WO2006039474A1

WO2006039474A1 - Stackable shipping and display box

Info

Publication number: WO2006039474A1
Application number: PCT/US2005/035168
Authority: WO
Inventors: Charles P. Weimer, Jr.
Original assignee: International Paper Company
Priority date: 2004-10-01
Filing date: 2005-10-03
Publication date: 2006-04-13
Also published as: CA2581847A1; MX2007003678A; EP1796972A1; US20050199694A1

Abstract

An elongate, rectangular box (16, 60, 80) and method for packaging containers (C), wherein the box can be cross-stacked for stable stacking of the boxes, and optimizes utilization of pallet space. Containers (C) are placed in the box in diagonally offset relationship to one another in a parallelogram-shaped arrangement, and interior corner inserts (14,15, 61,62, 81,82) are placed in the boxes to form diagonal interior corner panels extending across two diagonally opposite corners of the box, defining an interior box shape closely conforming to the parallelogram-shaped arrangement of the containers. The inserts also define structure that supports one box on top of one another when the boxes are stacked. The box is especially suited for packaging four one-gallon containers.

Description

STACKABLE SHIPPING AND DISPLAY BOX

This application is a continuation-in-part of application serial number 10/799,967, filed March 12, 2004.

Technical Field:

This invention relates to packaging, and more particularly to a stackable shipping and display box.

Background Art:

Many products are shipped in cartons or boxes that enable the product to be displayed in the shipping box at the point of sale. These types of boxes are particularly suitable for products sold in club stores, where many products, e.g., juices, typically are packaged in one-gallon containers. Conventional boxes for handling one-gallon containers usually comprise full depth closed regular slotted containers (RlSCs), although partial depth boxes or trays are sometimes used. A divider that extends between the containers normally is used in the partial depth trays to provide adequate strength. Further, conventional boxes for holding one-gallon containers are commonly designed for holding six containers, although some packages, such as those shown in figures 1 and 2, are designed for holding four containers, primarily due to weight concerns. In this regard, normally it is desired to not exceed a case weight of 40 pounds. These conventional boxes are square in plan view, with the one-gallon containers orthogonally oriented in side-by- side relationship to one another.

To facilitate handling, it is common practice to stack several layers of filled boxes on a pallet, and sometimes to stack two or more pallets high. Conventional square boxes are often column stacked, and typically require internal or external support to eliminate or reduce load on the bottles. Column stacking of the boxes is inherently unstable, and layer sheets, or slip sheets, may be employed between adjacent layers of boxes to improve the stability of the stacked boxes.

Moreover, the pallets used typically have dimensions of 48X40 inches, and the square boxes do not utilize the pallet space well, i.e., a plurality of the boxes placed in a layer either do not occupy the entire pallet space, or they overhang the pallet, depending upon how the boxes are oriented and how many are placed in a layer on the pallet. Conventional square boxes do not permit any arrangement of the boxes on a pallet that will result in the footprint of the area occupied by the boxes being substantially equal to the shape and area of the pallet. When conventional square boxes holding four one-gallon containers are placed on a conventional 48X40 inch pallet, often only nine boxes, or thirty- six one-gallon containers, can be accommodated in each layer of boxes without overhanging the edges of the pallet, depending upon the bottle diameter and/or footprint.

Applicant's prior copending application, serial number 10/799,967, discloses a shipping and display box that, when filled with containers of product, has a maximum desired weight, is configured to enable stable stacking of filled boxes, optimally utilizes pallet space, and places no load on the product containers, all without requiring the use of separate layer sheets, or separate internal or external pieces intended solely as reinforcements. The box in the prior application is designed for machine set-up, and except for the embodiment illustrated in figures 16-18 is made from a single unitary blank of corrugated board. However, in some instances it may be desirable to manufacture the box in a flattened condition for storage and shipment to a user, where the box can be set up by hand.

Accordingly, there is need for a stackable shipping and display box having the novel features of the box disclosed in prior copending application serial number 10/799,967, but wherein the box can be set up by hand.

Disclosure of the Invention:

The present invention comprises a box for shipping and displaying product, wherein the box can be set up by hand, has a desired case weight, is configured so that filled boxes can be stacked in stable interlocked relationship, optimally utilizes pallet space, and the product containers are not subjected to load when filled boxes are stacked on top of one another.

