Patent Publication Number: US-11383878-B2

Title: Box container and display

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part application of each of the following:
         U.S. patent application Ser. No. 15/596,381, filed May 16, 2017, now U.S. Pat. No. 10,647,468, which is a continuation application of U.S. patent application Ser. No. 14/997,685, filed Jan. 18, 2016, now U.S. Pat. No. 9,682,795, which is a continuation application of U.S. patent application Ser. No. 13/955,925, filed Jul. 31, 2013, now U.S. Pat. No. 9,238,523, which claims priority benefit, with regard to all common subject matter, of earlier-filed U.S. Provisional Patent Application No. 61/677,979, filed Jul. 31, 2012, and entitled “IMPROVED STACKABLE TRAY,” the entire disclosures of which are incorporated herein by reference.   U.S. patent application Ser. No. 16/505,137, filed on Jul. 8, 2019, which is a continuation application of U.S. patent application Ser. No. 15/960,338, filed Apr. 23, 2018, now U.S. Pat. No. 10,342,365, which is a continuation application of U.S. patent application Ser. No. 13/955,865, filed Jul. 31, 2013, now U.S. Pat. No. 9,949,579, which claims priority benefit, with regard to all common subject matter, of earlier-filed U.S. Provisional Patent Application No. 61/677,966, filed Jul. 31, 2012, and entitled “TRIFEED HUTCH SHELF,” the entire disclosures of which are incorporated herein by reference.   U.S. patent application Ser. No. 15/952,928, filed Apr. 13, 2018, which is a continuation application of U.S. patent application Ser. No. 14/679,586, filed Apr. 6, 2015, now U.S. Pat. No. 9,947,245, which is a continuation application of U.S. patent application Ser. No. 13/955,811, filed Jul. 31, 2013, now U.S. Pat. No. 8,997,388, which claims priority benefit, with regard to all common subject matter, of earlier-filed U.S. Provisional Patent Application No. 61/677,937, filed Jul. 31, 2012, and entitled “FACETED CORRUGATED SIGNAGE,” the entire disclosures of which are incorporated herein by reference.   U.S. patent application Ser. No. 16,520,270, filed Jul. 23, 2019, which is a continuation application of U.S. patent application Ser. No. 15/956,575, filed Apr. 18, 2018, now U.S. Pat. No. 10,390,634, which is a continuation application of U.S. patent application Ser. No. 15/363,256, filed Nov. 29, 2016, now U.S. Pat. No. 9,986,856, which is a continuation application of U.S. patent application Ser. No. 14/968,352, filed Dec. 14, 2015, now U.S. Pat. No. 9,578,978, which is a continuation application of U.S. patent application Ser. No. 14/146,130, filed Jan. 2, 2014, now U.S. Pat. No. 9,212,019, which claims priority benefit, with regard to all common subject matter, of earlier-filed U.S. Provisional Patent Application No. 61/748,672, filed Jan. 3, 2013, and entitled “MODULAR GREETING CARD RACK,” the entire disclosures of which are incorporated herein by reference.   U.S. patent application Ser. No. 15/912,180, filed Mar. 5, 2018, which is a continuation application of U.S. patent application Ser. No. 15/369,574, filed Dec. 5, 2016, now U.S. Pat. No. 9,908,663, which is a continuation application of U.S. patent application Ser. No. 14/216,274, filed Mar. 17, 2014, now U.S. Pat. No. 9,511,899, which claims priority benefit, with regard to all common subject matter, of earlier-filed U.S. Provisional Patent Application No. 61/793,340, filed Mar. 15, 2013, and entitled “ONE PIECE PALLET SKIRT,” the entire disclosures of which are incorporated herein by reference.   U.S. patent application Ser. No. 16/236,920, filed Dec. 31, 2018, which is a continuation application of U.S. patent application Ser. No. 15/790,692, filed Oct. 23, 2017, now U.S. Pat. No. 10,170,021, which is a continuation application of U.S. patent application Ser. No. 14/840,417, filed Aug. 31, 2015, now U.S. Pat. No. 9,799,239, which is a continuation application of U.S. patent application Ser. No. 14/216,721, filed Mar. 17, 2014, now U.S. Pat. No. 9,123,262, which claims priority benefit, with regard to all common subject matter, of earlier-filed U.S. Provisional Patent Application No. 61/791,437, filed Mar. 15, 2013, and entitled “FACETED CORRUGATED SIGNAGE,” the entire disclosures of which are incorporated herein by reference.   U.S. patent application Ser. No. 15/687,791, filed Aug. 28, 2017, which is a continuation application of U.S. patent application Ser. No. 14/595,988, filed Jan. 13, 2015, now U.S. Pat. No. 9,743,782, which claims priority benefit, with regard to all common subject matter, of earlier-filed U.S. Provisional Patent Application No. 61/926,805, filed Jan. 13, 2014, and entitled “RETAIL UPRIGHT SHELF EXTENDER,” the entire disclosures of which are incorporated herein by reference.       

