Note: Descriptions are shown in the official language in which they were submitted.
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PREASSEMBLED DISPLAY
WITH AUTOMATIC STACKABLE SUPPORTS
FIELD OF THE INVENTION
[0001] One or more embodiments of the present disclosure relate to a
display with
stackable supports. More specifically, one or more embodiments relate to a
preassembled
display that includes a single insert blank that automatically forms stackable
supports when
an outer blank is erected.
BACKGROUND
[0002] Flat sheets of corrugated paperboard, sometimes referred to as
blanks, have
been used for many years as the starting material to form containers.
Corrugated paperboard
generally refers to a multi-layer sheet material comprised of two sheets of
liner bonded to a
central corrugated layer. Containers formed from corrugated paperboard are
sometimes
referred to as corrugated boxes. Over ninety percent of all goods in most
developed
countries are shipped in corrugated boxes.
[0003] One style of corrugated box is the slotted box style. Slotted boxes
may be
formed from one or more pieces of corrugated paperboard (blanks). A blank may
include
portions that will form sides (including side panels and end panels) of a box
as well as one or
more sets of flaps, for example flaps that may form the top and/or bottom of
the box. A
blank may be scored and slotted to permit folding and/or erecting. A blank
that has been
erected into a box may form a joint at the point where one side panel and one
end panel of
the blank and/or box are brought together.
[0004] Boxes may be shipped flat (not erected) to a user. When a box is
needed, a
box user may erect (fold and/or "square up" and/or open) the box, insert
product into the box
and close any top flaps. A half slotted container (HSC) is a style of slotted
container that
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may include a single set of flaps, for example flaps that form the bottom of
the container. An
HSC may have an open top and/or no top flaps.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 depicts an illustration of a top angled view of an example
preassembled
display with automatic stackable supports, in accordance with one or more
embodiments of
the present disclosure.
[0009] FIG. 2A depicts an illustration of a side schematic view of a flattened
outer blank of
an example preassembled display with automatic stackable supports, in
accordance with one
or more embodiments of the present disclosure.
[0010] FIG. 2B depicts an example display knock down process, in accordance
with one or
more embodiments of the present disclosure.
[0011] FIG. 3A depicts an illustration of a side schematic view of a flattened
insert blank of
an example preassembled display with automatic stackable supports, in
accordance with one
or more embodiments of the present disclosure.
[0012] FIG. 3B depicts a top view of an example erected and/or folded insert
blank nested
inside of an example erected and/or folded outer blank, in accordance with one
or more
embodiments of the present disclosure.
[0013] FIG. 4A depicts an illustration of an example container erecting
machine, in
accordance with one or more embodiments of the present disclosure.
[0014] FIG. 4B depicts an illustration of an example container erecting
machine, in
accordance with one or more embodiments of the present disclosure.
[0015] FIG. 4C depicts an illustration of an example container erecting
machine, in
accordance with one or more embodiments of the present disclosure.
2
DETAILED DESCRIPTION
[0016] One or more embodiments of the present disclosure describe a
preassembled display
with automatic stackable supports that addresses a number of disadvantages of
prior stackable
displays. One disadvantage of prior displays is that they are labor intensive
and/or difficult to
manufacture and assemble. Another disadvantage of prior displays is that they
may require
excessive materials and/or, in some cases, extraneous components to secure
separate pieces of the
container.
[0017] The present disclosure describes a preassembled display with
automatic stackable
supports (PDASS). A PDASS may be a custom-designed container (for example, an
HSC)
including two or more blanks (for example pieces of corrugated paperboard)
that are joined
together, for example to initially form a knocked down flat (KDF). The PDASS
may include an
insert formed from a single blank, where the single insert blank, when the
whole display is
erected, automatically provides supports at opposing corners of the outer
blank. In some
embodiments, one or more opposing supports may be asymmetrically shaped. The
PDASS is
designed to enable the KDF to be erected and automatically form stackable
supports, resulting in
a finished container that includes supports that act as corner "posts" of
sorts. The supports and/or
corner posts provide support to similar containers that may be stacked upon
the immediate
container.
