US20060038000A1

US20060038000A1 - Stacking display containers

Info

Publication number: US20060038000A1
Application number: US10/922,355
Authority: US
Inventors: Phil Sheffer
Original assignee: McLean Packaging Corp
Current assignee: McLean Packaging Corp
Priority date: 2004-08-20
Filing date: 2004-08-20
Publication date: 2006-02-23

Abstract

A one-piece container having front, back and end walls is disclosed for use in storing, shipping and displaying the contents thereof. The front and back walls are reinforced in high stress areas, such as wall diagonals, by column members formed from panels that are integrally connected to the side and back walls. These column members thus remain tightly associated with the side and back walls and provide maximum strength and structural rigidity to the container. The column members are held in place by folding end wall panels that are integrally formed with the container bottom and which fold over the column members and lock into place with the bottom. The column members may be hollow geometric structures, or they may be flat sandwich structures formed from plural material layers. The container can be provided with registration tabs and corresponding openings to allow like containers to be stacked for storage or display.

Description

FIELD OF THE INVENTION

The invention relates to paperboard, corrugated craft and similar containers in which goods are packed for shipping, wherein the containers used for shipping, or parts thereof, also display the goods at the destination and permit customer access.

BACKGROUND OF THE INVENTION

It is desirable to structure a shipping container to support stresses associated with supporting products in the containers and also stresses resulting from stacking two or more containers atop one another. Various techniques have been employed to strengthen containers. The material thickness of the container walls can be made more or less, e.g., by choice of material or by providing more or fewer overlapping plies. Added support structures can be included such as reinforcing webs, hollow walls, inserts and so forth.
Material additions, structural complexities for reinforcement and the like, add strength, but only at the expense of using up some of the volume available within the outer boundaries of the container. Some containers are used for displaying products at their shipping destinations. Structural reinforcements are usually inconsistent with providing easy product access provisions such as removable lids or panels.
Containers that are intended to present goods in an appealing visual way and/or to invite customers to reach in to remove goods from the container, advantageously have ample openings. The openings permit lines of sight to the products and room for manually reaching for the items in the containers.
Containers with openings can be integrally structured so that the product is exposed when originally packed, or the containers can have panels that are readily removed to expose the products. Container lids are routinely removed or folded back and provide a type of removable panel, but removing lid panels alone generally is insufficient to attractively display the product or to convert the container from an enclosed shipping container to a more open and accessible product carrier.
Containers can bear rough handling during shipping and also when used as receptacles for products on display. Containers are known that completely enclose products during shipping and are modified by removal of tear-off panels for use as displays. Whether a container is structured originally with openings or provided with removable panels, the openings reduce the area over which the container contents are covered and protected, and the openings can compromise the structural integrity of the container. Openings often detract from stacking strength or container rigidity, that might be available if the openings were occupied by container material.
Recognizing that openings can limit container strength and expose the contents to damage, providing removable panels and the like are useful because greater protection is provided before the panel is removed, during shipping, and greater exposure is provided after the panel is removed, for display and access. Similar advantages may be provided by using outer shipping containers that enclose and protect inner display containers. There is a need to resolve conflicts between desirable strength and product protection versus the need for access openings and display exposure. It would be advantageous on one level to determine the optimal balance between these interests. On another level, it would be advantageous to provide new structures that tend to serve both interests at the same time.
Some previous efforts to resolve the need for stacking strength, rigidity variations in containers having windows or structured openings are shown, for example, in U.S. Pat. Nos. 5,839,650; 6,098,873; 6,029,886; 5,826,728; 5,524,815; 5,413,276 (each to P. Sheffer). The teachings of these patents are hereby incorporated.
A shipping carton or container or box can be integrally made from a thickness of paperboard, corrugated craft or similar sheet material that has been cut from a blank and creased along spaced parallel lines. The panels between successive spaced creases define the side wall panels. In a nominal orientation (and assuming a rectilinear configuration), the side wall panels can be in vertical planes when the creased blank is opened to the extent that the creases form 90° folds at each of the four corners, as seen in plan view. Arbitrarily, two opposite vertical walls can be deemed the front and back side walls. The remaining opposite vertical side walls can be deemed the end walls.
In single-piece integral die cuts, the bottom may be formed by one complete panel, or the bottom may have bottom flaps that are joined at creases to the side walls and folded inwardly under the container. Similarly, along the free edges along the top edge, the side walls can each have at least one flap to be folded inwardly to form a top. Alternatively, extensions that occupy the same structural locations on the die cut as such flaps can be provided at the top and/or bottom edges of one or more side wall panels. The extensions are foldable to form reinforcing structures when folded inwardly in a lateral or longitudinal direction relative to a side wall panel.
There are numerous possibilities for arranging adjacent panels of an integral die cut sheet. Some panels can be joined to adjacent panels at creases. Some panels can be joined at tearable perforation lines. Some panels can be separated from adjacent panels by die cut slots. Portions of the sheet can be removed to leave gaps. Given the numerous possibilities, a challenge is presented to produce a container that is protective during shipping and stacking, and also permits access to the product (with or without the need to remove a tear-away panel or to remove an outer covering container).

