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;  
         [0011]      FIG. 7  is still further another perspective view of a partially assembled container assembly according to an aspect of the present invention;  
         [0012]      FIG. 8  is still further another perspective view of the assembled container according to an aspect of the present invention;  
         [0013]      FIG. 9  is still further another perspective view of a partially assembled container assembly according to an aspect of the present invention;  
         [0014]      FIG. 10  is still further another perspective view of a partially assembled container assembly according to an aspect of the present invention; and,  
         [0015]      FIG. 11  is a perspective view of the assembled container according to an aspect of the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0016]     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 No.  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.  
         [0017]      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 various forms may also be constructed in single wall, double wall, or triple wall configuration. 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.  
         [0018]     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  and subsequent container  50 .  
         [0019]     Attached to the side panel  24 , opposite the bottom panel  22 , is a top panel  28 . Top panel  28  is attached to side panel  24  along a fold line  27 . 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 , in a direction away from side panel  24 , is about ½ the width of the bottom panel  22  measured along fold line  25 .  
         [0020]     Top panel  28  includes a top panel flap  30  which is connected to top panel  28  along fold line  29 . Fold line  29  is lies substantially perpendicular to fold lines  27  and  23 . The length of the top panel flap  30  when measured perpendicularly from fold line  29  and in a direction away from the top panel  28  is substantially equal to the width of side panel  26  measured along fold line  33 .  
         [0021]     End panel  26  includes a corner assembly that when erected into a container, form a unique corner configuration. The corner assembly generally includes a first corner assembly panel  36  attached with the end panel  36  along a fold line  33 . Fold line  33  is substantially parallel to fold line  23  and is substantially formed in the same plane. Connected with the first corner assembly panel  36  opposite the end panel  26  is a second corner assembly panel  38 . The second corner assembly panel is connected to the first corner assembly panel  36  along a fold line  35 . Connected with the second corner assembly panel  38  is a third corner assembly panel  40 . Said third corner assembly panel  40  is connected to second corner assembly panel  38  along a fold line  37 . Fold lines  33 ,  35  and  37  are substantially parallel to one another.  
         [0022]     As formed, the first corner assembly panel  36 , second corner assembly panel  38 , and third corner assembly panel  40  lie substantially adjacent to side panel  24  and portions of top panel  28  and top panel flap  30 . In an embodiment, the collective widths of the panels making up the corner assembly ( 36 ,  38 , and  40 ) measured along cut line  43  are greater than or equal to the length of the side panel measured along fold line  23 . However, it will be appreciated that the collective widths could also be less than the length of the side panel measured along fold line  23 .  
         [0023]     Additionally, formed in the bottom panel  22  and the side end panel  26  are end panel slots  42 . In an embodiment, the end panels slots  42  are spaced a distance from the corner defined by the intersection of fold lines  23  and  25  about equal to the width of the third corner assembly panel  40  measured along cut line  43 . However, it will be appreciated and understood from the figures and description below that as formed, the container  50  includes corners that are several cellulose material thicknesses thick. As such, the width of the third corner assembly panel  40  measured along cut line  43  will be reduced accordingly.  
         [0024]     In order to further illustrate the various aspects of the embodiments,  FIGS. 2 through 8  show the blank  20  being erected into container  50 .  
         [0025]     With specific reference to  FIGS. 2 and 3 , the assembly of the container  50  is initiated by folding the first corner assembly panel  36 , second corner assembly panel  38 , and third corner assembly panel  40  upwardly approximately 90 degrees along fold line  33 . The end panel  26  may also be folded upwardly approximately 90 degrees along a fold line  25 . As best seen in  FIG. 2 , this forms a substantially U-shaped corner between the end panels and the opposed first corner assembly panels. Also, this places the corner assembly panels that are attached to the opposed panels  26  in a substantially juxtaposed relationship to one another along those portions of the respective corner assembly panels that overlap. The next step in the box erection process is to fold side panels  24  upwardly approximately 90 degrees so that side panel  24  is juxtaposed to the various corner assembly panels, as best seen in  FIG. 3 .  
         [0026]     With specific reference to  FIGS. 4 and 5 , the assembly of the L-corners is depicted. Specifically, the second corner assembly panel  38  and third corner assembly panel  40  are folded inwardly approximately 180 degrees along fold line  35 . As such, fold line  37  is substantially in the corner of the container  50 , and the third corner assembly panel  40  is adjacent to the end panel  26 , and the second corner assembly panel is substantially adjacent to the first corner assembly panel  36 . At this time, the third corner assembly panel  40  may be engaged into the end panel slot  42  to lock the L-corner panels together, as best seen in  FIG. 5 .  
         [0027]     With specific reference to  FIGS. 6 through 8 , the top panel flaps  30  may then be folded inwardly approximately 90 degrees along fold line  29 . Top panel  28  may then be folded inwardly approximately 90 degrees along fold line  27 . In this manner the container may be formed closing the lids, It will be appreciated that top panel flaps provide support to the top panels  28  as they extend between the bottom panel  22  and the top panel  28 .  
         [0028]     An additional embodiment is depicted in  FIGS. 9 through 11 . This aspect of an embodiment includes all panels discussed above, with the exception that the top panel  28  does not include a top panel flap  30 . In this embodiment, as best seen in  FIG. 11 , the top panel  28  rests solely upon the top edge of the end panel, and that portion of the top edges of the L-corner assemblies.  
         [0029]      FIGS. 8 and 11  depict the container  50  that results from the assembly of blank  20 . As can be seen in this figure, the container  50  includes reinforced multi-panel corner arrangements. Specifically, all four corners receive added rigidity thanks to the overlapping relationship of the various side corner assembly panels and their respective side wall  24  or end wall  26 . The arrangement of the corner assembly panels help the container  50  control relative motion of the side panels  24  and end panels  26 . The corner assembly panels also provide a significant increase in the container&#39;s stacking strength. Further, top panel  28  provides a stacking or bearing surface for successive containers  50  to be stacked vertically on top of one another (not shown).  
         [0030]     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 the 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.  
         [0031]     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.  
         [0032]     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.  
         [0033]     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.  
         [0034]     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.