Materials for and method for manufacturing retail container and resulting retail container

In accordance with the invention, a method of manufacturing containers such as shipping, display and display ready packaging, for example, and resulting containers and associated preassemblies and blanks are provided, which, when utilized, result in preassemblies that are more easily and quickly assembled into fully assembled containers including a plurality of stacking shoulder provided at opposing ends of the containers.

FIELD OF THE INVENTION

The invention relates in general to the manufacture of containers that may be readily used to ship and/or display contents following delivery of the container, as specified in the independent claims.

BACKGROUND OF THE INVENTION

Various containers are conventionally provided as packaging for shipping or for display of product in a retail environment to prospective customers. As is conventionally known in the industry, such containers can be transported to manufacturing and/or retail environments for use in shipping or display in knock-down form, i.e., flattened but otherwise being glued, stapled or otherwise secured together, such that they are already substantially pre-assembled; such knock-down form containers are also referred to as preassemblies. In such a “knockdown” state (i.e., knocked down or not set-up), personnel assembling the product container need only open the sides and or ends of the container and affix the package bottom wall into its assembled condition. As a result, such containers' assembly may be performed such that the product can be placed into a resulting assembled container for shipping or as display package for ready display.

Conventionally, it has been deemed advantageous at times to stack a plurality of such containers, one on top of the other for the purposes of transport to a retail environment or during display or storage in the retail environment. In this use, it is necessary that the containers stacked above the bottom-most package are amply supported such that a stack of a number of such containers, when filled with product, will not collapse.

SUMMARY

In accordance with illustrated embodiments, a method of manufacturing containers and resulting containers and associated preassemblies and blanks, which, when utilized, result in containers having an interior formed by a primary blank serving as an exterior of the container, the interior including a plurality of stacking shoulders formed by a supplementary blank at opposing ends of the container interior, wherein the plurality of stacking shoulders are formed as part of the set up or final assembly of exterior of the container.

Additionally, in accordance with illustrated embodiments, the plurality of stacking shoulders is formed by coupling of the primary and supplementary blanks at at least one side panel of the primary blank. Alternatively, or in addition, the plurality of stacking shoulders is formed by coupling of the primary and supplementary blanks at both the front side panel and the back side panel of the primary blank.

Further, in accordance with at least some illustrated embodiments, the stacking shoulders include one or more keys configured to provide horizontal alignment of stacked containers. In at least one embodiment of the invention, keys also interact with keyhole apertures provided on a bottom side of the containers, such that keys of a bottom most stacked container interact with the keyhole apertures provided on the container stacked above that container.

The illustrated embodiments of the invention have particular utility when used for the manufacture of preassemblies and associated containers that are flat bottomed tray type containers.

These illustrated embodiments are achieved by a combination of features recited in the independent claim. Accordingly, dependent claims prescribe further detailed implementations of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

As explained above, it is useful to be able to stack a plurality of containers one on top of the other for the purposes of transport to a retail environment or during display in the retail environment. This ability (also known as “stackability”) requires that containers stacked above the bottom-most package are amply supported also that a stack of a number of such containers, when filled with product, will not collapse.

Conventionally, there are various container designs that provide increased stackability by including, for example, stacking shoulders that utilize additional material and components to increase the vertical stability of the container. However, the skill level and time required for assembling such containers varies depending on the number of touches required for assembling the container. In fact, the time required for assembling conventional containers including stacking shoulders of some sort or another may be somewhat lengthy as assembly of a container may require a number of separate actions to be performed by the final assembler of a container. The number of such separate actions is conventionally referred to as the number of “touches” required for assembly; thus, a container requiring complex assembly requires a greater number of touches than a container requiring relatively simple assembly.

Another problem with such stackable containers is the increased height, length, width and weight of such containers due to the added material provided for the stacking shoulders. Therefore, although the use of such stackable containers is useful, the increased time for final assembly and increased dimensions and weight of the containers are deficiencies of conventional designs. Thus, there is a need for a design for a stackable container (e.g., a shipping package, display or display ready package or compartmentalized package so as to reduce fulfilment cost and time) that includes stacking shoulders with less affect on the overall dimensions and weight of the stackable container, while reducing the amount of material used in the container and reducing the number of touches required for final assembly of the container.

With this understanding in mind, a description of various embodiments is now provided.

According to at least one illustrated embodiment, there is provided equipment (described herein in connection withFIG. 8) configured to manufacture containers, e.g., for shipment or display of product (as well as corresponding container preassemblies and blanks) that result in containers having an interior formed by a primary blank serving as an exterior of the container, the interior including a plurality of stacking shoulders formed by a supplementary blank at opposing ends of the container interior, wherein the plurality of stacking shoulders are formed as part of the set up or final assembly of exterior of the container.

Understanding of the manufacturing of a container, blanks and/or preassemblies in accordance with embodiments may best be understood by first reviewing an illustration of a manufactured container provided in accordance with one illustrated embodiment. As illustrated inFIG. 1, one example of such a container100may be a flat bottomed tray container, which may include a main compartment defined between a plurality of stacking shoulders formed by a corresponding plurality of supplementary blanks104and included in an interior space of a primary blank102following assembly. These stacking shoulders may be formed by coupling the supplementary blanks104to locations on the primary blank102. For example, as part of preassembly manufacture for a preassembly for container, the supplementary blank may be affixed to the primary blank as explained in connection withFIGS. 2-23in various alternative configurations to provide for improved ease of final assembly for the container.

