Tapered end containers

A container includes a base panel. An opposed pair of end panels extends from the base panel at opposite ends of the base panel. A front panel extends from the base panel and extends from a first one of the end panels to a second one of the end panels. A back panel extends from the base panel and extends from the first one of the end panels to the second one of the end panels. The end panels taper so top edges of the front and back panels are either longer or shorter than bottom edges of the front and back panels. Each end panel includes a plurality of overlapping end flaps adhered to one another. The end flaps of each of the end panels are connected to a respective one of the base panel and each of the front and back panel at respective fold lines.

BACKGROUND

The present disclosure relates to containers, and more particularly to containers for products with non-rectangular form factors.

2. Description of Related Art

Many products have a top footprint that is larger than the base footprint. Tubs of margarine, yogurt, Italian Beef, and other similar products are just a few examples. When packing multiple such products, e.g., multiple tubs of margarine, into a single container, e.g. a single corrugated card board container, certain problems can arise in the automated equipment that forms the container around the products. A gap between the base of the products and the base of the container can prevent proper glue sealing pressure from occurring, resulting in outer base flaps popping open and potentially jamming the line. Even if it does not jam the line, incomplete adhesion of the base flaps can cause other problems such as reduced stackability.

The conventional techniques have been considered satisfactory for their intended purpose. However, there is an ever present need for improved systems and methods for packaging products with non-rectangular form factors. This disclosure provides a solution for this need.

SUMMARY

A container includes a base panel. An opposed pair of end panels extends upward from the base panel at opposite ends of the base panel. A front panel extends upward from the base panel and extends from a first one of the end panels to a second one of the end panels. A back panel extends upward from the base panel and extends from the first one of the end panels to the second one of the end panels. The end panels taper so top edges of the front and back panels are either longer or shorter than bottom edges of the front and back panels. Each end panel includes a plurality of overlapping end flaps adhered to one another. At least some of the end flaps of each of the end panels are connected to a respective one of the base panel and each of the front and back panels at respective fold lines.

Product having a tapered form factor can be contained within an interior space defined by the base panel, the front panel, the back panel, and the end panels. The end panels can be flush against the product.

The front and back panels can taper so the top edges of the front and back panels are farther apart than are the bottom edges of the front and back panels. A top panel can be foldably connected to one of the front or back panels, the top panel being opposed to the base panel, wherein the top panel, base panel, end panels, front panel, and back panel form a wrap container.

A front top panel can be foldably connected to the front panel and opposed to the base panel. A back top panel can be foldably connected to the back panel and opposed to the base panel. The front top panel, back top panel, base panel, end panel, front panel, and back panel can form a harness container. The front top panel and the back top panel can completely enclose an interior space defined within the front panel, pack panel, end panels, and base panel. The front top panel and the back top panel can be spaced apart from one another, leaving an opening therebetween into an interior space defined within the front panel, pack panel, end panels, and base panel.

Each end panel can include: a respective front end flap foldably connected directly to the front panel, a respective back end flap foldably connected directly to the back panel, and a respective base end flap foldably connected directly to the base panel so the front panel, back panel, and end panels form four sides around an interior space.

Each end panel can includes: a respective front end flap foldably connected to the front panel by a front corner panel, a respective back end flap foldably connected to the back panel by a back corner panel, and a respective base end flap foldably connected directly to the base panel so the front panel, back panel, front and back corner panels, and end panels form eight sides around an interior space.

A top lid panel can be foldably connected to the back panel. A front lid panel can be foldably connected to a front edge of the top lid panel opposite the back panel. A pair of opposed side lid panels can each be connected to the top lid panel and front lid panel at opposite ends of the top lid panel, wherein the container is a 6-corner container.

The end panels can taper so the top edges of the front and back panels are longer than bottom edges of the front and back panels. The end panels can taper so the top edges of the front and back panels are shorter than bottom edges of the front and back panels.

A method of forming a container as described above includes folding the front and back panels upward to be upright relative to the base panel and folding a respective base end flap of each end panel downwards relative to the base panel and relative to the upright front and back panels to allow clearance of minor flaps of the end panels. The method includes folding minor flaps of each end panel inward against product, and folding the respective base end flap of each end panel upward and adhering the base end flaps to the minor panels.