The box of the invention comprises a rectangular tray having predetermined length and width dimensions to hold a desired number of product containers in contiguous, side- by-side, diagonally offset relationship to one another. The diagonally offset placement of the containers results in interior spaces at two diagonally opposite corners of the box, and at least one separate insert is placed in the box, forming angled corner panels that extend into these spaces to contact the containers to help retain them in the box and to provide stacking support and prevent vertical loads on the containers. The tray and insert are each made from respective blanks of corrugated board that can be folded by hand.

The rectangular shape of the boxes enables boxes in adjacent layers to be cross- stacked and interlocked for stable stacking, and the diagonally offset relationship of the containers in the box results in outer box dimensions that maximally utilize pallet space when the boxes are stacked on a pallet. These boxes can be placed on a conventional 48X40 inch pallet so that the footprint of the area occupied by a layer of boxes is substantially the same as the area of the pallet surface. With the invention, eleven boxes holding forty-four containers can be placed in a layer on a 48X40 inch pallet, although it should be understood that these numbers can vary, depending upon the bottle diameter and footprint. Boxes incorporating the invention can be stably stacked two or more pallets high and without imposing a vertical load on the containers.

Although the boxes could be configured to hold different numbers and sizes of containers and still incorporate the features of the invention, in the particular embodiments illustrated and described herein they are sized to hold four one-gallon containers. When loaded with four one-gallon containers of juice, for example, a package using the box of the invention has a case weight that is less than about 40 pounds.

Additionally, empty containers, e.g., bottles, can be inverted and placed upside down in the box by the bottle manufacturer for shipment to a facility for filling the bottles. The shape of the box, including the angled corner panels, securely holds the inverted empty bottles in place even when some of the side walls have a reduced height to define openings through which the bottles are visible.

The box of the invention is equally suitable for use with containers having a round cross-section or a non-round cross section, e.g., square.

Brief Description of the Drawings:

The foregoing, as well as other objects and advantages of the invention, will become apparent from the following detailed description taken in conjunction with the accompanying drawings, wherein like reference characters designate like parts throughout the several views, and wherein: Figure 1 is a top perspective view of conventional partial depth square boxes or trays filled with four containers placed side-by-side in orthogonal relationship relative to one another and column-stacked on a pallet.

Figure 2 is a top perspective view of a single prior art box conventionally filled with four containers disposed in side-by-side orthogonal relationship to one another, and showing an H-shaped divider in dot-and-dash lines.

Figure 3 is a top plan view depicting how conventional square boxes designed for holding four one-gallon containers occupy the space on a conventional 48X40 inch pallet.

Figure 4 is a top perspective view of rectangular boxes according to the invention filled with containers placed in offset side-by-side relationship relative to one another and cross-stacked on a pallet in interlocking relationship.

Figure 5 is a top perspective view of a single rectangular box according to the invention filled with four containers disposed in side-by-side offset relationship to one another. Figure 6 is a top plan view depicting how rectangular boxes according to the invention and designed for holding four one-gallon containers occupy the space on a conventional 48X40 inch pallet.

Figure 7 is a top plan view depicting how the rectangular boxes of the invention might be alternately arranged on a pallet. Figure 8 is a top perspective view of a first embodiment of a box according to the invention, showing four containers of round cross-section disposed therein in offset relationship to one another, and wherein the box comprises a rectangular tray having roll¬ over side panels and two inserts placed in diagonally opposite corners, with the inserts held in place by tabs folded inwardly from the tray end walls through adjacent panels of the inserts, and wherein the inserts have a first panel extending completely across the end of the tray, and a reversely folded panel for enhanced stacking strength. Figure 9 is a top plan view of the box of figure 8.

Figure 10 is a top perspective view of a second embodiment of the box, showing only one insert, although it is to be understood that an identical insert would be placed in the opposite end of the tray, wherein the insert has a first panel that extends only partially across the end wall of the tray, and a second panel with a first diagonally extending portion extending to adjacent the end of the first panel, and a second portion extending from the end of the first panel the rest of the way across the end of the tray, with a tab on the end of the first panel engaged in a slot in the top edge of the second panel at the juncture between the first and second portions . Figure 11 is a fragmentary top plan view of the box of figure 10.

Figure 12 is a top plan view of a third embodiment, wherein the inserts have reversely folded panels, but the tabs are omitted.

Figure 13 is a fragmentary top perspective view of a portion of the box of figure 12, showing an end panel on the insert terminating adjacent the roll-over panel on the tray side wall.

Figure 14 is a plan view of a blank for making the tray of figures 8-13.

Figure 15 is a plan view of a blank for making the insert of figures 8 and 9.

