Abstract:
A packaging container with a reinforced bottom and corners is a lamination of a container material alternating with a reinforcing material that is shaped to form a rigid unit of generally U-shaped cross-section having a main body portion with a generally flat bottom wall and upstanding, opposing sidewalls. The bottom and corners are reinforced with the reinforcing material to withstand additional stresses associated with dropping, bumping, scratching or general handling of packaging containers.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention is directed to an extra strength packaging container. More particularly, the present invention pertains to a packaging container formed from a rigid U-shaped material having a reinforced base and corners to withstand stresses associated with lifting, dropping, or general handling of packaging containers. 
         [0002]    U-shaped packaging containers, or U-board, are known packaging material for many objects. The board is formed from a layered, or laminated, construction of paper and/or paper board that is subsequently formed into a U-shape (U-shaped cross-section). The board generally is rigid; that is, the walls are rigidly formed into the U-shape (transverse relative to the base) and are rigid longitudinally along the length of the channel. The walls do not fold down onto the base, nor can the board, without more, be folded length-wise onto itself. 
         [0003]    U-board is used for a wide variety of commonly packaged items. U-board can be used to package long, fragile items to prevent creasing or other damage that may be caused by dropping, bumping or general handling of the package. To prevent such damage requires that the corner strength of the packaging container be durable and of good integrity. In a common use, U-board is used for packaging doors and windows to protect the edges and corners of these items from damage due to bumping, dropping or general handling. The sides of the U-board that extend beyond the corners may be used for advertising. 
         [0004]    While U-board has been used with a great deal of success for packaging such items, it would be desirable to further strengthen U-boards, particularly with regard to the base and the corners, which are subject to the greatest stresses during handling. 
         [0005]    Accordingly, there is a need for extra strength, reinforced U-board. Desirably, such reinforcement minimizes the amount of additional materials and cost needed to reinforce the unit. More desirably, reinforcement of the U-board is readily made and usable, and has a high degree of integrity. 
       BRIEF SUMMARY OF THE INVENTION 
       [0006]    A U-board packaging container having a reinforced base and corners is fashioned from alternating layers of paper and/or paper board material of varying widths or strips, and laminating the strips into a board. Narrow strips of material are disposed between wider strips of material such that the narrow strips of material serve as a reinforcing material. The narrow strips of reinforcing material may or may not be the same material as the wider strips of material. 
         [0007]    The laminated board is shaped into a rigid unit of generally U-shaped cross-section, creating an extra-strength U-board, having a main body portion with a generally flat bottom wall and upstanding, opposing side walls. 
         [0008]    In a preferred embodiment, the reinforcing material layer extends across the bottom wall and at least partially up the side walls of the U-board to cover fully the bottom wall of the internal channel as well as the radius of curvature of the corners of the internal channel. 
         [0009]    The U-board may be foldable to form an internal base channel and opposing internal side channels to create a protective package for an associated item, such as a window or a door. 
         [0010]    These and other features and advantages of the present invention will be apparent from the following detailed description, in conjunction with the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0011]    The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein: 
           [0012]      FIG. 1  is a perspective view of the extra-strength U-board embodying the principles of the present invention, the U-board shown mounted to a door; 
           [0013]      FIG. 2  is a perspective view of the extra-strength U-board; 
           [0014]      FIG. 3  is a top view of a flattened extra-strength U-board; 
           [0015]      FIG. 4  is a cross-sectional view of the extra-strength U-board; 
           [0016]      FIG. 5  is a perspective view of the extra-strength U-board in a flat state, prior to folding. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0017]    While the present invention is susceptible of embodiment in various forms, there is shown in the drawings, and will hereinafter be described, a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiment illustrated. 
         [0018]    It should be further understood that the title of this section of this specification, namely, “Detailed Description Of The Invention”, relates to a requirement of the United States Patent Office, and does not imply, nor should be inferred to limit the subject matter disclosed herein. 
         [0019]    Referring now to the figures and in particular to  FIG. 1 , there is shown an extra-strength U-board packaging container  10 . The extra-strength U-board  10  is configured to support and protect an object, such as door D. This is one typical use for U-board packing container  10 . 
         [0020]    As shown in  FIG. 2 , the U-board  10 , although defined as having a generally U-shaped cross-section, is formed from a material having a channel-like or squared U-shape, with a flat or near-flat (e.g., planar) bottom wall  16  and straight (e.g., generally planar) upstanding side walls  18 . The corners  20  are typically formed having a radius of curvature (i.e., rounded), however, the corners may be formed having relatively sharp angles. Nevertheless, for purposes of the present disclosure, the extra-strength U-board  10  is referred to as “U-shaped”. 
