US3773171A

US3773171A - Corrugated bathtub package

Info

Publication number: US3773171A
Application number: US00255148A
Authority: US
Inventors: R Edsall
Original assignee: Owens Illinois Inc
Current assignee: Georgia Pacific Corrugated LLC
Priority date: 1972-05-19
Filing date: 1972-05-19
Publication date: 1973-11-20
Anticipated expiration: 1990-11-20

Abstract

A shipping container for a bulky item, such as a bathtub or the like, which is formed entirely from corrugated paperboard material. A wrap-around body portion is provided in combination with a pair of corrugated end closures which incorporate build-up blocks to suspend the bathtub within the body portion and close the ends of the body portion to completely enclose the bathtub for shipping.

Description

United States Patent Edsall [451 Nov. 20, 1973 [54] CORRUGATED BATHTUB PACKAGE 1,852,832 4/1932 Beaman 229/14 C [75] Inventor. Robert N. Edsall, Saline, Mich. 3,385,502 5/1968 73 Assigneez OwensJllinois, Inc. Toledo i 3,680,688 8/1972 Smith 206/46 H [22] Filed: May 19, 1972 Appl. No.: 255,148

Primary ExaminerDavis T. Moorhead Attorney-Alan J. Steger et a1.

[57] ABSTRACT A shipping container for a bulky item, such as a bathtub or the like, which is formed entirely from corrugated paperboard material. A wrap-around body portion is provided in combination with a pair of corrugated end closures which incorporate build-up blocks to suspend the bathtub within the body portion and close the ends of the body portion to completely enclose the bathtub for shipping.

1 Claim, 8 Drawing Figures PATENIEUnuvzo I975 SHEET 10F 3 E m 4 2 o DJ n l wy 2 IBM A U I 1 n. F m m l 1w w m m 4 fl H LH G /0 0 MW /lfi 2H1 6 r 2 4 id 5 m 5 A s I (0 mfi v 5 8 m M mw Z FIG.

PATENTEU NUY P 0 I975 SHUT 3 {F CORRUGATED BATI-ITUB PACKAGE BACKGROUND OF THE INVENTION This invention relates to containers and, more particularly, relates to a container constructed of fibrous material such as corrugated paperboard or the like and which may be folded or collapsed for shipping or storage and unfolded and set up as needed.

It is very desirable to have an inexpensive container suitable for packaging large, bulky items, such as bathtubs, metal cabinets, etc. Suitable containers for such large, bulky items have typically been rather expensive due to the high storage characteristics necessary to contain such products. In general, bathtubs, for example, have been shipped in heavy wooden crates or in paperboard containers which were reinforced by means of wooden or metal support inserts. These wooden containers or paperboard containers reinforced with wooden or metal inserts are not only extremely heavy and cumbersome, but expensive, both from the standpoint of material cost and the assembly time involved.

Hence, there is a significant need for and it is an object of this invention to provide an inexpensive, lightweight container formed entirely from corrugated paperboard which is adapted for packaging and shipping large, bulky items such as bathtubs. Other objects, features, and advantages of this invention will become obvious to those skilled in the art upon reference to the following detailed description and the drawings illustrating a preferred embodiment thereof.

IN THE DRAWINGS:

FIG. 1 is a plan view of a paperboard blank adapted to be folded to form the main body portion of the subject container.

FIG. 2 is a perspective view of an end closure member including build-up blocks which is adapted to close one end of the main body portion of FIG. 1.

FIG. 3 is a perspective view of the main body portion of FIG. 1 and a pair of-end closure members of FIG. 2 in a partially assembled relationship with a bathtub.

FIG. 4 is a perspective view of the main body portion and end closure members of FIG. 3 in the completely assembled portion.

FIG. 5 is a partial sectional view taken in the direction of arrows AA in FIG. 4.

FIG. 6 is a partially cut-away sectional view showing the relationship of the bottom support build-up block of the end closure member and a corner of the bathtub.

FIG. 7 is a partially cut-away sectional view showing the relationship of the upper rim portion of the bathtub with respect to the rim engaging build-up block of the end closure members.

FIG. 8 is a perspective view showing a pop-in corner which is formed in the main body portion.

SUMMARY OF THE INVENTION In general, this invention provides a substantially rigid container which may be constructed of a fibrous product, such as corrugated paperboard, and which is adapted to hold a rather large, bulky product, such as a bathtub. More specifically, this invention provides a three-piece shipping container for a bathtub which is formed entirely from corrugated paperboard material. A wrap-around body portion is provided with a pair of end closure members which incorporate build-up blocks which suspend the bathtub within the body portion and close the ends of the body portion to completely enclose the tub. The end closure members incorporate a grooved upper build-up block which is adapted to be inserted over the upper rim of a bathtub to securely position each end of the bathtub. In addition, the end closures incorporate a build-up block portion which is adapted to extend under the lower comers of a bathtub for supporting it within the main body portion of the container. Once the end closures have been inserted into engagement with the bathtub, the wraparound main body portion is set up and folded into encircling relationship with the bathtub and stapled to the end closures to completely enclose the bathtub. Thus, a large rectangular shipping container is provided which exhibits sufficient rigidity and strength properties to make it well suited for containing and shipping a large, bulky item, such as a bathtub, but which is also light in weight and inexpensive when compared with wooden crates or paper-board containers utilizing wooden or metal reinforcements used for the same purpose.

