Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to US provisional patent application serial no. 61/705,692, filed on 26 Sep. 2012, which is hereby incorporated hereinto by reference as if fully restated herein. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present disclosure relates to trays and containers, and particularly to trays and containers made of paperboard. More particularly, the present disclosure relates to a sturdy tray or container made of corrugated material and configured to contain food or other items. 
       BACKGROUND OF THE INVENTION 
       [0003]    Containers made of paperboard, i.e., corrugated paperboard, are commonly used in the produce industry to pack, store and ship fresh produce. These containers typically have a bottom, opposite side walls, opposite end walls, and an open or partially open top, and when filled with fresh produce are placed on a pallet for shipping and handling. These containers have an inside minor flap which is divided, and shared with an outside full depth flap, to provide four additional corners in the same amount of material as other shipping containers. To enable the containers to be stacked on one another in stable relationship, they must have sufficient structural strength and rigidity to withstand the stacking forces. Thus, the side and/or end walls of the containers are usually constructed with multiple thicknesses, and/or additional reinforcing structure also may be provided, and the flutes of the corrugated material are typically arranged to extend vertically. 
         [0004]    There is need for a paperboard container that is stackable, structurally rigid, and easy to set-up, reliably remains in set-up condition, and requires a minimum amount of material in its construction. 
       SUMMARY OF THE INVENTION 
       [0005]    An article-transport container or tray is adapted to transport food or other articles from one site to another. The container includes a floor, a left-side closure, a right-side closure, a front end closure coupled to the floor and to the two side closures, and a rear end closure coupled to the floor and to the two side closures. These closures cooperate to form an interior article-receiving region. 
         [0006]    In illustrative embodiments, the container further includes a first quad-layer corner formed between the front end closure and the right-side closure. The first quad-layer corner includes an outer layer formed from a portion of the right side closure, a first medial layer formed from another portion of the right side closure, a second medial portion formed from a portion of the front end closure, and an inner layer formed from another portion of the front end closure. The first medial layer is positioned to lie between the outer and second medial layers and is configured to provide means for interconnecting the outer layer and the second medial layer to cause stacking strength of the container to be improved while minimizing scrap produced during blank forming so that costs associated with producing the container are minimized. 
         [0007]    In illustrative embodiments, the medial layer includes corrugation. The corrugation is arranged to extend horizontally parallel to the floor of the container. 
         [0008]    Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The detailed description particularly refers to the accompanying figures in which: 
           [0010]      FIG. 1  is a perspective view of an erected article-transport container with four quad-layer corners in accordance with a first embodiment of the present disclosure showing that the article-transport container includes (on the lower left) a front end wall coupled to a left side closure (on the left side) including a horizontal left canopy and a right side closure (on the right side) including a horizontal right canopy and a rear end wall coupled to the left and right side closures; 
           [0011]      FIG. 2  is a sectional view taken along line  2 - 2  of  FIGS. 1 and 10  showing that a first quad-layer corner included in the article-transport container includes, from outside in, an outer layer in which the corrugation is oriented vertically, a first medial layer in which the corrugation is oriented horizontally, a second medial layer in which the corrugation is oriented vertically, and an inner layer in which the corrugation is oriented vertically; 
           [0012]      FIG. 3  is a plan view of a blank of corrugated material used to form the container of  FIG. 1  and showing that the blank includes an octagon-shaped floor, a left side closure coupled to the floor (at the left of the page), a rear end closure (at the top of the page), a right side closure (at the right of the page) comprising, from left to right, a right inner strip including, from top to bottom, a second wall anchor flap, a right side wall coupled to the floor, and a first wall anchor flap that forms the first medial layer of the first quad-layer corner and a right outer strip including, from top to bottom, a second auxiliary canopy anchor flap, a second primary canopy anchor flap, a right canopy coupled to the right side wall, a first primary canopy anchor flap, and a first auxiliary canopy anchor flap forming the outer layer of the first quad-layer corner, and a front end strip (at the bottom of the page) including, from left to right, a second front anchor flap, a front end wall coupled to the floor, and a first front anchor flap including a right corner bridge including a first bridge panel that forms the second medial layer of the first quad-layer corner and a second bridge panel and a right corner tab including a first tab panel and a second tab panel that forms the inner layer of the first quad-layer corner and a front end canopy coupled to the front end wall; 
           [0013]      FIGS. 4-11  are a series of views showing a method of forming the article-transport container of  FIG. 1  using the blank of  FIG. 3 ; 
           [0014]      FIG. 4  is a perspective view of the blank of  FIG. 3  being folded to form the container showing that the rear end strip is folded about a rear-end fold line and at the same time both first and second rear anchor flaps included in the rear end strip are folded about associated anchor-flap fold lines toward the octagon-shaped floor so that the left and right side closures can be folded upwardly as suggested in  FIG. 5 ; 
           [0015]      FIG. 5  is a view similar to  FIG. 4  showing continued forming of the container by folding a left corner bridge about a left corner-bridge fold line back onto a left corner tab so that the second medial layer and inner layer of the third quad-layer corner are established and by folding the right corner bridge about a right corner-bridge fold line back onto the right corner tab so that the second medial layer and inner layer of the fourth quad-layer corner are established; 
