JP2024525092A - Method for forming a container having a top flange with glued corners, said container, and blank for forming said container - Google Patents

Abstract

A method of forming a container from a blank includes applying an adhesive to the interior surfaces of the side flange tabs of the blank, rotating the end panels of the blank inwardly toward the bottom panel, rotating the side panels of the blank inwardly toward the bottom panel, and rotating the side flange panels of the blank outwardly to a parallel orientation relative to the bottom panel. The method further includes, after the step of rotating the side flange panels, rotating the end flange panels to a parallel orientation relative to the bottom panel and connecting the end flange tabs to the side flange tabs to form a container having a fully formed top flange.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63/220,311, filed July 9, 2021, U.S. Provisional Patent Application No. 63/309,805, filed February 14, 2022, and U.S. Provisional Patent Application No. 63/320,428, filed March 16, 2022, all of which are entitled "METHOD OF FORMING CONTAINERS HAVING TOP FLANGE WITH GLUED CORNERS, SAME CONTAINERS, AND BLANKS FOR FORMING SAME," and each of which is incorporated by reference in its entirety herein.

The field of the disclosure relates generally to methods of forming containers, and more specifically to containers having a top flange whose corners are glued during formation of the container, and methods for forming the container.

Containers come in a variety of forms. Certain conventional containers (e.g., boxes, punnets, trays, etc.) typically have an enclosed bottom portion with four sides. Some containers include a top portion or lid to close the container, while other containers are open at the top. In some cases, the container is formed and later filled with product and then sealed with a film that is adhered across the top to close the container.

In some such cases, the containers are initially formed with an open top portion so that they can be filled later. Often, such containers are formed, stacked or nested on top of one another, and shipped to another location for filling and/or sealing. In some cases, the container includes a flange-like portion around its top edge to which a sealing film is ultimately adhered. In some known containers that contain these flange-like portions, the flange is not formed at the same time that the container is initially formed. Rather, the formed containers with planar (flange-less) sidewalls are stacked and shipped for filling. Once filled, the flanges of the containers are folded outward to form a sealing surface during the sealing process.

Other conventional containers may have a flange formed during the initial formation of the container, but the flange is formed by simply bending the flange into place; that is, the flange is not set or glued into place.

These known containers may be weak and may have various portions of the flanges that tend to release from one another. Furthermore, such containers may experience poor sealing because the flanges tend to release, or may require more robust seals, which may be complex, time consuming, and/or expensive to produce. Furthermore, when the containers are nested, they may stick together, which may create problems when the containers are to be separated for filling and/or sealing.

The containers can be separated by hand or by machine as part of an automated packing process. Regardless of the method used to fill the containers, difficulties can arise when the containers are nested too tightly. When the flanges between each container are placed directly on top of each other, it can be difficult to separate the flanges and pull the containers apart, either by machine or manually. If the flanges are spaced far enough apart, it is easier to reliably separate the containers.

In one aspect, a method of forming a container from a blank is provided. The blank includes a bottom panel, two opposing side panels, two opposing end panels, respective end flange panels extending from top edges of the respective end panels, and respective end flange tabs extending from respective side edges of the respective end flange panels. The blank further includes respective side flange panels extending from top edges of the respective side panels, and respective side flange tabs extending from respective end edges of the respective side flange panels. The method includes applying adhesive to an interior surface of the side flange tabs, rotating the end panels inwardly toward the bottom panel, rotating the side panels inwardly toward the bottom panel, and rotating the side flange panels outwardly to a parallel orientation relative to the bottom panel. The method further includes, after the step of rotating the side flange panels, rotating the end flange panels into a parallel orientation relative to the bottom panel and connecting the end flange tabs to the side flange tabs to form a container having a fully formed top flange.

In another aspect, a container is provided. The container includes a bottom panel, two opposing side panels connected to the bottom panel along respective first set fold lines, and two opposing end panels connected to the bottom panel along respective second set fold lines. The container further includes respective end flange panels extending from top edges of the respective end panels in a generally parallel orientation to the bottom panel, respective end flange tabs extending from respective side edges of the respective end flange panels, and respective side flange panels extending from top edges of the respective side panels in a generally parallel orientation to the bottom panel. The container further includes respective side flange tabs extending from respective end edges of the respective side flange panels, the side flange tabs being respectively connected to the respective end flange tabs to form a top flange of the container.

In yet another aspect, a method of stacking a first container on a second container is provided. The first container and the second container are each formed from respective blanks having substantially the same size and shape. The blanks each include a bottom panel, two opposing side panels, and two opposing end panels. The blanks further include respective end flange panels extending from a top edge of the respective end panels, respective end flange tabs extending from a respective side edge of the respective end flange panels, respective side flange panels extending from a top edge of the respective side panels, and respective side flange tabs extending from a respective end edge of the respective side flange panels. The method includes forming a first container by applying adhesive to the inner surface of the side flange tabs, rotating the end panel inwardly toward the bottom panel, rotating the side panel inwardly toward the bottom panel, rotating the side flange panel outwardly to a parallel orientation relative to the bottom panel, rotating the end flange panel to a parallel orientation relative to the bottom panel after the side flange panel rotating step, and connecting the end flange tabs to the side flange tabs to form a container having a fully formed top flange. The method further includes forming a second container and positioning the first container in a cavity of the second container such that a denesting assembly of one of the first container and the second container engages the other of the first container and the second container to space the top flange of the first container from the top flange of the second container.

In other aspects, containers formed using such methods, and blanks for forming such containers, are also provided.

FIG. 2 is a top view of an exemplary blank of sheet material for forming a container according to the present disclosure. 2 is a perspective view of an exemplary container formed from the blank shown in FIG. 1. FIG. 3 is a side perspective view of a stack of multiple containers shown in FIG. 2. FIG. 13 is a top view of another embodiment of a blank of sheet material for forming a container according to the present disclosure. FIG. 5 is a perspective view of an exemplary container formed from the blank shown in FIG. 4. FIG. 13 is a top view of another embodiment of a blank of sheet material for forming a container according to the present disclosure. FIG. 13 is a top view of another embodiment of a blank of sheet material for forming a container according to the present disclosure. FIG. 8 is a perspective view of an exemplary container formed from the blank shown in FIG. 7. 1 is a flow diagram of a method of forming a container from a blank according to the present disclosure. FIG. 1 is a top view of an exemplary blank of sheet material for forming a container with a de-nesting assembly according to the present disclosure. FIG. 10B is an enlarged view of area B of the blank sheet of material shown in FIG. 10A illustrating one of the de-nesting assemblies of the blank. FIG. 10B is a perspective view of an exemplary container formed from the blank shown in FIG. 10A. FIG. 12 is another perspective view of the container shown in FIG. FIG. 12 is another perspective view of the container shown in FIG. FIG. 14 is a perspective view of a stack of multiple containers shown in FIGS. 11-13. FIG. 13 is a top view of another embodiment of a blank of sheet material for forming a container according to the present disclosure. FIG. 16 is a perspective view of an exemplary container formed from the blank shown in FIG. FIG. 17 is a side perspective view of a stack of multiple containers shown in FIG. 16. FIG. 13 is a top view of another embodiment of a blank of sheet material for forming a container according to the present disclosure. FIG. 19 is a perspective view of an exemplary container formed from the blank shown in FIG. 18. FIG. 20 is a side perspective view of a stack of multiple containers shown in FIG. 19.

The following detailed description illustrates the present disclosure by way of example and not by way of limitation. This specification clearly enables one of ordinary skill in the art to make and use the present disclosure, describing several embodiments, adaptations, variations, and alternatives, and to utilize the present disclosure, including what is currently believed to be the best mode of carrying out the disclosure.

Embodiments of the present disclosure provide stackable containers that include a top flange. The containers are constructed from blanks of sheet material using a machine and/or by hand. For example, the blanks can be folded around a mandrel to form the containers, or the containers can be formed by hand and/or by another style tray forming machine. Alternatively, a folding/gluing machine can be used to form the containers. In one embodiment, the containers are constructed from paperboard material. However, the containers can be constructed using any suitable material and are therefore not limited to a particular type of material. In alternative embodiments, the containers are constructed using cardboard, plastic, fiberboard, foam board, corrugated paper, and/or any suitable material known to those skilled in the art and guided by the teachings provided herein.

In an exemplary embodiment, the container includes at least one marking thereon, including, but not limited to, indicia that communicate the product, the manufacturer of the product, and/or the distributor of the product. For example, the marking can include printed text that identifies the product and briefly describes the product, a logo and/or trademark that identifies the manufacturer and/or distributor of the product, and/or an attention-grabbing design and/or decoration. Any other forms of "printing," "printed," and/or "printing" as used herein can include, but are not limited to, inkjet printing, laser printing, screen printing, giclee, pen and ink, painting, offset lithography, flexography, relief printing, rotogravure printing, dye transfer, and/or any suitable printing technique known to those skilled in the art and guided by the teachings provided herein. In another embodiment, the container is devoid of markings (such as, but not limited to, indicia that communicate the product, the manufacturer of the product, and/or the distributor of the product).

In some embodiments, the interior and/or exterior surfaces of the blank and the resulting container are coated or sealed. Such coating or sealing can make the container water or bacteria resistant. In other embodiments, the seal or coating can help preserve the freshness of a product (e.g., a produce product) held within the container. In any embodiment, such coating or sealing can be applied to any section of any surface of the container.

In some embodiments, the containers can include a means for de-nesting the containers when they are in a stacked configuration. In some embodiments, the de-nesting assembly is located at a bottom corner. The de-nesting assembly can include a de-nesting tab that prevents the containers from sticking together in the stacked configuration when folded inwardly and provides a gap between the flanges of the stacked containers. In another embodiment, the de-nesting tab can be located at a top corner of the container along the lower surface of the container flanges. When the containers are stacked, the lower edge of the de-nesting tab of one container rests on the flange of the container below, thus providing a space between the flanges. This space allows the flanges to be more easily grasped by a human or machine and aids in separation of the containers.

