Leak-resistant corrugated paperboard container with exterior hand grips

A container foldably assembled from a single blank of treated corrugated paperboard for carrying iced canned or bottled beverages and food, with hand grips exterior of the container defined by a hole in each corner panel that folds against the end panels of the container. A hook at each end of a strap engages a respective hand grip for carrying the container on the shoulder of a person using the container.

TECHNICAL FIELD 
The present invention relates to containers for carrying iced canned or 
bottled beverages and foods. More particularly, the present invention 
relates to a container foldably assembled from a single blank of 
corrugated paperboard with exterior hand grips for carrying the container. 
BACKGROUND OF THE INVENTION 
Small containers of various construction have been used for maintaining a 
cold atmosphere for canned or bottled beverages and foods. Such containers 
are known as coolers, and are typically used at picnics, parties, 
tail-gate parties, travel, beach outings, and the like. The coolers are 
partially filled with ice or a cold-inducing package that is known in the 
art. The beverages and foods are then placed in the container for being 
kept cool. A lid closes the cooler. 
A coolers loaded with ice, beverages, and food is heavy. Coolers 
accordingly are typically sized for convenient carrying, such as by a 
single individual or by two or more persons holding the ends of the 
cooler. Often the coolers include a handle or hand grip at the ends of the 
cooler to facilitate carrying. For example, some known coolers are made of 
a metal skin and plastic inner liner that sandwich a thermally insulative 
barrier. Such coolers often include a U-shape pivotable handle on each 
longitudinal end for carrying the cooler. Other coolers are sized for 
carrying six canned beverages. These coolers typically have plastic walls 
and a pivotable top for closing the cooler. A handle in these known 
coolers is molded into the top. 
The coolers discussed above are of a type and quality that they are kept 
for re-use. In some instances however, low cost, disposable coolers are 
preferred for use. One such inexpensive cooler is made from molded 
styrofoam, and is typically available in several sizes. The ends in some 
known styrofoam coolers have wedge-shaped built-up sections on the end 
walls for hand grips. 
Other low cost cartons for foods are known. For instance, U.S. Pat. No. 
3,904,106 describes a carton formed from a single piece of corrugated 
paperboard called a blank. A plurality of scores in the blank define 
several panels that form the walls, bottom, and top of the carton. A 
corner connector panel attaches to a side and end panels, and a diagonal 
score divides the corner connector into first and second triangular 
sections. A locking panel attaches to one of the triangular sections at 
each end of the blank. A tab extends outwardly from the locking panel for 
insertion into a slot in a bottom panel. The carton assembles by folding 
the triangular sections into face contact and sandwiching the first 
triangular section between an end panel and the second triangular section. 
The locking panel extends over the upper edge of the first triangular 
section and into the carton. The tab inserts into the slot in the bottom 
panel to maintain the carton in its erected position. One embodiment of 
the carton in the ,106 patent includes a handle cut-out in each end wall. 
The corner panels in this embodiment each require a separate tab and slot 
to maintain the carton in its erected position. 
While accomplishing the goal of providing a container, the above-discussed 
low-cost containers still have drawbacks for use as a cooler for iced 
beverages and foods. The carton described in the '106 patent is not 
useable as a cooler for iced beverages and foods. First, the carton is not 
easily carried as an individual container. A single carton would be held 
and carried awkwardly from the bottom. Second, the carton also requires at 
least one slot in the bottom panel for securing the tab on the locking 
panel to hold the carton in its erected position. The slots allow water 
from the melted ice to flow out of the container. A person would thereby 
get wet by carrying the carton. The water would leak out into cars, 
stores, and other places where the container is being used. Third, the 
cut-out in the end panel (and the slots) create thermal leak paths into 
the carton. These reduce significantly the thermal insulative performance 
of the carton. Such cartons are suitable for use in refrigerated storage 
rooms, but are not desirable for use as a cooler for picnics, parties, and 
the like. 
Styrofoam, while providing a low cost container, also has drawbacks which 
limit its suitability for use as a cooler. The hand grips are difficult to 
grasp and a loaded styrofoam cooler is awkward to carry. Styrofoam is 
brittle, and the walls easily break under load. Although styrofoam 
provides insulative characteristics, the beads of styrofoam in the walls 
of the container define interstices through which fluids and thermal 
energy may pass. Molded styrofoam coolers are necessarily formed in the 
completed shape, as are the metal coolers discussed above. A stack of such 
coolers occupies display and floor space, such as at the retail outlet 
selling the cooler. Finally, the lid for a styrofoam cooler typically is a 
separate piece which may break or become lost from the cooler. 
