US2261164A - Filler package - Google Patents

Description

A. KRAu ss FILLER PACKAGE Nov. 4, 1941.

Filed Aug. 25, 1939 ll Sheets-Sheet l I Nov. 4; 1941. A. KRAUSS FILLER PACKAGE Filed Aug. 25, 1939 fiCDIQ 35K),

11 Sheets-Sheet 2 Nov. 4, 1941; A. KRAUSS 2,261,164

FILLER PACKAGE Filed Afigf 25," 1939 ll Sheets-Sheet 4 A. KRAUSS FILLER PACKAGE Nov. 4, 1941.

Filed Aug. '25, 1959 ll Sheets-Sheet 5 Nov. 4, 1941.

'A. KRAuss FILLER PACKAGE 11 Sheets-Sheet 6 Filed Aug. 25, 1939 flllllllllllllllll A. KRAUSS FILLER PACKAGE Nov. 4,1941.

v w t w e m 4 S w ,w w w z /I l l 3 V Z I A a g 7; I Z 3 v w 7 t f 5 a. 05 0 45 025 r g. r m M M. 4 h A F i w I a Hg VH awuim 5 1 v w v, v 2: \A 41 mmw m MW H I Fm E w w 9) 4 Z. v m MW L A. KRAUSS FILLER PACKAGE Nov. 4, 1941.

Filed Aug. 25, 1939 l1 Sheets-Sheet 8 Nov. 4, 1941. I

A. KRAUSS 7 2,261,164

FILLER PACKAGE Filed Aug. 25, 1959 11 Sheets-Sheet 9 Nov. 4, 1941.

A. KRAUSS FILLER PACKAGE Filed Au 25, 1939 11 Sheets-Sheet 10 NOV. 4, 1941. uss 2,261,164

FILLER PACKAGE Filed Aug. 25, 1939 ll Sheets-Sheet ll .mm'llW i .nlllllllmlll w Patented Nov. 4, 1941 UNITED STATES P TENT QFFICE mesne assignments, to Egg-Safety Carton Corporation, New York, N. Y., a. corporation of Delaware Application August 25, 1939, Serial No. 291,979

35 Claims.

My present-invention relates to a filler package comprising one or more cellseach adapted to receive and protect whatever article or object is placed therewithin. The present application is a continuation-in-part of my application filed August 16, 1937, Ser. No. 159,261 for a Filler package, and the structure herein disclosed will serve as a package which, with others, complete with intended contents, may be stored or shipped in packing cases or other containers, and, when removed therefrom, be delivered to customers in quantities of one package or multiples or fractions thereof.

The filler package herein described may be advantageously produced from a single sheet of paper or other suitable material which provides in an integral structure a number of individual load sustaining cells each having capacity for a single egg or other like article which requires protection. The sheet itself, in its initial stage, is desirably scored along lines whereon the sheet is to be bent for erection into a filler. In. this operation the overall size of the sheet contracts. Owing to its inherent resiliency or otherwise, the sheet may tend either to flatten out again, thus expanding toward its original size and shape, or to further contract. Such a filler, in certain of the exemplifications disclosed, may require in its assembly a second element, viz., a securing means by which to retain the filler structure in a fixed condition of erection. Such a securing means may be of various kinds, as for example a sticker applied to one or more sides of the filler, a band, an enclosing carton, or any like device.

The present filler package is advantageous on account of its simplicity of construction, the ease with which it may be produced and erected, and the low cost which is involved in. its manufacture. Additionally, the filler, which is of onepiece construction, may be shipped or stored substantially flat in knocked-down condition, requiring for its erection only a pressure applied to its opposite sides by which to produce a bending of the sheet along the lines of its preformed scorings; or it may be stored or shipped in a partially or completely erected condition, nested withv others so as to occupy a minimum of Space. When fully erected, the filler is contracted to a minimum, its multi-lateral cells being then reduced to their smallest size although of maximum depth; when erected only partially, however, the filler contraction is somewhat less, the size of the cells being then increased with a consequent lessening of their depth. Itis accordinglypossible to utilize the filler for the accommodation of articles of Varying sizes depending upon the extent to which the filler is contracted or expanded. A

cushion support is furnished to the articles contained within the cells so as to afford adequate protection against-breakage. Being made of a single piece of paper, thereare no operations of pasting or assembling with a consequent increase in time, effort and expense; the weight of the filler is'also kept down to a minimum. The form of the cells is such that the filler may, if desired, be reversed, in which event other cells are afforded on the'under side of the filler. I may provide in the cells spring seats for the sustained articles which also hold them securely in place, so that if the filler is tilted or overturned there will be no loss of contents. The construction also lends itself to severability along lines which may in large part be non-coincident with-the bend lines of the sheet, thereby obviating any excess .of weakness in the filler when it is to be handled as a unit.

It is possible to variously embody my invention while still retaining the features of advantage and improvement which have been set forth herein and which will be more fully developed later. .By way of exemplification, the accompanying drawing illustrates filler packages or filler units .in the manner following:

Figure 1 is a view in perspective of a packing or. shipping case with the walls broken away to exhibit a plurality of-filler packages arranged .therewithin; Fig. 2 is a perspective view of a filler package, size 6 x 6, a portion of the retaining element being broken away; and Fig. 3 is a perspective view of the filler package sub-divided into three smaller units, two of which are 3 x 4 and the other 2 x 6.

Fig. 4 is a development view .of a sheet which is shaped and scored (or otherwise acted upon) for producing one form of a 3 x 4 filler unit; Fig. 5 is a view in perspective of the completed package in which the filler unit is made from a sheet partial erection; and Fig. 9 is a similar View showing the filler unit completely erected.

for production of a 3 x 4 filler unit of modified form; Fig.11 is a view of the completely erected filler. unit made from a sheet according to Fig.

Fig. 10 is a development view of a sheet which is shaped and scored (,or otherwise acted upon) and Fig. 12 is a side elevation of the same filler unit.

Fig. 13 is a development view of a sheet which is shaped and scored (or otherwise acted upon) for the production of a 3 x 4 filler unit having vertical walls at its ends instead of at its sides as in the two filler units of the preceding figures.