SUMMARY OF THE INVENTION

Additional objects and aspects of the invention will become apparent from the following discussion of examples.
A container is disclosed comprising a plurality of panels defining a bottom, longitudinally opposite first and second end walls, and laterally opposite first and second side walls. Each end wall may have an outer end wall panel joined to the bottom, the end wall panel having end, top and inner panel portions. Each side wall further may comprise a side portion joined to the bottom, and a pair of column-forming panels, one of the column-forming panels disposed adjacent to the first end wall and the other column-forming panel disposed adjacent to the second end wall. Each column-forming panel further may have an assembled configuration in which the panel is folded to assume a column member having a substantially geometric shape. Each end wall panel may be sized and configured such that when a pair of associated column-forming panels are in the assembled configuration, the end, top and inner panel portions of the end wall are foldable about the resulting column members and securable to the bottom to form the first or second end wall to configure the container to an assembled state.
At least one of the first and second side walls may have a cutout for manual access to contents of the container; and the cutout may extend only part way from a top edge of the associated side wall to the bottom. The container may further comprise a reinforcing panel folded inwardly along an edge of the cutout such that the associated wall is at least a double thickness from the cutout to the bottom.
The side walls and the end walls may be integrally joined at mutually orthogonal folds to a bottom panel, and the reinforcing panel of the cutout may be folded inwardly along a line parallel to and spaced from one of said folds that joins one of said side walls containing said cutout to the bottom panel, said reinforcing panel having a lateral edge. At least one of said column forming panels may be integrally joined to the side wall containing the cutout at a fold line perpendicular to said one of the folds joining the side wall containing the cutout to the bottom. The column forming panels may further comprise a terminal tab portion that is folded inwardly and glued to an inside of the side wall containing the cutout such that a terminal edge abuts against the lateral edge of the reinforcing panel.
Each of the column members associated with the first end wall may be sized to span about half of the lateral width of the end wall. Alternatively, each of the column members associated with the first end wall may be sized to span less than half of the lateral width of the end wall. Each of the column members associated with the first end wall may be sized to span from about 20% to about 40% of the lateral width of the end wall.
The geometric shape of the column member may be a rectangle. Additionally, the side walls and end walls may be integral with the container bottom. Also, the column-forming panels may be integral with their respective side walls.
The inner panel portion of each end wall comprises a locking tab that engages with at least one of the bottom and side wall when the extension may be folded over the associated column members. The container bottom may comprise a tab receptacle and the tab may lock in the tab receptacle in the assembled state of the container.
The side wall may comprise a tab receptacle and the tab may lock in the tab receptacle in the assembled state of the container. The bottom may comprise at least one registration tab configured to lock into a corresponding opening in the top panel portion of one of the end walls such that the container is stackable in registry with similar said containers by engaging the registration tab of one said container with the registration opening of a similar said container stacked thereon.
The side wall cutout may disposed between corners of the container, each corner comprising the location at which the top and inner panel portions of the end wall. The first and second portions of the column-forming panel may be adhesively attached together to form the associated column member. Likewise, the reinforcing panel may be adhesively attached to the associated side wall portion.
The end panel portion of at least one of the end walls may comprise a removable panel for manual access to a portion of the contents of the container. The portion of the contents of the container that is accessible via the end panel portion may be separate from the contents of the container that is accessible via the side wall cutout. The column-forming panels associated with the at least one end wall each may be configured so that the resulting column member has a cutout disposed toward the end wall for allowing manual access to an interior portion of the column member.

BRIEF DESCRIPTION OF THE DRAWINGS

A number of additional objects and aspects are apparent from the appended description and the associated illustrations of preferred embodiments, wherein:
FIG. 1 is a perspective view of an assembled stacking container of the present invention;
FIG. 2 is a plan view of the container of FIG. 1 in the unassembled “flat” condition;
FIG. 3 is a perspective view of the container of FIG. 1 in a partially assembled condition, showing column members in the assembled condition and the partial folding of side and end members;
FIG. 4 is a cross-section view of an assembled end wall member of the container of FIG. 1, taken along line 4-4 of FIG. 1;
FIG. 5 is a perspective view of the container of FIG. 3 in a more complete stage of assembly, showing the end panels being folded over the column members;
FIG. 6 is a perspective view of the container of FIG. 5 in yet a further stage of assembly;
FIGS. 7 a and 7 b are plan unassembled and perspective fully assembled views, respectively, of an alternative embodiment of the container of FIG. 1;
FIGS. 8 a and 8 b are plan unassembled and perspective fully assembled views, respectively, of another alternative embodiment of the container of FIG. 1.