Therefore, there is a need in the art for a leakresistant, easily assembled 
container with hand grips exterior of the walls of the container for 
carrying iced canned or bottled beverages and foods. 
SUMMARY OF THE PRESENT INVENTION 
Generally described, the present invention provides a container that 
includes hand grips exterior of the walls for carrying the container. The 
container is formed from a single sheet of corrugated paperboard having a 
bottom panel, two end panels and two side panels. At least one corner 
panel foldably attaches to each end panel of the container and has a hole 
therein for a hand grip exterior of the walls of the container when 
assembled. 
More particularly described, the container comprises a single sheet of 
corrugated paperboard treated with a wax and polyethylene film as a 
moisture barrier. The container includes a bottom panel with two side 
panels and two end panels each foldably joined along a respective score 
defining an edge of the bottom panel. A corner panel foldably joins 
adjacent end and side panels along a respective score therewith and has a 
hole therein. A foldable score extends diagonally from an outer corner of 
the corner panel to the bottom panel to define a pair of triangular 
sections in the corner panel. Each corner panel folds on the diagonal 
score into a triangular wing which, being folded against the end panels, 
then positions the holes for hand grips exterior of the end panels for 
carrying the container. 
More particularly described, the container is held in the assembled 
position by an inside end panel foldably attached to one of the corner 
panels on each end of the container. The inside end panel folds inwardly 
over the corner panels into the container and against the inside surface 
of the end panel. A flange on the inside end panel is thereby brought 
firmly into contact with the bottom panel. The inside end panels hold each 
end of the folded assembled container. 
More particularly described, the hand grip may receive a J-hook which 
connects to a strap for carrying the container. 
Accordingly, it is an object of the present invention to provide a hand 
grip exterior to a leak-resistant container. 
It is another object of the present invention to provide a hand grip in a 
container formed by folding a single piece of corrugated paperboard. 
It is another object of the present invention to provide a hand grip for a 
container, which receives a hook from a strap for carrying the container. 
It is another object of the present invention to provide a container that 
is shipped and stored flat prior to assembly for use as a cooler with iced 
beverages and foods. 
These and other objectives, features, and advantages will become apparent 
from a reading of the following detailed description of the invention and 
claims in view of the appended drawings.

DETAILED DESCRIPTION 
Referring now in more detail to the drawings, in which like numerals 
indicate like parts throughout the several views, FIG. 1 shows an upper 
and right perspective view of a container 10 constructed in accordance 
with the present invention, having hand grips generally designated 12 on 
the ends 14 thereof for holding and carrying the container. The 
illustrated embodiment of the container 10 includes a strap 16 exploded 
therefrom, which may also be used for carrying the container. The 
container 10 includes a bottom panel 18, two end panels 20 and two side 
panels 22. Each end 14 includes a first corner panel 24 and a second 
corner panel 26. As discussed below, the corner panels 24 and 26 foldably 
attach to edges of a pair of adjacent end panel 20 and side panel 22. The 
corner panels 24 and 26 fold along an interior score 28 (best shown in 
FIG. 2) to define triangular wings 30 which overlap outside the respective 
end panel 20. The corner panels 24 and 26 each include a hole 32 (best 
shown in FIG. 2). The holes 32 form the hand grips 12 in the triangular 
wings 30. The present invention positions the hand grips 12 exterior of 
the end panels 20 which define end walls of the container 10, so there is 
no opening through the wall of the container. 
An inside end panel 36 foldably attaches with a pair of spaced apart scores 
38 to each of the second corner panels 26 on a first side 40 of the 
container 10. The scores 38 in each inside end panel 36 define a cover 
panel 42. The cover panel 42 covers the upper edges of the folded 
triangular wings 30, as illustrated in FIG. 1. A flap 44 foldably attaches 
by a score 46 to one edge of the inside end panel 36. When the container 
10 is folded together, the flap 44 is brought firmly into contact with the 
bottom panel 18, as illustrated in cut-away view, for a purpose discussed 
below. A notch 48 extends from the corner panel 26 along a portion of the 
edge of the inside end panel 36, for a purpose discussed below. 