Such a container100may be used for various purposes including shipping and placement on a display floor along with other such containers in a stack. However, it should be understood that the manufactured container may be any type of container including, for example, any carton, package, box, etc. of any suitable type; accordingly, the actual configurations of the primary blank102and the interrelationship with the supplementary blank104may change without departing from the scope of the embodiments.

Thus, in accordance with illustrated embodiments, a method is provided of manufacturing containers and resulting containers100and associated preassemblies (the combination of102,104) and blanks102,104, which, when utilized, result in containers100that include a plurality of supplementary blanks104that provide a plurality of stacking shoulders that serve as a mechanism for improving the stackability of the container100, whereby the container100may be configured to bare larger amounts of force (e.g., weight) applied from a top direction; in addition, the provision of the supplementary blanks104may also provide improved strength of the end panels of the resulting container100against force applied from side directions.

Based on the illustrated examples of container designs provided with stacking shoulders as disclosed herein, it should be appreciated that the incorporation of the stacking shoulders increases stackability of the resulting containers without requiring a lengthier time period for final assembly and without a need for assemblers having superior skill. This is because, as explained herein, the majority of manipulation of the preassembly to form the stacking shoulders are already performed as part of the assembly of the primary blank as the exterior of the container. As a result, the number of additional touches needed to provide the stacking shoulders is reduced relative to what is conventionally required.

Further, the illustrated examples of container designs provide stacking shoulders but with significantly less material than is conventionally required for stacking shoulders. This reduction in material results in a reduction in the container weight and resources expended to produce the container, while still providing improved strength.

As will be appreciated from the remaining disclosure by one of ordinary skill in the art, the container100may be used to ship or display product therein in a retail environment. Thus, subsequent to arrival at a retail environment or off-site fulfilment or contract packaging facility, a knockdown version of the container100(e.g., a preassembly) may be assembled and product placed in the container100for transport and/or display. BecauseFIG. 1illustrates a container configured for use as a display container. However, it should be appreciated that additional panels may be included on/attached to the illustrated container for purposes of transporting the container. Accordingly, such panels may be removed from the container to provide the illustrated container ofFIG. 1.

FIG. 2illustrates an example of a primary blank102, which may be thought of as a conventional tray type container such as the one illustrated inFIG. 1. The knockdown of the container100is manufactured by joining the primary blank102with a plurality of supplementary blanks104(which may be thought of as pads) illustrated inFIG. 3, as explained herein. The primary blank102illustrated inFIG. 2corresponds to a majority of an exterior of the container100illustrated inFIGS. 1 and 7; therefore, the container100includes primary blank102. Likewise, the container100also includes supplementary blanks104illustrated separately inFIG. 3and in conjunction with primary blank102inFIGS. 4-7.

As shown inFIG. 2, the primary blank102includes a bottom panel106, a back side panel108, a front side panel110and end panels112,114. The back and front side panels108,110and end panels112,114are lateral panels that form the lateral enclosure of the container. Each end panel has corresponding end sub-panels; thus end panel114is connected to sub-panels116,120and end panel112is connected to sub-panels118,122. Likewise, each side panel is connected to corresponding side sub-panels; therefore, back side panel108is connected to back side sub-panel124and front side panel110is connected to front side sub-panel126.

When the primary blank is assembled as the exterior of the container100, the two end panels112,114are folded towards the bottom panel106and each of the sub-panels116,120(corresponding to end panel114) and118,122(corresponding to end panel112) are folded towards the bottom panel106as well. As a result, pairs of the end sub-panels116,118and120,122are parallel to one another and positioned on respective edges of the bottom panel106and the side panels108and110. As a result, when the side panels124,126are folded towards the side panels108,110respectively and over the end sub-panels along fold lines128,130, the end sub-panels are positioned in place. Accordingly, when tabs134provided on the side sub-panels124,126are inserted into corresponding apertures136provided along the edge of the bottom panel106, the side panels and end panels are locked in place. This assembly process is discussed in further detail with reference toFIGS. 4-7.

FIG. 3illustrates an example of a supplementary blank104used in manufacturing the container of the type illustrated inFIG. 1. The supplementary blank104includes first and second major sections138and144. The first major section138is attached to first sub-sections140,142; likewise the second major section144is attached to second sub-section146. Sub-sections140and142actually form a portion of the exterior of the container100. Sub-section146is provided as a point for attaching the supplementary blank104to the bottom panel106of the primary blank102. Likewise, as discussed herein with reference toFIGS. 4-7, first major section138is also affixed to an end panel (112or114) of the primary blank.102. Accordingly, during assembly of the container100, the second major section144is folded towards the first major section138such that a shoulder section148is provided by the folding of the secondary blank104along fold lines156,158. As an additional result of this folding, the key150is formed on the upper side of the shoulder section148. As mentioned briefly above and explained in further detail herein, the key150is configured to interact with the keyhole aperture (formed from the aperture132on the primary blank102and the aperture152on the supplementary blank104, but referred to hereafter as keyhole aperture152) provided on the underside of another container100following final assembly.

As explained above, illustrated embodiments may provide improved assembly of containers for shipping and/or display ready packaging that have increased stackability as a result of stacking shoulders formed by the interaction of the supplementary blank104with the primary blank102through at least one of adhering a plurality of parts of the supplementary and primary blanks to one another.