[0017a] In accordance with one aspect, the present application provides a
preassembled
display, comprising an outer blank including outside and inside surfaces; and
an insert blank
adhered to one or more of the inside surfaces of the outer blank at a
plurality of adhesion zones,
wherein the plurality of adhesion zones includes at least one fast curing
adhesion zone and at
least one slow curing adhesion zone, wherein the insert blank is adapted to
automatically erect
when the outer blank is erected, wherein the insert blank is adapted to form a
plurality of
supports located at corners of the outer blank automatically when the outer
blank is erected,
wherein the plurality of supports comprises a first support located at a first
corner of the outer blank
and a second support located at a second corner of the outer blank, wherein
the first corner and the
second corner_are diagonally opposed to each other, wherein the first and
second supports are
asymmetrically shaped when compared to each other.
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[0018] FIG.
1 depicts an illustration of a top angled view of an example preassembled
display with automatic stackable supports (PDASS) 100, in accordance with one
or more
embodiments of the present disclosure. PDASS 100 may include a number of
blanks, for example
an outer blank 102 and an insert blank 104. Outer blank 102 may include a
number of panels, for
example a front panel 106, a rear panel 108 and two side panels 110, 112.
Insert blank 104 may
also include a number of panels. When PDASS 100 is fully erected, the insert
blank 104 may nest
or wrap inside the outer blank 102 such that the insert blank substantially
abuts the inside of the
outer blank. For example, the outer surface of a number of the panels of the
insert blank 104 may
abut portions of the inside surface of the panels of the outer blank, as shown
in FIG. 1. In some
examples, the insert blank may nest or wrap along less than the entire inside
of the outer blank
(best shown in FIG. 3B). In other words,
3a
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the insert blank may be a partial insert blank. Portions of the insert blank
panels may be
adhered to portions of the outer blank panels. For example, glue, tape or
other adhesive (for
example fast curing and/or slow curing adhesives) may reside between the
insert blank and
the outer blank, for example where the adhesive touches portions of the outer
surface of a
number of the panels of the insert blank and touches portions of the inside
surface of the
panels of the outer blank.
[0019] FIG. 2A depicts an illustration of a side schematic view of a
flattened outer
blank 200 of an example preassembled display with automatic stackable supports
(PDASS),
in accordance with one or more embodiments of the present disclosure. Outer
blank 200 may
be substantially similar to outer blank 102 of FIG. I. Outer blank 200 may
include a number
of panels, for example a front panel 206, a rear panel 208, two side panels
210, 212 and a
connection panel 214. Outer blank 200 may include a number of flaps, for
example a front
flap 220, a rear flap 222 and two side flaps 224, 226. Each panel and flap may
include an
inside surface and an outside surface, such surfaces forming inside and
outside surfaces of
blank 200. In the example shown in FIG. 2A, outside surfaces may face the
viewer of the
illustration, and inside surfaces (surfaces that face the center of the
erected box) may face
away from the viewer of the illustration. Outer blank 200 may include one or
more handles
246, 247, each handle defined by an edge of a panel that encircles, for
example in an oval
shape, an empty space.
[0020] Outer blank 200 may include a window and/or cutout 248 defined by an
edge
of panel 206 that curves downward from the top, curves horizontal, and then
curves upward
back to the top of panel 206. In some embodiments, the outer blank and/or the
inner blank
may be adapted to stabilize the window and/or cutout 248, for example during
use when a
portion of the outer blank is removed to form window 248. If the outer blank
and/or the
insert blank are not adapted to stabilize the window and/or cutout 248,
additional pressure
may be exerted on front panel 220, for example when the PDASS is erected and
filled with
product. In some embodiments, one or more adhesive zones of outer blank 200
(for example,
adhesive zone 264) may be adhered to one or more zones of the insert blank to
provide
stabilization and/or support to the window 248. In other embodiments, the
insert blank may
be adapted to include a bottom flap 328. This bottom flap may stabilize the
window 248 and
=
may be used in conjunction with one or more adhesive zones of outer blank 200.
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[0021] Outer blank 200 may be partially erected into a KDF, or a portion
thereof, by
folding and/or creasing panels 206, 208, 210, 212, 214 at joints 230, 232,
234, 236, such that
a substantially right angle exists at each joint, formed by the panels on
either side of the joint.
