Patent Publication Number: US-9409670-B2

Title: Blanks for containers, and containers, boxes, and methods thereof

Description:
FIELD OF THE INVENTION 
     The present invention relates to packaging for a container, blanks for a container, methods of assembly, uses of the container, and methods of using the container. 
     BACKGROUND OF THE INVENTION 
     There is an ongoing need in the field of packaging for a container (e.g., a tray that may optionally include a lid) configured for functioning as a tray for display and/or containment of an article, such as a consumer product. There is an ongoing need for an alternative container that is capable of being printed on one or both sides of any paperboard used for making the product (e.g., by pixelated type printing, such as ink-jet, laser jet or other suitable printing devices, by screen printing, or other printing). There is also an ongoing need for a container that can be made from a single sheet of stock material, such as a paperboard material. There is also an ongoing need for a container that is capable of supporting loads from one or more contained articles, without buckling or otherwise plastically deforming from the load of the one or more contained articles. 
     SUMMARY OF THE INVENTION 
     One or more of the above needs are met by the teachings herein. 
     One aspect of the invention is directed at a container comprising a generally rectangular base portion having a first pair of peripheral edges and a second pair of peripheral edges. The container preferably includes a first pair of opposing spaced apart side walls each projecting generally orthogonally from respective edges of the first pair of peripheral edges; a second pair of opposing spaced apart side walls each projecting generally orthogonally from respective edges of the second pair of peripheral edges and being connected with the first pair of opposing spaced apart side walls to define four corners. The container may preferably be constructed from a continuous single sheet having a first face and an opposing second face and wherein one or both of the first face or the second face is adapted for printing directly onto its surface. The base portion preferably includes at least two layers of the single sheet that are folded from the continuous single sheet to define the base portion and cooperate to define a portion of the first and second pair of sidewalls. The container may include an adhesive that bonds at least two layers defining at least one of the side walls. 
     Another aspect of the invention is directed to a box including one or more of the containers according to the teachings herein. 
     Another aspect of the invention is directed to a container according to the teachings herein, wherein the container is configured to receive an electronic device, a cosmetic, a kit, an article of clothing, a houseware item, an automotive accessory, paper goods, a food item or any combination thereof. 
     Yet another aspect of the invention is directed at a blank for a container according to the teachings herein. Preferably the blank is a die cut paperboard preform. The container is preferably made from a single blank. A blank may include features as shown in  FIGS. 1 through 9 and 14 through 17 , or may be substantially as depicted in any of those figures. 
     A method related aspect of the invention is directed at a method of making a container, comprising folding a blank (e.g., a die cut paperboard preform) according to the teachings herein, forming a container, such as a container according to the teachings herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is drawing of an illustrative container according to the teachings herein. 
         FIG. 2  is a top-down view of an illustrative container according to the teachings herein. 
         FIG. 3  is a cross-sectional view of an illustrative portion of a container according to the teachings herein. 
         FIG. 4A  is a top-down view of a blank illustrating features that may be used in a blank for a container according to the teachings herein. 
         FIG. 4B  is a top-down view of a blank illustrating features that may be used in a blank for a container according to the teachings herein. 
         FIG. 4C  is a top-down view of a blank illustrating features that may be used in a blank for a container according to the teachings herein. 
         FIG. 4D  is a bottom view of a blank illustrating features that may be used in a blank for a container according to the teachings herein. 
         FIG. 4E  is a top-down view of a blank illustrating features that may be used in a blank for a container according to the teachings herein. 
         FIG. 5  is a drawing of an illustrative box including one or more containers according to the teachings herein. 
         FIG. 7  is a top-down view of a portion of an illustrative blank. 
         FIGS. 7A and 7B  are illustrative partial cross-section of different regions of a container showing illustrative features of a wall and a base that may be employed according to the teachings herein. 
         FIG. 7C  is an illustrative top-down view a partially constructed container showing features of a layer of a base that may be employed in a container according to the teachings herein. 
