Patent Publication Number: US-2013240614-A1

Title: Collapsible Container

Description:
RELATED APPLICATIONS 
     This patent application claims the benefit of U.S. Provisional Application No. 61/604,908, filed on Feb. 29, 2012, entitled, “Reusable, Collapsible Tray,” the contents and teachings of which are hereby incorporated by reference in their entirety. 
    
    
     BACKGROUND 
     Container devices, such as corrugated containers, can be used for packing a variety of objects. For example, in the envelope manufacturing area, corrugated envelope container devices are configured to hold stacks of envelopes and to allow for easy delivery to customers. Accordingly, envelope container devices should be relatively sturdy to withstand stacking and to protect the envelopes from deformation. 
     SUMMARY 
     Container devices, such as envelope container devices, suffer from a variety of deficiencies. For example, in their assembled state, conventional container devices such as corrugated envelope container devices, can take up a relatively large volume of space, thereby requiring a facility to provide a storage area for the unused in the area of the envelope and inserter machinery. Additionally, conventional corrugated paper container devices are relatively expensive as a one-use type of product, but are commonly utilized in today&#39;s trade. Furthermore, conventional corrugated envelope container devices are not easily disassembled to allow for easy storage. For example, certain conventional containers are held together with adhesives or fasteners, which cannot be removed without damaging the container. 
     By contrast to conventional container devices, embodiments of the present innovation relate to a container that includes a base, a first sidewall extending along a first direction from the base, and a second sidewall extending along the first direction from the base, the first sidewall opposing the second sidewall. The container includes a first end wall extending along the first direction from the base and a second end wall extending along the first direction from the base, the first end wall opposing the second end wall and each of the first end wall and the second end wall disposed between the first sidewall and the second sidewall. Each of the first end wall and the second end wall include a first end wall panel coupled to the base and defining an opening and a second end wall panel hingedly coupled to the first end wall panel, the second ends wall panel defining a set of tabs configured to engage a set of slots defined by the base and further defining a panel flexion portion extending at least partially along a length of the second end wall panel, the panel flexion portion substantially aligned with the opening defined by the first end wall panel. The second end wall panel is configured to flex about the panel flexion portion in response to a load applied to the panel flexion portion through the opening defined by the first end wall panel. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing and other objects, features and advantages will be apparent from the following description of particular embodiments of the innovation, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of various embodiments of the innovation. 
         FIG. 1  illustrates a blank used to create a storage tray, according to one arrangement. 
         FIG. 2  illustrates a partial perspective view of the blank of  FIG. 1  during assembly, according to one arrangement 
         FIG. 3  illustrates a side sectional view of a portion of the blank of  FIG. 1  where an end wall panel engages a base of the blank, according to one arrangement. 
         FIG. 4  illustrates a perspective view of the blank of  FIG. 1  formed into a storage tray, according to one arrangement. 
         FIG. 5  illustrates a side sectional view of a portion on the blank of  FIG. 1  where an end wall panel disengages engages a base of the blank, according to one arrangement. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the present innovation relate to a collapsible container, such as is configured to hold envelopes, tubes, or injected molded bottles, for example. The container is assembled from a pre-cut and scored sheet of corrugated material, such as a container form or blank. In one arrangement, the container is configured to allow for ease of disassembly. For example, a base of the container includes a pair of opposing end walls. Each end wall includes an outer end wall panel coupled to the base and an inner end wall panel coupled to the outer end wall panel. The inner wall panel includes set of tabs that engage corresponding openings defined by the base and a flexion portion, such as a score line, that allows the inner wall panel to flex relative to the base. The outer wall panel defines an opening that is substantially aligned with the score line. To disassemble the container, a user accesses the inner wall panel through the opening defined by the outer wall and applies a load against flexion portion. The load causes the inner wall panel to fold or buckle relative to the flexion portion, thereby shortening the length of the inner wall panel and releasing the tabs from the corresponding openings. In the case where the container is manufactured from a relatively stiff material, such as corrugated plastic or paper, this configuration of the container allows the user to easily disassemble tray and store in a substantially flat arrangement 
       FIG. 1  illustrates an arrangement of a unitary blank of material or container form  10 , used to create a container, such as an envelope storage tray. In one arrangement, the container form  10  is die cut and scored from a flat sheet of material. The container form  10  can be constructed from a variety of relatively strong, durable, and lightweight materials. For example, the container form  10  can be manufactured from a single thickness corrugated material, such as corrugated paper or corrugated plastic, having two layers of linerboard separated by a single layer of fluted material. As indicated in  FIG. 1 , the set of corrugations  11  of the corrugated material define a longitudinal axis that extends along axis  13  of the container form  10  between a first end wall  51  and a second end wall  61 . 
