Container with air flow cooling channels

A container has a plurality of planar panels integrally arranged with respect to each other and with respect to a set of orthogonal x, y and z axes, the z-axis defining a direction line in which the container is configured to support a stacking load, the plurality of panels being foldable to create the container. The plurality of planar panels form at least one outer surface disposed orthogonal to the z-axis, wherein a substantial portion of the outer surface has a recessed central portion of the outer surface that extends substantially across an entire outside dimension of the container.

BACKGROUND OF THE INVENTION

The subject matter disclosed herein relates to containers, particularly to packing containers, and more particularly to packing containers suitably configured for stacking one on top of another and having air flow cooling channels disposed therebetween.

Packing containers are often formed from a corrugated sheet product material that is cut with a die to form a flat blank, or scored and slotted to form a flat blank. The flat blank is folded into a three-dimensional container that may be secured using an arrangement of flaps, adhesive liquids, staples or adhesive tapes.

In use, packing containers may be subjected to considerable forces during shipping, storage and stacking, and may be stacked on a pallet in close proximity to each other. Some packing containers are used for shipping product, such as harvested vegetables for example, where some of the vegetables, such as spinach or broccoli for example, may generate heat during shipping via post-harvest respiration. While existing packing containers may be suitable for their intended purpose, the art relating to packing containers would be advanced with the inclusion of integrally formed features that improve the interior cooling of the packing containers, particularly with respect to the interior cooling of stacked packing containers containing harvested vegetables.

BRIEF DESCRIPTION OF THE INVENTION

An embodiment includes a container having a plurality of planar panels integrally arranged with respect to each other and with respect to a set of orthogonal x, y and z axes, the z-axis defining a direction line in which the container is configured to support a stacking load, the plurality of panels being foldable to create the container. The plurality of planar panels form at least one outer surface disposed orthogonal to the z-axis, wherein a substantial portion of the outer surface comprises a recessed central portion of the outer surface that extends substantially across an entire outside dimension of the container.

Another embodiment includes a flat blank having a plurality of planar panels integrally arranged with respect to each other with a plurality of fold lines, score lines, perforated lines, or any combination of fold, score, or perforated lines, disposed therebetween, wherein the plurality of panels are foldable to form the aforementioned container.

DETAILED DESCRIPTION OF THE INVENTION

A packing container, also referred to as a carton or simply as a container, may be fabricated by, for example, cutting or scoring a sheet product with a die or other type of cutting or scoring tool, such as cutting, scoring and slotting tooling and equipment, to form a flat sheet having various panels, flaps, tabs, recesses and creases. The sheet may be folded and secured using, for example, liquid or hot melt adhesives, tapes or mechanical means such as staples or straps to form a three-dimensional packing container. Packing containers may be formed from a variety of sheet products. The term “sheet products” as used herein is inclusive of natural and/or synthetic cloth or paper sheets. Sheet products may include both woven and non-woven articles. There are a wide variety of nonwoven processes and they can be either wetlaid or drylaid. Some examples include hydroentangled (sometimes called spunlace), DRC (double re-creped), air laid, spunbond, carded, and meltblown sheet products. Further, sheet products may contain fibrous cellulosic materials that may be derived from natural sources, such as wood pulp fibers, as well as other fibrous material characterized by having hydroxyl groups attached to the polymer backbone. These include glass fibers and synthetic fibers modified with hydroxyl groups. Sheet product for packing containers may also include corrugated fiber board, which may be made from a variety of different flute configurations, such as A-flute, B-flute, C-flute, E-flute, F-flute, or micro-flute, for example, as well as multi-wall configurations such as single-wall (A, B or C-flute for example) or double-wall (AC-flutes or BC-flutes for example). In an embodiment, a packing container as disclosed herein may be fabricated from a single piece of corrugated fiber board, or from multiple pieces of corrugated fiber board that are typically assembled by, but not limited to, automated forming equipment.

In use, a packing container may be subjected to various forces during handling, shipping and stacking of the packing container including, for example, compressive forces exerted between the top and bottom panels of the container. It is desirable for a packing container to withstand the various forces to protect objects inside the container and to maintain a presentable appearance following shipping. In certain applications, it is also desirable for a packing container to counteract overheating of objects in the container, particularly when stacked with other containers, and particularly when the objects inside the container are perishable items, such as raw vegetables for example.

Although the following detailed description contains many specifics for the purposes of illustration, anyone of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the claims. Accordingly, the following example embodiments are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention.