           [0016]      FIG. 6  is a view similar to  FIG. 5  showing continued forming of the container by folding the left side closure about the left-side fold line so that a portion of the second rear anchor flap is between a left side wall included in the left side panel and an interior region of the container and by folding the right side closure about a right-side fold line so that a portion of the first rear anchor flap is between the right side wall and the interior region of the container; 
           [0017]      FIG. 7  is an enlarged partial view of the first quad-layer corner of the container of  FIG. 6  showing continued forming of the container by folding the right side wall about the right side fold line so that the right side wall mates with the second bridge panel of the right corner bridge included in the front end strip and suggesting that the first wall anchor flap included in the inner strip mates with the first bridge panel of the right corner bridge included in the front end strip as suggested in  FIG. 8 ; 
           [0018]      FIG. 8  is a view similar to  FIG. 7  showing continued forming of the container by folding the first primary and auxiliary canopy anchor flaps about a first primary flap fold line toward the floor to cause the first primary canopy anchor flap to mate with the front end wall as suggested in  FIG. 9 ; 
           [0019]      FIG. 9  is a view similar to  FIG. 8  showing continued forming of the container by folding the first auxiliary canopy anchor flap about a first auxiliary flap fold line toward the right wall anchor flap to mate with the right wall anchor flap as suggested in  FIG. 10 ; 
           [0020]      FIG. 10  is a view similar to  FIG. 9  showing completed forming of the container and formation of the first quad-layer corner as a result; 
           [0021]      FIGS. 11-13  show how the blank of  FIG. 3  can be varied to produce a container characterized by each quad-layer corner having a first medial layer that extends partially between the right side wall and the front end wall when the container is formed; 
           [0022]      FIG. 11  shows a portion of a blank in accordance with a second embodiment of the present disclosure; 
           [0023]      FIG. 12  is a view similar to  FIG. 10  following folding of a first auxiliary canopy anchor flap towards a first right wall anchor flap trapping the first right wall anchor flap between the first auxiliary canopy anchor flap and a first bridge panel of the right corner bridge causing a quad-layer corner to be established; and 
           [0024]      FIG. 13  is a section view taken along line  13 - 13  of  FIG. 12  showing that the front-right quad-layer corner included in the article-transport container includes, from outside in, an outer layer formed by the first auxiliary canopy anchor flap, a first medial layer formed by the first right wall anchor flap, a second medial layer formed by the first bridge panel of the right corner bridge, and an inner layer formed by the second tab panel included in the right corner tab and showing that the first right wall anchor flap is arranged to lie between the second medial layer and the outer layer and is arranged to extend partially between the right side wall and the front end wall. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0025]    An erected article-transport container  10  in accordance with the present disclosure is shown in  FIG. 1 . Article-transport container  10  includes four quad-layer corners  21 ,  22 ,  23 ,  24  in accordance with a first embodiment of the present disclosure and first quad-layer corner  21  is shown in  FIG. 2 . Article-transport container  10  includes, in series starting in the front left, a front end closure  12  coupled to a floor  14  included in container  10 , a left side closure  16  coupled to floor  14  and including a left canopy  70 L overlying floor  14 , a rear end closure  18  coupled to floor  14 , and a right side closure  20  coupled to floor  14  and including a right canopy  70  overlying floor  14 . Front end closure  12 , left side closure  16 , rear end closure  18 , right side closure  20 , floor  14 , and quad-layer corners  21 ,  22 ,  23 ,  24  cooperate to define an interior region  26  therebetween that is adapted to receive articles (not shown) therein. Another embodiment of a quad-layer corner  221 A is shown in  FIGS. 11-13 . 
         [0026]    Quad-layer corners  21 ,  22 ,  23 ,  24  cooperate to provide means for increasing stack strength of container  10  while simplifying blank forming and minimizing scrap produced during blank forming. As an example, first quad-layer corner  21  includes an outer layer  211 , a first medial layer  212 , a second medial layer  213 , and an inner layer  214  as shown in  FIG. 2 . First medial layer  212  is positioned to lie between second medial layer  213  and outer layer  211 . Second medial layer  213  is positioned to lie between first medial layer  212  and inner layer  214 . First medial layer  212  is configured to provide means for interconnecting outer layer  211  to second medial layer  213  to cause stack strength of container  10  to be improved while minimizing scrap produced during blank forming so that costs associated with producing container  10  are minimized. 
         [0027]    Container  10  is made from a blank  28  after blank  28  is formed in a blank-forming process. As shown in  FIG. 3 , blank  28  includes floor  14 , left side closure  16  appended to floor  14  along a left-side fold line  30 , right side closure  20  appended to floor  14  along a right-side fold line  32 , rear end closure  18  appended to floor  14  along a rear-end fold line  34 , and front end closure  12  appended to floor  14  along a front-end fold line  36 . Right side closure  20 , left side closure  16 , rear end closure  18 , front end closure  12 , and quad-layer corners  21 ,  22 ,  23 ,  24  cooperate to form a border coupled to floor  14  and arranged to cooperate with floor  14  to define interior region  26  of container  10 . 
         [0028]    Rear end closure  18  cooperates with left side closure  16  and right side closure  20  to establish a rear end  38  of container  10  as shown in  FIG. 1 . Front end closure  12  cooperates with left side closure  16  and right side closure  20  to establish a front end  40  of container  10  as shown in  FIG. 1 . It is within the scope of the present disclosure to make blank  28  from a variety of materials including corrugated paperboard, folding carton, and solid fiber and other materials such as plastic sheeting and corrugated plastic. 