         FIG. 8  is a top-down view of a blank for a container illustrative features of a container according to the teachings herein. 
         FIG. 9  is a top-down view of a blank for a container illustrating features of a container according to the teachings herein. 
         FIG. 10  is a perspective view an illustrative example of a container in accordance with the present teachings. 
         FIG. 11  is a perspective view of an illustrative example of a partially assembled container in accordance with the present teachings. 
         FIG. 12  is a perspective view of an illustrative example of a partially assembled container in accordance with the present teachings. 
         FIG. 13  is a view of an illustrative example of a corner of a partially assembled container in accordance with the present teachings. 
         FIGS. 14A, 14B, and 14C  are top-down views of illustrative blanks according to the teachings herein. 
         FIGS. 15A-15C  are top-down views of illustrative blanks according to the teachings herein. 
         FIGS. 15D-15F  are views of illustrative blanks in various stages of assembly in accordance with the present teachings. 
         FIGS. 15G-15N  are views of illustrative examples of container comes in various stages of assembly in accordance with the present teachings. 
         FIGS. 15O-15Q  are views of illustrative blanks in various stages of assembly in accordance with the present teachings. 
         FIGS. 15R-15T  are views of illustrative examples of container corners in various stages of assembly in accordance with the present teachings. 
         FIGS. 15U-15Z  are views of illustrative examples of container portions including fold lines in various stages of assembly in accordance with the present teachings. 
         FIGS. 16A, 16B, and 16C  are perspective views of assembled container portions in accordance with the present teachings. 
         FIGS. 17A, 17B, and 17C  are perspective views of an illustrative box including a container for a box bottom, a container for a box lid, having one or more containers according to the teachings herein. 
     
    
    
     DETAILED DESCRIPTION 
     This application is related to and claims the benefit of the priority date of U.S. Provisional Application Ser. No. 61/644,192, filed on May 8, 2012. The entirety of that application is hereby incorporated by reference for all purposes. 
     The teachings herein contemplate the structures and features depicted in the accompanying drawings. Variations to the structures and features are also contemplated within the teachings. For example, any dimensions, angles, tolerances and/or proportions shown in the drawings are part of the teachings herein. Departures from the dimensions, angles, tolerances and/or relative proportions shown in the drawings are part of the teachings herein to the extent that such variations do not materially affect the intended operation or functionality of the depicted structures and features. For example, variations in an amount of less than 50%, 30% or 10% are envisioned; variations in an amount of more than 50% 30% or 10% are also envisioned. 
     Unless otherwise stated or reasonably apparent from the context of the teachings, geometries may vary from those depicted in the drawings. Sharp corners at free ends of the structures may be rounded. Rounded corners at free ends of structures may be sharp. 
     Perforations depicted in the drawings may be located generally as shown. Additional perforation may be added. Perforations may be omitted. They may be located intermittently substantially entirely along a crease. They may be located along only a portion of a crease (e.g., a total length of slit material being about 90% or less, about 60% or less, about 40% or less, about 20% or less, or about 10 or less). 
     The container includes a base portion and side walls formed from a single continuous sheet. The container includes sufficient support features, such as side wall connection features so that one or more of the side walls are maintained in a generally orthogonal orientation relative to the base portion, so that adjacent side walls are maintained in a generally orthogonal orientation relative to each other, or both. For example the container may include a sufficient number of support features so that the base portion and any pair of adjacent side walls are generally mutually orthogonal. 
     Preferred containers include four side walls. Each side wall may be connected to a peripheral edge of the base portion. Each side wall may have two lateral peripheral edges. The lateral peripheral edges of a side wall may be located at opposing edges of the side wall. The lateral peripheral edges of the side walls may be generally orthogonal to the peripheral edge of the base portion. Adjacent side walls may be connected along their lateral side wall edges. The container may have four corners defined by the intersection of a lateral side wall edge and a peripheral edge of the base portion. 