An embodiment, as shown and described by the various figures and accompanying text, provides an engineered container having a plurality of sides and having at least one cooling feature, which may be employed with at least one strength reinforcement feature, that provides improved interior cooling of the container as compared to a similarly configured container absent the same cooling features disclosed herein. While an embodiment described herein depicts an eight-sided container with a plurality of panels having certain structural dimensional relationships relative to each other as an exemplary container, it will be appreciated that the disclosed invention is not so limited and is also applicable to other multi-sided containers having four or more sides, such as five, six, seven or eight sides, with a plurality of panels having different structural dimensional relationships relative to each other but consistent with an embodiment disclosed herein.

FIG. 1depicts a rotated perspective view of an example embodiment of a container100in accordance with an embodiment disclosed herein,FIG. 2depicts a side view of the container ofFIG. 1,FIG. 3depicts an expanded view of a portion140of the container100ofFIG. 2,FIG. 4depicts a flat blank150suitable for forming the container100ofFIG. 1, andFIG. 5depicts an expanded view of a portion160of the flat blank150ofFIG. 4. Reference will now be made toFIGS. 1-5collectively.

In an embodiment, a container100includes a plurality of planar panels200integrally arranged with respect to each other, via fold lines, score lines, perforated lines, or any combination thereof, which may be continuous or intermittent, and are enumerated by reference numeral300, and with respect to a set of orthogonal x, y and z axes, where the z-axis defines a direction line in which the container100is configured to support a stacking load, and the plurality of panels200are foldable to create the container100. The plurality of planar panels200form a plurality of outer surfaces, and in particular form at least one outer surface such as a top surface102and a bottom surface104, disposed orthogonal to the z-axis. At least one of the outer surfaces includes a recessed central portion106that extends substantially across an entire outside dimension of the container100, such as the entire width W of the container100for example. Alternatively, the recessed central portion106that extends substantially across an entire outside dimension of the container100, may extend substantially across the entire length L of the container100. In an embodiment, both the top surface102and the bottom surface104each comprise the recessed central portion106that extends across the entire outside dimension of the container. In an embodiment, the recessed central portion106is flanked by first and second end portions108,110at respective first and second ends112,114of the container100, where the first and second end portions108,110extend substantially across the entire outside dimension of the container and form a part of the at least one outer surface102,104. The recessed central portion106, relative to the first and second end portions108,110, is recessed by a defined amount116, and is formed via a strategic arrangement of fold lines, which will be discussed in more detail below.

As used herein, the phrase “extend(s) substantially across” is intended to account for any gap that may be present between edges of folded panels, such as gap124between panels204and212, for example (seeFIGS. 1 and 7for example), which is discussed further below.

The plurality of panels200include a first panel202and a second panel204that form a contiguity with a first fold line302disposed therebetween, wherein the first panel202is disposed parallel to the z-axis, the second panel204is disposed orthogonal to the z-axis, and the second panel204forms at least part of one of the top surface102or the bottom surface104(as depicted inFIGS. 1, 2 and 4, the second panel204forms a portion of the top surface102). The first fold line302has a first end fold line portion302.1that transitions to a central fold line portion302.2with a first transition fold line portion303disposed therebetween, and the central fold line portion302.2transitions to a second end fold line portion302.3with a second transition fold line portion305disposed therebetween. The central fold line portion302.2is offset towards the first panel202by a defined first offset dimension118with respect to the first and second end fold line portions302.1,302.3, with the first and second transition fold line portions303,305being disposed therebetween. In an embodiment, the recessed central portion106may occupy, but is not limited to, about 50%-90% of the container length L, or alternatively about 60%-80% of the container length L. In an embodiment, the first and second end portions108,110have land surface dimensions107,109, respectively. In an embodiment, the ratios of107/L and109/L are each equal to or greater than 0.15 and equal to or less than 0.25. In an embodiment, the central fold line portion302.2has a length that is longer than the length of either the first end fold line portion302.1or the second end fold line portion302.3. In an embodiment, the central fold line portion302.2has a length that is longer than the sum of the lengths of the first end fold line portion302.1and the second end fold line portion302.3. In an embodiment, the plurality of planar panels200are fabricated from a corrugated fiber material having flutes and a defined caliper thickness, e, with the corrugations of at least the first panel202being oriented parallel to the z-axis. In an embodiment, the defined first offset dimension118is equal to or less than e. As depicted inFIG. 4, the flutes of the corrugated fiber board are oriented parallel to the direction line “F”.

