Patent ID: 12208942

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

Broadly, embodiments of the present invention provide an improved self-contained continuous carton system with erecting reinforced shoulders and stacking stab. Aspects of the invention provide a dual purpose PDQ with structural integrity for withstanding the rigors of the entire supply chain and as well as serving as a product display vehicle.

The reinforced shoulders to support stacking of one or more additional cartons on top of the reinforced shoulders to significantly reduce the incidence of the shoulders collapsing or buckling. A stacking stab protrudes from a top surface of the reinforced shoulder. The stacking stab is configured to engage with a recess defined in a bottom of a display carton stacked on the shoulder to retain the stacked carton in engagement with the subjacent display carton. The recess may be defined in a side panel and a bottom panel of the self-contained continuous carton system as described in U.S. Pat. No. 11,130,611 and U.S. patent application Ser. No. 17/304,805, which define an alcove with a secondary purpose as a hand hold that facilitates carriage and stacking of the carton by warehouse and stocking workers.

Aspects of the present invention include features for a reinforced side panel for a continuous carton system (SC3S) container. For ease of description, other panels of the SC3S are omitted. In the drawings, fold lines are shown with a dashed line, score lines are depicted with a solid line with intersecting bars at the ends, and cut lines shown in solid lines. A fold line is a marking or depression defined along the surface of the carton material, such as corrugated cardboard. A score line is a partial cut into the surface of the carton material and may be indicated with a prime mark, ′, following the associated reference number. For ease of description, the score line reference numbers may be omitted from the description. A cut line is defined as a cut extending through the carton material.

A first non-limiting embodiment of a multi-function reinforced sidewall for a container is shown in reference toFIGS.1a-1d. The multi-function reinforced side panel includes an interior sidewall10, an outer sidewall11, and a bottom panel12. The bottom panel12forms at least a portion of a bottom of the SC3S. The multi-function reinforced sidewall is configured to automatically erect when folded to form the SC3S.

The interior sidewall10is joined with the outer sidewall11along an upper fold line14. An intermediate section of the upper fold line14may include a score line14′ to facilitate folding of the interior sidewall10along the upper fold line14. Side edges16of the interior sidewall10may be inset to avoid interference with the inner sidewalls of the SC3S when the reinforced sidewall is erected. The outer sidewall11may be joined with adjacent sections of the SC3S along one or more side edges11′. The bottom panel12is joined with the outer sidewall11along a bottom fold line19.

The interior sidewall11has a pleat defined at a distal end, opposite the upper fold line14. The pleat includes a first pleat16and a second pleat15that are formed with a first pleat line17and a second pleat line18, disposed between the first pleat line17and the distal end of the interior sidewall11. Each of the first pleat line17and the second pleat line18may include one or more of a score line18′ or a slot cutout13along a portion thereof to facilitate folding. The slot cutout13defined along a portion of the first pleat fold line18. The slot cutout13configured to facilitate a folding of the first pleat16along the first pleat fold line17, before a folding of the second pleat15along the second pleat fold line.

Assembly and erection of a first functional structure of the multi-function reinforced sidewall is shown in reference to the drawings ofFIGS.1cand1d. InFIG.1c. A first step, the interior sidewall10is folded along the upper fold line14to overly an inner surface of the outer sidewall11. An inner surface of the second pleat15may be joined with the bottom panel12with a fastener15′, such as a staple, or an adhesive.

As the overlapping outer sidewall11and the interior sidewall10are rotated towards the bottom panel12, the interior sidewall10will be urged inwardly along the first pleat line17and the first pleat16and the second pleat15will fold towards each other along the second pleat line18. When the outer sidewall11and the interior sidewall10are in an upright condition, the first pleat16will overly the second pleat15with the interior sidewall10bracing the outer sidewall11in a cantilevered supporting relation with the outer sidewall11positioned in the upright condition. When a height of the interior sidewall10is greater than that of the outer sidewall11, the interior sidewall10will act as a brace for the reinforced sidewall.

