Fruit and produce container

An improved fruit and product container has a bottom and two side walls formed of a common piece of corrugated cardboard and two end walls formed of laminated paperboard attached to the bottom and side walls so as to define a box. The two laminated paperboard end walls enhance the stacking strength and moisture resistance of the container. Optionally, a top removably attaches to stacking alignment tabs extending upwardly from the end walls.

FIELD OF THE INVENTION 
The present invention relates generally to containers and more particularly 
to an improved fruit and produce container used to store and transport 
fruit, produce, and the like. 
BACKGROUND OF THE INVENTION 
Containers for transporting fruit and produce, such as grapes and the like, 
from the fields where they are grown to markets where the fruit or produce 
is purchased by consumers, are well known. Such containers are generally 
formed of either wood or corrugated cardboard. Wood containers resist 
degradation due to handling and/or moisture absorption substantially 
better than those formed of corrugated cardboard and are thus structurally 
superior thereto. 
However, the cost of shipping produce is proportional to the weight 
thereof, including the container. The use of the heavier wood containers 
therefore results in substantially greater shipping expense. As such, 
because wood containers are substantially heavier than corrugated 
cardboard containers, the cost to ship produce contained therein is 
substantially greater. 
Additionally, wooden containers are comparatively more expensive to 
manufacture than corrugated cardboard containers. Reuse of wood containers 
is prohibited because wood absorbs harmful bacteria which cannot be 
efficiently removed therefrom. Furthermore, wood containers cannot be 
recycled, whereas corrugated cardboard produce containers can be recycled 
into various paper products. 
Because the cost of storage and shipping of fruit and produce is, at least 
in part, further determined by the amount of floor space occupied thereby, 
it is commonly necessary that containers be configured in relatively high 
stacks so as to minimize the floor space occupied thereby. Thus, it is 
necessary that such containers possess sufficient structural strength to 
support the weight of those containers stacked above. 
When corrugated cardboard containers are stacked, it is common for lower 
stacked corrugated containers to splay or spread apart such that at least 
some of the four corners of those containers stacked above tend to slide 
into the lower containers and thereby damage the produce contained 
therein. Also, degradation of such lower containers frequently results in 
collapse of the entire stack, thereby further increasing the amount of 
damage to the fruit or produce contained therein. Thus, it is desirable 
that the structural integrity of such containers be maintained so as to 
prevent damage to the contents of such containers. 
Transportation of the fruit and produce containers commonly exposes them to 
moisture which tends to deteriorate or degrade the containers, 
particularly those comprised of corrugated cardboard. Handling of the 
containers during the loading and unloading processes subjects them to 
impacts which may cause damage thereto. Wetted corrugated cardboard 
containers are particularly susceptible to such damage. 
Also, when a vehicle transporting the containers turns, the inertia of the 
containers tends to cause the stacks to twist or sway, thereby increasing 
the forces applied thereto, particularly to those containers at or near 
the bottom member of the stack. Such forces may thus cause damage to the 
stacked containers. Wetted corrugated cardboard containers are 
particularly susceptible to such damage. 
The fruit or produce contained within such stored and/or transported 
containers is frequently wet. Fruit and produce may be picked wet or may 
sweat and thereby release moisture during shipping and storage. Also, 
ambient moisture may condense upon the product and/or container. Such 
ambient moisture is typically absorbed by corrugated cardboard containers, 
thus causing structural degradation thereof. 
Although it is known to add plastic reinforcements to contemporary 
corrugated cardboard containers, the use of such plastic reinforcements 
presents certain inherent problems. For example, the plastic 
reinforcements must be purchased and then installed in the corrugated 
cardboard cartons prior to their use, thus adding to the cost thereof. 
Additionally, in order to facilitate recycling of the cardboard comprising 
the corrugated cardboard cartons, the plastic reinforcements must be 
removed therefrom. Removal of the plastic reinforcements from the 
corrugated cardboard cartons is labor intensive and thus adds 
substantially to the costs associated with their use. 
Prior art corrugated produce containers are frequently configured such 
that, when stacked, channels are formed therebetween and thereinto in 
order to facilitate adequate ventilation of the produce contained therein 
and to insure effective control of the environment, i.e., temperature and 
humidity. Uppermost and lowermost longitudinal corners of the containers 
may be beveled in order to form air conduits in the region where four 
stacked containers abut. Apertures formed along the bevel of each 
container facilitate air flow from the conduit into the container. By 
utilizing the conduits formed by such bevels and apertures, the 
application of pesticides and the like or inert gasses reduces the 
likelihood of insect infestation and/or the growth of fungus. Two examples 
of contemporary containers having such bevels and apertures are those 
produced by Maxco, of Reedley, Calif. and those produced by Weyerhauser of 
Bakersfield, Calif. 
However, in forming such bevels, the structural strength, i.e., the ability 
to withstand stacking, of the containers is substantially reduced and the 
problems associated with wetting of the containers is exacerbated. Thus, 
the use of such bevels to form conduits further decreases the useful life 
of corrugated cardboard containers. 