Fig. 14 is a development view of a rectangular sheet which is shaped and scored (or otherwise acted upon) for the production of a 3 x 4 filler unit of still diiferent form; Fig. 15 is a perspective view of the erected filler unit made from the sheet according to Fig. 14; Fig. 16 is a transverse section taken on line l6--l6 of Fig. 15; and Fig. 1'7 is a detail in section taken on line lT-l'l of Fig. 16.

Fig. 18 is a view in perspective of a filler package 3 x 4 in size, which is complete with its own covers, one of which is opened to expose some of the cells therewithin; Fig. 19 is a development view of the sheet which is shaped and scored (or otherwise acted upon) for the production of the filler package shown in Fig. 18; and Figs. 20 and 21 are detail views thereof in vertical section, the former taken on line 20-20 of Fig. 18, and the latter taken on line 2l-2| of Fig. 20.

Fig. 22 is a View in perspective of another form of filler package 3 x 4 in size, complete with covers, one of which is opened to expose some of the cells interiorly thereof; Fig. 23 is a development view of the sheet which is shaped and scored (or otherwise acted upon) for the production of the filler package shown in Fig. 22; and Fig. 24 is a detail thereof in section taken on line 2424 of Fig. 22.

Fig. 25 is a top plan view of another form of filler unit 3 x 4 in size, having a special cellular structure; Figs. 26 and 27 are details thereof in section taken respectively on lines 2626 of Fig. 25 and 21-21 of Fig. 26; and Fig. 28 is a development view of one half the sheet which is shaped, scored (or otherwise acted upon) and slitted for the production of the filler unit shown in Fig. 25.

Fig. 29 is a view in perspective of another form of filler package 3 x 4 in size, complete with covers of its own, the sheet from which this package is produced being illustrated in a development View in Fig. 30.

Figs. 31 and 32 are perspective views of another form of filler package, 3 x 4 in size, opposite side and end walls being shown in these figures; and Fig. 33 is a development view of onehalf the sheet which is shaped and scored (or otherwise acted upon) for the production thereof.

Fig. 34 is a view in perspective of another form of filler package, 3 x 4 in size, producible from a sheet which is shaped and scored (or otherwise acted upon) as illustrated in the development view of Fig. 35, a detail of the cellular structure thereof being shown in Fig. 36, which is a section taken on line 36- -36 of Fig. 34.

Fig. 37 is a View in perspective of another form of filler package, 3 x 4 in size; Fig. 38 is a sectional detail taken on line 38-38 of Fig. 3'7; and Fig. 39 is a development view of one-half the sheet which is shaped, scored (or otherwise acted upon) and slitted for the production thereof.

Fig. 40 is a view in perspective of another form of filler package, 2 x 6 in size; Fig. 41 is a sectional detail thereof taken on line 4|4| of Fig. 40; and Fig. 42 is a development view of the sheet which is shaped, scored (or otherwise acted upon) and slitted for the production thereof.

Fig. 43 is a view in perspective of another form of filler unit, 3 x 4 in size, producible from a sheet which is shaped and scored (or otherwise acted upon) as illustrated in the development view, Fig. 44.

Fig. 45 is a view in perspective of another form of filler unit, 2 x 3 in size, producible from a sheet which is shaped and scored (or otherwise acted upon) as illustrated in the development (fragmentary) view, Fig. 46, a transverse section thereof, taken on line 41-41 of Fig. 45, being shown in Fig. 47.

Fig. 48 is a view in perspective of another form of filler unit, 1 x 3 in size, producible from a sheet which is shaped and scored (or otherwise acted upon) as illustrated in the development view, Fig. 49, a longitudinal section thereof, taken on line 50-50 of Fig. 48, being shown in Fig. 50.

Referring to Figure 1, I have shown a case A such as is customarily used for the packing of thirty dozen eggs. According to general practice, a succession of flats and 6 x 6 bottomless fillers are arranged in tiers with an egg accommodated within each of the filler cells so as to provide a separation and protection as well. When so packed, the case may be stored or shipped. It is convenient herein to refer to eggs by way of illustration, and in the ensuing description I shall so proceed, it being understood, however, that the filler package of this invention is adapted for advantageous use with articles other than eggs and often in environments which are entirely foreign thereto.

In the case shown in Fig. l, the eggs E are sustained within the individual cells of packages each comprising a 6 x 6 filler unit F and an associated retainer 1'. Upon opening of the case, each filler package which is removed therefrom will appear as in Fig. 2. For convenience in retail sales, it may be desirable to sub-divide each filler package into smaller units of one dozen capacity, such for example as are shown in Fig. 3. When so sub-divided, the filler units may each require an associated retainer 1. The precise form of the retainer is relatively unimportant; it may be an enclosing carton C (as shown in Fig. 5), a band (as shown in Figs. 1 and 2), or it may be a sticker (as indicated in Figs. 3 and 5), or even a piece of string (not shown). The purpose of the retainer is to maintain the filler unit in a fixed size and shape such as is required for the safe accommodation of the articles contained therewithin.

The construction of the filler unit having the form illustrated in Figs, 4 to 9 will now be described. As already indicated, the fillers may be of various forms, each produced from a sheet which is specially prepared therefor. The sheet of Fig. 4 is generally rectangular with opposite sides straight and unbroken. Parallel with the sides are certain straight lines of bend, a, b, c, d, e, and 1, here shown as equally spaced, and produced conveniently as by scoring of the material. Any other way of producing lines along which the sheet material is induced to bend may also be employed-perforations, for example. By using six bend lines, as shown in Fig, 4, I define seven rows extending lengthwise of the sheet. Crossing the sheet so as to intersect the straight bend lines are other bend lines, Z, m, n, o, and p, which proceed in zigzag fashion. By way of distinction I shall refer to these zigzag lines as angular. Each angular bend line traverses the first row obliquely, the second row transversely, the third row obliquely at a complementary angle, the fourth row transversely, the fifth row obliquely at an angle the same as in the first row, the sixth row transversely, and the seventh row obliquely the same as in the third row. The sections of all angular lines within the same vertical row are parallel, and in consequence the horizontal rows between each pair of angular lines are of constant width from end to end. The terms vertical and horizontal are here used in a location sense in relation to the position of the parts as shown in Fig, 4 of the drawings.

