Abstract:
An elongate, rectangular box ( 12, 14, 40, 60, 70, 90, 100 ) and method for packaging containers (C), wherein the box can be cross-stacked for stable stacking of the boxes, and optimizes utilization of pallet space. Containers (C) are placed in the box in nested, offset relationship in a parallelogram shaped arrangement, and in one embodiment interior corner panels ( 20, 21 ) extend angularly across two diagonally opposite corners of the box, defining an interior box shape closely conforming to the parallelogram-shaped arrangement of the containers. The corner panels may be cut from the side walls ( 18, 19 ) and folded inwardly and secured at a free edge ( 28 ) to an adjacent end wall ( 16, 17 ), defining openings ( 22, 23 ) in the side wall through which the containers are visible. Side wall segments ( 24, 25, 26 ) at the bottom and sides of the opening, in cooperation with the corner panels, retain the containers in place in the box. The box is especially suited for packaging four one-gallon containers.

Description:
TECHNICAL FIELD 
       [0001]    This invention relates to packaging, and more particularly to a stackable shipping and display box. 
       BACKGROUND ART 
       [0002]    Many products are shipped in cartons or boxes that enable the product to be displayed in the shipping box at the point of sale. These types of boxes are particularly suitable for products sold in club stores, where many products, e.g., juices, typically are packaged in one-gallon containers. Conventional boxes for handling one-gallon containers usually comprise full depth closed RSC&#39;s, although partial depth boxes or trays are sometimes used. A divider that extends between the containers normally is used in the partial depth trays to provide adequate strength. Further, conventional boxes for holding one-gallon containers are commonly designed for holding six containers, although some packages, such as those shown in  FIGS. 1 and 2 , are designed for holding four containers, primarily due to weight concerns. These conventional boxes are square in plan view, with the one-gallon containers orthogonally oriented in side-by-side relationship to one another. 
         [0003]    To facilitate handling, it is common practice to stack several layers of filled boxes on a pallet, and sometimes to stack two or more pallets high. Conventional square boxes are often column stacked, and typically require internal or external support to eliminate or reduce load on the bottles. Column stacking of the boxes is inherently unstable, and layer sheets, or slip sheets, may be employed between adjacent layers of boxes to improve the stability of the stacked boxes. 
         [0004]    Moreover, the pallets used typically have dimensions of 48×40 inches, and the square boxes do not utilize the pallet space well, i.e., a plurality of the boxes placed in a layer either do not occupy the entire pallet space, or they overhang the pallet, depending upon how the boxes are oriented and how many are placed in a layer on the pallet. Conventional square boxes do not permit any arrangement of the boxes on a pallet that will result in the footprint of the area occupied by the boxes being substantially equal to the shape and area of the pallet. When conventional square boxes holding four one-gallon containers are placed on a conventional 48×40 inch pallet, often only nine boxes, or thirty-six one-gallon containers, can be accommodated in each layer of boxes without overhanging the edges of the pallet, depending upon the bottle diameter and/or footprint. 
         [0005]    Accordingly, there is need for a box for shipping and displaying product, wherein the box, when filled with containers of product, has a maximum desired weight and is configured to enable stable stacking of filled boxes, pallet space is optimally utilized, and no load is produced on the product containers, all without requiring the use of separate layer sheets, or separate internal or external reinforcements. 
       DISCLOSURE OF THE INVENTION 
       [0006]    The present invention comprises a box for shipping and displaying product, wherein the box is configured so that filled boxes can be stacked in stable, interlocked relationship, pallet space is optimally utilized, and the product containers are not subjected to load when filled boxes are stacked on top of one another. 
         [0007]    To accomplish the foregoing, the box of the invention is rectangular, i.e., has a greater length than width, and containers of product are placed in the box in diagonally offset side-by-side relationship to one another. The diagonally offset placement of the containers results in interior spaces at two diagonally opposite corners of the box, and angled corner panels extend into these spaces to contact the containers to help retain them in the box and to provide stacking support and prevent vertical loads on the containers. 
         [0008]    The rectangular shape of the boxes enables boxes in adjacent layers to be cross-stacked and interlocked for stable stacking. Boxes incorporating the invention can be stably stacked two or more pallets high and without imposing a vertical load on the containers. 
         [0009]    Although the boxes could be configured to hold different numbers and sizes of containers and still incorporate the features of the invention, in the particular embodiments illustrated and described herein they are sized to hold four one-gallon containers. These boxes can be placed on a conventional 48×40 inch pallet so that the footprint of the area occupied by a layer of boxes is substantially the same as the area of the pallet surface. With the invention, eleven boxes holding forty-four containers can be placed in a layer on a 48×40 inch pallet, although it should be understood that these numbers can vary, depending upon the bottle diameter and footprint. 