Joints 230, 232, 234, 236 may be scored, perforated and/or slotted to permit
easy folding
and/or erecting. It should be understood that even though FIG. 2A may show one
or more of
the joints as being scored and/or perforated, different embodiments may
utilize an outer
blank with different combinations of joint types (scored, perforated, slotted,
etc.). For
example, an outer blank may include joints that are all scored or all
perforated.
Alternatively, an outer blank may include some joints that are perforated,
some that are
scored and optionally some that are of a different type. Different types of
joints (scoring,
perforating, etc.) may adapt the outer blank to provide the appropriate
pressure against the
insert blank during and/or after erection of the carton. Once the panels of
the outer blank
have been folded to form substantially right angles at joints 230, 232, 234,
236, end 209 of
panel 208 may meet and overlap with connection panel 214. End 209 may be
adhered to
connection panel 214, for example with glue, tape or other adhesive (for
example fast curing
and/or slow curing adhesives) residing at the adhesive zone 215. At this
point, when viewed
from the top (viewing angle can be seen in FIGS. 2A and 2B), the partially
erected outer
blank may substantially resemble a rectangle 240, with the panels appearing as
lines or edges
of the rectangle and the joints appearing as corners of the rectangle.
[0022] A partially erected outer blank may then be "knocked down" to form a
KDF,
or a portion thereof. FIG. 2B depicts the knock down process. By creasing some
joints
completely and allowing other joints to return to (or remain in) an unfolded
orientation, the
outer blank, when viewed from the top may substantially resemble a
parallelogram 242, and
then substantially resemble a line 244. At this point the outer blank is
configured as a KDF,
meaning it is partially assembled in a substantially flat configuration. This
configuration
may adapt a partially erected container for easy stacking, storing and/or
shipping. Later, a
consumer goods manufacturer may erect a KDF into a container that is adapted
to hold
goods. It should be understood that a KDF may be created by folding and/or
creasing a blank
at all of the joints to form a rectangle, and then collapsing the rectangle,
for example like the
process shown in FIG. 2B. Alternative, a KDF may be created by refraining from
creasing
some joints and fully creasing other joints such that the blank is constructed
directly into the
CA 02820309 2013-07-04
substantially flat configuration. A KDF may include more than one blank, and
the folding
required to create the KDF may occur before or after multiple blanks have been
adhered
together. In one example, an insert blank is adhered to an outer blank before
the outer blank
is folded to create a KDF.
[0023] Referring to FIG. 2A, and assuming blank 200 has already been
partially
erected by folding the panels, outer blank 200 may be fully erected by folding
and/or
creasing flaps 220, 222, 224, 226 at joints 231, 233, 235, 237 such that a
substantially right
angle exists at each joint, formed by the flap and panel and on either side of
the joint. Blank
200 may be fully erected from a KDF with unfolded flaps 220, 222, 224, 226, or
it may be
fully erected from an unfolded blank, such as the one depicted in FIG. 2A. In
one example,
panels 206, 208, 210, 212 are folded and adhered at adhesive zone 215 before
flaps 220, 222,
224, 226 are folded. In this example, when the flaps are folded, each flap may
partially
overlap one or more of the other flaps. Flaps may be adhered to each other
with glue, tape or
other adhesive (for example fast curing and/or slow curing adhesives).
Alternatively, each
flap may hold in place by interlocking with other flaps.
[0024] In one example, an insert blank may be adhered to an outer blank and
a KDF
may be assembled on a different machine than the machine that erects the the
KDF to form a
box. In this respect, a KDF comprising the insert blank may be formed in one
event, perhaps
at one location, and the KDF may be opened, erected, filled, closed and/or
sealed as a
separate event, perhaps at a different location. In a commercial example, a
carton supplier
may create a KDF, including the insert blank, and ship it to a consumer goods
manufacturer,
where the consumer goods manufacturer may open, erect, fill, close, seal
and/or ship the
carton filled with product. Having the KDF preassembled may allow a consumer
goods
manufacturer to utilize the same carton erecting machines that they already
utilize for cartons
without automatic stackable supports and/or inserts. In another example, the
insert blank
may be adhered to the outer flat and the KDF may be assembled on the same
machine (and
perhaps at the same location) that erects the box.