Figure 16 is a plan view of a blank for making the insert of figures 12 and 13.

Figure 17 is a plan view of a blank for making the insert of figures 10 and 11. Figure 18 is a plan view of a blank for making a tray similar to the tray shown in figures 12 and 13, except that the tray has roll-over end panels rather than roll-over side panels.

Figure 19 is a plan view of a blank for making a tray intended for machine set up.

Figure 20 is a top perspective view of the box of figure 10, showing four inverted containers placed therein in upside-down, offset relationship.

Description of the Preferred Embodiments:

A conventional box of square shape designed for holding four one-gallon containers C is shown at 10 in figures 1-3. In accordance with conventional practice, the containers are placed in the box in orthogonally disposed side-by-side relationship to one another, and an H-shaped divider 11, shown in dot-and-dash lines in figure 2, is placed in the box between the containers. Boxes filled with containers are typically stacked in layers on a pallet P, and as depicted in figures 1 and 2, the boxes are stacked on top of one another in columnar relationship. This arrangement is unstable, and layer sheets (not shown) are commonly placed between adjacent layers. Moreover, often only nine boxes may be placed in a layer without producing pallet overhang, but this results in a substantial area of the pallet not being used.

The invention solves this problem, as depicted somewhat schematically in figures 4-7, by making the boxes 12 rectangular in shape, with a greater length dimension L than width dimension W, i.e., the width dimension is approximately 75% of the length dimension, and by sizing the box in relation to the containers to be placed in it so that when a predetermined number of rows of containers are placed in the box they will assume a staggered, diagonally offset relationship, as seen best in figures 5, 6, 8 and 9. The rectangularly shaped boxes may be cross-stacked in interlocking relationship to produce a stable stack without requiring the use of layer sheets. Moreover, the boxes may be arranged on the pallet P so that the footprint or area occupied by the boxes is substantially equal to the surface area of the pallet, thus enabling optimum pallet utilization. The boxes may be arranged in different ways to achieve interlocking when stacked and to maximize use of the pallet surface, as depicted for example in figures 6 and 7. Inserts 14 and 15 are placed in the boxes to define a generally parallelogram- shaped box interior, as seen best in figures 9, 12 and 20, that conforms generally- to the outline of the diagonally offset containers and helps hold the containers in place, as well as to provide a strong structure for supporting boxes filled with containers in stacked relationship on top of one another. A first embodiment of a box according to the invention is shown at 16 in figures 8,

9, 14 and 15. The box 16 comprises a tray 17 with opposite side walls 18 and 19, opposite end walls 20 and 21, and a bottom wall 22. As depicted herein, the side and end walls have a relatively short height, although they could have greater height if desired.

The inserts 14 and 15 placed in diagonally opposite corners of the tray form diagonally extending panels 23 and 24 across the corners. Containers C placed in the tray are supported in diagonally offset relationship by the rectangularly shaped tray and the inserts. The inserts also enable loaded boxes to be stacked on top of one another without imposing load on the containers.

The tray is erected by hand from a single blank Bj as shown in figure 14, and is manufactured and shipped to a user in the flattened condition shown in this figure. The blank comprises a central rectangular panel 22 that forms the bottom wall of a tray erected from the blank. A pair of spaced slots 25 and 26 are formed through the panel 22 at each of its opposite side edges. End wall panels 20 and 21 are foldably joined along fold scores or creases 27 to the opposite ends of the bottom-forming panel 22, and flaps 28 and 29 are foldably joined to opposite ends of the panels 20 and 21. A bendable tab 30 is formed in the outer edge of each end wall panel 20 and 21 for a purpose to be described hereinafter.

First side wall panels 31 and 32 are each foldably joined along a first edge thereof to respective opposite side edges of the panel 22 by fold scores or creases 33, and second side wall panels 34 and 35 are foldably joined along a first edge thereof to a second edge of respective first side wall panels by closely spaced double scores or crease lines 36, 37. The second side wall panels 34 and 35 comprise roll-over panels, and a pair of tabs 38 and 39 on the outer edge of the roll-over panels engage in the slots 25 and 26 when the side wall panels are folded up and inwardly to form the side walls 18 and 19. It will be noted that the roll-over panels 34 and 35 are cut away at one end 40. These cut-outs form a space for accommodating an insert panel as described hereinafter. To erect the tray 17 from the blank Bi, the end wall panels 20 and 21 are first folded upwardly, with the flaps 28 and 29 being folded inwardly in general alignment with opposite side edges of the bottom panel 22. The first side wall panels 31 and 32 are then folded upwardly, and the second side wall panels 34 and 35 are folded inwardly and downwardly, capturing the flaps 28 and 29 between the first and second side wall panels, which form outer and inner side wall panels, respectively, in the erected container. The tabs 38 and 39 are then engaged in the slots 25 and 26 to hold the tray in assembled position.

