Container and method for manufacture thereof

A container having a housing enclosing an internal compartment and having a wall bounding the compartment with an opening therein and a substantially transparent band for extending across the opening for retaining the container in a sealed condition after filling while permitting viewing of the contents of the compartment through the band. A method for the manufacture of a container including the steps of forming a pair of end walls by adhesively bonding a plurality of corrugated panels in facing relation to each other to form the end walls with the flutes thereof disposed in substantially parallel relation to each other; sawing the end walls to form end walls having end surfaces substantially normal to the panels; positioning the end walls in spaced, substantially parallel relation; extending a wrapper having lid portions about the end walls in adhesive attachment thereto with the lid portions movable between opened positions for filling the container and closed positions having portions disposed in spaced relation to each other to define an opening; and, after filling the container as formed, sealing the container by extending a substantially transparent strip of tape across the lid portions and the opening to retain them in the closed positions and forming a window for viewing the contents of the container through the opening.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates to a container and method for manufacture 
thereof and more particularly to such a container and method which result 
in a container which obviates the problems associated with conventional 
containers including the impossibility of examining the contents of such 
conventional containers without damaging them, the collapsing of 
palletized stacks of containers while in cold storage, the difficulty in 
interfitting containers within the stacks thereof and a multiplicity of 
other problems incident to the manufacture and use of associated with 
conventional containers. 
2. Description of the Prior Art 
The use of containers of a variety of types employed in the packing, 
shipping and storage of fungible goods, and particularly perishable goods 
such as fresh fruit, fresh vegetables and the like, is compromised by 
problems inherent in the manufacture and use of such containers. In the 
packing of perishable goods such as fresh fruit and fresh vegetables, 
millions of containers of a variety of types are employed each season. The 
cost of containers must be balanced against their dependability in use and 
this has resulted in the production and use of containers of a host of 
different designs and construction materials. Since the containers are 
disposable, one of the most cost efficient construction materials has been 
corrugated cardboard or fiberboard. Such containers typically consist of a 
pair of end panels about which is folded a wrapper whose end portions form 
top panels or lid portions for the container and are sealed into position 
using a suitable adhesive. The most common form of adhesive presently in 
use in the fabrication of conventional containers is known as a "hot melt" 
adhesive which is applied mechanically. While methods and apparatuses for 
applying such adhesive work adequately in normal operation, they are 
subject to a host of difficulties including maintaining the heat of the 
adhesive at the appropriate temperature, avoiding plugging of the 
dispensing mechanisms, uneven application and the like. 
Such conventional containers may be shipped to the end user, or packer, in 
flattened blanks and assembled mechanically in the plant just prior to 
packing, or may be assembled by the box manufacturer leaving the lid 
portions open for packing and sealing by the packer. In any case, the 
above noted problems with hot melt adhesives are experienced by the packer 
in sealing the containers once packed. Such adhesives are normally applied 
to the side flaps of the lid portions of the container and mechanically 
folded downwardly into engagement with the side walls as the filled 
containers are transported along an assembly line. In a sealed container, 
the juxtaposed marginal edges of the lid portions are typically not 
adhesively bonded and therefore serve as an entry point for dust, dirt, 
pests and the like as well as presenting a convenient gripping point for 
ripping the containers open in unauthorized entry. Furthermore, the 
strength of the container is compromised by such construction. Upon 
receipt at the point of destination after shipping, there is no way for 
the contents of the container to be examined without inflicting permanent 
damage to the container. 
Another problem with containers of this type becomes apparent when the 
containers are stacked, as is the conventional practice, for storage and 
shipment. This problem is particularly acute where such containers are 
stacked in cold storage. The combined weight of the stacked containers 
causes them individually to collapse under load crushing some or all the 
contents of the containers and the stack ultimately to lose its integrity. 
