US20030146126A1 - Stackable container having support flanges - Google Patents

Stackable container having support flanges Download PDF

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Publication number
US20030146126A1
US20030146126A1 US10/357,736 US35773603A US2003146126A1 US 20030146126 A1 US20030146126 A1 US 20030146126A1 US 35773603 A US35773603 A US 35773603A US 2003146126 A1 US2003146126 A1 US 2003146126A1
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Prior art keywords
flange
sidewalls
attached
flanges
sidewall
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US10/357,736
Inventor
Allen Kanter
Brian Tibbels
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Innovative Packaging Designs LP
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Innovative Packaging Designs LP
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Priority to US10/357,736 priority Critical patent/US20030146126A1/en
Assigned to INNOVATIVE PACKAGING DESIGNS L.P. reassignment INNOVATIVE PACKAGING DESIGNS L.P. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KANTER, ALLEN, TIBBELS, BRIAN J.
Publication of US20030146126A1 publication Critical patent/US20030146126A1/en
Abandoned legal-status Critical Current

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D5/00Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/001Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper stackable
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D5/00Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/02Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding or erecting a single blank to form a tubular body with or without subsequent folding operations, or the addition of separate elements, to close the ends of the body
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D5/00Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/42Details of containers or of foldable or erectable container blanks
    • B65D5/44Integral, inserted or attached portions forming internal or external fittings
    • B65D5/48Partitions
    • B65D5/48002Partitions integral
    • B65D5/48014Partitions integral formed by folding extensions hinged to the side edges of a tubular body
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D5/00Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/42Details of containers or of foldable or erectable container blanks
    • B65D5/44Integral, inserted or attached portions forming internal or external fittings
    • B65D5/52External stands or display elements for contents

Definitions

  • the invention relates to containers used for packaging, shipping and displaying goods. More particularly, the invention relates to display containers such as corrugated paperboard boxes having flanges to facilitate the stacking of such containers on top of one another.
  • Display containers for example, boxes of corrugated paperboard, are widely used for shipping and marketing products. Such containers are especially popular in warehouse-type marketing settings and supermarkets where many containers are stacked on top of one another and have open tops and partially open sides to display the food or merchandise held within them. Examples include containers of packaged candy which may be decorated for display purposes. The containers of candy are shipped to the store in stacked form. Store personnel remove the tops of the containers and, in many cases, fold down or remove a side display panel from the container which exposes the candy within the container to view and allows access thereto by the consumer. The containers are then stacked one on top of another on the retail floor for display of the candy to the consumer.
  • a major problem with stacked containers having open tops and sides is that a container may partially fall into or “nest” within the container beneath it.
  • Another problem is the lack of strength for stacking. All too often loaded containers near or at the bottom of a stack collapse or become misshapen under the weight of the containers above them. This impairs the aesthetic appearance of the display sought by the seller, ruins the products within, and requires clean up.
  • One known container disclosed in U.S. Pat. No. 5,791,555, and which is hereby incorporated by reference, provides a shelf like flap to help support a container stacked on top and prevent nesting.
  • This container is configured to automatically pull the shelf into position upon the assembly of the container.
  • One end of the shelf is connected to a side wall of the container to pull the shelf down, the other end being free and typically resting on the top of one of the side walls. While this container provides advantages over other type containers, further improvements are believed desirable. For example, many products, such as candy, are drop loaded into the containers. If the shelf is already in place, this can interfere with the loading process. Furthermore, it has been found that in some uses the free end of the shelf can be forced into the container, creating a nesting problem.
  • the invention concerns a container upon which another container having similar dimensions may be stacked without nesting in the container.
  • the container comprises a plurality of panels attached to one another along adjacent edges to form a plurality of sidewalls surrounding a central space.
  • a plurality of flaps extend from the sidewalls inwardly toward the central space, the flaps being positioned substantially co-planarly in one of overlapping and adjacent positions relative to one another to form a bottom.
  • a first flange is attached to a first of the sidewalls along an edge thereof positioned opposite to the bottom.
  • a second flange is attached to a second of the sidewalls along an edge thereof positioned opposite to the bottom, the second sidewall being attached to the first sidewall, the second flange being attached to the first flange along a common edge.
  • the first flange is oriented substantially parallel to the bottom and extends inwardly toward the central space for supporting the other container when stacked thereon.
  • the second flange is folded along a fold line oriented at an angle to the common edge, the second flange being thereby divided into overlying flange portions.
  • Each of the overlying flange portions has an outer face, the outer faces being attached to one another in face to face relationship, thereby holding the first flange in position substantially parallel to the bottom. Attachment of the faces is preferably by adhesive.
  • the invention also concerns support surfaces useable on containers to permit stacking of the containers one atop another without nesting.
  • the containers comprise a plurality of interconnected panels forming sidewalls surrounding a central space.
  • the sidewalls have flaps extending therefrom which are foldable to form a bottom.
  • First and second support flanges are respectively attached to first and second sidewalls which face one another in opposing relationship.
  • the support flanges extend lengthwise along edges of the sidewalls in spaced relation to the bottom.
  • the support flanges are each oriented at a substantially right angle to the first and second sidewalls and project inwardly toward the central space.
  • Side flanges are attached to each end of the first and second flanges.
  • Each side flange is also attached to a respective sidewall adjacent to one of the first and second sidewalls.
  • the side flanges are folded along respective fold lines extending diagonally across each side flange, the fold lines dividing each of the side flanges into overlying flange portions facing one other and extending inwardly toward the central space, the overlying flange portions being adhered together, preferably by adhesive.
  • one object of the present invention is to provide a display-ready container with improved anti-nesting capabilities.
  • Another object is to provide a container with anti-nesting capabilities that can be assembled by machine.
  • Another object is to provide a display-ready container that is economical to produce.
  • a further object of the present invention is to provide a display-ready container that is easy to assemble and use.
  • Another object is to provide a display-ready container that can be safely stacked during shipping and display.
  • FIG. 1 is a perspective view of a container according to the invention stacked atop similar containers
  • FIG. 2 is a plan view of a blank from which the container shown in FIG. 1 is formed;
  • FIGS. 3A through 3C are perspective views of a container being formed from a knockdown shown in 3 A;
  • FIG. 4 is an alternate embodiment of a container according to the invention.
  • FIG. 5 is a blank from which the container in FIG. 4 is formed.