[0025] FIG. 3A depicts an illustration of a side schematic view of a
flattened insert
blank 300 of an example preassembled display with automatic stackable supports
(PDASS),
in accordance with one or more embodiments of the present disclosure. Insert
blank 300 may
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be substantially similar to insert blank 104 of FIG. I. Insert blank 300 may
include a number
of panels, for example a front panel 306, two side panels 310, 312 and a
number of support
panels 320, 321, 322, 323, 324, 325, 326. Insert blank 300 may include a
number of flaps,
for example a bottom flap 306. Each panel and flap may include an inside
surface and an
outside surface, such surfaces forming inside and outside surfaces of blank
300. In the
example shown in FIG. 3A, outside surfaces (surfaces that abut the outer
blank) may face the
viewer of the illustration, and inside surfaces (surfaces that face the center
of the erected box)
may face away from the viewer of the illustration. Insert blank 300 may
include one or more
handles 340, 342, each defined by an edge of a panel that encircles, for
example in an oval
shape, an empty space. Outer blank 200 may include a window or cutout 344.
[0026] One or more embodiments of the present disclosure may use a single
insert
blank (formed from a single piece of corrugated paperboard), as opposed to
multiple-piece
inserts of existing containers. The single insert blank can be seen in FIGS.
3A and 3B. One
benefit of a single insert blank may be that a KDF with a single insert blank
may be easier to
manufacture and to assemble into a KDF with an outer blank. For example, a
single insert
blank can be automated manufactured and assembly into a KDF with an outer
blank can
likewise be automated. Another benefit of a single insert blank may be that
the KDF may
flatten down more uniformly and flatter than multi-part inserts. Another
benefit of a single
insert blank may be that the KDF may erect more reliably, without binding
and/or crushing.
Another benefit may be that a single insert blank works more reliably together
with an outer
blank, for example the interaction between adhered panels, un-adhered panels
and/or scored
and/or perforated joints, such that acceptable pressure is applied by the
insert blank against
the outer blank, as described more herein.
[0027] Insert blank 300 may be partially erected in a similar manner to the
outer
blank 200 of FIG. 2. The panels of the inner blank may be folded and/or
creased at
horizontal joints. Joints may be scored, perforated and/or slotted to permit
easy folding
and/or erecting. It should be understood that even though FIG. 3A may show one
or more of
the joints as being perforated and/or scored, different embodiments may
utilize an insert
blank with different combinations of joint types (scored, perforated, slotted,
etc.). For
example, an insert blank may include joints that are all scored or all
perforated.
Alternatively, an insert blank may include some joints that are perforated,
some that are
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scored and optionally some that are of a different type. Different types of
joints (scoring,
perforating, etc.) may adapt the insert blank to provide the appropriate
pressure against the
outer blank during and/or after erection of the carton. In some
configurations, joints may
form angles other than right angles, as can be seen in FIG. 3B. FIG. 3B shows
a top view of
an erected and/or folded insert blank 352 nested or wrapped inside of an
erected and/or
folded outer blank 352, similar to the configuration depicted in FIG. I. In
some examples,
the insert blank may nest or wrap along less than the entire inside of the
outer blank (best
shown in FIG. 3B). In other words, the insert blank may be a partial insert
blank. As can be
seen in FIG. 3B, a variety of angles may form at the joints when an insert
blank 354 is nested
or wrapped inside of an erected outer blank 352. An insert blank may be
partially erected by
folding the panels at joints and then inserting the insert blank inside of an
erected outer
blank. Alternatively, an insert blank may be partially erected by adhering the
insert blank to
an outer blank and then partially erecting the outer blank as described
herein. In other
embodiments, the insert blank may be adhered to an outer blank before the
outer blank is
folded to create a KDF.
[0028] Referring to FIG. 3B, an erected insert blank 354 inside of an
erected outer
blank 352 may form corners or supports 356, 357, 358 and 359. In some
embodiments, when
the whole display (i.e., a KDF including an insert blank adhered to an outer
blank) is erected,
the corners or supports may extend substantially the entire height of the
outer blank. Insert
blank 354 may form two sets of diagonally opposing corners or supports, for
example
diagonally opposing corners 357 and 358 and diagonally opposing corners 356
and 359. In
some embodiments, insert blank 354 may form less than four corners or
supports, for
example with two diagonally opposing corners and one additional corner without
a
diagonally opposing partner corner.