A blank for a container includes a base panel. A front panel is foldably connected to the base panel. A back panel is foldably connected to the base panel opposite the front panel. A bottom end flap is foldably connected to the base panel along a bottom fold line. A first minor end flap is foldably connected to the front panel along a first oblique fold line that is oblique relative to the bottom fold line. A second minor end flap is foldably connected to the back panel along a second oblique fold line that is oblique relative to the bottom fold line. The first and second oblique fold lines are defined on lines that converge to a point on the base panel spaced inward from the bottom fold line. The bottom end flap and the first and second minor end flaps are configured to form an end panel that is tapered relative to the base panel. Top edges of the front and back panels are either longer or shorter than bottom edges of the front and back panels.

Bottom edges of the minor end flaps can be oblique relative to the bottom fold line to allow the bottom edges to be flush with the bottom panel in the formed container.

A top panel can be foldably connected to the back panel, the top panel being configured to opposed to the base panel in a wrap container formed from the blank.

A front top panel can be foldably connected to the front panel opposite the base panel. A back top panel can be foldably connected to the back panel opposite the base panel. The front top panel, back top panel, base panel, end panel, front panel, and back panel can be configured to form a harness container. The front top panel and the back top panel can be dimensioned to completely enclose an interior space defined within the front panel, pack panel, end panels, and base panel in a container formed from the blank. The front top panel and the back top panel can be dimensioned to be spaced apart from one another in a container formed from the blank, leaving an opening therebetween into an interior space defined within the front panel, pack panel, end panels, and base panel.

The first minor flap can be a front end flap foldably connected directly to the front panel. The second minor flap can be a respective back end flap foldably connected directly to the back panel. The front panel, back panel, the bottom end flap, and the first and second minor end flaps can be configured to form one end of a container with four sides around an interior space.

The first minor flap can be a front end flap foldably connected to the front panel by a front corner panel. The second minor flap can be a respective back end flap foldably connected to the back panel by a back corner panel. The front panel, back panel, front and back corner panels, and the front and back end flaps can be configured to form one end of a container with eight sides around an interior space.

A top lid panel can be foldably connected to the back panel. A front lid panel can be foldably connected to a front edge of the top lid panel opposite the back panel. A pair of opposed side lid panels can beach each connected to the top lid panel and front lid panel at opposite ends of the top lid panel. The blank can be configured to form a container that is a 6-corner container.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an embodiment of a container in accordance with the disclosure is shown inFIG.1and is designated generally by reference character100. Other embodiments of systems in accordance with the disclosure, or aspects thereof, are provided inFIGS.2-46, as will be described. The systems and methods described herein can be used for packaging products with tapered shapes, to and to improve end flap adhesion during packaging the same.

The container100includes a base panel102. An opposed pair of end panels104,106extends upward from the base panel102at opposite ends of the base panel.FIG.1shows the container100before it is completely closed, so the base panel102and end panels104,106are all visible.FIG.2shows container100completely closed. A front panel108extends upward from the base panel102and extends from the end panel104to the end panel106. A back panel110extends upward from the base panel102and extends from the end panel104to the end panel106. The end panels104,106taper out of square relative to the base panel102so top edges112,114of the front and back panels108,110are either longer or shorter than the respective bottom edges116,118of the front and back panels108,110. Each end panel106,104includes a plurality of overlapping end flaps120,122,124,126are adhered and128,130,132,134, are adhered respectively, to form the respective panels104,106. The end flaps120,122,124, and128,130,132, are connected to a respective one of the base panel102, and each of the front and back panels108,110at respective fold lines, shown inFIG.3in broken lines. End flaps126and134are connected to top panel150at respective fold lines.

Referring now toFIG.3, which shows the blank101for making the container100ofFIGS.1and3, the bottom end flaps122,130are foldably connected to the base panel102along respective bottom fold lines136,138. First minor end flaps120,128are foldably connected to the front panel along respective first oblique fold lines140,142that are each oblique relative to the bottom fold lines136,138. Second minor end flaps124,132are foldably connected to the back panel110along respective second oblique fold lines144,146that are oblique relative to the bottom fold lines136,138. The first and second oblique fold lines140,144are defined on lines that converge to a point148on the base panel102spaced inward from the bottom fold line136. The same can be said of the third and fourth oblique fold lines142,146and the bottom fold line138. The bottom end flap122and the first and second minor end flaps120,124are configured to form an end panel104(shown inFIGS.1and2) that is tapered relative to the base panel102, i.e. the end panel104is defined along a plane that is obliquely angled relative to the bottom panel102. The opposite end panel106(shown inFIGS.1and2) is similarly made of the bottom end flap130and the first and second minor end flaps128,132. A top panel150is foldably connected to one of the front or back panels, inFIGS.1-3it is connected to the back panel110but could be instead connected to the front panel108. The top panel150is opposed to the base panel in the container100, wherein the top panel150, base panel102, end panels104,106, front panel108, and back panel110form a wrap container100.