The crease of each angular bend line is unidirectional, but the direction of crease of each angular line is reversed with respect to those adjacent, i. e., there is no alternation from end to end; the straight bend lines, however, are alternately creased between the several angular bend lines, i. e., each section of a straight bend line between one pair of angular bend lines is creased for a bend in one direction and then in the next adjacent section is creased for bending in the opposite direction, and so on alternately throughout its length. This alternate creasing arrangement of the straight bend line a, for example, is duplicated for the next adjacent straight bend line b, but is reversed for the next two straight bend lines and d, and again is reversed for the last two straight'bend lines e and f whose creasing arrangement is the same as that for the lines a and b.

By the provision of intersecting sets of bend lines, one straight and the other angular, there is defined over the surface of the sheet a plurality of panels in rows, those in one row lengthwise of the sheet, designated as P, being parallelograms in the form of rhomboids, and those in the next row, designated as B, being rectangular, and so on alternately crosswise of the sheet.

As already indicated, the shape of the sheet illustrated in Fig. 4 is generally rectangular. While its opposite sides are straight and unbroken, the two ends are otherwise formed. One, shown at the top, is characterized by a pair of wings to one being extended beyond the end of each outermost row of parallelograms and separated from the adjacent parallelograms and separated from the adjacent parallelogrammatic panel by an angular bend line as and by a truncated extension piece with triangular wings which continues beyond the three center rows for a distance slightly more than two of the rectangular panels. Between this extension piece and the body of the sheet the angular bend line is extended, being coincident with the sheet ends opposite the outer rows of rectangular panels, and proceeding in parallelism with the remaining angular bend lines. The extension piece is traversed by an angular bend line 11 which crosses its triangular wings and two rectangular panels, this line being parallel with the others just referred to. Near the end of the extension piece is a small end flap 25 defined by a bend line 2.

The opposite or lower sheet end is configured in a way which is complementary to the extension pieces along its top end, i. e., by the provision of two extension pieces with end flaps 25, one adjacent each side of the sheet. and each separated from the other opposite the center row of rectangular panels Each extension piece which is traversed by an angular bend line 1/ is joined to the body of the sheet along an angular bend line at, the same as is the extension piece at the top of the sheet. In the center between the two extension pieces, beyond a bend line 11:, is a small flap 26. The material for the sheet from which the filler is to be made may be paper having somedegree of resiliency Any other material which will meet satisfactorily the requirements of this invention may also be used. The bend lines may, however, be formed otherwise than by scoring. If desired, they may be partially slitted, or be perforated or otherwise weakened. It is desirable, however, that lines of bend be provided so that in the ensuing operation of erection the several panels of the sheet will take up predetermined positions in which they serve as walls to define cushion cells each capable of sustaining an intended load. It may be found advantageous to impart to the sheet initial bends when the bend lines are first produced, in which event the sheet will no longer remain perfectly flat. Such an initial bend, however, need be only slight in order to facilitate the further bending that is required for complete erection of the filler. The bending movements following the initial bend just described may be induced manually by applying to opposite sides of the sheet a contracting pressure whereby to cause a further bending in the direction of the creases with a consequent repositioning of the panels for defining multi-lateral. cells.

In commercial practice the sheets with bend lines thereon may be stacked one upon another so as to occupy a minimum of space. It makes little difierence whether the sheets be perfectly flat or whether they have an initial bend, when so stacked. In this condition they may be conveniently shipped to a packing plant or other point of use where erection takes place.

A sheet according to Fig. 4 is designed, while undergoing erection, to pass through a stage which is indicated in Fig. 8; with continued contraction of the sheet, a final stage of erection will be reached, as shown in Fig. 9. The erected filler is thereupon conditioned for association with its retainer 1' which may be of any of the forms already suggested, such as a small band 21 or a carton C, or both, as shown in Fig. 5. When erected and so retained, the filler unit and retainer become a complete package with a plurality of load sustaining cells each providing a cushion support and protection for the articles contained therewithin.

In the erected structure (see Fig. 9) all of the parallelogrammatic panels in the outside rows are arranged in pleats to form two of the outer sides of the filler. Each panel which is in interlapped relation with the oneadjacent provides along the top and bottom edges of the filler a discontinuous line which is made up of the several angular bend lines Z-p with the bend lines at also occurring in the same longitudinal row. Each cell of the filler is formed by two adjacent rectangular panels in diverging relation with a line of joinder in the bottom plane of the filler, and by opposite side walls each made up of interlapped parallelogrammatic panels from adjacent rows of the sheet. Each cell is multi-lateral in that it comprises a plurality of sides, four being the number shown. One of the diverging rectangular walls of each cell is joined to the adjacent parallelogrammatic panels which extend'in substantially vertical planes, there being a continuous top edge, formed by a fold along the bend lines, extending around three sides of the cell. The top edge for the remaining side is formed by a fold along the bend line between the other diverging wall of the same cell and the diverging wall in the next adjacent cell.

The ends of the filler may be left substantially open, as shown in Figs. 5 and 9, where the flaps 25 and 26, of which there are several, are downturned to exert an outward pressure against any adjacent walls-an enclosing carton for example. In this way the filler is adequately cushioned against external shocks.

As suggested in Fig. 8, the filler passes through an intermediate stage before reaching a condition of complete erection. In this intermediate stage the cells of the filler are partially distended as well as open. The depth of the cells is also somewhat less than when complete erection has taken place. Owing to the fact that the cells are of different size than when the filler is completely erected, it is possible to accommodate within such distended cells articles whose shape or character may adapt them for fitting therewithin. Under such conditions the retainer may be applied to the filler so as to hold it at the desired point of erection. By so proceeding, it is possible to utilize a single set of dies or other instruments for producing bend lines in the sheet which may thereafter be erected to whatever extent is desired, according to the nature and size of the articles to be contained therewithin.

The filler just described is produced from a sheet which is other than rectangular. form of the filler, made from a sheet having three straight unbroken edges, is illustrated in Figs. 10-12. Inasmuch as this sheet is provided with six straight bend lines parallel with each other and with opposite sides of the sheet, I have desig- 1 nated them as a to f, respectively, the same as in Fig. 4. Also, angular cross lines I to p, the same as those shown in Fig. 4, are employed to define with the other set of lines rows of parallelogrammatic panels P in alternation with other rows of rectangular panels R. In addition, other angular cross lines a: and y beyond the lines 2-1) are provided, as shown. At the end of the sheet which is straight and unbroken, a triangular flap 30 is defined opposite each outside 1 row of parallelograms; a rectangular flap 3| extends beyond the outer row and adjacent thereto are other triangular flaps 32 opposite the adjacent rows.