     The single continuous sheet may be formed of any material capable of being folded to form multiple layers of the container components, such as multiple layers of the walls, multiple layers of the base portion, or both. 
     The single continuous sheet has a first face and an opposing second face. The thickness of the single continuous sheet the distance between the two opposing faces) may be uniform or may vary. Preferably the single continuous sheet has a thickness that is sufficiently uniform so that it can be made from stock materials (e.g., card stock, sheet stock) or other material having generally uniform thickness. As used herein, a sheet having uniform thickness has thickness with a standard deviation of about 20% or less, about 10% or less, about 5% or less, or about 1% or less. For example, the standard deviation of the thickness may be about 0%. 
     One or both of the faces of the sheet may be adapted for printing directly on its surface. Preferably at least one of the faces is adapted for printing directly on its surface. For example, the sheet may include one face that is a show surface and an opposing face that is a hidden surface. When folded into a container, one or more portions of the show surface may be visible. When folded into a container, preferably none of the hidden surface is visible. Nevertheless, it may be advantageous to have printing on a hidden surface so that instructions or other features may be provided on that surface. It is also possible to fold a sheet and/or employ openings in a sheet so that portions of both faces are visible. 
     The container may include any number of layers base layers, wall layers, or both). For example, the base portion may include a plurality of base layers, one or more side walls (e.g., each side wall) may include a plurality of base layers, or both. Although a single layer will generally have insufficient strength to support the container, by using a plurality of stacked layers, a container having sufficient strength may be achieved. The number of base layers that form, the base portion may be about 2 or more or about 3 or more. Preferably, the number of base layers is about 4 or more. The number of side wall layers that form a side wall may be about 2 or more or about 3 or more. Preferably, the number of side wall layers is about 4 or more. Each side wall may have the same number of side wall layers or may differ in the number of side wall layers. Preferably, each side wall has the same number of side wall layers. 
     The container may have any shape. A preferred container includes a tray shape. The container may be used as a box including a tray portion and a lid portion. For example a box may include a container having a tray portion and an integrated lid portion. Alternatively, a box may include a container and a separate lid portion. As an example, a box may include two trays including a first tray that is used as the bottom of the box and a second tray that is used as the lid or cover of the box. It will be appreciated that a box may include one or more containers according to the teachings herein. 
     A base layer preferably extends over a majority of, a substantial portion of, or even the entirety of the base portion. The example a base layer may span about 50% or more, about 70% or more, about 90% or more, about 95% or more, or about 99% or more of the base portion, as defined by the ratio of the area of the base layer to the area of the base portion. Preferably the base portion includes 3 or more layers that are folded form a continuous single sheet and span substantially the entirety (e.g., at least about 90% or more, or at least about 95% or more) of the base portion. 
     A base layer may be divided into a plurality of sections. If a base lay divided into a plurality of sections, two or more of the sections may abut each other along an interior edge (i.e., an edge that is not a peripheral edge of the base portion). Preferably two sections of a single base layer do not overlap. As such, faces of two sections of the same base layer preferably do not contact one another. The base portion may include a bottom base layer, a top base layer, and one or more intermediate base layers interposed between the bottom as layer and the top base layer. Any base layer that includes a plurality of sections is preferably an intermediate base layer and not a top base layer or a bottom base layer. 
     The base portion may have any shape, and preferably has a polygonal shape. More preferably the base portion has a generally rectangular shape which may be a square shape. The base portion may have a first pair of peripheral edges along opposing sides of a polygonal (e.g., rectangular) base. The base portion may have a second pair of peripheral edges along different opposing sides of a polygonal base. For example the base portion may have four sides and the two pairs of peripheral edges may define the circumference of the base portion. 
