NZ205186A - Paperboard component for box - Google Patents

Description

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Publication Date: P.O. Journal, No: 23 JAN 1987 -8 AUG1983 V* XfCBivV ■\ NEW ZEALAND PATENTS ACT, J953 No.: Date: COMPLETE SPECIFICATION A. J. P. & S, . CONTAINER WITH PAPERBOARD LID AND INTEGRAL BOTTOMLAND SIDE PANELS THEREFOR Per-^A? A 0 »o/ni^V BOOK COVERS INC, a corporation of the State of New Jersey, of 17 Blanchard Street, Newark, New Jersey 07105, United States of America hereby declare the invention for which I / we pray that a patent may be granted to me/us, and the method by which it is to be performed, to be particularly described in and by the following statement: - - 1 - (followed by page la) 5186 ia.

NBB 3.0 010 CONTAINER WITH PAPERBOARD LID AND INTEGRAL BOTTOM PANEL AND SIDE PANELS THEREFOR: FIELD OF THE INVENTION The present invention relates to a novel product and method for making containers used for packaging and shipping fruit products and the like, and more particularly, it is directed to an integral component for such containers wherein the bottom panel and both side panels are integrally formed in one component for assembly into a complete container having end panels and a cover. The present invention is also directed to a novel cover for such a container formed of paperboard material.

BACKGROUND OF THE INVENTION Containers for the packaging and shipping of fruit and the like, such as grapes, are well known in the art. In the past, such containers or boxes used for this purpose, and their covers, have been made of wood, since wooden containers have sufficient strength to withstand being stacked and to also withstand storage in a humid environment. Typically, the wooden covers have wooden cleats at the ends thereof for attaching the wooden covers to the wooden end panels of the boxes. In addition, shipping containers used in the past have also been formed from fiberboard material and corrugated paperboard material. Such fiberboard and paperboard boxes have been impregnated with various materials to protect them. Still further, other shipping containers have been formed from slats of wooden material covered and held together with paper, as shown, for example, in U.S. Patent No. 3,905,478. 51 5 6 Although a number of different constructions have been utilized in the past to provide an inexpensive and practical container for this purpose, none of those which have been developed thus far have proved to be entirely satisfactory for the storage and shipping of fruit and the like, such as grapes. For example, the container formed of wooden slats and covered with paper has a number of disadvantages. Since its oottom panel is formed of two or more separate slats which are held together by paper, such a bottom panel has a tendency to bend and/or deform when subjected to the weight of the contents of the container. In addition, typically, such boxes do not have dimensional stability in that the wooden slats are not uniform in size, and this has caused problems in the use of such boxes. Also, it is necessary to print product information on such shipping containers, but in those boxes formed of wooden slats, which have spaces between them, the printing surfaces are uneven, which causes difficulty in printing on such boxes, especially in high-speed processes. Still further, the edges of such boxes formed of wooden slats are exposed to the elements, such as moisture and humidity, which causes such boxes to deteriorate in strength.

In addition, wooden covers having wooden cleats have also been unsatisfactory. More particularly, the wooden cleats tend to split during use, and tend to cause injuries as a result of splinters. In addition, there is the disadvantage that the wooden cleats have to be assembled with the wooden board or sheet to form the cover, and such handling at the point of use is time consuming and costly. Further, wooden covers have the additional disadvantage that they cannot be recycled after use. 205!$6 Broadly, it is an object of the present invention to provide an improved container for the packaging and shipping of fruit which overcomes one or more of the aforesaid drawbacks. Specifically, it is within the contemplation of the present invention to provide an improved container and cover which is simple and inexpensive to construct, which has greater strength and stability than prior art constructions, and which is recycable.

It is a further object of the present invention to provide an integral box component for a container which includes in one unit the bottom panel and side panels, which is ready to be assembled with end panels and a cover to form a complete box, so that the integral box component of the present invention may be shipped in a flat configuration, which substantially reduces shipping and storage costs for such containers.

It is a further object of the present invention to provide an integral box component for a container which is formed from a single sheet of paperboard material, so that the side panels and bottom panel of the box are strong, resistant to bending, uniform in size, and provide a smooth surface on which to print product information and the like.