DETAILED DESCRIPTION

Referring to FIGS. 1, 2 and 3, a reinforced stackable and self-erecting open-top container 10 is formed by an open-top receptacle having a front wall 20 a back wall 30 and end walls 40 each of which project upwardly from a one-piece bottom 50. Front and back walls 20, 30 and end walls 40 are integral with container bottom 50 and are joined to bottom 50 by respective longitudinally extending folds 120, 130 and transversely extending folds 140, respectively. Advantageously, all the panels forming container 10 are integral portions of a single flat blank 1 shown in FIG. 2, and are cut, folded and attached to one another to form the assembled container shown in FIG. 1.
As will be appreciated, terms such as “horizontal”, “vertical”, “left”, “right”, “up”, “down”, “top”, and “bottom”, etc., used as nouns, adjectives or adverbs (e.g. “horizontally”, “rightward”, “upwardly”, “downwardly”, etc.) refer to the orientation of the structure of the invention as it is illustrated in the particular drawing figure when that figure faces the reader. Such terms are not intended to limit the invention to a particular orientation. Similarly, the terms “inwardly” and “outwardly” generally refer to the orientation of a surface or other structure relative to an axis of elongation or axis of rotation, as appropriate.
The terms “connected” and “interconnected”, when used to describe the relationship between two or more structures, mean that such structures are secured or attached either directly or indirectly through intervening structures and include movable connections such as pivoting connections. The term “operatively” means that the foregoing direct or indirect connections between such structures allow the structures to operate as described and intended by virtue of such connection. The term “integral” or “integrally connected” when used to describe the relationship between two or more structures means that the structures comprise a single piece of material.
Furthermore, the term “column” when used to describe structural members means a member formed from the combination of two or more thicknesses of material with or without a space therebetween.
Lines representing fold lines are shown in the drawings by broken and solid lines that represent lines along which the material can be weakened or caused preferentially to fold by any of various means. For example, corrugated or other material can be compressed along a thin line defining a fold, or can be cut part way through along the line, or cut all or part way through the line, or cut all or part way through at spaced intervals, forming preferential fold lines in the knocked-down flat (“KDF”) blank and/or in the erected container.
Furthermore, portions of joints to which glue is applied are shown in the relevant figures by “XXX” patterns. Covered areas containing glue on a rear face of a respective panel are shown in broken line “XXX” patterns.
Referring again to FIGS. 1-3, front and back walls 20, 30 have full height sections 200, 300 disposed adjacent to the corners of the container, and these sections 200, 300 are of plural thickness along at least a portion of their width “w1”. The end walls 40 comprise column structures and thus are of plural thickness. Adjacent to the corners the end walls 40 have an exterior panel 44 and an interior panel 42, the two being connected via a top panel 46. Interior panel 42 folds over a pair of front and back column members 60, 62 that are integral with front and back sides 20, 30 respectively. Locking tabs 142 protrude outward from the extreme extension of the interior panel 42 and engage corresponding openings 52 in the container bottom 50. These locking tabs 142 maintain the column members 60, 62 in position within the interior and exterior panels 42, 44 and also maintain the vertical orientation of the end walls 40.
The front and back walls 20, 30 have respective cutout portions 22, 32, and each cutout portion has a reinforcing fold-over panel 24, 34 that is foldable along a longitudinally extending fold 124, 134. The fold-over panels 24, 34 provide the center cutout portions 22, 32 with a plural thickness of material for the lower wall sections 28, 38 of the of the respective cutout portions.
Thus, the combination of front and back wall- integral column members 60, 62 and reinforced fold-over panels 24, 34 provides enhanced structural rigidity to the assembled container 10, and also provides enhanced support to the container along traditionally low-strength high-stress lines such as the corner diagonals “A-A” (FIG. 1) to minimize breakage or tearing of the front and back walls 20, 30 during loading, unloading, stacking, or other manipulation of the container 10.
To facilitate stacking of multiple containers 10, registration tabs 54 are cut from the container bottom 50 where the bottom meets each exterior panel 44 of the end walls 40. These tabs 54 protrude downward for engagement with corresponding openings 146 formed in the top panels 46 to allow engagement with a next container in a stack (not shown). In addition to openings 146, panel cutouts 70 e, 72 e are also provided in the outer lateral portions of panel segments 72 b, c since it is these portions that directly underlie openings 146 when the container is in the assembled condition. Without such cutouts 70 e, 72 e the lateral portions of panel segments 72 b, c would interfere with the insertion of the registration tabs 54.
As previously noted, container 10 has front and back walls 20, 30 and end walls 40, each of which is integrally formed with and projects upwardly from a one-piece bottom 50. The front wall and back walls 20, 30 each may have a central cutout portion 22, 32 that is integrally connected to the bottom 50 along longitudinal fold line 120, 130. The walls 20, 30 further may each comprise a pair of column-forming panels 70, 72 that upon assembly will provide structural strength and stability to the end walls 40. As shown in FIG. 2, these panels 70, 72 are integrally connected to respective full- height sections 200, 300 of walls 20, 30 along transverse fold lines 64 a.
Column-forming panels 70, 72 each comprise four panel segments, namely inner 70 a, 72 a, outer 70 b, 72 b, lateral 70 c, 72 c, and lateral flap 70 d, 72 d panel segments. Each segment is integrally connected to an adjoining segment via a respective transverse fold line 64 b, 64 c, 64 d, thus allowing the segments to be folded together to form a substantially geometric column member 60, 62 (FIG. 3), which in the illustrated embodiment is a rectangle. To maintain the column members 60, 62 In the assembled state, the lateral flap panels 70 d, 72 d may be glued to adjoining portions of the respective full- height sections 200, 300 of the front and back walls 20, 30.
