Patent Publication Number: US-10329046-B2

Title: Tie-lock shipper

Description:
FIELD OF THE INVENTION 
     The present invention relates to improvements in shipping containers and, more particularly, to a shipping container that combines aspects of a regular slotted container and a “bow-tie” structure. 
     BACKGROUND OF THE INVENTION 
     A regular slotted container (RSC) is a common construction for forming corrugated cardboard containers. This type of container is typically formed from a blank that includes side and end wall panels connected in series at vertical edges along fold lines, and top and bottom end flaps may extend from opposing upper and lower edges of the side and end panels. The blank is folded about the vertical edges to position an end of the blank defining an edge of a side panel in association with an opposing end of the blank defining an edge of an end panel adjacent to each other at a joint that is typically adhered together by a manufacturer to form a rectangular tube. The blank formed with the manufacturer&#39;s joint can be collapsed and provided to an end user where the blank can be reconfigured to a rectangular tube and the flaps folded perpendicular to the side and end panels to complete the container. 
     SUMMARY OF THE INVENTION 
     In accordance with an aspect of the invention, a blank is provided for making a one-piece container. The blank comprises a central first section, a pair of second sections connected to the first section along a respective first longitudinal score line, the second sections defining side walls and end walls of the container, and a pair of third sections, each third section connected to a second section along a respective second longitudinal score line, the third sections defining bottom flaps of the container. The first section includes a pair of top lateral flaps located on either side of a longitudinal slit that divides the blank in half, and a pair of top end flaps spanning across opposing longitudinal ends of the top lateral flaps. Each top end flap comprises a triangular section defining a bow-tie lock connecting two halves of the blank on either side of the longitudinal slit. 
     The longitudinal slit may extend into the top end flaps, and may include first lateral slits bisected by the longitudinal slit and defining a separation between the top lateral flaps and each top end flap. 
     Each bow-tie lock may be defined by a pair of perforated score lines that diverge from an area at an outer longitudinal side of the corresponding top end flap. 
     The perforated score lines of each bow-tie lock may have distal ends connected by a second lateral slit that is bisected by an end of the longitudinal slit. 
     Each top end flap may divided into two half sections along a first portion by the longitudinal slit and along a remaining portion by a central score line extending longitudinally across the bow-tie lock, and the two half sections of each top end flap may be pivotable relative to each other about the bow-tie lock during formation of the container to position the outer longitudinal sides of the two half sections adjacent to each other. 
     Each of the second sections may include a side wall and first and second end wall panels connected to opposing longitudinal ends of the side wall along respective lateral score lines. 
     First lateral slits may span between the first longitudinal score lines, and the lateral score lines may be collinear with respective ones of the first lateral slits. 
     A lateral edge of each of the end wall panels may be connected to a lateral edge of one of the top end flaps at a respective first longitudinal score line. 
     Each of the third sections may include a bottom lateral flap connected to one of the side walls at a respective second longitudinal score line, and one of the third sections may further include first and second bottom end flaps connected to adjacent first and second end wall panels along one of the second longitudinal score lines. 
     In accordance with another aspect of the invention, a container is provided including a pair of opposing side walls and a pair of opposing end walls, a top lateral flap hingedly connected to each side wall, a top end flap hingedly connected to each end wall, and bottom flaps hingedly connected to the side walls and the end walls. The container further comprises each top end flap comprising two half sections separated by a flap slit. Each top end flap further comprises a bow-tie lock integrally formed as part of the two half sections of the top end flap, the bow-tie lock spanning the flap slit and connecting the two half sections. 
     Each bow-tie lock may define a triangular section having a base extending laterally across the flap slit and sides extending diagonally from the base to a point at the flap slit. 
     Each end wall may comprise an inner end wall panel hingedly connected to one of the side walls and an outer end wall panel hingedly connected to the other of the side walls and overlapping an adjacent inner end wall panel. 
     One of the two half sections of each top end flap may be hingedly connected to one of the inner end wall panels and the other of the two half sections may be hingedly connected to one of the outer end wall panels. 
     In accordance with a further aspect of the invention, a method of forming a container from a blank is provided. The blank for performing the method comprises a central first section; a pair of second sections connected to the first section along a respective first longitudinal score line, the second sections defining side walls and end walls of the container and comprising first and second end wall panels connected at lateral score lines to longitudinal ends of each of the side walls; a pair of third sections, each third section connected to a second section along a respective second longitudinal score line, the third sections defining bottom flaps of the container; the first section including a pair of top lateral flaps located on either side of a longitudinal slit that divides the blank in half, and a pair of top end flaps spanning across opposing longitudinal ends of the top lateral flaps; each top end flap including a triangular section defining a bow-tie lock connecting two halves of the blank on either side of the longitudinal slit. The method comprises folding the blank in half at the longitudinal slit line to position a first half of the blank adjacent to a second half of the blank; and folding the first and second end wall panels about the lateral score lines to orient the end wall panels perpendicular to the side walls, wherein the end walls of the container are each defined by a pair of the end wall panels positioned in overlapping relationship adjacent to each other. 
