is placed within the container100. At this point, a product, such as a package of tortillas, may be placed in the container100prior to placement of the blank20within the container100.FIG. 5illustrates the container100having product underneath the shelf102in an assembled state, with tabs26pointing in a direction toward the bottom panels10a,10b,10c,10d.

FIG. 6illustrates the container100after more product, such as another tortilla package, is placed on the previously assembled shelf102, and a second shelf102has been placed within the container100over the additional productFIG. 7illustrates the container100after another product has been placed within the container100on the shelf102and panels10a,10b,10c,10dare folded to close the container100. Tabs26may be protruding through the vent holes14. The container100may then be rotated to a “right side up” position and placed onto a pallet200illustrated inFIG. 8.

In another embodiment, illustrated inFIG. 9, the shelf102may be adjacent top panels8a,8b,8c,8dand may have flaps24folded toward bottom panels10a,10b,10c,10d. Product is placed on. bottom panels10a,10b,10c,10d, and then is placed on the center panel22once the shelf102is placed within the container100.FIG. 10shows an array of stacked shelves102. The tabs26may fit into slits created by folding sections52,54at fold lines29,31. By inserting the tabs26into the slits, the tabs26may be locked into place. This may prevent the shelf102from becoming unassembled during transport within the container100. The lowermost shelf102which is placed within the container100has tabs26which may lock into vent holes14in the bottom panels10a,10b,10c,10d.FIG. 11illustrates an overhead view of a stacked arrangement of shelves102which may have product placed in between each shelf102. The container100may then be completely closed (i.e., panels8a,8b,8c,8dare folded) and placed on a pallet200.

“Corner block” may be achieved by using an octagonal-shape shelf and locating the tabs26from the flaps24into the vent holes14of the container100. The flaps24are then “reverse-tapered” to force the bottom edges of the flaps24inward from the corners of the container100. The flaps24are then convinced into ideal near-columnar locations with the leg below it by the use of tabs26with slits created by folding sections52,54. Thus, the legs are essentially self-locating, and require no physical manipulation beyond insertion into the box.

Handholds (not shown) allow the container100to be easily manipulated by stock personnel or others, individually or in stacks of two or more. While an embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. For example, the blank may also include other features specified by the customer, such as the aforementioned hand holds, additional vent holes, grease or moisture barriers and the like without exceeding the scope of the present invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.