  • FIG. 6 is a knockdown formed from the blank shown in FIG. 5 and transformable into the container shown in FIG. 4.
  • FIG. 1 shows a container 10 according to the invention.
  • Container 10 is preferably formed of a stiff, lightweight substrate such as corrugated paperboard and comprises a plurality of panels 12 attached to one another along adjacent edges 14 to form a plurality of sidewalls 16 , 18 , 20 and 22 .
  • the sidewalls define and surround a central space 24 where merchandise is received for storage, transport and display.
  • Container 10 is depicted in a stack of similar containers 10 b and 10 c (shown in phantom line) and without a top as it might be seen in a display on a market floor.
  • Sidewall 18 is a partial panel and has a reinforcing fold-down portion 26 , the partial panel 18 providing an opening 28 in the container 10 allowing display and access to the goods therein even when the containers are stacked one atop another as shown.
  • Flaps 30 , 32 , 34 and 36 extend respectively from the lower edge of each sidewall 16 , 18 , 20 and 22 and are folded inwardly toward the central space 24 along respective fold lines (identified in detail below) to form a bottom 38 .
  • the flaps 30 , 32 , 34 and 36 are positioned substantially co-planarly in overlapping and adjacent positions relatively to one another.
  • the sidewalls, flaps, fold down portions and other parts comprising the container 10 are joined together at adjacent edges defined by fold lines formed in the substrate comprising the container.
  • the fold lines may be formed in any of a number of ways, such as by cutting, creasing or perforating the paperboard as is known in the art.
  • the fold line and the edge are denoted by the same reference character. This does not imply, however, that all edges are necessarily fold lines or that all parts of the container need be joined at fold lines in the substrate.
  • Containers 10 have support flanges 40 and 42 which form flat support surfaces 44 across the tops of the containers upon which other containers sit when the containers are stacked as illustrated in FIG. 1.
  • the support flanges 40 and 42 prevent nesting of the containers within one another when stacked and also strengthen the container sidewalls against collapse.
  • the support flanges 40 and 42 extend across the entire width or length of the container and are respectively positioned on opposing sidewalls such as 16 and 20 .
  • Each support flange 40 and 42 is preferably integrally formed with its respective sidewall 16 and 20 and extends from a respective edge 74 and 92 located on each sidewall opposite to the bottom 38 of the container.
  • the edges 74 and 92 are defined by respective fold lines in the container substrate which preferably have lengthwise perforations 46 along at least a portion of the span of the support flange.
  • the perforations provide increased flexibility for folding the support flange without significantly compromising the strength of the flange attachment to its respective sidewall. Further details related to the construction of the support flanges 40 and 42 are provided below.
  • Container 10 is preferably formed from a unitary substrate blank 48 , shown in FIG. 2.
  • the substrate blank 48 is preferably die-cut from a sheet of corrugated paperboard during which the fold lines defining the panel edges are formed, by creasing, perforating and cutting operations as described above.
  • Sidewalls 16 , 18 , 20 and 22 are shown as they would appear after the blank 48 is cut from the paperboard sheet.
  • the surfaces visible in FIG. 2 comprise the outwardly facing surfaces of the container 10 in FIG. 1.
  • sidewall 22 there is a portion of sidewall 22 , denoted 22 a , which is later attached to a counterpart portion 22 b (described below) to form the sidewall 22 .
  • a portion of flap 36 denoted 36 a , extends from a lower edge of the sidewall portion 22 a , that edge being defined by a fold line 50 .
  • Sidewall portion 22 a is joined to sidewall 16 at an edge defined by a fold line 52 .
  • Flap 30 extends from a lower edge of sidewall 16 , that edge being defined by fold line 54 .
  • Sidewall 16 is joined to sidewall 18 along an edge defined by a fold line 56 .
  • Flap 32 extends from a lower edge of sidewall 18 , that edge being defined by a fold line 58 .
  • Sidewall 18 has a large cut-out region defining the display opening 28 in the sidewall for access to the container's central space once assembled.
  • Sidewall 18 also has a fold down portion 26 , shown before folding, which reinforces the sidewall.
  • fold down portion 26 is defined by two parallel cuts 60 and 62 respectively positioned at either end of the fold down portion, and a fold line 64 which extends lengthwise along the fold down portion between the cuts. Cuts 60 and 62 extend through the entire thickness of the substrate blank 48 to free the ends of the fold down portion 26 from the sidewall 18 and allow it to be reverse folded inwardly to reinforce the sidewall 18 .
  • Sidewall 18 is joined to sidewall 20 along an edge defined by a fold line 66 .
  • Flap 34 extends from a lower edge of sidewall 20 , that edge being defined by a fold line 68 .
  • Sidewall 20 is joined to sidewall portion 22 b along an edge defined by a fold line 70 .
  • Sidewall portion 22 b is the counterpart to sidewall portion 22 a , and when joined together, the sidewall portions 22 a and 22 b form sidewall 22 .
  • a portion of flap 36 denoted 36 b , extends from a lower edge of the sidewall portion 22 b , that edge being defined by a fold line 72 .
  • Joining of sidewalls 22 a and 22 b also effect the joining of flaps 36 a and 36 b which form bottom flap 36 .
  • Support flange 40 extends from an upper edge of sidewall 16 , that edge being defined by a fold line 74 .
  • Support flange 40 preferably runs along the entire length of sidewall 16 , and each end of the support flange is attached to a respective side flange 76 and 78 .
  • Side flange 76 extends from an upper edge of sidewall portion 22 a , that edge being defined by a fold line 80 .
  • Another fold line, 82 defines the edge between support flange 40 and the side flange 76 .
  • Yet another fold line, 84 extends across the side flange 76 at an angle to the edge defined by fold line 82 .
  • side flange 78 extends from an upper edge of sidewall 18 , that edge being defined by a fold line 86 .
  • Another fold line, 88 defines the edge between support flange 40 and the side flange 78 .
  • Yet another fold line, 90 extends across the side flange 78 at an angle to the edge defined by fold line 88 .
  • support flange 42 extends from an upper edge of sidewall 20 , that edge being defined by a fold line 92 .
  • Support flange 42 preferably runs along the entire length of sidewall 20 , and each end of the support flange is attached to a respective side flange 94 and 96 .