         [0029]    Article-transport container  10  is established as result of passing blank  28  through a container-forming process shown, for example, in  FIGS. 4-10 . As shown in  FIG. 3 , blank  28  includes floor  14 , front end closure  12  coupled to floor  14  along front-end fold line  36 , left side closure  16  coupled to floor  14  along left-side fold line  30 , rear end closure  18  coupled to floor  14  along rear-end fold line  34 , and right side closure  20  coupled to floor  14  along right-side fold line  32  as shown in  FIG. 4 . 
         [0030]    Front end closure  12  illustratively includes a front end strip  42  and a front end canopy  43  coupled to front end strip  42  about a front end canopy fold line  43 F as shown in  FIG. 3 . Front end strip  42  includes front end wall  13 , a first front anchor flap  46  coupled to front end wall  13  about a first front anchor-flap fold line  48 , and a second front anchor flap  50  coupled to front end wall  13  about a second front anchor-flap fold line  52  as shown in  FIG. 3 . First front anchor flap  46  is positioned to lie in spaced-apart relation to second front anchor flap  50  to locate front end wall  13  therebetween. As shown in  FIGS. 2 and 6 , portions of first front anchor flap  46  are used to establish second medial layer  213  and inner layer  214  of first quad-layer corner  21 . Similarly, portions of second front anchor flap  50  are used to establish second medial layer  223  and inner layer  224  of second quad-layer corner  22 . 
         [0031]    First front anchor flap  46  includes a front right corner bridge  90  that is coupled to front end wall  13  about a first front anchor-flap fold line  48  and a front right corner tab  94  that is coupled to front right corner bridge  90  about a first front corner-tab fold line  96  as shown in  FIG. 3 . Second medial layer  213  and inner layer  214  of first quad-layer corner  21  are established during an initial stage of container forming as suggested in  FIGS. 4-10 . 
         [0032]    Front right corner bridge  90  includes a first bridge panel  901  and a second bridge panel  902  as shown, for example, in  FIG. 3 . First bridge panel  901  is coupled to front end wall  13  by first front anchor-flap fold line  48 . Second bridge panel  902  is coupled to first bridge panel  901  by a bridge-panel fold line  903 . Front right corner tab  94  is coupled to second bridge panel  902  by first front corner-tab fold line  96 . First bridge panel  901  establishes second medial layer  213  as shown in  FIG. 2 . 
         [0033]    Front right corner tab  94  includes a first tab panel  941  and a second tab panel  942  as shown in  FIG. 3 . First tab panel  941  is coupled to second bridge panel  902  by first front corner-tab fold line  96 . Second tab panel  942  is coupled to first tab panel  941  by a tab-panel fold line  943 . Second tab panel  942  establishes inner layer  214  as shown in  FIG. 2 . 
         [0034]    During the initial stage of container formation, front end closure  12  is folded about front-end fold line  36  toward floor  14 . At the same time, front right corner bridge  90  is folded inwardly toward floor  14  about first front anchor-flap fold line  48  and front right corner tab  94  is folded inwardly toward floor  14  about first front corner-tab fold line  96  as shown in  FIG. 4 . Next, first right corner tab  94  is folded back toward front right corner bridge  90  along first front corner-tab fold line  96  to cause first tab panel  941  to lie in confronting relation with second bridge panel  902  and second tab panel  942  to lie in confronting relation with first bridge panel  901  as shown in  FIG. 5 . As a result, front end strip  42  is arranged to extend upwardly away from floor  14  and second bridge panel  902  is arranged to extend along right-side fold line  32 . First bridge panel  901  is arranged to extend between and interconnect second bridge panel  902  and front end wall  13 . 
         [0035]    Right side closure  20  illustratively includes a right inner strip  54  coupled to floor  14  about right-side fold line  32  and a right outer anchor strip  56  coupled to right inner strip  54  about a right anchor-strip fold line  58  as shown in  FIG. 3 . Right inner strip  54  includes, for example, a right side wall  60 , a first right wall anchor flap  62  coupled to right side wall  60  about a first right wall flap fold line  64 , and a second right wall anchor flap  66  coupled to right side wall  60  about a second right wall flap fold line  68  as shown in  FIG. 3 . First right wall anchor flap  62  is used to establish first medial layer  212  of first quad-layer corner  21 . First medial layer  212  of first quad-layer corner  21  is established during a subsequent stage of container forming as suggested in  FIGS. 4-10 . 
         [0036]    During the subsequent stage of container forming, right side closure  20  is folded about right-side fold line  32  toward floor  14  so that right side wall  60  and first and second right wall anchor flap  62 ,  66  extend upwardly away from floor  14  as shown in  FIG. 6 . At the same time, first and second right wall anchor flaps  62 ,  66  are folded inwardly toward floor  14  about associated right wall flap fold lines  64 ,  68 . As an example, first right wall anchor flap  62  is arranged to extend away from right side wall  60  toward front end wall  13  and is coupled to first bridge panel  901  of front right corner bridge  90  and forms first medial layer  212  as shown in  FIGS. 2 and 7 . 
         [0037]    Right outer anchor strip  56  includes a right canopy  70 , a first right primary canopy anchor flap  72 , a first right auxiliary canopy anchor flap  74 , a second right primary canopy anchor flap  76 , and a second right auxiliary canopy anchor flap  78  as shown in  FIG. 3 . Right canopy  70  is coupled to right side wall  60  about right anchor-strip fold line  58 . First right primary canopy anchor flap  72  is coupled to right canopy  70  by a first right primary flap fold line  80 . First right auxiliary canopy anchor flap  74  is coupled to first right primary canopy anchor flap  72  by a first right auxiliary flap fold line  84  as shown in  FIG. 3 . Second right primary canopy anchor flap  76  is coupled to right canopy  70  by a second right primary flap fold line  86 . Second right auxiliary canopy anchor flap  78  is coupled to second right primary canopy anchor flap  76  by a first right auxiliary flap fold line  88  as shown in  FIG. 3 . Outer layer  211  of first quad-layer corner  21  is established during a last stage of container forming as suggested in  FIGS. 9 and 10 . 
