Note: Descriptions are shown in the official language in which they were submitted.
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CORRUGATED CREMATION CONTAINERS
[0001]
FIELD OF THE INVENTION
[0002] This invention relates generally to caskets, and more particularly
to
corrugated cremation containers.
BACKGROUND OF THE INVENTION
[0003] Traditional caskets have historically been employed for both in-
ground burial
and above-ground interment. Traditional caskets are typically fabricated from
fine
furniture-grade wood or from highly polished/finished sheet metal, for
aesthetic reasons.
[0004] While traditional in-ground burial and above-ground interment in a
traditional
casket continue to be the method of choice for the ultimate disposition of the
remains of
the deceased for a majority of funeral customers, cremation nevertheless
continues to
be a growing segment of the death care industry. Cremation caskets are
typically
fabricated of corrugated fiberboard, sometimes referred to as cardboard, of
hardboard,
or of plywood, due to the combustibility and low cost of these materials. Of
these
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materials, cardboard generally tends to be the least expensive, and
accordingly a
significant percentage of cremation caskets are fabricated from cardboard.
[0005] Briefly, corrugated board or cardboard is made from papers made up
of
cellulose fibers, either virgin or recycled. Two sheets of paper, called
liners, are glued
to opposite surfaces of a corrugated inner medium, called the fluting. These
three
layers of paper, assembled in this way, form a series of connected arches that
provide a
structure having overall better strength/stiffness characteristics than that
of each
individual layer.
[0006] Cardboard cremation caskets present significant design challenges.
Both
traditional caskets and cremation caskets include a lower body containing
portion
known as a shell or base, and an upper portion known as a cap or lid closeable
on the
lower portion. One particularly compelling challenge in designing cardboard
cremation
caskets is how to achieve the required stiffness of the shell portion of the
cardboard
casket so that the cardboard casket will not twist, deflect, or otherwise have
its shape
distorted under the load of the deceased. Another compelling design challenge
for
designers of cardboard cremation caskets is aesthetics ¨ how to present the
cardboard
cremation casket in the most aesthetically pleasing manner.
[0007] While advances have been made in the design of cardboard cremation
caskets, there nevertheless continues to be room for improvement in this area.
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SUMMARY OF THE INVENTION
[0008] In one aspect, a cardboard cremation container is provided. The
container
has a cardboard base having a pair of opposed side walls, a pair of opposed
end walls,
and a bottom wall, and a cardboard lid on the base, the lid having a pair of
opposed
side walls, an end wall, a header wall, and a top wall. Each of the side walls
of the base
has a notch formed in an upper edge thereof. The side walls and the end wall
of the lid
extend outwardly beyond the side walls and one end wall of the base, and lower
edges
of the side walls and the end wall of the lid are positioned below upper edges
of the side
walls and the one end wall of the base. The header wall of the lid fits in the
notches in
the side walls of the base. The lid includes a riser at each corner of the lid
formed by
each lid side wall and a respective end of the lid end wall. The risers are
supported on
respective corners of the base formed by each base side wall and a respective
end of
the one base end wall.
[0009] The notches have a depth dimension, and the lower edges of the
risers are
positioned above lower edges of the lid side walls and end wall by a height
dimension.
The depth dimension and the height dimension are preferably about equal. The
notches have a width dimension measured in a direction generally parallel to
the side
walls of the base. The width dimension is preferably about equal to twice the
thickness
of the header wall of the lid. The container can have a second lid. The side
walls and
the end wall of the second lid extend outwardly beyond the side walls and the
other end
wall of the base, and lower edges of the side walls and the end wall of the
second lid
are positioned below upper edges of the side walls and the other end wall of
the base.
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The header walls of the lids fit snugly in the notches in the side walls of
the base. The
risers of the second lid are supported on respective corners of the base
formed by each
base side wall and a respective end of the other base end wall.