     The container may include a first pair of opposing, spaced apart side walls that each project generally orthogonally from the respective edges of the first pair of peripheral edges of the base portion. The container may include a second pair of opposing, spaced apart side walls that each project generally orthogonally from the respective edges of the second pair of peripheral edges of the base portion. Preferably the base portion includes four sides and the second pair of opposing side walls are connected to the first pair of spaced apart opposing side walls to define four corners. The base portion preferably includes at least two layers of a continuous single sheet that are folded to define the base portion and that cooperate to define at least a portion of the first and second pairs of side walls. 
     The single continuous sheet for a base portion may be formed by die cutting a sheet stock material. As such, the single continuous sheet may be a die cut preform for a container. Any material suitable for folding, die cutting, or both may be employed. The sheet material may be a single layered material or may have multiple layers. For example the sheet may include a layer of a polymer, a layer of a paper, or both. A particularly preferred material is a paperboard. Any paperboard may be, employed. The sheet material preferably has a thickness that is sufficiently low so that the sheet can be easily folded, die cut, or both. The thickness of the sheet material preferably is about 2 mm or less, more preferably about 1.5 mm or less, even more preferably about 1.2 mm or less, even more preferably about 1.0 mm or less and most preferably about 0.8 mm or less. The thickness of the sheet material preferably is sufficiently high so that the container can be assembled without having to fold an excessive number of layers of the base portion. The thickness of the sheet material preferably is about 0.1 mm or more, more preferably about 0.2 mm or more, even more preferably about 0.25 mm or more, even more preferably about 0.30 mm or more, and most preferably about 0.35 mm or more. For example, the sheet material may be a paperboard characterized as about 8 point, 10 point, about 12 point, about 14 point, about 16 point, about 18 point, about 20 point, about 22 point, about 24 point, or about 26 point, about 28 point, about 30 point, or about 32 point. 
     The blank for a container may include regions having creases, regions having slits, regions having perforations, or any combination thereof. Creases preferably are employed in areas that provide a structural feature, such as a connection between two adjacent side walls. Creases are also preferably employed to allow easy folding, defined folding, or both in regions that will be visible in the assembled container. Preferably, the assembled container is free of visible slits or perforations. Perforations and/or slits preferably are employed for folding in regions that are not visible in the assembled container and may not be required to provide a structure between the areas on either side of the fold. 
     The container may include one or more side wall connection features capable of providing a connection between two adjacent side walls. The two adjacent side walls may meet at a corner of the container and the side wall connection feature may provide strength or structural support to an edge of the container, orientation of the walls at an edge, or both. The side wall connection feature preferably is connected to at least one peripheral edge of a side wall layer. Examples of side wall connection features that may be employed include lateral projections (e.g., tabs), gussets, or both. It will be appreciated that a side wall connection feature that is not connected to a side wall layer may also be employed. However, it is preferred that each side wall connection feature is connected to at least one side wall layer so that a single sheet may be used for all of the components and layers of the side walls that meet at a corner. 
     The container may include lateral projections that project from a lateral peripheral edge of a side wall layer. Such projections may be a tab or other feature capable of orienting in a direction so that it forms part of an adjacent side wall. The lateral projection may provide reinforcement to a side wall. The lateral projection may provide support and or reinforcement for a corner. For example, a lateral projection may provide sufficient reinforcement for a container so that the corner does not tear during use. Preferably the lateral projection is of a sufficient size (e.g. length width or both) so that the walls of the corner are maintained in a generally upright orientation. A blank preferably include a sufficient number of lateral projections that are arranged so that each of the corners is supported and/or reinforced by a lateral projection. 
     The container may include one or more side wall connection features that are connected to two side wall layers of adjacent side walls (e.g., orthogonal side wall layers). Such side wall connection features may be a gusset or other feature capable of folding and/or orienting in a direction so that it forms part of one of the side walls, while maintaining a connection with an adjacent side wall. The gusset may provide reinforcement to a side wall. The gusset may provide support and or reinforcement for a corner. For example, a gusset may provide sufficient reinforcement for a container so that the corner does not tear during use. Preferably the gusset is of a sufficient size (e.g. length width, or both) so that the walls of the corner are maintained in a generally upright orientation. A blank preferably includes a sufficient number of gussets that so that each of the corners is supported and/or reinforced by a gusset. 