Referring now to the drawings, and more particularly to FIG. 1, a top view of an exemplary embodiment of a blank 100 of sheet material is depicted. A container 200 (see FIG. 2) is formed from the blank 100. The blank 100 has a first or interior surface 101 and an opposing second or exterior surface 103. Additionally, the blank 100 defines a leading edge 102 and an opposing trailing edge 104. In one embodiment, the blank 100 includes, in series from the leading edge 102 to the trailing edge 104, a first end panel 106, a bottom panel 108, and a second end panel 110, which are joined together along preformed, generally parallel fold lines 112 and 114, respectively.

More specifically, the first end panel 106 extends from the front edge 102 to a fold line 112, the bottom panel 108 extends from the fold line 112 to a fold line 114, and the second end panel 110 extends from the fold line 114 to the rear edge 104. As further described herein, when the container 200 is formed from the blank 100, the fold line 112 defines a bottom edge of the first end panel 106 and a first end edge of the bottom panel 108, and the fold line 114 defines a second end edge of the bottom panel 108 and a bottom edge of the second end panel 110.

The first side panel 116 extends from a fold line at a first side edge 118 of the bottom panel 108 to a fold line 120, and the opposing second side panel 122 extends from a fold line at a second side edge 124 of the bottom panel 108 to a fold line 126. As further described herein, when the container 200 is formed from the blank 100, the fold line at the first side edge 118 defines the bottom edge of the first side panel 116 and the first side edge of the bottom panel 108, and the fold line at the second side edge 124 defines the second side edge of the bottom panel 108 and the bottom edge of the second side panel 122.

In an exemplary embodiment, the first end panel 106, the second end panel 110, the first side panel 116, and the second side panel 122 include a plurality of cutouts 128 defined therein. In an exemplary embodiment, the cutouts 128 are leaf-shaped, with each of the first end panel 106, the second end panel 110, the first side panel 116, and the second side panel 122 having six cutouts. Alternatively, the blank 100 can include any suitable number of cutouts 128 in any suitable shape and/or in any suitable location that enables the blank 100 and/or the container 200 to function as described herein. In still other embodiments, one or more of the panels 106, 110, 116, and 122 of the blank 100 may not have a cutout 128.

The first end panel 106 has a height _H1 , the second end panel 110 has a height _H2 , the first side panel 116 has a height _H3 , and the second side panel 122 has a height _H4 . In an exemplary embodiment, the height _H1 of the first end panel 106, the height _H2 of the second end panel 110, the height _H3 of the first side panel 116, and the height _H4 of the second side panel 122 are substantially the same. Additionally, the bottom panel 108 has a length _L1 and a width _W1 . In an exemplary embodiment, the length _L1 is greater than the width _W1 such that the bottom panel 108 is rectangular. In alternative embodiments, the width _W1 is substantially equal to or greater than _the length _L1 .

In the exemplary embodiment, the side edges 170 of the end panels 106, 110 and the end edges 172 of the side panels 116, 122 are generally linear and extend at respective angles relative to the bottom panel 108. In other words, in the exemplary embodiment, the side edges 170 of the end panels 106, 110 are not parallel to the side edges 118, 124 of the bottom panel 108, and the end edges 172 of the side panels 116, 122 are not parallel to the end edges (at the fold lines 112 and 114) of the bottom panel 108.

Thus, the first end panel 106, the second end panel 110, the first side panel 116, and the second side panel 122 each have a generally trapezoidal shape, with the panels 106, 110, 116, 122 tapering outward as they extend away from the bottom panel 108. That is, the width (not shown specifically) of each of the end panels 106, 110 adjacent the bottom panel 108 is less than the width (not shown specifically) of each of the end panels 106, 110 opposite the bottom panel 108. Similarly, the length (not shown specifically) of each of the side panels 116, 122 adjacent the bottom panel 108 is less than the length (not shown specifically) of each of the side panels 116, 122 opposite the bottom panel 108.

Alternatively, the first end panel 106, the second end panel 110, the first side panel 116, the second side panel 122, and/or the bottom panel 108 can have any suitable shape and/or any suitable dimensions that enable the blank 100 and/or the container 200 to function as described herein.

An interior side panel 130 (also referred to as a glue panel) extends from each side edge of each end panel 106, 110 at a respective fold line 132. As such, the blank 100 includes four interior side panels 130. Each interior side panel 130 has a respective free edge 178 opposite the respective fold line 132 from which the interior side panel 130 extends. In an exemplary embodiment, the free edge 178 includes multiple linear portions (e.g., four adjacent linear portions, etc.). In alternative embodiments, the free edge 178 can be partially or completely arcuate, or can have any suitable shape that enables the blank 100 and/or container 200 to function as described herein.

Additionally, a first end flange panel 134 extends from the first end panel 106, and a second end flange panel 138 extends from the second end panel 110. More specifically, the first end flange panel 134 extends from the leading edge 102 to a fold line 136 at the top edge of the first end panel 106, and the second end flange panel 138 extends from a fold line 140 at the top edge of the second end panel 110 to the trailing edge 104.

The first and second end flange panels 134, 138 each include a first end flange tab 142 and a second end flange tab 144. The first end flange tab 142 extends from a respective fold line 166 at a respective side edge of the first end flange panel 134, and the second end flange tab 144 extends from a respective fold line 168 at a respective side edge of the second end flange panel 138. In an exemplary embodiment, each of the first and second end flange tabs 142, 144 has a generally arcuate free outer edge 146 and a generally linear free inner edge 148. As described further herein with respect to the container 200, the shape of the free outer edge 146 generally defines the shape of the corner 218 (see FIG. 2) of the formed top flange 214 of the container 200 when the container 200 is formed from the blank 100. Thus, in various alternative embodiments, the first end flange tab 142 and the second end flange tab 144 can have any suitable shape that enables the blank 100 and/or the container 200 to function as described herein.

The first side flange panel 150 extends from the first side panel 116, and the second side flange panel 152 extends from the second side panel 122. More specifically, the first side flange panel 150 extends from the fold line 120 to a free edge 154 (also referred to as the first side edge of the blank 100), and the second side flange panel 152 extends from the fold line 126 to a free edge 156 (also referred to as the second side edge of the blank 100).

The first and second side flange panels 150, 152 include a first and second side flange tab 158, 160, respectively. The first and second side flange tabs 158, 160 extend from an end edge of the first and second side flange panels 150, 152, respectively. In an exemplary embodiment, the first and second side flange tabs 158, 160 each have a generally arcuate free outer edge 162 and a generally linear free inner edge 164, respectively. As described further herein with respect to the container 200, the shape of the free outer edge 162 generally defines the shape of the corner 218 (see FIG. 2) of the formed top flange 214 of the container 200 when the container 200 is formed from the blank 100. Thus, in various alternative embodiments, the first side flange tab 158 and the second side flange tab 160 can have any suitable shape that enables the blank 100 and/or container 200 to function as described herein.

Also, in the exemplary embodiment, the first end flange tab 142 and the second end flange tab 144 each include a respective notch 184 defined between its inner edge 148 and the side edge of the respective end flange panel 134/138 from which the end flange tab 142/144 extends. Similarly, the first side flange tab 158 and the second side flange tab 160 each include a respective notch 186 defined between its inner edge 164 and the end edge of the respective side flange panel 150/152 from which the side flange tab 158/160 extends. These notches 184, 186 improve the formation of the container 200 formed from the blank 100 by reducing interference between adjacent end flange tabs 142/144 and side flange tabs 158/160 when the blank 100 is folded into the container 200, as described further herein. Additionally, the notches 184, 186 can facilitate folding and/or joining or mating of the respective flange panels and/or flange tabs.

In an exemplary embodiment, the side flange tabs 158, 160 are "deeper" or extend further inward toward the bottom panel 108 than the end flange tabs 142, 144. That is, the side flange tabs 158, 160 may have more extension horizontally (with respect to the view of FIG. 1) than the end flange tabs 142, 144 extend vertically (with respect to the view of FIG. 1).

In an exemplary embodiment, the fold lines 166, 168 adjacent the end flange tabs 142, 144 are generally aligned with the side edges 170 of the end panels 106, 110. That is, each end flange tab 142, 144 can be folded diagonally relative to the end flange panel 134/138 from which each end flange tab 142, 144 extends. Additionally, the fold lines 180, 182 adjacent the side flange tabs 158, 160 are generally perpendicular to the fold lines 120, 126. That is, each side flange tab 158, 160 can be folded substantially perpendicular to the side flange panel 150/152 from which each side flange tab 158, 160 extends. In other embodiments, the respective fold lines 166, 168, 180, 182 of the respective flange tabs 142, 144, 158, 160 can have any orientation that enables the blank 100 and/or container 200 to function as described herein.

In some embodiments, portions of the flange tabs 142, 144, 158, 160 have a reduced thickness such that when the container 200 is formed from the blank 100, the corners 218 (see FIG. 2) of the flange 214 formed from the joined flange tabs have improved de-nesting characteristics. The thickness of the flange tabs 142, 144, 158, 160 can be reduced by scoring, compressing, crushing, etc., of one or more portions of the flange tabs 142, 144, 158, 160.