[0010] In one embodiment, the side walls and the end wall of the lid are
generally
vertically oriented and connected directly to the top wall of the lid. In
another
embodiment, the side walls and the end wall of the lid are generally
vertically oriented
and are connected indirectly to the top wall of the lid with planar lid
portions that slope
outwardly and downwardly from the top wall to the lid side walls and lid end
wall. In
either embodiment, the side walls and the end walls of the base preferably
slope
inwardly and downwardly from the upper edges of the side walls and the end
walls to
the bottom wall.
[0011] The side walls and the end walls of the base can include a plurality
of hand
hold cut-outs, each of the cut-outs defined by an upper horizontal score line,
a lower
horizontal cut line, and end semi-circular cut lines. Alternatively, the
container can have
a pair of longitudinal carrying straps and a pair of transverse carrying
straps. Either
way, the container can have an outer base and an inner base disposed in the
outer
base, the inner base also having a pair of opposed side walls, a pair of
opposed end
walls, and a bottom wall.
[0012] In another aspect, another cardboard cremation container is
provided. The
container has a cardboard base having a pair of opposed side walls, a pair of
opposed
end walls, and a bottom wall, and a cardboard lid on the base, the lid having
a pair of
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opposed side walls, an end wall, a header wall, and a top wall. The container
also has
a pair of longitudinal carrying straps, and a pair of transverse carrying
straps. Each of
the pair of longitudinal carrying straps has a loop on one end, passes through
an
opening in one of the end walls of the base, extends under an upper surface of
the
bottom wall of the base, passes through an opening in the other end wall of
the base,
and has a loop on the other end. Each of the pair of transverse carrying
straps has a
loop on one end, passes through an opening in one of the side walls of the
base,
extends under the upper surface of the bottom wall of the base, passes through
an
opening in the other side wall of the base, and has a loop on the other end.
[0013] The container can have an outer base and an inner base disposed in
the
outer base, the inner base having a pair of opposed side walls, a pair of
opposed end
walls, and a bottom wall. Each of the pair of longitudinal carrying straps
passes through
an opening in one of the end walls of the inner base, extends under the bottom
wall of
the inner base, and passes through an opening in the other end wall of the
inner base.
Each of the pair of transverse carrying straps passes through an opening in
one of the
side walls of the inner base, extends under the bottom wall of the inner base,
and
passes through an opening in the other side wall of the inner base.
[0014] In other aspects, cardboard blanks from which to fold cremation
container
bases and lids are provided, as are cremation container bases and lids folded
from the
cardboard blanks.
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[0015] A cardboard blank for a lid for a cardboard cremation container is
provided.
The blank has a top wall panel, a side wall panel foldably connected to each
opposite
side of the top wall panel, a side wall roll over panel foldably connected to
each side
wall panel, a riser tab foldably connected to an end of each side wall roll
over panel, an
end wall panel foldably connected to one end of the top wall panel, a flap
foldably
connected to each opposite end of the end wall panel, and a header wall panel
foldably
connected to the other end of the top wall panel, a flap foldably connected to
each
opposite end of the header wall panel.
[0016] Each riser tab has a first free edge opposite a fold line foldably
connecting the
riser tab to a respective side wall roll over panel. The riser tab fold line
is positioned
inward of an adjacent end of the side wall panel. The riser tab first free
edge is
positioned outward of the adjacent end of the side wall panel. Each riser tab
also has a
second free edge adjacent the fold line foldably connecting the riser tab to a
respective
side wall roll over panel. The riser tab second free edge is positioned
outward of a fold
line foldably connecting the side wall roll over panel to the side wall panel.
A free edge
of the header wall panel can be inwardly curved.