         [0021]    As shown in  FIGS. 4 and 5 , the U-board  10  is formed in a layered construction (e.g., a lamination) of strips of material: reinforcing material  12  and container material  14 . The materials  12  and  14  are preferably paper and/or paper board, but it is anticipated that other non-paper type material may be used. The laminations  12  and  14 , are formed by using means known to those skilled in the art, and preferably by adhering layers together with an adhesive; however, alternative means to adhere the materials  12 ,  14  into a board  10  may be used. In a commonly used method, the laminations and adhesive are made in a wet environment (a wet adhesive), the walls  18  are then folded up from the base  16  and allowed to dry. The result is the rigid U-shape illustrated. 
         [0022]    In manufacturing of an extra-strength U-board  10 , one or more narrow strips of reinforcing material  12 , is centered on the top of one or more strips of wider container material  14 , of differing or of the same width, with an adhesive means placed between the two layers  12 ,  14 . A strip or strips of container material  14  is centered on top of the previously laid narrower reinforcing strips  12 . This alternating layered sequence is repeated until a sufficiently rigid board  10  is fashioned. Specifically, build-up of reinforcing material  12  in the center of the flattened board strengthens the bottom  16 , bottom corners  20 , and bottom edges  21  of the folded board  10 . Reinforcing only the bottom wall  16  and the bottom corners  20  provides reinforcement only in the areas of the U-board likely to endure the greatest stresses in addition to reducing costs. 
         [0023]      FIG. 3  shows a top view of an embodiment of the flattened, pre-folded extra-strength U-board, wherein the reinforcing material  12  extends along l 14  and entirely across the width W 14  of the bottom wall  16  and partially up the sidewalls  18  to enable reinforcement of the base  16  and corners  20  of the extra-strength U-board  10 . In an alternate embodiment, while the length l 14  remains the same for the container material  14 , the width of the container material  14  layers may differ. 
         [0024]    Fold lines F illustrate where the flattened extra-strength U-board can be folded to produce the U-shaped channel  22 . Prior to the adhesive of the board  10  setting, the board  10  is bent or folded along fold lines F as shown in  FIG. 3 , such that the board  10  is molded into a channel  22  in the shape of a “U,” with a base  16 , sidewalls  18 , and edges  21  as shown in  FIG. 2 . The molded board  10  dries to form a rigid, extra-strength U-board  10 . A perspective view of  FIG. 5  of the U-board  10  prior to folding is shown, illustrating plies of container material  14  alternating with plies of reinforcing material  12 . It is understood that the layers of material  12 ,  14  can be sequenced in various ways, but that a preferred method sequences the materials  12 ,  14  such that the container material  14  forms the bottom and top layer of the flattened board  10 . Fold lines F illustrate where the extra-strength U-board can be folded to produce the reinforced U-shape. 
         [0025]    The extra-strength U-board  10  is rigid, and accordingly, the walls  16 ,  18  are rigidly formed into the U-shape (transverse relative to the bottom wall  16 ) and are rigid longitudinally along the length l 14  of the reinforced channel  22 . In other words, the walls  18  do not fold down onto the bottom  16 , nor can the reinforced channel  22  be readily folded, length-wise onto itself. 
         [0026]    The extra-strength U-board  10  can be folded and positioned around the particular item D (as seen in  FIG. 1 ) using mitered or straight cuts in the U-board or by other methods known in the art and the U-board  10  can be wrapped or strapped (as needed) to protect the item D, the item D sitting in the base channel  32 , with its sides S protected by side channels  34 . 
         [0027]    It will be appreciated that while the board container material  14  is typically a paper or paperboard-based material, the reinforcing material  12  can be a paper or paperboard-based material, a polymeric material (such as high-density polyethylene (HDPE), low density polyethylene (LDPE) or the like), or any other suitable material that can be inserted between the container material  14  layers in the desired formation (e.g., wet adhesive) process to provide the enhanced strength. It will also be appreciated that the reinforcing material layers  12  can be formed from whole or non-perforated material, perforated material, mesh-like material and the like, the later two having open areas. The mesh-like material, having open areas, can facilitate bonding by allowing communication of adhesive between layers of material  12 ,  14  and around the reinforcing material layers  12 . 
         [0028]    All patents referred to herein are hereby incorporated by reference, whether or not specifically referred to within the text of this disclosure. 
         [0029]    In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular. 
         [0030]    From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.