Patent Publication Number: US-11661256-B2

Title: Packaging system for an appliance

Description:
FIELD OF THE INVENTION 
     The present disclosure relates to a packaging system for an appliance and more particularly, a packing system comprising an upper assembly, a lower assembly, and a plurality of elongated posts. 
     BACKGROUND OF THE INVENTION 
     Packaging systems for appliances such as refrigerators, ovens, etc. can include a bottom cap that supports the appliance, elongated corner posts that are arranged vertically along the edges of the appliance, a top cap member that rests over a top of the appliance, and an outer box that contains the bottom and top caps, posts, and appliance. The packaging system is designed to protect the appliance during shipping, particularly along the areas in which the cap members and corners posts are arranged. 
     BRIEF SUMMARY OF THE INVENTION 
     The following presents a simplified summary of example embodiments of the invention. This summary is not intended to identify critical elements or to delineate the scope of the invention. 
     In accordance with a first aspect, a packaging system includes a cap having a main panel extending along a plane, first and second opposing side panel assembles extending respectively from first and second opposing edges of and substantially perpendicular to the main panel, and an elongated brace extending between the first and second side panel assemblies. 
     In accordance with a second aspect, a packaging system includes an elongated post; a cap having a main panel extending along a plane, and first and second side panel assemblies extending from and substantially perpendicular to the main panel; and a packaging block fixed to the main panel. The packaging block and the first and second side panel assemblies together define a socket that receives an end portion of the post, such that packaging block and the first and second side panel assemblies together inhibit lateral movement of the end portion along the plane. 
     In accordance with a third aspect, a cap for packaging includes a main panel extending along a plane; a plurality of side panel assemblies extending from and substantially perpendicular to the main panel; a plurality of stacking protuberances; and a plurality of stacking sockets. The stacking protuberances and stacking sockets are configured such that the cap is stackable with an identical cap by mating the stacking protuberances of the cap with the stacking sockets of the identical cap. 
     In accordance with a fourth aspect, a packaging system includes first and second caps, each cap having a main panel that extends along a plane, first and second side panel assemblies extending from and substantially perpendicular to the main panel, a plurality of stacking protuberances, and a plurality of stacking sockets. The stacking protuberances and stacking sockets are configured such that the cap is stackable with an identical cap by mating the stacking protuberances of the cap with the stacking sockets of the identical cap. The packaging system further includes an elongated post; an elongated brace; and a packaging block fixed to the main panel of the first cap. The first and second side panel assemblies of the first cap are adjacent to one another and together with the packaging block define a post socket that receives an end portion of the post and inhibits lateral movement of the post along the plane of the first cap. Moreover, the first and second side panel assemblies of the second cap are opposed to one another and respectively support first and second ends of the brace extending therebetween. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other features, aspects, and advantages of the present application are better understood when the following detailed description of the present application is read with reference to the accompanying drawings, in which: 
         FIG.  1    is a perspective view of an example packaging system for an appliance; 
         FIG.  2    is an enlarged, partial cross-section view of the packaging system; 
         FIG.  3    is a perspective view of a lower assembly of the packaging system; 
         FIG.  4    is a partial top view of the lower assembly; 
         FIG.  5    is a perspective view of a cardboard blank used to form a bottom cap of the lower assembly, in an unfolded state; 
         FIG.  6    is a perspective, bottom view of an upper assembly of the packaging system; 
         FIG.  7    is an enlarged, perspective bottom view of the upper assembly; and 
         FIG.  8    is a perspective view of a cardboard blank used to form a top cap of the upper assembly, in an unfolded state. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to  FIG.  1   , an example packaging system  10  for an appliance (not shown) includes a lower assembly  16  that supports the appliance, an upper assembly  18  that covers and protects a top of the appliance, and a plurality of elongated posts  22  extending between the lower and upper assemblies  16 ,  18 . The posts  22  rest on the lower assembly  16  and vertically support the upper assembly  18  while also protecting the corners of the appliance. The posts  22  also mate with the lower and upper assemblies  16 ,  18  so as to provide horizontal rigidity to the packaging system  10 , as described further below. 
     As shown in  FIG.  2   , each post  22  is an elongated, tubular body preferably formed from a sheet of wound laminated paper. Each post  22  has first and second legs  26 ,  28  that preferably extend substantially perpendicular to each other and terminate in rounded ends  30 ,  32 . The legs  26 ,  28  are formed by an inner wall  36  (defined as the wall closest the appliance) and an outer wall  38  (defined as the wall farthest from the appliance) that are continuous with each other and define a hollow core  42 . Moreover, beads  48  may be formed in the outer wall  38  along each leg, which extend toward and abut the inner wall  36 . 