A second functional structure of the multi-function reinforced sidewall is seen in reference toFIG.1d. In this embodiment, the adhesive or fastener may be omitted, or applied to each of the first pleat16and the second pleat15, the outer sidewall11and the interior sidewall10provide a double walled reinforcement for the SC3S.

An embodiment of the SC3S with a shouldered stab structure is shown in reference to the drawings ofFIGS.2a-2d. In this embodiment an articulating shoulder surface is provided at the top edge of the reinforced sidewall of the SC3S with the shouldered stab30interposed between the articulating shoulder surface. As seen in reference toFIGS.2aand2b, the reinforced sidewall includes an interior sidewall20and an outer sidewall21, and a bottom panel22. The outer sidewall21is joined with the bottom panel22along a bottom fold line23. The bottom panel22forms at least a portion of the bottom of the SC3S, when formed. In the embodiment shown inFIGS.2aand2b, a folding recess110is defined between the outer sidewall21and the bottom panel22.

Referring first toFIG.2a, the articulating shoulder surface is formed between the outer sidewall21and the interior sidewall20between a top fold line24and a shoulder fold line26. The shoulder fold line26extends partially across a top end of the outer sidewall21, with a portion of the shouldered stab structure30interrupting the top fold line segments26at an intermediate position between opposed side edges of the outer sidewall21. The top fold line24is spaced apart from the shoulder fold line26by a distance corresponding to a width of the shoulder. An intermediate shoulder fold line25is spaced apart from the top fold line24by a distance corresponding to a height of the shouldered stab30protrusion from a top surface of the shoulder.

An engagement slot28may be defined in the bottom panel22. A corresponding engagement tab29is defined at a distal end of the interior panel20. The engagement tab29is dimensioned to be received within the engagement slot, when the reinforced sidewall of the SC3S is formed.

Referring next toFIG.2b, the shouldered stab30structure is shown defined between the interior sidewall20and the outer sidewall21. The shouldered stab30includes an outer stab tab31protruding from a top end of the outer sidewall21interposed between segments of the top fold line24and terminating at an intermediate shoulder fold line25. An inner stab tab32extends from the top fold line24and terminates at a stab shoulder fold line35. The stab shoulder fold line35is spaced apart from the intermediate shoulder fold line25by a distance corresponding to a width of a stab shoulder surface34.

A pair of stab cut lines33are defined between the top fold line24and the shoulder brace fold line27. The pair of stab cut lines33are disposed in a parallel spaced apart relation corresponding to a length of the shouldered stab30. The pair of stab cut lines33intersect each of the shoulder fold line26and the intermediate shoulder fold line25. The structure ofFIG.2cillustrates the shouldered stab structure with the folding recess110omitted.

Assembly and erection of the shouldered stab structure with articulating shoulder is shown in reference toFIG.2d. In a first step, the interior sidewall10is folded along the intermediate shoulder fold line25so that the interior sidewall10overlies an interior surface of the outer sidewall11. The engagement tabs29are indexed with the corresponding engagement slot28. As the outer sidewall11and interior sidewall10are elevated and rotated inwardly relative to the bottom panel22, the engagement of the engagement tabs29with the engagement slots28urges the interior sidewall upwardly to deploy each of the shoulder surfaces37and the shouldered stab30.

The shoulder surface37,38is deployed by a flexing of the shoulder area about the top fold line24, the intermediate shoulder fold line25, the shoulder fold line26, and the shoulder brace fold line27with a separation at the stab cut lines33. A shoulder brace36of the shoulder area is cantilevered inwardly towards an interior of the SC3S by a flexing about the shoulder brace fold line27and the shoulder fold line26. As the rotation continues to an upright position of the interior sidewall10and the outer sidewall11, the shoulder surfaces37,38are urged into a flattened condition to define the shoulder surface.