In the illustrated embodiment, the four walls of each column member 60, 62 are formed by respective inner, outer and lateral panel segments 70 a-c, 72 a-c in conjunction with a portion of the respective full- height section 200, 300 of front and back walls 20, 30. Lateral flap panels 70 d, 72 d do not form part of column members 60, 62 but rather are folded away from the column members 60, 62 and are glued to full- height sections 200, 300 of the front and back walls 20, 30. This arrangement provides the full- height sections 200, 300 with a plural thickness of material except for the portion of the full-height sections that form part of the column members 60, 62. In the illustrated embodiment, the lateral flap panels 70 d, 72 d cover approximately half of the width “w1” of the corresponding full- height section 200, 300. As will be appreciated by one of skill in the art, the lateral flap panels 70 d, 72 d may be dimensioned to cover greater or lesser portions of this width “w1.” Thus, in one embodiment the column members 60, 62 may be flat, without a hollow center, and lateral flap panels 70 d, 72 d may have approximately the same width as the corresponding full- height section 200, 300 to provide the entire width “w1” of these sections with a plural thickness of material. Alternatively, lateral flap panels 70 d, 72 d could be sized to cover less than about half the width “w1” of the corresponding full- height sections 200, 300.
Providing a plural thickness of material for at least a portion of the full- height sections 200, 300 enhances the structural strength and stability of the front and back walls 20, 30 because it provides a plural thickness of material for the portion of the full-height sections directly adjacent to the cutout portions 22, 32, thus reinforcing the front and back walls along traditionally low strength and high-stress corner diagonals “A-A.” Lateral flap panels 70 d, 72 d are configured to correspond to the general shape of the portion of the full- height section 200, 300 to which they will attach so as to maximize the area of the sections 200, 300 for which a plural thickness of material is provided. Thus, the extreme extensions 170 d, 172 d of flap panels 70 d, 72 d, upon assembly, are configured to conform to the transverse edges 202, 302 of the respective full- height sections 200, 300.
A pair of column members 60, 62 will combine to form the structural core of each end wall 40. As can be seen in FIG. 5, the column members 60, 62 each have a column width “cw” that is approximately half the width “w2” of the container 10 and a column height “ch” that is approximately equal to the container height “h,” thus providing maximum stiffness and strength to the end walls 40.
As previously noted, the front and back walls 20, 30 each may have a cutout 22, 32 formed therein. Each cutout is a relatively large opening in the respective wall 20, 30 provided for manual access, that is, to enable a person to reach into the container 10 through the front or back and to remove or add contents. The cutouts 22, 32 are each spaced inwardly from the opposite ends (delineated by folds 64 a) of the respective wall 20, 30 and from the four corners of the container 10, thus forming full- height sections 200, 300 adjacent to the corners. Likewise, each cutout 22, 32 extends only part way from the upper edge 26, 36 of the respective wall to the bottom of the container 50, thereby leaving a lower wall section 28, 38 of reduced height in the central area of each of the walls 20, 30.
Preferably, the lower wall sections 28, 38 are each doubled in thickness by an inwardly folded reinforcing section 24, 34 that is folded inwardly and is glued to the inner surface of the respective lower wall section. When folded and glued, the lateral edges 25, 35 of reinforcing sections 24, 34 preferably abut extreme extensions 170 d, 172 d of lateral flap panels 70 d, 72 d to maximum the portion of the front and back walls having plural thickness of material, again strengthening the container along high-stress, low-strength lines such as corner diagonal “A-A.”
End walls 40 comprise integrally formed exterior 44, top 46 and interior 42 panels. Each panel is integrally connected to its adjoining panel via a respective transverse fold line 140 b, c, while the exterior panel 44 is integrally connected to the container bottom 50 via transverse fold line 140 a. Thus, the panels may be folded about one another to form a substantially geometric shape, which in the illustrated embodiment is a rectangle.
The end wall panels 42, 44, 46 are sized and configured to enclose column members 60, 62 which will be assembled and folded into place prior to folding the end wall panels 42, 44, 46. The sequence of assembly may best be explained with reference to the accompanying figures. FIG. 3 show column members 60, 62 assembled from flat column-forming panels 70, 72 of blank 1 in FIG. 2. Front and back walls 20, 30 are shown partially folded along longitudinal fold lines 120, 130. FIG. 5 shows the front and back walls 20, 30 and corresponding column members 60, 62 folded in their final configuration abutting container bottom 50, with exterior end wall panels 44 folded along transverse fold lines 140 a so as to partially enclose the columns. The near end wall 40 is shown in a more fully-folded state than the far end wall 40. In FIG. 6, the top 46 and interior 42 panels have been folded over the respective column members 60, 62 to form far end wall 40, while the top and interior panels 46, 42 of the near end wall 40 are shown in a partially folded state. The fully assembled container 10 is shown in FIG. 1.
To lock the end walls in place, a pair of locking tabs 142 may be provided at the extreme extension of each interior panel 42. These tabs 142 are configured to engage corresponding openings 52 in the container bottom 50 so that when the end wall panels 42, 44, 46 are folded over column members 60, 62, the tabs 142 lock in the openings 52 thus locking the members 60, 62 in position within the interior and exterior panels 42, 44 and maintaining the vertical orientation of the end walls 40.