FIG. 4illustrates the relative placement and interconnectedness of the primary and secondary blanks illustrated inFIGS. 2 and 3to provide the container illustrated inFIG. 1. Accordingly, as illustrated inFIG. 4, the primary and supplementary blanks102,104may be configured so as to interact in a manner that enables the stacking shoulders to be formed easily and quickly as part of the final assembly of the container100. Accordingly, the total length and width dimensions for the blanks102,104and their constituent panels, walls and sections may be selected so as to facilitate the positioning of the supplementary blanks104with respect to the interior of the assembled primary blank102.

In one potential implementation, one or more portions of the primary and supplementary blanks102,104may be affixed to one another via, for example, adhesive such as glue, staples, tape, etc. so as to produce a preassembly (e.g., a knockdown or preassembly for the container illustrated inFIG. 1), wherein the positioning of supplementary blank104in cooperation with primary blank102is controlled. For example, the primary and supplementary blanks102,104may be affixed to each other on their mating faces (e.g., the bottom face of supplementary blanks104and the top face of the primary blank102). More specifically, adhesive may be applied to that portion of the first major sections138A,138B of the supplementary blanks104A,104B that mate with the end panels114,112of the primary blank102. Additionally, and optionally, adhesive may be applied to a portion of sections138A,140A,138B,140B,142A, and/or142B; as a result, these sections may mate with and be affixed to panels120,116,122,118, as appropriate.

Subsequently, the sections138A,140A,142A of supplementary blank104A and sections138B,140B,142B of supplementary blank104B may be placed in contact with corresponding portions of the panels of the primary blank102during preassembly manufacture. More specifically, section138A is placed in contact with panel114, section140A is placed in contact with panel120and section142A is placed in contact with panel116; likewise, section138B is placed in contact with panel112, section140B is placed in contact with panel122and section142B is placed in contact with panel118. Thus, following application of adhesive, the supplementary blanks104may be placed in contact with the primary blank102to provide adherence between primary and supplementary blanks102,104.

As a result of such a process, a preassembly may be provided that which, when utilized, results in a container having an interior formed primarily by a primary blank102serving as an exterior of the container, the interior including a plurality of stacking shoulders formed by supplementary blanks104at opposing ends of the container interior, wherein the plurality of stacking shoulders are formed as part of the set up or final assembly of exterior of the container.

Thus, it should be appreciated that, as a first operation in manufacturing the preassembly for the container100, the faces of the primary and supplementary blanks102,104are affixed together at various locations. Thus, although not shown, a preassembly may be provided wherein the primary and supplementary blanks102,104are affixed to one another via adhesive but the panels, walls, etc. are not configured for final assembly. As a result, such a preassembly may be delivered to a location for final assembly and placement of product; such a preassembly may be effectively and easily stacked with other preassemblies because such preassemblies are flat having not yet been built or assembled as shown inFIG. 1. Accordingly, it should be understood that the faces of the blanks102,104may be affixed in one or more suitable manners including, for example but not limited to, application of adhesive on one or both of the affixed faces, use of staples, tape, etc.

FIG. 5illustrates a side perspective of the preassembly manufactured from the blanks illustrated inFIG. 4. As shown inFIG. 6, the supplementary blanks104are affixed to the primary blank102and located such that the second major sections144A-B of the supplementary blanks104A-B may be folded towards the first major sections138A-B along fold lines158A-B respectively. As a result of this folding, one face of each of the first major sections138A-B meets a face of the corresponding second major sections144A-B. Additionally, a face of each of the second sub-sections146A-B meets the bottom panel106of the primary blank102. Prior to this folding, adhesive has been applied to the face of each of the second sub-sections146A-B meeting the bottom panel106. As a result, when the faces meet the bottom panel106, the adhesive acts to affix the second sub-sections146A-B to the bottom panel106. As a result of the adherence between the primary blank102and the supplementary blanks104A-B a preassembly is provided that lays flat and is configured for shipping to a manufacturing or distribution center for final assembly.

FIG. 6illustrates a side perspective of the preassembly manufactured from the blanks illustrated inFIG. 4during final assembly. As shown inFIG. 6, the end panels112,114are folded towards the bottom panel106. As a result of this movement and the adherence between the end panels112,114and the corresponding supplementary blanks104A-B, the supplementary blanks form end walls of the container100together with the end panels112,114. Additionally, the sub-section pairs116,120and118,120respectively associated with each end panel112,114are positioned so as to enable the pairs to folded so as to align with corresponding front and back sides of the container100. More specifically, sub-sections120and122are folded so as to align with the edge between the bottom panel106and the front side panel110; likewise, the sub-sections116,118are folded so as to align with the edge between the bottom panel106and the back side panel108.

FIG. 7illustrates the preassembly in a second stage of final assembly. As shown inFIG. 7, the front and back side panels110,108are folded upward along the fold lines separating those panels from the bottom panel106. Subsequently or simultaneously, the sub-panels126,124are folded along fold lines130,128over the corresponding sub-sections120,122and116,118respectively. The tabs134provided on each of the sub-panels126,124are then inserted into the respective apertures136. This interaction between the tabs134and the apertures locks the sub-sections120,122and116,118into place along with the erected front and back side panels110,108to form front and back side walls of the container100as shown inFIG. 1.