[0017] A cardboard lid for a cardboard cremation container is provided. The
lid has
a top wall panel, a side wall panel foldably connected to each opposite side
of the top
wall panel, a side wall roll over panel foldably connected to each side wall
panel, a riser
tab foldably connected to an end of each side wall roll over panel, an end
wall panel
foldably connected to one end of the top wall panel, a flap foldably connected
to each
opposite end of the end wall panel, and a header wall panel foldably connected
to the
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other end of the top wall panel, a flap foldably connected to each opposite
end of the
header wall panel. The side wall panels, end wall panel, and header wall panel
are
folded relative to the top wall panel to form a pair of opposed side walls, an
end wall, a
header wall, and a top wall of the lid, with the flaps on the end wall panel
and on the
header wall panel folded so as to be positioned inward of the side wall
panels. The side
wall roll over panels are folded relative to the side wall panels so as to be
positioned
inward of the side wall panels and the flaps. The riser tabs are folded so as
to angle
across a respective corner of the lid formed by each lid side wall and a
respective end
of the lid end wall.
[0018] The lower edges of the risers are positioned above lower edges of
the lid side
walls and end wall. A free edge of the header wall can be upwardly curved.
[0019] Another cardboard blank for a lid for a cardboard cremation
container is
provided. The blank has a top wall panel, a side rim wall panel foldably
connected to
each opposite side of the top wall panel, a side wall panel foldably connected
to each
side rim wall panel, a side wall roll over panel foldably connected to each
side wall
panel, a riser tab foldably connected to an end of each side wall roll over
panel, an end
rim wall panel foldably connected to one end of the top wall panel, an end
wall panel
foldably connected to the end rim wall panel, an end wall roll over panel
foldably
connected to the end wall panel, a flap foldably connected to each opposite
end of the
end wall roll over panel, and a header wall panel foldably connected to the
other end of
the top wall panel, a flap foldably connected to each opposite end of the
header wall
panel.
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[0020] Each riser tab has a first free edge opposite a fold line foldably
connecting the
riser tab to a respective side wall roll over panel. The riser tab fold line
is positioned
inward of an adjacent end of the side wall panel. The riser tab first free
edge is
positioned outward of the adjacent end of the side wall panel. Each riser tab
also has a
second free edge adjacent the fold line foldably connecting the riser tab to a
respective
side wall roll over panel. The riser tab second free edge is positioned
outward of a fold
line foldably connecting the side wall roll over panel to the side wall panel.
A free edge
of the header wall panel can be inwardly curved.
[0021] Another cardboard lid for a cardboard cremation container is
provided. The
lid has a top wall panel, a side rim wall panel foldably connected to each
opposite side
of the top wall panel, a side wall panel foldably connected to each side rim
wall panel, a
side wall roll over panel foldably connected to each side wall panel, a riser
tab foldably
connected to an end of each side wall roll over panel, an end rim wall panel
foldably
connected to one end of the top wall panel, an end wall panel foldably
connected to the
end rim wall panel, an end wall roll over panel foldably connected to the end
wall panel,
a flap foldably connected to each opposite end of the end wall roll over
panel, and a
header wall panel foldably connected to the other end of the top wall panel, a
flap
foldably connected to each opposite end of the header wall panel. The side rim
wall
panels, side wall panels, end rim wall panel, end wall panel, and header wall
panel are
folded relative to the top wall panel to form a pair of opposed side rim
walls, a pair of
opposed side walls, an end rim wall, an end wall, a header wall, and a top
wall of the lid,
with the flaps on the end wall roll over panel and on the header wall panel
folded so as
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to be positioned inward of the side wall panels. The side wall roll over
panels are folded
relative to the side wall panels so as to be positioned inward of the side
wall panels and
the flaps. The riser tabs are folded so as to angle across a respective corner
of the lid
formed by each lid side wall and a respective end of the lid end wall.
[0022] The
lower edges of the risers are positioned above lower edges of the lid side
walls and end wall. A free edge of the header wall can be upwardly curved.
