Abstract:
The present invention is directed to a container and container blank for shipping and displaying product that are generally flat and round. In accordance with the present invention, a single sheet of foldable material is cut and scored to define a container blank. The blank includes a variety of panels, flaps and tabs, that when erected, form a container that includes an interior volume having gussets in the corners. The gusseted corners provide a contact surface for product stability within the container. Likewise, the gussets provide overall stability and increased strength to the container. The container includes top panels that close the container.

Description:
FIELD OF THE INVENTION 
     This invention relates generally to cellulose-based blanks and containers and more specifically to wood cellulose-based blanks and containers used for shipping and displaying flat and round shaped objects. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various embodiments of this present invention are described in detail below with reference to the following drawings. 
         FIG. 1  is a perspective view of a single piece of container blank formed in accordance with an aspect of the present invention; 
         FIG. 2  is a perspective view of a partially assembled container assembly according to the present invention; 
         FIG. 3  is another perspective view of a further partially assembled container assembly according to the present invention; 
         FIG. 4  is a perspective view of a still further partially assembled container assembly according to the present invention; and, 
         FIG. 5  is a perspective view of an assembled container from the blank of  FIG. 1 , ready for receipt of product. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention will now be described with reference to the accompanying drawings. The present invention is directed to a container and associated blank that is configured to hold generally flat and round objects, such as, without limitation, packages of tortilla wraps or pizza crusts. One suitable embodiment of a container  50  constructed in accordance with aspects of the present invention is illustrated in  FIGS. 1-5 . Specific details of the blank  20  and resulting container  50  are described with more particularity below. 
       FIG. 1  depicts a blank  20  used to form the container  50 . The blank  20  is preferably constructed from a single piece of formable material such as, without limitation, sheets of cellulose-based materials formed from cellulose materials such as wood pulp, straw, cotton, bagasse or the like. Cellulose-based materials used in this present invention come in many forms such as fiberboard, containerboard, corrugated containerboard and paperboard. 
     The blank  20  is cut and scored, perforated or otherwise formed to include a plurality of panels that when assembled form container  50 . In all FIGURES, like numbers indicate like parts. Additionally, cut lines are shown as solid lines, score lines as dashed lines, and lines of perforation as broken lines. For the purpose of further description herein, the downward direction is defined as the direction perpendicular to first bottom panel  32  that corresponds to the outer surface of the bottom panel when the container has been erected. The upward direction is defined as the direction perpendicular to the first bottom panel  32  that corresponds to the inner surface of the bottom panel when the container has been erected. 
     With respect to  FIG. 1 , the blank  20  includes first side panels  22   a , second side panels  22   b , first top panels  26  foldably attached to said first side panels, second top panels  28  foldably attached to said second side panels, and polygon shaped gusset panels  30  foldably attached to the second top panels. Further the blank  20  includes first bottom panels  32  and second bottom panels  34 . The first side panels  22   a  are connected along fold lines  23   a  to respective first top panels  26  and also connected with a respective first bottom panel  32  along fold lines  23   b . The second side panels  22   b  are connected to first side panels  22   a  along respective fold lines  21 ,  29  and  31 , and to second bottom panels  34  along respective fold lines  27 . 
     Opposite the fold lines  27  are fold lines  25 , which connect second top panels  28  with respective adjacent second side panels  22   b . The second top panels  28  include shaped gusset panels  30  attached to the second top panel  28  along respective fold lines  35  extending angularly with respect to the folded attachment of the gusset panel with the respective second top panel. As clearly shown in the drawings, it will be noted that the fold lines  35  extend angularly from a first end thereof at a respective adjacent outer side edge of the second top panel to a second end thereof spaced from the folded attachment of the second top panel to an associated second side panel, whereby the second top panel includes a narrow strip  39  extending between the gusset panels and their folded attachment with the second side panel. 
     As best seen in  FIG. 1 , the first bottom panels  32  are shown to be slightly different sizes. Specifically, as measured perpendicular to fold line  23 , one first bottom panel is slightly longer than the other first bottom panel  32 . However, it will be appreciated that this arrangement may be desired in situations where a certain overlap is desired on the bottom side of the container. However, it will also be appreciated that these first bottom panels may be of equal size, either with or without an overlap section. This configuration is within those skilled in the art and therefore will not be described in detail herein. 
     With respect to  FIGS. 2-5 , erection of the container  50  from the blank  20  is depicted. Initially, the various side panels  22  are folded around fold lines  21 ,  29 ,  31 , respectively, such that the manufacturer&#39;s panel  24  is brought juxtaposed a portion of one of the side panels  22 . The manufacturer&#39;s panel  24  may then be joined to the respective side panel  22  in any methods such as staples, brads, tacks, adhesives or tapes such that the panels are held to the extent needed. As can best be seen in  FIG. 2 , this will form a substantially rectangular-shaped tube. 
     As the box erection process continues, the second bottom panels  34  may be folded inwardly approximately 90 degrees along fold lines  27 . Subsequently, the first bottom panels  32  may be folded inwardly 90 degrees along fold lines  23 . These respective bottom panels may then be joined together in any manner discussed above, or left not joined. As depicted best in  FIG. 3 , you may see that the first top panels  26  and the second top panels  28  still stand vertically, and the container  50  is in a generally open, yet not fully formed, condition. 
     With reference to  FIG. 4 , the second top panels  28  are folded inwardly approximately 90 degrees along a fold line  25  such that the second top panels  28  lies in a substantially parallel plane to the first bottom panel  32  and second bottom panel  34 . Subsequently, each of the gusset panels  30  may be folded downwardly approximately 90 degrees along fold lines  35 . The tabs  38  may then be inserted into the slots  36  to substantially lock these respective container portions in place. This stage of erection is depicted in  FIG. 4 . At this stage, the container  50  is ready to accept product (not shown). Products such as tortillas or other substantially round and generally flat objects may be placed within this box. The gussets panels  30  provide contact points for the products (not shown) and to help keep the product positioned where desired within the container  50 . Additionally, the gusset panels  30  increase overall container  50  stability and strength. 
       FIG. 5  simply depicts the container  50  in its closed state. Specifically, the first top panels are folded approximately 90 degrees inwardly along fold lines  23 . The container  50  may then be sealed by tape, adhesive, staples, braids, or combinations thereof. 
     The container  50  as shown is simple to manufacture, easy to assemble and may be a design of considerable usage in stores when the need for shipping or even displaying products having a substantially flat, yet round, geometry. However, it will be appreciated that this design may also be used in other a variety of other retail or wholesale environments or product configurations. 
     Any variety of additional elements may be included, such as, without limitation, vents, specialized liners or grease barriers, etc., without departing from the spirit and scope of the present invention. Similarly, rounding or otherwise trimming the various panels is considered within the scope of the instant invention. 
     While various embodiments of this invention have been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of this invention. Accordingly, the scope of this invention is not limited by the disclosure of the various embodiments. Instead, the invention should be determined entirely by references to the claims that follow.