         [0038]    During the last stage of container forming, right outer anchor strip  56  is folded about right anchor-strip fold line toward floor  14  so that right canopy  70  is arranged to lie in spaced-apart parallel relation above floor  14  as shown in  FIG. 2 . At the same time, first right primary and auxiliary canopy anchor flaps  72 ,  74  are folded downwardly about first right primary flap fold line  80  so that first right primary canopy anchor flap  72  extends downwardly and mates with front end wall  13  as suggested in  FIG. 8  and shown in  FIG. 9 . Finally, first quad-layer corner  21  is established as a result of folding first right auxiliary canopy anchor flap  74  about first right auxiliary flap fold line  84  toward first right wall anchor flap  62  as suggested in  FIG. 9  and shown in  FIG. 10 . 
         [0039]    First quad-layer corner  21  is established as a result of coupling first right wall anchor flap  62  to first bridge panel  901  of front right corner bridge  90  and by coupling first right auxiliary canopy anchor flap  74  to first right wall anchor flap  62  as shown in  FIGS. 6-10 . As an example, first right wall anchor flap  62  is coupled to first bridge panel  901  by adhesive  98  as shown in  FIG. 7 . First right auxiliary canopy anchor flap  74  is coupled to first right wall anchor flap  62  by adhesive  100  as shown in  FIGS. 8 and 9 . While adhesive  98 ,  100  is shown as an example, any other suitable alternative may be used. 
         [0040]    In an illustrative embodiment, the corrugation of blank  28  is positioned to run in a transverse direction TD as shown in insert A in  FIGS. 1 and 3 . As a result, outer layer  211 , second medial layer  213 , and inner layer  214  of quad-layer corners  21 ,  22 ,  23 ,  24  have corrugation which runs vertically as shown in  FIGS. 3 and 7  after container  10  has been formed. First medial layer  212  has corrugation which runs horizontally as shown in  FIG. 6  after container  10  has been formed. 
         [0041]    In one illustrative example, it was found surprisingly that the first medial layers of quad-layer corners  21 ,  22 ,  23 ,  24  increases stacking strength of container  10  as compared to those containers lacking first medial layer  212 . Stacking strength may be measured using standard industry test methods. As an example, stacking strength may be evaluated using the TSL-8.2-WI-005 test method and procedure reference T804 of the Technical Association of the Pulp and Paper Industry (TAPPI). 
         [0042]    As illustrated in  FIG. 3 , floor  14  has an octagon shape that includes in series, a first mitered edge  102 , a front end edge  104 , a second mitered edge  106 , a left edge  108 , a third mitered edge  110 , a rear end edge  112 , a fourth mitered edge  114 , and a right edge  116 . As an illustrative example, left and right edges  108 ,  116  have lengths greater than lengths of front and rear end edges  104 ,  112 . Front and rear end edges  104 ,  112  have lengths greater than first, second, third, and fourth mitered edges  102 ,  106 ,  110 ,  114 . Edges  102 ,  104 ,  106 ,  108 ,  110 ,  112 ,  114  cooperate to define a floor perimeter  92  as shown in  FIG. 3 . 
         [0043]    First quad-layer corner  21  is arranged to extend between front end wall  13  and right side wall  60  and lie at an angle  118  relative to front end wall  13  as shown in  FIG. 2 . Angle  118  is defined to be between first mitered edge  102  of floor  14  and front end edge  104  of floor  14 . As shown in  FIG. 2 , angle  118  is illustratively an acute angle. Inner layer  214  of quad-layer corner  21  is positioned to lie inside floor perimeter  92  and is arranged to extend between front end edge  104  and right edge  116  and between floor  14  and right canopy  70 . First medial layer  212  is positioned to lie outside floor perimeter  92  is and is arranged to extend along first mitered edge  102  so that first medial layer  212  lies at angle  118 . Outer layer  211  is positioned to lie outside floor perimeter  92  and is arranged to lie in spaced-apart relation to first mitered edge  102  to cause first medial layer  212  to lie there between. 
         [0044]    Blank  28  is formed during an illustrative blank forming process in which a corrugated sheet is processed to establish blank  28  and scrap which is separated from blank  28 . During blank forming, first right wall anchor flap  62  is formed to have a proximal end  62 P and a distal end  62 D which is spaced-apart from proximal end  62 P. First right wall anchor flap  62  is appended to right side wall  60  along first right wall flap fold line  64  by proximal end  62 P. As shown in  FIG. 3 , first right wall anchor flap  62  extends away from first right wall flap fold line  64  toward first front anchor flap  46  and first right auxiliary canopy anchor flap  74  such that distal end  62 D abuts first front anchor flap  46  and first right auxiliary canopy anchor flap  74 . Distal end  62 D is separated from first front anchor flap  46  and first right auxiliary canopy anchor flap  74  by a cut line  142  as shown in  FIG. 3 . 