As shown inFIG. 7, the stacking shoulders are formed at opposing ends of the container100by the first and second major sections138A-B,144A-B coupled together by the shoulder sections148A-B respectively. The shoulders are secured in place by the adhesive provided between the146A-B and the bottom panel106as well as the interaction between the sub-sections116,118and120,122and the corresponding back and front side panels108,110and associated sub-panels. As a result of the force exerted on the first major sections138A-B during erection of the end walls, the keys150A-B are forced to disengage from the shoulder sections148A-B (having been provided by a perforation during manufacturing of the supplementary blank138). These illustrated keys150A-B are configured to interact respectively with the keyhole apertures152A-B provided on other non-illustrated containers100stacked above the container100. Likewise, the illustrated keyhole apertures152A-B are configured to interact respectively with the keys150A-B provided on other non-illustrated containers100stacked below the container100.

As a result of such a process, a preassembly may be provided which, when utilized, results in a container having an interior formed primarily by a primary blank serving as the majority of the exterior of the container; the container interior includes a plurality of stacking shoulders formed by the supplementary blanks at opposing ends of the container interior, wherein the plurality of stacking shoulders are formed as part of the set up or final assembly of exterior of the container.

Accordingly, the inclusion of stacking shoulders is implemented with minimal effort and deviation from the assembly required for the exterior of the container. Thus, stacking shoulders may be provided with improved ease and consistency as part of final assembly of a container exterior.

FIG. 8illustrates a functional block diagram used to describe the manufacturing method of containers in accordance with an illustrated embodiment. As alluded to in the background section, and as conventionally known, the manner of manufacturing containers such as the examples illustrated inFIGS. 1-7may be conveniently described in two phases: preassembly and final assembly/use.

Preassembly is normally performed at a container manufacturing facility to produce a preassembly which may also be thought of and referred to as a knockdown of the container. These preassemblies may be shipped to a customer location such as a product manufacturing facility or retail environment or third party fulfilment contract packaging facility. At that destination, the container customer may perform final assembly/use of the containers by, for example, folding and assembling various panels of the container to provide a container that is configured to hold manufacture product, e.g., for shipping and/or display.

In such operations, the manufacturing of the container preassemblies may be performed by the customer of the preassemblies and/or as part of manufacture of the preassemblies as illustrated inFIG. 8.

FIG. 8illustrates various functional operations performed as part of the manufacture of a preassembly by, for example, a display, shipping or display ready packaging manufacturer. The operations may begin, for example, with printing805of container material prior to the container material being die cut and/or scored810as part of an overall blank manufacturing operation815. The manufactured blanks830may or may not be printed on one or both sides of the blanks830depending on customer requirements. Accordingly, the printing operation805may be omitted.

Subsequent to blank manufacturing815, the manufactured blanks may be affixed to one another as part of the joining of multi-blank preassembly operations820. The operations performed at820may be performed in various suitable manners including by hand or using various commercially available machines (for example, those produced by Bahmueller Technologies, Inc. of Charlotte, N.C., USA or Bobst Group North America of Roseland, N.J., USA). Thus, the operations performed at820may produce preassemblies for containers such as that illustrated inFIGS. 3-7.

Therefore, it should be appreciated that one or more of the operations performed to produce blanks, preassemblies, knockdowns and containers may be performed in whole or in part by machines and or human personnel. Moreover, human personnel may utilize one or more different types of machines and/or tools to perform assembly operations performed either to manufacture preassemblies or finally assembled containers.

Thus, at the beginning of such operations, raw material825is used to produce blanks830. Such raw materials825may include but are not limited to various grades, types, configurations and combinations of corrugated fiberboard and/or solid paperboard, liner board, board of various fluting types and combinations as well as various types of sealants, non-organic materials and inks and dies of various suitable types.

While this invention has been described in conjunction with a specific embodiment outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. For example, as illustrated inFIG. 9, another example of a container200may be a flat bottomed tray container, which may also include a main compartment defined between a plurality of stacking shoulders formed by a corresponding plurality of supplementary blanks204and included in an interior space of a primary blank202following assembly. As in the first illustrated embodiment, these stacking shoulders may be formed by coupling the supplementary blanks204to locations on the primary blank202. The primary differences between the first illustrated embodiment and that illustrated inFIG. 9are that the embodiment ofFIG. 9includes two keys250and the associated keyhole apertures233are configured somewhat differently. Additionally, the relative dimensions of the primary blank202are also different, e.g., the dimensions of the end panels212,214.

Accordingly, the container200may be used for various purposes including shipping and placement on a display floor along with other such containers in a stack. However, it should be understood that the manufactured container may be any type of container including, for example, any carton, package, box, etc. of any suitable type; accordingly, the actual configurations of the primary blank202and the interrelationship with the supplementary blank204may change without departing from the scope of the embodiments.

Thus, in accordance with illustrated embodiments, a method is provided of manufacturing containers and resulting containers200and associated preassemblies (the combination of202,204) and blanks202,204, which, when utilized, result in containers200that include a plurality of supplementary blanks204that provide a plurality of stacking shoulders that serve as a mechanism for improving the stackability of the container200, whereby the container200may be configured to bare larger amounts of force (e.g., weight) applied from a top direction; in addition, the provision of the supplementary blanks204may also provide improved strength of the end panels of the resulting container200against force applied from side directions.

The container200may be used to ship or display product therein in a retail environment. Thus, subsequent to arrival at a retail environment or off-site fulfilment or contract packaging facility, a knockdown version of the container200(e.g., a preassembly) may be assembled and product placed in the container200for transport and/or display. BecauseFIG. 9illustrates a container configured for use as a display container. However, it should be appreciated that additional panels may be included on/attached to the illustrated container for purposes of transporting the container. Accordingly, such panels may be removed from the container to provide the illustrated container ofFIG. 9.