[0029] In some embodiments, insert blank 354 may form one or more sets of
diagonally opposing corners or supports. Diagonally opposing corner supports
may be
asymmetrically shaped when the two corners of the set are compared to each
other. In some
embodiments, all (i.e., three or four) of the corner supports may be
asymmetrically shaped
when compared to each other. When the whole display (i.e., a KDF including an
insert blank
adhered to an outer blank) is erected, asymmetric corners or corner posts or
stackable
supports may be automatically created. Corners of the insert blank may include
different
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numbers of support panels, the support panels may be differently sized and/or
the angles at
the joints near the support panels may be different. As one example, corner
356 of insert
blank 354 may include two support panels that are oriented in a substantially
straight line,
whereas corner 359 may include one support panel where unequal angles exist
between the
support panel and adjacent side and front panels.
[0030] One benefit of asymmetric corners and/or supports may be to allow
the KDF
to easily and reliably fold flat and/or erect. In some existing containers,
for example with
symmetrical corners, there is too much material (i.e., "bulk") in the corners,
and when the
container gets folded to form a KDF, the bulk in the corners may prevent the
container from
being flat. If the container cannot fold to become a flat enough KDF, the KDF
may not work
efficiently with automatic erecting equipment designed to erect simple, one-
part boxes.
Asymmetric corners and/or supports may be to allow the KDF to fold flatter,
and may allow
efficiencies, for example in storing and shipping the KDF's. Asymmetric
corners and/or
supports may also allow the KDF's to be loaded properly into the automatic
erecting
equipment and/or machines, for example erecting equipment designed to erect
simple, one-
part boxes.
[0031] Referring to FIG. 2A and 3A as an example, an inner blank 300 may be
adhered to an outer blank 200. For example glue, tape or other adhesive (for
example fast
curing and/or slow curing adhesives) may reside between a portion of the
inside surface of
the outer blank and a portion of the outer surface of the insert blank.
Referring to FIG. 2A,
adhesive may reside at adhesive zones 260, 261, 262, 263, 264, 265, 266, 267,
which are
located on the inside surfaces of outer blank 200. Outer surfaces of insert
blank 300 may
contact adhesive zones 260, 261, 262, 263, 264, 265, 266, 267. For example,
adhesive zones
260, 261 may contact panel 310 of insert blank 300, adhesive zones 260, 261,
262, 263, 264,
265, 266 may contact panel 306, and adhesive zone 267 may contact panel 312.
In this
respect, insert panel 300 may adhere tightly to outer blank, at least at the
adhesive zones, for
example as can be seen in FIG. 1.
[0032] The adhesive used to adhere the insert blank to the outer blank (for
example at
adhesions zones 260, 261, 262, 263, 264, 265, 266, 267) may be selected from a
variety of
adhesives depending on the adhesive properties desired and perhaps the
location of the blank
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at which the adhesive is applied. In some embodiments, a fast curing type of
adhesive may
be used that cures and bonds quickly during the KDF forming process, for
example to
stabilize the two blanks during the KDF forming/folding process. In one
example, the fast
curing adhesive may substantially bond before the blanks are folded to create
the KDF. On
example of a fast curing adhesive is a hot melt adhesive. In some embodiments,
a slow
curing type of adhesive may be used that cures more slowing and delays
bonding, for
example until after the KDF is formed. For example, slow curing adhesives may
allow time
for folding before the adhesive sets, for example so that the blanks can move
relative to each
other during folding and then have all adhesion points be secure before the
erection process
begins. One example of a slow curing adhesive is a cold melt adhesive. In some
embodiments, more than one type of adhesive may be used, for example both fast
curing and
slow curing adhesives. In some examples, the fast curing adhesive may be used
at locations
on the inside surface of the outer blank, for example where it may be
desirable to have little
or no movement of the outer blank relative to the insert blank. In some
examples, the slow
curing adhesive may be used at locations on the inside surface of the outer
blank, for
example where it is desirable to have some movement of the outer blank
relative to the insert
blank. Movement between the outer blank and insert blank can occur when the
adhered
blanks are folded to form the KDF, for example. In some specific examples, the
fast curing
adhesive is used at adhesion zones 262, 263, 264, 265, and 266. In some
specific examples,
the slow curing adhesive is used at adhesion zones 260, 261, and 267.
