Abstract:
The embodiments of the present invention provide a blank foldable material that may be configured to form a container. When formed, the container is self-locking and includes top panel assemblies that form additional bearing surfaces. The blank is configured to form a container that includes corners having multiple thicknesses. However, despite the multiple thickness of the corner assemblies, the panels are only adhered in one location per corner. The single adhesion/corner arrangement provides a multi-wall corner arrangement that is strong, yet has flexible applications. The single adhesive/corner adds vertical stacking strength and lateral stability between the panels. The unique approach of only adhering at one place per corner is a space and cost saving improvement that maintains a container integrity and usefulness.

Description:
FIELD OF THE INVENTION  
       [0001]     This invention relates generally to cellulose-based blanks and containers and more specifically, to wood cellulose-based blanks and containers used for storing and displaying goods.  
       BACKGROUND  
       [0002]     Containers having multiple thickness corner assemblies are useful where increased container integrity is desired. However, a standard practice employed with using containers with multiple thickness corner assemblies is to adhere all the relative panels together with glue or other type adhesive. Conversely, the containers are often hand-set, in which case the container does not container any adhesive at all. In the former, in order to erect a container with all relative panels adhered together large box equipment is necessary, which is prohibitively costly not only in the price of the machine but in the price of the floor space required to house such a machine. In the later, the resulting hand-set box is generally not as strong.  
         [0003]     What is needed is a method for erecting and the subsequent container that is simple to erect, cost effective and maintains desired container integrity. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0004]     Various embodiments of the present invention are described in detail below with reference to the following drawings.  
         [0005]      FIG. 1  is a plan view of a single piece of container plank formed in accordance with an aspect of the present invention;  
         [0006]      FIG. 2  is a perspective view of a partially assembled container assembly according to an aspect of the present invention;  
         [0007]      FIG. 3  is another perspective view of a partially assembled container assembly according to yet an another aspect of the present invention;  
         [0008]      FIG. 4  is still further another perspective view of a partially assembled container assembly according to an aspect of the present invention;  
         [0009]      FIG. 5  is still further another perspective view of a partially assembled container assembly according to an aspect of the present invention;  
         [0010]      FIG. 6  is still further another perspective view of a partially assembled container assembly according to an aspect of the present invention; and,  
         [0011]      FIG. 7  is a perspective view of the assembled container according to an aspect of the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0012]     The present invention provides a blank and resulting container for holding any variety of goods. By way of overview and with references to  FIGS. 1 through 8 . An embodiment of the present invention includes a single piece blank  20  of foldable material arranged to form a container  50 . Specific details of the blank  20  in container  50  are described with more particularity below.  
         [0013]      FIG. 1  depicts a blank  20  used to form the container  50 . The blank  20  is preferably constructed from a single piece of formable material such as, without limitation, sheets of cellulose-based materials formed from cellulose materials such as wood pulp, straw, cotton, bagasse or the like. Cellulose-based materials used in this present invention come in many forms such as fiberboard, containerboard, corrugated containerboard and paperboard. The blank  20  is cut and scored, perforated or otherwise formed to include a plurality of panels that when assembled form container  50 . In all FIGURES, like numbers indicate like parts. Additionally, cut lines are shown as solid lines, score lines as dashed lines, and lines of perforation as broken lines.  
         [0014]     With respect to  FIG. 1 , the blank includes a bottom panel  22 , opposed side panels  24  and opposed end panels  26 . The bottom panel  22  is generally rectangular in shape and is connected with the side panels along a fold line  23 . The bottom panel is connected with end panels  26  along a fold line  25 . As depicted in the FIGURE, fold line  23  is substantially perpendicular to fold line  25 . The intersection of the respective fold lines  23  and  25  substantially define the corner of the bottom panel  22 .  
         [0015]     Side panel  24  is generally rectangular in shape. The length of the side panel  24  measured along fold line  23  is substantially equal to the length of the bottom panel  22  measured along the same fold line. Side panel  24  is connected to a top panel  28  along a fold line  27 .  
         [0016]     In an embodiment, top panel  28  is substantially rectangular in shape. The length of the top panel  28  measured along fold line  27  is substantially equal to the length of the side panel  24  measured along the same fold line. The width of the top panel  28 , measure in a direction perpendicular to fold line  27 , is about 1/2  the width of the bottom panel  22  measured along fold line  25 .  
         [0017]     Top panel  28  includes a top panel flap  30  attached to the top panel  28  along a fold line  29 . The fold line  29  is substantially perpendicular to fold line  27 . Attached to the top panel flap  30 , opposite said top panel  28 , is a locking flap  32  which is separated from top panel flap  30  via spaced apart fold lines  31 . A locking tab  34  is connected with the locking flap  32  along a fold line  33 . The fold line  33  and spaced apart fold lines  31  are at an acute angle relative to one another.  
         [0018]     End panel  26  is also generally rectangular in shape. End panel  26  may include optional cut-out  44 . Said cut-out  44  may be a hand-hold vent or other type structure. The length of the end panel  26  measured along fold line  25  is substantially equal to the width of the bottom panel  22  measured along the same fold line.  
         [0019]     Attached to the end panel  26  is a first corner assembly panel  36 . The first corner assembly panel  36  is connected to the end panel  26  along a fold line  35 . Connected to the first corner assembly panel  36  opposite said end panel  26  is a second corner assembly panel  38 . The second corner assembly panel  38  is attached with the first corner assembly panel  36  along a fold line  37 . The third corner assembly panel  40  is attached to the second corner assembly panel  38  along a fold line  39 . A fourth corner assembly panel  42  is connected with the third corner assembly panel along a fold line  41 .  