FIG. 10illustrates an example of a primary blank202, which may be thought of as a conventional tray type container such as the one illustrated inFIG. 9. The knockdown of the container200is manufactured by joining the primary blank202with a plurality of supplementary blanks204(which may be thought of as pads) illustrated inFIG. 11, as explained herein. The primary blank202illustrated inFIG. 10corresponds to an exterior of the container200illustrated inFIG. 9; therefore, the container200includes primary blank202and supplementary blanks204illustrated separately inFIG. 11and in conjunction with primary blank202inFIGS. 12-14.

As shown inFIG. 10, the primary blank202includes a bottom panel206, a back side panel208, a front side panel210and end panels212,214. Each end panel has corresponding end sub-panels; thus end panel214is connected to sub-panels216,220and end panel212is connected to sub-panels218,222. Likewise, each side panel is connected to corresponding side sub-panels; therefore, back side panel208is connected to back side sub-panel224and front side panel210is connected to front side sub-panel226.

When the primary blank is assembled as the exterior of the container200, the two end panels212,214are folded towards the bottom panel206and each of the sub-panels216,220(corresponding to end panel214) and218,222(corresponding to end panel212) are folded towards the bottom panel206as well. As a result, pairs of the end sub-panels216,218and220,222are parallel to one another and positioned on respective edges of the bottom panel206and the side panels208and210. As a result, when the side panels224,226are folded towards the side panels208,210respectively and over the end sub-panels along fold lines228,230, the end sub-panels are positioned in place. Accordingly, when tabs234provided on the side sub-panels224,226are inserted into corresponding apertures236provided along the edge of the bottom panel206, the side panels and end panels are locked in place. This assembly process is discussed in further detail with reference toFIGS. 12-14.

FIG. 11illustrates an example of a supplementary blank204used in manufacturing the container of the type illustrated inFIG. 9. The supplementary blank204includes first and second major sections238and244. The second major section244is attached to sub-section246, which is provided as a point for attaching the supplementary blank204to the bottom panel206of the primary blank202. Likewise, as discussed herein with reference toFIGS. 13-14, first major section238is also affixed to an end panel (212or214) of the primary blank.202. Accordingly, during assembly of the container200, the first major section244is folded towards the second major section238such that a shoulder section248is provided by the folding of the secondary blank204along fold lines256,258. As an additional result of this folding, the keys250are formed on the upper side of the shoulder section248. As mentioned briefly above and explained in further detail herein, the keys250are configured to interact with the keyhole apertures233provided on the underside of another container200following final assembly.

FIGS. 12 and 13illustrate the relative placement and interconnectedness of the primary and secondary blanks illustrated inFIGS. 10 and 11to provide the container illustrated inFIG. 9. Accordingly, as illustrated inFIGS. 12 and 13, the primary and supplementary blanks202,204may be configured so as to interact in a manner that enables the stacking shoulders to be formed easily and quickly as part of the final assembly of the container200. Accordingly, the total length and width dimensions for the blanks202,204and their constituent panels, walls and sections may be selected so as to facilitate the positioning of the supplementary blanks204with respect to the interior of the assembled primary blank202.

In one potential implementation, one or more portions of the primary and supplementary blanks202,204may be affixed to one another via, for example, adhesive such as glue, staples, tape, etc. so as to produce a preassembly (e.g., a knockdown or preassembly for the container illustrated inFIG. 9), wherein the positioning of supplementary blank204in cooperation with primary blank202is controlled. For example, the primary and supplementary blanks202,204may be affixed to each other on their mating faces (e.g., the bottom face of supplementary blanks204and the top face of the primary blank202). More specifically, adhesive may be applied to that portion of the second major sections238A,238B of the supplementary blanks204A,204B that mate with the end panels214,212of the primary blank202.

Subsequently, the section238A of supplementary blank204A and section238B of supplementary blank204B may be placed in contact with end panels214,212, respectively, during preassembly manufacture. As a result of such a process, a preassembly may be provided that which, when utilized, results in a container having an interior formed primarily by a primary blank202serving as an exterior of the container, the interior including a plurality of stacking shoulders formed by supplementary blanks204at opposing ends of the container interior, wherein the plurality of stacking shoulders are formed as part of the set up or final assembly of exterior of the container.

Thus, it should be appreciated that, as a first operation in manufacturing the preassembly for the container200, the faces of the primary and supplementary blanks202,204are affixed together at various locations. As a result, the preassembly illustrated inFIG. 13is provided by the adherence of the primary and supplementary blanks202,204to one another via adhesive but the panels, walls, etc. are not configured for final assembly. The resulting preassembly may be delivered to a location for final assembly and placement of product; such a preassembly may be effectively and easily stacked with other preassemblies because such preassemblies are flat having not yet been built or assembled as shown inFIG. 9.

FIG. 14illustrates a side perspective of the preassembly manufactured from the blanks illustrated inFIG. 12during final assembly. As shown inFIG. 14, the supplementary blanks204affixed to the primary blank202are located such that the second major sections244A-B of the supplementary blanks204A-B may be folded towards the first major sections238A-B along fold lines258A-B respectively during final assembly. As a result of this folding, one face of each of the first major sections238A-B meets a face of the corresponding second major sections244A-B. Additionally, a face of each of the second sub-sections246A-B meets the bottom panel206of the primary blank202. Prior to this folding, adhesive has been applied to the face of each of the second sub-sections246A-B meeting the bottom panel206. As a result, when the faces meet the bottom panel206, the adhesive acts to affix the second sub-sections246A-B to the bottom panel206. As a result of the adherence between the primary blank202and the supplementary blanks204A-B a preassembly is provided that lays flat and is configured for shipping to a manufacturing or distribution center for final assembly.