2 is a perspective view of an exemplary container 200 formed from blank 100 (shown in FIG. 1). Container 200 includes a bottom wall 202, first and second opposing end walls 204, 206, and first and second opposing side walls 208, 210. Generally, the bottom wall 202 comprises the bottom panel 108 of the blank 100, the first end wall 204 comprises the first end panel 106, the second end wall 206 comprises the second end panel 110, the first side wall 208 comprises the first side panel 116 and two interior side panels 130 (one extending from each of the first and second end panels 106, 110), and the second end wall 210 comprises the second side panel 122 and two interior side panels 130 (one extending from each of the first and second end panels 106, 110). The end walls 204, 206, the side walls 208, 210, and the bottom wall 202 define a cavity 212 of the container 200 for receiving and holding a product (not shown) therein.

In an exemplary embodiment, due to the trapezoidal shape of the panels 106, 110, 116, and 122, the first and second end walls 204, 206 and the first and second side walls 208, 210 extend at an angle away from the bottom wall 202. Specifically, in one embodiment, each end wall 204, 206 and each side wall 208, 210 each form an internal angle with the bottom wall 202 that is greater than about 90 degrees. That is, in an exemplary embodiment, the walls 204, 206, 208, 210 of the formed container 200 are generally angled outwardly (i.e., away from) the bottom wall 202 of the container 200. Thus, the resulting container 200 is generally of a trapezoidal prism or truncated pyramid shape. However, in alternative embodiments, the end walls 204, 206 and side walls 208, 210 can form any angle with the bottom wall 202 that enables the blank 100 and/or container 200 to function as described herein.

The container 200 also includes a flange 214 extending from the top of each of the first and second end walls 204, 206 and the first and second side walls 208, 210. In the exemplary embodiment, the flange 214 extends outwardly (or away from the cavity 212) and is bounded by a free edge 216, which includes both straight and arcuate segments, and specifically, the corners 218 of the flange 214 are generally arcuate. In the exemplary embodiment, the flange 214 is oriented parallel to the bottom wall 202. Due to the orientation of the walls of the container 200, the flange 214 is oriented obliquely relative to the first and second end walls 204, 206 and the first and second side walls 208, 210. Alternatively, the flange 214 can extend in any direction and can have any suitable shape that enables the blank 100 and/or container 200 to function as described herein.

The container 200 is formed by folding the various panels and tabs of the blank 100 along respective fold lines. Specifically, each interior side panel 130 is rotated about fold line 132 toward the interior surface 101 of the respective end panel 106, 110 such that each interior side panel 130 is substantially perpendicular to the respective end panel 106, 110. The first end panel 106 and the second end panel 110 are rotated about fold lines 112 and 114, respectively, toward the interior surface 101 of the bottom panel 108 to form the first and second end walls 204, 206, respectively. In one embodiment, the first and second end panels 106, 110 are rotated to form an angle greater than 90 degrees with respect to the bottom panel 108. However, in alternative embodiments, the first and second end panels 106, 110 can form any angle with the bottom panel 108 that enables the blank 100 and/or container 200 to function as described herein.

The first side panel 116 is rotated about the fold line 118 toward the inner surface 101 of the bottom panel 108 and into a facing relationship with the outer surfaces 103 of the two inner side panels 130. Similarly, the second side panel 122 is rotated about the fold line 124 toward the inner surface 101 of the bottom panel 108 and into a facing relationship with the outer surfaces 103 of the other two inner side panels 130. In one embodiment, the first and second side panels 116, 122 are rotated to form an angle greater than 90 degrees with the bottom panel 108. However, in alternative embodiments, the first and second side panels 116, 122 can be rotated to form any angle with the bottom panel 108 that enables the blank 100 and/or container 200 to function as described herein.

In an exemplary embodiment, an adhesive (particularly a hot melt adhesive) is applied to the end portions of the interior surfaces 101 of the first side panel 116 and the second side panel 122. Thus, when the panels 116, 122 are rotated into face-to-face contact with the interior side panel 130, the end portions of the interior surfaces 101 of the panels 116, 122 are coupled and bonded to the exterior surface 103 of the interior side panel 130, respectively. End walls 204, 206 and side walls 208, 210 are thereby formed.

In alternative embodiments, adhesive can be applied to the interior surface 101 of the interior side panel 130. In such cases, the side panels 116, 122 can be rotated into position first, and the end panels 106, 110 can be rotated thereafter, such that the interior side panel 130 is coupled and adhered to the exterior surface 103 of the side panels 116, 122. In further alternative embodiments, the interior side panels can instead extend from the side panels 116, 122, and in such cases, adhesive can be applied and the panels 106, 110, 116, 122 can be rotated in any suitable order to form the container 200.

In addition, substantially simultaneously with the formation of the walls of the container 200 (e.g., during the same forming step), the side flange panels 150, 152 are rotated outward (e.g., away from the bottom wall 202) about the fold lines 120, 126, respectively, until the side flange panels 150, 152 are parallel to the bottom wall 202. The side flange tabs 158, 160 are moved along with the side flange panels 150, 152. That is, the rotation of the side flange panels 150, 152 results in the simultaneous rotation of the side flange tabs 158, 160 to a parallel orientation relative to the bottom wall 202.

In one exemplary embodiment, the walls of the container 200 are formed substantially simultaneously with the rotation of the side flange panels 150, 152. However, the rotation of the side flange panels 150, 152 can occur prior to or during the folding of the end panels 106, 110 to form the side walls 204, 206. In particular, the side flange panels 150, 152 are folded such that the end flange tabs 142, 144 and the side flange tabs 158, 160 do not interfere at the corners of the partially formed container. Even more specifically, because the end flange tabs 142, 144 are "shorter" or "shallower" than the side flange tabs 158, 160 (e.g., their interior edges extend less than the interior edges of the side flange tabs 158, 160), the interior edges of the end flange tabs 142, 144 do not "catch" the folded side flange tabs 158, 160 when the end panels 106, 110 are folded inwardly to form the side walls 204, 206.

In a separate step (e.g., after a predetermined amount of time has elapsed, which may be from a few milliseconds to a few seconds), the end flange panels 134, 138 are rotated outward (e.g., away from the bottom wall 202) about the fold lines 136, 140, respectively, until the end flange panels 134, 138 are parallel to the bottom wall 202. The end flange tabs 142, 144 are moved along with the end flange panels 134, 138. That is, the rotation of the end flange panels 134, 138 results in the simultaneous rotation of the end flange tabs 142, 144 to a parallel orientation relative to the bottom wall 202. Moreover, this rotation of the end flange panels 134, 138 couples the outer surfaces 103 of the end flange tabs 142, 144 in a face-to-face relationship to the inner surfaces 101 of the side flange tabs 158, 160 (which are already in their final positions since they have been previously rotated).

In particular, in an exemplary embodiment, an adhesive (e.g., a hot melt adhesive, etc.) is applied to the inner surfaces 101 of the side flange tabs 158, 160 prior to formation of the container 200 (e.g., simultaneously with application of the adhesive to the side panels 116, 122). Thus, when the end flange panels 134, 138 are rotated following rotation of the side flange panels 150, 152, the outer surfaces 103 of the end flange tabs 142, 144 are coupled and adhered to the inner surfaces 101 of the side flange tabs 158, 160.

Thereafter, the end flange panels 134, 138, the side flange panels 150, 152, the end flange tabs 142, 144, and the side flange tabs 158, 160 are appropriately oriented and secured to form the flange 214. A flange corner 218 is formed at the overlap of the corresponding end flange tabs 142, 144 and side flange tabs 158, 160. In an exemplary embodiment, the flange 214 (also referred to as the "top flange") is substantially flat or planar and is stronger than a conventional flange that is not glued (or is not glued until the container is sealed). In at least some cases, when the end flange tabs 142, 144 and/or the side flange tabs 158, 160 feature a reduced thickness, the overall flange 214 can be even more desirably planar, which can improve the sealing characteristics and/or rigidity of the container 200.

Once formed, the containers 200 are nested or stacked (see stack 300 of containers 200 shown in FIG. 3) for storage and/or transport. In some cases, these containers 200 are ultimately used to hold various objects. In some embodiments, the stack 300 of containers 200 is delivered to a filling location where individual containers 200 are removed from the stack 300. As described herein, the flange corners 218 of the containers 200 (including end flange tabs 142, 144 and/or side flange tabs 158, 160 that are embossed and/or feature reduced thickness) can improve the de-nesting characteristics of the containers 200.

The open, empty, de-nested container 200 is then filled with product (e.g., produce). A film 220 is placed across the top of the container 200 and sealed to the flange 214 to form a seal. The film 220 can be coupled and adhered to the flange 214 using any suitable method or material (e.g., adhesive, heat sealing, etc.).

As described elsewhere herein, the flange 214 of the container 200 provides a structural advantage over the flanges of similar containers. That is, applying adhesive to the side flange tabs 158, 160 to connect the end flange tabs 142, 144 to the side flange tabs 158, 160 during the initial formation of the container 200 improves both the structural integrity and sealing capabilities of the container 200. Although conventional containers may have top flanges, as described above, such conventional containers are not formed in the same manner as the container 200 (i.e., do not include a formed flange or do not have adhesive applied to join the flange tabs during initial container formation), and thus the container 200 provides an improvement over known conventional containers.

Applying adhesive when connecting the end flange tabs 142, 144 to the side flange tabs 158, 160 reinforces and strengthens the corners 218 of the flanges 214, thus improving the structural rigidity of the container 200. For example, the container 200 may hold a greater weight of product and/or more effectively prevent liquid leakage. Such improvements may also reduce the risk of structural failure of the container 200 when filled and sealed. Additionally, such reinforcement promotes improved sealing of the container 200. Moreover, the flanges 214 may be substantially flatter than flanges of conventional containers. Such flanges 214 may allow for easier, faster, simpler, and/or more cost-effective (e.g., using less sealing material) application of sealing films to the sealed container 200. These improvements allow the container 200 to function more effectively than other conventional containers.