It is not uncommon for palletized stacks to collapse in storage resulting 
in the substantial or total loss of the contents thereof. The moisture in 
the humid environment to which such stacks of containers are exposed in 
cold storage is absorbed by the containers over time causing the 
corrugated cardboard to lose its rigidity and fail in the manner 
described. Since typically such prior art containers are formed by folding 
along score lines, cutting of panels along courses and other such 
conventional assembly processes, the flutes of the corrugations are 
frequently crushed, flattened, or otherwise weakened so that the resulting 
containers are frequently of weakened and irregular configurations, 
particularly on the folded portions which constitute the load bearing 
portions of the containers. In stacks of such containers, the irregular 
load bearing portions, weakened side walls, and the absorption of moisture 
all contribute to structural failure. 
In an effort to enhance the integrity of stacks of such containers, it has 
been known to use standardized containers having predefined projections 
which interfit in corresponding slots in adjacent containers to interlock 
the containers within the stack. However, typically such container 
construction necessitates that each container individually be lifted into 
a position of precise registry with the lower container before being 
rested thereon so that the projections and slots register with each other. 
However, in actual practice many of the containers are partially or 
entirely positioned by sliding on the lower container and against the 
projections. This practice damages the projections and frequently tears 
the containers. Commonly the containers do not reach the position of 
registry for which they were designed. 
Therefore, it has long been known that it would be desirable to have a 
container and method for manufacture thereof in which the lid portions are 
provided with more supporting strength than has heretofore been possible, 
which permit the contents of a sealed container to be examined without 
opening or damaging the container, which produce a container having 
greater vertical strength than is conventionally the case at a cost which 
is consistent with that of conventional container; which dependably 
possess the predetermined configuration of their design within 
substantially closer tolerances, particularly on the load bearing portions 
thereof; and which have interlocking portions which can be slidably 
interfitted without damage to the containers or interlocking portions. 
SUMMARY OF THE INVENTION 
Therefore, it is an object of the present invention to provide an improved 
container and method for manufacture thereof. 
Another object is to provide such a container and method which obviate many 
of the problems associated with conventional containers used in packing, 
shipping and storing fungible goods, and particularly perishable products 
such as fresh fruit, fresh vegetables and the like. 
Another object is to provide such a container and method which produce a 
container which allows examination of the contents thereof without opening 
the container, breaking the seal thereof, or otherwise damaging the 
container. 
Another object is to provide such a container and method which permit the 
lid portions of the container to be strengthened over conventional 
containers without in any respect departing from any advantages associated 
with conventional containers while at the same time preventing an influx 
of dust, dirt, pests and the like to the container through the lid 
portions. 
Another object is to provide such a container and method which result in 
the production of the container having substantially greater strength at 
little or no increase in cost and, more particularly, having strengthened 
load bearing portions permitting a multiplicity of such containers to be 
stacked in palletized form reducing to an absolute minimum any possibility 
that the palletized stack will fail in any manner even during prolonged 
cold storage. 
Another object is to provide such a container and method which permit the 
containers to be constructed within substantially closer tolerances such 
that the containers possess a regularity of form not heretofore achieved 
in the art. 
Another object is to provide such a container and method which result in a 
container which possesses an interlocking capability, but which need not 
be lifted and positioned precisely for interlocking with an adjacent 
container. 
Another object is to provide such a container and method which avoid the 
use of hot melt adhesives in the sealing of the lid portions thereof and 
the attendant problems associated therewith. 
Another object is to provide such a container and method which result in 
the production of a container which readily reveals when it has been 
tampered with, but which can instantly be opened without any damage 
whatsoever to the container or to the contents thereof. 
Further objects and advantages are to provide improved elements and 
arrangements thereof in an apparatus for the purposes described which is 
dependable, economical, durable and fully effective in accomplishing its 
intended purposes. 
These and other objects and advantages are achieved in the container of the 
preferred embodiment having a housing enclosing an internal compartment 
and having a wall bounding the compartment having an opening therein; and 
substantially transparent means obstructing the opening permitting viewing 
of the contents of the compartment therethrough.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring more particularly to the drawings, the container of the present 
invention is generally indicated by the numeral 10 in FIG. 1. While the 
container of the present invention can take a wide variety of forms, the 
container of the preferred embodiment has a variety of advantages believed 
well suited to the packing, shipping and storage of perishable goods such 
as fresh fruit, fresh vegetables and the like. It will, however, be 
understood that the container can be manufactured and employed in a 
variety of different forms for receiving a wide variety of different goods 
without departing from the invention hereof. 