         [0045]    During blank forming, scrap is separated from blank  28  which causes two triangle-shaped apertures  120 A,  120 B to be formed therein. As a result of distal end  62 D of first right wall anchor flap  62  abutting first front anchor flap  46  and first right auxiliary canopy anchor flap  74 , friction is developed during container forming as front end strip  42  is folded upwardly about front-end fold line  36 . A first right-wall anchor-flap crush area  144  is established during blank forming to provide means for minimizing friction developed between first right wall anchor flap  62  and first front anchor flap  46  and first right auxiliary canopy anchor flap  74  during container forming so that the likelihood of creating improperly formed containers is minimized. 
         [0046]    Also during blank forming, a first crush area  121  is formed in blank  28 . First crush area  121  is configured to provide means for minimizing friction developed between front right corner tab  94  and first right auxiliary canopy anchor flap  74  during container forming as front right corner tab  94  of front end strip  42  is folded upwardly about front-end fold line  36 . Second, third, and fourth crush areas  122 ,  123 ,  124  are also formed. 
         [0047]    First, second, third, and fourth crush areas  122 ,  123 ,  124  are substantially similar to first crush area  121 , and thus, only first crush area  121  will be discussed in detail. First crush area  121  is established along a cut line  125  formed between front right corner tab  94  and first right auxiliary canopy anchor flap  74  as shown in  FIG. 3 . A rate of container forming may be increased as a result of minimizing friction which decreases the likelihood of improperly forming containers. These improperly formed containers are also called as cripples. Blank  28  and resulting container  10  minimize waste because the number of improperly formed containers is minimized. 
         [0048]    Second quad-layer corner  22  is formed during container forming by folding front end closure  12  and left side closure  16  so that second quad-layer corner  22  is established as a result as suggested in  FIGS. 4-6 . A portion of second front anchor flap  50  establishes an inner layer  224  of second quad-layer corner  22 . 
         [0049]    Second front anchor flap  50  includes a front left corner bridge  90 L that is coupled to front end wall  13  about a second front anchor-flap fold line  52  and a front left corner tab  94 L that is coupled to front left corner bridge  90 L about a second front corner-tab fold line  96 L as shown in  FIG. 3 . Second medial layer  223  and inner layer  224  of second quad-layer corner  22  are established during the initial stage of container forming as suggested in  FIGS. 4-10 . 
         [0050]    Front left corner bride  90 L includes a first bridge panel  90 L 1  and a second bridge panel  90 L 2  as shown, for example, in  FIG. 3 . First bridge panel  90 L 1  is coupled to front end wall  13  by second front anchor-flap fold line  52 . Second bridge panel  90 L 2  is coupled to first bridge panel  90 L 1  by a bridge-panel fold line  90 L 3 . Front left corner tab  94 L is coupled to second bridge panel  90 L 2  by second front corner-tab fold line  96 L. First bridge panel  90 L 1  establishes second medial layer  223 . 
         [0051]    Front left corner tab  94 L includes a first tab panel  94 L 1  and a second tab panel  94 L 2  as shown in  FIG. 3 . First tab panel  94 L 1  is coupled to second bridge panel  90 L 2  by second front corner-tab fold line  96 L. Second tab panel  94 L 2  is coupled to first tab panel  94 L 1  by a tab-panel fold line  94 L 3 . Second tab panel  94 L 2  establishes inner layer  224  as shown in  FIG. 2 . 
         [0052]    During the initial stage of container formation, front end closure  12  is folded about front-end fold line  36  toward floor  14 . At the same time, front left corner bridge  90 L is folded inwardly toward floor  14  about second front anchor-flap fold line  52  and front left corner tab  94 L is folded inwardly toward floor  14  about second front corner-tab fold line  96 L. Next, first left corner tab  94 L is folded back toward front left corner bridge  90 L along second front corner-tab fold line  96 L to cause first tab panel  94 L 1  to lie in confronting relation with second bridge panel  90 L 2  and second tab panel  94 L 2  to lie in confronting relation with first bridge panel  90 L 1 . As a result, front end strip  42  is arranged to extend upwardly away from floor  14  and second bridge panel  90 L 2  is arranged to extend along left-side fold line  30 . First bridge panel  90 L 1  is arranged to extend between and interconnect second bridge panel  90 L 2  and front end wall  13 . 
         [0053]    Left side closure  16  illustratively includes a left inner strip  54 L coupled to floor  14  about left-side fold line  30  and a left outer anchor strip  56 L coupled to left inner strip  54 L about a left anchor-strip fold line  58 L as shown in  FIG. 3 . Left inner strip  54 L includes, for example, a left side wall  60 L, a first left wall anchor flap  62 L coupled to left side wall  60 L about a first left wall flap fold line  64 L, and a second left wall anchor flap  66 L coupled to left side wall  60 L about a second left wall flap fold line  68 L as shown in  FIG. 3 . First left wall anchor flap  62 L is used to establish first medial layer  222  of second quad-layer corner  22 . First medial layer  222  of second quad-layer corner  22  is established during a subsequent stage of container forming as suggested in  FIGS. 4-10 . 
         [0054]    During the subsequent stage of container forming, left side closure  16  is folded about left-side fold line  30  toward floor  14  so that left side wall  60 L and first and second left wall anchor flap  62 L,  66 L extend upwardly away from floor  14 . At the same time, first and second left wall anchor flaps  62 L,  66 L are folded inwardly toward floor  14  about associated left wall flap fold lines  64 L,  68 L. As an example, first left wall anchor flap  62 L is arranged to extend away from left side wall  60 L toward front end wall  13  and is coupled to first bridge panel  90 L 1  of front left corner bridge  90 L and forms first medial layer  222 . 
