Abstract:
An elongate, rectangular box ( 16, 60, 80 ) 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 diagonally offset relationship to one another in a parallelogram-shaped arrangement, and interior corner inserts ( 14,15, 61,62, 81,82 ) are placed in the boxes to form diagonal interior corner panels extending across two diagonally opposite corners of the box, defining an interior box shape closely conforming to the parallelogram-shaped arrangement of the containers. The inserts also define structure that supports one box on top of one another when the boxes are stacked. The box is especially suited for packaging four one-gallon containers.

Description:
[0001]     This application is a continuation-in-part of application Ser. No. 10/799,967, filed Mar. 12, 2004. 
     
    
     TECHNICAL FIELD  
       [0002]     This invention relates to packaging, and more particularly to a stackable shipping and display box.  
       BACKGROUND ART  
       [0003]     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 regular slotted containers (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. In this regard, normally it is desired to not exceed a case weight of 40 pounds. These conventional boxes are square in plan view, with the one-gallon containers orthogonally oriented in side-by-side relationship to one another.  
         [0004]     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.  
         [0005]     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.  
         [0006]     Applicant&#39;s prior copending application Ser. No. 10/799,967, discloses a shipping and display box that, when filled with containers of product, has a maximum desired weight, is configured to enable stable stacking of filled boxes, optimally utilizes pallet space, and places no load on the product containers, all without requiring the use of separate layer sheets, or separate internal or external pieces intended solely as reinforcements. The box in the prior application is designed for machine set-up, and except for the embodiment illustrated in  FIGS. 16-18  is made from a single unitary blank of corrugated board. However, in some instances it may be desirable to manufacture the box in a flattened condition for storage and shipment to a user, where the box can be set up by hand.  
         [0007]     Accordingly, there is need for a stackable shipping and display box having the novel features of the box disclosed in prior copending application Ser. No. 10/799,967, but wherein the box can be set up by hand.  
       DISCLOSURE OF THE INVENTION  
       [0008]     The present invention comprises a box for shipping and displaying product, wherein the box can be set up by hand, has a desired case weight, is configured so that filled boxes can be stacked in stable interlocked relationship, optimally utilizes pallet space, and the product containers are not subjected to load when filled boxes are stacked on top of one another.  
         [0009]     The box of the invention comprises a rectangular tray having predetermined length and width dimensions to hold a desired number of product containers in contiguous, side-by-side, diagonally offset relationship to one another. The diagonally offset placement of the containers results in interior spaces at two diagonally opposite corners of the box, and at least one separate insert is placed in the box, forming angled corner panels that 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. The tray and insert are each made from respective blanks of corrugated board that can be folded by hand.  
         [0010]     The rectangular shape of the boxes enables boxes in adjacent layers to be cross-stacked and interlocked for stable stacking, and the diagonally offset relationship of the containers in the box results in outer box dimensions that maximally utilize pallet space when the boxes are stacked on a pallet. 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. Boxes incorporating the invention can be stably stacked two or more pallets high and without imposing a vertical load on the containers.  
         [0011]     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. When loaded with four one-gallon containers of juice, for example, a package using the box of the invention has a case weight that is less than about 40 pounds.  
         [0012]     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.  
         [0013]     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  
       [0014]     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:  
         [0015]      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.  
         [0016]      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.  
         [0017]      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.  
         [0018]      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.  
         [0019]      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.  
         [0020]      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.  
         [0021]      FIG. 7  is a top plan view depicting how the rectangular boxes of the invention might be alternately arranged on a pallet.  
         [0022]      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 comprises a rectangular tray having roll-over side panels and two inserts placed in diagonally opposite corners, with the inserts held in place by tabs folded inwardly from the tray end walls through adjacent panels of the inserts, and wherein the inserts have a first panel extending completely across the end of the tray, and a reversely folded panel for enhanced stacking strength.  
         [0023]      FIG. 9  is a top plan view of the box of  FIG. 8 .  
         [0024]      FIG. 10  is a top perspective view of a second embodiment of the box, showing only one insert, although it is to be understood that an identical insert would be placed in the opposite end of the tray, wherein the insert has a first panel that extends only partially across the end wall of the tray, and a second panel with a first diagonally extending portion extending to adjacent the end of the first panel, and a second portion extending from the end of the first panel the rest of the way across the end of the tray, with a tab on the end of the first panel engaged in a slot in the top edge of the second panel at the juncture between the first and second portions.  
         [0025]      FIG. 11  is a fragmentary top plan view of the box of  FIG. 10 .  
         [0026]      FIG. 12  is a top plan view of a third embodiment, wherein the inserts have reversely folded panels, but the tabs are omitted.  
         [0027]      FIG. 13  is a fragmentary top perspective view of a portion of the box of  FIG. 12 , showing an end panel on the insert terminating adjacent the roll-over panel on the tray side wall.  
         [0028]      FIG. 14  is a plan view of a blank for making the tray of  FIGS. 8-13 .  
         [0029]      FIG. 15  is a plan view of a blank for making the insert of  FIGS. 8 and 9 .  