    
    
     FIELD OF THE INVENTION 
     Embodiments of the present invention relate generally to the field of point of purchase merchandise shipping and display containers. More particularly, embodiments of the present invention relate to a corrugated, paperboard container and display that is manufactured in a fold and glue assembly process and that is traditionally provided to an end user in a collapsed or knockdown configuration for setup. 
     BACKGROUND 
     Corrugated containers are made from pieces of flat paperboard stock material that are die cut into shapes that define various panels. The shapes are folded along predefined lines between the panels with at least one overlapping strip or panel that is glued, taped or otherwise affixed to another panel to form an enclosed boundary. The panels are folded and/or glued into place to become the walls of the container. The containers are traditionally provided to product manufacturers and/or retailers in a collapsed or knock-down configuration for storage, handling and shipping. The manufacturer and/or retailers open the knockdown containers and fold appropriately to utilize the assembled container for packing and/or displaying products therein. 
     The knockdown containers are typically manufactured by feeding flat die cut sheets through a fold-and-glue machine. The fold-and-glue machine applies adhesive and folds over select panels so that the panels are in the knock-down configuration. One common knock-down container is an open-top style box container. An open-top style box container is typically used to ship products to retailers, who can then display the products to consumers at the retailer&#39;s point-of-sale location. It is desirable to minimize the time and effort necessary for retailers to assemble a container from its knock-down configuration. Thus, such container suppliers typically attempt to design containers that do not require separate discrete parts such as reinforcing inserts or dividers. However, in circumstances in which heavy products are being displayed in the containers, it is often necessary to utilize separate metal supports and/or corrugated support dividers to handle the heavy load. This adds considerably to the assembly labor as well as material costs for the container. Furthermore, other circumstances may require the containers to transport and secure fragile items. Standard open-top style box containers are generally not appropriate for handling such fragile items because the open-top does not provide the security required for the fragile items. 
     An example of such an open-top style box container is shown and described in U.S. Pat. No. 7,981,017 (the &#39;017 patent”), the entire disclosure of which is incorporated herein by reference. However, the container disclosed in the &#39;017 patent is not configured to handle heavy loads or to maintain fragile items therein. Therefore, it would be beneficial to provide a box container that can accommodate heavier product loads without requiring additional support members and that can support fragile items safely during transport and display. 
     SUMMARY 
     Embodiments of the present invention include a corrugated box container with a main component including a base section and first and second side sections. The box container additionally includes first and second side support components associated with the first and second side sections for reinforcing the first and second side support sections. The box container further includes a cover component that can be engaged with the main component or the first and second side support components, such that the main component and the cover component present a fully enclosed space within the box container. 
     Embodiments of the present invention additionally include a method for making a corrugated box container, with the method including the initial step of forming a main component that includes a base section opposed on sides by a first side section and a second side section. The next step includes forming fold lines between the first side section and the base section and between the second side section and the base section. The method additionally includes the step of forming side support components that can be associated with each of the first and second side sections of the main component to reinforce the side sections. The method includes the final step of forming a cover component operable to be engaged with the main component or the first and second side support components so as to fully enclose a space within the box container. 