The inserts 14 and 15 are identically constructed and a blank for forming the inserts is indicated at B₂ in figure 15. Each insert comprises: a first panel 41 extending the width of the respective end wall 20, 21; a second, relatively narrow panel 42 extending perpendicular to one edge of the first panel and lying against an adjacent corner portion of the respective side wall 18, 19 and fitted in the space left by the cut-out 40 in the roll-over panel; a third panel 43 narrower than the first but wider than the second panel foldably connected at a first edge to the other edge of the first panel and extending perpendicularly therefrom and lying against an adjacent portion of the side wall opposite that against which second panel 42 lies; a fourth panel 44 wider than the third but narrower than the first foldably connected at a first edge to a second edge of the third panel and extending diagonally therefrom with its second edge in a position adjacent the first panel and between the opposite side edges of the first panel; and a fifth panel 45 foldably connected to the second edge of the fourth panel and extending therefrom in contiguous, parallel relationship to the first panel and terminating at a free edge at the juncture of the first and third panels.

The bendable tab 30 formed in an upper edge of each tray end wall is inserted through aligned openings 51 and 52 in the first and fifth panels 41 and 45 to hold the insert in its operative folded position and in the tray. The inserts are erected by hand from a single blank B₂ (figure 15). To erect the insert, it is folded into generally the configuration shown in figures 8 and 9 and then placed in the tray, after which the tab 30 is inserted through the openings 51 and 52 to hold the insert in place.

A second embodiment of the invention is indicated generally at 60 in figures 10, 11, 17 and 20. In this form, the inserts 61 and 62 (both are shown in figure 20) comprise a first panel 63 that extends only part way across the respective end wall 20, 21 from a first edge located in a first corner of the tray, terminating at a free edge 64 spaced from the opposite corner. A second panel 65 is foldably connected at one edge to said first edge of the first panel, and extends perpendicularly therefrom to lie against the respective adjacent side wall 18 or 19. A third panel 66 is foldably connected at a first edge thereof to a second edge of the second panel 65 and extends diagonally across the interior corner of the tray to a second edge adjacent the free edge of the first panel. A fourth panel 67 is foldably connected at one edge to the second edge of the third panel and extends at an angle therefrom to lie against the end wall between the free edge of the first panel and a second corner of the tray opposite the first corner. A fifth panel 68 is foldably connected to a second edge of the fourth panel and extends perpendicularly therefrom to lie against the side wall in said second corner. A notch 69 is formed in the top edge of the insert at the juncture of the third and fourth panels, and a tab 70 at the upper end of the free edge of the first panel is engaged in the notch to hold the insert in its operative folded relationship. The tab 30 on the upper edge of the tray end wall is engaged in opening 51 in the first panel to hold the insert in the tray. A third embodiment is indicated generally at 80 in figures 12, 13 and 16. In this embodiment the inserts 81 and 82 are constructed essentially the same as the inserts 14, 15 shown in figures 8, 9 and 15, except that the tab 50 and openings 51, 52 are omitted. The inserts 81 and 82 are retained in place by their snug fit and frictional engagement with the side and end walls of the tray 17'. Each insert is made from a blank B₃, shown in figure 16, and comprises a first panel 41' extending the width of the respective end wall 20, 21; a second, relatively narrow panel 42 extending perpendicular to one edge of the first panel and lying against an adjacent corner portion of the respective side wall 18, 19 and fitted in the space left by the cut-out 40 in the roll-over panel; a third panel 43 narrower than the first but wider than the second panel foldably connected at a first edge to the other edge of the first panel and extending perpendicularly therefrom and lying against an adjacent portion of the side wall opposite that against which second panel 42 lies; a fourth panel 44 wider than the third but narrower than the first foldably connected at a first edge to a second edge of the third panel and extending diagonally therefrom with its second edge in a position adjacent the first panel and between the opposite side edges of the first panel; and a fifth panel 45' foldably connected to the second edge of the fourth panel and extending therefrom in contiguous, parallel relationship to the first panel and terminating at a free edge at the juncture of the first and third panels.