The container 10 has opposite end walls 11 which are substantially 
identical both in construction and size. Each end wall has an upper 
marginal edge 12, a lower marginal edge 13 parallel thereto, and opposite 
inner face 16, the terms "outer" and "inner" having reference to their 
respective positions in the container once manufactured. As will 
hereinafter be discussed in greater detail, the marginal edges 12 and 13 
are substantially precisely right-angularly related to the opposite 
lateral edges 14. Similarly, the marginal edges 12 and 13 and the lateral 
edges 14 define substantially flat planes individually right-angularly 
related to the outer and inner faces 15 and 16. 
Each opposite end wall 11 is constructed, in the preferred embodiment, of 
three corrugated panels 20 each having rectangular peripheral edges 21 
coincident with their respective marginal edges 12 and 13 and lateral 
edges 14 of their respective opposite end walls. Each corrugated panel has 
a plurality of substantially parallel internal flutes 22 which, in 
assembled form, extend in right angular relation to and between the upper 
marginal edge 12 and the lower marginal edge 13 of the end wall 11. The 
panels are adhesively bonded together in facing engagement to form each 
end wall as heretofore described. 
The container 10 has a container wrapper 30, best shown in FIG. 4. The 
container wrapper in the preferred embodiment is formed from a blank of 
corrugated cardboard material having opposite terminal edges 31 and 
opposite lateral edges 32. Lateral score lines 33 are formed in the 
wrapper and are interconnected by transverse score lines 34 extended 
therebetween in positions substantially right-angularly related to the 
lateral score lines. The lateral score lines form opposite bottom flaps 35 
and opposite side flaps 36, extending outwardly therefrom, as can best be 
seen in FIG. 4. The transverse score lines define a rectangular bottom 
panel 37 of predetermined size, opposite side panels 38 and top or lid 
panels 39. 
In the preferred embodiment of the container 10, the side panels 38 have a 
plurality of air vents 45 formed therein to allow air circulation to the 
contents of the container. The air vents have particular utility where the 
contents to be placed in the container may be perishable goods such as 
fresh fruit or fresh vegetables. The lid panels 39 are severed along 
courses to define projections 46 extending, in a packed and sealed 
container 10, upwardly at right angles to the sealed lid panels, as best 
shown in FIGS. 1, 2 and 3. Similarly, the side panels 38 and bottom panel 
37 are severed in predetermined positions corresponding to the positions 
of the projections in the assembled container to form receptacles or slots 
47 which extend through the score lines 34 between the bottom panel and 
the respective side panels, as best shown in FIG. 4. As will hereinafter 
be described in greater detail, in a stack of the containers 10 the 
projections of a lower container are adapted individually to interfit with 
the slots 47 of an upper container rested thereon so as to interlock the 
containers. Similarly, since the projections extend upwardly from the 
score lines 34 and the slots 47 extend through their respective score 
lines 34, the upper container can be slidably moved into place on the 
lower container so that the projections of the lower container interfit in 
the slots of the upper container. This is not possible in conventional 
container construction. 
The lid panels 39 have convergent portions 48 which, in the assembled 
container 10, overlay the upper marginal edges 12 of the opposite end 
walls 11 in juxtaposition to each other. In the assembled and sealed 
container, the opposite terminal edges 31 of the wrapper 30 and the 
convergent portions 48 of the lid panels define a window opening 49, best 
shown in FIG. 1. 
The container 10 in the assembled and sealed configuration employs a 
transparent band, preferably transparent pressure sensitive tape 55. The 
tape has opposite end portions 56, a lower adhesive surface 57 and an 
upper surface 58. As can best be seen in FIG. 1, in the sealed container 
10 of the present invention, the opposite end portions 56 of the tape 
extend downwardly about the outer faces 15 of the end walls 11 and across 
the lid panels 39 in covering relation to the opposite terminal edges 31 
and the convergent portions 48 of the lid panels. 
OPERATION 
The operation of the described embodiment of the present invention is 
believed to be readily apparent and is briefly summarized at this point. 