It i.s a still further object of the present invention to provide a paperboard lid which is simple and inexpensive to manufacture in a continuous process, which does not require assembly in use, which can be shipped in a flat configuration at a reduced cost, and which can be recycled after use.

SUMMARY OF THE INVENTION Briefly, in accordance with the principles of the present invention, there is provided an improved container having top and bottom panels, a pair of side panels, and a 2 0 5 I S 6 pair of end panels, with the bottom panel and the pair of side panels being formed as a single integral unit for assembly with the end panels and cover to form a completed box or container. The integral unit comprises a bottom panel formed of a single sheet of paperboard material, and a first side panel formed of a single sheet of paperboard material and spaced apart from the bottom panel to form a first folding section therebetween for folding the first side panel relative to the bottom panel. In addition, the integral unit includes a second side panel formed of a single sheet of paperboard material and spaced apart from the bottom panel to form a second folding section therebetween for folding the second side panel relative to the bottom panel. In this manner, the bottom panel and the first and second side panels define an inner surfacc, an outer surface, and outer longi. tudinnl ly-extendi.ng edges on the first and second aide panels. A single sheet of bottom wrap paper material is provided to cover the outer surface of the bottom panel and the outer surface of the first and second side panels, and to also cover the outer edges of the first and second side panels, and a portion of the inner surface adjacent to the outer edges of the first and second side panels. In addition, a single sheet of top wrap paper material is provided to cover the inner surface of the bottom panel and the first and second side panels and to overlap and cover a portion of the bottom wrap material which is covering the inner surface of the panels. In addition, the top wrap material and the bottom wrap material are glued to each other in the areas forming the first and second folding sections, so that an integral and unitary construction is formed comprising the bottom panel and first and second side panels. This integral box component also has transversely-extending edges of exposed 205 t 86 paperboard material which are coated with a waterproofing material to seal such edges against the absorption of moisture and humidity.

The present invention is also directed to an improved method of forming the integral box component or unitary construction of the present invention. The method comprises ; the steps of laminating layers of paperboard material to form a single sheet of paperboard material which is continuously supplied to a work station. At the work station, the sheet of paperboard material is slit along two longitudinally-extending and spaced-apart lines to form the central bottom panel and to form the first and second side panels spaced apart from the central bottom panel and defining first and second longi tudinally-extendi.ig spaces. In addition, the bottom panel and the first and second side panels define an upper or inner surface, a lower or outer surface, and outer longitudinally-extending edges on the edges of the first and second side panels. A single sheet of bottom wrap material is applied to cover the outer surface of the bottom panel and the first and second side panels, and is also applied to cover the outer edges of the first and second side panels, and is also applied to wrap around and cover a portion of the inner surface adjacent the outer edges of the first and second side panels. Such covering is applied while maintaining the first and second longitudinally-extending spaces. In addition, a single sheet of top wrap material is applied to cover the inner surface of the bottom panel and the first and second side panels and also covers a portion of the bottom wrap material, which has been wrapped around to cover a portion of the inner surface. As part of the method, the top wrap material and the bottom wrap material are glued to each other at the first and second longitudinally-extending 205 1 S spaces to form first and second folding sections for folding the first and second side panels relative to the bottom panel. At this point in the method, the integrally-wrapped sections of paperboard material are slit transversely at spaced apart points to form an integral box component of the desired length. Then, the transversely-extending edges of the integral box component are coated with a suitable waterproofing material, such as liquid plastic, to seal such transverse edges against the absorption of moisture and humidity.