A blank B₄ for making a modified tray that could be used with the embodiment of figures 12, 13 and 16 is shown in figure 18. A tray made from this blank has generally the same function as the tray 17 shown in figure 14. A tray made from blank B₄ differs from tray 17 in that the positions of the roll-over panels 34', 35' and the end wall panels 20', 21' and their associated flaps 28', 29' are reversed, so that the roll-over panels are on the ends of the tray rather than the sides, and the slots 25', 26' for receiving the tabs 38' and 39' on the roll-over panels are at the ends rather than the sides of the tray bottom 22'. Further, in this embodiment the tabs 30 in the end walls and the corresponding openings 51, 52 in the insert are omitted.

A further modified blank Bs that could be used with any of the inserts described herein is shown in figure 19. This blank would be used for machine set up of a tray, wherein the side panels 90, 91 would be folded upwardly, with the flaps 92, 93 at the ends of the side panels folded inwardly in general alignment with the scores or creases 94 joining end panels 95, 96 to the bottom-forming panel 97. The end panels 95, 96 would be folded up and glued to the flaps to hold the tray in erected position.

When four one-gallon containers C are placed in any of the embodiments of the box of the invention, they are oriented in nested, offset or staggered relationship as depicted in figures 5, 6, 8, 9 and 20. The containers, and thus labels or graphics on the containers, are visible through the large openings or spaces between the inserts at the sides of the box, and the containers are retained in the box by the upstanding side walls and inserts, and the angled interior corner panels.

The inserts and adjacent side and end wall portions define triangular reinforcing structures at two diagonally opposite corners of the box, lending stacking strength to the box and enabling boxes filled with containers to be stacked two or more pallets high without imposing load on the containers.

While particular embodiments of the invention have been illustrated and described in detail herein, it should be understood that various changes and modifications may be made to the invention without departing from the spirit and intent of the invention as defined by the scope of the appended claims. WHAT IS CLAIMED IS:

Claims

1. A box for shipping and storing containers of product, said box comprising a rectangularly shaped tray having a greater length dimension than width dimension and having a bottom wall, opposite end walls, and opposite side walls disposed orthogonally to the end walls and defining an elongate interior space, the ratio of said length and width dimensions being such that when containers of product are placed in the tray they are constrained to a side-by-side, diagonally offset relationship to one another in a generally parallelogram-shaped arrangement.

2. A box as claimed in claim 1, wherein: angled interior corner panels extend diagonally across two diagonally opposite interior corners the tray, defining a generally parallelogram-shaped box interior; and said parallelogram-shaped arrangement of the containers therein conforms to the interior shape of the box, whereby the containers are closely constrained against movement in the box.

3. A package as claimed in claim 2, wherein: the angled interior corner panels comprise inserts placed in the tray.

4. A package as claimed in claim 3, wherein: the inserts define structure extending above the height of containers placed in the tray to support an upper box when boxes loaded with containers are stacked on top of one another.

5. A shipping and display box for containers of product, comprising: a box having a bottom wall, opposite end walls, and opposite side walls disposed orthogonally to the end walls to define an elongate rectangularly shaped box having four corners; and angled interior corner panels extending diagonally across two diagonally opposite corners of the box, defining a generally parallelogram-shaped interior space in the box, said interior space having a dimensional relationship to containers to be placed therein such that when a number of containers are placed in the box they are contstrained to a side- by-side parallelogram-shaped arrangement that conforms closely to the interior shape of the box, said elongate rectangular shape of the box enabling the boxes to be cross-stacked and interlocked with one another to produce a stable stack of the boxes.

6. A box as claimed in claim 5, wherein: the diagonally extending interior corner panels have a height that is at least as great as the height of containers placed in the box, whereby boxes filled with containers may be stacked on top of one another without imposing a load on the containers, said interior corner panels serving to support an upper box on a lower box and imparting stacking strength to the box as well as defining said parallelogram-shaped interior space that conforms closely to the parallelogram-shaped arrangement of containers placed therein.

7. A box as claimed in claim 6, wherein: said interior corner panels comprise separate inserts placed in the box.

8. A box as claimed in claim 7, wherein: said inserts each include a first panel extending parallel to and lying against an adjacent end wall, second and third panels extending parallel to and lying against respective opposite side walls, and a fourth panel extending from the third panel to adjacent the first panel and forming said diagonally extending interior corner panel.

9. A box as claimed in claim 8, wherein: said box is configured to closely conform to and hold four one-gallon containers disposed in said box in side-by-side diagonally offset relationship.