     The container may include an adhesive for attaching some or all of a face of a first layer to the face of a second layer. For example, adhesive may be employed for attaching two facing surfaces of side wall layers, for attaching two facing surfaces of two base portion layers, or both. Preferably one or more side walls of the container includes an adhesive for attaching two adjacent side wall layers. The adhesive may be provided to one or both of the faces to be attached. The adhesive may be selected to provide a durable adhesion to the surfaces being attached. The adhesive may be characterized as a glue, a curable adhesive, a one-part adhesive, a two-part adhesive, a polar adhesive, a non-polar adhesive, a reactive adhesive, an adhesive that covalently bonds to a surface, an adhesive that bonds to a surface with van der Waals forces, or any combination thereof. The adhesive may be provided on the entirety of a surface or on a portion of a surface. For example, the adhesive may be provided as a pattern on a surface, as a uniform layer, irregularly, along a periphery of a surface, or any combination thereof. More preferably, one side wall includes a plurality of pairs of surfaces (e.g., two or more pairs of facing surfaces, three or more pairs of facing surfaces, or even all pairs of facing surfaces) that are attached with an adhesive. For example, a container may include a single wall that includes two or more (e.g., three or more) pairs of facing layers that are attached with an adhesive. Preferably only one wall of the container includes adhesive. 
     The container may be free of a separate insert. The container preferably is free of separate insert components and cover components (i.e., that are not part of a single sheet). As such, the process may be free of a step of covering one or more surfaces of an insert made from a first sheet with a cover made from a second sheet, such as a second sheet that is the same or different (e.g., different thickness, different material, different shape, or any combination thereof) from the first sheet. 
     The single sheet blank preferably is free of attachment features (e.g., protrusions) and corresponding openings, such as slits or slots for connecting two regions of a blank, or for connecting two components of a container (e.g., for connecting an insert component to a cover component). As such, the process of assembling the container may be free of a step of inserting an attachment feature into an opening (e.g., a slit or slot). For example the container may be free of an attachment feature that secures a first layer to a second layer by inserting a feature of the first layer into an opening of the second layer. 
       FIG. 1  is an illustrative container  10  showing features of a container according to the teachings herein. The container  10  may include a base portion  14  that is generally polygonal in shape. For example the base portion  14  may have a generally rectangular shape. The base portion  14  may have peripheral edges  16 . For example the perimeter of the base portion may be defined by the peripheral edges  16 . The container  10  may have a tray-like shape including a plurality of side walls  12 . For example the side walls  12  may extend from the peripheral edges  16  of the base portion  14 . The container  10  may include a first pair of side walls  20 , a second pair of side walls  21 , or both. A pair of side walls  20 ,  21  may be spaced apart, parallel, have the same length, or any combination thereof. Preferably, a pair of side walls  20 ,  21 , are spaced apart, parallel, and have the same length (e.g., in the direction of the peripheral edge  16  of the base portion  14  where the side wall and the base portion form an edge of the container  10 . The container may include lateral side wall edges  18  where two adjacent side walls  12  meet. The container may include one or more side wall connection features (not shown) that connect two side walls  12 . Preferably, the side walls  12  are oriented generally orthogonally to the base portion  14 . The container  10  may include corners  19  (e.g., four corners) where two side walls  12  and the base portion  14  meet. 