The preassembly illustrated inFIG. 14may be manipulated to finally assemble the container200ofFIG. 9in a manner similar to the first embodiment as illustrated inFIGS. 6-7. More specifically, the end panels212,214are folded towards the bottom panel206. As a result of this movement and the adherence between the end panels212,214and the corresponding supplementary blanks204A-B, the supplementary blanks form end walls of the container200together with the end panels212,214. Additionally, the sub-section pairs216,220and218,220respectively associated with each end panel212,214are positioned so as to enable the pairs to folded so as to align with corresponding front and back sides of the container200. More specifically, sub-sections220and222are folded so as to align with the edge between the bottom panel206and the front side panel210; likewise, the sub-sections216,218are folded so as to align with the edge between the bottom panel206and the back side panel208.

Subsequently, the front and back side panels210,208are folded upward along the fold lines separating those panels from the bottom panel206. Subsequently or simultaneously, the sub-panels226,224are folded along fold lines230,228over the corresponding sub-sections220,222and216,218respectively. The tabs234provided on each of the sub-panels226,224are then inserted into the respective apertures236. This interaction between the tabs234and the apertures locks the sub-sections220,222and216,218into place along with the erected front and back side panels210,208to form front and back side walls of the container200as shown inFIG. 9.

Like the first illustrated embodiment, the stacking shoulders of the second embodiment are formed at opposing ends of the container200by the first and second major sections238A-B,244A-B coupled together by the shoulder sections248A-B respectively. The shoulders are secured in place by the adhesive provided between the246A-B and the bottom panel206as well as the interaction between the sub-sections216,218and220,222and the corresponding back and front side panels208,210and associated sub-panels. As a result of the force exerted on the first major sections238A-B during erection of the end walls, the keys250A-B are forced to disengage from the shoulder sections248A-B (having been provided by a perforation during manufacturing of the supplementary blank238). These illustrated keys250A-B are configured to interact respectively with the keyhole apertures233provided on other non-illustrated containers200stacked above the container200. Likewise, the illustrated keyhole apertures233are configured to interact respectively with the keys250A-B provided on other non-illustrated containers200stacked below the container200.

As a result of such a process, a preassembly may be provided which, when utilized, results in a container having an interior formed primarily by a primary blank serving as the exterior of the container; the container interior includes a plurality of stacking shoulders formed by the supplementary blanks at opposing ends of the container interior, wherein the plurality of stacking shoulders are formed as part of the set up or final assembly of exterior of the container.

Accordingly, the inclusion of stacking shoulders is implemented with minimal effort and deviation from the assembly required for the exterior of the container. Thus, stacking shoulders may be provided with improved ease and consistency as part of final assembly of a container exterior.

While this invention has been described in conjunction with the specific embodiments pertaining to a flat bottom container outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. For example, as illustrated inFIG. 15, another example of a container300may be a flat bottomed tray container, which may also include a main compartment defined between a plurality of stacking shoulders formed by a corresponding plurality of supplementary blanks304and included in an interior space of a primary blank302following assembly. As in the first and second illustrated embodiments, these stacking shoulders may be formed by coupling the supplementary blanks304to locations on the primary blank302. The primary differences between the first and second illustrated embodiments and that illustrated inFIG. 15is that the embodiment ofFIG. 15is a slotted bottom container as opposed to a flat bottom container; like the second embodiment, the container includes a plurality of keys350provided on the top of the shoulder and associated keyhole apertures333on the bottom side of the container300.

Accordingly, the container300may be used for various purposes including shipping and placement on a display floor along with other such containers in a stack. However, it should be understood that the manufactured container may be any type of container including, for example, any carton, package, box, etc. of any suitable type; accordingly, the actual configurations of the primary blank302and the interrelationship with the supplementary blank304may change without departing from the scope of the embodiments.

Thus, in accordance with illustrated embodiments, a method is provided of manufacturing containers and resulting containers300and associated preassemblies (the combination of302,304) and blanks302,304, which, when utilized, result in containers300that include a plurality of supplementary blanks304that provide a plurality of stacking shoulders that serve as a mechanism for improving the stackability of the container300, whereby the container300may be configured to bare larger amounts of force (e.g., weight) applied from a top direction; in addition, the provision of the supplementary blanks304may also provide improved strength of the end panels of the resulting container300against force applied from side directions.

The container300may be used to ship or display product therein in a retail environment. Thus, subsequent to arrival at a retail environment or off-site fulfilment or contract packaging facility, a knockdown version of the container300(e.g., a preassembly) may be assembled and product placed in the container300for transport and/or display. BecauseFIG. 9illustrates a container configured for use as a display container. However, it should be appreciated that additional panels may be included on/attached to the illustrated container for purposes of transporting the container. Accordingly, such panels may be removed from the container to provide the illustrated container ofFIG. 15.

FIG. 16illustrates an example of a primary blank302, which may be thought of as a conventional tray type container. The knockdown of the container300is manufactured by joining the primary blank302with a plurality of supplementary blanks304(which may be thought of as pads) illustrated inFIG. 17, as explained herein. The primary blank302illustrated inFIG. 16corresponds to the exterior of the container300illustrated inFIG. 15; therefore, the container300includes primary blank302and supplementary blanks304illustrated separately inFIG. 11and in conjunction with primary blank302inFIGS. 17-23.