Simultaneously, the shouldered stab30is deployed to its upright condition protruding from an intermediate portion of the shoulder surface37,38. When the shoulder surfaces37,38separate along the stab cut line33, the relative movement of the inner stab tab32with the interior sidewall20causes a flexing along the stab shoulder fold line35which progressively urges the stab shoulder34to a deployed condition, protruding above the adjacent shoulder surfaces37,37′. A flattening of the shoulder surface37,37′, such as by placement of a superjacent carton on the shoulder surface37,37′, urges the shoulder brace36to its fully deployed, cantilevered position.

A third embodiment of a reinforced sidewall for a SC3S container is shown in reference toFIGS.3a-3d. In this embodiment, the reinforced sidewall includes a shoulder surface57and a protruding stab50forming a top surface of the reinforced sidewall when deployed. The embodiments shown inFIGS.3aand3bhave an optional folding recess110formed in the sidewall and the bottom of the container, while the embodiment shown inFIG.3cthe folding recess110is omitted.

As with the previous embodiments, the reinforced sidewall includes an interior sidewall40, an outer sidewall41, and a bottom panel42. The bottom panel42forms at least a portion of the bottom of the SC2S container and is joined with the outer sidewall41along a bottom fold line43. The interior sidewall40is joined with a shoulder brace56along a shoulder brace fold line44. One or more segments of the top fold line44may include a score line44′ to facilitate folding of the interior panel40about the top fold line44. A shoulder fold line45is spaced apart from the top fold line44by a distance corresponding to a width of the shoulder57. Likewise the shoulder fold line45is spaced apart from an shoulder brace fold line46by a distance corresponding to a width of a shoulder brace56. The shoulder brace fold line46is interposed between the shoulder surface57and the outer sidewall41.

As seen in reference toFIG.3b, a stab structure50is located at an intermediate position of the shoulder surface57. The stab structure50includes an inner stab tab52that is joined with an outer stab tab51along a stab fold line55. As with the embodiments ofFIGS.2a-2d, the stab structure50is automatically deployed to protrude from the shouldered surface57when the interior sidewall40and the outer sidewall41are elevated to an upright, deployed condition. In this embodiment, the stab structure50is somewhat simplified from the stab structure30ofFIGS.2a-2d. In this embodiment, the stab structure50is deployed as an angular protrusion, rather than a shouldered protrusion. In either case, the stab structure30,50is engageable with a recess, such as the optional folding recess110, to index a subjacent SC3S with a superjacent SC3S positioned atop the shoulder surface57of the reinforced sidewall.

Assembly and erection of the angled stab structure50with the shoulder is shown in reference toFIG.3d. In a first step, the interior sidewall40is folded inwardly along the top fold line44. The engagement tabs49are engaged with the corresponding slots48. As the interior sidewall40and the outer sidewall41are elevated and rotated inwardly the interior sidewall40urges the shoulder brace56to fold along the shoulder brace fold line46and the shoulder57to fold along the shoulder fold line45. As the outer sidewall41and the interior sidewall40reach their upright condition, the shoulder brace56supports the shoulder57in a cantilevered supporting position.

Simultaneously, the angled stab structure50is automatically deployed to its protruding position. Movement of the interior sidewall40urges the inner stab52to flex along the stab fold line55, with a separation of the inner stab52and the outer stab tab51along the stab cut lines53. Once deployed, the stab structure50is formed as an angled protrusion from the top surface of the shoulder57. The stab structure50is configured to engage with a recess in a bottom surface of a superjacent SC3S placed atop the shoulder57.

A fourth embodiment of a reinforced sidewall for a SC3S container is shown in reference toFIGS.4a-4d. In this embodiment, a shouldered SC3S is provided with a shoulder brace76supporting the shoulder surface77,78, in a cantilevered manner from the interior sidewall60. As with other embodiments, the reinforced sidewall includes an interior sidewall60, an outer sidewall61, and a bottom panel62. The bottom panel62is joined with the outer sidewall61along a bottom fold line67. The bottom panel62forms at least a portion of a bottom of the SC3S.