     A top view of a container  10  is shown in  FIG. 2  illustrating features according to the teachings herein that may be employed in a container or a blank for a container. The base portion  14  may include a first pair of peripheral edges  22 , a second pair of peripheral edges  23 , or both. A pair of peripheral edges  22 ,  23 , may be characterized as being spaced apart, having the same length, being parallel, or any combination thereof. Preferably, a pair of peripheral edges  16  are spaced apart, have the same length, and are parallel. More preferably, each of the first pair of peripheral edges  22 , and the second pair of peripheral edges are paced apart, have the same, length, and are parallel. 
     A cross-section of a portion of a container  10  is illustrated in  FIG. 3 . The cross-section shows features that may be included in a wall  12 , features that may be included in a base portion  14 , or both. For example, the base portion  14  may include a plurality of base layers  24 . The base layers  24  may be stacked. Facing base layers  24  may contact each other over a portion or the entirety of their facing surfaces. The base portion  14  may include a base layer  24 A that is on the bottom of the stack of base layers. The base portion  14  may include a base layer  24 D that is on the top of stack of base layers. The base portion may include on or more intermediate base layers  24 B,  24 C that are interposed between the top base layer and the bottom base layer. One or more of the base layers  24  may be sufficiently long so that it forms a contact with a side wall  12  and a compressive force is established that maintains the position of the base layer. For example, the top base layer  24 D may form a sufficient compressive force with a side wall  12  so that the top base layer  24 D and the layers below it are maintained in a stacked arrangement. The number of base layers may be two or more, three or more, or four or more. 
     The side wall  12  may include a plurality of wall layers  26 . The wall layers in a side wall  12  may be in a generally stacked arrangement. The side wall may include two or more wall layers. Preferably the side wall includes three or more wall layers. More preferably, the side wall includes four or more wall layers.  FIG. 3  illustrates a wall  12  having an adhesive  48  between two facing surfaces of adjacent wall layers. It will be appreciated that some or all of the side wall layers in a side wall may be attached to an adjacent layer using an adhesive. According to the teachings herein, other side was (for example all of the other side walls) may be free of an adhesive attaching adjacent wall layers. The side wall  12  may include outer side wall layers  26 A,  26 D. The side wall  12  may include one or more intermediate side wall layers  26 B,  26 C, interposed between the outer wall layers  26 A,  26 D. All of the wall layers of one side may be connected by sequential folds. For example, the side wall illustrated in  FIG. 3  has cuter wall layers  26 A and  26 D that are connected by a fold wall layers  26 D and  26 C that are connected by a fold, and wall layers  26 C and  26 B that are connected by a fold. It will be appreciated that for other side walls, the wall layers may not be sequentially connected. Preferably for ail of the side walls  12 , the outer wall layers  26 A and  26 B are connected by a fold, such as fold along a crease. As illustrated in  FIG. 3 , all of the adjacent faces of the wall layers (e.g.,  26 A and  26 B;  26 B and  26 C;  26  C and  26 D) may be attached using an adhesive  48 . As illustrated in  FIGS. 3 and 4A . a wall layer (e.g.,  26 A,  26 B,  26 C, or  26 D) may extend substantially the entire length of a wall (e.g., horizontal direction of the upright wall). 