DESCRIPTION OF A PREFERRED EMBODIMENT More particularly, FIG. 1 shows a box blank 10 which has been scored and sized so as to make it foldable into a main body portion, indicated generally by the numeral 12 in FIGS. 3 and 4. The box blank I0 is seen to include a front panel 14, a bottom panel 16, a back panel 18, a top panel 20, and a closing flap 22 all of which are hingedly connected along suitable score lines 24. Formed along the opposite edges of these panels are a pair of end

engaging flaps

26 and 28. These

end engaging flaps

26 and 28 are connected to the various panel components along suitable score lines 30. The transformation of the box blank 10 into the main body portion 12 can best be understood by reference to the transition from FIG. 1 to FIG. 3 to FIG. 4. Each of the panels 14, I6, 18, and 20 are folded degrees so as to be perpendicular to each other along their respective score lines 24 so that the

opposed panels

14 and 18 form the front and back, respectively, and the

opposed panels

16 and 20 form the bottom and top, respectively, of the main body portion 12. The closing flap 22 is then folded along its score line 24 into engagement with the front panel 14 so that it can either be stitched or stapled to the front panel 14 to secure the main body portion 12 into set-up condition. It is suggested that the closing flap 22 be tucked into engagement with the interior side of front panel 14 as shown in FIG. 5. It should be understood that the main body portion 12 of this invention is well suited to form a wrap-around container for a number of bulky items; however, for the purposes of illustration, it is described in its preferred embodiment as being adapted to form a shipping container for a bathtub 32.

FIG. 2 shows one of a pair of end closure and bathtub supporting members 34 which are utilized in cooperation with the main body portion 12 to form a completed package. The end closure member 34 includes an end panel 36 and four build-

up blocks

38, 40, 42, and 44. Each of these build-up blocks is formed from a plurality of layers of corrugated paper-board which have been adhesively joined together and then die cut to provide a desired shape. The upper build-up block 44 incorporates a groove or recess 46 which is adapted to fit over an upper rim 418 on the bathtub 32. The vertically extending build-up

blocks

38 and 42 are positioned and attached to the end panel 36 so as to provide vertical support to the resulting container and abut the end portions of the bathtub 32. The remaining build-up block 40 is positioned to the lower corner of the end panel 46 and is shaped to provide a supporting surface 50 for the lower edge of the bathtub 32. Each end panel 36 also includes a pair of hand-holding cutouts 52 which facilitate easy handling of the resulting package. While the end closure member 34 illustrated in FIG. 2 is shaped and sized to perform as the end closure member shown at the front edge of FIG. 3, it should be understood that the end closure member at the opposite end of the bathtub 32 is virtually identical to the end closure member 34.

A further feature of the main body portion 12 can be understood by reference to FIGS. 1 and 3. In FIG. 1 it can be seen that the box blank I includes a pair of pop-in corners 54 formed by means of a pair of parallel slits 56 which are perpendicular to and overlap the score line 24 between front panel 14 and bottom panel 16. These pop-in corners 54 are pushed inwardly when the main body portion is assembled to the position shown in FIG. 4 so as to abut build-up block 38 and provide lateral support for the end closure member 34 at the front corners of the bathtub 32.

When it is desired to package a bathtub, such as the one indicated by the numeral 32 in this illustration, a pair of the end closure members 34 are first placed into engagement with the opposite ends of the bathtub 32. As can be seen in FIG. 3, each end closure member 34 is positioned over the upper edge of the bathtub 32 so that the rim 48 resides within the groove 46 in the upper build-up block 44 of end closure member 34$. This relationship can best be seen by reference to FIG. 7. When placed in position, the lower build-up block 40 of end closure member 34 rests under the back edge of the bathtub 32 so that the bathtub 32 is supported on the surface 50. This supporting relationship can best be seen by reference to FIG. 6. The vertically extending build-up biock 42 serves as an external support and separator along the back edge of the bathtub 32 and the vertically extending build-up block 38 provides vertical support to the front edge of the bathtub 32.

Once the end closure members 34 have been placed into engagement with the bathtub 32, the bathtub 32 maybe positioned in overlying relationship with respect to the box blank so that the bottom edges of the end closure members 34 rest directly on the bottom panel 16 as shown in FIG. 3. It should also be understood that the bathtub 32 may be positioned over the bottom panel 16 of the box blank 10 prior to the attachment of the end closure members 34. The box blank I6 is then folded as viewed in FIG. 3 so that the front panel 14, back pnael 18, and top panel 20 assume their proper locations as shown in FIG. 4. The top closing flap 2 may then be tucked into contact with the inside of the front panel 14 and stitched or stapled thereto to assume the closed position shown in FIGS. 4 and 5. The

end engaging flaps

26 and 28 are then folded along their respective score lines 30 into overlying relationship with respect to the end closure members 34 as shown in FIG. 4. These

end engaging flaps

26 and 28 may then be either stapled or stitched to the end closure members 34 to form the completed shipping container for the bathtub 32. As a last step, the pop-in corners S4 may be pushed inwardly as shown in FIG. 8 so that they engage, respectively, vertical buildup blocks 38 and 42 to provide additional lateral support at the front edges of the bathtub 32.