     Each top end flap may comprise two half sections and a bow-tie lock integrally formed as part of the two half sections. 
     The two half sections of each top end flap may be pivotable relative to each other about the bow-tie lock during folding of the blank so as to position outer longitudinal sides of the two half sections adjacent to each other and define a flap slit separating the two half sections. 
     The end wall panels defining each end wall may comprise adjacent inner and outer end wall panels, and one of the two half sections of each top end flap may be hingedly connected to one of the inner end wall panels and the other of the two half sections may be hingedly connected to one of the outer end wall panels. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the present invention will be better understood from the following description in conjunction with the accompanying Drawing Figures, in which like reference numerals identify like elements, and wherein: 
         FIG. 1  is a plan view of blank for forming a container; 
         FIG. 2  is a plan view of the blank of  FIG. 1  folded in half for forming the container; 
         FIG. 3  is a perspective view illustrating an initial folding of end wall panels for forming the container; 
         FIG. 4  is a perspective view illustrating further folding of the end wall panels in a position approaching perpendicular to side walls for the container; 
         FIG. 5  is a perspective view illustrating the container formed with bottom flaps folded to form a container bottom; and 
         FIG. 6  is a perspective view illustrating partial closure of the top flaps of the container. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In the following detailed description of the preferred embodiment, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration, and not by way of limitation, specific preferred embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and that changes may be made without departing from the spirit and scope of the present invention. 
     The present description is directed to a container construction that combines aspects of a regular slotted container (RSC) with a bow-tie structure that enables different sides of a blank for the container to be held together. In accordance with an aspect described herein, a one piece container is provided formed of a flat die cut blank that is folded to define a rectangular tube shape having top and bottom flaps that fold to replicate an RSC style container. The container is further characterized by a pair of bow-tie locks defining a connection between two halves of the blank that forms the RSC style container. 
     Referring to  FIG. 1 , a die cut blank  10  is shown for illustrating one or more aspects of the invention. In a use of the blank to form a one piece container, the blank  10  may be formed of a corrugated cardboard material and may be die cut to the shape shown herein, although other materials and variations of the illustrated shape may be provided within the scope of the container described and claimed herein. The blank  10  illustrated in  FIG. 1  is a planar piece of material in which an inner side  11  is shown facing out of the page and an outer side  13 , see  FIG. 2 , is facing in an opposite direction from the inner side  11 . 
     As seen in  FIG. 1 , the blank  10  extends in a longitudinal direction between first and second longitudinal edges, generally designated  12  and  14 , respectively, and further extends in a lateral direction between first and second lateral edges, generally designated  16  and  18 , respectively. The blank  10  comprises a central first section  100 , a pair of second sections  200   a,    200   b  connected to the first section  100  along a respective first longitudinal score line  210   a  and  210   b  extending from the first longitudinal side  12  to the second longitudinal side  14 . The blank further comprises a pair of third sections  300   a,    300   b.  Each third section  300   a,    300   b  is connected to a corresponding second section  200   a,    200   b  along a respective second longitudinal score line  310   a  and  310   b  extending from the first longitudinal side  12  to the second longitudinal side  14 . 
     A longitudinal slit  102 , defining a longitudinal slit line, is formed in the blank  10  halfway between the lateral edges  16 ,  18  and divides the blank into two halves, generally designated first half “a” and second half “b”. The first section  100  includes a pair of top lateral flaps  20   a,    20   b  located on either side of the longitudinal slit  102 . The first section  100  further includes a pair of top end flaps  22 ,  24  spanning across opposing longitudinal ends of the top lateral flaps  20   a,    20   b,  wherein a pair of first lateral slits  26 ,  28  define a separation between the top lateral flaps  20   a,    20   b  and the top end flaps  22 ,  24 . Each top end flap  22 ,  24  comprises a triangular section defining a respective bow-tie lock  30 ,  32  adjacent the respective longitudinal edges  12 ,  14 . The longitudinal slit  102  bisects the pair of first lateral slits  26 ,  28  and extends into the top end flaps  22 ,  24  up to a longitudinal location adjacent to the bow-tie locks  30 ,  32 . The bow-tie locks  30 ,  32  form bridge pieces connecting the two halves “a” and “b” of the blank  10  on either side of the longitudinal slit  102 . 