       FIGS. 4A, 4B, 4C, 4D, and 4E  are drawings illustrating a blank  40  that may be used for a container according to the teachings herein. The blank may have any or all of the features illustrated in  FIGS. 4A, 4B, 4C, 4D, and 4E . The blank may include a plurality of wall layers  26  and a plurality of base layers  24  that are provided as a single continuous sheet. The lateral peripheral edges  33  of some of the wall layers  26  may be connected to a wall connection feature, such as a gusset  32 , or a lateral projection  28 ,  30 . As illustrated in  FIG. 4A , one or more of the layers (e.g., a base layer  24 C) may be divided into a plurality of segments. When the blank  40  is folded into a container  10 , the segments of the base layer  24 C may form a single base layer, may abut one another, or preferably both. Preferably, the two segments  24 C do not overlap one another. With reference to  FIGS. 4B, 4C and 4D , the blank  40  may include an edge of a base layer that is connected to a side wall  60 . The blank may include a common edge between two side wall layers  62 . The blank  40  may include a bottom base layer  24 A having edges  64  that are connected to wall layers. The blank  40  may include edges  66  of a side wall layer  26 A that are connected to an intermediate side wall layer (e.g.,  26 C or  26 D). The blank  40  may include an edge  68  of other base layers (other than the bottom base layer) that are connected with a side wall layers. The blank  40  may include an edge  70  of a side wall layer that is connected to a lateral projection, such as a tab. The blank  40  may include an edge  72  of a side wall layer that is connected to a gusset. The blank may include surfaces that are later attached to each other using an adhesive (e.g.,  84 A,  84 B, and  84 C). The blank may include regions  74  that connect two parts of a gusset so that the gusset can be folded. The blank may include one base layer (e.g., a bottom base layer)  24 A having edges  66  connected to opposing side wall layers  26 A, and a second base layer  24 B having edges connected to opposing side wall layers  26 B. 
     Folding of a blank may be facilitated by the employment of one or more creases, one or more perforations, one or more cuts (such as a slit or other opening), or any combination thereof.  FIG. 4C  illustrates regions that may be folded. With reference to  FIG. 4C , these regions may include a crease  42 , a perforation,  33 , or a cut  46 , or any combination thereof. It will be appreciated that cuts, perforations and creases may be interchanged provided that the folding and assembly of the container is maintained.  FIG. 4C  illustrates a first face  52  of the blank  44 , and  FIG. 4D  illustrates a second face  54  of the blank.  FIG. 4E  illustrates a relationship between the dimensions of two of the base layers that may be employed in a blank according to the teachings herein. 
       FIG. 5  illustrates a box  8  including a first container  10  according to the teachings and a second container  10  according to the teachings herein. 
       FIG. 6  illustrates features of an intermediate base layer  24 B and an intermediate wall layer  26 B that may be employed in a container according to the teachings herein. 
       FIGS. 7A and 7B  illustrate cross-sections of a container from two regions of a container such as illustrated by A-A and B-B in  FIG. 2 . As illustrated in  FIGS. 7A and 7B , the wall layers may have, different thicknesses in different regions. As such, the mating of the segments of a base layer  24 C may be tighter in one region  90  than in another region  92 , as illustrated in  FIG. 7C . This may allow for easier assembly of the layer  24 C. 
       FIGS. 8 and 9  illustrate exemplary dimensions of a blank. One or more of the features of the blank may have dimensions that are in the same relationship (e.g. larger than, smaller than, the same size as, having a difference in size greater than, having a ratio of about, etc.) that is about the same as the relationships shown in these figures. Other relationships are also possible. As an example, base layers,  24 A,  24 B and  24 D may each have a width and length that is greater than that of  24 C. Base layers  24 A,  24 B and  24 D may each of substantially the same width and length. Wall layers  26 A,  26 B,  26 C,  26 D may each have substantially the same width. Wall layers  26 A,  26 B,  26 C,  26 D may each have substantially the same width as any adjacent wall layer. 
       FIG. 10  shows a nearly fully assembled container showing base layer  24 D being located onto another base layer  24  (which may be  24 A,  24 B or  24 C). The exterior wall layer  26 A is visible about the exterior edge of the container. 
       FIG. 11  illustrates an example insert portion of a container in the event that the container includes separate inserts as opposed to be formed from one integrally formed blank. Similar to an integrally formed blank, the insert may include a base layer  24  and wall layers  26 . The insert may be located within a shell portion (not shown) whereby the shell portion also includes a base layer and wall layers.  FIGS. 12 and 13  illustrate additional embodiments of inserts that may be included in forming the container. The containers according to the teachings herein may be free of one or any combinations of the features illustrated in  FIGS. 10-13 . 