FIG. 4 shows a cross-section of an assembled end wall 40 taken at line 4-4 in FIG. 1, illustrating the assembled relationship between column 60, end wall panels 42, 44, 46 and container bottom 50. Also shown are registration tab 54, tab opening 146, panel cutout 70 e. Interior panel 42 is shown locked into opening 142 in container bottom 50.
Advantageously, column members 60, 62 are formed as integral extensions of the front and back walls 20, 30 instead of extensions of the end walls 40. This arrangement ensures that the columns, which provide stiffness to the container 10, remain in tight engagement with the front and back walls 20, 30 to provide maximum reinforcement of the container along traditionally low-strength and high-stress areas such as corner diagonals “A-A.”
Additional reinforcement of corner diagonals “A-A” is provided by the placement and gluing of the flap panels 72 d on full- height sections 200, 300 to provide a plural-thickness layer over the entire height “h” of these sections. A portion of this plural-thickness layer forms the innermost portion of the corner diagonal “A-A,” which is typically the portion that is subject to tearing in the prior art containers.
The panels forming the container 10 are cut, preferably from a single integral flat blank, then glued and folded. The integral flat blank 1 that forms the KDF and erected container is shown in FIG. 2. Blank 1 is processed, by folding and gluing operations, to provide the KDF structure that can be provided to a packer in a compact collapsed arrangement, for example in stacks or bales wherein all the containers are completely flattened as compared to their erected states. Container blank 1 can be integrally cut, for example, from a sheet of corrugated board, paperboard or other sheet material. A number of thicknesses can be die cut in a single step. However, container blanks 1 preferably are cut out individually so that the blank can be scored or compressed along lines that are to be folded, at the same time that the perimeter of the blank is cut from the sheet. The blank is folded along certain lines when it is formed into a collapsed state for shipment, and other lines are folded or partially unfolded when the collapsed blank is erected for packing.
When forming container 10 as shown from flat corrugated craft board or similar material that has distinct load-bearing aspects in mutually perpendicular directions, it is preferred to orient the board so that the best load-bearing direction is substantially parallel to front and back walls 20, 30. Thus for corrugated board, the flutes of the corrugation run longitudinally in FIG. 1, from one end wall 40 to the other.
Container 10 is erected from its KDF state by first rotating individual panel segments 70 a-d, 72 a-d of column-forming panels 70, 72 inwardly about their respective transverse folds 64 a-d until lateral flap panels 70 d, 72 d approach respective portions of side walls 20, 30, respectively. Segments 70 a, 72 a are glued (thus the designation “XXX”) and upon contact with the inner surfaces of the side walls 20, 30 the column-forming panels 70, 72 create respective parallelogram columns 60, 62 whose four sides are formed, respectively, by panel segments 70 a-c and front wall 20; and panel segments 72 a, 72 b, 72 c and back wall 30. In the illustrated embodiment these columns are in the form of a rectangle, although other geometric shapes are contemplated. These columns 60, 62 are wholly flattened in the KDF state, and when the container 10 is erected by rotating front and back walls 20, 30 upwardly about folds 120, 130, panel segments 70 c, 72 c are positioned substantially horizontally, i.e., in approximately ninety-degree relation to panel segments 70 a-b, 72 a-b and approximately parallel to respective front and back walls 20, 30.
Reinforcing fold-over panels 24, 34 are folded inwardly at longitudinal folds 124, 134 and glued (designation “XXX”) to their corresponding lower wall sections 28, 38. The exterior panels 42 of each end wall 40 are then rotated inwardly about transverse folds 140 a, and the interior and top panels 42, 46 of each end wall 40 are rotated about transverse folds 140 b, c until the locking tabs 142 disposed on the extreme end of interior panel 42 engage the corresponding locking tab openings 52 in container bottom 50. Thus assembled, the end wall panels 42, 44, 46 encompass corresponding pairs of columns 60, 62 to create end wall structures 40 at opposite longitudinal ends of the container 10.
FIGS. 7 a and 7 b show an alternative embodiment of the container of FIG. 1 in which openings 1000 are provided in the exterior panels 1044 of each end wall 1040 to allow access to the interior of the end walls for storage and retrieval of contents. Container 1010 is similar to container 10 of FIGS. 1-6, with significant differences explained below. Otherwise, like features of container 1010 have the reference numerals of corresponding features of container 10, increased by 1000. These like features include single-piece construction, column end walls, registration tabs, reinforced front and back walls, and others.
Notably, the container 1010 provides additional product storage and display space owing to the openings 1000, 2000 in the end containers and column members 1060, 1062. As can be seen in FIG. 7 b, openings 1000, 2000 may comprise appropriately positioned cutout sections in container blank 1001. Opening 1000 is substantially centrally disposed within exterior panels 1044, while opening 2000 spans across outer panels 1070 b, 1072 b and lateral panels 1070 c, 1072 c. In the illustrated embodiment, a majority of the opening 2000 is disposed in outer panel 1070 b, 1072 b to ensure that the opening 2000 corresponds to the full width “ow” (FIG. 7 b) of the opening 1000 when the end wall 1040 is assembled.
Since a user may wish to utilize the secondary storage capacity within the end walls 1040 for a variety of different purposes, the dimensions of column-forming panels 1070, 1072 and end wall panels 1042, 1044, 1046 may be adjusted as appropriate to provide the desired capacity.
As can be seen in FIG. 7 a, openings 1000, 2000 may be accessed from the interior of the container 1010, and likewise the interior of the container may be accessed through openings 1000, 2000. This arrangement provides an additional measure of convenience for a user wishing to remove or restock materials in the container 1010. This accessibility feature is provided by manufacturing each interior panel 1042 so that its length “pl” is less than the height “h” of the associated full- height sections 1200, 1300 of front and back walls 1020, 1030, and further by sizing column members 1060, 1062 so that their widths “cw” are less than half the width “w2” of the container 1010.