  • Side flange 94 extends from an upper edge of sidewall portion 22 b , that edge being defined by a fold line 98 .
  • Another fold line, 100 defines the edge between support flange 42 and the side flange 94 .
  • Yet another fold line, 102 extends across the side flange 94 at an angle to the edge defined by fold line 100 .
  • side flange 96 extends from an upper edge of sidewall 18 , that edge being defined by a fold line 104 .
  • Another fold line, 106 defines the edge between support flange 42 and the side flange 96 .
  • Yet another fold line, 108 extends across the side flange 96 at an angle to the edge defined by fold line 106 .
  • the side flanges 76 , 78 , 94 and 96 are square in shape and the fold lines 84 , 90 , 102 and 108 extend diagonally across their respective side flanges. The reasons for these preferences are explained below.
  • Blank 48 is next formed into a knockdown 110 shown in FIG. 3A.
  • the knockdown is advantageous because it allows containers such as container 10 to be shipped from the manufacturer in a flat configuration, saving space and reducing shipping costs.
  • the knockdown is configured to be conveniently converted from the flat configuration into the container 10 as depicted in FIG. 1 through a series of simple steps (described below) performed by automated machinery. Once the container is formed from the knockdown, it is then loaded with merchandise, final actions are executed, and the container with its contents is ready for shipment.
  • Knockdown 110 is formed by first reverse folding fold down portion 26 along fold line 64 and into overlying relation with the inwardly facing surface of sidewall 18 .
  • Next blank 48 is reverse folded along fold lines 66 and 52 to bring sidewall portion 22 b into partial overlying relation with counterpart sidewall portion 22 a .
  • the two sidewall portions 22 a and 22 b are bonded together, preferably with an adhesive 112 (see FIG. 1) to form sidewall 22 , and the knockdown 110 shown in FIG. 3A.
  • Knockdown 110 comprises a first knockdown wall 114 formed of sidewalls 18 and 16 along with their respective flaps 32 and 30 as well as flanges 96 , 78 and 40 all aligned in a same first plane when the knockdown is in its flat configuration. Edges 66 and 52 form the first and second knockdown corners which define the ends of the first knockdown wall 114 .
  • a second knockdown wall 116 is formed of sidewalls 20 and 22 , their respective flaps 34 and 36 , and flanges 42 , 94 and 76 all in a same second plane which is parallel to the first plane.
  • the second knockdown wall 116 is joined to the first knockdown wall 114 at the first and second knockdown corners defined by edges 66 and 52 .
  • FIGS. 3A through 3C show a series of steps performed to transform the knockdown 110 into the container 10 .
  • the first and second knockdown walls 114 and 116 are separated from one another with the sidewalls 16 , 18 , 20 and 22 pivoting relatively to one another in the manner of a four bar linkage about fold lines 52 , 56 , 66 and 70 .
  • the sidewalls comprising the respective knockdown walls 114 and 116 move outwardly they are no longer substantially in the same plane and the knockdown 110 transforms into the configuration shown in FIG. 3B wherein adjacent sidewalls are oriented at right angles to one another.
  • flaps 30 , 32 , 34 and 36 are folded inwardly along respective fold lines 54 , 58 , 68 , 72 and 50 to form the bottom 38 .
  • flaps 30 and 34 are first folded inwardly followed by flaps 32 and 36 , the latter two flaps being preferably adhesively bonded to the first two to form a permanent bottom.
  • Other bottom configurations are of course feasible, as known in the art.
  • an auxiliary panel (not shown) will be installed within the central space 24 in overlying relation with sidewall 18 to close off the opening 28 . The auxiliary panel is removed at the point of sale to display the container contents in the stacked configuration as shown in FIG. 1.
  • the support flanges 40 and 42 are folded inwardly about respective fold lines 74 and 92 toward the central space 24 to provide the support surfaces 44 which strengthen the sidewalls and support a container stacked on top of the container 10 without allowing nesting of the containers.
  • the side flange 78 is attached to both support flange 40 and sidewall 18
  • side flange 76 is attached to both support flange 40 and sidewall 22
  • the side flanges 78 and 76 are at right angles to support flange 40 .
  • This configuration will generally prevent folding of support flange 40 about fold line 74 .
  • fold lines 90 and 84 are positioned diagonally across side flanges 78 and 76 respectively.
  • the fold lines 90 and 84 divide their respective side flanges 78 and 76 into respective overlying flange portions 78 a , 78 b , 76 a and 76 b .
  • Each overlying flange portion has an outer surface 78 c , 78 d , 76 c and 76 d also shown in FIG. 2.
  • the fold lines 90 and 84 allow the side flanges 78 and 76 to fold inwardly in the manner of a bellows or accordion pleat to respectively bring their outer faces 78 c , 78 d , 76 c and 76 d into face to face relationship as shown in FIG. 3C.
  • Flanges 42 , 94 and 96 are similarly configured with fold lines 102 and 108 , forming respective overlying flange portions 94 a , 94 b , 96 a and 96 b .
  • Each overlying flange portion has an outer surface 94 c , 94 d , 96 c and 96 d as shown in FIG. 2.
  • the fold lines 102 and 108 allow their respective side flanges 94 and 96 to fold inwardly, permitting support flange 42 also to fold as described for support flange 40 .
  • Adhesive 118 is applied between the outer facing surfaces 78 c , 78 d , 76 c , 76 d , 94 c , 94 d , 96 c and 96 d to secure them to one another in facing relationship and hold the support flanges 40 and 42 in the folded configuration. Adhering the faces together also serves to strengthen the container 10 , permitting deeper stacking without nesting or collapse. Side flanges 78 , 76 , 94 and 96 are preferably square in shape so as to minimize their size and yet provide a shape which will fold neatly within the perimeter of the container. The square shape allows the fold lines 76 , 78 , 102 and 108 to naturally be oriented diagonally and thus maximize the contact area when the flanges are folded to ensure good adhesion.
  • a top (not shown) is placed on the container 10 and the container is ready for shipping. It is clear that the steps involved in forming the container from the knockdown, filling the container, folding and adhering the support flanges 40 and 42 in place and placing a top on the container are relatively simple steps occasioned by the design of the knockdown 110 which allows these steps to be performed rapidly and reliably by automated machinery.
  • FIG. 4 shows another embodiment 120 of a container according to the invention.