As shown inFIG. 16, the primary blank302includes a back side panel301, end panels303,307and a front side panel305. The primary blank also includes a plurality of bottom sub-panel311,313,315,317that cooperate during final container assembly to form the bottom of the container300. The back side panel301is separated from the first end panel303by a fold line321; likewise, the first side panel303is separated from the front side panel305by a fold line323. Similarly, the front side panel305is separated from the second end panel307by a fold line325.

The front side panel includes a display aperture319that may be formed when a removable shipping section (not shown but including, e.g., a panel covering the top of the container300and attached to a panel attached to the front side panel305) is removed. The primary blank also includes a glue panel309provided on a lateral end of the second end panel307and separated there from by a fold line327.

FIG. 17illustrates an example of a supplementary blank304used in manufacturing the container of the type illustrated inFIG. 15. Like the supplementary blank204illustrated inFIG. 11, the supplementary blank304includes first and second major sections338and344. The second major section344is attached to sub-section346, which is provided as a point for attaching the supplementary blank304to the bottom sub-panels of the primary blank302(in particular bottom sub-panels313and317). Likewise, as discussed herein with reference toFIGS. 18-19, first major section338is also affixed to an end panel (303or307) of the primary blank.302. Accordingly, during assembly of the container300, the first major section344is folded towards the second major section338such that a shoulder section348is provided by the folding of the secondary blank304along fold lines356,358. As an additional result of this folding, the keys350are formed on the upper side of the shoulder section348. As mentioned briefly above and explained in further detail herein, the keys350are configured to interact with the keyhole apertures333provided on the underside of another container300following final assembly.

FIGS. 18 and 19illustrate the relative placement and interconnectedness of the primary and secondary blanks illustrated inFIGS. 16 and 17to provide the container illustrated inFIG. 5. Accordingly, as illustrated inFIGS. 18 and 19(illustrating first and second stages of preassembly manufacture), the primary and supplementary blanks302,304may be configured so as to interact in a manner that enables the stacking shoulders to be formed easily and quickly as part of the final assembly of the container300. Accordingly, the total length and width dimensions for the blanks302,304and their constituent panels, walls and sections may be selected so as to facilitate the positioning of the supplementary blanks304with respect to the interior of the assembled primary blank304.

In one potential implementation, one or more portions of the primary and supplementary blanks302,304may be affixed to one another via, for example, adhesive such as glue, staples, tape, etc. so as to produce a preassembly (e.g., a knockdown or preassembly for the container illustrated inFIG. 15) such as that illustrated inFIG. 18, wherein the positioning of supplementary blank304in cooperation with primary blank302is controlled. For example, the primary and supplementary blanks302,304may be affixed to each other on their mating faces (e.g., the bottom face of supplementary blanks304and the top face of the primary blank302). More specifically, adhesive may be applied to that portion of the second major sections338A,338B of the supplementary blanks304A,304B that mate with the end panels307,303of the primary blank302. Subsequently, the section338A of supplementary blank304A and section338B of supplementary blank304B may be placed in contact with end panels307,303, respectively, during preassembly manufacture.

Additionally, adhesive may be applied to the top faces of the sub-sections346A-B illustrated inFIG. 18. Subsequently, the second major sections344A-B may be folded towards the first major sections338A-B so that the adhesive covered face of the sub-sections346A-B contacts and affixes to the bottom sub-panels317,313respectively, as illustrated inFIG. 19.

FIG. 20illustrates a side perspective of the preassembly manufactured from the blanks illustrated inFIG. 18in a third stage of preassembly manufacture. As shown inFIG. 20, the supplementary blanks304affixed to the primary blank302have been located such that the second major sections344A-B of the supplementary blanks304A-B have been folded towards the first major sections338A-B along fold lines356A-B respectively during the third stage of pre-assembly manufacture.

As shown inFIG. 20, the third stage of pre-assembly manufacture involves first folding the second end panel307towards the front side panel305along fold line323and folding the back side panel301towards the second end panel303along fold line321. Adhesive applied to the adhesive panel309then comes in contact with the bottom face of the back end panel301to join the back end panel301to the second end panel307. As a result, in the preassembly illustrated inFIG. 21, the two fold lines327,329are co-located so as to form one corner of a corresponding container.

As a result, the preassembly illustrated inFIG. 21is provided by the adherence of the primary and supplementary blanks302,304to one another via adhesive but the panels, walls, etc. are not configured for final assembly. As a result of such a process, a preassembly may be provided that which, when utilized, results in a container having an interior formed by a primary blank302serving as an exterior of the container, the interior including a plurality of stacking shoulders formed by supplementary blanks304at opposing ends of the container interior, wherein the plurality of stacking shoulders are formed as part of the set up or final assembly of exterior of the container.

The resulting preassembly may be delivered to a location for final assembly and placement of product; such a preassembly may be effectively and easily stacked with other preassemblies because such preassemblies are flat having not yet been built or assembled as shown inFIG. 15.

FIG. 22illustrates the preassembly illustrated inFIG. 21in a first stage of final assembly. During final assembly, the side panels301,305and end panels303,307are manipulated to be parallel to one another respectively and orthogonal therebetween. As a result of this movement, the bottom sub-panels311,313,315and317are positioned to be folded towards one another to form the bottom wall of the container300. More specifically, first bottom sub-panels313and317are folded inward towards the interior of the container300, as shown inFIG. 23. Subsequently, sub-panels311and315are folded towards the interior of the container300to complete the finally assembled container300. It should be appreciated that the bottom sub-panels311-317may be affixed to one another via adhesive, tape, staples or any other conventionally known material or mechanism for adherence.