In a folded state, that is, when the second panel204is folded orthogonal to the first panel202via the first fold line302, the recessed central portion106coincides with and is a product of the central fold line portion302.2of the first fold line302, and the first and second end portions108,110coincide with and are a product of the first and second end fold line portions302.1,302.3, respectively, of the first fold line302. More specifically, the recessed central portion106of the top surface102(as depicted inFIGS. 1-5, but may also apply to the bottom surface104) is a product of the strategic arrangement of the aforementioned fold lines, that is, the first end fold line portion302.1that transitions to the central fold line portion302.2that transitions to the second end fold line portion302.3, having the above noted first offset dimension118. As illustrated, when folded along the first fold line302, the first and second panels202,204deform in an engineered manner to produce the recessed central portion106that provides an air passage substantially across the width W of the container100, where the air passage will have an open height of twice the defined amount116of the recess when two containers100are stacked on top of each other with the lower container having the recessed central portion106on the top surface102and the upper container having the recessed central portion106on the bottom surface104(best seen with reference toFIG. 6). Alternatively, the air passage will have an open height of only one-times the defined amount116of the recessed central portion106when two containers100are stacked on top of each other and the recessed central portion106is present on only the top surface or the bottom surface of each stacked container100.

In an embodiment, the first and second end fold line portions302.1,302.3are substantially collinear, resulting in the first and second end portions108,110being substantially coplanar, which serve to form strength enhancing support surfaces for stacking a first one of the container100with respect to a second one of the container100having like features, and the recessed central portion106forms the aforementioned air passage170, or cooling channel (best seen with reference toFIG. 6), between adjacent ones of the first and second stacked containers100.

In an embodiment where the container100has more than four sides, such as eight sides as depicted inFIG. 1for example, the plurality of planar panels200may have a third panel206that forms a contiguity with the first panel202with a second fold line304disposed therebetween. In an embodiment, the third panel206forms an approximately 45-degree corner panel of the eight sided container100. The third panel206has an edge first cut line306proximate the second end fold line portion302.3of the first fold line302. The second end fold line portion302.3of the first fold line302is disposed offset from and outboard of the edge first cut line306of the third panel206by a defined second offset dimension120. In an embodiment, the defined second offset dimension120is equal to or less than e/2. A second cut line308extends from the second fold line304across the first fold line302into the second panel204and is disposed orthogonal to and at a transition of the second end fold line portion302.3of the first fold line302and the edge first cut line306. The second panel204has a side edge cut line310that cooperates with the edge first cut line306of the third panel206to form a support surface portion208disposed proximate the orthogonal second cut line308and proximate the edge first cut line306of the third panel206, where the support surface portion208of the container100in the folded state is disposed on the edge first cut line306of the third panel206(best seen with reference toFIG. 3). As depicted inFIG. 5, the edge first cut line306has a portion312with a defined length126of equal to or greater than e, which serves to form the support surface portion208.

In an embodiment, the plurality of panels200include at least one strength enhancing feature (SEF)130disposed at the central fold line portion302.2of the first fold line302. In an embodiment, the strength enhancing feature130includes a cut planar edge132disposed a defined third offset dimension122away from and outboard of the central fold line portion302.2of the first fold line302. In an embodiment, the defined third offset dimension122is equal to or less than e. In an embodiment, the defined third offset dimension122is equal to or less than e/2. While only one SEF130is specifically described herein, and best seen with reference toFIG. 5, it will be appreciated by reference to at leastFIGS. 1, 2 and 4that an embodiment of the container100may include a plurality of SEFs130, which are illustrated but not specifically enumerated in at leastFIGS. 1, 2 and 4.