A top panel 50 foldably attaches along a score 52 to the side panel 22 on 
the first side 40 of the container 10. A tab 54 foldably attaches to the 
top panel 50 along a score 56. In the illustrated embodiment, the tab 54 
extends substantially the length L of the top panel 50 with a gap 57 at 
each end. This defines a lip 58 on each of the longitudinal ends of the 
top panel 50, for a purpose discussed below. 
The strap 16 comprises an elongate ribbon 60 having a J-shaped hook 62 
attached at each distal end. The hooks 62 each have an interior lip 64 
which is received in the hand grip 12 between the end panel 20 and the 
folded triangular wings 30 for carrying the container 10, as discussed 
below. The hooks 62 each have an exterior arm 66 which attaches in a 
conventional manner to the ribbon 60, such as with a ring 68, clip, or the 
like. The ribbon 60 can be made of a fabric or plastic fiber material. 
FIG. 2 illustrates a plan view of a blank 70 of corrugated paperboard for 
folding on scores to form the container 10 illustrated in FIG. 1. The 
blank 70 includes the bottom panel 18 with two end panels 20 and two side 
panels 22 foldably attached to the edges thereof by scores 72 and 74. The 
edges of a pair of adjacent side panel 22 and end panel 20 are connected 
by the corner panel 24 and the corner panel 26 on respective sides of the 
container 10. The corner panels 24 and 26 fold along the scores 72 and 74 
which extend edge-to-edge longitudinally and laterally across the blank 
70. 
Each corner panel 24 and 26 includes a diagonal score 28 that extends from 
a corner 78 to the edge of the bottom panel 18 at the respective 
intersections 80 of the scores 72 and 74. The diagonal score 28 divides 
the corner panels 24 and 26 into a pair of triangular sections 77 and 79. 
The triangular sections 77 and 79 fold on the score 28 to form the 
triangular wing 30 (shown in FIG. 1.) In the illustrated embodiment, the 
corners 78 each have a rectangular notch 82 which facilitates folding the 
corner panels 24 and 26 along the score 28. The width W of the corner 
panels 24 and 26, for example, from the score 74 and an edge 84, is 
preferably less than that of the side panels 22, thereby facilitating 
folding the blank 70 to form the container 10, as discussed below. A slot 
86 aligned with the score 74 extends inwardly from an edge 88 between the 
corner panel 24 and the end panel 20, for a purpose discussed below. 
The corner panels 24 and 26 each include a hole 32. The holes 32 in 
respective corner panels 24 and 26 cooperate to form the hand grip 12 when 
the blank 70 is folded to form the container 10. In the illustrated 
embodiment, the holes 32 are square. The holes 32 in the illustrated 
embodiment are symmetrical about the diagonal score 28. In an alternate 
embodiment (not illustrated), the holes are non-symmetrical about the 
diagonally score 28. A pair of first sides 92 in the hole 32 define the 
upper edge of the hand grip 12; the pair of second sides 94 define the 
side edge of the hand grip 12. In an alternate embodiment (not 
illustrated) the first sides 92 define arcs, so that the upper edge of the 
resulting hand grip is curved. In an alternate embodiment, the holes 32 
are rectangular with the first sides 92 longer than the second sides 94. 
This results in a relatively wide hand grip 12. 
In the illustrated embodiment, the holes 32 are positioned near the center 
of each of the corner panels 24 and 26. When the blank 70 is folded, the 
hand grip 12 defined by the holes 32 are thereby positioned just below the 
longitudinal axis of the container 10. This facilities balancing the 
container 10 for carrying. In an alternate embodiment (not illustrated), 
the holes 32 are positioned so that the hand grips 12 are closer to the 
top of the container 10. 
The inside end panel 36 attaches along the pair of spaced-apart scores 38 
to the corner panel 26. The parallel scores define the cover panel 42. The 
flange 44 foldably attaches to the inside end panel 36 along the score 46. 
The notch 48 extends along a portion of the edge of the inside end panel 
36 from the inner score 38 towards the flange 44, for a purpose discussed 
below. 
The top panel 50 attaches to the side wall 20 on the first side 40 along a 
score 52. The tab 54 foldably attaches along the score 56 to the top panel 
50. 