[0033] Adhesive
placement (the location on the blanks where adhesive is applied)
may determine how the KDF may move during the erecting process. Some panels of
the
outer and insert blank may have adhesive applied to them and other panels may
not. For
example, insert panels 326, 325, and 312 may not have adhesive applied to them
and these
panels may not be directly adhered to the outer blank. One benefit of some
panels of the
insert blank not being adhered to the outer blank is that they may move,
relative to panels of
the outer blank, when the KDF is erected. Adhered panels, un-adhered panels
and/or scored
and/or perforated joints of the insert and outer blanks may all work together
during the
formation and/or erection of the carton, for example such that acceptable
pressure is applied
by the adhered panels of the insert blank against the outer blank. One
advantage of the
present disclosure is that the insert blank may be a partial insert blank
(best seen in FIG. 3B
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where the insert blank wraps less than all the way around the inner surfaces
of the outer
blank). A partial insert blank in conjunction with the adhered panels, un-
adhered panels
and/or scored and/or perforated joints described above may create an insert
blank that
reliably moves within the outer blank such that KDFs may reliably be flattened
and/or
erected without binding and/or crushing of parts of the KDF. Additionally, a
partial insert
blank may allow the KDF to be folded flat enough such that the KDF works
efficiently with
automatic erecting equipment designed to erect simple, one-part boxes.
[0034] An insert blank may be adhered to an outer blank before or after the
outer
blank has been partially or fully erected. In one example, an insert blank may
be adhered to
an outer blank before the outer blank has been partially or fully erected. In
this respect the
insert bank and the outer blank may both be flat and unfolded when the insert
blank is
adhered. Then, as the outer blank is erected, the insert blank may be
automatically erected,
and may automatically form corner supports.
[0035] In other embodiments, an insert blank may be adhered to an outer blank
before the
KDF is folded. In such embodiments, the insert bank and the outer blank may
both be flat
and unfolded when the insert blank is adhered. Then, as the KDF is folded and
panels of the
outer blank are adhered, the insert blank and outer blank are simultaneously
folded to form a
substantially flat KDF.
[0036] An outer blank and insert blank may be erected together. For
example,
erecting an outer blank, as explained above, may automatically erect the
insert blank because
the insert blank may have joints and because the insert blank may be adhered
to the outer
blank at strategic adhesion zones. The joints and the strategic adhesion zones
may adapt a
KDF to automatically force the insert blank into an erected configuration at
the same time the
outer blank is erected. For example, the outer blank may pull and/or push the
insert blank at
the strategic adhesion zones, forcing it to erect. A machine may be utilized
to erect and/or
open a KDF that includes an insert blank adhered to an outer blank at
strategic adhesion
zones. The machine may hold in place one panel of the KDF while moving another
panel of
the KDF such that the substantially flat KDF transforms into a partially
erected container that
resembles a rectangle when viewed from the top. The machine may fold and/or
close the
bottom flaps of the outer blank until the bottom flaps are substantially
perpendicular to the
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side panels. The machine may cause the bottom flaps to interlock or adhere to
each other. In
some embodiments, the bottom flaps do not interlock or adhere and instead,
tape may be
applied to create a closed bottom for the container. The folding of the bottom
flaps of the
outer blank may cause one or more flaps (for example, bottom flap 328 of FIG.
3A) of the
insert blank, to the extent they exist, to fold into place as well. In some
embodiments, one or
more zones of the insert blank (for example bottom flap 328 of insert blank
300 in FIG. 3)
may provide stabilization and/or support to the window 248. The resulting
container may be
fully erected and ready to be filled with product.
[0037] Fully erected containers may be placed in retail stores as
production displays
or display trays, for example to display consumer goods. Fully erected
containers may be
shipped in a fully erected configuration, for example packed full of consumer
goods. Erected
containers may have covers placed over them at times, for example during
shipment. In some
examples, when a container with a cover arrives at the retailer location, the
cover may be
removed, and the display tray may be displayed in the store, showing the
consumer goods.
In some situations, fully erected contains may be built into multi-container
display pallets for
use in retail merchandising.
[0038] FIGS. 4A-4C depict illustrations of an example container erecting
machine
400 that may be operable to erect one or more KDFs, for example from a stack
of KDFs 402.
The KDFs depicted in stack 402 may be substantially similar to the KDFs
explained herein.