The present invention is also directed to a paperboard lid for a box having a bottom panel, a pair of side panels, arid a pair of end panels, wherein the novel paperboard lid of the present invention includes a central lid section having inner and outer surfaces, and a folded lid section or paperboard cleat formed on each end of the central lid section. The central lid section is formed from a sheet of paperboard material, with the inner and outer surfaces thereof each being covered by a layer of protective paper material. Preferably, the protective paper material is treated with waterproofing agents or wet-strength agents. In addition, each of the folded sections or cleats is formed from a plurality of sheets or strips of paperboard material, with each of the sheets being covered on their respective inner and outer surfaces with a layer of protective paper material. In the preferred embodiment, each of the folded sections or cleats is formed from three spaced-apart strips of paperboard material, which are folded relative to each other, and a portion of the edge of the central lid section. In addition, the folded strips of paperboard material are connected together by the protective paper material. Each of the folded sections rests 205186 on the outer surface of the central section adjacent the end thereof, and cohesive material adheres the folded sections to the central lid section upon contact. In addition, each of the folded sections or cleats is provided with holes formed therein adapted to receive nails or the like for attaching the paperboard lid to a box.

The present invention is also directed to an improved method of forming a paperboard lid for a box having a bottom panel, a pair of side panels, and a pair oC end panels. The method comprises the steps of continuously supplying a sheet of paperboard material having first and second surfaces to a work station and applying a first sheet of protective paper material to cover the first surface thereof. The covered sheet of paperboard material is then slit at a plurality of spaced-apart points to Eorm a central lid section, a first group of strips of paper-board material on one side of the central lid section, and a second group of strips of paperboard material on the other side of the cencral lid scction. Next, a second sheet of protective paper material is applied to cover the second surface of the central lid section and the first and second groups of strips so as to hold together the central lid section and the groups of strips to form a composite unit. Next, a cohesive material is applied to the central lid section, at the edges thereof, and to a strip in each of the groups of strips, so that when the strips are folded relative to the central lid section, each of the folded sections adheres to the central lid section to form a cleat on each end of the central lid section. Continuing with the method, after the cohesive material is applied, the composite unit is transversely slit to form separate lids, and in the final step of the process, holes are formed in the 2 0 5 I 86 lids, within the cleat portions thereof, and these holes are adapted to receive nails or the like for hoLding the lids on the container or box.

Advantageously, as a result of the present invention, an improved integral and unitary box component is formed which may be assembled with end panels and a cover to form a complete shipping and packaging container. Such an integral box component has the advantages of increased stability, since each panel is formed from a single sheet of paperboard material, instead of separate sections held together by wrapping paper. It also has dimensional stability, since all of the panels of the integral box component are uniform in size. Also, since the panels are formed of single sheets, they are less prone to bend and have the advantage of providing smoother surfaces on which to print necessary product information. Not only does the present invention provide an improved product of increased strength, but the present invention also provides an improved method of continuously forming said integral box components from a continuously supplied sheet of paperboard material and wrapping or covering material. Such a process substantially reduces the cost of manufacturing such integral box components, yet provides boxes of increased strength and dimensional stability.

Advantageously, as a result of the present invention, there is provided a novel paperboard lid which is simple and inexpensive to manufacture in a continuous proccss, and which can be shipped in a flat configuration at a reduced cost. At the point of use, the foldable sections of the lid are folded relative to the central section of the lid to form the end cleats and the completed lid. This folding 205186 step is simple and quickly performed, since the foldable sections already have the cohesive material applied, so that the foldable sections easily adhere to the central lid section to form the completed lid at the point of use. Still further, the improved paperboard lid of the present invention can be recycled after use, which is not the case of the lids and covers used in the prior art.