The opposite end of the sheet is formed with spaced extension pieces, much the same as those illustrated along the lower end of the sheet of Fig. 4, with small rectangular flaps 33 at the end of each. Between these extension pieces is a flap 34. change in the proportions to the extent that the rows of parallelogrammatic panels are somewhat narrower than the adjacent rows of rectangular panels, with the exception of the row of parallelograms along the left side of the sheet. In the erected filler (see Fig. 11) the narrower rows of parallelograms provide only a partial separation between adjacent rows of multi-lateral cells, there being open communication between these cells in their upper region. This may be of advantage in many cases, for example where ventilation is an important consideration. The wide row of parallelograms along the left side of the sheet provides a completely closed wall along one side of the filler, the same as shown in Fig. 9. Along the opposite side, however, the filler wall is not completely enclosed, but is open in its upper region due to the absence of a complete interlap between the narrower parallelograms. In all other respects, the filler illustrated in Figs.

Another In the sheet of Fig. 10, however, there is a--,

10 to 12 is the same in characteristics and formation as the one first described.

In the two forms of 3 x 4 filler units already described, the parallelogrammatic panels are extended vertically in pleated fashion along the longer sides of the structure. This is one way of doing it. Another way is to have such pleated parallelogrammatic panels form vertical walls along the shorter sides or ends of the filler. A sheet from which such a filler may be produced is illustrated in Fig. 13. Here it will be noted I employ the same arrangement of straight bend lines ah in intersection with angular bend lines l-n, defining alternate rows of parallelograms P and. rectangles R, the number of such rows, extended transversely of the sheet, being nine instead of seven as in the sheet previously considered. Beyond a bend line a: at each end are extension pieces each having an angular bend line 11. The resulting proportions of the sheet are somewhat altered. In all other respects, however, the construction is substantially the same as has been described in connection with Fig. 4. When erected, the sheet will produce a filler having its ends formed from the outer rows of parallelograms which interlap in pleated fashion.

Coming now to Figs, 14-17 inclusive, I have here shown a construction which is produced from a rectangular sheet each of whose sides is straight. As with the other sheets, I provide two sets of intersecting bend lines, one straight and the other angular. The straight lines are designated in order as a to k and the angular lines as Z to p. In addition, near one end of the sheet I provide a further angular bend line :L' and near the opposite edge of the sheet a straight bend line 2. The outermost rows of panels on opposite sides of the bend lines a and 7c are of the same width as the two intermediate rows of rectangular panels between the lines d-e and 9-71.. The remaining six rows, however, which are made up of parallelogrammatic panels, are shown as of substantially one-half this width. The panel row proximate to the bend line 2 is further defined by certain oblique bend lines 40 and 41 arranged in pairs each of which extends from a common point, at the juncture of one of the bend lines 0, f, and i with the angular bend line l, to the next adjacent straight bend line at its juncture with the line 2.

In the row of parallelograms to the outside of the bend line is, the line 40 continues on at 42 to the edge of the sheet at the end of the line m. From the opposite end of this line m a bend line 43 extends obliquely to the juncture of the lines a and a.

Each angular bend line is creased uni-directionally, but the direction of the crease in one such line alternates with that of the next adjacent angular bend line. The straight bend lines, on the other hand, are creased in reverse directions as they proceed from the space between two angular bend lines to the next adjacent space, such reverse arrangement being the same for all the straight bend lines except those designated as c, f and i which, while creased in alternate directions between successive spaces, are reversed with respect to the creases in the next adjacent straight lines. The arrangement is substantially the same as that already described in connection with Fig. 4.

In response to forces of compression, the sheet panels are bent as induced by the direction of its several creases to provide Walls which define a plurality of cushion cells each of which is load Sustaining. When fully erected, the adjacent rows of parallelogrammatic panels on opposite sides of the lines o, f and i will form V-walls interfitting in the lower portion of the filler so as to separate the cells at such points by four plies. Above this zone of interfittingthere is open communication between all cells in the same row. The ends of the filler are constituted by the outermost rows of parallelograms which interfit in pleated fashion. The sheet edges adjacent the bend lines a: and 2 may be turned outwardly and downwardly from the marginal edge, as shown. The triangles at the outside of the bend lines 42 and 43 may be bent over and downwardly. In

this manner I am enabled to use effectively a sheet which is rectangular in form, without having to specially configure any of its edges.

In the several forms of described filler units there are two sets of bend lines, one straight and the other angular, defining alternate rows of rectangles and parallelograms. The direction of creases of the bend lines are so faced as to induce movement of the panels to positions where they define multi-lateral cushion cells. In the erected filler, the outside walls upon two opposite sides (or ends) as well as the cell-defining walls parallel therewith, are all pleated. Each panel between the bend lines by which it is defined is endowed with life so as to be resilient to an appreciable degree; there is accordingly capacity on the part of several walls of each cell to yield, as required for the accommodation of articles of varying size and contour. A tensional engagement is maintained in consequence. Each filler unit, regardless of its form, is expansible or contractible in directions parallel with its sides and ends, all such movements proceeding. concurrently. The top edges of the several cells lie in a common plane and are folded in every instance. The same is true of the bottom edges of the filler, all such bends being at an acute angle. In every case the separating walls between the cells comprise at least two plies. The number of these plies may be increased, as in the case of parallelogrammatic panels, which are doubled and then interfitted (see Figs. and 17 for example).