The blank 70 is preferably made of a single flute corrugated paperboard 
comprising a 42 pound outer liner, a 33 pound medium having flutes, and a 
56 pound inner liner. Such corrugated paperboard is commonly known in the 
industry. The blank 70 is formed by passing the liners and medium through 
a corrugator which glues the liners and the medium together, preferably 
with a waterproof adhesive. In a preferred embodiment, the medium is wax 
impregnated before the corrugator adheres the three layers together. 
The blank 70 is then die-cut. This step in the manufacturing process prints 
the graphics (if any) on the blank, cuts the holes 32, and cuts the 
scores. 
A film of wax and polyethylene is then applied to the planar surfaces of 
the blank. This process is known in the industry as curtain coating. The 
coated film is a moisture barrier that makes the corrugated paperboard 
water resistant. In industry trade terminology, this corrugated paperboard 
is known as leak-proof board. The wax in the curtain coat and on the 
flutes in the medium form the moisture barrier which resists fluid 
transfer through the board 70 comprising the walls and bottom of the 
container 10. The boards 70 are in a knock-down position, and are readily 
shipped from the manufacturing plant to distribution and sales facilities. 
To use the container 10 of the present invention, the blank 70 is folded on 
the scores 74 to raise the side panels 22 perpendicular to the bottom 
panels 18. The end panels 20 are then raised by folding upwardly along the 
scores 72. As the side panels 22 are raised, the corner panels are folded 
along the scores 28 to form the triangular wings 30. The corner panel 24 
in its folded triangular shape is then folded along the score 74 against 
the end panel 20. The corner panel 26 in its folded triangular shape is 
then folded along its respective score 74 against the corner panel 24. The 
holes 32 are thereby aligned on the end 14 of the container 10. The holes 
32 form the hand grip 12 exterior of the container 10, as shown in FIG. 1. 
The inside end panel 36 is folded on the scores 38 with the cover panel 42 
extending over the upper edges of the corner panels 24 and 26. The reduced 
width of the corner panels provides a gap for receiving the cover panel 
42. The inside end panel 36 folds inwardly of the container 10 and against 
the inside surface of the end panel 20. The flange 44 is folded along the 
score 46 to firmly contact the bottom panel 18 as the inside end panel 36 
is positioned against the end panel 20. The inside end panel 36 and the 
flange 44 against the bottom panel 20 cooperate to lock the corner panels 
24 and 26 against the end panel 18. The corner panels 24 and 26 on the 
second end 14 of the container are like-wise folded along the scores and 
against the end panel, as illustrated in FIG. 1. 
The top panel 50 folds along the score 52 towards the opposite side of the 
container 10 to close the open interior of the container. The tab 54 
inserts inwardly of the opposite side 20 and is gripped in the notch 48 
and the slot 80 which together form a slot at each end 14 of the container 
10. The notch 48 and the slot 80 hold the tab 54 in order to hold the top 
panel 50 closed. The lip 58 on lateral sides of the top panel 50 extend 
outwardly over the cover panel 42. 
The container 10 can then be opened and filled with ice and canned or 
bottled beverages and food, for use as a cooler. The ice keeps the 
beverages and food cold. The curtain coating of the blank 70 resists 
moisture penetration through the walls of the container 10. The walls have 
no openings through which fluid can flow and which reduce the thermal 
efficiency of the container 10. The hand grips 12 are exterior of the 
walls of the container 10, and are grasped by the hand of a user to carry 
the cooler. 
In the illustrated embodiment, a strap 16 is provided for carrying the 
container "over the shoulder" of the user. The J-hooks 62 are engaged with 
the hand grips 12 by sliding the interior lip 64 between the end panel 20 
and the corner panels 24 and 26 so the upper edge of the hand grip 12 
catches on the hook. The exterior arm 66 is outside the corner panel 26, 
and the container 10 can then be carried by looping the strap 60 over the 
shoulder of the user. 
The specification has thus described various embodiments, including a 
preferred embodiment, of the present invention, including the assembly and 
use thereof. It is to be understood, however, that numerous changes and 
variations may be made in the construction of the present invention. It 
should therefore be further understood that modification of the present 
invention may be made without departing from the scope thereof as set 
forth in the appended claims.