         [0010]    Additionally, empty containers, e.g., bottles, can be inverted and placed upside down in the box by the bottle manufacturer for shipment to a facility for filling the bottles. The shape of the box, including the angled corner panels, securely holds the inverted empty bottles in place even when some of the side walls have a reduced height to define openings through which the bottles are visible. 
         [0011]    Further, the box of the invention, including the angled corner panels, can be made from a single unitary blank of corrugated board, and when loaded with four one-gallon containers of juice, for example, has a case weight less than 40 pounds. In an alternate embodiment, the angled corner panels can be formed from separate pieces inserted into the box. 
         [0012]    The box of the invention is equally suitable for use with containers having a round cross-section or a non-round cross section, e.g., square. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    The foregoing, as well as other objects and advantages of the invention, will become apparent from the following detailed description taken in conjunction with the accompanying drawings, wherein like reference characters designate like parts throughout the several views, and wherein: 
           [0014]      FIG. 1  is a top perspective view of conventional partial depth square boxes or trays filled with four containers placed side-by-side in orthogonal relationship relative to one another and column-stacked on a pallet. 
           [0015]      FIG. 2  is a top perspective view of a single prior art box conventionally filled with four containers disposed in side-by-side orthogonal relationship to one another, and showing an H-shaped divider in dot-and-dash lines. 
           [0016]      FIG. 3  is a top plan view depicting how conventional square boxes designed for holding four one-gallon containers occupy the space on a conventional 48×40 inch pallet. 
           [0017]      FIG. 4  is a top perspective view of rectangular boxes according to the invention filled with containers placed in offset side-by-side relationship relative to one another and cross-stacked on a pallet in interlocking relationship. 
           [0018]      FIG. 5  is a top perspective view of a single rectangular box according to the invention filled with four containers disposed in side-by-side offset relationship to one another. 
           [0019]      FIG. 6  is a top plan view depicting how rectangular boxes according to the invention and designed for holding four one-gallon containers occupy the space on a conventional 48×40 inch pallet. 
           [0020]      FIG. 7  is a top plan view depicting how the rectangular boxes of the invention might be alternately arranged on a pallet. 
           [0021]      FIG. 8  is a top perspective view of a first embodiment of a box according to the invention, showing four containers of round cross-section disposed therein in offset relationship to one another, and wherein the box is made from a single unitary blank, with two side walls of substantially reduced height. 
           [0022]      FIG. 9  is a top plan view of a blank for making the box of  FIG. 8 . 
           [0023]      FIG. 10  is a top plan view of the box of  FIG. 8 . 
           [0024]      FIG. 11  is a top perspective view of the box of  FIG. 8 , showing four inverted containers placed therein in upside-down, offset relationship. 
           [0025]      FIG. 12  is a top perspective view of a second embodiment of the box of the invention, wherein the box is constructed substantially the same as the box of  FIG. 8 , except that the side walls are only partially reduced in height. 
           [0026]      FIG. 13  is a top plan view of a blank for making the box of  FIG. 12 . 
           [0027]      FIG. 14  is a top perspective view of a third embodiment of the box of the invention, wherein the box is constructed substantially the same as the box of  FIG. 8 , except that the side walls are not reduced in height. 
           [0028]      FIG. 15  is a top plan view of a blank for making the box of  FIG. 14 . 
           [0029]      FIG. 16  is a top perspective view of a fourth embodiment of the box of the invention, wherein the box is made from one blank, the angled corner pieces comprise inserts made from additional blanks, and wherein the side walls and end walls are all of reduced height. 
           [0030]      FIG. 17  is a top plan view of a blank for making the box of  FIG. 16 . 
           [0031]      FIG. 18  is a top plan view of a blank for making the inserts used in the box of  FIG. 16 . 
           [0032]      FIG. 19  is a top plan view of the box of  FIG. 8 , with containers having a square cross-section therein. 
           [0033]      FIG. 20  is a top perspective view of a fifth embodiment of the box of the invention, wherein the reduced height side walls are defined by cut-outs in full height panels forming those side walls. 
           [0034]      FIG. 21  is a top plan view of a blank for making the box of  FIG. 20 . 
           [0035]      FIG. 22  is a top perspective view of an alternate embodiment of a box incorporating the invention, wherein one end wall is cut away to produce an opening through which the containers are visible. 