As shown inFIG.1, product154having a tapered form factor is contained within an interior space defined by the base panel102, the front panel108, the back panel110, and the end panels104,106. The end panels104,106are flush against the product154, which facilitates forming the end panels104,106including helping ensure complete adhesion of the flaps that make up the end panels104,106. The top flaps126,134,152are each foldably connected to the top panel150and are each adhered to respective ones of the front and end panels104,106,108.

It is contemplated that the top flap152can be moved to the opposite edge of the front panel108and can be adhered to the inside surface of the top panel150instead of the configuration ofFIG.2. Moreover, while the bottom flaps130and122are shown inFIG.1as only extending part of the way to the top of the end panels104,106, it is contemplated that they can be configured to extend all the way to the top.

With reference now toFIGS.4-6, another container200and corresponding blank201are described. Whereas the container100inFIGS.1-3is a wrap style container, the container200is a harness style container. The base, front, back, and side panels202,208,210,204,206are similar to those described above with respect to container100, but there are two opposed top panels250,251. A front top panel251is foldably connected to the front panel208and opposed to the base panel202in the erected container200as shown inFIGS.4-5. A back top panel250is foldably connected to the back panel210and is also opposed to the base panel202. The front top panel251and the back top panel250can be configured to be separated by a gap253, which can be of any suitable size for a given application in product. However, it is also contemplated that the top panels251,250can be configured to completely enclose an interior space defined within the front panel, pack panel, end panels, and base panels202,208,210,204,206, as shown inFIGS.7-9. It is also contemplated that while the containers200shown inFIGS.4-9have partial end panels204,206, i.e. due to shorter height in the bottom flaps222,230in the erected containers200, the bottom flaps222,230can be longer to provide full-height end panels204,206as shown inFIGS.10-12.

With reference now toFIGS.13-15, another container300and corresponding blank301. Whereas inFIGS.1-4, each end panel106,104includes a plurality of overlapping end flaps120,122,124,126and128,130,132,134, that together with the front and back panels108,110form four sides around an interior space for containing product, an interior of container300can be eight sided. For example, it is contemplated that the part of the blank301including the front and back panels308,310, as well as minor end flaps120,121,124,125,128,129,133,134, the blank configuration can be octagonal, however the base and top panels302,350, as well as the respective flaps connected to thereto may not be octagonal. Thus it is possible to have a rectangular package footprint while the internal flaps form an octagonal cavity, e.g. as shown inFIG.14for example. The basic panels302,308,310,350are much as described above withFIGS.1-4. However, each end panel304,306includes: a respective front end flap120,128foldably connected to the front panel308by a respective front corner panel121,129. Similarly on the back end, each respective back end flap124,134is foldably connected to the back panel310by a respective back corner panel125,133. It is possible that the corner panels121,129,125,133can add four sides to the perimeter of the container300as shown inFIGS.13-14so the front panel308, back panel310, front and back corner panels121,129,125,133, and end panels304,306form a perimeter with a total of eight sides around the interior space, while the base and top panels302,350can maintain rectangular. The end panels304,306can be partial as shown inFIG.13, or full as inFIGS.10-12. It is also contemplated that while the container300inFIGS.13-15is shown as a wrap container, it can also be configured as a harness container as shown inFIGS.16-18with any suitable gap between the top panels350,351or no gap much as described above with respect toFIGS.4-9.