Reference is now made toFIGS. 6-8, whereFIG. 6depicts a side view of a stacked arrangement of two of the containers100,FIG. 7depicts an end view of the stacked arrangement ofFIG. 6, andFIG. 8depicts a plan view of a side by side arrangement of a plurality of the containers100that may also be stacked in layers. As depicted inFIG. 6, where two stacked containers100have recessed central portions106on respective top and bottom surfaces102,104the resulting air passage170, or cooling channel, that is suitable for forced air flow and possibly passive air flow, has an open height that may be twice the defined amount116of the individual recesses, where the air passage170across the width of the containers100is oriented perpendicular to the z-axis. Other cooling features can be seen with reference toFIGS. 7 and 8, which will now be described individually.FIG. 7depicts an arrangement of the plurality of planar panels200where the top surface102comprises top panels204,212, and the bottom surface104comprises bottom panels214,216(best seen with reference toFIG. 4). In an embodiment, the lengths of the top and bottom panels204,212,214,216, from a respective fold line to an opposing edge, are designed so as to form a gap124between the cut edges of the respective panels when folded to form the container100, which serves to form an air passage172, or cooling channel, in a stacked arrangement of at least two of the containers100, where the air passage172across the length of the containers100is oriented perpendicular to the z-axis, and perpendicular to the air passage170.FIG. 8depicts a plan view of a side by side arrangement of a plurality of the containers100, where in an embodiment each container100has eight sides having corners formed by the aforementioned third panel206being present in each corner of each container100. When arranged in a side by side configuration, the corner sections provided by the respective third panel206of the plurality of containers100form a variety of air passages, or cooling channels, such as: corner air passages174formed by one third panel206corner section; V-shaped air passages176formed by two adjacent third panel206corner sections; triangular air passages178formed by two adjacent third panel206corner sections and a portion of a side panel of an adjacent container100; and/or, diamond-shaped air passages180formed by four adjacent third panel corner sections. WhileFIG. 8depicts a certain arrangement of a plurality of containers100forming a variety of air passages174,176,178,180that provide cooling channels oriented parallel with the z-axis, it will be appreciated that other arrangements of a plurality of containers100, whether the containers100be eight sided or otherwise, may produce different geometries to said air passages. Any and all such air passages consistent with an embodiment disclosed herein, whether by illustration or text, are contemplated and considered to be within the ambit of the appended claims.

In a stacked arrangement of containers100, it will be appreciated that air passages174,176,178and180are vertically oriented, and air passages170and172are horizontally oriented, and while all of the air passages will be instrumental in cooling the interior of the containers via forced air, the vertically oriented air passages will be instrumental in cooling the interior of the containers via convection.

While embodiments disclosed herein depict a container100having the gap124that creates the horizontal air passage172, it will be appreciated the associated panels may be sized differently to either increase or decrease the size of the gap124. In an embodiment, the gap124may be equal to or greater than zero and equal to or less than two inches, and in a typical container100may be on the order of ½ inch, or may be any other dimension suitable for a purpose of an end user, or for a purpose disclosed herein. In an embodiment where the gap124is substantially equal to zero, then the container100will be substantially absent the horizontal air passage172.

By providing air passages (cooling channels) formed in a manner as disclosed herein, applicant has found two-fold advantageous improvements in the performance of stacked containers100.

A first advantageous improvement was found regarding the internal temperature of a given container100(test sample) versus a similarly sized container but absent said air passages (control sample) as disclosed herein, during a cooling event. In a stacking arrangement perFIG. 8with containers stacked three high, and with an initial steady state ambient and internal temperature of 100 degree-F., it was found that the centermost container of the test sample cooled down to 35 degree-F. about 47% faster than the control sample, similarly situated, when the samples were removed from the 100 degree-F. environment and placed in an ambient of about 30 degree-F., under the influence of forced air and convection. Improvements in cooling were also found for containers on the periphery of all layers of the stack, but the cooling rate was not as dramatic, about 15% versus the centermost container. Applicant theorizes that the recessed central portion106of the container100not only serves to provide the horizontal air passage170that aids in forced air cooling, but also serves to reduce the conductive heat transfer in a vertical direction between stacked containers, thereby further aiding in cooling the interior of each container100of the stacked arrangement of containers. Testing was conducted without the slotted SEFs130, but with the horizontal cooling chamber170in combination with an eight-sided container100, versus a standard four-sided RSC, and was conducted with forced air.

A second advantageous improvement was found regarding the compression strength of a given container100(test sample), versus a similarly sized container but absent the recesses106, first and second end portions108,110, and SEFs130(control sample) as disclosed herein, during a box compression test (T804 om-12 test method). In single container compression testing, an improvement of greater than 25% in box compression strength was observed. While not being held to any particular theory, applicant surmises that the observed improvement of compression strength is due to the support surfaces formed by the first and second end portions108,110creating a more favorable stress distribution that directs the stacked load and stress to the vertical end walls of the container.

While an embodiment disclosed herein is depicted being formed from a single piece of corrugated fiber board, the scope of the invention is not so limited, and encompasses any design that falls within the ambit of the appended claims, which includes single or multi-piece designs consistent with the disclosure herein.

While the invention has been described with reference to example embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the claims. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the only mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Also, in the drawings and the description, there have been disclosed example embodiments and, although specific terms and/or dimensions may have been employed, they are unless otherwise stated used in a generic, exemplary and/or descriptive sense only and not for purposes of limitation, the scope of the claims therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Additionally, the term “comprising” as used herein does not exclude the possible inclusion of one or more additional features.