Patent ID: 7473215

Claim:
A method of forming a three-piece container from a preformed flat body blank and a preformed pair of separate individual wall blanks, each of the separate individual wall blanks being of a corrugated board material comprising a fluted media, the body blank comprising a central bottom panel having a length and a width and defining the box's bottom perimeter and having window flanges and having a pair of opposite ends comprising an erectable pair of end wall panels with two corner post flanges, each of the separate individual wall blanks comprising an end wall portion and at least one T-extension portion and at least one side portion, there being formed on the end wall portion an intermediate and two equally spaced apart outer fold lines which define a pair of extension panels of equal width that are substantially less than half the width of the box's central bottom panel, which pair of extension panels when folded along the fold lines and brought and affixed together form the at least one T-extension portion, the method comprising the steps of: folding each of the separate individual wall blanks along the intermediate and two equally spaced apart outer fold lines to bring the pair of extension panels together such that the at least one T-extension portion extends inwardly from the end wall portion and folding the at least one side portion orthogonal to the end wall portion; without first affixing the two separate individual wall blanks together, placing the pair of folded separate individual wall blanks generally into contact with the perimeter of the central bottom panel such that the at least one T-extension portion extends inwardly of the box's bottom perimeter; and erecting the opposite end wall panels of the body blank into contact with the end wall portions of the folded pair of separate individual wall blanks and affixing them together, affixing the corner post flanges of the end wall panels to the side portions of the separate individual wall blanks and affixing the window flanges to the side panels of the separate individual end wall portions, and not necessarily in that order.