  • Container 120 has many of the same features as container 10 , and the same reference characters are used to identify those parts common to both embodiments.
  • support flanges 40 and 42 are formed along edges 74 and 92 of opposite sidewalls 16 and 20 to strengthen the container 120 and provide support surfaces 44 to prevent nesting of containers one within the other when stacked.
  • Container 120 has a divider panel 122 extending from sidewall 22 to opposite sidewall 18 .
  • the divider panel 122 divides the central space 24 into separate regions 24 a and 24 b allowing the container to hold two different types of merchandise and keep them separated.
  • sidewall 18 is a partial panel and has openings 28 a and 28 b providing access to each of the separate regions 24 a and 24 b when the containers are stacked together.
  • Sidewall 18 has an upstanding middle extension 124 to which the divider panel 122 is attached.
  • Container 120 is formed from a blank 126 shown in FIG. 5.
  • Blank 126 is preferably die-cut from corrugated paperboard substrate and has fold lines defining the edges between sidewalls, flaps and flanges substantially as described above for container 10 .
  • the panel surfaces visible in FIG. 5 are those which face outwardly from the central space when the container 120 is formed.
  • divider panel 122 extends from sidewall portion 22 b , a fold line 128 defining the edge between the sidewall 22 b and the divider panel 122 .
  • Divider panel 122 also has an attachment flap 130 positioned at its end opposite to sidewall portion 22 b and defined by a fold line 132 . As shown in FIG. 4, the attachment flap 130 is folded along fold line 132 at a right angle to divider panel 122 and attached to middle extension 124 to effect the attachment of divider panel 122 to the sidewall 18 . Attachment of flap 130 is preferably effected by adhesive.
  • Knockdown 134 is shown in its flat configuration for shipping and has a first knockdown wall 136 comprising sidewalls 18 and 16 , their respective flaps 32 and 30 as well as flanges 96 , 78 and 40 in a substantially same first plane 138 .
  • Fold lines 66 and 52 define the first knockdown wall 136 .
  • a second knockdown wall 140 is attached to the first knockdown wall 136 at the fold lines 66 and 52 and is positioned in a substantially same second plane 142 parallel to and behind the first plane 138 .
  • the second knockdown wall 140 comprises sidewalls 20 and 22 (formed by attaching sidewall portions 22 a and 22 b together) along with their flaps 34 and 36 and flanges 94 , 42 and 76 all substantially in second plane 142 , not all of which can be shown in FIG. 6.
  • Knockdown 134 is transformed into the container 120 using substantially the same steps as described above for container 10 . Note that the divider panel 122 is sandwiched between the first and second knockdown walls 136 and 140 when the knockdown is in the flat configuration depicted in FIG. 6.
  • the divider panel 122 pivots about its fold lines 128 and 132 similar to the way sidewalls 16 and 20 (to which it is parallel) pivot about their respective fold lines in the manner of a four-bar linkage to effect transformation from the knockdown to the container configuration.
  • Containers according to the invention provide a convenient and cost effective item for packaging, transporting and displaying bulk items. Such containers are rugged and reliably stackable and avoid the problems of nesting and collapse from which other containers suffer.

Abstract

Containers are disclosed having a plurality of interconnected panels forming sidewalls surrounding a central space. Flaps extend from lower sidewall edges and fold along fold lines to form a bottom. Support flanges are arranged along upper sidewall edges on oppositely facing sidewalls. The support flanges are oriented at right angles to the sidewalls and provide a support surface allowing the containers to be stacked one atop another without collapsing or nesting within each other. Side flanges are attached to each end of the support flanges and to sidewalls joined to the sidewalls having the support flanges. The side flanges each have an angularly oriented fold line which divides the side flanges into facing portions and permits them to fold like a bellows or accordion pleat. The facing portions are adhered together to hold the support flanges in position.

Description

    RELATED APPLICATION
  • This application is based on and claims the benefit of U.S. Provisional Application No. 60/354,099, filed Feb. 4, 2002.[0001]
  • FIELD OF THE INVENTION
  • The invention relates to containers used for packaging, shipping and displaying goods. More particularly, the invention relates to display containers such as corrugated paperboard boxes having flanges to facilitate the stacking of such containers on top of one another. [0002]
  • BACKGROUND OF THE INVENTION
  • Display containers, for example, boxes of corrugated paperboard, are widely used for shipping and marketing products. Such containers are especially popular in warehouse-type marketing settings and supermarkets where many containers are stacked on top of one another and have open tops and partially open sides to display the food or merchandise held within them. Examples include containers of packaged candy which may be decorated for display purposes. The containers of candy are shipped to the store in stacked form. Store personnel remove the tops of the containers and, in many cases, fold down or remove a side display panel from the container which exposes the candy within the container to view and allows access thereto by the consumer. The containers are then stacked one on top of another on the retail floor for display of the candy to the consumer. [0003]
  • A major problem with stacked containers having open tops and sides is that a container may partially fall into or “nest” within the container beneath it. Another problem is the lack of strength for stacking. All too often loaded containers near or at the bottom of a stack collapse or become misshapen under the weight of the containers above them. This impairs the aesthetic appearance of the display sought by the seller, ruins the products within, and requires clean up. [0004]
  • One known container, disclosed in U.S. Pat. No. 5,791,555, and which is hereby incorporated by reference, provides a shelf like flap to help support a container stacked on top and prevent nesting. This container is configured to automatically pull the shelf into position upon the assembly of the container. One end of the shelf is connected to a side wall of the container to pull the shelf down, the other end being free and typically resting on the top of one of the side walls. While this container provides advantages over other type containers, further improvements are believed desirable. For example, many products, such as candy, are drop loaded into the containers. If the shelf is already in place, this can interfere with the loading process. Furthermore, it has been found that in some uses the free end of the shelf can be forced into the container, creating a nesting problem. [0005]
  • SUMMARY AND OBJECTS OF THE INVENTION