BRIEF DESCRIPTION OF THE DRAWINGS I' Further objects, features, and advantages of the present invention will become apparent upon the consideration of the detailed description of the presently-preferred embodiments when taken in conjunction with the accompanying drawings, wherein: Figure 1 is an elevational view of the various steps in forming the integral box component of the present invention ; Figure 2 is a plan view of the apparatus shown in Figure 1; Figure 3 is an end elevational view showing the top and bottom wrap material being glued to each other to form the folding sections of the integral box component; Figure k is a perspective view of the integral box component of the present invention in a flat configuration before the side panels are folded upwardly relative to the bottom panel; Figure 5 is an elevational view of the various steps in forming the paperboard lid of the present invention; Figure 6 is a plan view of the apparatus and steps shown in Figure 5; Figures 7, 8, and 9 show the successive steps of folding the foldable sections of the lid to form the cleats on the opposite edges thereof; 5186 Figure 10 is a perspective view illustrating the integral box component after it has been folded and attached to two wooden end panels; and Figure 11 is a perspective view illustrating the novel paperboard lid of the present invention being flexed and applied to a box formed in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to Figure 1, there is illustrated the steps in the method of manufacturing the improved integral box component of the present invention. More particularly, as shown in Figure 1, individual layers of paperboard material 10, 12, and 14 are supplied from a continuous supply of paperboard material to a gluing station 16 which includes three sets of gluing rollers 18, 20, and 22 which apply glue to the individual layers 10, 12, and 14 of paperboard. material. The individual layers are then supplied to a set of pinch rollers 24, so that the individual layers of paperboard material, are glued together to form a single sheet of paperboard material 26 as it leaves pinch rollers 24. Accordingly, it will be understood that in accordance with the present invention, a sheet of paper-board material 26 is continuously supplied to form the integral box component of the present invention. It will also be noted that individual layers 10, 12, and 14 of paperboard material may be of any desired thickness to provide the required strength. For example, in the packaging of fruit, such as grapes, it is desirable that cach of the individual layers 10, 12, and 14 be formed of paper-board material having a thickness of 40 points, so that the sheet 26 of paperboard material has a thickness of approximately 120 points.

I a 205186 Next, the sheet 26 of paperboard material is supplied to a slitting station 28, and as will be noted in Figure 2, the slitting station 28 includes spaced-apart cutters 30 and 32 for forming longitudinal slits 34 and 36 in sheet 26 as it passes through slitting station 28. In this manner, the single sheet 26 of paperboard material is divided into three separate sections 38, 40, and 42 which, as will be explained hereinafter, become the bottom panel and the side panels, respectively, of the integral box component of the present invention.

The spacing between central paperboard section 38 and side paperboard sections 40 and 42 is maintained while the t sections are supplied to wrapping stations for covering the upper and lower surfaces of each of the sections with suitable material, such as Kraft paper, or liner paper having a waterproof capability. As shown in Figure 1, a roll of such paper or bottom wrap material is shown at 50 and is supplied through a weight box 52 and a plurality of bar guides 54 to a gluing station 56 which applies glue to one surface of the bottom wrapping material. Bottom wrapping material 50 is slightly wider than paperboard sheet 26, and as it passes through rubber rolls 58, it is adhered to the bottom or lower surface of paperboard sections 38, 40 and 42, to hold them together in a spaced-apart relationship, as shown in Figure 2.

After wrap material 50 and paperboard sections 38, 40 and 42 are adhered to each other, they are supplied to a folding station 60 which includes folding elements 62 and 64, as shown in Figure 2, which operate to fold and wrap the edges of wrap material 50, shown at 50a and 50b, about the longitudinally-extending edges 26a and 26b of paper-board sheet 26. It will be noted that edges 50a and 50b of 205186 wrap material are of sufficient width not only to cover the Longitudinal edges 26a and 26b but are also of sufficient width to be wrapped around to covcr and be glued to a portion of the upper surfaces of paperboard sections 40 and 42. Accordingly, as sheet 26 and wrap material 50 pass through wrapping or turning elements 62 and 64, edge portions 50n and 50b are folded to cover the upper surface of X">. paperboard sections 40 and 42 along its edges with the wrap V>' material, as shown at 40a and 42a. The paperboard sections 38, 40 and 42 and the wrapped edges 40a and 42a are now ready to have their upper surfaces covered with top wrapping material 70. In this particular embodiment, wrap materials 50 and 70 have a thickness of 18 points, but as will be understood, the thickness can be varied for the desired purpose.