With reference now toFIGS.19-21, another container400and corresponding blank is described. The containers100,200,300described above all have tapered end panels, e.g. end panels104,106, but all have front and back panels, e.g. front and back panels108,110inFIG.1, that are perpendicular relative to their respective base panel, e.g. base panel102inFIG.1. In container400, all four sides taper. In addition to the end panels404and406(which are made of pluralities of panels much as described above) tapering, the front and back panels408,410also taper obliquely relative to the base panel402. The top panel450has a larger height H2than the height H1of the base panel402, much as in containers100,200,300described above, but additionally, the top panel450has a larger width W2than the width W1of the base panel102, meaning the top edges412,414are further apart than the bottom edges416,418. WhileFIGS.19-21show a container400with all sides tapered in a wrap configuration, the all sides tapering can be applied to a harness wrap container and blank500,501as shown inFIGS.22-24(with any suitable gap or lack thereof as described above with respect toFIGS.4-9). Also, the four main sides of an octagonal container and blank600,601can be tapered as shown inFIGS.25-27in a wrap style, or in a harness stile as in the container and blank700,701ofFIGS.28-30, which are otherwise similar to the containers300described above, thus it is possible to have a rectangular package footprint while the internal flaps form an octagonal cavity. Any of the four-sides tapered containers400,500,600,700can have full or partial end panels, as described above with reference toFIGS.4and10. Also, any of the wrap style containers, e.g. container600, can have inside or outside gluing of the top panel as described with respect toFIGS.1-3.

Referring now toFIGS.31-37, another container and blank800,801is shown with full support minor corners for added stacking strength, e.g. if multiple containers800are stacked. Bottom edges819of the minor end flaps820,824,828,832are oblique relative to the respective bottom fold lines836,838as shown by the angle indicators inFIG.31. This allows the bottom edges819to be flush with the bottom panel802in the formed container800as shown inFIG.37. As shown inFIG.32, in erecting the blank801into a container800, the method includes folding the front and back panels808,810upward, e.g. around product, to be upright relative to the base panel802. As shown inFIGS.32and34, the method includes folding the respective base end flap822,830of each end panel804,806downwards relative to the base panel802and relative to the upright front and back panels808,810to allow clearance of minor end flaps820,824,828,832. As shown inFIG.33, the method includes folding minor end flaps820,824,828,832inward against the product (which is not shown inFIG.33but seeFIG.1), and folding the respective base end flap822,830upward as shown inFIG.35and adhering the base end flaps822,830to the respective minor end panels820,824,828,832. The top panels850,851are then folded into place as shown inFIG.36, and their respective end flaps are folded down and adhered to form the container800as shown inFIG.37. As shown inFIG.33, since the minor end flaps820,824,828,832have edges819flush with the bottom panel820, and unnumbered top edges flush with the top panels850,851, the minor end flaps820,824,828,832can contribute considerably load bearing capabilities at the corners for the container, adding to stacking strength. This full support minor corner configuration is applied to the two tapered end, harness style container800, but can also be applied to wrap style containers, as well as containers where four sides taper as described above.

With reference now toFIGS.38-40, a container and blank900,901are shown and described with a six-corner tray configuration with tapered end panels904,906. A base panel902has end panels904and906foldably connected at either end of base panel902. The minor end flaps920,924,928,932are foldably connected to the respective end panels904,906and are adhered to the respective front and back panels908,910in the erected container900. The tapered edges140,142,144,146of the front and back panels908,910give the end panels904,906their taper relative to the base panel902much as described above with respect toFIGS.1-3. A top lid panel960is foldably connected to the back panel910. A front lid panel962is foldably connected to a front edge of the top lid panel920opposite the back panel910. A pair of opposed side lid panels964,966are each foldably connected to the top lid panel960and have respective end flaps968that are adhered to the front lid panel962at opposite ends of the top lid panel960.

With reference now toFIGS.41-43, another container1000and respective blank1001are shown. While inFIG.1, the base panel102is larger than the top panel150, and the end panels204,206taper so the top edges112,114of the front and back panels108,110are longer than bottom edges116,118, the opposite is true in container1000. The end panels1004,1006taper so the top edges1012,1014of the front and back panels1008,1010are shorter than bottom edges of the front and back panels1008,1010. Similar to that shown inFIG.3, inFIG.43, oblique fold lines1040,1044are defined on lines that converge to a point1048on the end flap1022spaced outward from the bottom fold line1036. There is also a four-tapered sides container1100and corresponding blank1101shown inFIGS.44-46, where the top panel1150has a longer length L1and wider width W1than those (L2, W2) of the base panel1102. These inverted taper containers1000,1100are suitable for packaging product that has a reverse tapered shape, or that has a normal tapered shape but benefits from being stored upside down, e.g. if it contains fluids that separate and therefore benefit from upside-down storage. Any of the foregoing container configurations can be adapted to be reverse tapered as are containers1000,1100.

The methods and systems of the present disclosure, as described above and shown in the drawings, provide for packaging products with tapered shapes, to and to improve end flap adhesion during packaging the same. While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.