  • The invention concerns a container upon which another container having similar dimensions may be stacked without nesting in the container. The container comprises a plurality of panels attached to one another along adjacent edges to form a plurality of sidewalls surrounding a central space. A plurality of flaps extend from the sidewalls inwardly toward the central space, the flaps being positioned substantially co-planarly in one of overlapping and adjacent positions relative to one another to form a bottom. A first flange is attached to a first of the sidewalls along an edge thereof positioned opposite to the bottom. A second flange is attached to a second of the sidewalls along an edge thereof positioned opposite to the bottom, the second sidewall being attached to the first sidewall, the second flange being attached to the first flange along a common edge. The first flange is oriented substantially parallel to the bottom and extends inwardly toward the central space for supporting the other container when stacked thereon. The second flange is folded along a fold line oriented at an angle to the common edge, the second flange being thereby divided into overlying flange portions. Each of the overlying flange portions has an outer face, the outer faces being attached to one another in face to face relationship, thereby holding the first flange in position substantially parallel to the bottom. Attachment of the faces is preferably by adhesive. [0006]
  • The invention also concerns support surfaces useable on containers to permit stacking of the containers one atop another without nesting. The containers comprise a plurality of interconnected panels forming sidewalls surrounding a central space. The sidewalls have flaps extending therefrom which are foldable to form a bottom. First and second support flanges are respectively attached to first and second sidewalls which face one another in opposing relationship. The support flanges extend lengthwise along edges of the sidewalls in spaced relation to the bottom. The support flanges are each oriented at a substantially right angle to the first and second sidewalls and project inwardly toward the central space. Side flanges are attached to each end of the first and second flanges. Each side flange is also attached to a respective sidewall adjacent to one of the first and second sidewalls. The side flanges are folded along respective fold lines extending diagonally across each side flange, the fold lines dividing each of the side flanges into overlying flange portions facing one other and extending inwardly toward the central space, the overlying flange portions being adhered together, preferably by adhesive. [0007]
  • Accordingly, one object of the present invention is to provide a display-ready container with improved anti-nesting capabilities. [0008]
  • Another object is to provide a container with anti-nesting capabilities that can be assembled by machine. [0009]
  • Another object is to provide a display-ready container that is economical to produce. [0010]
  • A further object of the present invention is to provide a display-ready container that is easy to assemble and use. [0011]
  • Another object is to provide a display-ready container that can be safely stacked during shipping and display. [0012]
  • Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned from making and using the invention. The objects and advantages of the invention may be realized and attained by means of the combinations pointed out in the appended claims.[0013]
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a perspective view of a container according to the invention stacked atop similar containers; [0014]
  • FIG. 2 is a plan view of a blank from which the container shown in FIG. 1 is formed; [0015]
  • FIGS. 3A through 3C are perspective views of a container being formed from a knockdown shown in [0016] 3A;
  • FIG. 4 is an alternate embodiment of a container according to the invention; [0017]
  • FIG. 5 is a blank from which the container in FIG. 4 is formed; and [0018]
  • FIG. 6 is a knockdown formed from the blank shown in FIG. 5 and transformable into the container shown in FIG. 4.[0019]
  • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • FIG. 1 shows a [0020] container 10 according to the invention. Container 10 is preferably formed of a stiff, lightweight substrate such as corrugated paperboard and comprises a plurality of panels 12 attached to one another along adjacent edges 14 to form a plurality of sidewalls 16, 18, 20 and 22. The sidewalls define and surround a central space 24 where merchandise is received for storage, transport and display. Container 10 is depicted in a stack of similar containers 10 b and 10 c (shown in phantom line) and without a top as it might be seen in a display on a market floor. Sidewall 18 is a partial panel and has a reinforcing fold-down portion 26, the partial panel 18 providing an opening 28 in the container 10 allowing display and access to the goods therein even when the containers are stacked one atop another as shown.
  • [0021] Flaps 30, 32, 34 and 36 extend respectively from the lower edge of each sidewall 16, 18, 20 and 22 and are folded inwardly toward the central space 24 along respective fold lines (identified in detail below) to form a bottom 38. Upon folding, the flaps 30, 32, 34 and 36 are positioned substantially co-planarly in overlapping and adjacent positions relatively to one another. There are several possible folding combinations used to form bottoms of containers, such as the 1-2-3-4 bottom or the “crash” bottom, all of which are known to those of skill in the art.
  • Generally the sidewalls, flaps, fold down portions and other parts comprising the [0022] container 10 are joined together at adjacent edges defined by fold lines formed in the substrate comprising the container. For containers made of corrugated paperboard, the fold lines may be formed in any of a number of ways, such as by cutting, creasing or perforating the paperboard as is known in the art. For economy of reference herein, when an edge of a part of the container is defined by a fold line, both the fold line and the edge are denoted by the same reference character. This does not imply, however, that all edges are necessarily fold lines or that all parts of the container need be joined at fold lines in the substrate.
  • [0023] Containers 10 according to the invention have support flanges 40 and 42 which form flat support surfaces 44 across the tops of the containers upon which other containers sit when the containers are stacked as illustrated in FIG. 1. The support flanges 40 and 42 prevent nesting of the containers within one another when stacked and also strengthen the container sidewalls against collapse. Preferably, the support flanges 40 and 42 extend across the entire width or length of the container and are respectively positioned on opposing sidewalls such as 16 and 20. Each support flange 40 and 42 is preferably integrally formed with its respective sidewall 16 and 20 and extends from a respective edge 74 and 92 located on each sidewall opposite to the bottom 38 of the container. The edges 74 and 92 are defined by respective fold lines in the container substrate which preferably have lengthwise perforations 46 along at least a portion of the span of the support flange. The perforations provide increased flexibility for folding the support flange without significantly compromising the strength of the flange attachment to its respective sidewall. Further details related to the construction of the support flanges 40 and 42 are provided below.
  • [0024] Container 10 is preferably formed from a unitary substrate blank 48, shown in FIG. 2. The substrate blank 48 is preferably die-cut from a sheet of corrugated paperboard during which the fold lines defining the panel edges are formed, by creasing, perforating and cutting operations as described above. Sidewalls 16, 18, 20 and 22 are shown as they would appear after the blank 48 is cut from the paperboard sheet. The surfaces visible in FIG. 2 comprise the outwardly facing surfaces of the container 10 in FIG. 1.