         [0030]      FIG. 16  is a plan view of a blank for making the insert of  FIGS. 12 and 13 .  
         [0031]      FIG. 17  is a plan view of a blank for making the insert of  FIGS. 10 and 11 .  
         [0032]      FIG. 18  is a plan view of a blank for making a tray similar to the tray shown in  FIGS. 12 and 13 , except that the tray has roll-over end panels rather than roll-over side panels.  
         [0033]      FIG. 19  is a plan view of a blank for making a tray intended for machine set up.  
         [0034]      FIG. 20  is a top perspective view of the box of  FIG. 10 , showing four inverted containers placed therein in upside-down, offset relationship. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0035]     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 in  FIG. 2 , 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, often 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.  
         [0036]     The invention solves this problem, as depicted somewhat schematically in  FIGS. 4-7 , by making the boxes  12  rectangular in shape, with a greater length dimension L than width dimension W, i.e., the width dimension is approximately 75% of the length dimension, and by sizing the box in relation to the containers to be placed in it so that when a predetermined number of rows of containers are placed in the box they will assume a staggered, diagonally offset relationship, as seen best in  FIGS. 5, 6 ,  8  and  9 . The rectangularly shaped 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. 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 .  
         [0037]     Inserts  14  and  15  are placed in the boxes to define a generally parallelogram-shaped box interior, as seen best in  FIGS. 9, 12  and  20 , that conforms generally to the outline of the diagonally offset containers and helps hold the containers in place, as well as to provide a strong structure for supporting boxes filled with containers in stacked relationship on top of one another.  
         [0038]     A first embodiment of a box according to the invention is shown at  16  in  FIGS. 8, 9 ,  14  and  15 . The box  16  comprises a tray  17  with opposite side walls  18  and  19 , opposite end walls  20  and  21 , and a bottom wall  22 . As depicted herein, the side and end walls have a relatively short height, although they could have greater height if desired.  
         [0039]     The inserts  14  and  15  placed in diagonally opposite corners of the tray form diagonally extending panels  23  and  24  across the corners. Containers C placed in the tray are supported in diagonally offset relationship by the rectangularly shaped tray and the inserts. The inserts also enable loaded boxes to be stacked on top of one another without imposing load on the containers.  
         [0040]     The tray is erected by hand from a single blank B 1  as shown in  FIG. 14 , and is manufactured and shipped to a user in the flattened condition shown in this figure. The blank comprises a central rectangular panel  22  that forms the bottom wall of a tray erected from the blank. A pair of spaced slots  25  and  26  are formed through the panel  22  at each of its opposite side edges. End wall panels  20  and  21  are foldably joined along fold scores or creases  27  to the opposite ends of the bottom-forming panel  22 , and flaps  28  and  29  are foldably joined to opposite ends of the panels  20  and  21 . A bendable tab  30  is formed in the outer edge of each end wall panel  20  and  21  for a purpose to be described hereinafter.  
         [0041]     First side wall panels  31  and  32  are each foldably joined along a first edge thereof to respective opposite side edges of the panel  22  by fold scores or creases  33 , and second side wall panels  34  and  35  are foldably joined along a first edge thereof to a second edge of respective first side wall panels by closely spaced double scores or crease lines  36 ,  37 . The second side wall panels  34  and  35  comprise roll-over panels, and a pair of tabs  38  and  39  on the outer edge of the roll-over panels engage in the slots  25  and  26  when the side wall panels are folded up and inwardly to form the side walls  18  and  19 . It will be noted that the roll-over panels  34  and  35  are cut away at one end  40 . These cut-outs form a space for accommodating an insert panel as described hereinafter.  
         [0042]     To erect the tray  17  from the blank B 1 , the end wall panels  20  and  21  are first folded upwardly, with the flaps  28  and  29  being folded inwardly in general alignment with opposite side edges of the bottom panel  22 . The first side wall panels  31  and  32  are then folded upwardly, and the second side wall panels  34  and  35  are folded inwardly and downwardly, capturing the flaps  28  and  29  between the first and second side wall panels, which form outer and inner side wall panels, respectively, in the erected container. The tabs  38  and  39  are then engaged in the slots  25  and  26  to hold the tray in assembled position.  
         [0043]     The inserts  14  and  15  are identically constructed and a blank for forming the inserts is indicated at B 2  in  FIG. 15 . Each insert comprises: a first panel  41  extending the width of the respective end wall  20 ,  21 ; a second, relatively narrow panel  42  extending perpendicular to one edge of the first panel and lying against an adjacent corner portion of the respective side wall  18 ,  19  and fitted in the space left by the cut-out  40  in the roll-over panel; a third panel  43  narrower than the first but wider than the second panel foldably connected at a first edge to the other edge of the first panel and extending perpendicularly therefrom and lying against an adjacent portion of the side wall opposite that against which second panel  42  lies; a fourth panel  44  wider than the third but narrower than the first foldably connected at a first edge to a second edge of the third panel and extending diagonally therefrom with its second edge in a position adjacent the first panel and between the opposite side edges of the first panel; and a fifth panel  45  foldably connected to the second edge of the fourth panel and extending therefrom in contiguous, parallel relationship to the first panel and terminating at a free edge at the juncture of the first and third panels.  