Therefore, as can be seen from the above description, a relatively simple, yet substantially rigid container is provided by this invention which is formed entirely from corrugated paperboard and yet is well suited for packaging a bulky item, such as bathtub. Since the entire package is formed from corrugated paperboard material, it is considerably less expensive and lighter in weight than previously used containers formed entirely from wood or incorporating portions formed from wood or metal. In addition, the bathtub is better protected because of the natural cushioning properties of the corrugated paperboard material. Furthermore, the unique relationship of the end closure members utilizing corrugated build-up blocks to completely suspend the bathtub inside the outer wrapper further insulates the bathtub from damage during packaging warehousing, handling, and shipping. The unique packages of this invention are designed so that they will nest together for shipment and also can be stacked for storage in a warehouse.

I claim:

1. A folded paperboard container for a bathtub comprising:

substantially rectangular wrap-around body means including a front panel, a bottom panel, a back panel, a top panel, and a closing flap adapted to be folded perpendicular to said top panel and attached to said front panel and having end closure engaging flaps formed on and hingedly connected to the opposite ends of said front panel, said bottom panel, said back panel, and said top panel, said back panel being formed between and integral with said top and bottom panels and said front panel being formed integral with and positioned adjacent to the opposite side of said bottom panel;

a pair of substantially rectangular end closure members engaging and supporting opposite ends of the bathtub and being attached to said end closure engaging flaps to completely enclose said bathtub, said pair of end closure members each including an end panel to which said end closure engaging flaps are attached and a plurality of paperboard build-up block portions which are attached to said end panel and engage and support the opposite ends of said bathtub, said build-up block portions on eacn of said pair of end closure members including an upper build-up block incorporating a groove therein into which an upper rim on the end of said bathtub may be inserted, a lower build-up block incorporating a supporting surface for supporting a lower edge on the end of said bathtub, and a pair of vertical-extending build-up blocks engaging the ends of said bathtub, said end panels on each of said pair of end closure members including a pair of hand-holding cutout apertures for use in handling said container;

and a pop-in corner being formed in said body means at each end of the fold between said front panel and said bottom panel by means of a pair of parallel slits which extend from said front panel into said bottom panel so that the pop-in corners can be pushed into engagement with said pair of vertically-extending build-up blocks on said end closure members.

i s i t UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3 773 171 Datedwzg ]913 Invent r( ROBERT N. EDSALL It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Col. 3, line 54, "pnael 18" should be panel l8-; Col. 3, line 56, "flap 2" should be flap 22. C01. 4, line 7, af-

ter "such as" insert -a; Col. 4 line 47 (Claim 1) ll ea'Crlll should be -each.

Signed and sealed this 25th day of June 197A.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. C. MARSHALL DANN Attesting Officer Commissioner of Patents )RM PO-IOSO (10-69) USCOMM-DC 60376-P69 r us. GOVERNMENT PRINTING OFFICE: 1969 o-ass-au.

Claims

1. A folded paperboard container for a bathtub comprising: substantially rectangular wrap-around body means including a front panel, a bottom panel, a back panel, a top panel, and a closing flap adapted to be folded perpendicular to said top panel and attached to said front panel and having end closure engaging flaps formed on and hingedly connected to the opposite ends of said front panel, said bottom panel, said back panel, and said top panel, said back panel being formed between and integral with said top and bottom panels and said front panel being formed integral with and positioned adjacent to the opposite side of said bottom panel; a pair of substantially rectangular end closure members engaging and supporting opposite ends of the bathtub and being attached to said end closure engaging flaps to completely enclose said bathtub, said pair of end closure members each including an end panel to which said end closure engaging flaps are attached and a plurality of paperboard build-up block portions which are attached to said end panel and engage and support the opposite ends of said bathtub, said build-up block portions on eacn of said pair of end closure members including an upper build-up block incorporating a groove therein into which an upper rim on the end of said bathtub may be inserted, a lower build-up block incorporating a supporting surface for supporting a lower edge on the end of said bathtub, and a pair of vertical-extending build-up blocks engaging the ends of said bathtub, said end panels on each of said pair of end closure members including a pair of hand-holding cutout apertures for use in handling said container; and a pop-in corner being formed in said body means at each end of the fold between said front panel and said bottom panel by means of a pair of parallel slits which extend from said front panel into said bottom panel so that the pop-in corners can be pushed into engagement with said pair of vertically-extending build-up blocks on said end closure members.