Thus, when the end wall panels 1042, 1046, 1044 are folded over the associated column members 1060, 1062 the interior panel will not reach the container bottom 1050 and the resulting gap between the column members 1060, 1062, the interior panel 1042, and the container bottom 1050 will result in an aperture that provides the desired access between the container interior and the openings 1000, 2000. The aperture will have a height equal to the difference between the height “h” of full- height sections 1200, 1300 and the interior panel length “pl,” and a width equal to the difference between the container width “w2” and the sum of the column widths “cw.” Thus, the dimensions of the individual column-forming panels 1070, 1072 may be manipulated during fabrication of blank 1001 to provide the desired aperture size and thus the desired degree of accessibility.
In the illustrated embodiment, interior panel length “pl” is about one half the height “h” of the associated full- height sections 1200, 1300, and the sum of the column member widths “cw” is about two thirds the width “w2” of the container 1010. Thus, in the illustrated embodiment, openings 1000, 2000 form three generally equally sized containment volumes 1000 a, b, c, each of which may be used to store separate products or amounts of product.
Since the extreme extension of the interior panels 1042 does not extend to the container bottom 1050, locking tabs 1142 are provided on the lateral sides of the interior panels. These tabs 1142 are configured to engage corresponding openings 1162, 1170 in the container bottom 1050 so that when the end wall panels 1042, 1044, 1046 are folded over column members 1060, 1062, the tabs 1142 lock in the openings 1162, 1170, thus locking the members 1060, 1062 in position within the interior and exterior panels 1042, 1044 and maintaining the vertical orientation of the end walls 1040.
The end walls 1040 each may have a reinforcement panel 1043 that is foldable along a laterally extending fold 1146. The reinforcement panels 1043 reinforce the portion of each end wall 1040 that is associated with the aperture between column members 1060, 1062. Locking tabs 1143 protrude outward from the extreme extension of the reinforcement panels 1043 and engage corresponding openings 1145 in the container bottom 1050 to lock the reinforcement panels in place.
The lower wall sections 1028, 1038 of front and back walls 1020, 1030 likewise may have glued reinforcing sections 1024, 1034, similar to previous embodiments, that serve to double the material thickness of the respective lower wall section. When folded and glued, the lateral edges 1025, 1035 of reinforcing sections 1024, 1034 preferably abut extreme extensions 1071, 1073 of lateral flap panels 1070 d, 1072 d to maximize the portion of the front and back walls 1020, 1030 having plural thickness of material, again strengthening the container along high-stress, low-strength lines such as corner diagonal “A-A.”
Multiple containers 1010 of the present embodiment may be stacked using registration tabs 1054 similar to those described in relation to previous embodiment of FIGS. 1-6. Registration tabs 1054 may be cut from the container bottom 50 where the bottom meets each exterior panel 1044 of the end walls 1040. These tabs 1054 protrude downward for engagement with corresponding openings 1146 formed in the top panels 1046 to allow engagement with a next container in a stack (not shown). In the illustrated embodiment, tabs 1054 and openings 1146 are offset with respect to the center of the container so as not to interfere with locking openings 1145 in the container bottom 1050. In addition to openings 1146, panel cutouts 1070 e, 1072 e are also provided in the outer lateral portions of panel segments 1072 b, c that directly underlie openings 1146 when the container is in the assembled condition. Without such cutouts 1070 e, 1072 e the lateral portions of these panel segments 1072 b, c would interfere with the insertion of the registration tabs 1054. As can be seen from the figure, only one set of panel segments 1070 b, c, 1072 b, c per front and back wall 1020, 1030 need have these cutouts 1070 e, 1072 e, since registration tabs 1054 and openings 1146 are offset with respect to the center of the container.
FIGS. 8 a and 8 b show another alternative embodiment of the container of FIG. 1 in which the entirety of the front wall is or reduced height in comparison to the end and back walls, the column-forming panels of the front and back walls have fewer than four panel segments, and the end walls each have only two sub-panels in lieu of the three-panel design of the previous embodiments.
Notably, the column-forming panels of this embodiment form flat columns having substantially no hollow space between panels. Rather, two-panels are sandwiched together to form compact columns that minimize the total thickness of the end walls and thereby maximize the amount of usable space within the container.
Container 2010 is similar to container 10 of FIGS. 1-6, with significant differences explained below. Otherwise, like features of container 2010 have the reference numerals of corresponding features of container 10, increased by 2000. These like features include single-piece construction, column-forming front and back wall panels, registration tabs, and others.
Notably, container 2010 is particularly well suited for the display of contained products. A reduced-height front wall 2020 meets with a tapered end wall portion 2045 to provide easy visual and physical access to container contents from the front and side. Container 2010 also is suited to be stacked in a terraced fashion, such which the front wall 2020 of the next higher container in the stack is positioned slightly rearward (i.e. toward the back wall) with respect to the lower container. This terraced configuration allows for better visualization of the contents of each stacked container, as well as easier physical access to the contents, and is facilitated by the offset placement of respective registration tabs 2054 and openings 2145, which will be discussed in greater detail later.