[0023] A cardboard base for a cardboard cremation is provided. The base
comprises cardboard outer base and a card board inner base. The outer base
comprises a bottom wall panel, a side wall panel foldably connected to each
opposite
side of the bottom wall panel, a flap foldably connected to each opposite end
of each
side wall panel, a side wall roll over panel foldably connected to each side
wall panel,
an end wall panel foldably connected to each opposite end of the bottom wall
panel,
and an end wall roll over panel foldably connected to each end wall panel. The
inner
base comprises a bottom wall panel, a side wall panel foldably connected to
each
opposite side of the bottom wall panel, and an end wall panel foldably
connected to
each opposite end of the bottom wall panel. The side wall panels and end wall
panels
of the outer base are folded relative to the bottom wall panel of the outer
base to form a
pair of opposed outer side walls, a pair of opposed outer end walls, and an
outer bottom
wall of the base, with the flaps on the side wall panels of the outer base
folded so as to
be positioned inward of the end wall panels of the outer base. The end wall
roll over
panels of the outer base are folded relative to the end wall panels so as to
be positioned
inward of the end wall panels and the flaps. The side wall panels and end wall
panels
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of the inner base are folded relative to the bottom wall panel of the inner
base to form a
pair of opposed inner side walls, a pair of opposed inner end walls, and an
inner bottom
wall of the base. The inner base is placed into the outer base. The side wall
roll over
panels of the outer base are folded relative to the side wall panels of the
outer base so
as to be positioned inward of the side walls of the inner base.
[0024] The height of the various panels can be variously dimensioned. For
example,
the height of the side wall panels of the inner base can be about equal to the
height of
the side wall panels of the outer base, the height of the side wall roll over
panels of the
outer base can be less than the height of the side wall panels of the outer
base, and the
height of the end wall roll over panels of the outer base can be less than the
height of
the end wall panels of the outer base. As another example, the height of the
side wall
roll over panels of the outer base can be about equal to the height of the end
wall roll
over panels of the outer base. And, the outer side walls and the outer end
walls of the
outer base can slope inwardly and downwardly from upper edges of the outer
side walls
and the outer end walls to the outer bottom wall.
[0025] The accompanying drawings, which are incorporated in and constitute
a part
of this specification, illustrate embodiments of the invention and, together
with the
summary of the invention given above, and the detailed description of the
drawings
given below, serve to explain the principles of the present invention.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Fig. 1 is a perspective view of a cardboard cremation container
according to
the principles of the present invention.
[0027] Figs. 2A-2D illustrate steps in folding the base blank into the base
of the
container of Fig. 1.
[0028] Fig. 3A-3C illustrate steps in folding the leak tray blank into the
leak tray of
the container of Fig. 1.
[0029] Figs. 4A and 4B illustrate steps in folding the lid blank into the
lid of the
container of Fig. 1.
[0030] Fig. 5 illustrates a plurality of containers of Fig. 1 configured
for shipping.
[0031] Fig. 6 is a view similar to Fig. 1 with the head end lid removed
from the base.
[0032] Fig. 7 is a perspective view of another embodiment of cardboard
cremation
container according to the principles of the present invention.
[0033] Figs. 8A-8F illustrate steps in folding the base blank into the base
of the
container of Fig. 7.
[0034] Figs. 9A-9D illustrate steps in folding the lid blank into the lid
of the container
of Fig. 7.
[0035] Fig. 10 illustrates a plurality of containers of Fig. 7 configured
for shipping.
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[0036] Figs. 11A-11C illustrate steps in trimming the container of Fig. 7.
DETAILED DESCRIPTION OF THE DRAWINGS
[0037] Referring first to Fig. 1, a cardboard cremation container 10
according to the
principles of the present invention is illustrated. The container 10 has a
base 12 and a
pair of identical lids 14, 14 closeable on the base 12. The base 12 has a pair
of
opposed side walls 20, 20, a pair of opposed end walls 22, 22, and a bottom
wall 24.
Each lid 14 has a pair of opposed side walls 30, 30, an end wall 32, a header
wall 34
(Fig. 6), and a top wall 36.