     Each bow-tie lock  30 ,  32  is defined by a pair of perforated score lines S 1 , S 2  that diverge from an area, such as near or at a point, at the outer longitudinal sides  12 ,  14  of the corresponding top end flap  22 ,  24 . The perforated score lines S 1 , S 2  of each bow-tie lock  30 ,  32  have distal ends connected by a second lateral slit  34  that is bisected by an end of the longitudinal slit  102 . Hence, the perforated score lines S 1 , S 2  and lateral slit  34  of each bow-tie lock  30 ,  32  define a triangular bridge piece spanning between the two blank halves “a” and “b”. Each top end flap  22 ,  24  is divided into two half sections  22   a,    22   b  and  24   a,    24   b.  The two half sections  22   a,    22   b  and  24   a,    24   b  are defined by a segment of the longitudinal slit  102  extending along a first portion of the corresponding top end flap  22 ,  24  and are further defined along a remaining portion of the top end flaps  22 ,  24  by a central score line Sc extending longitudinally across the bow-tie lock  30 ,  32 . During formation of a container, the two half sections  22   a,    22   b  and  24   a,    24   b  of each top end flap  22 ,  24  are pivotable relative to each other about the score line Sc of the bow-tie lock  30 ,  32  to position outer longitudinal sides of the two half sections  22   a,    22   b  and  24   a,    24   b  adjacent to each other. Specifically, as is discussed in greater detail below, during folding of the blank  10  to form a container, the outer longitudinal sides  12   a,    12   b  of the two half sections  22   a,    22   b  are repositioned adjacent to each other and the outer longitudinal sides  14   a,    14   b  of the two half sections  24   a,    24   b  are repositioned adjacent to each other, see  FIG. 5 . 
     The second sections  200   a,    200   b  define first and second side walls  36   a,    36   b  that are coextensive in the longitudinal direction with respective top lateral flaps  20   a,    20   b.  The second section  200   a  further includes first and second inner end wall panels  38   a,    40   a  that are connected to opposing longitudinal ends of the first side wall  36   a  along respective lateral score lines  42   a,    44   b.  The second section  200   b  further includes first and second outer end wall panels  38   b,    40   b  that are connected to opposing longitudinal ends of the second side wall  36   b  along respective lateral score lines  42   b,    44   b.    
     A lateral edge of each of the inner end wall panels  38   a,    40   a  is connected to and is coextensive in the longitudinal direction with a lateral edge of a respective top end flap  22 ,  24  at the first longitudinal score line  210   a.  A lateral edge of each of the outer end wall panels  38   b,    40   b  is connected to a lateral edge of a respective top end flap  22 ,  24  at the first longitudinal score line  210   b.  The outer end wall panels  38   b,    40   b  extend in the longitudinal direction a dimension that is approximately twice the longitudinal dimension of the top end flaps  22 ,  24 . It may be noted that the lateral score lines  42   a,    42   b  are collinear with the first lateral slit  26 , and that the lateral score lines  44   a,    44   b  are collinear with the other first lateral slit  28 . Also, it can be seen that the first lateral slits  26 ,  28  span between the first longitudinal score lines  210   a,    210   b,  such that the top end flaps  22 ,  24  are supported to the blank  10  solely at the connections to the inner and outer end wall panels  38   a,    40   a  and  38   b,    40   b  along the respective first longitudinal score lines  210   a  and  210   b.    
     The third sections  300   a,    300   b  include a bottom lateral flap  46   a,    46   b  connected to and coextensive in the longitudinal direction with the side walls  36   a,    36   b  at a respective second longitudinal score line  310   a,    310   b.  The third section  300   b  further includes first and second bottom end flaps  48   b,    50   b  connected to the adjacent first and second outer end wall panels  38   b,    40   b  along the second longitudinal score line  310   b.  The first and second bottom end flaps  48   b,    50   b  are separated from the longitudinal ends of the bottom lateral flap  46   b  at respective lateral flap slits  52   b,    54   b.    
     Referring to  FIGS. 2-5 , steps illustrating a method of folding the blank  10  to form a container are shown. In  FIG. 2  the blank  10  is initially folded about the longitudinal slit  102 . For example, the first half “a” of the blank  10  may be pivoted about the longitudinal slit  102  to position the inner side  11  of the first half “a” facing the inner side  11  of the second half “b” of the blank  10 . The folding of the blank  10  additionally includes folding of the bow-tie locks  30 ,  32  about the central score line SC. In the position shown in  FIG. 2 , the outer longitudinal side  12   a  of the half section  22   a  is positioned adjacent to and is coextensive with the outer longitudinal side  12   b  (not seen in  FIG. 2 ) of the half section  22   b  (not seen in  FIG. 2 ) extending in the lateral direction from the longitudinal slit  102 . Similarly, the outer longitudinal side  14   a  of the half section  24   a  is positioned adjacent to and is coextensive with the outer longitudinal side  14   b  (not seen in  FIG. 2 ) of the half section  24   b  (not seen in  FIG. 2 ) extending in the lateral direction from the longitudinal slit  102 . 