For example the KDFs of stack 402 may include an outer blank substantially
similar to outer
blank 200 and an insert blank substantially similar to insert blank 300.
Container erecting
machine 400 may include a rotational guide 404, one or more claws 406, 408, a
conveying
track 410 and a control system (not shown). A holding claw 408 (best seen in
FIG. 4B) may
hold a portion of a KDF (for example a side panel) substantially in place
while an opening
claw 406 may grab another portion of the KDF (for example the rear panel) and
move that
portion such that the KDF transforms from its substantially flat orientation
to a partially
erected orientation.
[0039] To open the KDF, opening claw 406 may slide in a rotational manner
along
rotational guide 404, starting in the orientation shown in FIG. 4A (where the
KDF is
substantially flat) and ending in the orientation shown in FIG. 4B (where the
KDF is
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substantially open and/or partially erected). Holding claw 408 may stay in
substantially the
same location throughout the opening process, although holding claw 408 may
move a small
distance to pull and/or engage the immediate KDF 412 from the stack 402 of
KDFs. During
the opening process, with the opening claw 406 sliding in a rotational manner
and the
holding claw 408 staying substantially in place, the moving claws 406, 408 may
resemble the
covers of an opening book, where the front cover moves in a rotational manner
and the back
cover stays substantially in place. During the opening process, the claws may
partially erect
the outer blank of the KDF 412, which automatically erects the insert blank of
the KDF, as
described herein, automatically creating corner posts / supports to the
container.
[0040] As the claws 406, 408 partially erect the KDF 412, they may also
lower the
KDF onto a conveying track 410, as best seen in FIGS. 4B and 4C. Conveying
track 410
may include components that complete the erection process by closing the
bottom flaps 414,
416 of KDF 412, which converts the KDF into a completed container. Once the
bottom flaps
are closed, the conveying track 410 may move the completed container in a
direction 418
away from the stack 402 of remaining KDFs. As the completed container moves
away from
the stack, the claws 406, 408 may grab and partially erect another KDF from
the stack 402.
This process of grabbing, erecting, and conveying away may repeat as long as
there are
KDFs remaining in stack 402 and/or as long as the container erecting machine
400 is
activated.
[0041] The container erecting machine 400 may include a control system (not
shown). The control system may direct the movement of components of the
container
erecting machine 400, for example one or more claws 406, 408 and/or one or
more sub-
components of a conveying track 410. The control system may include circuitry,
one or
more data processors, motors, wires, and/or other components common in
mechanical
systems.
[0042] The term "knocked down flat" (KDF) generally refers to a partially
assembled
container that is currently in a relatively flat configuration and is capable
of being erected
into a container adapted to hold goods. A KDF may include one or more blanks,
where the
one or more blanks may be adhered together at adhesion points. The terms
"carton,"
"container," "display" and "box" may generally be used interchangeably to
generally mean a
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structure, generally having a box shape, in which consumer goods and/or
product may be
shipped, transported and/or displayed to consumers in stores. Term "blank"
generally means
a flat sheet of some material, for example paperboard, that is ready to be
folded into and
become a portion of a container, or the whole container. The blanks and/or
KDFs and/or
containers of the embodiments described herein are typically manufactured
using corrugated
paperboard, for example with the corrugations running in a vertical direction
for increased
strength. As non-limiting examples, the containers may be manufactured from C-
flute, EB-
flute, E-flute or B-flute corrugated paperboard. It is to be understood that
the principles of
one or more embodiments of this disclosure may be applied to containers made
of other
materials, such as non-corrugated paperboards, cardboard, corrugated
fiberboard, non-
corrugated fiberboard, solid-fiber board, polymeric materials, and other
foldable materials. It
should also be understood that the principles of one or more embodiments of
this disclosure
may be applied to containers of varying styles, for example HSC-style
containers or other
styles of corrugated boxes or non-corrugated boxes.
[0043] In addition to the benefits of the preassembled display with
automatic
stackable supports already described in this disclosure, the following
describes further
benefits of one or more embodiments. It is to be understood that benefits and
advantages
described throughout this disclosure are not limitations or requirements, and
some
embodiments may omit or include more than one or more of the described
benefits and/or
advantages.