As will be noted in Figure 1, a roll 70 of top wrap material is continuously supplied through bar guides 72 and weight box 74 to a gluing station 76 for applying glue to the undersurface of wrap material 70. Wrap material 70 is adhered to the upper surfaces of paperboard sections 38, 40 .and 42 by suitable rollers at roller station 78. As will be noted in Figure 2, the width of wrap material 70 is slightly less than the width of paperboard sheet 26 and its respective longitudinal edges 70a and 70b are shown in Figure 2 between rollers 78 and 80. As will be noted, the edges 70a and 70b of top wrap material 70 slightly overlap and cover wrapped edges 40a and 42a, which have been wrapped around onto the upper surface of the paperboard sections 40 and 42. In this manner, the upper and Lower , surfaces of paperboard sheet 26 are completely wrapped and sealed by wrap materials 50 and 70, and in addition, the longitudinally-extending edges 26a and 26b of paperboard sheet 26 are completely wrapped and enclosed by bottom wrap material 50. w Next, the paperboard sections 38, 40 and 42 and layers of wrap material 50 and 70, which are now integrally connected, are supplied to a roller station 80 having rubber wheels 82 and 84 formed thereon, which arc in line with the longitudinally-extending slits 34 and 36, respectively. As shown in Figure 3, as the integral layers pass roller station 80, rubber wheels 82 and 84 engage the upper wrap material 70 and press it into engagement with lower wrap material 50, so that upper and lower wrap materials 50 and 70 are glued together along respective longitudinal slits 34 and 36.

Referring again to Figure 2, the integral layers are pulled by pulling rollers 92 to a transverse slitter 94 for transversely slitting the integral layers to form sheets of desired length. For example, typical for such box components are lengths of 17-1/2 inches, but as will be understood, such sheets may be cut transversely to form sheets of any desired length.

Next, sheets 96 which have been transversely cut to the desired length are supplied to a work station 98, partially shown in Figures 1 and 2 which, in one operation, prints necessary product information on one surface of each sheet 96. In addition, at the same time, sheet 96 is die cut to form ventilation holes 100 along longitudinally-extending sections 34 and 36 which form the folding sections. Finally, the transversely cut edges 1.02 are coated with suitable waterproofing material, such as liquid plastic, to seal such transverse edges against moisture .*ind humidity.

The completed integral. box component LL0 of the present invention is shown in Figure 4. As will be noted, central sheet section 38 is formed into bottom panel. 112, 2051 side section 40 is formed into side panel 114, and side section 42 is formed into side panel 116. In addition, the longitudinally-extending slits 34 and 36 which have the upper and lower layers of wrapping material 50 and 70 adhered together are shown in Figure 4 as folding sections 118 and 120, respectively, with ventilating holes 100 formed therein. As will be understood, side panels 114 and 116 are adapted to be folded upwardly relative to bottom panel 112 about longitudinal-folding sections 118 and 120. As will be seen in Figure 10, in this folded position, end panels 124 and 126 are placed between side panels 114 and 116 and are nailed or otherwise attached to the bottom panel 112 and side panels 114 and 116. In addition, a suitable cover is applied to the container after it has been filled with fruit or the like, such as grapes, for storage and shipping. The end panels are typically formed of wood, and the cover may be nailed or otherwise attached to the upper surfaces of the end panels to complete the assembly of the shipping container.

In view of the foregoing, it will be noted that there has been provided in accordance with this aspect of the present invention an improved product and a method of forming the product. More particularly, since the method of the present invention provides a continuous process for forming the integral box component 110, it is relatively inexpensive. In addition, because each of the panels 112, 114, and 116 are formed from a single sheet of paperboard material. 26, each panel is strong and less prone to bending than prior art arrangements. Further, the present invention provides increased dimensional stability, since each of the panels is uniform in size. Still further, the completed integral box component 110 provides a smooth surface for printing thereon, which is important in high-speed opera-t ion. 205 y We now turn to a detailed description of that part of the invention relating to the method and apparatus for forming the novel paperboard lid of the present invention, reference being had to Figures 5 through 11 of the drawings. More particularly, as shown in Figure 5, a continuous sheet of paperboard or chipboard material 130 is continuously supplied from pinch rollers 132 to a first station 134 at which a sheet of protective paper material 136 is applied to cover the upper surface 138 of paperboard sheet 130. As will be understood, such protective paper material 1.36 is supplied from a roll (not shown) through a weight box 140 to gluing rollers 142 which apply glue to the undersurface of protective paper 136 so that it may be glued to the upper surface 138 of paperboard sheet 130 as these sheets pass through pressing rolls 146 for adhering the two sheets 130, 136 to each other to form a composite. In the preferred embodiments, the protective paper material 136 may either be Kraft paper or paper material treated with waterproofing agents or wet-strength agents.