A top fold line64is defined across a top end of the outer sidewall61. In this embodiment, a first shoulder segment78is defined between the top fold line64and an intermediate shoulder fold line65, which may include intermediate shoulder score lines65′. A second shoulder segment77is defined between the intermediate shoulder fold line65and a shoulder fold line66. The first shoulder segment78and the second shoulder segment77define a shouldered surface for the SC3S when in the deployed condition.

The shoulder brace76is defined between the shoulder fold line66and a shoulder brace fold line67,67′. The shoulder brace76provides a cantilevered support for the shouldered surface when the SC3S is configured in the deployed condition. As with other embodiments, the embodiments shown inFIGS.4aand4bare depicted with the optional folding recess110. In the embodiment shown inFIG.4c, the optional folding recess110is omitted.

Assembly and erection of the shoulder77,78with cantilevered shoulder support76is shown in reference toFIG.4d. In a first step, the interior sidewall60is folded inwardly along the top fold line64so that the interior sidewall60overlies the outer sidewall61. As the interior sidewall60and the outer sidewall65are elevated and rotated inwardly relative to the bottom panel62, movement of the interior sidewall60urges against the shoulder brace76causing a flexure along the shoulder brace fold line67, the shoulder fold line66, the intermediate shoulder fold line65, and the top fold line64. As the interior sidewall60and the outer sidewall are elevated to an upright condition, the first shoulder segment78and the second shoulder segment77deploy to form the shouldered surface of the SC3S, with the shoulder brace76deployed to the cantilevered supporting position.

A fifth embodiment of a reinforced sidewall for a SC3S container is shown in reference toFIGS.5a-5d. In this embodiment, a shouldered SC3S is provided with a shoulder97with a stab structure90protruding from the shoulder97. In this embodiment, the reinforced sidewall includes an interior sidewall80, an outer sidewall81, and a bottom panel82. The bottom panel82is joined with a bottom end of the outer sidewall81along a bottom fold line83. The bottom panel82forms at least a portion of the bottom of the SC3S, when assembled. A top fold line84extends laterally across a top end of the outer panel, opposite the bottom fold line83. A shoulder97is defined between the top fold line84and a shoulder fold line86. The interior panel80is joined along the shoulder fold line86.

A stab structure80is provided to automatically deploy from a top surface of the shoulder97when the reinforced sidewall is assembled. The stab structure80is defined by stab cut lines93in an intermediate portion of the interior sidewall80and the shoulder97. The stab structure80extends between a stab fold line87and the top fold line84. The stab structure80includes a first tab stab91defined in the interior sidewall80between the stab cut lines93, the stab fold line87and the shoulder fold line86. A second stab tab92and a third stab tab94are defined in the shoulder97between the stab cut lines93. A stab fold line85, about which the second stab tab92and the third stab tab94will fold, is defined between the shoulder fold line86and the top fold line84. In the embodiment shown inFIGS.5aand5b, the reinforced sidewall is provided with the optional folding recess110. In the embodiment shown inFIG.5c, the folding recess110is omitted.

Assembly of the reinforced sidewall of the fifth embodiment is shown in reference toFIG.5d. In an initial step, the interior sidewall80is folded along the top fold line84and is positioned to overly the outer sidewall81, with a top edge of the interior sidewall80overlying the bottom panel82along the bottom fold line83. As the outer sidewall81and the interior sidewall80are elevated to their upright position, a bottom edge of the interior sidewall80is urged upwardly and the shoulder97is automatically formed by a flexure along the top fold line84and the shoulder fold line86.

Simultaneously, the stab structure90is formed by a separation of the first stab tab91, the second stab tab92, and the third stab tab93along the stab cut lines93. As the stab structure90is formed the first stab91is urged inwardly and the second stab tab92and third stab94fold along the stab tab fold line85to protrude from a top intermediate surface of the shoulder97.