It may be found desirable .to form in each filler cell a seat in which the egg or other accommodated article may be better fitted. Such a seat is shown in several figures of the drawings. For example, in Figs. 4 to 9, the seat s in each case comprises an oval cutout in one of the rectangular panels so that when the filler unit is erected two such openings will lie opposite each other to receive therebetween an egg or other article which is to be accommodated therewithin. In this manner the flexibility of each rectangular panel is somewhat enhanced, and it is permitted to make with the egg or other article an edge engagement which conforms with the article surface to a considerable extent. Another form of seat which may also be used to advantage is illustrated in the sheets of Figs. 13 and 14, where each rectangular panel is provided with an oval or circular bend line 58 from which radiate inwardly other slit lines 5| to a common central opening 52 to define a plurality of fingers 53 all of which yield sufiiciently to accommodate between them the egg or other article which is to be sustained (see Fig. 16) Due to the pleated character of the filler unit in which all of the cell walls retain a considerable degree of resiliency, a constant engagement may be maintained with the eggs or other accommodated articles at various points upon its surface entirely apart from the tensioned or frictional engagement which is afforded by the seats just referred to. An immovable retention of the eggs or other articles is accordingly assured, and, in practice, a loaded filler package may be tilted or even inverted without loss of the contents. As indicated in Figs. 1, 2 and 3, the filler pack ages may be of various sizes. For commercial purposes, 6 x 6, 3 X 4 and 2 x 6 filler units would probably be the most common. The filler units may be initially producedin, any of these sizes,

or they may be subsequently broken down to any of the smaller sizes. This may be accomplished conveniently with the aid of lines of severance which are provided in the sheet without, however. weakening the cell structure of the erected filler unit. As an example, reference is made to Fig. 4, Where a severance line 60, indicated by a succession of dashes, is shown as extending transversely across the sheet in angular fashion. It starts at one end of the angular bend line m, proceeding obliquely to the juncture of the second removed angular bend line 0 with the straight bend line a, thence coincident with the latter across the proximate row of rectangles, thence obliquely back to the line 111. at its juncture with the bend line 0, thence in coincidence with the latter across the proximate row of rectangles, thence obliquely once more to the oblique line 0 at its juncture with the straight line e, thence coincident with the former across the proximate row of rectangles. and thence obliquely to the end of the line an opposite to the starting point. A bend line so proceeding is characterized by seven sections. one for each of the rows of panels which are extended transversely of the sheet; and by an oblique extension of every alternate section for a distance of two panel rows. The result in the completed filler unit is a continuous line of severance which extends vertically and horizontally but always in a, single plane transversely across the filler unit at a central point. If the filler besevered along such a line, two smaller filler units, each 2 x 3 capacity, will be provided, each complete in itself and capable of use, with an associated retainer, for the support and protection of eggs or other contained articles.

It is to be noted that the line of separation just described traverses for the most part an area of the sheet which is not traversed with bend lines; it is only throughout the three of its shorter sections that the line of severance is coincident with any bend lines. The strength of the sheet is accordingly not impaired, nor is the action of its several panels at their respective lines of bend appreciably affected. The severance line may be variously formed as for example by a heavy scoring of the sheet material or by a slitting thereof, partial or otherwise, by perforations, etc., and it may be discontinuous where in coincidence with bend lines, in which event the filler would be required to separate along the latter without further treatment.

Application of a severance line to the filler unit may be otherwise arranged, as suggested for example in Fig. 13, where I have shown lengthwise of the central roW of panels (parallelograms) extending longitudinally of the sheet a line of severance 6! which continues straight from end to end. This line is preferably located centrally of the panel row referred to. In the erected 3 x 4 filler this line of severance will extend angularly from top to bottom along each parallelogrammatic panel which is comprised in the pleated wall extending centrally between six cells on one side and six cells on the other, so that if the filler be severed along this line, two 2 x 3 fillers will be produced in consequence. A severance line arranged as in Fig. 13 has the advantage that it does not at any point coincide with lines of bend, and therefore cannot weaken the erected filler in any way. This severance line is in fact so located as not to initiate tearing of the filler in two unless it be handled in a special manner which those whose business it will be to dispense and make use of such fillers will readily learn with a little practice.

Passing on to the filler package of Fig. 18, the half blank illustrated in Fig. 19 is formed with two sets of intersecting bend lines, one straight extending lengthwise and designated in order as a to c, the other set of bend lines 1 to q being angular and extended transversely of the blank. Straight transverse bend lines 64 and 65, one near each end of the blank, are also provided to define cover sections 65 and 61, respectively, as will presently be explained. Opposite sides of the blank are slanted inwardly, as at 68, from the transverse line m to the line 64, and between the lines 64 and Z I cut out an opening whose remaining sides 69 are divergently related. The longitudinal bend line a continues on through the cover 66 which is also formed with a pair of slits extending inwardly from its end, one coincident with each outermost longitudinal bend line of which one, designated as a, appears in the half blank illustrated. The cover 61 is of lesser width, its opposite sides terminating substantially in line with the outermost longitudinal bend lines. Between the line 85 and the adjacent transverse line q the blank iscut away adjacent opposite sides to a depth approximately of the longitudinal bend line b, thus providing, in efiect, a neck which connects the cover sections 6! to the main body of the blank. At the juncture of this neck with the blank body is a pair of inwardly extending notches H of which only one appears on the half blank illustrated. The outer corners of the cover section 61 are formed with oblique bend lines 12 to define ears 13.

The alternate transverse bend lines commencing with m and ending with 10 extend continuously and angularly, each in the form of a single line, and in the erected filler extend in the form of folded edges around the tops of the walls which define the cells therewithin. The remaining transverse lines, however, commencing with l and ending with 0, proceed angularly but straight from each blank side to the outermost longitudinal bend line a; between this bend line and the next adjacent bend line b, these transverse bend lines 1 et al. divide to form substantially a diamond figure 14 having a pair of parallel bend lines 15 extending between opposite sides of the diamond with a pair of inwardly bowed bend lines 16 extending therebetween at their points of juncture with the diamond, the inner figure 1! thus enclosed within the diamond being in the general form of a square with two of the opposite sides concave; these transverse bend lines I et a1. continue thusly across the blank, with spaced divisions each in the form of a diamond enclosing a concave square, one occurring in each alternate panel row defined by the longitudinal bend lines. In these same panel rows are other bend lines 18 and 19 extending angularly in an easy zigzag course lengthwise thereof between the adjacent longitudinal bend lines, as a and b, proceeding oppositely and inwardly from each to the proximate corner of the nearest diamond figures. From the opening side 69 and in substantial alignment therewith is a bend line which continues on to the longitudinal bend line c with which it meets at the point of crossing of the transverse bend line m, and near the opposite blank end the zigzag bend lines 18 and 19 extend on, the former to the blank end and the latter through the neck to the bend line 65 where th cover section 6'1 commences. Because of the complementary relationship of the angular lines I8 and 79 there is formed a set of diamond figures 8| all disposed within a single longitudinal panel row and each touching at its opposite ends the diamond figures 14 previously described.