Continuing with the description of Figures 5 and 6, paperboard sheet 130 and paper material 136 are supplied to a slitting station 150 which includes a plurality of slitting rollers 152, 154, 156 , 158, 160, and 162 mounted on a common shaft 164 for forming longitudinally-extending slits in the paperboard composite, which slits may be designated with the reference numerals 166, 168, 170, 172, 174, and 176. As a result of this slitting proccss, a central lid section 180 is formed, and a foldable section 182 is formed on one side of central lid section 180, and a foldable section 184 is formed on the other side of central lid section 180. Foldable lid section 182 includes a group of strips 186 , 188, and 190, and foldable lid section 184 2 01 I 8 includes a group of strips 192, 194, and 196. As the central lid section 180 and the foldable lid sections 182 and 184 are moved longitudinally to the next work station, the proper spacing of the slits between the strips is maintained by a series of guides or guide rollers 193. As will also be noted, the slits 166, 168, 170, 172, 174, and 176 within each group are of different sizes. For example, slit 166 is approximately equivalent to double the thickness of the paperboard sheet 130, whereas spacing or slit 168 is approximately equal to three thicknesses of paper-board sheet 130, and whereas spacing or slit 170 is approximately equal to four thicknesses of paperboard sheet 130. This is also true of the slits 172, 174, and 176 in foldable section 184.

Continuing with the process, central lid section 180 and foldable lid sections 182 and 184 are supplied to a bottom wrapping station 200 in which a bottom layer of protective paper material 202 is applied to the bottom surface 204 of paperboard sheet 130. Protective paper material 202 is of the same type as protective paper material 136. As will be understood, a sheet of protective paper material 202 is supplied from a supply roller (not shown) through a weight box 206 to a gluing station 208, which applies glue to one surface of paper material 202. As the layer of protective paper material 202 passes about roller 210 and passes through rollers 214, it is glued to the undersurface 204 of paperboard sheet 130 to form a composite unit 212 in which the layer of paper material 202 holds together central lid section 180 and the various strips of foldable sections 182 and 184. In addition, as the sheet of paper material 202 is adhered to the bottom surface of paperboard sheet 130, the spacing described 2 0 5 1 S above of slits 166, 168, 170, 172, 174, and 176 is maintained in a uniform manner, so that the foldable sections 182, 184 can be folded relative to central lid section 180, iri a manner to be explained.

Composite unit 212 is next applied to a gluing station 220 comprising a plurality of gluing rollers 222, 224, 226, and 228. Gluing rollers 222 and 228 are on the underside of composite unit 212 and respectively apply a cohesive material to the underside of strips 188 and 194. In addition, gluing rollers 224 and 226 respectively apply a cohesive material to the edges 180a and 180b of central lid section 180 on the upper surface thereof. As will be explained, when foldable section 182 is folded relative to central lid section 180, the cohesive material on the lower surface of strip 188 engages and adheres to cohesive strip 180a. Similarly, when foldable section 184 is folded relative to central lid section 180, the cohesive material on the lower surface of strip 194 engages and adheres to the strip of cohesive material 180b.