Figure 4 is a top view of an alternative blank 400 of sheet material for forming a container 500 (see Figure 5). Blank 400 is substantially similar to blank 100 (shown in Figure 1), except as described below. As such, components common to blank 100 and blank 400 are labeled with the same reference numerals.

In one embodiment, the blank 400 includes cutouts 402 extending from the fold lines 112, 114, 118, 120, 124, 126, 136, 140 into each of the first end panel 106, second end panel 110, first side panel 116, and second side panel 122. In this embodiment, the cutouts 402 have a generally rectangular shape adjacent the fold lines 112, 114, 118, 120, 124, 126, 136, 140 and a generally semicircular shape at the opposing ends. In an exemplary embodiment, each end panel 106, 110 contains four cutouts 402 and each side panel contains five cutouts 402. In alternative embodiments, the blank 400 can include any suitable number of cutouts 402 in any suitable location having any suitable shape that enables the blank 400 and/or the container 500 to function as described herein.

In one embodiment, the blank 400 also includes an interior side panel 430 having a different overall shape than the interior side panel 130 of the blank 100. The interior side panel 430 of the blank 400 has a free edge 178 opposite the fold line 132, the free edge 178 including a plurality of linear and curved portions. Notably, each free edge 178 includes a curved notch 404 such that the interior side edge 430 does not cover or otherwise interfere with the cutouts 402 in the side panels 116, 122 when the container 500 is formed from the blank. That is, the curved notch 404 in the interior side panel 430 keeps the interior side panel 430 from overlapping the cutouts 402 in the side panels 116, 122. In alternative embodiments, one or more of the free edges 178 can have any suitable shape that enables the blank 400 and/or container 500 to function as described herein.

Additionally, the bottom panel 108 of the blank 400 is smaller and more square than the bottom panel 108 of the blank 100. In an exemplary embodiment, like the blank 100, the blank 400 includes end flange tabs 142, 144 and side flange tabs 158, 160. However, in the blank 400, the fold lines 166, 168, 180, 182 that define the flange tabs are angled so that the respective flange tabs 142, 144, 158, 160 can be folded perpendicular to the respective flange panels 134, 138, 150, 152. In other embodiments, the fold lines 166, 168, 180, 182 can have any orientation that enables the blank 400 and/or the container 500 to function as described herein.

FIG. 5 is a perspective view of an exemplary container 500 formed from blank 400 (shown in FIG. 4). Container 500 is substantially similar to container 200 (shown in FIG. 2) and is formed from blank 400 using a method similar to forming container 200 from blank 100. Container 500 can have different dimensions than container 200.

Figure 6 is a top view of an alternative blank 600 of sheet material for forming a container. Blank 600 is substantially similar to blank 100 (shown in Figure 1) except as described below. As such, components common to blank 100 and blank 600 are labeled with the same reference numerals.

In one embodiment, the blank 600 includes cutouts 602 extending along the fold lines 112, 114, 118, 124, 120, 126, 136, and 140. Additionally, the fold line 604 between the side panels 116, 122 and the interior end panel 606 (described further herein) also has a cutout 602 extending therethrough. In an exemplary embodiment, the cutouts 602 have a general "stadium" shape. In alternative embodiments, the blank 600 can include any suitable number of cutouts 602 having any suitable shape that enables the blank 600 and/or any container formed therefrom to function as described herein.

In one embodiment, the blank 600 also includes an interior end panel 606 that extends from the end edges of the first side panel 116 and the second side panel 122 along a fold line 604, rather than from the interior side panel 130 as in the blank 100. As such, in the exemplary embodiment, the blank 600 includes four interior end panels 606. In the exemplary embodiment, the interior end panels 606 have a different overall shape than the interior side panels 130 of the blank 100. In the exemplary embodiment, the interior end panels 606 have a free edge 608 opposite the fold line 604, the free edge 608 including a plurality of linear and/or curved portions. In alternative embodiments, one or more of the free edges 608 can have any suitable shape that enables the blank 600 and/or any container formed therefrom to function as described herein.

In the exemplary embodiment, each end panel 106, 110 has a notch 610 formed in a side edge thereof. In the exemplary embodiment, when the container 700 is formed from the blank 600, the notch 610 accommodates the cutout 602 in the interior end panel 606 of the blank 600. That is, when formed, the notch 610 prevents the end panels 106, 110 from overlapping the cutout 602 in the interior end panel 606.

Additionally, the blank 600 includes notches 612 formed in the side panels 116, 122 between the bottom edge of the inner end panel 606 and the fold line 118/124. The notches 612 can facilitate folding and/or joining or mating of the respective flange panels and/or flange tabs.

In this exemplary embodiment, the end flange tabs 142, 144 and the side flange tabs 158, 160 of the blank 600 do not include notches 182/184 and are of a different general shape than the flange tabs in the blank 100. In the blank 600, each flange tab 142, 144, 158, 160 has a respective free edge 146, each free edge 146 including a curved portion and a straight portion. Additionally, the fold lines 166, 168, 180, 182 that define each flange tab 142, 144, 158, 160 are angled such that each flange tab 142, 144, 158, 160 may be folded at an angle relative to its respective flange panel 134, 138, 150, 152.

A container formed from blank 600 is formed in a manner similar to container 200, with inner end panel 606 of blank 600 folded in a manner similar to inner side panel 130 of blank 100, but connected to end panels 106, 110 instead of side panels 116, 122.

Figure 7 is a top view of an alternative blank 800 of sheet material for forming a container.

In the exemplary embodiment, similar to blank 100, blank 800 includes a first end panel 802, a second end panel 804, a first side panel 806, a second side panel 808, and a bottom panel 810. First end panel 802, second end panel 804, first side panel 806, and second side panel 808 each have a generally trapezoidal shape, and bottom panel 810 has a generally rectangular shape with chamfered corners. Thus, in the exemplary embodiment, bottom panel 810 has eight edges. Also, like blank 100, blank 800 includes a first end flange panel 812, a second end flange panel 814, a first side flange panel 816, and a second side flange panel 818, as well as a first end flange tab 820, a second end flange tab 822, a first side flange tab 824, and a second side flange tab 826.

In an exemplary embodiment, the flange tabs 820, 822, 824, 826 of the blank 800 have a different size and overall shape than the flange tabs of the blank 100. Notably, the flange tabs 820, 822, 824, 826 each have a respective free end edge 828 that includes a plurality of straight and/or curved lines. In an exemplary embodiment, the flange tabs 820, 822, 824, 826 also each include a respective notch 830 positioned on its respective inner edge 832. The flange tabs 820, 822, 824, 826 can have any suitable shape that enables the blank 800 and/or the container 900 to function as described herein.

Also, in the exemplary embodiment, the blank 800 includes corner panels 834 extending from fold lines 836 at the chamfered or angled corners of the bottom panel 810. An interior corner panel 838 (also referred to as a glue panel) extends from each side edge of each corner panel 834. As such, in the exemplary embodiment, the blank 800 includes eight interior corner panels 838. Each interior corner panel 838 extends from a side edge of each corner panel 834 at a fold line 840 (for clarity, only one fold line 840 is labeled in FIG. 7).

Additionally, the corner panels 834 of the blank 800 each include a corner flange panel 842. Each corner flange panel 842 extends from a respective fold line 844 to a free edge 845 at the top of each corner panel 834. A corner flange tab 846 extends from a respective end edge of each corner flange panel 842. In the exemplary embodiment, the corner flange tabs 846 are each bounded by a fold line 848 as well as a free edge 849. In the exemplary embodiment, the corner flange tabs 846 also include a notch 850 defined in an inner edge thereof. The fold line 848 bounding each corner flange tab 846 is angled such that each corner flange tab 846 may be folded diagonally relative to its respective corner flange panel 842. In other embodiments, the fold lines 848 can have any orientation that enables the blank 800 and/or container 900 to function as described herein.

In the exemplary embodiment, similar to the blank 100, the first end panel 802, the second end panel 804, the first side panel 806, and the second side panel 808 include a plurality of cutouts 852 defined therein. Specifically, the first and second end panels 806, 808 include three cutouts 852 positioned near the fold lines 854, 856, respectively, and the first and second side panels 806, 808 include four cutouts 852 positioned near the fold lines 858, 860, respectively. Alternatively, the blank 800 can include any suitable number of cutouts 852 of any suitable shape and/or in any suitable location that enables the blank 800 and/or the container 900 to function as described herein.

In some embodiments, portions of the flange tabs 820, 822, 824, 826, 846 have a reduced thickness such that when the container 900 is formed from the blank 800, the corners 918 (see FIG. 8) of the flange 914 formed from the joined flange tabs have improved de-nesting characteristics. The thickness of the flange tabs 820, 822, 824, 826, 846 can be reduced by scoring, compressing, crushing, and the like, of one or more portions of the flange tabs.

8 is a perspective view of an exemplary octagonal container 900 formed from blank 800 (shown in FIG. 7). Container 900 includes a bottom wall 902, first and second opposing end walls 904, 906, first and second opposing side walls 908, 910, and four angled corner walls 920. Generally, the bottom wall 902 comprises the bottom panel 810 of the blank 800, the first end wall 904 comprises the first end panel 802 and two interior corner panels 838, the second end wall 906 comprises the second end panel 804 and two interior corner panels 838, the first side wall 908 comprises the first side panel 806 and two interior corner panels 838, the second end wall 910 comprises the second side panel 808 and two interior corner panels 838, and each corner wall 920 comprises one of the corner panels 834. The end walls 904, 906, the side walls 908, 910, the corner walls 920, and the bottom wall 902 define a cavity 912 of the container 900 for receiving and holding a product (not shown) therein. Like container 200, the walls of container 900 are oriented at an angle greater than 90 degrees relative to bottom wall 902. In an exemplary embodiment, bottom wall 902 of container 900 has a generally rectangular shape with straight chamfered corners. Thus, bottom wall 902 of container includes eight sides. Alternatively, container 900 can have any suitable shape and/or dimensions that enable blank 800 and/or container 900 to function as described herein.