While the form and arrangement of the bend lines on this specially shaped blank may appear complicated, it is very inexpensive to provide and easy to erect into a cellular filler complete with covers, as shown in Fig. 18. Here it will be noted I have provided a plurality of cells in rows (3 x 4 being the size illustrated) with the folds produced along the alternate transverse bend lines m, p, at al. forming the top edges for the inclined walls which define cells, all as explained in connection with the structures previously described. The concave squares 11 are located at the bottoms of the cells with bends produced along the parallel lines 15 which in consequence stand up as spaced ridges symmetrically with respect to the longitudinal center line of each cell bottom. Between these ridges the concave square is downwardly bowed to provide in efiect a shallow pocket at the center of each cell bottom. The figures 82 defined by the two angular lines and an are adjacent each concave line 16 are bowed into each cell along the opposite inclined walls thereof, and adjacent each such figure, completing the same call wall, are three triangles having a common meeting point 83 which is coincident with the angle of the figure 82. These meeting points tend to flex outwardly or away from the interior of the cell so that each of the two slanting walls thereof is, in eifect, outwardly bowed in a transverse plane (see Fig. 21) with the exception of the inwardly bowed figure 82 adjacent the bottom, which latter is downwardly bowed between its spaced ridges. A cell so formed is advantageous in that it has (1) a cushion bottom which is (2) raised above the folded edges which extend in a common plane to define the bottom of the filler, the cushion bottOm of the cell being (3) wide, (4) so shaped that the load will tend to distribute itself, and (5) free from incisions or slits which tend to weaken the structure.

In the erected filler the two cover sections may be swung over the cells and there secured to complete an enclosure. The cover 66, being of full width, requires to be pleated in order that it may conform to the reduced width of the structure when it is contracted in the process of erection. For this purpose I provide a pair of parallel bend lines 84 and 85 along which the cover section is adapted to be folded in reverse directions, thus forming a longitudinal pleat (see Fig. 18). A second similar pair of bend lines may also be provided, with the consequence that the excess material is disposed of whereby the two bend lines a of the cover are shifted to remain in alignment with the folds extending longitudinal- 1y along the outside edge of the filler at the top. The end panels 86 of the cover section may thereupon be folded down and inserted within one of the pleats along the outside of the filler,

the slit" 10 facilitating this Operation which as= sures locking of the cover section in place. The other cover section Which is already of reduced width requires no pleat extending longitudinally thereof in order that certain bend lines 81 formed therein shall align with the folds extending along the top of the filler at its outside edge. Flaps 88 defined by these bend lines may be folded down, the ears 13 being then turned inwardly to lie within one of the pleats along the outside of the filler whereby the cover section is locked down in place. In the construction just described I have provided from a single piece of sheet material a filler package complete with covers, the cells having the cushion feature which is so important for the protection of fragile articles such as eggs.

Considering now the filler package of Figs. 2224, the blank body (see Fig. 23) may be generally similar to the one last described, and, except as to points of differentiation, will not be described in detail. One of these features is the angular disposition of the several longitudinal bend lines af, each of which proceeds in an easy zigzag course, with points of direction alternating at each intersection with one of the transverse bend lines Z-s. Beyond the endmost bend line 1 is a pair df aligned transverse incisions Bil, one extending inwardly from each side to a slanting bend line 9| which corresponds in position to the blank edge 58 in Fig. 19; and beyond the aligned incisions is a transverse bend line 92 which defines one cover section 93 having a width about equal to the outermost longitudinal bend lines a and b, the cover section being further provided with two longitudinal bend lines 94 and 95, about in line with the longitudinal bend lines I) and e respectively, to define side flaps 96 and 9'! each having an car 98 adapted to be reversely bent with respect to its associated flap in the manner presently to be explained.

A complementary cover section 99 at the opposite blank end is defined by the angular transverse bend line ill!) which is slitted at Illl in certain portions thereof between the bend lines 12-0 and de, respectively. This cover section, which may be full width, is provided with a pair of side flaps I02 defined by longitudinal bend lines I03, each of which terminates in a notch or slit L04 at its outer end. In addition, I provide for two pleats as by pairs of oppositely creased bend lines H15 and I06 having offset lines H35 and H16 the one pair, by preference, being extended divergingly with respect to the other. One other special feature is the optional angular disposition of the opposite sides of the blank whose edges may be so shaped as to proceed in slightly different directions, the angles occurring at the ends of the transverse bend lines l-r, and a shoulder H31 being provided at the end of the alternate in-between bend lines. At each end of the bend line 99 is a notch I08 extending inwardly as far as a bend line I09 which proceeds in a generally longitudinal direction to provide a flap H0. I also form an arcuate cut HI extending in the outermost longitudinal panel row from the intersection of the longitudinal bend line a with the transverse bend lines 11., p, and 1'.