     Referring to  FIG. 3 , an initial side folding step is illustrated in which the first and second inner end wall panels  38   a,    40   a  are pivoted inwardly about the lateral score lines  42   a,    44   a  toward the first and second outer end wall panels  38   b,    40   b.  Similarly, the first and second outer end wall panels  38   b,    40   b  are pivoted about the lateral score lines  42   b,    44   b  toward the first and second inner end wall panels  38   a,    40   a.  It should be noted that the bow-tie locks  30 ,  32  provide a flexible hinge connection between the first and second blank halves “a” and “b”, wherein the two half sections  22   a,    22   b  and  24   a,    24   b  of each top end flap  22 ,  24  are pivotable relative to each other about the bow-tie lock  30 ,  32 . As seen in  FIG. 3 , as the inner end wall panels  38   a,    40   a  and outer end wall panels  38   b,    40   b  are pivoted, the bow-tie locks  30 ,  32  fold out from a doubled-over configuration toward a flat configuration. The bow-tie locks  30 ,  32  permit movement of the inner end wall panels  38   a,    40   a  in a direction of pivoting movement that is opposite to the direction of pivoting movement of the outer end wall panels  38   b,    40   b.  As the inner end wall panels  38   a,    40   a  and outer end wall panels  38   b,    40   b  pivot, the side walls  36   a,    36   b  remain generally parallel to each other and move away from each other. 
       FIG. 4  illustrates a further pivoting movement of the inner end wall panels  38   a,    40   a  and outer end wall panels  38   b,    40   b  as they approach a final position perpendicular the side walls  36   a,    36   b,  and shows the outer end wall panels  38   b,    40   b  moving into overlapping relationship adjacent to the inner wall panels  38   a,    40   a  to form the first and second end walls  56 ,  58  of a formed container  60 , see  FIGS. 5 and 6 . The folded blank  10  comprising the end walls  56 ,  58  oriented perpendicular to the side walls  36   a,    36   b  defines a rectangular tube having top flaps  20   a,    20   b,    22 ,  24  and bottom flaps  46   a,    46   b,    48   b,    50   b  having a configuration corresponding to that of a regular slotted container, and can be formed without requiring use of tape, adhesive or similar attachment means between the end walls and side walls. 
     During the pivoting movement of the inner and outer end wall panels  38   a,    40   a  and  38   b,    40   b,  the outer longitudinal sides  12   a,    12   b  of the top end flap  22  move adjacent to each other to define a flap slit  62  in the top end flap  22 , and the outer longitudinal sides  14   a,    14   b  of the top end flap  24  move adjacent to each other to define a flap slit  64  in the top end flap  24 . It may be noted that the flap  22  of the formed container  60  comprises the two half sections  22   a,    22   b,  wherein the half section  22   a  is hingedly connected to the inner end wall panel  38   a  and the half section  22   b  is hingedly connected to the outer end wall panel  38   b.  Similarly, the flap  24  of the formed container  60  comprises the two half sections  24   a,    24   b,  wherein the half section  24   a  is hingedly connected to the inner end wall panel  40   a  and the half section  24   b  is hingedly connected to the outer end wall panel  40   b.  The bow-tie locks  30 ,  32  define connectors integrally formed as part of respective pairs of the half sections  22   a,    22   b  and  24   a,    24   b.  The bow-tie locks  30 ,  32  are formed with and extend between remaining parts  22   a ′,  22   b ′ and  24   a ′,  24   b ′ of the respective pairs of the half sections  22   a,    22   b  and  24   a,    24   b.  Each bow-tie lock  30 ,  32  defines a triangular section having a base  34   a  extending laterally across a respective flap slit  62 ,  64 , and including sides  31 ,  33  corresponding to the locations of the score lines S 1 , S 2  extending diagonally from opposing ends of the base  34   a  to a point at an end of a respective flap slit  62 ,  64 . 
     As seen in  FIGS. 5 and 6 , the bottom end flaps  48   b,    50   b  can be folded perpendicular to the end walls  56 ,  58 . The bottom lateral flaps  46   a,    48   b  can be folded over the bottom end flaps  48   b,    50   b  perpendicular to the side walls  36   a,    36   b.  The bottom lateral flaps  46   a,    46   b  can be attached together, such as by taping, to form a container bottom. Closure of the container  60  is completed by folding the top end flaps  22 ,  24  to a position perpendicular to the end walls  56 ,  58 , and the top lateral flaps  20   a,    20   b  can then be folded over the top end flaps  22 ,  24 , as illustrated by the partial closure of the top lateral flaps  20   a,    20   b  in  FIG. 6 . 
     While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.