     Embodiments of the present invention additionally include a method of erecting a corrugated box container, with the method including providing the box container in a knockdown configuration, with the box container having a main component comprising a base section opposed by first and second side sections, first and second side support components, and a cover component. The method includes folding the first and second side sections until the side sections are generally perpendicular with the base section. The method includes the next step of connecting the first and second side support components with the first and second side sections respectively, such that the support components are operable to reinforce the side sections. Finally, the method includes the step of connecting the cover component with the main component or the first and second side support components so as to provide a fully enclosed space within the box container. 
     The foregoing and other objects are intended to be illustrative of the invention and are not meant in a limiting sense. Many possible embodiments of the invention may be made and will be readily evident upon a study of the following specification and accompanying drawings comprising a part thereof. Various features and subcombinations of invention may be employed without reference to other features and subcombinations. Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, an embodiment of this invention and various features thereof. 
    
    
     
       BRIEF DESCRIPTION 
       Embodiments of the present invention are described in detail below with reference to the attached drawing figures, wherein: 
         FIG. 1  is a perspective view of the box container according to embodiments of the present invention, with the box container including a main component, two side support components, and a cover component; 
         FIG. 2  is a perspective view of the main component from  FIG. 1  in a knockdown configuration; 
         FIG. 3  is a perspective view of one of the side support components from  FIG. 1  in a knockdown configuration; 
         FIG. 4  is a perspective view of the cover component from  FIG. 1  in a knockdown configuration; 
         FIG. 5  is a perspective view of the main component from  FIGS. 1 and 2  in an erected configuration; 
         FIG. 6  is a perspective view of the main component from  FIGS. 1, 2, and 5  with two side support components from  FIGS. 1, and 3  secured thereto, each in an erected configuration; and 
         FIG. 7  is a perspective view of the main component from  FIGS. 1, 2, 5 and 6  with the two side support components from  FIGS. 1, 3, and 6  secured thereto, and further including the cover component from  FIGS. 1 and 4  secured thereto, all in an erected configuration. 
     
    
    
     APPENDIX A includes a copy of one issued patent from each of the seven patent families associated with this continuation-in-part application. 
     The drawing figures do not limit the present invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. 
     DETAILED DESCRIPTION 
     As required, a detailed embodiment of the present invention is disclosed herein; however, it is to be understood that the disclosed embodiment is merely exemplary of the principles of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. 
     As shown in  FIG. 1 , embodiments of the present invention include a box container  10  that includes a main component  12  having a base section  14  opposed by a first side section  16  and a second side section  18 ; side support components  20  operable engage with the first side section and the second side section of the main component; and a cover component  22  operable engage with portions of the first and second side support sections and to act as a cover for the box container. In some embodiments, the box container  10  is initially be produced in a knockdown configuration (i.e., a generally flat, two-dimensional form), such as illustrated in  FIGS. 2-4 . From the knockdown configuration, the box container  10  is transformed into the erected configuration shown in  FIG. 1 . When in the erected configuration, the box container  10  is operable to securely hold heavy and/or fragile items, and to support such items through transportation and/or shipping. In some embodiments, the box container  10  is formed from one or more sections of corrugated material. In some embodiments, such corrugated material includes paperboard. However, other embodiments provide for the corrugated material to include other similar type materials, such as cardboard, fiberboard, or the like. 
     Turning to  FIG. 2 , and as described above, the main component  12  of the box container  10  of embodiments of the present invention has three primary sections, including the base section  14  opposed by first and second side sections  16 , 18 . The main component  12  has thereon fold lines along which in some embodiments can be weakened, or in other embodiments, caused preferentially to fold by any of various means. For example, in some embodiments the corrugated material is compressed along a thin line defining a fold line. In other embodiments the corrugated material is cut part way through along the line, or cut all or part way through the line at spaced intervals. Thus, each of the first and second side sections  16 , 18  in some embodiments are separated from the base section by fold lines. As such, each of the first and second side sections  16 , 18  in some embodiments are operable to rotate or fold with respect to the base section  14 . For illustrative purposes, the fold lines of the box container  10  are illustrated by single dotted lines in the attached drawings, and are particularly illustrated in  FIGS. 2-4 . 