           [0036]      FIG. 23  is a top perspective view showing a plurality of the boxes of  FIG. 22  placed on a pallet, and showing how the footprint of the area occupied by the boxes is substantially the same as the area of the pallet surface. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0037]    A conventional box of square shape designed for holding four one-gallon containers C is shown at  10  in  FIGS. 1-3 . In accordance with conventional practice, the containers are placed in the box in orthogonally disposed side-by-side relationship to one another, and an H-shaped divider  11 , shown in dot-and-dash lines, is placed in the box between the containers. Boxes filled with containers are typically stacked in layers on a pallet P, and as depicted in  FIGS. 1 and 2 , the boxes are stacked on top of one another in columnar relationship. This arrangement is unstable, and layer sheets (not shown) are commonly placed between adjacent layers. Moreover, only nine boxes may be placed in a layer without producing pallet overhang, but this results in a substantial area of the pallet not being used. 
         [0038]    The invention solves this problem, as depicted in  FIGS. 4-7 , by making the boxes  12  rectangular in shape, with a greater length dimension L than width dimension W, and placing the containers C in the box so that they are in offset or staggered relationship, as seen best in  FIGS. 5 and 6 . With this arrangement, the boxes may be cross-stacked in interlocking relationship to produce a stable stack without requiring the use of layer sheets. Moreover, the boxes may be arranged on the pallet P so that the footprint or area occupied by the boxes is substantially equal to the surface area of the pallet, thus enabling optimum pallet utilization. 
         [0039]    The boxes may be arranged in different ways to achieve interlocking when stacked and to maximize use of the pallet surface, as depicted for example in  FIGS. 6 and 7 . 
         [0040]    A second embodiment of a box according to the invention is shown at  14  in  FIGS. 8-11  and  19 . The box  14  has a bottom wall  15 , opposite end walls  16  and  17 , opposite side walls  18  and  19 , and angled interior corner panels  20  and  21  extending across the interior of the box from a respective side wall to an adjoining end wall at each of two diagonally opposite corners of the box, defining a generally parallelogram-shaped box interior, as seen best in  FIG. 10 . 
         [0041]    Large openings  22  and  23  are formed in the side walls, extending from the top of the wall to an upstanding, narrow, bottom side wall segment  24  at the bottom of the opening, and offset slightly toward respective opposite ends of the box, defining a narrow first side wall end segment  25  at one end of the side wall, and a relatively wider second side wall end segment  26  at the other end of the side wall. The angled interior corner panels are foldably joined at one edge  27  to the respective second side wall end segments at the edge of the respective openings  22  and  23 , and are affixed to the adjacent end wall by a glue flap  28  on the opposite free edge of the corner panel. 
         [0042]    When four one-gallon containers C are placed in the box, they are oriented in nested, offset or staggered relationship as depicted in  FIGS. 5 ,  6  and  8 . The containers, and thus labels or graphics on the containers, are visible through the large openings  22  and  23 , and the containers are retained in the box by the upstanding narrow bottom side wall segment  24 , the angled interior corner panels  20  and  21 , and the narrow first side wall end segment  25 . 
         [0043]    The interior corner panels  20  and  21  and adjacent side and end wall portions define triangular reinforcing structures at two diagonally opposite corners of the box, lending stacking strength to the box and enabling boxes filled with containers to be stacked two or more pallets high without imposing load on the containers. 
         [0044]    A blank B 1  for forming the box of  FIGS. 8 and 10  is shown in  FIG. 9 , and comprises a single unitary piece of corrugated board that is die-cut and scored to form an elongate, rectangular center panel  30  that forms the bottom wall  15  in the erected box. First side wall panels  31  and  32  are foldably joined to opposite side edges of the bottom-forming panel  30 , and define the bottom side wall segments  24  in the erected box. End-wall-forming panels  33  and  34  are foldably joined to opposite ends of the bottom-forming panel  30 , and a second side wall panel  35  is foldably joined along one edge of each panel  33  and  34  to form the narrow first side wall segments  25  in the erected box. Relatively wider third side wall panels  36  and  37  are foldably joined along one edge to the opposite side edges of the panels  33  and  34 , and form the second, wider side wall segments  26  in the erected box. Corner panel-forming panels  38  and  39  of greater width than the panels  36  and  37  but narrower than panels  30 - 34  are foldably joined along one edge to the panels  36  and  37  and form the angled interior corner panels in the erected box. Narrow flaps  40  and  41  are foldably joined to the opposite edges of panels  38  and  39  and form the glue flaps  28 . In the erected box, the glue flaps  28  are adhesively secured to an interior surface of the adjacent end wall, and the flaps  31  and  32  are folded upwardly and glued to an outer surface of the respective side end wall segments  25  and  26 . 