     The container form  10  includes a base  12 , opposing first and second sidewalls  18 ,  20  hingedly coupled to the base  12  via score or fold lines  171 ,  172 , and opposing first and second end walls  50 ,  60  hingedly coupled to the base  12  between first and second sidewalls  18 ,  20  via fold lines  133 ,  132 . 
     The base  12  is configured to form the bottom of a container or tray, following assembly. In one arrangement, the base  12  defines one or more openings  14  and  16  configured to allow air to pass through base  12  to help release envelopes from the base  12 . The openings  14 ,  16  are also sized to allow the container form  10  to be stacked over corresponding supports or poles. With such a configuration, multiple container forms  10  can be stacked in a substantially flat, unassembled state in a secure manner, thereby minimizing the space needed for storage of the forms  10 . 
     The first and second sidewalls  18 ,  20  each include respective first end flaps  30 ,  32  hingedly coupled to a first end of the sidewall  18 ,  20 , and respective second end flaps  31 ,  33  hingedly coupled to a second end of the of the sidewall  18 ,  20 . For example, the end flaps  30 ,  31  are connected to the sidewall  18  by hinges or fold lines  173 ,  174  and the end flaps  32 ,  33  are connected to the sidewall  20  by hinges or fold lines  175 ,  176 . In one arrangement, cuts or openings  41 ,  43  separate the end flaps  30 ,  31  from the first and second end walls  50 ,  60  and cuts or openings  42 ,  44  separate the end flaps  32 ,  33  from the first and second end walls  50 ,  60 . For example, panels  52  and  62  can be die cut such that the end flaps  32 - 33  can be separated from the adjacent panels of the end walls  50 ,  60 . 
     The end flaps  30 ,  31 ,  32 ,  33  include tabs configured to secure the sidewalls  18 ,  20  to the base  12 . For example, first end flaps  30 ,  32  include tabs  35 ,  36  that are configured to be inserted within openings  101 ,  102  defined by the base  12 . Additionally, second end flaps  31 ,  33  include tabs  37 ,  38  configured to be inserted within openings  201 ,  202  defined by the base  12 . As will be described below, as part of the assembly process, the first and second end flaps  30 ,  32  are configured to be further secured to the base  12  by the first end wall  50  and the first and second end flaps  31 ,  33  are configured to be further secured to the base  12  by the second end wall  60 . 
     Each of the first and second end walls  50 ,  60  are disposed between the first and second sidewalls  18 ,  20  and include a first end wall panel  52 ,  62  and a second end wall panel  51 ,  61 , respectively, separated by respective fold lines  130  and  131 , such as a double fold mechanism. Each of the first end wall panels  52 ,  62  are coupled to the base  12  and define corresponding openings  56 ,  66 . Additionally, each of the second panels  51 ,  61  are hingedly connected to the corresponding first end wall panels  52 ,  62  and define corresponding sets of tabs  54 ,  55  and  64 ,  65  engage a set of corresponding slots  101 ,  102  and  201 ,  202  defined by the base  12 . 
     Each of the second end wall panels  51 ,  61  also define corresponding panel flexion portions  53 ,  63  extending at least partially along a length of the second end wall panels  51 ,  61  and along a direction that is substantially perpendicular to the longitudinal axis  13  of the corrugations  11 . As will be described in detail below, the panel flexion portions  53 ,  63  are configured as weakening in the second end wall panels  51 ,  61  to allow the wall panels  51 ,  61  to flex in response to a load applied to the panel flexion portions  53 ,  63  to allow the tabs  54 ,  55 ,  64 , and  65  to either engage or disengage corresponding slots  101 ,  102 ,  201  and  202 . 
     The panel flexion portions  53 ,  63  can be configured in a variety of ways. For example, the panel flexion portions  53 ,  63  can be configured as a weakening in the second end wall panels  51 ,  61 , such as substantially continuous score lines or as substantially perforated score lines extending at least partially along the length of the second end wall panel. Alternately, the panel flexion portions  53 ,  63  can be configured as a living hinge disposed between an upper second end wall panel portion and a lower second end wall panel portion. The panel flexion portions  53 ,  63  can extend either the full width of the end wall panels  51 ,  61  or partially across the panels  51 ,  61 . The purpose of these lines lying across the corrugation direction is to allow the panels to flex just enough to engage and disengage tabs  54 ,  55 ,  64  and  65  from slots  101 ,  102 ,  201  and  202 . 