[0038] Referring to Figs. 2A-2D, a blank 40 from which to erect the base 12
is
illustrated. Blank 40 has a bottom wall panel 42, a side wall panel 44
foldably
connected to each opposite side of the bottom wall panel 42 via a score line
or crease
line or fold line 46, and a side wall roll over panel 48 foldably connected to
each side
wall panel 44 via a pair of closely spaced score lines or crease lines or fold
lines 50, 52.
(As used herein, the term "score line" shall be deemed to embrace a fold line
whether
that fold line is actually scored or not, and shall also be deemed to embrace
the term
''crease line." In other words, the terms "score line," "crease line," and
"fold line" are
used interchangeably herein.) Closely spaced score lines 50, 52 form a roll
over edge
therebetween. A flap 60 is foldably connected to each opposite end of each
side wall
panel 44 via a score line 62. Blank 40 has an end wall panel 66 foldably
connected to
each opposite end of the bottom wall panel 42 via a score line 68, and an end
wall roll
over panel 70 foldably connected to each end wall panel 66 via a pair of
closely spaced
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score lines 72, 74. Closely spaced score lines 72, 74 form a roll over edge
therebetween.
[0039] An inner base 13 is erected from a blank 80. Blank 80 likewise has a
bottom
wall panel 82, a full height side wall panel 84 foldably connected to each
opposite side
of the bottom wall panel 82 via a score line 86, and a shorter end wall panel
88 foldably
connected to each opposite end of the bottom wall panel 82 via a score line
90.
[0040] To erect base 12 from blank 40, side wall panels 44 are folded upwardly
and
flaps 60 are folded inwardly. End wall panels 66 are folded upwardly. Flaps 60
are
secured to end wall panels 66 with hot melt glue. End wall roll over panels 70
are
folded inwardly and secured to flaps 60 and/or end wall panels 66 with hot
melt glue.
Inner base 13 is placed in outer base 12, and side wall roll over panels 48
are folded
inwardly onto side wall panels 82 of inner base 13 and secured with hot melt
glue.
[0041] Side
wall panels 44 and end wall panels 66 of blank 40 include a plurality of
hand hold cut-outs 96, each cut-out defined by an upper horizontal score line,
a lower
horizontal cut line, and end semi-circular cut lines. Similar hand hold cut-
outs 98 are
provided in side wall roll over panels 48 and end wall roll over panels 70 so
as to not
interfere with hand holds 96. Clearance holes 97 are provided in flaps 60 of
outer base
blank 40 so as to not interfere with hand holds 96 in end wall panels 66.
Clearance
holes 100 are provided in side wall panels 84 of inner base blank 80 so as to
not
interfere with hand holds 96.
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[0042] Referring to Figs. 3A-3C, a drip tray 120 for use with container 10
is
illustrated. Drip tray 120 is erected from a blank 122 having a bottom wall
panel 124, a
side wall panel 126 foldably connected to each opposite side of the bottom
wall panel
124 via a score line 128, and an end wall panel 130 foldably connected to each
opposite end of the bottom wall panel 124 via a score line 132. Corners of the
tray 120
are formed by triangular pleats or gussets 136, 138 foldably connected to one
another
via score line 140. Pleat or gusset 136 is foldably connected to end wall
panel 130 via a
score line 144, and pleat or gusset 138 is foldably connected to side wall
panel 126 via
a score line 146. Tray 120 is preferably coated with a liquid impervious
coating such as
that available from Michelman, Inc. of Cincinnati, OH,. Blank 122 also
includes a
number of transverse score lines 150 permitting the blank 122 to be folded for
shipment,
as will be subsequently described.
[0043] To erect tray 120 from blank 122, side wall panels 126 and end wall
panels
130 are folded upwardly, and pleats or gussets 136, 138 are folded inwardly.
Tray 120
may then be placed in base 12. Note that the height of the side wall panels 44
and side
wall roll over panels 48 and end wall panels 66 and end wall roll over panels
70 of base
blank 40 and the height of the side wall panels 126 and end wall panels 130 of
drip tray
blank 122 are chosen such that the free edges of the side wall panels 126 and
end wall
panels 130 of drip tray blank 122 will securely "snap in" below the free edges
of the side
wall roll over panels 48 and end wall roll over panels 70 of base blank 40.