     The packaging system  10  of the present embodiment has four “corner” posts  22  that are arranged at the corners of the lower and upper assemblies  16 ,  18  and will extend vertically along the edges of the appliance. However, the posts  22  may be arranged at other locations along the sides of the lower and upper assemblies  16 ,  18 , and in some examples may be located inward from the sides and corners of the lower and upper assemblies  16 ,  18 . Furthermore, the posts  22  can comprise other materials and configurations than described. For instance, each post  22  can comprise a single sheet of laminated paper that is folded to form a non-tubular body having first and second legs that are perpendicular or oblique to each other. As another example, each post  22  can comprise an elongated column of EPS with a solid core. Broadly speaking, each post  22  can be any elongated body that extends between the lower and upper assemblies  16 ,  18  to provide vertical and/or horizontal support to the packaging system  10 . 
     Turning to  FIGS.  3 - 5   , the lower assembly  16  includes a bottom cap  60  comprising a single, unitary blank of cardboard  62  that is folded to form a main panel  64  and a plurality of side panel assemblies  66   a - d  extending from the main panel  64 .  FIGS.  3  and  4    show the blank  62  in its folded state, while  FIG.  5    shows the blank  62  prior to folding (broken lines in  FIG.  5    show the lines along which the blank  62  is folded to yield the bottom cap  60  shown in  FIG.  3   ). The bottom cap  60  has a main panel  64  that defines a floor of the bottom cap  60 , and four side panel assemblies  66   a - d  extending upward therefrom at the edges thereof. The main panel  64  and side panel assemblies  66   a - d  are formed by folding the blank  62  shown in  FIG.  5    along the broken lines shown in that figure.  FIG.  5    indicates corresponding portions of the unfolded blank  62  using the same reference numerals that will form the associated features and their sub-elements once the blank  62  is folded. 
     The main panel  64  of the bottom cap  60  is substantially planar, rectangular in shape, and extends along and defines a horizontal plane P 1 . The main panel  64  has a perimeter  70  (see  FIG.  5   ) with four edges  72   a - d  in the rectangular embodiment illustrated, although it is understood that the main panel  64  can comprise other shapes with more or fewer edges. 
     Each side panel assembly  66   a - d  is connected to and extends from a respective edge  72   a - d  of the main panel  64 . In particular, each side panel assembly  66   a - d  includes an outer panel  80  that is connected to a respective edge  72   a - d  of the main panel  64 , and is folded along line  82  coinciding with such edge  72   a - d  such that the outer panel  80  extends upward from the main panel  64 , substantially perpendicular to the plane P 1 . Each side panel assembly  66   a - d  further includes an inner panel  86  that extends from the outer panel  80  and is folded along line  88  defining an interface between them such that the inner panel  86  extends downward from that interface toward the main panel  64 , substantially perpendicular to the plane P 1  and parallel to the adjacent outer panel  80 . The opposing side panel assemblies  66   a  and  66   c  extend substantially parallel to each other, and the opposing side panel assemblies  66   b  and  66   d  also are substantially parallel. In the illustrated embodiment, each pair of opposing side panel assemblies extends substantially perpendicular to the other pair. 
     Moreover, two of the side panel assemblies  66   b ,  66   d  (comprising one opposing pair thereof) further include connecting tabs  92  that extend from lateral ends of their outer panels  80 . The tabs  92  are folded along lines  94  and then fixed to the outer panels  80  of the adjacent side panel assemblies  66   a ,  66   c  constituting the other opposing pair (e.g., using adhesive and/or staples) such that the panel assemblies  66   a - d  collectively form a rigid frame that surrounds and extends upward from the edges of the main panel  64 . Moreover, the bottom cap  60  as assembled has four corners  98   m - p  that are each defined by the main panel  64  and a pair of adjacent side panel assemblies  66   a - d.    
     The lower assembly  16  further includes a plurality of packaging blocks  102   m - p  that are positioned on the main panel  64  of the cap member  60  at the corners  98   m - p . Each block  102   m - p  is made from an EPS material and includes detailed geometries that are configured to mate with and support corresponding portions (e.g., corners, edges, etc.) of the appliance. However, the material and/or geometry of each block  102   m - p  can vary by embodiment. Generally speaking, each block  102   m - p  can be any block of material that is positioned on the main panel  64  and configured to support the appliance. 
