Patent ID: 8092360

Claim:
A method for creating a multi-wall container precursor from a single blank of material that defines a longitudinal direction from a first end to a second end, the method comprising: defining an inner panel that forms inner sidewalls of the container when assembled, the inner panel comprising a plurality of inner panel portions, each inner panel portion being contiguous with any adjacent inner panel portion and each inner panel portion comprising one inner sidewall of the container when assembled; defining at least one pair of opposing middle flaps that extends from the inner panel to a distal edge, wherein the sum of the lateral length of the pair of middle flaps from their intersection with the inner panel to the distal edge is equal to or less than the lateral length of the inner panel from the intersection of a first opposing middle flap to the intersection of a second opposing middle flap, and wherein each middle flap comprises a plurality of flap portions, each flap portion being contiguous with any adjacent flap portion and each opposing pair of flap portions comprising one middle sidewall of the container when assembled; defining an outer panel that extends from the inner panel and forms outer sidewalls of the container when assembled, the outer panel comprising a plurality of outer panel portions, each outer panel portion being contiguous with any adjacent outer panel portion and each outer panel portion comprising an outer sidewall of the container when assembled; and involuting at least one pair of opposing middle flaps to bring their respective distal edges into proximity with each other and attaching them to the inner panel, thereby forming intermediate sidewalls when the blank is assembled into the container.