[0044] Referring to Figs. 4A and 4B, a blank 160 from which to erect lid 14
is
illustrated. Blank 160 has a top wall panel 162, a side wall panel 164
foldably
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connected to each opposite side of the top wall panel 162 via a score line
166, and a
side wall roll over panel 168 foldably connected to each side wall panel 164
via a pair of
closely spaced score lines 170, 172. Closely spaced score lines 170, 172 form
a roll
over edge therebetween. A riser tab 174 is foldably connected to one end of
each side
wall roll over panel 168 via a score line 176. Each riser tab 174 has a first
free edge
174a opposite its score line 176 and a second free edge 174b adjacent its
score line
176. The riser tab score line 176 is positioned inward of the adjacent end of
the side
wall panel 164, the riser tab first free edge 174a is positioned outward of
the adjacent
end of the side wall panel 164, and the riser tab second free edge 174b is
positioned
outward of the score lines 170, 172 foldably connecting the side wall roll
over panel 168
to the side wall panel 164. Blank 160 has an end wall panel 180 foldably
connected to
one end of the top wall panel 162 via a score line 182. A flap 184 is foldably
connected
to each opposite end of the end wall panel 180 via a score line 186. Blank 160
has a
header wall panel 190 foldably connected to the opposite end of top wall panel
162 via
a score line 192. Header wall panel 190 has a flap 194 foldably connected to
each
opposite end of the header wall panel 190 via a score line 196. A transverse
score line
200 permits the blank 160 to be folded for shipment, as will be subsequently
described.
The free edge 202 of header wall panel 190 is preferably inwardly curved to
accommodate larger bodies.
[0045] To assemble the lid 14 from the blank 160, the end wall panel 180 and
header wall panel 190 are folded upwardly and flaps 184 and 194 are folded
inwardly.
Side wall roll over panels 168 are folded inwardly against flaps 184, 194 and
side wall
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panels 164, which causes riser tabs 174 to "pop out" and extend across the
corners of
lid 14. The side wall panels 164 are secured with double sided tape 206.
[0046] Referring back to Figs. 2A-2D, it will be seen that base blank 40
includes a
notch 210 formed in each side wall panel 44, side wall roll over panel 48, and
the roll
over edge therebetween. A complimentary aligned notch 212 is formed in the
free edge
of each side wall panel 84 of blank 80 used to erect inner base 13. Once outer
base 12
and inner base 13 are assembled as described above, notches 210, 212 provide a
means of retaining lids 14 securely on base 12. More particularly, the outer
free edges
of the header wall 34 of each lid fit into the notches 210, 212 on either side
of the base
12. Preferably, the notches 210, 212 have a width dimension that is just about
equal to
the combined thickness of the header walls 34 of the two lids 14 so as to
snugly and
securely retain the free edges of the header walls 34 in the notches 210, 212.
The
notches 210, 212 maintain the header walls 34 in abutting relation, so as to
not let the
lids 14 slip off either end of the base 12 or allow visibility into the
container 10, as well
as keep the lids 14 in place even if the container 10 twists or contorts
during handling
and transport.
[0047] When lids 14 are placed on base 12, the lower edges of the side walls
30, 30
and end wall 32 of each lid 14 extend outwardly beyond and downwardly below
the
upper edges of the side walls 20, 20 and end wall 22 of the base 12. Thus, the
lids 14
will lower downwardly until the riser tabs 174 contact and thus are supported
by the
corners of the base 12. Preferably, the depth of the notches 210, 212 is about
the same
as the amount by which the lower edges of the riser tabs 174 are positioned
above the
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lower edges of the side walls 30, 30 and end wall 32 of the lid 14. This will
cause the
lids 14, 14 to be supported on the base 12 substantially horizontally. See
Fig. 6. The
above described geometry of riser tabs 174 determines the amount by which the
lower
edges of the riser tabs 174 are positioned above the lower edges of the side
walls 30,
30 and end wall 32 of the lid 14.