The container 10 can be assembled at the main plant of the manufacturer 
requiring only that it be filled and sealed by the end user or packer. 
Alternatively, the container can be shipped in flattened, blank form to 
the end user and assembled at the site prior to such filling and sealing. 
In either case, the components of the container can be assembled using 
conventional assembly equipment to produce the container in the form as 
shown in FIG. 1 except that the lid panels 39 are not sealed and thus can 
be disposed in either opened or closed positions. 
In both cases, the method for manufacture of the present invention calls 
for the opposite end walls 11 to be formed by sawing from a larger piece 
of such sheet material. The sheet material is composed, in the preferred 
embodiment, of three corrugated panels 20 adhesively bonded together so 
that the flutes 22 thereof are aligned in a common direction. This 
threeply sheet material can either be purchased in this form from a 
supplier or fabricated in the plant. Once the sheet material is formed as 
described, the end walls 11 are individually formed by sawing the sheet 
material along courses corresponding to the upper marginal edge 12, lower 
marginal edge 13 and lateral edges 14. The attitude of the saw during the 
sawing operation is at right angles to the outer face 15 and inner face 16 
of the resulting end wall. This method for forming the end walls has been 
discovered not to crush or otherwise damage the flutes 22 of the 
corrugated panels comprising the end wall and to form precisely configured 
surfaces about which the wrapper 30 can be extended in accordance with the 
method of the present invention to form a container having substantially 
closer tolerances to the predesigned configuration and size for the 
container 10. The container wrapper 30 is constructed from a blank of 
corrugated cardboard which, in accordance with the method hereof, is 
severed along the opposite terminal edges 31 and the opposite lateral 
edges 32 while being scored along the lateral score lines 33 and 
transverse score lines 34, as shown in FIG. 4 to form the components of 
the wrapper heretofore described. Similarly, the wrapper is severed to 
form the air vents 45, projections 46 and slots 47. 
As previously noted, the container 10 can be assembled further in the 
manufacturing plant or the wrappers 30 in flattened form and the end walls 
11 can be bundled and shipped to the end user, typically a packer, for 
assembly there. In either case, the actual assembly of the components 
heretofore described to form an unsealed container is performed using 
conventional equipment well known in the art. 
The end walls 11 of each container are placed in predetermined spaced 
relation so that the interior faces 16 of the end walls face each other. 
The wrapper 30 is subsequently extended about the end walls, as 
illustrated in FIG. 4, so that the side panels 38 individually facingly 
engage the lateral edges 14 of the end walls, the bottom panel 37 facingly 
engages the lower marginal edges 13 of the end walls and the lid panels 39 
are left open. Adhesive is applied to the inner surfaces of the opposite 
bottom flaps 35 and the opposite side flaps 36 and the flaps are folded 
into facing engagement with the respective outer faces 15 of the end walls 
11. Pressure is applied so that proper adhesion is achieved and an opened 
container is so formed. 
Typically in a commercial operation, the containers 10 are packed with 
fresh fruit or fresh vegetables using conventional mechanical packing 
machines which fill the interior compartment of each container during 
passage along a packing line. In any case, the interior compartment of 
each container is filled with contents and, typically, the lid panels 39 
are folded downwardly mechanically in such a machine. In any case, whether 
done manually, or mechanically, the lid panels are folded downwardly into 
facing engagement with the upper marginal edges 12 of the end walls 11. As 
shown in FIG. 1, the convergent portions 48 of the lid panels are thus 
disposed in juxtaposition, leaving the window opening 49 to expose the 
contents of the container. 
Thereafter, manually or by any suitable mechanical equipment, a strip of 
transparent pressure sensitive tape 55 is extended across the lid panels 
39 overlapping the opposite terminal edges 31 and across the window 
opening 49 in adhesive engagement with the lid panels. The opposite end 
portions 56 of the tape is folded downwardly into sealing engagement with 
the outer faces 15 of the end walls 11. This securely retains the lid 
panels in sealed condition while leaving the contents of the container 
visible through the tape as permitted by the window opening 49. The tape 
additionally improves the strength of the container over conventional 
containers in that a seal is formed entirely across the top of the 
container. Where the end user, or packer, has purchased the containers in 
assembled, opened condition, there is in addition no requirement for the 
use of hot melt adhesive in sealing the container since only the 
transparent pressure sensitive tape is employed for sealing the lid 
panels. This avoids all of the problems associated with the use of such 
hot melt adhesives. Still further, the use of the tape provides a seal 
serving as a barrier against the influx of dust, dirt, pests and the like 
through the top of the container. 