         [0055]    Left outer anchor strip  56 L includes a left canopy  70 L, a first left primary canopy anchor flap  72 L, a first left auxiliary canopy anchor flap  74 L, a second left primary canopy anchor flap  76 L, and a second left auxiliary canopy anchor flap  78 L as shown in  FIG. 3 . Left canopy  70 L is coupled to left side wall  60 L about left anchor-strip fold line  58 L. First left primary canopy anchor flap  72 L is coupled to left canopy  70 L by a first left primary flap fold line  80 L. First left auxiliary canopy anchor flap  74 L is coupled to first left primary canopy anchor flap  72 L by a first left auxiliary flap fold line  84 L as shown in  FIG. 3 . Second left primary canopy anchor flap  76 L is coupled to left canopy  70 L by a second left primary flap fold line  86 L. Second left auxiliary canopy anchor flap  78 L is coupled to second left primary canopy anchor flap  76 L by a first left auxiliary flap fold line  88 L as shown in  FIG. 3 . Outer layer  221  of second quad-layer corner  22  is established during the last stage of container forming. 
         [0056]    During the last stage of container forming, left outer anchor strip  56 L is folded about left anchor-strip fold line  58 L toward floor  14  so that left canopy  70 L is arranged to lie in spaced-apart parallel relation above floor  14  as shown in  FIG. 2 . At the same time, first left primary and auxiliary canopy anchor flaps  72 L,  74 L are folded downwardly about first left primary flap fold line  80 L so that first left primary canopy anchor flap  72 L extends downwardly and mates with front end wall  13  as suggested in  FIG. 8  and shown in  FIG. 9 . Finally, second quad-layer corner  22  is established as a result of folding first left auxiliary canopy anchor flap  74 L about first left auxiliary flap fold line  84 L toward first left wall anchor flap  62 L. 
         [0057]    Second quad-layer corner  22  is established as a result of coupling first left wall anchor flap  62 L to first bridge panel  90 L 1  of front left corner bridge  90 L and by coupling first left auxiliary canopy anchor flap  74 L to first left wall anchor flap  62 L. As an example, first left wall anchor flap  62 L is coupled to first bridge panel  90 L 1  by adhesive  98  as suggested in  FIG. 7 . First left auxiliary canopy anchor flap  74 L is coupled to first left wall anchor flap  62 L by adhesive  100  as suggested in  FIGS. 8 and 9 . While adhesive  98 ,  100  is shown as an example, any other suitable alternative may be used. 
         [0058]    Rear end closure  18  illustratively includes a rear end strip  42 R and a rear end canopy  43 R coupled to rear end strip  42 R about a rear end canopy fold line  43 FR as shown in  FIG. 3 . Rear end strip  42 R includes a rear end wall  15 , a first rear anchor flap  46 R coupled to rear end wall  15  about a rear anchor-flap fold line  48 R, and a second rear anchor flap  50 R coupled to rear end wall  15  about a second rear anchor-flap fold line  52 R as shown in  FIG. 3 . First rear anchor flap  46 R is positioned to lie in spaced-apart relation to second rear anchor flap  50 R to locate rear end wall  15  therebetween. Portions of first rear anchor flap  46 R are used to establish second medial layer  243  and inner layer  244  of fourth quad-layer corner  24 . Similarly, portions of second rear anchor flap  50 R are used to establish second medial layer  233  and inner layer  234  of third quad-layer corner  23 . 
         [0059]    First rear anchor flap  46 R includes a rear right corner bridge  90 R that is coupled to rear end wall  15  about a first rear anchor-flap fold line  48 R and a rear right corner tab  94 R that is coupled to rear right corner bridge  90 R about a first rear corner-tab fold line  96 R as shown in  FIG. 3 . Second medial layer  243  and inner layer  244  of fourth quad-layer corner  24  are established during an initial stage of container forming. 
         [0060]    Rear right corner bride  90 R includes a first bridge panel  901 R and a second bridge panel  902 R as shown, for example, in  FIG. 3 . First bridge panel  901 R is coupled to rear end wall  15  by first rear anchor-flap fold line  48 R. Second bridge panel  902 R is coupled to first bridge panel  901 R by a bridge-panel fold line  903 R. Rear right corner tab  94 R is coupled to second bridge panel  902 R by first rear corner-tab fold line  96 R. First bridge panel  901 R establishes second medial layer  243  as shown in  FIG. 2 . 
         [0061]    Rear right corner tab  94 R includes a first tab panel  941 R and a second tab panel  942 R as shown in  FIG. 3 . First tab panel  941 R is coupled to second bridge panel  902 R by first rear corner-tab fold line  96 R. Second tab panel  942 R is coupled to first tab panel  941 R by a tab-panel fold line  943 R. Second tab panel  942 R establishes inner layer  244  as shown in  FIG. 2 . 
         [0062]    Second rear anchor flap  50 R includes a rear left corner bridge  90 LR that is coupled to rear end wall  15  about a second rear anchor-flap fold line  52 R and a rear left corner tab  94 LR that is coupled to rear left corner bridge  90 LR about a second rear corner-tab fold line  96 LR as shown in  FIG. 3 . Second medial layer  233  and inner layer  234  of third quad-layer corner  23  are established during the initial stage of container forming as suggested in  FIGS. 4-10 . 