As indicated previously, each embodiment of the reinforced sidewall may also be provided with the optional folding recessed truss110. The folding recessed truss110is shown inFIGS.6a-6E, with reference numbers to common components shown in the fifth embodiment of the reinforced sidewall ofFIGS.5aand5bwith the stab structure90omitted.

The folding recessed truss110provides a structural support truss between the interior sidewall80and the outer sidewall81when folded to form the SC3S. The folding recessed truss110also provides a convenient hand hold for carrying or manipulating the SC3S. When utilized with the stab structures90disclosed herein, the folding recessed truss110provides a recess to receive the stab structures90and provides for a positive indexing of the SC3S for stacking of a superjacent SC3S atop a subjacent SC3S. The indexing of the stab structure90with the recess improved stability in the stacked SC3S containers.

As best seen in reference toFIGS.6a-6e, the folding recessed truss110includes a vertical truss kick-in112extending along a lower truss fold line118of the folding recessed truss110. The lower truss fold line118is offset from the bottom fold line83of the bottom tab82by a distance corresponding to a gap G separation between the outer sidewall81and the interior sidewall80and the width of the shoulder87, when erected.

A fastener117, such as a an adhesive or a staple joins the vertical truss kick-in112with an inner surface of the interior sidewall80. Once joined with the interior sidewall80, the folding recess truss110will deploy automatically with the formation of the shoulder87and, when provided with the shoulder87, the stab structure90.

To facilitate separation of the vertical truss kick-in112and automatic erection of the folding recessed truss110, one of a horizontal truss cut line115and/or an intermediate truss cut line113spaced apart from the horizontal truss cut line115define a top edge of the vertical truss kick-in112. The horizontal truss cut line115is defined above the bottom fold line83by a distance corresponding to a vertical height of the folding recess truss110, when erected. Likewise, one or more vertical truss cut lines114defines a lateral edge of the vertical truss kick-in112to facilitate separation of the vertical truss kick-in112from the outer sidewall81and the bottom panel82. Corrugated material between the horizontal truss cut line115and the intermediate truss cut line113may be discarded as scrap. Similarly, excess corrugated material between adjacent vertical truss cut lines114may be discarded as scrap.

When provided with the optional folding recess truss110, the assembly and erection of the reinforced sidewall may include applying a fastener or an adhesive to join the vertical recess truss112with an inner surface of the interior sidewall80. Once joined, the folding recess truss110will deploy automatically with the formation of the shoulder and the stab structure90.

When the bottom panel82is folded inwardly approaching 90 degrees, the scored and adhered area within the vertical truss cut lines114and one of the horizontal truss cut line115or the intermediate truss cut line113folds inwardly towards the center of the structure creating an alcove of the folding recessed truss110, including vertical truss kick-in112within the confines of the die cut section. Accordingly, the reinforced truss110is formed automatically between the bottom panel82, the outer sidewall81, and the interior sidewall80. The folding recess truss110area has multiple purposes. First the folding recess truss110reinforces the interior sidewall80preventing it from imploding or collapsing. Second, the folding recess truss110provides a handhold for easier access lifting, carrying, and stacking of the PDQ, often weighing up to 40 lbs. when full of goods. Third, the folding recess truss110provides a recess for indexed stacking of the SC3S with the stab structure90of a subjacent SC3S.

In use, the SC3S made with the reinforced sidewalls of the present invention may be used for shipment and display of goods in almost any retail environment where packages, preferably of the same size footprint, are stacked on top of each other. The SC3S is also an ideal solution for any manufacturer whose customers require their packaging to withstand the rigors of a demanding supply chain, such as but not limited to club stores.

The SC3S 10 is manufactured to survive: warehouse exposure to elements, such as high humidity; transcontinental and intercontinental transport to retailer distribution centers; and transit or storage environments where pallets of other vendor product maybe stacked on top other theirs. The product stacked on top could substantially outweigh their product.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.