Stacking alignment tabs are typically formed along the upper edge of each 
end member of the produce containers. The stacking alignment tabs are 
configured to be received within cut-outs formed along the lower edge of 
each of the containers in order to facilitate stacking thereof. When 
containers are stacked one atop another, the stacking alignment tabs of 
the lower container are positioned within the cut-outs of the upper 
container, thereby assuring proper alignment of the containers in order to 
form a straight vertical stack. This interlocking of adjacent containers 
also makes each stack more stable and thus less likely to topple over. 
The storage life of produce stored within such containers is typically not 
limited by degradation of the fruit contained therein, but rather is often 
limited by the storage life of the corrugated cardboard containers 
themselves. Degradation of the corrugated cardboard containers due to 
handling and the absorption of moisture commonly prevents such containers 
from being used for extended periods of time. 
In light of the problems associated with transporting and storing produce 
in corrugated cardboard containers, it is desirable that contemporary 
containers be improved in some manner so as to increase the structural 
strength thereof. It is important, however, that the means utilized to 
increase the strength of the corrugated cardboard containers not add 
significantly to the weight, bulk, or to the cost of manufacturing the 
containers. Thus, the design of such improved corrugated cardboard 
containers must lend itself to simple and inexpensive mass production 
techniques. 
The improved containers should be as simple in design as possible and 
should be comprised of inexpensive materials. The entire container should 
be recyclable without the need to separate any portion of the container 
therefrom. By simplifying the design of the container, automation of the 
fabrication process is maximized and the cost associated therewith 
minimized. 
Furthermore, it is desirable that the container resist degradation due to 
the presence of moisture. Thus, it is desirable that the strength of the 
materials utilized in the fabrication of the container not be affected by 
the absorption of moisture. 
As such, although the prior art has recognized to a limited extent the 
problem of increasing the strength of corrugated cardboard containers, the 
proposed solutions, to date, have been ineffective in providing a 
satisfactory remedy. 
SUMMARY OF THE INVENTION 
The present invention addresses and alleviates the above-mentioned 
deficiencies associated with the prior art. More particularly, the present 
invention comprises an improved fruit and product container comprising a 
bottom and two side walls formed of a common piece of corrugated 
cardboard, and two end walls formed of laminated paperboard attached to 
the bottom and end walls so as to define a box. The use of laminated 
paperboard end walls enhances the stacking strength and moisture 
resistance of the container. 
The container preferably further comprises two top flaps, one top flap 
formed at the upper end of each end wall such that each top flap and its 
associated end wall are formed of a common piece of laminated paperboard 
and such that the top flaps rest upon the side walls. A single piece of 
laminated paperboard is scored so as to define each top flap and its 
associated end wall. The top flaps enhance the stacking strength of the 
carton and also help maintain the contents of the carton therein while 
mitigating the introduction of undesirable debris. The top flaps also help 
prevent cartons stacked above from sliding into those stacked below. 
The container preferably further comprises stacking alignment tabs 
extending upwardly from the end walls and formed of a common piece of 
laminated paperboard therewith. 
The container preferably further comprises two side flaps formed upon each 
end wall, one side flap extending perpendicularly from each side of the 
end wall and attaching to a side wall, each side flap further enhancing 
the stacking strength of the container. 
The container preferably further comprises a top which is removably 
attachable thereto. The top preferably comprises two openings formed 
therein and configured to receive the stacking alignment tabs. The 
stacking alignment tabs are preferably configured so as to engage the 
openings formed in the top in order to removably attach the top to the end 
walls. The stacking alignment tabs preferably comprise notches formed 
therein so as to receive portions of the periphery of the openings formed 
therein, so as to effect such removable attachment of the top to the end 
walls. The top preferably further comprises end flaps extending downwardly 
therefrom along the end walls. 
The container preferably further comprises slots formed at perpendicular 
intersections of the bottom and side walls. Openings are preferably formed 
intermediate the stop and side walls. The slots cooperate with the 
openings of stacked boxes to form conduits which facilitate the 
introduction of desired gases into such stacked containers. 
Forming the slots at the perpendicular intersection of the bottom and side 
walls further enhancing the stacking strength of the container by 
eliminating the beveled intersection of the bottom and side walls of prior 
art containers. Those skilled in the art will recognize that 
perpendicularly intersecting bottom and side walls possess substantially 
greater stacking strength than do beveled intersections. 
The cartons are preferably configured to have lengths and widths which 
facilitate efficient stacking upon pallets. For example, the containers 
may optionally be configured to define a 4.times.5 carton array upon a 
conventional 40-inch by 48-inch pallet. A 5.times.4 carton array could 
then be stacked atop the 4.times.5 carton array and the stacking sequence 
then repeated, i.e., providing alternating stacked 4.times.5 and 5.times.4 
carton arrays, so as to provide stable stacks. 
These, as well as other, advantages of the present invention will be more 
apparent from the following description and drawings. It is understood 
that changes in the specific structure shown and described may be made 
within the scope of the claims without departing from the spirit of the 
invention.