         [0063]    Rear left corner bride  90 LR includes a first bridge panel  90 L 1 R and a second bridge panel  90 L 2 R as shown, for example, in  FIG. 3 . First bridge panel  90 L 1 R is coupled to rear end wall  15  by second rear anchor-flap fold line  52 R. Second bridge panel  90 L 2 R is coupled to first bridge panel  90 L 1 R by a bridge-panel fold line  90 L 3 R. Rear left corner tab  94 LR is coupled to second bridge panel  90 L 2 R by second rear corner-tab fold line  96 LR. First bridge panel  90 L 1 R establishes second medial layer  233 . 
         [0064]    Rear left corner tab  94 LR includes a first tab panel  94 L 1 R and a second tab panel  94 L 2 R as shown in  FIG. 3 . First tab panel  94 L 1 R is coupled to second bridge panel  90 L 2 R by second rear corner-tab fold line  96 LR. Second tab panel  94 L 2 R is coupled to first tab panel  94 L 1 R by a tab-panel fold line  94 L 3 R. Second tab panel  94 L 2 R establishes inner layer  234  as shown in  FIG. 2 . 
         [0065]    During the initial stage of container formation, rear end closure  18  is folded about rear-end fold line  34  toward floor  14 . At the same time, rear left corner bridge  90 LR is folded inwardly toward floor  14  about second rear anchor-flap fold line  52 R and rear left corner tab  94 LR is folded inwardly toward floor  14  about second rear corner-tab fold line  96 LR. Next, rear left corner tab  94 LR is folded back toward rear left corner bridge  90 LR along second rear corner-tab fold line  96 LR to cause first tab panel  94 L 1 R to lie in confronting relation with second bridge panel  90 L 2 R and second tab panel  94 L 2 R to lie in confronting relation with first bridge panel  90 L 1 R. As a result, rear end strip  42 R is arranged to extend upwardly away from floor  14  and second bridge panel  90 L 2 R is arranged to extend along left-side fold line  30 . First bridge panel  90 L 1 R is arranged to extend between and interconnect second bridge panel  90 L 2 R and rear end wall  15 . 
         [0066]    During the subsequent stage of container forming, left side closure  16  is folded about left-side fold line  30  toward floor  14  so that left side wall  60 L and first and second left wall anchor flap  62 L,  66 L extend upwardly away from floor  14 . At the same time, first and second left wall anchor flaps  62 L,  66 L are folded inwardly toward floor  14  about associated left wall flap fold lines  64 L,  68 L. As an example, second left wall anchor flap  66 L is arranged to extend away from left side wall  60 L toward rear end wall  15  and is coupled to second bridge panel  90 L 1 R of rear left corner bridge  90 LR and forms first medial layer  232 . 
         [0067]    During the last stage of container forming, left outer anchor strip  56 L is folded about left anchor-strip fold line  58 L toward floor  14  so that left canopy  70 L is arranged to lie in spaced-apart parallel relation above floor  14  as shown in  FIG. 2 . At the same time, second left primary and auxiliary canopy anchor flaps  76 L,  78 L are folded downwardly about first left primary flap fold line  86 L so that first left primary canopy anchor flap  76 L extends downwardly and mates with rear end wall  15  as suggested in  FIG. 8  and shown in  FIG. 9 . Finally, third quad-layer corner  23  is established as a result of folding second left auxiliary canopy anchor flap  78 L about second left auxiliary flap fold line  88 L toward first left wall anchor flap  62 L. 
         [0068]    Third quad-layer corner  23  is established as a result of coupling second left wall anchor flap  66 L to first bridge panel  90 L 1 R of rear left corner bridge  90 LR and by coupling second left auxiliary canopy anchor flap  78 L to second left wall anchor flap  66 L. As an example, second left wall anchor flap  66 L is coupled to first bridge panel  90 L 1 R by adhesive  98  as suggested in  FIG. 7 . Second left auxiliary canopy anchor flap  78 L is coupled to second left wall anchor flap  66 L by adhesive  100  as suggested in  FIGS. 8 and 9 . While adhesive  98 ,  100  is shown as an example, any other suitable alternative may be used. 
         [0069]    Also during the initial stage of container formation, rear end closure  18  is folded about rear-end fold line  34  toward floor  14 . At the same time, rear right corner bridge  90 R is folded inwardly toward floor  14  about second rear anchor-flap fold line  52 R and rear right corner tab  94 R is folded inwardly toward floor  14  about first rear corner-tab fold line  96 R. Next, first right corner tab  94 R is folded back toward first right corner bridge  90 R along first rear corner-tab fold line  96 R to cause first tab panel  941 R to lie in confronting relation with second bridge panel  902 R and second tab panel  942 R to lie in confronting relation with first bridge panel  901 R. As a result, rear end strip  42 R is arranged to extend upwardly away from floor  14  and second bridge panel  902 R is arranged to extend along right-side fold line  32 . First bridge panel  901 R is arranged to extend between and interconnect second bridge panel  902 R and rear end wall  15 . 
         [0070]    During the subsequent stage of container forming, right side closure  20  is folded about right-side fold line  32  toward floor  14  so that right side wall  60  and first and second right wall anchor flap  62 ,  66  extend upwardly away from floor  14 . At the same time, first and second right wall anchor flaps  62 ,  66  are folded inwardly toward floor  14  about associated right wall flap fold lines  64 ,  68 . As an example, second right wall anchor flap  66  is arranged to extend away from right side wall  60  toward rear end wall  15  and is coupled to second bridge panel  901 R of rear right corner bridge  90 R and forms first medial layer  242 . 