[0048] Referring to Fig. 5, a plurality of containers 10 are illustrated
ready for
shipment. The geometry of various ones of the panels, flaps, and score lines
of the
blank 40 described above is selected so as to provide side walls 20 and end
walls 22 of
base 12 which taper inwardly, by, for example, about 12.75 degrees, and to
provide a
depth of about 9.5 inches. This permits five bases 12 to be nested for
shipment as
illustrated, with each base containing therein its two unerected (i.e. flat)
lids 14 folded in
half and its unerected (i.e. flat) drip tray 120 folded in half and then
folded in half again.
The entire contents can be shipped in a standard cardboard shipping box
measuring
about 82.5 inches long by about 29 inches wide by about 20.75 inches deep. At
the
shipping destination, only the lids 14 need be assembled and drip tray 120
folded and
placed into base 12.
[0049] Referring to Fig. 6, to trim the container 10 a pillow 220, a
mattress 222, and
a header skirt 224 are provided. Header skirt 224 is attached to the inner
surface of
header wall 34 with double sided tape 226. Double sided tape 226 can be pre-
applied
to either the header skirt 224 or to the inner surface of header wall 34 (Fig.
4B). Five
sets of trim components can be placed in the top base 12 of the five nested
bases 12
discussed above, for shipment.
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[0050] Referring to Fig. 7, another cardboard cremation container 250
according to
the principles of the present invention is illustrated. The container 250 has
a base 252
and a pair of identical lids 254, 254 closeable on the base 252. The base 252
has a
pair of opposed side walls 256, 256, a pair of opposed end walls 258, 258, and
a bottom
wall 260. Each lid 254 has a pair of opposed side walls 266, 266, a pair of
opposed
side rim walls 268, 268, an end wall 270, an end rim wall 272, a header wall
274 (Fig.
9D), and a top wall 276.
[0051] Referring to Figs. 8A-8F, a blank 280 from which to erect base 252
is
illustrated. Blank 280 has a bottom wall panel 282, a side wall panel 284
foldably
connected to each opposite side of the bottom wall panel 282 via a score line
286, and
a side wall roll over panel 288 foldably connected to each side wall panel 284
via a pair
of closely spaced score lines 292, 294. Closely spaced score lines 292, 294
form a roll
over edge therebetween. A flap 296 is foldably connected to each opposite end
of each
side wall panel 284 via a score line 298. Blank 280 has an end wall panel 302
foldably
connected to each opposite end of the bottom wall panel 282 via a score line
304, and
an end wall roll over panel 306 foldably connected to each end wall panel 302
via a pair
of closely spaced score lines 308, 310. Closely spaced score lines 308, 310
form a roll
over edge therebetween. As in the prior embodiment, it will be seen that base
blank
280 includes a notch 314 formed in each side wall panel 284, side wall roll
over panel
288, and the roll over edge therebetween, for accepting the edges of two
header walls
of two lids, as in the previously discussed. Side wall panels 284 and end wall
panels
302 of blank 280 include a plurality of handling strap cut-outs 316, each cut-
out being
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generally trapezoidally shaped and having bottom score line and top and side
cut lines.
Cut-outs 316 are designed to blend into the base 252 and to reduce visibility
into the
container 250 during handling. Clearance holes 317 are provided in flaps 296
of outer
base blank 280 so as to not interfere with handling strap cut-outs 316 in end
wall panels
302. Clearance notches 318 are provided in the free edges of the side wall
roll over
panels 288 and end wall roll over panels 306 so as to not interfere with strap
cut-outs
316.