     Additionally, each block  102   m - p  is configured to define a socket with adjacent side panel assemblies  66   a - d , which can receive a lower end portion of a post  22  to inhibit horizontal movement thereof. For example, as shown in  FIG.  4   , the block  102   m  has abutment surfaces  104 ,  106  that are configured such that the block  102   m  can be set on the main panel  64  and moved toward the corner  98   m  of the bottom cap  60  until the abutment surfaces  104 ,  106  respectively contact and are flush with the inner panels  86  of the adjacent side panel assemblies  66   a ,  66   b . The block  102   m  can then be fixed to the main panel  64  and/or side panel assemblies  66   a ,  66   b  using, for example, adhesive. 
     In this fixed position, the block  102   m  and side panel assemblies  66   a ,  66   b  will together define an L-shaped socket  108   m  that can receive a lower end portion of a post  22 , as shown in  FIG.  2   . In particular, a first portion  110  of the socket  108   m  can receive the first leg  26  of the post  22 , while a second portion  112  of the socket  108   m  can receive the second leg  28  of the post  22 . 
     Moreover, the socket  108   m  defined between the block  102   m  and side panel assemblies  66   a ,  66   b  will together inhibit (i.e., prevent or limit) lateral movement of the lower end portion of the post  22  along the plane P 1 , as well as rotation thereof about an axis perpendicular to plane P 1 . In particular, the side panel assembly  66   a  will inhibit movement of the lower end portion of the post  22  in a first direction D 1 ; an abutment surface  114  of the block  102   m  will inhibit movement of the lower end portion in a second direction D 2  opposite to first direction D 1 ; the side panel assembly  66   b  will inhibit movement of the lower end portion in a third direction D 3  transverse (e.g., substantially perpendicular) to the first and second directions D 1 , D 2 ; and an abutment surface  116  of the block  102   m  will inhibit movement of the lower end portion in a fourth direction D 4  opposite to third direction D 3 , all four directions D 1-4  being along the plane P 1 . 
     Preferably, the surfaces  114 ,  116  of the block  102   m  and the inner panels  86  of side panel assemblies  66   a ,  66   b  will directly abut the lower end portion of the post  22  such that no movement is permitted in the four directions D 1-4 . 
     As another example, the block  102   p  can be set on the main panel  64  and moved toward the corner  98   p  of the bottom cap  60  until it is a predetermined distance d from the inner panel  86  of side panel assembly  66   d  and an abutment surface  118  of the block  102   p  is flush with and contacts the inner panel  86  of the adjacent side panel assembly  66   a . The block  102   p  can then be fixed to the main panel  64  and/or side panel assemblies  66   a ,  66   d  using, for example, adhesive. In this fixed position, the block  102   p  and side panel assemblies  66   a ,  66   d  will together define an L-shaped socket  108   p  that can similarly receive an end portion of another post  22  and inhibit lateral movement (or rotation) of the end portion of that post  22  along (or about an axis perpendicular to) the plane P 1 . 
     The other two blocks  102   n ,  102   o  can be similarly configured to define sockets at their respective corners  98   n ,  980 . In this manner, all four posts  22  can be inserted into associated sockets  108  of the lower assembly  16  such that each post  22  rests on the main panel  64  and is inhibited from moving horizontally (laterally). However, the blocks  102   m - p  can comprise a variety of other configurations that define respective sockets  108  for the posts  22 . For example, two or more blocks  102   m - p  can be integrated into a single block that defines sockets  108  at multiple corners  98 . In some examples, all four blocks  102   m - p  can be integrated into a single block that spans across the main panel  64  and defines a socket  108  at every corner  98  of the cap member  60 . 
     Turning to  FIGS.  6 - 8   , the upper assembly  18  similarly includes a top cap  120  made from folding a single, unitary blank of cardboard  122  that is folded to form a main panel  124  and a plurality of side panel assemblies  126   a - d  extending from edges of the main panel  124 .  FIGS.  6  and  7    show the completed top cap  120  formed from the blank  122 , while  FIG.  8    shows the blank  122  prior to folding to form the top cap  120 . Similarly as for the bottom cap  60  discussed above, the blank  122  is folded along fold lines (illustrated using broken lines in the figures) disposed at the interfaces between adjacent panels or sections of the bank  122 .  FIG.  8    indicates corresponding portions of the unfolded blank  122  using the same reference numerals that will form these features and their sub-elements once the blank  122  is folded to yield the top cap  120  (shown in  FIGS.  6 - 7   ). 