10. A box as claimed in claim 5, wherein: said box is formed from a single unitary blank of corrugated cardboard.

11. A box as claimed in claim 10, wherein: the side walls of said box comprise outer side wall panels and inner roll-over side wall panels; the end walls comprise an end wall panel having a flap on each of opposite ends thereof, said flaps being captured between the outer side wall panel and inner roll-over panel of respective adjacent side walls; and tabs on a lower edge of the roll-over panels engaged in slots in the bottom wall to hold the roll-over panels in place, and thus hold the box in erected position.

12. A box as claimed in claim 7, wherein: said box, including said bottom wall, side walls and end walls, is formed from a first blank of corrugated cardboard, and said inserts are formed from respective second and third blanks of corrugated cardboard.

13. A box as claimed in claim 8, wherein: said inserts each include a reversely folded fifth panel extending from the fourth panel toward the third panel, said fifth panel extending parallel to and lying against the first panel.

14. A box as claimed in claim 8, wherein: said inserts each include a fifth panel extending from the fourth panel toward the second panel, said fifth panel extending parallel to and lying against an adjacent end wall of the box.

15. A box as claimed in claim 14, wherein: a notch is formed in an upper edge of the insert at the juncture of the fourth and fifth panels, and a tab on an upper end edge of the first panel is engaged in the notch to hold the insert in operative folded relationship.

16. A box as claimed in claim 13, wherein: aligned openings are formed through the first and fifth panels of the insert, and a tab is formed in an adjacent end wall of the box, said tab being engaged in the openings to hold the insert in operative folded position and to hold it in the box.

17. A box as claimed in claim 15, wherein: an opening is formed through the first panel, and a tab is formed on the adjacent end wall, said tab being engaged in the opening to hold the insert in the box.

18. A blank for forming an elongate, rectangular box having a bottom wall, opposite end walls, and opposite side walls, comprising: an elongate, rectangular center panel that forms said bottom wall in an erected box; opposite end panels foldably connected along a first edge to opposite ends of the center panel for forming said end walls in an erected box; a flap foldably connected to each of opposite ends of the end panels; a first side wall panel foldably connected at a first edge thereof to each of the opposite side edges of the center panel; a second side wall panel foldably connected at a first edge to a second edge of the first side wall panel, said second side wall panel comprising a roll-over panel and having tabs projecting from a second edge thereof, and one end edge of each said roll-over panel having a cut out; and slots in said center panel at opposite side edges thereof for receiving said tabs on said roll-over panel when a box is erected from said blank, and said flaps on the end panels being captured between the first side wall panel and the roll-over panel when a box is erected from said blank.

19. A blank for forming an insert to be placed iri a corner of a box to form a stacking support to support one box on top of another when they are stacked, and to form an interior diagonally extending corner panel in a box, said blank comprising: a first rectangular panel adapted to lie against an end wall of a box; a second rectangular panel foldably joined to a first edge of the first panel and adapted to lie against an adjacent first side wall of a box; a third rectangular panel foldably joined to a second edge of the first panel and adapted to lie against an adjacent second side wall opposite the first side wall; and a fourth rectangular panel foldably joined to the third panel and adapted to extend diagonally from the third panel to the first panel to form with the first and third panels a triangularly shaped structure when the blank is operatively folded and placed in a box.

20. A blank as claimed in claim 19, wherein: a fifth rectangular panel is foldably joined to said fourth panel, said fifth panel being foldable toward said third panel to lie against said first panel when said blank is operatively folded and placed in a box.

21. A blank as claimed in claim 19, wherein: a fifth rectangular panel is foldably joined to said fourth panel, said fifth panel being foldable toward said second panel to lie against an end wall of a box when said blank is operatively folded and placed in a box..

22. A method of packaging containers in boxes to optimize utilization of pallet space on which said boxes are stacked, and to enable the boxes to be cross-stacked and interlocked with one another to produce a stable stack, comprising the steps of: folding a first blank of corrugated cardboard to form a tray having an elongate rectangular shape with side walls and end walls disposed orthogonally to one another; folding second and third blanks of corrugated cardbord to form first and second inserts having opposite side panels, an end panel, and a diagonal panel extending from one side panel to the end panel; placing the inserts in opposite ends of the tray to provide diagonally extending corner panels in diagonally opposite corners of the tray; and placing a predetermined number of containers in the tray in side-by-side, diagonally offset relationship to one another in a substantially parallelogram-shaped arrangement.

23. A method as claimed in claim 22, wherein: the containers are one-gallon containers, and four of the containers are placed in the box.