     Remaining with  FIG. 2 , the base section  14  of the main component  12  generally includes a rectangular or square-shaped central section and two lip sections  24  connected with the rectangular or square-shaped section via fold lines. As such, each of the lip sections  24  in some embodiments is operable to be rotate or fold with respect to the central section. In some embodiments, such fold lines each additionally include one or more slits  26 , cutouts, and/or slots extending down a portion thereof. The lip sections  24  in some embodiments include one or more tabs  28 . Remaining with  FIG. 2 , the base section  14  further includes the first and second side sections  16 , 18 , which each include two end portions  30  connected with the side sections via fold lines. As such, each of the end portions  30  in some embodiments are operable to rotate or fold with respect to the side sections  16 , 18  to which they are attached. The end portions  30  in some embodiments each include main tabs  32  and side tabs  34  that function to secure the box container  10  in an erected position, as will be discussed in more detail below. The tabs  32  in some embodiments include tab fingers  36  that extend from sides of the tabs and that operate to secure the tabs  32  within a corresponding opening (e.g., a cutout), as will be discussed in more detail below. 
     Turning to  FIG. 3 , the side support components  20  each include an inner panel  40  and an outer panel  42 , with the inner and outer panels separated by a central panel  44  via fold lines. As such, each of the inner and outer panels  40 , 42  in some embodiments are operable rotate or fold with respect to the central panel  44 . In certain embodiments, the inner and outer panels  40 , 42  have shapes and sizes that generally correspond to the shape and size of the side sections  16 , 18  of the main component  12 . In certain embodiments, the outer panel  42  includes two flange sections  46  that are each operable to fold along fold lines. The inner panel  40  includes two openings  48  in the form of slits or notch-shaped cutouts. In certain embodiments, the inner panel  40  includes a single flange section  50  that extends from a side of a main portion of the inner panel opposite the central panel  44 . Further, the central panel  44  includes two openings  52  in the form of slits or notch-shaped cutouts. As will be discussed in more detail below, the openings  48  of the inner panel  40  are used in some embodiments for mating with tabs  32  of the main component  12 , and the openings  52  of the central panel  44  are used with portions of the cover component  22  so as to secure the box container  10  in an erected configuration. 
     With reference to  FIG. 4 , in certain embodiments, the cover component  22  of the box container  10  includes a top section  60  and end sections  62 , with the end sections separated from the top section by fold lines. As such, each of the end sections  62  is operable to rotate or fold with respect to the top section  60 . In certain embodiments, the top section  60  has a size and a shape that corresponds to the size and shape of the central section of the base section  14  of the main component  12 . The top section  60  in some embodiments has four main tabs  64 , with two tabs being positioned on each side of the top section. The end sections  62  in some embodiments each include two flange sections  66  positioned on sides of the end sections and separated from main portions of the end sections via fold lines. As such, each of flange sections  66  are operable to rotate or fold with respect to the main portions of the end sections  60 . The four main tabs  64  and the flange sections  66  are operable to secure the box container  10  in an erected position, as will be discussed in more detail below. 
     In operation of embodiments of the present invention, the box container  10  is transformed in a quick and efficient manner from the knockdown configuration of  FIGS. 2-4  to the erected configuration of  FIG. 1 . To begin, and with reference to  FIG. 5 , the first and second side sections  16 , 18  of the main component  12  are folded in along their fold lines until the side section are generally parallel with each other and are generally perpendicular with the base section  14 . Next, the lip sections  24  are folded about the fold lines connecting the lip sections with the central section of the base section  14  until the lip sections are orientated generally perpendicularly with the central section. As such, the tabs  28  (not shown in  FIG. 5 ) are capable of being inserted within the slits  26  (not shown in  FIG. 5 ) to secure the lip sections  24  in place. In addition, the side tabs  34  (not shown in  FIG. 5 ) of the end portions  30  (not shown in  FIG. 5 ) of the side sections  16 , 18  are capable of being inserted between a portion of the lip sections  24  that were folded together, such that the side sections are secured in position that is generally perpendicular to the base section  14 . In certain embodiments, the first and second side sections  16 , 18  are secured via frictional forces imparted between the lip sections  24  and the side tabs  34 . In other embodiments, the side tabs  34  are secured to the lip sections  24  via an adhesive, such as glue, tape, or the like. As such, the main component  12  is erected to present a box-shaped container that includes a base and two side sections. 