     The main panel  124  of the top cap  120  is substantially planar and extends along and defines a plane P 2  of the top cap  120 . The main panel  124  is rectangular and has a perimeter  126  (see  FIG.  8   ) with four edges  128   a - d , although it is understood that the main panel  124  can comprise other shapes with more or fewer edges. 
     Each side panel assembly  126   a - d  is connected to and extends from a respective edge  128   a - d  of the main panel  124 . In particular, each side panel assembly  126   a - d  includes an outer panel  130  that is connected to the adjacent edge  128   a - d  of the main panel  124  and folded along line  132  such that the outer panel  130  extends perpendicular (i.e. downward) from the main panel  124  (when oriented as it will be in use), substantially perpendicular to the plane P 2 . Each side panel assembly  126   a - d  also includes a lateral spacer  136  that is connected to the outer panel  130  along fold line  138  such that the lateral spacer  136  extends inward from the outer panel  130  substantially parallel to the plane P 2 . An inner panel  142  of each side panel assembly  126   a - d  is connected to the spacer  136  and folded along fold line  144  such that the inner panel  142  extends downward from the lateral spacer  136  substantially perpendicular to and toward the plane P 2 . 
     The pair of opposing side panel assemblies  126   a ,  126   c  extend substantially parallel to each other. The adjacent pair of side panel assemblies  126   b ,  126   d  also extend substantially parallel to one another, and perpendicular to the other pair. Moreover, each side panel assembly  126   a - d  includes a plurality of support tabs  148 ,  154  that are connected to and extend from the inner panel  142  (see  FIG.  8   ). The outer support tabs  148  are folded along fold line  150  such that they extend outward and upward from the inner panel  142  (as seen in  FIG.  6   ); and the center support tab  154  is folded along fold line  150  such that it extends inward from the inner panel  142  along the main panel  124 . 
     One pair of opposing side panel assemblies  126   b ,  126   d  further include an aperture  160  defined at least partially by the associated inner panel  142 , and a pair of flaps  162  that can be folded along respective fold lines  144 ,  164  to selectively block the aperture  160 . The aperture  160  and flaps  162  are formed by making slits in the blank  122 , wherein folding the flaps  162  of an aperture  160  along their respective fold lines effectively ‘punches out’ the blank to yield the aperture  160 . However, it is to be appreciated that each panel assembly  126   b ,  126   d  in some examples can have a single flap  162  that folds to selectively block or ‘punch out’ the aperture  160 . In other examples, each panel assembly  126   b ,  126   d  may simply define the aperture  160  without having any flaps. 
     The other pair of opposing side panel assemblies  126   a ,  126   c  (adjacent to the pair discussed in the preceding paragraph) further include connecting tabs  172  that extend from lateral ends of their outer panels  130 . The tabs  172  are folded along fold lines  174  and then fixed to the outer panels  130  of the adjacent panel assemblies  126   a ,  126   c  (e.g., using adhesive and/or staples) such that all of the panel assemblies  126   a - d  collectively form a rigid frame that surrounds and extends downward (in the use orientation of the top cap  120 ) from the main panel  124 . Moreover, in the fully formed top cap  120  the support tab  154  of each side panel assembly  126   a - d  can be affixed in planar adjacency to the main panel  124  (e.g., using adhesive see  FIG.  6   ) to secure the inner panel  142  thereof in position, while the other support tabs  148  can function as braces for the spacer  136  and the inner panel  142  to add further rigidity thereto. 
     In the fully formed top cap  120 , each pair of adjacent panel assemblies  126   a - d  will define a socket  180   m - p , which can receive an upper end portion of a post  22  to inhibit horizontal (lateral) movement thereof. For example, as shown in  FIG.  7   , the panel assemblies  126   a ,  126   b  together define a socket  180   m  at a corner of the top cap  120 . In particular, the socket  180   m  is defined by edges  182 ,  184  of the spacers  136  and inner panels  142 , and inner surfaces  186  of the outer panels  130 . A first portion  190  of the socket  180   m  can receive the first leg  26  of the post  22 , while a second portion  192  of the socket  180   m  can receive the second leg  28  of the post  22 . 