The container 900 also includes a flange 914 extending from the top of the walls 904, 906, 908, 910, 920. In an exemplary embodiment, the flange 914 extends outwardly (or away from the cavity 912) and is bounded by a free edge 916, which includes both straight and arcuate segments, and specifically, the corner 918 of the flange 914 formed by the corner flange panel 842 is generally arcuate. In an exemplary embodiment, the flange 914 is oriented parallel to the bottom wall 902. Due to the orientation of the walls of the container 900, the flange 914 is oriented at an angle to the walls 904, 906, 908, 910, 920. Alternatively, the flange 914 can extend in any direction and have any suitable shape that enables the container 900 to function as described herein.

The container 900 is formed by folding the various panels and tabs of the blank 800 along their respective fold lines. Specifically, the corner panel 834 is rotated inward (towards the bottom panel 810) about fold line 836, and the interior corner panel 838 is rotated inward (towards its respective corner panel 834) about fold line 840. The first side panel 806 is rotated toward the interior surface of the bottom panel 810 about fold line 858, and the second side panel 808 is rotated toward the interior surface of the bottom panel 810 about fold line 860. Each of the first side panel 806 and the second side panel 808 is coupled to the two respective interior corner panels 834 using an adhesive (e.g., a hot melt adhesive, etc.) to form the side walls 908, 910. The first end panel 802 is rotated toward the interior surface of the bottom panel 810 about fold line 854, and the second end panel 804 is rotated toward the interior surface of the bottom panel 810 about fold line 856. Each of the first end panel 802 and the second end panel 804 is coupled to two respective interior corner panels 838 using an adhesive (e.g., a hot melt adhesive, etc.) to form end walls 904, 906. The first side panel 806, the second side panel 808, the first end panel 802, and the second end panel 804 can be rotated about fold lines 858, 860, 854, 856, respectively, and attached to the interior corner panels 838 in any order that enables the blank 800 and/or the container 900 to function as described herein.

Additionally, substantially simultaneously with the formation of the walls of the container 900 (e.g., during the same formation step), the end flange panels 812, 814 and the side flange panels 816, 818 are rotated outwardly (e.g., away from the bottom wall 902) until the flange panels 812, 814, 816, 818 are parallel to the bottom wall 902. This rotation of the flange panels 812, 814, 816, 818 results in the simultaneous rotation of the flange tabs 820, 822, 824, 826 to a parallel orientation relative to the bottom wall 202.

In a separate step (e.g., after a predetermined amount of time has elapsed, which may be from a few milliseconds to a few seconds), the corner flange panel 842 is rotated outwardly about the fold line 844 until the corner flange panel 842 is substantially parallel to the bottom panel 810. The rotation of the corner flange panel 842 results in a simultaneous rotation of the corner flange tab 846 to a parallel orientation relative to the bottom wall 202. Moreover, this rotation of the corner flange panel 842 couples the corner flange tab 846 in an overlapping relationship with the end and side flange tabs 820, 822, 824, 826 (which are already in their final positions because they have been previously rotated).

In particular, in an exemplary embodiment, an adhesive (e.g., a hot melt adhesive, etc.) is applied to the interior surfaces of the end and side flange tabs 820, 822, 824, 826 prior to formation of the container 900. Thus, when the end and side flange panels 812, 814, 816, 818 are rotated followed by the corner flange panel 842, the exterior surfaces of the corner flange tabs 846 are coupled and adhered to the interior surfaces of the corresponding end and side flange tabs 820, 822, 824, 826.

When formed using the methods described herein, container 900 includes the same advantages as container 200. Specifically, flange 914 (also referred to as the "top flange") is substantially flat or planar and is more sturdy as compared to conventional flanges that are not glued (or are not glued until the container is sealed). In at least some cases, if any flange tabs 820, 822, 824, 826 and/or 846 are characterized by a reduced thickness, the overall flange 914 can be even more desirably planar, which can improve the sealing characteristics and/or rigidity of container 900.

Once formed, the containers 900 are nested or stacked for storage and/or transport. In some cases, these containers 900 are ultimately used to hold various objects. In some embodiments, a stack of containers 900 is delivered to a filling location where individual containers 900 are removed from the stack. As described herein, flange corners 918 of the containers 900 (including flange tabs 820, 822, 824, 826, and/or 846 that are embossed and/or feature reduced thickness) can improve the de-nesting characteristics of the containers 900.

The open, empty, de-nested container 900 is then filled with product (e.g., produce). A film (not shown) is placed across the top of the container 900 and sealed to the flange 914 to form a seal. The film can be connected and adhered to the flange 914 using any suitable method or material (e.g., adhesive, heat sealing, etc.). As described elsewhere herein, the flange 914 of the container 900 provides a structural advantage over the flanges of similar conventional containers. That is, applying an adhesive to the end and side flange tabs 820, 822, 824, 826 to connect the corner flange tabs 846 to the end and side flange tabs 820, 822, 824, 826 during the initial formation of the container 900 improves both the structural integrity and the sealing capabilities of the container 900. Conventional containers may have an upper flange, but as explained above, such conventional containers are not formed in the same manner as container 900 (i.e., do not include a formed flange or do not have adhesive applied to join the flange tabs during initial container formation), and thus container 900 provides an improvement over known conventional containers.

Applying adhesive when connecting the end and side flange tabs 820, 822, 824, 826 to the corner flange tabs 846 reinforces and strengthens the corners 918 of the flanges 914, thus improving the structural rigidity of the container 900. For example, the container 900 may hold a greater weight of product and/or more effectively prevent liquid leakage. Such improvements may also reduce the risk of structural failure of the container 900 when filled and sealed. Additionally, such reinforcement promotes improved sealing of the container 900. Moreover, the flanges 914 may be substantially flatter than flanges of conventional containers. Such flanges 914 may allow for easier, faster, simpler, and/or more cost-effective (e.g., using less sealing material) application of sealing films to the sealed container 900. These improvements allow the container 900 to function more effectively than other conventional containers.

9 is a flow diagram of a method 1000 of forming a container from a blank. In some embodiments, the blank includes a bottom panel, two opposing side panels, two opposing end panels, respective end flange panels extending from top edges of the respective end panels, respective end flange tabs extending from respective side edges of the respective end flange panels, respective side flange panels extending from top edges of the respective side panels, and respective side flange tabs extending from respective end edges of the respective side flange panels. The method 1000 includes step 1002 of applying hot melt adhesive to an interior surface of the side flange tabs, step 1004 of rotating the end panels inwardly toward the bottom panel, and step 1006 of rotating the side panels inwardly toward the bottom panel. Method 1000 also includes step 1008 of rotating the side flange panels outwardly to a parallel orientation relative to the bottom panel, and step 1010 of rotating the end flange panels to a parallel orientation relative to the bottom panel after rotating step 1008. Method 1000 also includes step 1012 of connecting the end flange tabs to the side flange tabs to form a container having a fully formed top flange.

In some embodiments, the blank further includes a respective interior side panel extending from a respective side edge of each end panel. In some such cases, the method 1000 further includes applying hot melt adhesive to a portion of an interior surface of the side panel, rotating the interior side panel inwardly, and performing a rotating step 1008 after the step of rotating the interior side panel, and coupling the side panel to the interior side panel.

Method 1000 may include additional, fewer, and/or alternative steps (including steps disclosed elsewhere herein).

Figure 10A is a top view of an alternative blank 1100 of sheet material for forming a container 1200 (see Figure 11). Blank 1100 is substantially similar to blank 100 (shown in Figure 1), except as described below. As such, components common to blank 100 and blank 1100 are labeled with the same reference numerals.

In one embodiment, the blank 1100 includes cutouts 1102 defined in the first end panel 106 and the second end panel 110. In an exemplary embodiment, each end panel 106, 110 contains four cutouts 1102. In alternative embodiments, cutouts can be defined in the first side panel 116 and the second side panel 122. The blank 1100 can include any suitable number of cutouts 1102 in any suitable location having any suitable shape that enables the blank 1100 and/or the container 1200 to function as described herein.

In the exemplary embodiment, the blank 1100 includes interior side panels 1104 having a different overall shape than the interior side panels 130 of the blank 100. The interior side panels 1104 of the blank 1100 each include a free edge 178 that is opposite and substantially parallel to the fold line 132. The free edges 178 each extend along the length of the respective fold line 132 and each terminate transversely at the end edges 172 of the side panels 116, 122.

Additionally, the bottom panel 108 of the blank 1100 is smaller and more square than the bottom panel 108 of the blank 100. In the exemplary embodiment, four de-nesting assemblies 1105 are included, which are positioned at each corner of the bottom panel 108. Alternative embodiments may include any suitable number of de-nesting assemblies 1105. For example, only one de-nesting assembly 1105 may be positioned at one corner of the bottom panel 108. The blank 1100 may include any number of de-nesting assemblies 1105 that enable the blank 1100 and/or the container 1200 to function as described herein.

10B depicts an enlarged view of region B of the blank 1100 shown in FIG. 10A. The de-nesting assembly 1105 includes a de-nesting tab 1106 and a de-nesting cutout 1118. The de-nesting tab 1106 includes a first triangular section 1108 defined in the interior side panel 1104, a second triangular section 1110 defined in the end panels 106, 110, a side fold line 1112, a central fold line 1122, a bottom fold line 1124, a first teardrop shaped lobe 1116, and a second teardrop shaped lobe 1117. The triangular sections 1108, 1110 are defined by side fold lines 1112, a center fold line 1122, and a bottom fold line 1124, where the side fold lines 1112 extend from a point 1114 along the fold line 132 (shown in FIG. 10A ) and extend outward at an acute angle. Teardrop shaped lobes 1116, 1117 are adjacent the triangular sections 1108, 1110 and extend into a de-nesting cutout 1118. The bottom fold line 1124 is positioned between the triangular sections 1108, 1110 and the teardrop shaped lobes 1116, 1117. The de-nesting cutout 1118 is an empty space in the blank where no sheet material is present. The de-nesting cutout 1118 is located at a corner of the bottom panel 108 and further extends at an angle across the corner of the side panels 116, 122.