     With reference to  FIG. 6 , in the embodiment shown, the two side support components  20  are secured to the main component  12  to reinforce each of the first and second side sections  16 , 18 . In more detail, the inner and outer panels  40 , 42  (outer panel not shown in  FIG. 6 ) of each of the side support components  20  are folded about the central panel  44  until the inner and outer panels are generally parallel with each other and perpendicular to the central panel. As such, the outer panel  40  of a first side support component  20  in the embodiment shown is positioned adjacent to an interior-facing surface of the first side section  16  of the main component  12 . Similarly, in the embodiment shown, the outer panel  40  of a second side support component  20  is positioned adjacent to an interior-facing surface of the second side section  18  of the main component  12 . Next, in the embodiments shown, the end portions  30  of the first and second side sections  16 , 18  are wrapped around the side support components  20 , and each the main tabs  32  (not shown in  FIG. 6 ) of the end portions are mated within the openings  48  of the inner panels  40  of the side support components. In certain embodiments, before the main tabs  32  are inserted within the openings  48 , the tab fingers  36  (not shown in  FIG. 6 ) are folded against the remaining portions of the main tabs  32 . Once the main tabs  32  have been inserted, the tab fingers  36  are capable of unfolding, thus securing the main tabs within the openings  48 . As such, the side support components  20  are secured in place to the main component  12  and are operable to reinforce the side sections  16 , 18  of the main component. 
     Finally, with reference to  FIGS. 1 and 7 , in the embodiment shown, the cover component  22  is arranged into position by folding the end sections  62  about the fold lines until the end sections are generally parallel with respect to each other and perpendicular to the top section  60 . Next, the flange sections  66  (not shown in  FIG. 7 ) of the end sections are folded about their fold lines until they are generally perpendicular to their respective end section  62 . As such, the cover component  22  is capable of being secured to the remaining components of the box container  10 , so as to provide a top cover and end covers for securely enclosing a space within the box container. In particular, the end sections  62  are capable of being positioned between the first and second side sections  16 , 18 , such that the flange sections  66  of the end sections are adjacent to the inner panels  40  of the side support components  20  (not shown in  FIG. 7 ). As such, the flange sections  66  are operable to provide frictional support to secure the cover component  22  in place. Further, the four main tabs  64  of the cover component  22  are mated with the openings  52  (not shown in  FIGS. 1 and 7 ) on the central section  44  of each of the side support components  20 . Such mating further provides for the cover component  22  to be secured in place, such as illustrated by  FIG. 7 . 
     With the box container  10  in an erected configuration as described above, the box container is operable to provide a reinforced, enclosed container that is capable of securely holding fragile items during shipping or transportation. Because the box container  10  includes the side support components  20  and the cover component  22 , the box container is reinforced to protect the container, and the items stored therein, from external forces. Furthermore, the side support components  20  and cover component  22  are operable to provide an enclosed area within the box container  10 , such that items included within the box container are protected from the elements during shipping or other transportation. Furthermore, because the box container  10  is reinforced and has all sides covered, multiple box containers can be stacked on top of each other to facilitated efficient use of space. Furthermore, once the box container  10  has reached its intended destination, the cover component  22  is removed from the remaining components of the box container, and the remaining components are used to display the items that were enclosed therein. Thus, embodiments of the present invention provide for the box container  10  to be used to securely transport items, and further to display such items after transport. 
     In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the inventions is by way of example, and the scope of the inventions is not limited to the exact details shown or described. 
     Although the foregoing detailed description of the present invention has been described by reference to an exemplary embodiment, and the best mode contemplated for carrying out the present invention has been shown and described, it will be understood that certain changes, modification or variations may be made in embodying the above invention, and in the construction thereof, other than those specifically set forth herein, may be achieved by those skilled in the art without departing from the spirit and scope of the invention, and that such changes, modification or variations are to be considered as being within the overall scope of the present invention. Therefore, it is contemplated to cover the present invention and any and all changes, modifications, variations, or equivalents that fall within the true spirit and scope of the underlying principles disclosed and claimed herein. Consequently, the scope of the present invention is intended to be limited only by the attached claims, all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 
     Having now described the features, discoveries and principles of the invention, the manner in which the invention is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims. 
     It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.