Like the previous embodiments, front and back walls 2020, 2030 each have a pair of integral column-forming panels 2070, 2072 that upon assembly will provide structural strength and stability to the end walls 2040. As shown in FIG. 8 b, these panels 2070, 2072 each comprise three panel segments, namely inner 2070 a, 2072 a, outer 2070 b, 2072 b and lateral flap 2070 c, 2072 c panel segments. This arrangement results in the formation of column members that are not hollow (i.e. there is no substantial space between the inner and outer panel segments), thus providing a simplified and more compact reinforced end wall structure.
Panels 2070 a, b have tapered lateral perimeter edge segments 2170 a, b that correspond to the tapered portions 2045 of end walls 2040. These panels 2070 a, b also have cutout portions 2070 e to accommodate registration tabs of the next container in a stack, as discussed in relation to previous embodiments. Similar cutouts 2070 e are provided in panel segments 2072 a, b associated with the back wall 2030.
As with previous embodiments, the panel segments of each column-forming panel 2070, 2072 are integrally connected via respective transverse fold lines, and lateral flap panel segments 2070 c, 2072 c are glued to adjoining portions of the front and back walls 2020, 2030 to maintain the resulting column members in the assembled state.
The extreme extension of lateral flap panel segments 2070 c is divided into a laterally disposed edge segment 2071 a and a forward tapered edge segment 2071 b, with each segment configured to correspond with, and to abut, an edge segment 2025 a, b, of front wall reinforcing fold-over panel 2024. This fold-over panel 2024 is foldable along a longitudinally extending fold 2124 to provide the front wall 2020 with a plural thickness of material. The fold-over panel 2024 has a first portion associated with edge segment 2025 b that extends the full length of the front wall 2020 and a second portion associated with edge segment 2025 a that extends less than the full length of the front wall, to accommodate glued panel 2070 c. The complementary arrangement of the fold-over panel 2024 and the lateral flap panel segments 2070 c provides a plural thickness of material over nearly the entire surface of the front wall 2020.
The back wall 2030 of the present embodiment will have only a single thickness of material over a portion of the center of the wall, since the lateral flap panel segments 2072 c extend only a short distance beyond the respective end wall 2040. It will be appreciated, however, that these panel segments could be made longer as desired to provide a plural thickness of material along a greater portion of the back wall 2030.
As with the previous embodiments, the end walls 2040 are comprised of multiple sub-panel that are connected to each other via respective transverse fold lines. These sub-panels are configured to fold over the column members formed by panels 2070 a, 2070 b; 2072 a, 2072 b. Since the column members of this embodiment are not hollow, the end walls 2040 are substantially flat, thereby maximizing the amount of usable space within the assembled container 2010. The end walls 2040 are held in place via a locking tab arrangement similar to that described in relation to previous embodiments.
The end walls of this embodiment further have a two- panel segment 2080, 2082 that folds over the tapered portions 2170 a, b of column-forming panel 2070 to hold these portions in place. Segment 2080 has a tab 2180 that is captured between the interior, top, and exterior panel segments 2042, 2046, 2044 of the end wall 2040 upon assembly, to thereby lock the column members firmly in place.
To facilitate the previously described stacking of container 2010, two sets of registration tabs 2054, 2055 can be provided. The first set of tabs are cut from the container bottom 50 directly adjacent to the end walls 2040 and near the front wall 2020. The tabs protrude downward for engagement with corresponding openings 2146 formed in the top panels 2046 to allow engagement with a next container in the stack. It is noted that, unlike the previous embodiments, openings 2146 are laterally offset with respect to tabs 2054, lying approximately midway between the front and back walls of the container. Thus, when the registration tabs of a first container are fit into the openings of the next container in the stack, the front wall of the first container is offset from the front wall of the next container, resulting in a terraced stack of containers. As will be apparent to one of skill in the art, the degree of lateral offset of the tabs and openings may be adjusted to provide the desired terraced effect.
An additional center registration tab 2055 is also cut from the container bottom 50 adjacent to the front wall 2020. [Please explain how this registration tab engages an adjacent container in the stack.]
The various embodiments of the invention as shown are characterized by substantial vertical stacking strength, and resistance to deformation from rectilinear shape that is beyond what could be expected simply by multiplying the thicknesses of vertical structures provided. Nevertheless, the container is easily formed by die cutting through the blank of FIGS. 2, 7 b or 8 b, processing the cut blank through a fold and glue machine, such as those available from Bobst Group, Inc. of Roseland, N.J., to apply adhesive and preliminarily fold over any panels, whereupon the container can be compactly shipped in its KDF configuration. The container is readily erected on site by simply raising the column members, front and back walls and end walls relative to the container bottom. The end wall panels are folded over the erected column members and locked to the bottom or front/back walls.
The container can be loaded with product, stacked and shipped, stored and presented to customers who can readily withdraw product from the container through the cutouts. In the embodiment in which the end wall contents are subdivided (FIGS. 7 a, b), the respective subdivided areas can be advantageously used, for example, to contain different flavors of a given product, to contain complementary types of products, or otherwise used to the advantage of the retailer and the convenience of the customer.
The invention having been disclosed in connection with the foregoing variations and examples, additional variations will now be apparent to persons skilled in the art. The invention is not intended to be limited to the variations specifically mentioned, and accordingly reference should be made to the appended claims rather than the foregoing discussion of preferred examples, to assess the scope of the invention in which exclusive rights are claimed.