[0044] Customers, industry standards and the like may exhibit a preference
for low
cost, paperboard containers that provide structural stacking strength with a
minimal amount
of corrugated paperboard. Customers, industry standards and the like may
exhibit a
preference for a shipping container that is free of excessive structural
elements. Existing
displayable containers tend to be somewhat weak, and in certain situations
they may deform
when stacked. The preassembled display with automatic stackable supports may
address
these preferences.
[0045] Some prior HSC-style stackable displays have disadvantages. For
example
they may fashion stackable supports from folded sections of the outer display
blank or may
use multiple insert sections to reinforce corners of the container. These
displays may suffer
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from disadvantages. For example, these displays may include bulky regions (too
much
material in an area) when the display is flattened which may make storage,
shipping and
interaction with an erecting machine less reliable. The excessive materials of
these displays
may also cause binding during erection of a KDF, which may cause less
consistent and less
reliably erecting. Some prior HSC-style stackable displays utilize symmetric
supports
located at opposing corners of the outer display blank. In these displays,
there may be too
much material (i.e., "bulk") in the corners, and when the container gets
folded to form a
KDF, the bulk in the corners may prevent the container from being flat. Some
prior HSC-
style stackable displays have been constructed by manually inserting end
panels and/or
corner posts to create the stackable supports. In some situations, end panels
and/or corner
posts are manually inserted after the outer box is erected. The manual and/or
subsequent
insertion of end panels and/or corner posts may result in higher costs, for
example due to
additional labor and/or equipment requirements. For example, the conversion
(e.g., folding,
erecting, etc.) may require additional workers to manually insert supports,
which adds labor
costs. Additionally, manual and/or subsequent insertion may require additional
area (e.g.,
floor space) within a container production line to accommodate additional
container
components and additional equipment and workers. Some prior HSC-style
stackable
displays have required specialized container-erecting equipment beyond the
standard
equipment used by manufacturers to erect displays and/or containers that do
not require
subsequent insertion of supports. Further, in some situations, existing
production lines have
been decommissioned because they are not capable of supporting the assembly
needs of
containers that require manual and/or subsequent insertion of end panels
and/or corner posts.
KI0461 The
preassembled display with automatic stackable supports may provide
improved stackability with the efficiency of automatic erection of a single
insert that
provides corner supports. The display described herein eliminates the need to
manually
insert supports in the display during production. Existing stackable displays
(for example,
HSC-style stackable displays) may require manual insertion of inserts and/or
supports, such
as end panels. The display described herein includes stacking components (an
insert blank)
built into a pre-assembled KDF, which eliminates the need for manual
placement. Existing
stackable displays may either fashion stackable supports from folded sections
of the display
blank or use multiple insert sections to reinforce corners. The display
described herein may
CA 02820309 2013-07-04
use a single insert blank that may provide asymmetric corners when the KDF is
erected. The
asymmetric corner may offer improved stackability.
[0047] The display described herein may be erected using existing
case erecting
equipment to enable in-house production of display trays. Eliminating the need
for manual
placement of supports may result in a lower cost of conversion and may require
less area
within the production line for labor associates and packaging components.
Manually
inserting supports may be slow and expensive but such stackable containers may
be required
by retailers, Erection of the pm-assembled KDFs of the present disclosure does
not require
specialized case erecting equipment and may run on standard container erecting
equipment
that a good manufacturer may already utilize. This may be particularly
valuable in that the
implementation will not require additional capital investments nor an extended
timeline prior
to launching into market. This may remove incremental labor cost from
conversion of KDFs.
Eliminating the need for manual placement of supports may also enable
reduction in the
amount of floor space that a production line occupies. The containers and
equipment
described herein may enable production lines to be brought back into use, ones
that were not
initially capable of supporting displays that require manual insertion of
supports. Allowing a
goods manufacturer to get multiple uses out of a single case erecting
equipment may give the
manufacturer the flexibility of creating various cartons and only investing in
one type of
carton erecting machine. Some existing stackable displays cannot be erected by
the same
equipment because they require more complicated erection processes.
[0048] While the present invention has been described with
reference to one or more
particular embodiments, those skilled in the art will recognize that many
changes may be
made thereto without departing from the spirit and scope of the present
invention, Each of
these embodiments and obvious variations thereof is contemplated as falling
within the spirit
and scope of the claimed invention,
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