11 is a perspective view of an exemplary container 1200 (shown in FIG. 11 ) formed from a blank 1100 (shown in FIG. 10A ). The container 1200 is substantially similar to the container 200 (shown in FIG. 2 ) and is formed from the blank 1100 using a method similar to forming the container 200 from the blank 100. The container 1200 can have different dimensions than the container 200 and further includes a de-nesting assembly 1105. In addition to the method described with respect to forming the container 200 from the blank 100, additional steps are required to form the container 1200 from the blank 1100. When the panels 106, 110, 116, and 122 are folded upward to form the container 1200, the de-nesting tabs 1106 are folded along the fold lines 1112, 1122, 1124 into the cavity 1220 (as shown in FIG. 12 ) of the formed container 1200. The de-nesting assembly 1105, and in particular each of the fold lines 1112, 1122, 1124 and the cutout 1118, cooperate to allow the de-nesting tab 1106 to bend inwardly towards the cavity 1220. The de-nesting cutout 1118 further includes an arched edge 1120 that provides clearance for the teardrop-shaped lobes 1116, 1117 of the de-nesting tab 1106 to bend inwardly towards the cavity 1220. As a result, the de-nesting tabs 1106 on the formed container 1200 each extend into the cavity 1220 at an acute angle relative to a starting position.

12 is another perspective view of container 1200 (shown in FIG. 11) formed from blank 1100 (shown in FIG. 10A). Container 1200 includes a bottom wall portion 1210, a first end wall portion 1212, a second end wall portion 1214, a first side wall portion 1216, and a second side wall portion 1218. The bottom wall 1210 includes the bottom panel 108 of the blank 1100, the first end wall 1212 includes the first end panel 106, the second end wall 1214 includes the second end panel 110, the first side wall 1216 includes the first side panel 116 and two interior side panels 1104 (one extending from each of the first and second end panels 106, 110), and the second side wall 1218 includes the second side panel 122 and two interior side panels 1104 (one extending from each of the first and second end panels 106, 110). The walls form a cavity 1220.

The container 1200 also includes a flange 1222 extending from the top of each of the first and second end wall portions 1212, 1214 and the first and second side wall portions 1216, 1218. In the exemplary embodiment, the flange 1222 extends outwardly (or away from the cavity 1220).

Figure 13 is another perspective view of container 1200 (shown in Figure 11) formed from blank 1100 (shown in Figure 10A).

FIG. 14 is a perspective view of a stack 1300 of multiple containers 1200 that are nested or stacked for storage and/or transport. The extended de-nesting tabs 1106 ensure that the containers 1200 do not stick together when nested in the stack 1300 and provide approximately equal spacing 1302 between the flanges 1222 of each container 1200. The spacing 1302 between the flanges 1222 allows an operator or machine to grasp an individual container 1200 and prevents the container from sticking to another container in the stack 1300.

Figure 15 is a top view of an alternative blank 1400 for forming a container 1500 (see Figure 16). Blank 1400 is substantially similar to blank 100 (shown in Figure 1) and blank 1100 (shown in Figure 10A), except as described below. As such, components common to blank 100, blank 1100, and blank 1400 are labeled with the same reference numerals.

The blank 1400 includes a bottom panel 108, a first end panel 106, a second end panel 110, a first side panel 116, a second side panel 122, and an interior side panel 130 that projects outwardly from opposing sides of the first end panel 106 and the second end panel 110. In one embodiment, the blank 1400 includes cutouts 1402 defined in the first end panel 106 and the second end panel 110. In an exemplary embodiment, each end panel 106, 110 contains four cutouts 1402. In alternative embodiments, cutouts may be defined in the first side panel 116 and the second side panel 122. The blank 1400 can include any suitable number of cutouts 1402 in any suitable location having any suitable shape that enables the blank 1400 and/or the container 1500 to function as described herein.

15 further illustrates a close-up view of the de-nesting tabs 1404 (alternatively referred to as a "de-nesting assembly" in the embodiment of FIG. 15). The blank 1400 includes four de-nesting tabs 1404 positioned at the upper or top corners of the side panels 116, 122 (i.e., adjacent flange panels 150), although other embodiments may include any suitable number of de-nesting tabs. The de-nesting tabs 1404 extend outwardly from the end edge 172 and along the fold line 120 of the first side flange panel 150. The de-nesting tabs 1404 include a curved edge 1406 along the first side flange tab 158 and a lower edge 1408 that is approximately perpendicular to the end edge 172.

16 is a perspective view of an exemplary container 1500 formed from blank 1400 (shown in FIG. 15). Container 1500 is substantially similar to container 200 (shown in FIG. 2) and container 1200 (shown in FIG. 11) and is formed from blank 1400 using a method similar to forming container 200 from blank 100, except for differences described below. Container 1500 may have different dimensions than container 200 and further includes a de-nesting tab 1404. Container 1500 includes a bottom wall (not shown), a first end wall 1502, a second end wall (not shown), a first side wall 1504, and a second side wall (not shown). The bottom wall (not shown) includes the bottom panel 108 of the blank 1400, the first end wall 1502 includes the first end panel 106, the second end wall (not shown) includes the second end panel 110, the first side wall 1504 includes the first side panel 116 and two interior side panels 130 (one extending from each of the first and second end panels 106, 110), and the second side wall (not shown) includes the second side panel 122 and two interior side panels 130 (one extending from each of the first and second end panels 106, 110). The walls form a cavity 1506. The container 1500 further includes a flange 1508 that protrudes from an upper portion of each of the first end wall portion 1502, the second end wall portion (not shown), the first side wall portion 1504, and the second side wall portion (not shown).

The de-nesting tabs 1404 are positioned adjacent the flange 1508 and project outwardly from the side wall 1504, beyond the end wall 1502, and in the same plane as the side wall 1504. In the exemplary embodiment, at least one de-nesting tab 1404 is provided at each corner of the container 1500 when assembled into the container 1500. The de-nesting tabs 1404 extend into the profile of the flange 1508 and do not extend beyond the peripheral outer edge 1512 of the flange 1508. A notch 1510 is formed between the curved edge 1406 and the flange 1508.

FIG. 17 is a perspective view of a stack 1600 of multiple containers 1500, showing the containers 1500 when nested or stacked for storage and/or transport. The lower edges 1408 of the de-nesting tabs 1404 are in contact with the upper surfaces of the flanges 1508, and a space 1602 is defined between the respective flanges 1508. Force is translated through the lower edges 1408 of the de-nesting tabs 1404 of one container 1500 to the flanges 1508 of the container 1500 below. The space 1602 is essentially equal between the respective flanges 1508 and is maintained by the de-nesting tabs 1404.

The space 1602 prevents the flanges 1508 from directly contacting each other. In some cases, the flanges 1508 may have excess glue from the process of forming the containers 1500. Preventing the flanges from contacting each other prevents any excess glue from causing the containers 1500 to stick together in a stacked configuration. In other cases, the space 1602 can prevent the containers 1500 from being compressed and sticking together. Once the containers are compressed, it can result in additional friction between the surfaces of the containers 1500, making it more difficult to separate the containers 1500. Additionally, the sizing of the space 1602 can be selected to provide sufficient clearance for an operator or machine to pull individual containers 1500 from the stack 1600.

Figure 18 is a top view of an alternative blank 1700 for forming a container 1800 (see Figure 19).

In the exemplary embodiment, similar to blank 800, blank 1700 includes a first end panel 1702, a second end panel 1704, a first side panel 1706, a second side panel 1708, and a bottom panel 1710. Bottom panel 1710 has a generally rectangular shape with chamfered corners, giving it eight edges in the exemplary embodiment. Blank 1700 also includes a first end flange panel 1712, a second end flange panel 1714, a first side flange panel 1716, and a second side flange panel 1718.

The blank 1700 also includes a corner panel 1720 extending from a fold line 1722 at the chamfered corner of the bottom panel 1710. An internal corner panel 1724 extends from a respective side edge 1726 of each corner panel 1720. Each corner panel 1720 further includes a corner flange tab 1728 that includes a curved outer edge 1730 and additionally forms a notch 1732 on an inner edge adjacent the corner panel 1720. The corner flange tab 1728 can have any suitable shape that enables the blank 1700 and/or the container 1800 to function as described herein. A fold line 1734 is defined between the internal corner panel and each of the first and second end panels 1702, 1704 and the first and second side panels 1706, 1708.

Each of the first and second end panels 1702, 1704 and the first and second side panels 1706, 1708 further includes a de-nesting tab 1736 positioned on either side of the respective panel 1702, 1704, 1706, 1708. The de-nesting tabs 1736 are substantially similar to the de-nesting tabs 1404 (shown in FIG. 15 ) in that they are provided adjacent the flange panels 1712, 1714, 1716, 1718. However, unlike the blank of FIG. 15 (which includes four de-nesting tabs 1404), in the exemplary embodiment, eight de-nesting tabs are included, although other embodiments may include any suitable number of de-nesting tabs. The de-nesting tabs 1736 extend along the flange panels 1712, 1714, 1716, 1718 away from the respective panels 1702, 1704, 1706, 1708. A recess 1738 is defined along a bottom edge 1740 of the de-nesting tabs 1736.