Such a blank is adapted, upon erection, to produce the filler package of Fig. 22 in which the cells are characterized by substantially the same features as those which have been pointed out in connection with the filler package of Fig. 18. By reason of the angularity of the longitudinal bend lines, however, the several cells in each longitudinal row are somewhat wider at the bottom (see Fig. .24), the longitudinally extending walls which define such cells being more nearly vertical and lying closer to each other than when disposed at a greater angle of divergence, as in Fig. 20 for example. This may be desirable, es-. pecially when lateral pressure upon the articles contained within the cells should be avoided. The cover section 99, when folded over to closure position, is contracted as to width, by the two pleats produced by the two sets of bendlines I05, I05 and 106, los with the consequence that its side flapslilZ may be folded down to engage the notches IM within one of the pleats formed along the package sides, thereby securing the cover section in place. The remaining cover section 93 is substantially the same in form and manner of looking as the cover 61 alreadydescribed in connection with Fig. 18. In the erected package the shoulders ill! appear as short single ply top edges along theouter sides of the filler, lying adjacent the arcuate cuts III which, when opened slightly, will permit such shoulders to enter, thereby holding the several pleats along the package sidesin aligned relation. The showing in Figs. 2528 is of a filler unit in which the blank (only one-half of which is illustrated in Fig. 28) is characterized by straight parallel longitudinal bend lines ac et al. and by angular trans-verse bend lines 1-47, the contour of the blank being much the same as the one of Fig. 4 which has already been described in detail. The point of distinction to which attention is directed is the shape of the cells produced by dividing each alternate, transverse bend line m, o, q, and an additional bend line :1: adjacent an end extension piece H3, into two facing bows which define a pointed ellipse H5 whose major axis extends crosswise of the alternately occurring longitudinal panel rowsbetween the bend lines ab, etc. .Adjacent each ellipse, in the same panel row therewith, is a pair of circular bend lines H6, one (slightly smaller) preferably closer to the ellipse than the other (slightly larger), and each circular bend line defining the outer terminus of certain radial slits H1 which form between them a plurality of fingers I I8 which may yield to accommodate between them an egg or other article which is to be sustained. In the erected filler the ellipses will be bowed upwardly longitudinally (see Fig. 27),,thus providing elevated bottoms for the cells, and the yielding areas on the adjacent diverging walls, defined by each group of fingers H8, will afford cushion supports laterally upon opposite sides of the article which is placed within the cell. By forming one such yielding area larger than the other I induce a suspension of the article with its axis disposed obliquely instead of vertically, thereby economizing on space.

Proceeding on to Figs. 2930, I have shown a structure which is generally similar in contour to that of Fig.4 but modified to the extent'of providing in one and the same blank means which will afford to the erected filler a set of covers whereby it becomes a completed package. For this purpose the outermost longitudinal bend line a is slitted at I29 between alternate transverse rows of panels defined by the lines m-n, op, and q-r, with a further diverging slit l2l at one end. Each alternate transverse bend line I, n, and p is slitted inwardly at I22 at its end for perhaps the width of the outermost side panel row, and the remaining transverse bend lines m, o and q are inwardly slitted at I23 for the full width of the same rows to form, in one outermost side panel row, hooks I24 which extend across into the next adjacent transverse panel row, and, in the opposite outermost end panel row, tongues I25 each internally slitted as at I26. A hook I21 similar to the hOOks I24 is provided beyond one end of the outermost side panel row.

When the blank of Fig. is erected it will produce the filler package shown in Fig. 29 wherein the ends of alternate transverse panel rows, between the bend lines m-n, 0-1), and qr, become flaps free to swing around upon the next adjacent panel row ends. The piece which carries the hook I2! also becomes one such flap. With the filler in erected condition, the flaps on one side may be folded over toward the flaps which extend from the other side, the several flaps on each side lapping in part over each other, and those on one side lapping in part over those on the other side, so as to place the hooks I24 and I21 in register with the slits I26 with which they are adapted. to engage so that an interlock may be provided. It will be observed that at one end I have provided a pair of diverging bend lines I28, one adjacent each side of the blank so that when erected a pair of flaps, one triangular I29,

and the other truncated I30, will be infolded from the top and side along the proximate end portion of the package.

Another form of filler unit, shown in Figs. 31-33, will now be described. The blank, of which only one-half (for the major part) is shown in Fig. 33, is characterized by straight longitudinal bend lines a, b, 0, et al., and angular transverse bend lines Zs, there being other bend lines in the alternate longitudinal rows of panels defined by the bend lines a, I), et al., in the form of diamonds I32, each of which is subdivided into four smaller diamonds by a pair of crossed bend lines I33. In addition there are two bend lines I34, each of which passes through the diamond I 32 at a point which bisects one of the smaller diamonds therein, and continues in opposite directions therefrom to the point of intersection of the next adjacent transverse bend lines with the proximate longitudinal bend line; and further radiating bend lines I35 proceed from two of the longitudinally spaced corners of the large diamond I32 to the corners provided by intersection of the proximate transverse and longitudinal bend lines.

The transverse bend lines proceed angularly through the outermost longitudinal rows of panels, and adjacent their outer ends the blank is cut away to provide shoulders I36. Arcuate slits I31 extend into the outermost longitudinal panel row, commencing at the longitudinal bend line a, one at the intersection of each of the transverse bend lines m, s, and in addition one further arcuate slit I38 is formed in the outermost longitudinal panel row between the transverse bend lines 11. and o, slightly spaced from the proximate slit I31 and curved reversely thereto.

The blank for this filler is furthermore slanted inwardly at I39 toward one end, starting with the point near the transverse bend line n, the blank continuing on to form one additional transverse panel row beyond the transverse bend line I, from which is extended a neck I40 connecting with a head I 4| adapted to provide an end wall for the erected filler. The head is characterized by a pair of longitudinal bend lines I42 defining flaps I43 each having a notch to provide a hook I44.

The neck sides I45 diverge outwardly as they proceed toward the body of the blank, and the end of the proximate transverse panel row bends close to this neck so as to meet therewith at a right angle, there being a bend line I46 in line with this bend end, continuing in angular formation transversely across the blank, the same as the remaining transverse bend lines except for its shorter length which is occasioned by the reduced width of the neck. The bend lines I34 and I35, which radiate from the diamond figure as hereinbefore explained, continue on into the neck to meet the diamond figure which is formed therein, so that this schematic arrangement of bend lines is carried out clear up to the transverse bend line I41 which is the juncture point of the head I 4| The opposite end of the bank is characterized by two heads I50 and I5I carried by separate necks I52 and I 53 respectively, and between these necks is an open space extending beyond the transverse bend line .5 for the full width of one transverse panel row. Opposite sides of this opening, defined by the sides I54, are divergingly related, each being in line with one of the bend lines I35 which radiates from a diamond figure in substantially the middle longitudinal panel of the blank. Each of the heads I50 and I5I approaches but does not meet the other, one of the heads at its end proximate to the other being notched to provide a hook I55. In the remaining head is an arcuate slot I56, the purpose of which will presently appear. The outermost longitudinal bend lines continue through these two heads, as do also the outermost proximate bend lines I34 and I35 which proceed from the nearest diamond figure.