Next, the composite unit 212 is applied to a cutting station 240 which transversely slits the composite unit 212 at appropriate intervals to form unfolded lids 214 of the appropriate width. Next, the paperboard lids 214 are supplied to a die-cutting station 250 which die cubs a plurality of slits into the unfolded lid as shown at 252, 254, 256, 258, 260, 262, 264, and 266. As will be noted, these slits are longitudinally extending and are adapted to be folded relative to each other, in a manner to be explained, to form holes for receiving nails. In this manner, the unfolded paperboard lid member 214 of the present invention is formed in a flat configuration and is ready to be stacked, transported, and shipped to the desired location where it will be folded up to form the completed lid ready for use. 205 *86 More particularly, Figures 7, 8, and 9 illustrate the procedure for folding foldable lid sections 182 and 184 relative to central lid section 180 to form the completed lid. As will be noted, the strips of each of the foldable lid sections are held together by the sheet of protective paper 202 which covers each of the slits between the strips. In this manner, at the point of use, outermost strip 186 can be folded about slit 166 to overlap middle strip 188, and at the other end of the lid, outermost strip 196 is folded about slit 176 to overlap middle strip 194. As explained above, slits 166 and 176, and the protective paper 202 in the slits, have a width equal to approximately two layers of paperboard material 130, so that this folding step can take place. Next, as shown in Figure 8, strips 186 and 188 are folded about slit 168 to overlap strip 190, and at the other end of the lid, strips 196 and 194 are folded about slit 174 to overlap and engage strip 192. As explained above, slits 168 and 174 and the paper 202 in the slits have a width approximately equal to three sheets of paperboard material 130 to accommodate these folding steps. At this point in the folding process, the glue or cohesive material 188a on the underside of strip 188 and the glue 194a on the underside of strip 194 are now on the top of the respective folded sections 270, 272. Accordingly, as shown in Figure 8, when folded section 270 is folded about slit 170 relative to central lid section 180, the cohesive strip 188a engages and adheres to the cohesive strip 180a on the edge of central lid section 180 to form cleat 282. Similarly, at the other end of the lid, when folded section 272 is folded about slit 172, cohesive strip 194a engages and adheres to cohesive strip 180b on the edge of central lid section 180 to form cleat 284, as shown in Figure 9. As explained above, slits 170, 172, and the protective paper 2 0 518 6 202 in the slits, have a width equal to approximately four sheets of paperboard 130 to allow for the folding operation.

As will also be noted in Figure 9, during the folding process, slits 252 and 258 become vertically aligned with each other to form nail hole 274 in cleat 282, whereas slits 254 and 256 become vertically aligned with each other to form nail hole 276 in cleat 282, whereas slits 262 and 264 form nail hole 278, and slits 260 and 266 form nail hole 280, both in cleat 284.

As will be understood, in accordance with the present invention, this folding process shown in the sequence of Figures 7 through 9 is easily and quickly performed at the point of use to easily and quickly form the completed paperboard lid of the present invention.

Referring now to Figures 10 and 11, there is shown the integral box component 110, formed in accordance with the present invention, which is nailed by a plurality of nails 290 to end wooden panels 124 and 126 to form the base of the container. In addition, nails 292 are placed within the upper surface of the wooden end panels 124 and 126 so that they are adapted to receive the folded-up lid shown in Figure 9. As shown in detail in Figure 11, the completed lid is flexed so that the nail holes 274 and 276 are adapted to be slid into engagement with nails 292 on panel 126, and once these are in place, the remaining nail holes 278 and 280 are adapted to be slid into engagement with nails 292 on end panel 124.

In this manner, the box and cover are completely assembled and ready to be shipped with the grapes and/or other fruit contained therein. It will be appreciated that there has been provided in accordance with the present invention a paperboard box component 110 and a paperboard lid which are simple and inexpensive to manufacture in a 205186 continuous process, and which can be shipped in a flat configuration at a reduced cost. In addition, at the point of use, the box component 110 is easily assembled with the wooden end panels 124 and .126. Also, at the point of use, the novel paperboard lid can easily and quickly be folded from its flat configuration into its final configuration to form cleats 282, 284, and the respective nail holes, so that the cover may easily and quickly be applied to the box. Finally, as the entire lid and the integral box component 110 are made from paperboard and paper material, they can be recycled after use.

A latitude of modification, change, and substitution is intended in the foregoing disclosure, and . in some instances, some features of the invention will be employed without a corresponding use of other features. For example, the folded sections may be held together by staples or other fastening means, such as glue, hot melt adhesive, or contact adhesive, instead of by cohesive material, as described herein. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the spirit and scope of the invention herein.

