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 air cell structure that allows for a container with a constant outside volume to have a variable inside volume. The air cell structure container functions to prevent telescoping of vertically stacked container and for strength and stability. The container may be partially assembled for shipping and hand set into final assembly as needed.

Description:
FIELD OF THE INVENTION 
     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 
       Various embodiments of the present invention are described in detail below with reference to the following drawings. 
         FIG. 1  is a plan view of a single piece of container blank formed in accordance with an aspect of the present invention; 
         FIG. 2  is a perspective view of a partially assembled container assembly according to an aspect of the present invention; 
         FIG. 3  is another perspective view of a partially assembled container assembly according to yet an another aspect of the present invention; 
         FIG. 4  is a perspective view of the assembled container blank of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     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 4 . An embodiment of the present invention includes a single piece blank  20  of foldable material arranged to form a container  60 . Specific details of the blank  20  in container  60  are described with more particularity below. 
       FIG. 1  depicts a blank  20  used to form the container  60 . 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  60 . 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. 
     With respect to  FIG. 1 , the blank includes an outer back panel  22 , opposed outer side panels  24  and outer front flaps  26 . The outer back panel  22  is generally rectangular or square in shape and is connected with the outer side panels  24  along a fold line  23 . The outer back panel  22  is also connected with a rear top panel  30  along a fold line  25 , and with an outer bottom panel  44  along a fold line  27 . 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 outer back panel  22 . 
     An outer side panel  24  is generally rectangular or square in shape. The length of the outer side panels  24  measured along fold line  23  is substantially equal to the length of the outer back panel  22  measured along the same fold line. 
     Outer front flap  26  is generally L-shaped and is connected with the outer side panel  24  along fold line  29 . The length of the outer front flap  26  measured along fold line  29  is substantially equal to the width of the outer side panel  24  measured along the same fold line. However, an outer front flap that is shorter than the outer side panel  24  when measured along fold line  23  is considered within the scope of this aspect of the invention. 
     Inner bottom panel  28  is connected with the outer side panels  24  along fold line  33 . The length of the outer side panels  24  measured along fold line  33  is generally greater than the length of the inner bottom panel  28  measured along the same fold line. Inner bottom panel  28  may include cutout  54  formed in a periphery of the panel. Likewise, inner bottom panel  28  may have a profile such that the width of the panel measured in a directed parallel to fold line  33 , and at the fold line  33  is not equal to the width measured a distance perpendicular to fold line  33 . 
     Top side panel  32  is connected with the outer side panels  24  along fold line  31 . Also an inner side panel  38  is connected with the top side panel  32  along a fold line  35 , which is opposite the outer side panel  24 . The length of the outer side panels  24  measured along fold line  31  is generally greater than the length of the top side panel  23  measured along fold line  35 . 
     Connected with the inner side panel  38  along a fold line  39  is an inner side panel flap  40 . In overall shape, the inner side panel flap  40  is similar in partial profile to a portion of the inner bottom panel  28 , however, their relative overall sizes may be either the same or different. It will be appreciated that the cutouts  54 , or portions thereof, if present, will be at least partially aligned once the container  60  is erected as disclosed below. 
     Inner back panels  34  are generally rectangular or square in shape. The inner back panels  34  are connected with the rear top panel  30  along a fold line  41 . The length of the inner back panel  34  measured along fold line  41  is than the length of the outer back panel  22  measured along fold line  25 . Additionally, an inner back panel flap  36  is connected with both of the inner back panels  34  along a fold line  43 . Generally, the inner back panel flap  36  is trapezoidal in shape, however it will be appreciated that it my have other geometries as well. 
     Connected with each of the inner back panels  34  are back panel flaps  56 . The back panel flaps  56  are connected with the inner back panels  34  along fold lines  57 . Generally, the back panel flaps  56  are rectangular or square in shape, with their ultimate geometry being a function of container design. 
     In order to further illustrate the various aspects about the embodiments,  FIGS. 2 through 4 , depict the blank  20  being erected into container  60 . Typically, this is a hand-set container  60 . However, it will be understood that mechanical box erecting equipment may be used in the erection of the container  60 . 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. Typically, this container  60  will use a combination of mechanical box forming equipment and hand set forming, as is discussed in more detail below. 
     With specific reference to  FIG. 2 , blank  20  is folded inwardly approximately 180 degrees along fold lines  31  and  25 . In doing so, the inner side panels  38  and top side panel  30  are juxtaposed the outer side panel  24 . Likewise, the inner back panel  34  and rear top panel  30  are juxtaposed the outer back panel  22 . Also, the various inner side and back panels  38  and  34 , respectively, are arranged such that inner side panel flap  40  is juxtaposed and aligned with inner bottom panel  28 . Also, inner back panel flap  36  is juxtaposed a portion of the outer bottom panel  44 . 
     At this point the respective panels and flaps may be glued where needed and shipped in the flattened state. This aspect allows for partial assembly of the boxes to be shipped efficiently. Once the partially assembled container arrives at a final destination, they may be finally assembled and used. 
     The erection process continues with folding the various panels around fold line  23 , as best seen in  FIG. 3 . This move puts the inner bottom panels  28  juxtaposed the outer bottom panel  44 . This double bottom panel arrangement provides considerable strength to the final container  60 . 
     Outer front panel  46  may them be folded upwardly approximately 90 degrees along fold line  27 . Subsequently, the inner front panel  50  may be folded downwardly about spaced apart fold line  48 , trapping the projection portion of outer front flap  26  between the inner front panel  50  and outer front panel  46 . As best seen in  FIG. 4 , the inner front panel  50  may be locked in place by any variety of means, including locking tabs, fasteners or adhesives (not shown). Likewise, back panel flaps  56  may be folded outwardly approximately 90 degrees. The container  60  is now ready for use. 
     The inner and outer side and back panels being separated by the rear top panel  30  and top side panel  32  form “air cells” between the respective inner and outer panels. Those skilled in art will appreciate that the respective size of the rear top panel  30  and top side panel  32  may be varied to achieve air cells of differing size. Thus, for a single outer container volume, any variety of inner container volume may be achieved. Having a container design with a constant outer box volume yet variable inner box volume serves to, among other things, maximize pallet space usage regardless of the overall geometry of the product being placed in the container  60 . Also, the variable top, side, and rear panel size provides additional bearing surface and stability when stacking the containers  60  vertically. Further, it will be appreciated that this one piece design does not require additional corrugated inserts typically required for additional stacking strength, and/or void fillers. 
     The container  60  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. It is display ready once formed. 
     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.