     The side panel assemblies  126   a ,  126   b  will together inhibit (i.e., prevent or limit) lateral (as well as rotational) movement of the end portion along (or about an axis perpendicular to) the plane P 2 . In particular, the surface  186  of the panel assembly  126   a  will inhibit movement of the upper end portion of the post  22  in a first direction X 1 ; the edges  182 ,  184  of the side panel assembly  126   b  will inhibit movement of the upper end portion of the post  22  in a second direction X 2  opposite to first direction X 1 ; the surface  186  of the side panel assembly  126   b  will inhibit movement thereof in a third direction X 3  transverse (e.g., substantially perpendicular) to the first and second directions X 1 , X 2 ; and the edges  182 ,  184  of the side panel assembly  126   s  will inhibit movement thereof in a fourth direction X 4  opposite to third direction X 3 , all four directions X 1-4  being substantially along the plane P 2 . Preferably, the surfaces  186  and edges  182 ,  184  of the side panel assemblies  126   a ,  126   b  will directly abut the upper end portion of the post  22  such that no movement is permitted in these four directions X 1-4 . 
     The other sockets  180   n - p  in the upper assembly  18  can be similarly configured to receive upper end portions of other posts  22  and inhibit movement thereof along the plane P 2 . In this manner, upper end portions of all four posts  22  can be inserted into associated sockets  180   n - p  such that each post  22  supports the top cap  120  and is inhibited thereby from moving horizontally (laterally). However, it is to be appreciated that the side panel assemblies  126   a - d  and sockets  180   n - p  can comprise other configurations that accomplish similar effects. For example, each side panel assembly  126   a - d  can comprise other configurations of folded elements defining surfaces and/or edges that form a socket with an adjacent side panel assembly  126   a - d.    
     The upper assembly  18  further includes a support brace  192  having a first end  194  that is inserted into the aperture  160  of panel assembly  126   b , and a second end  196  that is inserted into the aperture  160  of the opposing panel assembly  126   d . The brace  192  is an elongated column of material (e.g., paper, EPS, etc.) preferably with a solid core, and has a length that approximates a distance (and which extends) between the outer panels  130  of the opposing panel assemblies  126   b ,  126   d . Moreover, the brace  192  will rest along a bottom edge of the aperture  160 , thus being supported by the side panel assemblies  126   b ,  126   d . The brace  192  as installed can provide horizontal (lateral) support to the top cap  120  in the direction of brace&#39;s longitudinal axis; for example sufficient to oppose a clamping force of an external clamping machine used to capture and move the packaged appliance within the completed packaging assembly; i.e. packaged between top and bottom caps  120  and  160  with posts  22  extending vertically therebetween at the corners of the appliance. As a result, the brace  192  provides additional clamping support to the completed package so that the clamping force will not be experienced directly by the appliance. Rather, the clamping force will be transmitted largely through the brace  192  along its axis. 
     The packaging system  10  as described above can be assembled by placing the appliance on the blocks  102  of the lower assembly  16 , inserting the posts  22  into the sockets  110  of the lower assembly  16 , and then placing the upper assembly  18  on top of the appliance such that the upper ends of the posts  22  are received within its sockets  180 . The entire assembly can then be covered in stretch or shrink wrap  200  (see  FIG.  1   ) and shipped. In some examples, the wrapped assembly can be shipped within an outer, cardboard box, although it may be shipped without such a box in other examples. It is to be appreciated that the appliance can be any consumer appliance such as, for example, a refrigerator, oven, washer, dryer, dishwasher, etc. 
     As discussed above, the insertion of the posts  22  into the lower and upper sockets  110 ,  180  will inhibit horizontal movement of the posts  22  and add rigidity to the packaging system  10  as a whole. Moreover, the lower assembly  16 , upper assembly  18 , and posts  22  as assembled will protect the appliance. In some examples, additional packaging blocks made of EPS or some other material can be applied to any of these elements for added protection. For example, packaging blocks can be glued to the inner sides of the posts  22  or the main panels  64 ,  124  of the bottom and top caps  60 ,  120 . 
     Preferably, the first and second legs  26 ,  28  of each post  22  will extend substantially perpendicular to each other so that the posts  22  properly fit into the lower and upper sockets  110 ,  180  during assembly. However, it has been found that if the posts  22  are manufactured at this angle and then stored for a period of time before assembly, they can warp over that time such that the angle decreases, thereby making it difficult to insert the posts  22  into the sockets  110 ,  180 . Accordingly, in some examples, it may be desirable to manufacture each post  22  so that its first and second legs  26 ,  28  extend at an angle that is greater than 90 degrees to account for subsequent warping. In particular, it may be desirable to manufacture each post  22  so that its first and second legs  26 ,  28  extend at an angle that is between 95 degrees and 105 degrees, or between 100 degrees and 105 degrees. At these angles, each post  22  can still be inserted into the sockets  110 ,  180  by providing a slight bending force to reduce the angle to substantially 90 degrees. Moreover, the posts  22  can be stored for a period of time and still maintain an angle that is 90 degrees or more. 