Like the first and second illustrated embodiments, the stacking shoulders of the third embodiment are formed at opposing ends of the container300by the first and second major sections338A-B,344A-B coupled together by the shoulder sections348A-B respectively. The shoulders are secured in place by the adhesive provided between the sub-sections346A-B and the bottom panel portion formed by317,313as well as the adhesive provided between the first major sections338A-B and the corresponding end panels307,303of the primary blank302.

Unlike the first and second illustrated embodiments, the force exerted on the first major sections238A-B during the folding over of the second major sections244A-B forces the keys250A-B to disengage from the shoulder sections248A-B (having been provided by a perforation during manufacturing of the supplementary blank238). However, like the first and second embodiments, the formation of the shoulder sections at opposing ends of the container300does not occur until final assembly of the container. This is because the shoulders are not formed including shoulder sections348A-B until the bottom sub-panels313,317are folded towards the interior of the container300because the sub-sections346A-B are affixed to the bottom panels313,317. These illustrated keys350A-B are configured to interact respectively with the keyhole apertures333provided on other non-illustrated containers300stacked above the container300. Likewise, the illustrated keyhole apertures333are configured to interact respectively with the keys350A-B provided on other non-illustrated containers300stacked below the container300.

As a result of such a process, a preassembly may be provided which, when utilized, results in a container having an interior formed primarily by a primary blank serving as the majority of the exterior of the container; the container interior includes a plurality of stacking shoulders formed by the supplementary blanks at opposing ends of the container interior, wherein the plurality of stacking shoulders are formed as part of the set up or final assembly of exterior of the container.

Accordingly, the inclusion of stacking shoulders is implemented with minimal effort and deviation from the assembly required for the exterior of the container. Thus, stacking shoulders may be provided with improved ease and consistency as part of final assembly of a container exterior.

For example, various illustrated features of the preassembly and resulting containers may be omitted. Furthermore, it should be understood that invention embodiments are capable of variations practiced or carried out in various ways. Therefore, it should be appreciated that, in accordance with at least one embodiment of the invention, any and all of the walls may be constructed of corrugated cardboard. However, it should be understood that the walls, panels, any tabs on various panels, etc., may be constructed of various industry recognized appropriate materials that meet various transporting and/or display criteria. As a result, it should be understood that containers manufactured in accordance with at least one embodiment of the invention may also be considered “cartons,” which may be considered packaging or display containers, commonly made from cardstock or cardboard. Further, it should be understood that cartons come in many different varieties but most cartons can be folded and assembled from a flat form, known as a carton blank. Thus, it should be understood that the pattern for any blank, preassembly or container may be different than those described herein.

Alternatively, or more specifically, the packaging and/or display containers may be made using corrugated board, e.g., material made by a corrugator (a machine that produces corrugated board by attaching fluting to liners) which is a structured board formed by gluing one or more arched layers of corrugated medium to one or more flat-facing linerboards.

It should be understood that implementation of the method and system of the present invention involves performing or completing certain selected tasks or steps manually, automatically, or a combination thereof.

Additionally, it should be appreciated that material used in accordance with at least one embodiment of the invention may be laminated to provide barrier properties. Further, other barrier materials may be used including Ultra Violet (UV), moisture and gas barriers. Additionally, though not discussed in detail herein, it should be understood that any adhesive used to provide a bond between materials used in containers provided in accordance with the invention may include any substance that helps bond two materials together, examples including but not limited to glue and paste.

Further, it should be appreciated that the material used to form the primary blank may be different, stronger, or weaker than the blank used to form the supplementary blank. Thus, for example, use of a supplementary blank that is of a heavier, more durable or stronger material than the material used for primary blank, may provide the increased ease of final assembly as well as increased durability or strength to the resulting container while reducing the amount of material in the container (something of interest for environmental and cost issues).

Additionally, it should be understood that the functionality described in connection with various described components of various invention embodiments may be combined or separated from one another in such a way that the structure of the invention is somewhat different than what is expressly disclosed herein.

For example, it should be understood that, unless otherwise specified, there is no essential requirement that methodology operations be performed in the illustrated order; therefore, one of ordinary skill in the art would recognize that some operations may be performed in one or more alternative order and/or simultaneously.

Moreover, it should be appreciated that the supplementary blank and/or resulting stacking shoulders may be, for example, may have a shape that is different than that illustrated inFIG. 1, for example, relative dimensions may be different and/or varied at various points along the interior of the container. Likewise, various alternative configurations for both the primary and supplementary blanks may be implemented without deviating from the inventive concept.

Additionally, it should be appreciated that although a plurality of supplementary blanks may be provided at opposing ends of a container, it is foreseeable that a single supplementary blank may be included.

Further, the disclosure of application of adhesive on a surface of a blank to provide adherence with a panel of the primary blank or a section of the supplementary blank is not critical; rather, adhesive may, instead, be applied on the panel or section to which the surface is to be affixed. Therefore, placement of adhesive on one surface or the other, mating, surface is not critical.

It should be apparent for those skilled in the art that the illustrative embodiments described are only examples and that various modifications can be made within the scope of the invention as defined in the appended claims.