  • Beginning at the rightmost side of blank [0025] 48, there is a portion of sidewall 22, denoted 22 a, which is later attached to a counterpart portion 22 b (described below) to form the sidewall 22. A portion of flap 36, denoted 36 a, extends from a lower edge of the sidewall portion 22 a, that edge being defined by a fold line 50. Sidewall portion 22 a is joined to sidewall 16 at an edge defined by a fold line 52. Flap 30 extends from a lower edge of sidewall 16, that edge being defined by fold line 54. Sidewall 16 is joined to sidewall 18 along an edge defined by a fold line 56. Flap 32 extends from a lower edge of sidewall 18, that edge being defined by a fold line 58. Sidewall 18 has a large cut-out region defining the display opening 28 in the sidewall for access to the container's central space once assembled. Sidewall 18 also has a fold down portion 26, shown before folding, which reinforces the sidewall. When the blank 48 is formed, fold down portion 26 is defined by two parallel cuts 60 and 62 respectively positioned at either end of the fold down portion, and a fold line 64 which extends lengthwise along the fold down portion between the cuts. Cuts 60 and 62 extend through the entire thickness of the substrate blank 48 to free the ends of the fold down portion 26 from the sidewall 18 and allow it to be reverse folded inwardly to reinforce the sidewall 18.
  • [0026] Sidewall 18 is joined to sidewall 20 along an edge defined by a fold line 66. Flap 34 extends from a lower edge of sidewall 20, that edge being defined by a fold line 68. Sidewall 20 is joined to sidewall portion 22 b along an edge defined by a fold line 70. Sidewall portion 22 b is the counterpart to sidewall portion 22 a, and when joined together, the sidewall portions 22 a and 22 b form sidewall 22. A portion of flap 36, denoted 36 b, extends from a lower edge of the sidewall portion 22 b, that edge being defined by a fold line 72. Joining of sidewalls 22 a and 22 b also effect the joining of flaps 36 a and 36 b which form bottom flap 36.
  • [0027] Support flange 40 extends from an upper edge of sidewall 16, that edge being defined by a fold line 74. Support flange 40 preferably runs along the entire length of sidewall 16, and each end of the support flange is attached to a respective side flange 76 and 78. Side flange 76 extends from an upper edge of sidewall portion 22 a, that edge being defined by a fold line 80. Another fold line, 82, defines the edge between support flange 40 and the side flange 76. Yet another fold line, 84, extends across the side flange 76 at an angle to the edge defined by fold line 82. Similarly, side flange 78 extends from an upper edge of sidewall 18, that edge being defined by a fold line 86. Another fold line, 88, defines the edge between support flange 40 and the side flange 78. Yet another fold line, 90, extends across the side flange 78 at an angle to the edge defined by fold line 88.
  • Similarly, [0028] support flange 42 extends from an upper edge of sidewall 20, that edge being defined by a fold line 92. Support flange 42 preferably runs along the entire length of sidewall 20, and each end of the support flange is attached to a respective side flange 94 and 96. Side flange 94 extends from an upper edge of sidewall portion 22 b, that edge being defined by a fold line 98. Another fold line, 100, defines the edge between support flange 42 and the side flange 94. Yet another fold line, 102, extends across the side flange 94 at an angle to the edge defined by fold line 100. Similarly, side flange 96 extends from an upper edge of sidewall 18, that edge being defined by a fold line 104. Another fold line, 106, defines the edge between support flange 42 and the side flange 96. Yet another fold line, 108, extends across the side flange 96 at an angle to the edge defined by fold line 106.
  • Preferably, the [0029] side flanges 76, 78, 94 and 96 are square in shape and the fold lines 84, 90, 102 and 108 extend diagonally across their respective side flanges. The reasons for these preferences are explained below.
  • Blank [0030] 48 is next formed into a knockdown 110 shown in FIG. 3A. The knockdown is advantageous because it allows containers such as container 10 to be shipped from the manufacturer in a flat configuration, saving space and reducing shipping costs. The knockdown is configured to be conveniently converted from the flat configuration into the container 10 as depicted in FIG. 1 through a series of simple steps (described below) performed by automated machinery. Once the container is formed from the knockdown, it is then loaded with merchandise, final actions are executed, and the container with its contents is ready for shipment.
  • [0031] Knockdown 110 is formed by first reverse folding fold down portion 26 along fold line 64 and into overlying relation with the inwardly facing surface of sidewall 18. Next blank 48 is reverse folded along fold lines 66 and 52 to bring sidewall portion 22 b into partial overlying relation with counterpart sidewall portion 22 a. The two sidewall portions 22 a and 22 b are bonded together, preferably with an adhesive 112 (see FIG. 1) to form sidewall 22, and the knockdown 110 shown in FIG. 3A.
  • [0032] Knockdown 110 comprises a first knockdown wall 114 formed of sidewalls 18 and 16 along with their respective flaps 32 and 30 as well as flanges 96, 78 and 40 all aligned in a same first plane when the knockdown is in its flat configuration. Edges 66 and 52 form the first and second knockdown corners which define the ends of the first knockdown wall 114. A second knockdown wall 116 is formed of sidewalls 20 and 22, their respective flaps 34 and 36, and flanges 42, 94 and 76 all in a same second plane which is parallel to the first plane. The second knockdown wall 116 is joined to the first knockdown wall 114 at the first and second knockdown corners defined by edges 66 and 52.
  • FIGS. 3A through 3C show a series of steps performed to transform the knockdown [0033] 110 into the container 10. In the first step, shown in FIG. 3A, the first and second knockdown walls 114 and 116 are separated from one another with the sidewalls 16, 18, 20 and 22 pivoting relatively to one another in the manner of a four bar linkage about fold lines 52, 56, 66 and 70. As the sidewalls comprising the respective knockdown walls 114 and 116 move outwardly they are no longer substantially in the same plane and the knockdown 110 transforms into the configuration shown in FIG. 3B wherein adjacent sidewalls are oriented at right angles to one another.
  • Once the [0034] sidewalls 16, 18, 20 and 22 are moved into the right angled configuration, the flaps 30, 32, 34 and 36 are folded inwardly along respective fold lines 54, 58, 68, 72 and 50 to form the bottom 38. In the example shown in FIGS. 3B and 3C, flaps 30 and 34 are first folded inwardly followed by flaps 32 and 36, the latter two flaps being preferably adhesively bonded to the first two to form a permanent bottom. Other bottom configurations are of course feasible, as known in the art. Typically, an auxiliary panel (not shown) will be installed within the central space 24 in overlying relation with sidewall 18 to close off the opening 28. The auxiliary panel is removed at the point of sale to display the container contents in the stacked configuration as shown in FIG. 1.