DETAILED DESCRIPTION OF THE INVENTION 
The detailed description set forth below in connection with the appended 
drawings is intended as a description of the presently preferred 
embodiment of the invention, and is not intended to represent the only 
form in which the present invention may be constructed or utilized. The 
description sets forth the functions and sequence of steps for 
constructing and operating the invention in connection with the 
illustrated embodiment. It is to be understood, however, that the same or 
equivalent functions and sequences may be accomplished by different 
embodiments that are also intended to be encompassed within the spirit and 
scope of the invention. 
The improved fruit and product container of the present invention is 
illustrated in FIGS. 1-7 which depict a presently preferred embodiment of 
the invention. Referring now to FIGS. 1-7, each improved fruit and produce 
container 10 is comprised generally of a bottom 12 and two side walls 14 
formed of a common piece of corrugated cardboard. Two end walls 16 are 
formed of laminated paperboard attached to the bottom 12 and the side 
walls 14 so as to define a box. The two laminated paperboard end walls 16 
substantially enhance the stacking strength and moisture resistance of the 
container. 
One top flap 18 is formed at an upper end of each end wall 16 such that 
each top flap 18 and its associated end wall 16 are formed of a common 
piece of laminated paperboard and such that the top flaps rest upon the 
side walls 14. 
In the preferred embodiment of the present invention a single piece of 
laminated paperboard comprises a score 20 so as to define the top flap 18 
and its associated end wall 16. The score 20 preferably further defines 
stacking alignment tabs 22 extending upwardly from the end walls 16 and 
formed of a common piece of laminated paperboard therewith. 
Two side flaps 24 (best shown in FIG. 3) are preferably formed upon each 
end wall 16, one side flap 24 extending perpendicularly from each side of 
the end wall 16 and attaching to a side wall 14 so as to further enhance 
the stacking strength of the container 10. 
Similarly, two end flaps 26 are formed upon each side wall 14, one end flap 
26 extending perpendicularly from each side of the side wall 14 and 
attaching to an end wall 16 so as to yet further enhance the stacking 
strength of the container 10. 
An optional top 28 is removably attachable to the container 10. The top 28 
preferably comprises two openings 30, one opening 30 formed at either end 
thereof and configured to receive a stacking alignment tab 22. 
With particular reference to FIG. 1, the stacking alignment tabs 22 are 
preferably configured to engage the openings 30 of the top 28 so as to 
removably attach the top 28 to the end walls 16. The stacking alignment 
tabs 22 thus preferably comprise notches 32 (best shown in FIG. 7) formed 
therein so as to receive portions of the top 28 at the periphery of the 
openings 30 formed therein and thereby effect removable attachment of the 
top 28 to the end walls 16. 
With particular reference to FIG. 2, the top 28 preferably further 
comprises end flaps 34 extending perpendicularly downwardly therefrom 
along the end walls 16. 
With particular reference to FIG. 3, the bottom 12 of the carton 10 
preferably further comprises upwardly extending end flaps 36. Cutouts 38 
formed at the intersection of the bottom 12 and the upwardly extending end 
flaps 36 and complimentary cutouts 40 formed in the end walls 16 define 
recesses 42 (as shown in FIGS. 1 and 2) for receiving the stacking 
alignment tabs 22 of inferiorly stacked cartons 10. 
Each end wall 16, side flap 24, and top flap 18 is preferably adhesively 
bonded to corresponding portions of the floor's 12 upwardly extending end 
flap 36 thereof, side walls 14, and end flaps 26 so as to optimize the 
stacking strength of the improved fruit and produce carton of the present 
invention. Such adhesive bonding is preferably via hot glue, e.g., a 
heated polymer. Those skilled in the art will recognize that various other 
adhesive bonding materials are likewise suitable. 
The container preferably further comprises slots 44 formed at the 
perpendicular intersections of the bottom 12 and the side walls 14 so as 
to facilitate the introduction of desired gases into the container 10. 
Forming the slots 44 at the perpendicular intersection of the bottom 12 
and side walls 14 further enhances the stacking strength of the container 
10. Openings or cutouts 46 formed intermediate the top 28 and side walls 
14 cooperate with the slots so as to form conduits. The conduits 
facilitate the introduction of desired gases into the container 10 when a 
plurality of such containers 10 are stacked. 
Thus, a balanced combination of corrugated cardboard and laminated 
paperboard cooperate so as to maximize stacking strength and moisture 
resistance while minimizing cost and weight of the container in the 
present invention. 
It is understood that the exemplary improved fruit and produce container 
described herein and shown in the drawings represents only a presently 
preferred embodiment of the invention. Indeed, various modifications and 
additions may be made to such embodiment without departing from the spirit 
and scope of the invention. For example, those skilled in the art will 
recognize that various different configurations of the slots 44 and the 
cutout 46 are likewise suitable for forming conduits so as to facilitate 
the introduction of desired gases into the container 10. Also, various 
different complimentary shapes of the stacking alignment tabs 22 and the 
openings 30 of the top 28 are contemplated.