         [0044]     The bendable tab  30  formed in an upper edge of each tray end wall is inserted through aligned openings  51  and  52  in the first and fifth panels  41  and  45  to hold the insert in its operative folded position and in the tray.  
         [0045]     The inserts are erected by hand from a single blank B 2  ( FIG. 15 ). To erect the insert, it is folded into generally the configuration shown in  FIGS. 8 and 9  and then placed in the tray, after which the tab  30  is inserted through the openings  51  and  52  to hold the insert in place.  
         [0046]     A second embodiment of the invention is indicated generally at  60  in  FIGS. 10, 11 ,  17  and  20 . In this form, the inserts  61  and  62  (both are shown in  FIG. 20 ) comprise a first panel  63  that extends only part way across the respective end wall  20 ,  21  from a first edge located in a first corner of the tray, terminating at a free edge  64  spaced from the opposite corner. A second panel  65  is foldably connected at one edge to said first edge of the first panel, and extends perpendicularly therefrom to lie against the respective adjacent side wall  18  or  19 . A third panel  66  is foldably connected at a first edge thereof to a second edge of the second panel  65  and extends diagonally across the interior corner of the tray to a second edge adjacent the free edge of the first panel. A fourth panel  67  is foldably connected at one edge to the second edge of the third panel and extends at an angle therefrom to lie against the end wall between the free edge of the first panel and a second corner of the tray opposite the first corner. A fifth panel  68  is foldably connected to a second edge of the fourth panel and extends perpendicularly therefrom to lie against the side wall in said second corner. A notch  69  is formed in the top edge of the insert at the juncture of the third and fourth panels, and a tab  70  at the upper end of the free edge of the first panel is engaged in the notch to hold the insert in its operative folded relationship. The tab  30  on the upper edge of the tray end wall is engaged in opening  51  in the first panel to hold the insert in the tray. A third embodiment is indicated generally at  80  in  FIGS. 12, 13  and  16 . In this embodiment the inserts  81  and  82  are constructed essentially the same as the inserts  14 ,  15  shown in  FIGS. 8, 9  and  15 , except that the tab  50  and openings  51 ,  52  are omitted. The inserts  81  and  82  are retained in place by their snug fit and frictional engagement with the side and end walls of the tray  17 ′. Each insert is made from a blank B 3 , shown in  FIG. 16 , and comprises a first panel  41 ′ extending the width of the respective end wall  20 ,  21 ; a second, relatively narrow panel  42  extending perpendicular to one edge of the first panel and lying against an adjacent corner portion of the respective side wall  18 ,  19  and fitted in the space left by the cut-out  40  in the roll-over panel; a third panel  43  narrower than the first but wider than the second panel foldably connected at a first edge to the other edge of the first panel and extending perpendicularly therefrom and lying against an adjacent portion of the side wall opposite that against which second panel  42  lies; a fourth panel  44  wider than the third but narrower than the first foldably connected at a first edge to a second edge of the third panel and extending diagonally therefrom with its second edge in a position adjacent the first panel and between the opposite side edges of the first panel; and a fifth panel  45 ′ foldably connected to the second edge of the fourth panel and extending therefrom in contiguous, parallel relationship to the first panel and terminating at a free edge at the juncture of the first and third panels.  
         [0047]     A blank B 4  for making a modified tray that could be used with the embodiment of  FIGS. 12, 13  and  16  is shown in  FIG. 18 . A tray made from this blank has generally the same function as the tray  17  shown in  FIG. 14 . A tray made from blank B 4  differs from tray  17  in that the positions of the roll-over panels  34 ′,  35 ′ and the end wall panels  20 ′,  21 ′ and their associated flaps  28 ′,  29 ′ are reversed, so that the roll-over panels are on the ends of the tray rather than the sides, and the slots  25 ′,  26 ′ for receiving the tabs  38 ′ and  39 ′ on the roll-over panels are at the ends rather than the sides of the tray bottom  22 ′. Further, in this embodiment the tabs  30  in the end walls and the corresponding openings  51 ,  52  in the insert are omitted.  
         [0048]     A further modified blank B 5  that could be used with any of the inserts described herein is shown in  FIG. 19 . This blank would be used for machine set up of a tray, wherein the side panels  90 ,  91  would be folded upwardly, with the flaps  92 ,  93  at the ends of the side panels folded inwardly in general alignment with the scores or creases  94  joining end panels  95 ,  96  to the bottom-formning panel  97 . The end panels  95 ,  96  would be folded up and glued to the flaps to hold the tray in erected position.  
         [0049]     When four one-gallon containers C are placed in any of the embodiments of the box of the invention, they are oriented in nested, offset or staggered relationship as depicted in  FIGS. 5, 6 ,  8 ,  9  and  20 . The containers, and thus labels or graphics on the containers, are visible through the large openings or spaces between the inserts at the sides of the box, and the containers are retained in the box by the upstanding side walls and inserts, and the angled interior corner panels.  
         [0050]     The inserts 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.  
         [0051]     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.