Claims

1. A container comprising:

a plurality of panels defining a bottom, longitudinally opposite first and second end walls, and laterally opposite first and second side walls;

each end wall having an outer end wall panel joined to the bottom, the end wall panel having end, top and inner panel portions; each side wall further comprising a side portion joined to the bottom, and a pair of column-forming panels, one of the column-forming panels disposed adjacent to the first end wall and the other column-forming panel disposed adjacent to the second end wall, each column-forming panel further having an assembled configuration in which the panel is folded to assume a column member having a substantially geometric shape;

wherein each end wall panel is sized and configured such that when a pair of associated column-forming panels are in the assembled configuration, the end, top and inner panel portions of the end wall are foldable about the resulting column members and securable to the bottom to form the first or second end wall to configure the container to an assembled state.

2. The container of claim 1, wherein at least one of the first and second side walls has a cutout for manual access to contents of the container; and wherein the cutout extends only part way from a top edge of the associated side wall to the bottom, and further comprising a reinforcing panel folded inwardly along an edge of the cutout such that the associated wall is at least a double thickness from the cutout to the bottom.

3. The container of claim 2, wherein:

the side walls and the end walls are integrally joined at mutually orthogonal folds to a bottom panel;

wherein the reinforcing panel of the cutout is folded inwardly along a line parallel to and spaced from one of said folds that joins one of said side walls containing said cutout to the bottom panel, said reinforcing panel having a lateral edge;

wherein at least one of said column forming panels is integrally joined to the side wall containing the cutout, at a fold line perpendicular to said one of the folds joining the side wall containing the cutout to the bottom;

wherein said column forming panels comprise a terminal tab portion that is folded inwardly and glued to an inside of the side wall containing the cutout such that a terminal edge abuts against the lateral edge of the reinforcing panel.

4. The container of claim 3, wherein each of the column members associated with the first end wall is sized to span about half of a lateral width of the end wall.

5. The container of claim 3, wherein each of the column members associated with the first end wall is sized to span less than half of a lateral width of the end wall.

6. The container of claim 3, wherein each of the column members associated with the first end wall is sized to span from about 20% to about 40% of a lateral width of the end wall.

7. The container of claim 3, wherein the geometric shape is a rectangle.

8. The container of claim 3, wherein the side walls and end walls are integral with the bottom.

9. The container of claim 3, wherein the column-forming panels are integral with their respective side walls.

10. The container of claim 9, wherein the inner panel portion of each end wall comprises a locking tab that engages with at least one of the bottom and side wall when the extension is folded over the associated column members.

11. The container of claim 10, wherein the bottom comprises a tab receptacle and the tab locks in the tab receptacle in the assembled state of the container.

12. The container of claim 10, wherein the side wall comprises a tab receptacle and the tab locks in the tab receptacle in the assembled state of the container.

13. The container of claim 10, wherein the bottom comprises at least one registration tab configured to lock into a corresponding opening in the top panel portion of one of the end walls such that the container is stackable in registry with similar said containers by engaging the registration tab of one said container with the registration opening of a similar said container stacked thereon.

14. The container of claim 2, wherein the cutout is disposed between corners of the container, each corner comprising the location at which the top and inner panel portions of the end wall meet the associated side wall side portion.

15. The container of claim 14, wherein first and second portions of the column-forming panel are adhesively attached together to form the associated column member.

16. The container of claim 15, wherein the reinforcing panel is adhesively attached to the associated side wall portion.

17. The container of claim 14, wherein the end panel portion of at least one of the end walls comprises a removable panel for manual access to a portion of the contents of the container.

18. The container of claim 17, wherein the portion of the contents of the container that is accessible via the end panel portion is separate from the contents of the container that is accessible via the side wall cutout.

19. The container of claim 17, wherein the column-forming panels associated with the at least one end wall each are configured so that the resulting column member has a cutout disposed toward the end wall for allowing manual access to an interior portion of the column member.

20. A container comprising:

a plurality of corrugated paperboard panels defining a bottom, laterally opposite front and back walls, and longitudinally opposite end walls;

each front and back wall further comprising a pair of column-forming panels, one panel disposed adjacent to each end wall, each column-forming panel further having an assembled configuration in which the panel is folded to assume a column member having a substantially geometric shape;

wherein the end walls comprise an outer end wall panel joined adjacent to a respective one of the front and back walls to an extension at each opposite end of each of the end walls, each extension being foldable over one of said pairs of column members, the extension having fixation means for enclosing the column members; and

wherein each of the front and back walls has a cutout extending part way from a top end toward a lower wall portion adjacent the bottom for manual access to contents of the container.

21. The container of claim 20, wherein the panels are integral parts of a single piece of flat stock.

22. The container of claim 20, wherein the fixation means comprises gluing.

23. The container of claim 20, wherein the fixation means comprises a locking tab formed on the extension and configured to engage a corresponding recess formed in the container bottom.

24. The container of claim 20, wherein the lower wall portion of the front and back walls comprises a folded-inward reinforcing web.

25. The container of claim 24, wherein the reinforcing web is glued to the associated lower wall portion.