         [0020]     As formed the first corner assembly panel  36 , second corner assembly panel  38 , third corner assembly panel  40  and fourth corner assembly panel  42  lie adjacent to, but are not connected with, side panel  24  and a portion of top panel  28 . The fourth corner assembly panel may include another cut-out  46  which is substantially U-shaped and formed in an edge of the fourth corner assembly panel opposite said fold line  41 .  
         [0021]     In order to further illustrate the various aspects about the embodiments,  FIGS. 2 through 8 , depicted the blank  20  being erected into container  50 . It will be understood that mechanical box erecting equipment may be used in the erection of the container  50 . However, another aspect is that this container may be hand erected at a packaging facility or the like.  
         [0022]     With specific reference to  FIGS. 2 and 3 , the first corner assembly  36 , second corner assembly  38 , third corner assembly  40  and fourth corner assembly  42  are folded upward approximately 90 degrees along a fold line  35 . Subsequently the end panel  26  may be folded inwardly approximately 90 degrees along a fold line  25 . Subsequently side panels  24  and top panels  28  are folded inwardly along a fold line  23 . As best seen in  FIG. 3 , this relationship substantially forms the general container shape. As can be seen, one corner assembly panel associated with one end panel  26  lie adjacent to side panel  24 . The opposite corner assembly panel like adjacent to first corner assembly panel, as illustrated in  FIG. 3 .  
         [0023]     With specific references now to  FIGS. 4 and 5 , the second corner assembly panel  38 , third corner assembly panel  40 , and fourth corner assembly panel  42  can be folded back along fold line  37  such that the second corner assembly panel  38  lies adjacent to the first corner assembly panel  36 . The third corner assembly panel  40  extends across the corner of the container  50  and the fourth corner assembly panel  42  lies substantially adjacent to the end panel  26 . As can best be seen in  FIG. 5 , once the various corner assembly panels are folded back into their formed position, the container  50  has all the third corner panel assemblies  40  extending across the corners forming a gusseted corner within the container  50 .  
         [0024]     With specific reference to  FIG. 7 , the closing and locking of the various panels to form the container  50  is illustrated. Specifically, once the various corner assembly panels are folded to their formed position, as shown in  FIGS. 6 and 7 , the top panels can be folded inwardly 90 degrees along fold line  27 . The top panel flap  30  can then be folded downwardly approximately 90 degrees along fold line  29  to bring the top panel flap  30 , locking flap  32  and locking tab  34  into a juxtaposed position with end panel  26 . The locking flap  32  and locking tab  34  can then be folded substantially through the cut-out  44  along said double spaced apart fold line  29  and fold line  31 .  
         [0025]      FIG. 8  depicts the container  50  that results from the assembly of blank  20 . As can be seen in this FIGURE, the container  50  includes multi-post corner areas, where in its four corners gussets are provided via the third corner assembly panel to add to the rigidity of the container and to help control relative motion of the side panels  24  and end panels  26  and reduce telescoping of one box into the next. These assorted corner panel assemblies are configured to form multi-panel corner assemblies once the container  50  is formed. As these panels will, to an extent, fold over each, their juxtaposed positioned relative to each other combined with their association with the side panel  24  provide a container with significantly increased corner stacking strength. Further, as the various corner assembly panels are connected, and as they extend along both the side panel  24  and end panel  26 , the lateral strength of the container  50  is greatly increased. Also top panel  28  provides a stacking or bearing surface for successive containers  50  to be stacked vertically on top of one another (not shown).  
         [0026]     One of the many unique features of this embodiment is the extremely limited use of adhesive. Specifically, with reference to all FIGURES, the only adhesive used in the formation and use of container  50  is located between side panel  24  and the first corner assembly panel  36 . The specific location where an adhesive  47  is placed between the respective panels will be known to those skilled in the art and it its location shown in  FIG. 1  is strictly exemplary. However, it will be appreciated that the location and amount of adhesive  47  used will be sufficient to ensure container integrity. The other panels are essentially free from adhesive or the like. They may be hand set and are generally friction fit.  
         [0027]     A unique benefit is that the forming of container  50  may be done much more efficiently than before. Specifically, if box formers are to be used in erecting the container  50 , a box former having a relatively small footprint may be use. Suitable, non-limiting examples of such a box formers are the vertical box formers manufactured by either SWF, Inc. or W.E. Plemons, Inc. each of these companies manufacture relatively simple box formers having footprints around 4′×6′. This footprint is significantly smaller than box formers typically used to erect fully glued containers, which a major cost savings. Conversely, the single point of adhesive/corner provides for a container that is simple to form, yet is stronger than a basic hand-set container.  
         [0028]     The simple adhesive arrangement of the disclosed container  50  and the minimal assembly space requirement provides a variety of efficiencies for a user. As discussed above, the actual floor space needed for either machine formation or hand formation is reduced by the unique and limited adhesive  47  application. This reduced floor space usage is a cost savings. Also, smaller entities that formerly could not justify the expense of larger box erecting equipment may now utilize less voluminous box erecting equipment and produce a container  50  having desirable structural qualities.  
         [0029]     The container  50  as shown is simple to manufacture, easy to assemble and may be a design of considerable usage in club stores or bulk stores where products are sold in large quantities on the open floor. The container  50  may be erected by standard box erecting equipment (not shown) or else is may be hand-set and tape/glued when needed. However, this design is also useful in any variety of retail or wholesale environments.  
         [0030]     While various embodiments of this invention have been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of this invention. Accordingly, the scope of the invention is not limited by the disclosure of the various embodiments. Instead, the invention should be determined entirely by references to the claims that follow.