Claims (17)

205186 -21- WMAT f/WE CLAIM IS:

1. An integral box component for use in a box having a bottom panel, first and second side panels, and a pair of end panels, said integral box component:, comprising: a bottom panel formed of a sheet of paperboard material; a first side panel formed of a sheet of paper-board material and spaced apart from said bottom panel to form a first folding section therebetween for folding said first side panel relative to said bottom panel; a second side panel formed of a sheet of paper-board material and spaced apart from said bottom panel to form a second folding section therebetween for folding said second side panel relative to said bottom panel; said bottom panel and said first and second side panels defining an inner surface, an outer surface, and outer longitudinally-extending edges on said first and second side panels; a sheet of bottom wrap protective paper material covering said outer surfacc, said outer edges, and a portion of said inner surface adjacent said outer edges of said first and second side panels; a sheet of top wrap protective covering said inner surfaces of said bottom first and second side panels; and said top wrap material and said bottom wrap material being adhered to each other "to form said first and second folding sections and form said integral box ccsnnponent. paper material panel and said 20b1S& -22-

2. The integral box component in accordance with Claim 1, having transversely-extending edges covered with a waterproofing material to seal same against the absorption of moisture and humidity.

3. The integral box component in accordance with Claim 1, said first and second folding sections having ventilation holes formed therein.

4. The integral box component in accordance with Claim 1, wherein said top and bottom wrap paper materials are formed of Kraft paper.

5. The integral box component in accordance with Claim 1, wherein said top and bottom wrap paper materials are treated with waterproofing agents or wet-strength agents.

6. The integral box component in accordance with Claim 2, wherein said waterproofing material is liquid plastic .

7. The integral box component in accordance with Claim 1, wherein said top and bottom wrap materials are glued to said bottom panel and said first and second side panels.

8. The integral box component in accordance with Claim 1, the edges of said top wrap material overlapping and covering said bottom wrap material on said inner surface . -23- 205186

9. The integral box component in accordance with Claim 1, said bottom panel and said first and second side panels each being formed of a single sheet of paperboard material formed from a plurality of layers of paperboard material.

10. A method of forming an integral box component for a box having a bottom panel, first and second side panels, and a pair of end panels, comprising the steps of: laminating layers of paperboard material to form a single sheet of paperboard material; longitudinally slitting said sheet of paperboard material to form a central bottom panel, and first and second side panels spaced from said central bottom panel and defining first and second longitudinally-extending spaces; said bottom panel and said first and second side panels defining an inner surface, an outer surface, and outer longitudinally-extending edges on said first and second side panels; applying a sheet of bottom wrap protective material to cover said outer surface, said outei" edges, and a portion of said inner surface adjacent said outer edges of said first and second side panels, and to cover said first and second longitudinally-extending spaces; applying a sheet of top wrap protective material to cover said inner surface of said bottom panel and said first and second side panels and to cover said first and second longitudinally-extending spaces to form a composite of said paperboard sheet, and said sheets of bottom and top wrap materials; 205186 -24- adhering said top wrap material and said bottom wrap material to each other at said first and second longitudinally-extending spaces to form first and second folding sections for folding said first and second side panels relative to said bottom panel; and transversely slitting said composite to form said integral box component.

11. A method in accordance with Claim 10, further including the step of coating the transversely-extending edges of said integral box component with a waterproofing material to seal same against the absorption of moisture and humidity.

12. A method in accordance with Claim 10, further including the step of forming ventilation holes in said first and second folding sections.

13. A method in accordance with Claim 10, wherein said step of applying said top wrap material includes the step of covering a portion of said bottom wrap material on said inner surface.

14. A method in accordance with Claim 10, wherein the step of applying said sheets of bottom and top wrap material includes the step of gluing said sheet of bottom and top wrap materials to said sheet of paperboard material.

15. A method in accordance with Claim 10, wherein the step of adhering includes the step of gluing said top and bottom wrap materials to each other. 205186 -25-

16. An integral box component as claimed in claim 1 and substantially as herein described with reference to the accompanying drawings.

17. A method of forming an integral box component as claimed in claim 10 and substantially as herein described with reference to the accompanying drawings. •gccK Gcvetfs pkc, £•■/ !*=»/>: :'r r.-j^oriscd Agents. A. J. FAHK Ci SON,