  • With [0035] sidewalls 16, 18, 20 and 22 in right-angle relation, an auxiliary panel in place, and bottom 38 formed, the container 10 is now ready to be loaded with merchandise. It is advantageous to perform the loading step before the support flanges 40 and 42 are folded into the final configuration shown in FIG. 1. This allows for a maximum sized opening in the container for receiving the contents.
  • In the next step, shown in FIG. 3C, the [0036] support flanges 40 and 42 are folded inwardly about respective fold lines 74 and 92 toward the central space 24 to provide the support surfaces 44 which strengthen the sidewalls and support a container stacked on top of the container 10 without allowing nesting of the containers. Note that the side flange 78 is attached to both support flange 40 and sidewall 18, side flange 76 is attached to both support flange 40 and sidewall 22, and the side flanges 78 and 76 are at right angles to support flange 40. This configuration will generally prevent folding of support flange 40 about fold line 74. However, fold lines 90 and 84 are positioned diagonally across side flanges 78 and 76 respectively. As shown in FIG. 2, the fold lines 90 and 84 divide their respective side flanges 78 and 76 into respective overlying flange portions 78 a, 78 b, 76 a and 76 b. Each overlying flange portion has an outer surface 78 c, 78 d, 76 c and 76 d also shown in FIG. 2. The fold lines 90 and 84 allow the side flanges 78 and 76 to fold inwardly in the manner of a bellows or accordion pleat to respectively bring their outer faces 78 c, 78 d, 76 c and 76 d into face to face relationship as shown in FIG. 3C. This permits support flange 40 to fold inwardly and be positioned at a right angle to the sidewall 16, thus, forming one of the support surfaces 44. Flanges 42, 94 and 96 are similarly configured with fold lines 102 and 108, forming respective overlying flange portions 94 a, 94 b, 96 a and 96 b. Each overlying flange portion has an outer surface 94 c, 94 d, 96 c and 96 d as shown in FIG. 2. The fold lines 102 and 108 allow their respective side flanges 94 and 96 to fold inwardly, permitting support flange 42 also to fold as described for support flange 40. Adhesive 118 is applied between the outer facing surfaces 78 c, 78 d, 76 c, 76 d, 94 c, 94 d, 96 c and 96 d to secure them to one another in facing relationship and hold the support flanges 40 and 42 in the folded configuration. Adhering the faces together also serves to strengthen the container 10, permitting deeper stacking without nesting or collapse. Side flanges 78, 76, 94 and 96 are preferably square in shape so as to minimize their size and yet provide a shape which will fold neatly within the perimeter of the container. The square shape allows the fold lines 76, 78, 102 and 108 to naturally be oriented diagonally and thus maximize the contact area when the flanges are folded to ensure good adhesion.
  • Once loaded and with [0037] support flanges 40 and 42 folded, a top (not shown) is placed on the container 10 and the container is ready for shipping. It is clear that the steps involved in forming the container from the knockdown, filling the container, folding and adhering the support flanges 40 and 42 in place and placing a top on the container are relatively simple steps occasioned by the design of the knockdown 110 which allows these steps to be performed rapidly and reliably by automated machinery.
  • FIG. 4 shows another [0038] embodiment 120 of a container according to the invention. Container 120 has many of the same features as container 10, and the same reference characters are used to identify those parts common to both embodiments. Again, support flanges 40 and 42 are formed along edges 74 and 92 of opposite sidewalls 16 and 20 to strengthen the container 120 and provide support surfaces 44 to prevent nesting of containers one within the other when stacked. Container 120 has a divider panel 122 extending from sidewall 22 to opposite sidewall 18. The divider panel 122 divides the central space 24 into separate regions 24 a and 24 b allowing the container to hold two different types of merchandise and keep them separated. Again, sidewall 18 is a partial panel and has openings 28 a and 28 b providing access to each of the separate regions 24 a and 24 b when the containers are stacked together. Sidewall 18 has an upstanding middle extension 124 to which the divider panel 122 is attached.
  • [0039] Container 120 is formed from a blank 126 shown in FIG. 5. Blank 126 is preferably die-cut from corrugated paperboard substrate and has fold lines defining the edges between sidewalls, flaps and flanges substantially as described above for container 10. The panel surfaces visible in FIG. 5 are those which face outwardly from the central space when the container 120 is formed. Note that divider panel 122 extends from sidewall portion 22 b, a fold line 128 defining the edge between the sidewall 22 b and the divider panel 122. Divider panel 122 also has an attachment flap 130 positioned at its end opposite to sidewall portion 22 b and defined by a fold line 132. As shown in FIG. 4, the attachment flap 130 is folded along fold line 132 at a right angle to divider panel 122 and attached to middle extension 124 to effect the attachment of divider panel 122 to the sidewall 18. Attachment of flap 130 is preferably effected by adhesive.
  • The configuration of the [0040] divider panel 122 allows the container 120 to be formed into a knockdown 134, shown in FIG. 6. Knockdown 134 is shown in its flat configuration for shipping and has a first knockdown wall 136 comprising sidewalls 18 and 16, their respective flaps 32 and 30 as well as flanges 96, 78 and 40 in a substantially same first plane 138. Fold lines 66 and 52 define the first knockdown wall 136. A second knockdown wall 140 is attached to the first knockdown wall 136 at the fold lines 66 and 52 and is positioned in a substantially same second plane 142 parallel to and behind the first plane 138. The second knockdown wall 140 comprises sidewalls 20 and 22 (formed by attaching sidewall portions 22 a and 22 b together) along with their flaps 34 and 36 and flanges 94, 42 and 76 all substantially in second plane 142, not all of which can be shown in FIG. 6. Knockdown 134 is transformed into the container 120 using substantially the same steps as described above for container 10. Note that the divider panel 122 is sandwiched between the first and second knockdown walls 136 and 140 when the knockdown is in the flat configuration depicted in FIG. 6. When the knockdown walls 136 and 140 are separated, the divider panel 122 pivots about its fold lines 128 and 132 similar to the way sidewalls 16 and 20 (to which it is parallel) pivot about their respective fold lines in the manner of a four-bar linkage to effect transformation from the knockdown to the container configuration.