The packed and sealed containers 10 are typically stacked in palletized 
form. When this is done, the projections 46 and slots 47 serve to 
interlock the containers in the stack. However, as previously noted, 
unlike conventional containers, the upper container being moved to an 
interlocking position can slidably be moved across the top of the lower 
container if desired. Since the projections extend upwardly from the sides 
of the container below, the upper container can slide therebetween, but 
once the projections are aligned with the slots 47, they will typically 
pop into position in their respective slots to interlock the containers. 
The transparent pressure sensitive tape 55 additionally serves to afford a 
low coefficient of friction to facilitate slidable positioning of the 
upper container on the lower container. 
It has been found that the construction of the end walls 11 heretofore 
described composed of three adhesively bonded corrugated panels 20 having 
vertical flutes 22, substantially increases the strength of the container 
under vertical load and this is particularly important in a palletized 
stack permitting more of the containers to be stacked on top of each 
other. Since the end walls provide the main load bearing strength to the 
containers, the upper and lower marginal edges 12 and 13 thereof form 
precise planar surfaces normal to the end walls and the flutes 22 are 
vertically oriented, strength is substantially enhanced. Still further, 
sawing of the end panels during construction, prevents damage to the 
flutes which in conventional construction methods weakens the resulting 
container. Finally, the precise formation of the end walls using the 
sawing step heretofore set forth, produces a container which has much 
closer tolerances than has heretofore been possible. This, in itself, 
increases the strength of the resulting containers, particularly in a 
stack of the containers. 
The containers 10 so packed and sealed, are capable of being stacked in 
cold storage for prolonged periods of time, shipped over great distances 
under adverse conditions, and otherwise serve to protect the contents to 
the maximum extend. Upon arrival at a destination point, anyone wishing to 
check the contents of the container for the quality and condition of the 
contents thereof can easily do so through the window opening without 
breaking the seal on the container. This is important where purchase is 
conditioned on the condition of the contents upon arrival. Such 
observation can be achieved without ever opening the container and so if 
the product is unacceptable it is quickly determined. In this way, some or 
all of the shipment can be rejected without in any way damaging the 
container or its contents. 
Nonetheless, when it is desired to open the container 10, this is easily 
accomplished with a pocketknife, or even automobile keys by sliding the 
knife or key along the pressure sensitive tape 55 over the window opening 
49 to slice the tape without in any way damaging the contents of the 
container. The tape is simply sliced longitudinally thereof and between 
the convergent portions 48 of the lid panels 39 and the upper marginal 
edges 12 of the end walls. This frees the lid panels 39 for opening and 
the container remains entirely intact. Should it be desired to seal the 
container again, this is simply accomplished by applying a new strip of 
pressure sensitive tape 55 across the lid panels and window opening to 
again seal the container. However, if the container has been tampered 
with, the severed portions of the original transparent pressure sensitive 
tape 55 will reveal that this has taken place, whether the container is 
again sealed or not. 
Therefore, the container and method for manufacture thereof of the present 
invention provide a container in which the lid portions are provided with 
more supporting strength than has heretofore been possible; which permits 
the contents of the sealed container to be examined without opening or 
damaging the container; which produces a container having greater vertical 
strength than is conventionally the case at a cost which is consistent 
with that of conventional containers; which dependably possesses the 
predetermined configuration of the original design within substantially 
closer tolerances, particularly on the load bearing portions thereof; and 
which has interlocking portions which can slidably be interfitted without 
damage to the containers or the interlocking portions. 
Although the invention has been herein shown and described in what is 
conceived to be the most practical and preferred embodiment, it is 
recognized that departures may be made therefrom within the scope of the 
invention which is not to be limited to the illustrative details disclosed 
.