     With continued reference to  FIG. 1 ,  FIGS. 2-4  illustrate an example of an assembly process for folding the container blank  10  into a three dimensional container or tray  300 . 
     To assemble form  10  into the three dimensional container, an assembler rotates sidewalls  18 ,  20  about score or fold lines  171 ,  172  and relative to the base  12  until the sidewalls  18 ,  20  extend from the base  12  along direction  302 . In one arrangement, with such rotation, the sidewalls  18 ,  20  are disposed at an orientation that is substantially orthogonal to the base  12 . The assembler then rotates or folds end flaps  30 - 33  about respective hinges or fold lines  173 - 176  relative to the sidewalls  18 ,  20  such that the end flaps  30 - 33  are disposed at an orientation that is substantially orthogonal to the sidewalls  18 ,  20 . Next, the assembler inserts the tabs  35 - 38  of the end flaps  30 - 33  into corresponding slots  101 ,  102 ,  201 , and  202  to secure the sidewalls  18 , to the base  12 . With such insertion, as indicated in  FIG. 2 , the end flaps  30 - 33  are disposed at an orientation that is substantially orthogonal to the base  12 . Additionally, as indicated in  FIGS. 1 and 2 , cutout portions  81 - 84 , such as semicircular cutouts, meet at about the center of the base  12  to form a cut out relief that allows a user to access panel flexion portions  53  and  63  from the outside of the tray through openings  56 ,  66 , respectively, as described below. 
     Next, the assembler folds the first end wall panels  52 ,  62  relative to the base  12  and about respective fold lines  132 ,  133  to dispose the first end wall panels  52 ,  62  at an orientation that is substantially orthogonal to the base  12 . Such positioning substantially aligns the openings  56 ,  66  defined by the first end wall panels  52 ,  62  with the corresponding cutout portions  81 - 84  defined by the end flaps  30 - 33 , as indicated in  FIG. 2 . 
     The assembler then folds the second end wall panels  51 ,  61  about respective fold lines  130 ,  131  to capture the respective end walls  30 - 33  there between and to dispose the second end wall panels  51 ,  61  at an orientation as illustrated in  FIG. 3 . With continued reference to  FIG. 3 , the assembler applies a load  304  to a lower second end wall panel portion  306  of the second end wall panel  51  to cause the lower second end wall panel portion  306  to rotate about the panel flexion portions  53  relative to an upper second end wall panel portion  308 . Such rotation causes tabs  54  and  55  to be inserted within openings  101 ,  102 . The assembler can repeat the process with respect to the second end wall panel  61  to insert tabs  64 ,  65  into slots  201 ,  202 , respectively. 
     As a result of the assembly process, the assembler generates a container  300  as illustrated in  FIG. 4 . The container  300  can be used to hold envelopes stacked vertically on the long edge. However, this is not a limitation of the disclosure as the container can be used to hold, contain, or carry other objects. 
     In one arrangement, when the box is formed, tabs  57 ,  67  project upwardly from the first and second end walls  50 ,  60 , respectively. These tabs  57 ,  67  are configured to insert into corresponding slots  103 ,  203 , such as indicated in  FIG. 1  of a substantially identical container located on top of the subject container  300 . This allows containers  300  to be stacked with some registration between them such that the sidewalls  18 ,  20  and end walls  50 ,  60  of the subject container  300  support a container above it. Multiple containers, such as trays filled with envelopes, can thus be stacked in a footprint area equal to that of only one tray. 
     In order to store the container  300  when not in use, the container can be disassembled to the substantially flat container form  10  illustrated in  FIG. 1 . 
     With reference to  FIGS. 4 and 5 , once assembled, the panel flexion portions  53 ,  63  are configured to substantially align with the openings  56 ,  66  defined by the corresponding first end wall panels  51 ,  61  and with the cutouts  81 - 84  defined be corresponding end flaps  30 - 33 . With such a configuration, and with reference to  FIG. 5 , to disassemble the container  300  an end user applies a load  310  to the panel flexion portion  53  of the first end wall panel  51 . This loading causes the lower second end wall panel portion  306  and the upper second end wall panel portion  308  to buckle or rotate about the panel flexion portions  53 . Such rotation causes the tabs  54  and  55  to slide relative to the base and to be extracted from the openings  101 ,  102 . The assembler can repeat the process with respect to the second end wall panel  61  to disengage the tabs  64 ,  65  from the  201 ,  202 , respectively. This allows the container  300  to be disassembled back into the flat form  10  shown in  FIG. 1 . 
     While various embodiments of the innovation have been particularly shown and described, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the innovation as defined by the appended claims.