         [0071]    During the last stage of container forming, right outer anchor strip  56  is folded about right anchor-strip fold line  58  toward floor  14  so that right canopy  70  is arranged to lie in spaced-apart parallel relation above floor  14  as shown in  FIG. 2 . At the same time, second right primary and auxiliary canopy anchor flaps  76 ,  78  are folded downwardly about second right primary flap fold line  86  so that first right primary canopy anchor flap  76  extends downwardly and mates with rear end wall  15  as suggested in  FIG. 8  and shown in  FIG. 9 . Finally, fourth quad-layer corner  24  is established as a result of folding second right auxiliary canopy anchor flap  78  about second right auxiliary flap fold line  88  toward first right wall anchor flap  66 . 
         [0072]    Fourth quad-layer corner  24  is established as a result of coupling second right wall anchor flap  66  to first bridge panel  901 R of rear right corner bridge  90 R and by coupling second right auxiliary canopy anchor flap  78  to second right wall anchor flap  66 . As an example, second right wall anchor flap  66  is coupled to first bridge panel  901 R by adhesive  98  as suggested in  FIG. 7 . Second right auxiliary canopy anchor flap  78  is coupled to second right wall anchor flap  66  by adhesive  100  as suggested in  FIGS. 8 and 9 . While adhesive  98 ,  100  is shown as an example, any other suitable alternative may be used. 
         [0073]    A blank  228  made of corrugated material in accordance with a second embodiment of the present disclosure is shown in  FIG. 11  and can be assembled as suggested in  FIG. 112  to produce a first quad-layer corner  221 A of a container  210  as shown in  FIG. 12 . In most respects, blank  228  is similar to blank  28  of  FIG. 3 . 
         [0074]    Blank  228  is formed during an illustrative blank forming process, for example in a manufacturing facility. During the blank forming process, a corrugated sheet is processed to establish blank  228  and scrap which separated from blank  228 . During blank forming, first right wall anchor flap  262  is formed to have a proximal end  262 P and a distal end  262 D which is spaced-apart from proximal end  262 P. First right wall anchor flap  262  is appended to right side wall  60  along first right wall flap fold line  64  by proximal end  262 P. As shown in  FIG. 11 , first right wall anchor flap  262  extends away from first right wall flap fold line  64  toward first front anchor flap  46  and first right auxiliary canopy anchor flap  74  such that distal end  262 D is spaced apart from first front anchor flap  46  and first right auxiliary canopy anchor flap  74 . 
         [0075]    During the blank forming process which may be performed in a manufacturing facility, scrap is separated from blank  228  which causes two triangle-shaped apertures  120 A,  120 B and an interconnecting rectangle-shaped aperture  120 C to be formed therein. As a result of the scrap piece being monolithic, it simplifies removal and separation from blank  228 . Another result of distal end  262 D being spaced apart from first front anchor flap  46  and first right auxiliary canopy anchor flap  74  is that rectangle-shaped aperture  120 C is formed by removing scrap. Container forming is simplified as a result of distal end  262 D of first right wall anchor flap  262  being spaced-apart from first front anchor flap  46  and first right auxiliary canopy anchor flap  74  is that friction between distal end  262 D of and first front anchor flap  46  and first right auxiliary canopy anchor flap  74  is eliminated. Because friction has been eliminated, the likelihood of forming improperly formed containers is minimized. 
         [0076]    Blank  228  includes floor  14 , a right side closure  220  appended to floor  14  along right-side fold line  32 , and a front end closure  12  appended to floor  14  along front-end fold line  36  as shown in  FIG. 10 . Right side closure  220  and front end closure  12  are configured to be folded in a manner similar to that shown in  FIGS. 4-9  to produce first quad-layer corner  221 A. 
         [0077]    As discussed previously, first quad-layer corner  221 A is similar to first quad-layer corner  21  except first medial layer  2212 A is different. As shown in  FIG. 2 , first medial layer  212  of first quad-layer corner  21  has a first length  150 . As shown in  FIG. 13 , first medial layer  2212 A has a relatively smaller second length  250 . 
         [0078]    In an illustrative embodiment, the corrugation of blank  228  is positioned to run in a transverse direction TD as shown in insert A in  FIG. 11 . As a result, outer layer  2211 A, second medial layer  2213 A, and inner layer  2214 A has corrugation which runs vertically as shown in  FIG. 13  after container  210  has been formed. First medial layer  2212 A has corrugation which runs horizontally as shown in  FIG. 11  after container  210  has been formed. In one illustrative example, it was found surprisingly that the medial layer  2212 A of quad-layer corner  221 A increases stacking strength of container  210 . Stacking strength may be measured using standard industry test methods. As an example, stacking strength may be evaluated using the TSL-8.2-WI-005 test method and procedure reference T804 of the Technical Association of the Pulp and Paper Industry (TAPPI). 
         [0079]    In another embodiment, the right canopy and the left canopy may be configured so as to establish a lid after the container has been formed. In an example, the right canopy has a width about equal to one half a width of the floor and the left canopy has a width about equal to one half the width of the floor. After the container has been erected, the right canopy is folded inwardly toward the floor about the right anchor-strip fold line so that the right canopy lies above the floor and extends away from the right side wall toward the left sidewall. The left canopy is also folded inwardly toward the floor about the left anchor-strip fold line so that the left canopy lies above the floor and extends away from the left side wall toward the right side wall. As a result, the interior region is defined by the floor, the right side closure, the left side closure, the front end wall, the rear end wall, the four quad-layer corners, and the lid established upon completion of forming the container. In another embodiment, a container may omit a front canopy and a rear canopy.

Technology Category: 7