In the erected filler shown in Figs. 31 and 32, the head MI is folded downwardly so as to extend across one end, its two flaps I43 being turned around the proximate corners so that the hooks I44 thereof may look within the arcuate slots I38. The remaining arcuate slots will be arranged along the sides of the filler, which is of pleated formation, with one set of such slots disposed relatively high, and the other set relatively low, in positions to engage the edges of the turned ends of the transverse panel rows which provide the side walls for the filler.

The two heads I50 and I5I at the opposite filler end are folded down in partially overlapping relation so that the hook I55 of the one may be locked within the arcuate slot I56 of the other. An infold I57 may be provided at two adjacent corners of the filler, by forming bends I58 along the lines I34-435, with a reverse bend along an intermediate bend line I 38. This corner infold may be provided wherever desired, two such formations being shown by way of example.

In the erected condition of the filler, the side edges of the blank are engaged within the arcuate slots, both upper and lower sets, so as to secure all the pleats in aligned relation. The cells which are formed in this filler are characterized by bottoms much the same as shown in Fig. 36, a description of which will follow at a later point.

The slanting walls of the cells comprise in each instance five triangular panels defined by the bend lines I34I 35 in conjunction with the proximate longitudinal and transverse bend lines, and in consequence these slanting walls tend to bow outwardly away from each other so as to provide between them cells whose maximum width is in the center line thereof. This construction has advantage where it is desired to accommodate articles whose contours should be closely followed by the enclosing walls of the cells.

Adverting now to Figs. 34 to 36, the filler unit here shown utilizes a blank having longitudinal and transverse bend lines, af and Z-s, respectively, much the same as those in the construction last described, and insofar as there is correspondence thereto like reference numerals are applied. There is also a diamond figure I58 within each alternate longitudinal panel row in line with each alternate transverse bend line, each of such diamond figures being subdivided by crossed bend lines I59 in the manner already explained. From the opposite corners of each large diamond figure, bend lines I60 and I6I proceed on to the intersection of the proximate longitudinal and transverse bend lines in much the same manner as already described in connection with Figs. 19 and 23.

One end of the main blank is defined by a pair of angle slits I62, each of which proceeds inwardly from opposite sides to substantially the center of the longitudinal panel rows defined by the lines 12-0 and de, each slit then proceeding outwardly in diverging relation to a further transverse bend line I63 which is spaced from the line I62 the same distance as the remaining transverse bend lines Zs are spaced apart from each other, the slits I62 ending at the juncture of the longitudinal bend lines and d with the transverse bend line I63. The part of the blank which is confined between the diverging slits constitutes a neck whereon is carried a head I60 having longitudinal bend lines I65 and I66, which nearly registerwith the longitudinal bend lines D and e. It will be noted that the head extends along the neck for the distance of the diverging portions of the two slits I62, but, as will presently be explained, the bend line I63 constitutes a fold, when the filler is erected, so as to produce a two-ply end wall therefor.

The opposite end of the blank is extended outwardly to provide two necks I61 each defined by opposed diverging sides I68 and I69, the latter being a continuation of the bend lines I60, I6I proceeding from the diamond figure I58 in the central longitudinal panel row at the intersection of the transverse bend line q. A bend line I10,

which is located beyond the transverse line s a distance equal to the spacing between the remaining transverse bend lines, establishes a juncture with the head III which is extended for the full width of the blank. Certain bend lines extend across the head, i. e., longitudinally of the blank, one, H2, in line with the bendline a;

another, I13, in line with the bend line e; and

another, I'M, in line with the bend line i. In

addition, a pair of flaps I are connected by bend lines I16 with the head, each fiap extending toward the main body of the blank, from which it is separated by the slit I68. Near each end of the head is a notch defining a hook I"; a further notch defines a hook I78 about in line with the longitudinal bend line e; and anarcuate slot I19 is provided in the head at a point between the bend lines I13 and I'M.

A blank so formed is adapted to be erected for the production of a 3 x 4 filler unit as shown in Fig. 34. Here it will be noted that the head I64 is folded along the line I63 to provide an end wall of two plies in the outer one of which a pair of arcuate slots I80 remain exposed. The parts of this end wall beyond the bend lines I65I;66 are folded around the sides of the carton so that these arcuate slots I80 are disposed at apoint substantially midway of the length of the filler. The opposite head is folded down along the bend line I10 with its two ends swung around upon the bend lines I'I2I'I3 so as to lie along the sides of the carton in partially adapted to be used independently of any outer panel rows.

enclosure or other fastening device by which to maintain it in erectedand operative condition.

The interior of the cells in the construction last described is characterized by a bottom having eight triangles defining between them four ridges. Two ridges IBI extend in a horizontal plane in spaced relation longitudinally of the cell,

and the other two ridges I82 extend from the lowermost point in the center of the cell bottom, diverging upwardly toward a meeting point I83 where three triangles, forming one of the slanting walls of the cell, come together. Due .to the presence of these triangles which form the walls of the cell, an outward bowing tendency is set up whereby the interior of the cell is rounded out so as to better conform to the contour of a similarly shaped article when accommodated therewithin.

Passingon to the filler unit of Figs. 37-39, it will be observed from the half blank shown in Fig. 39 that I employ a plurality of straight longitudinal bendlines a, I), et al., intersected by transverse bend lines Z-s, each of which proceeds angularly across the outermost longitudinal These outermost angular sections of the transverse lines are each interconnected by double sets of curved lines, alternating in character lengthwise of the blank. The transverse bend line Z proceeds across the longitudinal panel row w-b, in the form of two bowed lines in back to back relation, repeating the same double convex formation I88 throughout each of theline m, however, the form is that of a pair of bows which face each other, thereby defining a pointed ellipse I89 extending crosswise of each longitudinal panel row ab, et al., until juncture is made with the angular section of the bend line in the outermost panel row at the opposite blank side. By reason of this opposite disposition of the bowed lines, the point of maximum width between them occurs at the longitudinal bend lines in the case of one set of bend lines, and in the case of the other set of transverse bend lines, intermedially of adjacent longitudinal bend intermedially of the ends of the bend line. By

this arrangement of slits and bend lines I provide three flaps, two of them, designated I91, being alike and disposed on opposite sides of the slit I90, and the third, I98, being defined in large

Images