  • Containers according to the invention provide a convenient and cost effective item for packaging, transporting and displaying bulk items. Such containers are rugged and reliably stackable and avoid the problems of nesting and collapse from which other containers suffer. [0041]

Claims (17)

What is claimed is:
1. A container upon which another container having similar dimensions may be stacked without nesting in said container, said container comprising:
a plurality of panels attached to one another along adjacent edges to form a plurality of sidewalls surrounding a central space;
a plurality of flaps extending from said sidewalls to form a bottom;
a first flange attached to a first of said sidewalls along an edge thereof positioned opposite to said bottom; and
a second flange attached to a second of said sidewalls along an edge thereof positioned opposite to said bottom, said second sidewall being attached to said first sidewall, said second flange being attached to said first flange along a common edge, said first flange being oriented substantially parallel to said bottom and extending inwardly toward said central space for supporting said other container when stacked thereon, said second flange being folded along a fold line oriented at an angle to said common edge, said second flange being thereby divided into second overlying flange portions, each of said second overlying flange portions having an outer face, said outer faces being attached to one another in face to face relationship thereby holding said first flange in position substantially parallel to said bottom.
2. A container according to claim 1, wherein said first flange extends across the length of said first sidewall.
3. A container according to claim 2, further comprising a third flange attached to a third of said sidewalls along an edge thereof opposite to said bottom, said third sidewall being attached to said first sidewall in facing relationship opposite to said second sidewall, said third flange being attached to said first flange along a second common edge and being folded along a fold line oriented at an angle to said second common edge, said third flange being thereby divided into third overlying flange portions, each of said third overlying flange portions having an outer face, said outer faces of said third overlying flange portions being attached to one another in face to face relationship thereby holding said first flange in position substantially parallel to said bottom.
4. A container according to claim 3, further comprising:
a fourth flange attached to a fourth of said sidewalls along an edge thereof positioned opposite to said bottom, said fourth sidewall being in facing relationship opposite said first sidewall and attached to said second and third sidewalls; and
a fifth flange attached to one of said second and third sidewalls along an edge thereof positioned opposite to said bottom, said fifth flange being attached to said fourth flange along a third common edge, said fourth flange being oriented substantially parallel to said bottom and extending inwardly toward said central space for supporting said other container when stacked thereon, said fifth flange being folded along a fold line oriented at an angle to said third common edge, said fifth flange being thereby divided into fifth overlying flange portions, each of said fifth overlying flange portions having an outer face, said outer faces of said fifth overlying flange portions being attached to one another in face to face relationship thereby holding said fourth flange in position substantially parallel to said bottom.
5. A container according to claim 4, wherein said fourth flange extends across the length of said fourth sidewall.
6. A container according to claim 5, further comprising a sixth flange attached to the other of said second and third sidewalls along an edge thereof opposite to said bottom, said sixth flange being attached to said fourth flange along a fourth common edge and being folded along a fold line oriented at an angle to said fourth common edge, said sixth flange being thereby divided into sixth overlying flange portions, each of said sixth overlying flange portions having an outer face, said outer faces of said sixth overlying flange portions being attached to one another in face to face relationship thereby holding said fourth flange in position substantially parallel to said bottom.
7. A container according to claim 1, wherein said faces of said overlying flange portions facing each other are adhesively bonded together.
8. A container according to claim 6 and formable from a knockdown having first and second knockdown walls attached to one another at first and second knockdown corners to form a substantially flat assembly, said first knockdown wall including said first and said second sidewalls and said first, second and sixth flanges in a substantially same first plane, said second knockdown wall including said third and fourth sidewalls and said third, fourth and fifth flanges in a second substantially same plane parallel to said first plane.
9. A container according to claim 6, wherein said second, third, fifth and sixth flanges are square in shape and said fold line on each of said flanges extends diagonally thereacross.
10. A container according to claim 6, wherein said flanges, said sidewalls and said flaps comprise corrugated paperboard.
11. A container according to claim 10, wherein said fold lines dividing said flanges into said overlying flange portions are defined by respective perforations of said flanges.
12. Support surfaces useable on containers to permit stacking of said containers one atop another without nesting, said containers comprising a plurality of interconnected panels forming sidewalls surrounding a central space, said sidewalls having flaps extending therefrom and foldable to form a bottom, a first and a second of said sidewalls facing one another in opposing relationship, said support surfaces comprising:
first and second support flanges respectively attached to said first and second sidewalls and extending lengthwise along edges thereof in spaced relation to said bottom, said support flanges each being oriented substantially at a right angle to said first and second sidewalls and projecting inwardly toward said central space; and
side flanges attached to each end of said first and second support flanges, each said side flange also being attached to a respective sidewall adjacent to one of said first and second sidewalls, said side flanges each being folded along a respective fold line extending diagonally across each said side flange, said fold line dividing each of said side flanges into overlying flange portions, each of said overlying flange portions having an outer face, said outer faces of overlying flange portions being attached to one another in face to face relationship.
13. Support surfaces according to claim 12, wherein said flanges, said sidewalls and said flaps comprise corrugated paperboard.
14. Support surfaces according to claim 13, wherein said fold lines dividing said side flanges into said overlying flange portions are defined by respective perforations of said side flanges.
15. Support surfaces according to claim 13, wherein said first and second support flanges are integrally formed with said first and second sidewalls respectively, said first and second support flanges being defined by perforated fold lines located between said first and second sidewalls and said first and second flanges respectively.
16. Support surfaces according to claim 13 wherein said faces of said overlying flange portions are adhered together by an adhesive positioned therebetween.
17. Support surfaces according to claim 13 wherein said containers are formed from a knockdown having first and second knockdown walls attached to one another at first and second knockdown corners to form a substantially flat assembly, said first knockdown wall including said first sidewall, said first support flange, one of said adjacent sidewalls attached to said first sidewall, and two of said side flanges attached to said one adjacent sidewall, all located in a substantially same first plane, said second knockdown wall including said second sidewall, said second support flange, another of said adjacent sidewalls attached to said second sidewall, and two of said side flanges attached to said other adjacent sidewall, all located in a substantially same second plane parallel to said first plane.
US10/357,736 2002-02-04 2003-02-04 Stackable container having support flanges Abandoned US20030146126A1 (en)

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US11312525B2 (en) * 2018-07-10 2022-04-26 Menasha Corporation Container with knockout-stackable gable with top tab
US11807428B2 (en) 2018-07-10 2023-11-07 Menasha Corporation Container with knockout-stackable gable with top tab

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