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 a rollover panel assemblies formed by spaced apart fold lines that forms bearing surfaces for vertically stacked containers. The container includes a inside taper that functions to prevent telescoping of vertically stacked container, and to hold the various corner panels in their proper location. The blank is configured to form a container that includes corners having multiple thicknesses for strength and stability. The container is self locking, easy us manufacture yet high strength.

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. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0002]    Various embodiments of the present invention are described in detail below with reference to the following drawings. 
           [0003]      FIG. 1  is a plan view of a single piece of container blank formed in accordance with an aspect of the present invention; 
           [0004]      FIG. 2  is a perspective view of a partially assembled container assembly according to an aspect of the present invention; 
           [0005]      FIG. 3  is another perspective view of a partially assembled container assembly according to yet an another aspect of the present invention; 
           [0006]      FIG. 4  is still further another perspective view of a partially assembled container assembly according to an aspect of the present invention; 
           [0007]      FIG. 5  is still further another perspective view of a partially assembled container assembly according to an aspect of the present invention; 
           [0008]      FIG. 6  is still further another perspective view of a partially assembled container assembly according to an aspect of the present invention; 
           [0009]      FIG. 7  is still further another perspective view of a partially assembled container assembly according to an aspect of the present invention; 
           [0010]      FIG. 8  is still further another perspective view of a partially assembled container assembly according to an aspect of the present invention; and, 
           [0011]      FIG. 9  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 9 . 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. 
         [0016]    End panel  26  is also generally rectangular in shape and is connected with the bottom panel along fold line  25 . 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. 
         [0017]    Rollover panel  28  is connected with the end panel  26  via spaced apart fold lines  33 . H-cuts are formed in a portion of the end panel  26  and a portion of rollover panel  28 , and lie substantially perpendicular to the spaced apart fold lines  33 . 
         [0018]    Attached to the side panel  24  is a first corner assembly panel  30 . The first corner assembly panel  30  is connected to the side panel  24  along a fold line  27 . Connected to the first corner assembly panel  30  opposite said side panel  24  is a second corner assembly panel  32 . The second corner assembly panel  32  is attached with the first corner assembly panel  30  along a fold line  29 . The third corner assembly panel  34  is attached to the second corner assembly panel  32  along a fold line  31 . As formed the first corner assembly panel  30 , second corner assembly panel  32 , and third corner assembly panel  34  lie adjacent to, but are not connected with end panel  26 . 
         [0019]    It is to be understood that the various panels are to be cut such that when the container is erected as disclosed below, the open top are of the container is smaller than the bottom panel. This is achieved by forming the various side, end and corner assembly panels with an inside taper to them. The inside taper design causes the various sidewalls to lean slightly inwardly when the container is erected. Two distinct advantage result from the inside taper. First, since the top is smaller4 than the bottom, it helps to discourage telescoping when multiple containers are stacked vertically. Secondly, the inside taper helps keep the various corner panels locked into position. Both of these advantages are not typically found in straight walled containers. 
         [0020]    In order to further illustrate the various aspects about the embodiments,  FIGS. 2 through 9 , depict the blank  20  being erected into container  50 . Typically, this is a hand-set container  50 . However, it will be understood that mechanical box erecting equipment may be used in the erection of the container  50 . As mechanical box erecting equipment is well know in the art a detailed description of such equipment is not necessary to understand the spirit and scope of the embodiments contained herein. 
         [0021]    With specific reference to  FIGS. 2 and 3 , side panels  24  are generally folded upward along fold line  23  approximately 90 degrees. The folding of the side panel  24  in this manner, also results in the disposition of the first corner assembly panel  30 , second corner assembly panel  32 , and third corner assembly panel  34  in a similar fashion. Subsequently, the second corner assembly panel  32  and third corner assembly panel  34  are folded inwardly about 180 degrees around fold line  29  such that the second corner assembly panel  32  and third corner assembly panel  34  lie juxtaposed the first corner assembly panel  30  and a portion of the side panel  24 . This folding procedure will bring the saddle cutouts  36  formed in both the first corner assembly panel  30  and the second corner assembly panel  32  into alignment. 
         [0022]    It should also be noted, as depicted in the FIGURES, the overall size of the second corner assembly panel  32  and third corner assembly panel  34  are such that the width of the bottom panel  22  measured along fold line  25  is greater than twice the combined length of the second corner assembly panel  32  and third corner assembly panel  34  measured along the same fold line  25 . However, it will be appreciated by those skilled in the art, that the width of the bottom panel  22  measured along fold line  25  may be equal to about twice the combined length of the second corner assembly panel  32  and third corner assembly panel  34  measured along the same fold line  25 . 
         [0023]    The next box erection step is to fold the first corner assembly panel  30  and the second corner assembly panel  32  inwardly about 90 degrees along fold line  27 . This step places the first corner assembly panel  30  and the second corner assembly panel  32  in a plane that is substantially perpendicular to the plane the third corner assembly panel  34  and the side panel  24  share. It will be appreciated that in this stage of container erection, the saddle cutouts  36  are substantially aligned with the H-cut  35 , this relationship will be described in more detail below. 
         [0024]    Subsequently end panels  26  and rollover panels  28  are folded inwardly along a fold line  23 . As best seen in  FIG. 7 , this relationship substantially forms the general container shape. 
         [0025]    With specific references now to  FIGS. 7-9 , the 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, the rollover panels  28  can be folded downwardly approximately 90 degrees along spaced apart fold line  33  to bring the rollover panel  28 , into a juxtaposed position with second corner assembly panel  32 . This erection step also includes the engagement of tab  38  through the H-cutout such that straps  37  are positioned within the saddle cutouts  36 . 
         [0026]    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 the spaced apart fold lines  33  that define the rollover panel  28  provides a stacking or bearing surface for successive containers  50  to be stacked vertically on top of one another (not shown). 
         [0027]    One of the many unique features of this embodiment is the extremely limited use of adhesive or the lack of needing to use adhesive at all. In one embodiment, no adhesive or fasters are used with this container  50 . In another embodiment adhesive is used only between side panel  24  and the first corner assembly panel  30 . The specific location where an adhesive is placed between the respective panels will be known to those skilled in the art and is therefore not discussed herein. However, it will be appreciated that the location and amount of adhesive, if used, will be sufficient to ensure container integrity. 
         [0028]    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. However, this design is also useful in any variety of retail or wholesale environments. 
         [0029]    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.