         [0045]    It will be noted that a continuous score  42  extends along the length of the blank at opposite sides of the bottom-wall-forming panel  30  and the end-wall-forming panels  33  and  34 , and in the particular example shown, short cuts  43  are spaced along these scores. Further, in the particular example shown, the scores  44  separating the panels  36  and  38  and the panels  37  and  39 , and the scores  45  separating the panels  38  and  40  and the panels  39  and  41  comprise lines of perforations  46 . It should be understood, however, that the cuts and perforations need not be employed and the scores could comprise creased areas. 
         [0046]    As indicated in  FIG. 11 , the containers C may be inverted and placed upside down in the box  14 , where they are retained by the angled corner panels  20  and  21 , the bottom side wall segment  24  and the narrow side wall segment  25 . This feature enables the container manufacturer to place empty containers in the box for shipment to a facility where the containers are to be filled. 
         [0047]    A third embodiment of the box of the invention is shown at  50  in  FIG. 12 . This embodiment is substantially the same as the first embodiment  14  described above, except the bottom wall segments  51  and  52  are substantially wider, resulting in effectively higher side walls and a smaller opening through the side walls, and the glue flaps  53  that attach the free edge of the angled interior corner panels  54  and  55  to the adjacent end walls are wider, extending all the way into the opposite corner of the box. 
         [0048]    A blank B 2  for forming the box of  FIG. 12  is shown in  FIG. 13 , and is essentially the same as the blank B 1  described above, except for the wider panels  56  forming the bottom side wall segments  51  and  52 , and the wider panels  57  forming the corner panel glue flaps  53 . 
         [0049]    A fourth embodiment of the box of the invention is shown at  60  in  FIG. 14 , and is essentially the same as the first embodiment  14  described above, except that the side walls  61  and  62  are full height, with no opening or cut-out in them. 
         [0050]    A blank B 3  for forming the box of  FIG. 14  is shown in  FIG. 15 , and is essentially the same as the blank B 1  described above, except for the width of side wall panels  61  and  62 , which have the same width as the height of the end walls. 
         [0051]    A fifth embodiment of the box of the invention is shown at  70  in  FIG. 16 . In this embodiment, separate inserts  71  and  72  of triangular cross-section are inserted into two diagonally opposite corners of a partial depth rectangular box or tray  73  similar to the box  12  shown in  FIGS. 4-6 . The box  73 , taken alone, is of substantially conventional construction and can be used for many purposes. It has side and end walls  74  and  75  of equal height, but only about one-half the height of the containers C placed in the box. In accordance with the present invention, the inserts  71  and  72  project above the height of the side and end walls and slightly above the height of the containers. 
         [0052]    A blank B 4  for forming the box  73  is shown in  FIG. 17 , and comprises four rectangular panels  76 ,  77 ,  78  and  79  foldably joined together along spaced transverse score lines  80 . A glue tab  81  is foldably joined to a panel  79  at one end of the blank for adhesive attachment to the panel  76  at the opposite end of the blank when the box is erected. Bottom forming flaps  82 ,  83 ,  84  and  85  are foldably connected along one edge of the respective side-wall-forming panels  76 ,  77 ,  78  and  79 . 
         [0053]    A blank B 5  for forming the triangular corner inserts  71  and  72  is shown in  FIG. 18  and comprises first, second and third panels  86 ,  87  and  88  joined along scores  89 . 
         [0054]    In  FIG. 19  a plurality of containers C′ of square cross-section are shown placed in the box  14  of  FIGS. 8-11 . This capability exists for all embodiments of the invention. This figure also clearly shows how the containers are retained in place in the box in spite of the large openings through the side walls. 
         [0055]    A sixth embodiment of the box of the invention is shown at  90  in  FIG. 20 . This embodiment is similar to the embodiment of  FIG. 8 , except the panels  91  and  92  foldably joined to opposite side edges of the bottom-forming panel  30  have a width to extend the full height of the box, and shaped cut-outs  93  are formed in them to provide the openings through which the containers are visible. This arrangement also produces a double thickness side wall  94  in the area between the respective angled interior corner panels  20  and  21  and the adjacent end walls. 
         [0056]    A blank B 6  for forming the box  90  is shown in  FIG. 21 . This blank is the same as the blank B 1  shown in  FIG. 9 , except for the panels  91  and  92  and the cut-outs  93  in these panels. 
         [0057]    A seventh embodiment  100  is shown in  FIGS. 22 and 23 , and is similar to the embodiment shown in  FIGS. 4 and 5 , except in this embodiment the side walls  101  and end walls  102  have a height greater than the height of containers C placed in the box, and a cut-out  103  is formed in one end wall. 
         [0058]    While particular embodiments of the invention have been illustrated and described in detail herein, it should be understood that various changes and modifications may be made to the invention without departing from the spirit and intent of the invention as defined by the scope of the appended claims.