       FIGS. 14A, 14B, and 14C  illustrate features of a blank according to the teaching herein. Specifically,  FIGS. 14B and 14C  illustrate opposite faces of the blank prior to the application of an adhesive for connecting a plurality of adjacent wall layers  94 .  FIG. 14A  illustrates a face of the blank after  4  adjoining wall layers  94  have been attached using an adhesive. 
       FIGS. 15A-15C  illustrate steps that may be used in the assembling of a container from a blank. For example, base layer  24 B (e.g., the second base layer) may be folded onto base layer  24 A (e.g., the first base layer). This may occur prior to folding any additional base layers onto base layer  24 A.  FIGS. 15D-15F  show additional view of folding  24 B onto  24 A such that  24 C (e.g., the third base layer) and  24 D (e.g., the fourth base layer) remain unfolded. Thus, folding  24 B may be the first step in assembly of the container.  FIGS. 15G-15J  show varying assembly arrangements of the gussets  32  in relation to the wall layers  26  and base layers  24 . As shown for example in  FIG. 15J , one or more wall layers  26  may fold over and substantially cover at least a portion of the gusset  32  during assembly of the container.  FIGS. 15O-15Q  show a continued exemplary assembly process, where base layer  24 C is folded over and onto (e.g., in direct planar contact with base layer  24 B. Base layers  24 C are shown as having a width that is less than the width of other base layers  24 A,  24 B, and  24 D. Upon folding two base layers  24 C onto base layer  24 B, at least a portion of the base layers  24 C may overlap with one another so that base layer  24 B is substantially completely covered by base layers  24 C. Alternatively, the base layers  24 C may not contact one another. A portion of base layer  24 B may thus still be visible even upon folding base layers  24 C onto base layer  24 B.  FIGS. 15R-15U  show additional exemplary steps in the container assembly process where the lateral projections  28  fold into the container and over (e.g., in direct planar contact with a wall, layer  26 . This occurs generally prior to folding the base layer  24 D onto (e.g., in direct planar contact with) onto the base layers  24 C. The step of folding base layer  24 D onto base layers  24 C is shown for example at  FIGS. 15V-15Z . The step of folding base layer  24 D may be the final step in the container assembly process. 
     It should be noted that the order in which the various base layers are folded onto the base layer  24 A may vary, such that base layers  24 C may be folded onto base layer  24 A before or after one or more of base layer  24 B and base layer  24 D. Further, one or more of base layers  24 B,  24 C, and  24 D may be omitted from the blank. Also, any of base layers  24 B,  24 C and  24 D may be formed of a single continuous, sheet or of more than one sheet being folded to join and form the layer. 
       FIGS. 16A-C  illustrate features of an assembled container according to the teachings herein. As an example, when the interior of the container is viewed from above (as shown), only base layer  24 D may be visible. 
       FIGS. 17A-C  illustrate a box including two containers according to the teachings herein. As only the exterior portions of the resulting box are shown, only base layer  24 A is visible in both the bottom of the box and the lid of the box. 
     The containers according to the teachings herein may be configured to receive one or more items for retail packaging purposes, for displaying purposes, for storage purposes, for transportation purposes, or any combination thereof. For example the container may be configured for receiving an electronic device (such as a consumer electronic device), a cosmetic, a kit, an article of clothing, a houseware item an automotive accessory, paper goods, a food item, or any combination thereof. 
     Though not necessarily drawn to al geometries relative proportions and dimensions shown in the drawings are also part of the teachings herein, even if not explicitly recited. However, unless otherwise stated, nothing shall limit the teachings herein to the geometries, relative proportions and dimensions shown in the drawing. 
     Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. Plural structural components can be provided by a single integrated structure. Alternatively, a single integrated structure might be divided into separate plural components. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention. 
     The preferred embodiment of the present invention has been disclosed. A person of ordinary skill in the art would realize however, that certain modifications would come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention. 
     The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application. Those skilled in the art may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present invention as set forth are not intended as being exhaustive or limiting of the invention. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.