19 is a perspective view of an exemplary octagonal container 1800 formed from blank 1700 (shown in FIG. 18). Container 1800 is substantially similar to container 900 (shown in FIG. 8) and is formed from blank 1700 using a method similar to forming container 900 from blank 800. Container 1800 may have different dimensions than container 900 and further includes a de-nesting tab 1736. Container 1800 includes a bottom wall (not shown), first and second end walls 1802, 1804, first and second side walls 1806, 1808, and four corner walls 1810. The bottom wall (not shown) includes a bottom panel 1710. The first end wall 1802 includes a first end panel 1702 and two interior corner panels 1724. The second end wall 1804 includes a second end panel 1704 and two interior corner panels 1724. The first side wall 1806 includes a first side panel 1706 and two interior corner panels 1724. The second side wall 1808 includes a second side panel 1708 and two interior corner panels 1724. The end walls 1802, 1804, the side walls 1806, 1808, and the corner wall 1810 form a cavity 1812. The container 1800 also has a flange 1814 extending from the tops of the walls 1802, 1804, 1806, 1808, 1810. The flange 1814 extends outwardly from the cavity 1812.

Container 1800 includes a de-nesting tab 1736 that extends from each end of each wall 1802, 1804, 1806, 1808 at an acute angle in the plane of each wall 1802, 1804, 1806, 1808 relative to corner wall 1810. De-nesting tab 1736 does not extend beyond plane 1816 defined by the edge of flange 1814.

20 is a perspective view of a stack 1900 of multiple containers 1800, where the containers 1800 are nested or stacked for storage and/or transport. The bottom edge 1740 of each de-nesting tab 1736 rests along the top surface of the flange 1814. This creates a space 1902 between each flange 1814 of each container 1800. The space 1902 is essentially equal between each container 1800 and is defined by the height of the de-nesting tab 1736. The space 1902 provides sufficient clearance between the containers 1800 to allow the containers 1800 to be separated by an operator or machine.

Further aspects of the present disclosure are provided by the subject matter of the following clauses:

A method of forming a container from a blank, the blank including a bottom panel, two opposing side panels, two opposing end panels, respective end flange panels extending from a top edge of each end panel, respective end flange tabs extending from a side edge of each end flange panel, respective side flange panels extending from a top edge of each side panel, and respective side flange tabs extending from a respective end edge of each side flange panel, the method including the steps of: applying adhesive to an inner surface of the side flange tabs; rotating the end panels inwardly toward the bottom panel; rotating the side panels inwardly toward the bottom panel; rotating the side flange panels outwardly to a parallel orientation relative to the bottom panel; rotating the end flange panels to a parallel orientation relative to the bottom panel after the step of rotating the side flange panels; and connecting the end flange tabs to the side flange tabs to form a container having a fully formed top flange.

A method according to any preceding clause, wherein the bottom panel, the two opposing side panels, and the two opposing end panels collectively define a container cavity for receiving a product therein, the method further comprising the steps of: positioning a film over the top flange so as to extend over and cover the cavity; and sealing the film to the top flange.

The method of any preceding clause, wherein the two opposing side panels and the two opposing end panels each have a generally trapezoidal shape such that after the step of rotating the end panels and side panels, the end panels and side panels each extend diagonally away from the bottom panel.

The method of any preceding clause, wherein the bottom panel, the two opposing side panels, and the two opposing end panels collectively define a container cavity for receiving a product therein, the cavity being further configured to receive a portion of an adjacent container therein to facilitate stacking of the adjacent containers within the container, and the container further including a de-nesting assembly configured to engage the adjacent container when received within the container such that the flanges of the adjacent container are spaced apart from the fully formed flanges of the container.

The method of any preceding clause, wherein the de-nesting assembly includes a de-nesting tab and a de-nesting cutout, the method further including the step of bending the de-nesting tab into the cavity.

The method of any preceding clause, wherein the blank further includes an interior side panel extending from a side edge of a first of the two end panels, the de-nesting tab is connected to the interior side panel and the end panel, and the de-nesting cutout is defined by the de-nesting tab, the bottom panel, and at least one of the side panel and the end panel.

The method of any preceding clause, wherein the de-nesting tab is positioned at a bottom corner of the container, the bottom corner of the container being defined by the bottom panel, a first of the two end panels, and a first of the two side panels, and the de-nesting tab is configured to engage an outer surface of the adjacent container when the de-nesting tab is folded into the cavity and the adjacent container is received in the cavity.

The method of any preceding clause, wherein the container defines four bottom corners and includes four de-nesting assemblies positioned at each of the bottom corners.

The method of any preceding clause, wherein the de-nesting assembly includes respective de-nesting tabs connected to end edges of respective side panels, the de-nesting tabs extending outwardly from the end edges and being flush with the respective side panels.

The method of any preceding clause, wherein the container is configured to be received within a cavity defined in an adjacent container having a substantially similar size and shape to the container, and the de-nesting tab is sized to engage an adjacent flange of the adjacent container such that the flange of the container is spaced apart from the adjacent flange of the adjacent container when the container is received within the cavity of the adjacent container.

A container comprising: a bottom panel; two opposing side panels connected to the bottom panel along respective first set fold lines; two opposing end panels connected to the bottom panel along respective second set fold lines; respective end flange panels extending from top edges of the respective end panels in a generally parallel orientation to the bottom panel; respective end flange tabs extending from respective side edges of the respective end flange panels; respective side flange panels extending from top edges of the respective side panels in a generally parallel orientation to the bottom panel; and respective side flange tabs extending from respective end edges of the respective side flange panels, the side flange tabs being respectively connected to respective end flange tabs to form a top flange of the container.

A container as described in any preceding clause, wherein the two opposing side panels and the two opposing end panels each have a generally trapezoidal shape, and the end panels and side panels each extend at an angle away from the bottom panel.

A container as described in any preceding clause, wherein the bottom panel, the two opposing side panels, and the two opposing end panels collectively define a container cavity for receiving a product therein, the cavity being further configured to receive a portion of an adjacent container therein to facilitate stacking of the adjacent container within the container, and the container further including a de-nesting assembly configured to engage the adjacent container when received within the container cavity such that a flange of the adjacent container is spaced from a flange of the container.

A container as described in any preceding clause, wherein the de-nesting assembly includes a de-nesting tab and a de-nesting cutout, the de-nesting tab being folded into the cavity.

A container as described in any preceding clause, wherein the container further includes an interior side panel extending from a side edge of a first of the two end panels, the de-nesting tab being connected to the interior side panel and the end panel, and the de-nesting cutout being defined by the de-nesting tab, the bottom panel, and at least one of the side panel and the end panel.

A container as described in any preceding clause, wherein the de-nesting tab is positioned at a bottom corner of the container, the bottom corner of the container being defined by a bottom panel, a first of two end panels, and a first of two side panels.

A container as described in any preceding clause, wherein the container defines four bottom corners and includes four de-nesting assemblies positioned at each of the bottom corners.

A container as described in any preceding clause, wherein the de-nesting assembly includes respective de-nesting tabs connected to end edges of respective side panels, the de-nesting tabs extending outwardly from the end edges and flush with the respective side panels.

A container as described in any preceding clause, wherein the container is configured to be received within a cavity defined in an adjacent container having a substantially similar size and shape to the container, and the de-nesting tab is sized to engage an adjacent flange of the adjacent container such that the flange of the container is spaced from the adjacent flange of the adjacent container when the container is received within the cavity of the adjacent container.

A method of stacking a first container on a second container, the first container and the second container each formed from a respective blank having substantially the same size and shape, the blanks each including a bottom panel, two opposing side panels, two opposing end panels, respective end flange panels extending from top edges of the respective end panels, respective end flange tabs extending from respective side edges of the respective end flange panels, respective side flange panels extending from top edges of the respective side panels, and respective side flange tabs extending from respective end edges of the respective side flange panels, the method comprising the steps of: applying adhesive to an inner surface of the side flange tabs; rotating the end panels inwardly toward the bottom panel; rotating the end flange panels inwardly toward the bottom panel; rotating the side flange panels outwardly to a parallel orientation relative to the bottom panel; rotating the end flange panels after the rotating the side flange panels to a parallel orientation relative to the bottom panel; forming a first container by connecting the end flange tabs to the side flange tabs to form a container having a fully formed top flange; forming a second container; and positioning the first container in a cavity of the second container such that a de-nesting assembly of one of the first and second containers engages the other of the first and second containers to space the top flange of the first container from the top flange of the second container.

Exemplary embodiments of containers and blanks for making same are described above in detail. The containers and blanks are not limited to the specific embodiments described herein, but rather, the blanks and/or container components can be utilized independently and separately from other components described herein.

Although particular features of various embodiments of the present disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the present disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

This written description uses examples to disclose various embodiments (including the best mode) and to enable any person of ordinary skill in the art to practice the disclosure (including making and using any device or system and practicing any incorporated methods). The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims or if they include equivalent structural elements with insignificant differences from the literal language of the claims.