     Still further, in some examples, the packaging system  10  and appliance will be transported using a device that applies a clamping force to the top cap  120 . As noted above, the brace  192  can provide horizontal support to the top cap  120  in the clamping direction, thereby preventing damage to the top cap  120  and appliance. 
     The bottom and top caps  60 ,  120  can also include stacking elements that enable them to be stacked and aligned with multiple identical cap members. For example, the bottom cap  60  in the present embodiment includes a plurality of stacking protuberances  204  in the form of projections that are connected to and extend upward from the inner panels  86  of opposing side panel assemblies  66   a ,  66   c , substantially perpendicular to and away from the main panel  64 . The bottom cap  60  further includes a plurality of stacking sockets  206  in the form of apertures that are defined by the main panel  64  and outer panels  80  of the side panel assemblies  66   a ,  66   c . The projections  204  and apertures  206  are configured such that the bottom cap  60  is stackable with an identical cap by inserting the projections  204  of the bottom cap  60  within the aligned apertures  206  of the identical cap. In particular, the projections  204  of the bottom cap  60  will be received within the apertures  206  of the identical cap so that the main panels  64  of the two caps are substantially parallel and their side panel assemblies  66   a - d  are substantially aligned. 
     Meanwhile, the opposing pair of side panel assemblies  126   a ,  126   c  of the top cap  120  each include a pair of stacking protuberances  224  in the form of projections that are connected to and extend downward (in the use orientation of the top cap  120 ) from lateral ends thereof, at the bends between their respective outer panel  130  and connecting tabs  172 . In particular, the projections  224  extend substantially perpendicular and away from the main panel  124 . Moreover, the main panel  124  and side panel assemblies  126   a - d  of the top cap  120  collectively define a plurality of stacking sockets  226  in the form of apertures at the corners of the top cap  120 . The projections  224  and apertures  226  are arranged at the corners of the top cap  120  at lower and upper locations thereon, respectively (relative to the user orientation of the top cap  120 ) and are configured such that the top cap  120  is likewise stackable with an identical cap by inserting the projections  224  of the top cap  120  within the apertures  226  of the identical cap. In particular, the projections  224  of the top cap  120  will be received within the apertures  226  of the identical cap so that the main panels  124  of the two caps are substantially parallel and their respective panel assemblies  126   a - d  are substantially aligned. 
     In this manner, multiple bottom and top caps  60 ,  120  can be manufactured and stacked for later assembly with the rest of the packing system  10 . However, it is to be appreciated that the number, shape, and/or location of the stacking elements described above can vary by embodiment. For instance, each cap  60 ,  120  can comprise any configuration of stacking protuberances (e.g., projections, bulges, lugs, shoulders, etc.) and stacking sockets (e.g., apertures, recesses, gaps, channels, etc.) such that the cap can be stacked with an identical cap by mating the protuberances of one with the sockets of the other. 
     As discussed above, the bottom and top caps  60 ,  120  are formed by folding respective single, unitary blanks of cardboard  62 ,  122 . The cardboard preferably comprises a core of corrugated paper that is sandwiched between inner and outer liners of paper. However, the bottom and top caps  60 ,  120  may be formed of other types of cardboard or heavy-duty paper. Moreover, the bottom and top caps  60 ,  120  may comprise multiple pieces of cardboard or heavy-duty paper that are separately formed and then attached together, e.g. via lamination. 
     The respective side panel assemblies  66   a - d  and  126   a - d  of the bottom and top caps  60 ,  120  described above each have inner and outer panels, in addition to other elements such as connecting tabs. However, it is to be appreciated that any of the respective side panel assemblies  66   a - d ,  126   a - d  may comprise additional or fewer elements without departing from the scope of this disclosure. Indeed, in some examples, a panel assembly  66   a - d ,  126   a - d  may simply comprise a single panel that extends upward from its associated main panel. 
     The invention has been described with reference to the example embodiments described above. Modifications and alterations will occur to others upon a reading and understanding of this specification. Example embodiments incorporating one or more aspects of the invention are intended to include all such modifications and alterations insofar as they come within the scope of the appended claims.