100 Blank
101 Internal Surface
102 Leading edge
103 External Surface
104 Trailing edge
106 first end panel
108 Bottom Panel
110 Second end panel
112 Folding Line
114 Folding Line
116 First Side Panel
118 first side edge
120 Folding line
122 Second Side Panel
124 second side edge
126 Folding Line
128 Cutout
130 Inner Side Panel
132 Folding Line
134 first end flange panel
136 Folding Line
138 Second End Flange Panel
140 Folding line
142 First End Flange Tab
144 Second End Flange Tab
146 Free outer edge
148 Free inner edge
150 first side flange panel
152 Second Side Flange Panel
154 Free edge
156 Free edge
158 First Side Flange Tab
160 Second Side Flange Tab
162 Free outer edge
164 Free inner edge
166 Folding Line
168 Folding Line
170 Side edge
172 End edge
178 Free edge
180 Folding line
182 Folding Line
184 Notch
186 Notch
200 containers
202 Bottom wall
204 First end wall portion
206 Second end wall portion
208 First side wall
210 second end wall portion
212 Cavity
214 Flange
216 Free edge
218 Corner
220 Film
300 stacks
400 Blank
402 Cutout
404 Notch
430 Inner side edge
500 containers
600 Blank
602 Cutout
604 Folding line
606 Inner End Panel
608 Free edge
610 Notch
612 Notch
800 Blank
802 first end panel
804 Second End Panel
806 First Side Panel
808 Second Side Panel
810 Bottom Panel
812 First End Flange Panel
814 Second End Flange Panel
816 First Side Flange Panel
818 Second Side Flange Panel
820 First End Flange Tab
822 Second End Flange Tab
824 1st Side Flange Tab
826 Second Side Flange Tab
828 Free end edge
830 Notch
832 Inner edge
834 Corner Panel
836 Folding Line
838 Interior Corner Panel
840 Folding line
842 Corner flange panel
844 Folding line
845 Free edge
846 Corner flange tab
848 Folding line
849 Free edge
850 Notch
852 Cutout
854 Folding line
856 Folding line
858 Folding line
860 Folding line
900 containers
902 Bottom wall
904 First end wall portion
906 Second end wall
908 First side wall
910 Second end wall portion
912 Cavity
914 Flange
916 Free edge
918 Corner
920 Corner wall
1100 Blank
1102 Cutout
1104 Inner Side Panel
1105 Nesting Elimination Assembly
1106 Nesting Dissolution Tab
1108 First Triangular Section
1110 Second Triangular Section
1112 Side fold line
1114 points
1116 First Teardrop Lobe
1117 Second teardrop-shaped lobe
1118 Nesting Elimination Cutout
1120 Arched Edge
1122 Center fold line
1124 Bottom fold line
1200 containers
1210 Bottom wall
1212 First end wall portion
1214 Second end wall
1216 First side wall
1218 Second side wall
1220 Cavity
1222 Flange
1300 Stack
1302 Interval
1400 Blank
1402 Cutout
1404 Nesting Dissolution Tab
1406 Curved Edge
1408 Lower edge
1500 containers
1502 First end wall
1504 First side wall
1506 Cavity
1508 Flange
1510 Notch
1512 Peripheral outer edge
1600 Stack
1602 Space
1700 Blank
1702 First End Panel
1704 Second End Panel
1706 First Side Panel
1708 Second Side Panel
1710 Bottom Panel
1712 First End Flange Panel
1714 Second End Flange Panel
1716 First Side Flange Panel
1718 Second Side Flange Panel
1720 Corner Panel
1722 Folding line
1724 Interior corner panel
1726 Side edge
1728 Corner flange tab
1730 curved outer edge
1732 Notch
1734 Folding line
1736 Unnesting Tab
1738 Depression
1740 Bottom edge
1800 containers
1802 First end wall
1804 Second end wall
1806 First side wall
1808 Second side wall
1810 Corner wall
1812 Cavity
1814 Flange
1816 Plane
1900 Stack
1902 Interval
H ₁ Height
_H2 Height
H ₃ Height
H ₄ height
L ₁ length
W ₁ width

Claims (20)

A container comprising:
A bottom panel;
two opposing side panels connected to the bottom panel along respective first set fold lines;
two opposing end panels connected to the bottom panel along respective second set fold lines;
a respective end flange panel extending from a top edge of each end panel in a generally parallel orientation to said bottom panel;
a respective end flange tab extending from a respective side edge of each end flange panel;
a respective side flange panel extending from a top end of each side panel in a generally parallel orientation to said bottom panel;
respective side flange tabs extending from respective end edges of respective side flange panels, said side flange tabs respectively coupled to respective end flange tabs to form a top flange of the container;
3. A container comprising: The container of claim 1, wherein the two opposing side panels and the two opposing end panels each have a generally trapezoidal shape, and the end panels and side panels each extend diagonally away from the bottom panel. The container of claim 1, wherein the bottom panel, the two opposing side panels, and the two opposing end panels collectively define a cavity of the container for receiving a product therein, the cavity being further configured to receive a portion of an adjacent container therein to facilitate stacking of the adjacent container within the container, and the container further includes a de-nesting assembly configured to engage the adjacent container when received within the cavity of the container such that a flange of the adjacent container is spaced apart from the flange of the container. The container of claim 3, wherein the de-nesting assembly includes a de-nesting tab and a de-nesting cutout, and the de-nesting tab is folded into the cavity. The container of claim 4, wherein the container further includes an interior side panel extending from a side edge of a first of the two end panels, the de-nesting tab is connected to the interior side panel and the end panel, and the de-nesting cutout is defined by the de-nesting tab, the bottom panel, and at least one of the side panel and the end panel. The container of claim 4, wherein the de-nesting tab is positioned at a bottom corner of the container, the bottom corner of the container being defined by the bottom panel, a first of the two end panels, and a first of the two side panels. The container of claim 6, wherein the container defines four bottom corners and includes four de-nesting assemblies positioned at each bottom corner. The container of claim 3, wherein the de-nesting assembly includes a respective de-nesting tab coupled to an end edge of each side panel, the de-nesting tab extending outwardly from the end edge and flush with the respective side panel. The container of claim 8, wherein the container is configured to be received within a cavity defined in an adjacent container having a substantially similar size and shape to the container, and the de-nesting tab is sized to engage an adjacent flange of the adjacent container such that the flange of the container is spaced apart from the adjacent flange of the adjacent container when the container is received within the cavity of the adjacent container. 1. A method of forming a container from a blank, the blank including a bottom panel, two opposing side panels, two opposing end panels, respective end flange panels extending from top edges of the respective end panels, respective end flange tabs extending from respective side edges of the respective end flange panels, respective side flange panels extending from top edges of the respective side panels, and respective side flange tabs extending from respective end edges of the respective side flange panels, the method comprising:
applying an adhesive to an inner surface of the side flange tab;
rotating the end panel inwardly toward the bottom panel;
rotating the side panels inwardly toward the bottom panel;
rotating the side flange panels outwardly to a parallel orientation relative to the bottom panel;
after the step of rotating the side flange panels, rotating the end flange panels to a parallel orientation relative to the bottom panel;
connecting the end flange tabs to the side flange tabs to form the container having a fully formed top flange;
A method comprising: The bottom panel, two opposing side panels, and two opposing end panels collectively define a cavity of the container for receiving a product therein, and the method includes:
positioning a film over the upper flange so as to extend over and cover the cavity;
sealing the film to the upper flange;
11. The method of claim 10, further comprising: 11. The method of claim 10, wherein the two opposing side panels and the two opposing end panels each have a generally trapezoidal shape such that after the step of rotating the end panels and the side panels, the end panels and the side panels each extend diagonally away from the bottom panel. 11. The method of claim 10, wherein the bottom panel, the two opposing side panels, and the two opposing end panels collectively define a cavity of the container for receiving a product therein, the cavity being further configured to receive a portion of an adjacent container therein to facilitate stacking of the adjacent container within the container, and the container further includes a de-nesting assembly configured to engage the adjacent container when received within the container, such that a flange of the adjacent container is spaced from the fully formed flange of the container. The method of claim 13, wherein the de-nesting assembly includes a de-nesting tab and a de-nesting cutout, the method further including the step of bending the de-nesting tab into the cavity. 15. The method of claim 14, wherein the blank further includes an interior side panel extending from a side edge of a first of the two end panels, the de-nesting tab is connected to the interior side panel and the end panel, and the de-nesting cutout is defined by the de-nesting tab, the bottom panel, and at least one of the side panel and the end panel. 15. The method of claim 14, wherein the de-nesting tab is positioned at a bottom corner of the container, the bottom corner of the container being defined by the bottom panel, a first of the two end panels, and a first of the two side panels, and the de-nesting tab is configured to engage an outer surface of the adjacent container when the de-nesting tab is folded into the cavity and the adjacent container is received in the cavity. The method of claim 16, wherein the container defines four bottom corners and includes four de-nesting assemblies positioned at respective bottom corners. The method of claim 13, wherein the de-nesting assembly includes a respective de-nesting tab coupled to an end edge of each side panel, the de-nesting tab extending outwardly from the end edge and coplanar with the respective side panel. 19. The method of claim 18, wherein the container is configured to be received within a cavity defined in an adjacent container having a substantially similar size and shape to the container, and the de-nesting tab is sized to engage an adjacent flange of the adjacent container such that the flange of the container is spaced apart from the adjacent flange of the adjacent container when the container is received within the cavity of the adjacent container. 1. A method of stacking a first container on a second container, the first container and the second container being each formed from a respective blank having substantially the same size and shape, the blanks each including a bottom panel, two opposing side panels, two opposing end panels, respective end flange panels extending from top edges of the respective end panels, respective end flange tabs extending from respective side edges of the respective end flange panels, respective side flange panels extending from top edges of the respective side panels, and respective side flange tabs extending from respective end edges of the respective side flange panels, the method comprising:
applying an adhesive to an inner surface of said side flange tabs;
rotating the end panel inwardly toward the bottom panel;
rotating the side panels inwardly toward the bottom panel;
rotating the side flange panels outwardly to a parallel orientation relative to the bottom panel;
after the step of rotating the side flange panels, rotating the end flange panels into a parallel orientation relative to the bottom panel; and connecting the end flange tabs to the side flange tabs to form the container having a fully formed top flange.
forming the first container;
forming the second container;
positioning the first container within the cavity of the second container such that a de-nesting assembly of one of the first container and the second container engages the other of the first container and the second container to space the top flange of the first container from the top flange of the second container;
A method comprising:

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