[0052] An inner base 253 is erected from a blank 322. Blank 322 likewise has a
bottom wall panel 324, a full height side wall panel 326 foldably connected to
each
opposite side of the bottom wall panel 324 via a score line 328, and a shorter
end wall
panel 330 foldably connected to each opposite end of the bottom wall panel 324
via a
score line 332. A pair of longitudinal carrying straps 336, 336 and a pair of
transverse
carrying straps 338, 338 are provided. All the straps have a loop 340 formed
on each
end to assist grasping the strap. The straps can be fabricated of
polypropylene, as one
example. End wall panels 330 have strap holes 342. Bottom wall panel 324 has a
pair
of longitudinal horseshoe shaped cut-outs 350, 350 each having a tab or tongue
352.
The central portion of each longitudinal strap 336 is looped above and over
its
respective tongue 352 in cut-outs 350 and its end loops 340 are passed through
its
respective holes 342 in the end wall panels 330 from the outside inwardly.
Side wall
panels 326 have lower strap holes 356 and upper strap holes 358. Bottom wall
panel
324 has a pair of transverse horseshoe shaped cut-outs 362, 362 each having a
tab or
tongue 352. The central portion of each transverse strap 338 is looped above
and over
CA 02821816 2013-07-25
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its respective tongue 352 in cut-outs 362 and its end loops 340 are passed
through its
respective lower holes 356 in the side wall panels 326 from the outside
inwardly. As in
the previous embodiment, a notch 360, complimentary to the notch 314 in outer
base
blank 280, is formed in the free edge of each side wall panel 326 of inner
base blank
322 used to erect inner base 253, which cooperates with notch 314 to accept
the
abutting header walls of two lids.
[0053] To erect base 252 from blank 280, side wall panels 284 are folded
upwardly
and flaps 296 are folded inwardly. End wall panels 302 are folded upwardly.
Flaps 296
are secured to end wall panels 302 with hot melt glue. End wall roll over
panels 306 are
folded inwardly and secured to flaps 296 and/or end wall panels 302 with hot
melt glue.
Inner base 253 is placed in outer base 252, and side wall roll over panels 288
are folded
inwardly onto side wall panels 326 of inner base 253 and secured with hot melt
glue.
Loops 340 of longitudinal handling straps 336 are then passed outwardly
through holes
316 in end wall panels 302 of inner base blank 280. Loops 340 of transverse
handling
straps 338 are passed outwardly through upper holes 358 in side wall panels
326 of
inner base blank 322 and outwardly through cut-outs 316 in side wall panels
284 of
outer base blank 280. Finally, the above described tray 120 may then be placed
in
base 252. As in the prior embodiment, the height of the side wall panels 284
and side
wall roll over panels 288 and end wall panels 302 and end wall roll over
panels 306 of
base blank 280 and the height of the side wall panels 126 and end wall panels
130 of
drip tray blank 122 are chosen such that the free edges of the side wall
panels 126 and
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end wall panels 130 of drip tray blank 122 will securely "snap in" below the
free edges of
the side wall roll over panels 288 and end wall roll over panels 306 of base
blank 280.
[0054] Referring to Figs. 9A-9D, a blank 370 from which to erect lid 254 is
illustrated.
Blank 370 has a top wall panel 372, a side rim wall panel 374 foldably
connected to
each opposite side of the top wall panel 372 via a score line 376, a side wall
panel 378
foldably connected to each side rim wall panel 374 via a score line 380, a
side wall roll
over panel 382 foldably connected to each side wall panel 378 via a pair of
closely
spaced score lines 384, 386 (forming a roll over edge therebetween), a side
rim wall roll
over panel 388 foldably connected to each side wall roll over panel 382 via a
score line
390, and a top wall roll over panel 392 foldably connected to each side rim
wall roll over
panel 388 via a score line 394. A flap 400 is foldably connected to one end of
each side
wall panel 378 via a score line 404. A riser tab 410 is foldably connected to
one end of
each side wall roll over panel 382 via a score line 412. Each riser tab 410
has a first
free edge 410a opposite its score line 412 and a second free edge 410b
adjacent its
score line 412. The riser tab score line 412 is positioned inward of an
adjacent end of
the side wall panel 378, the riser tab first free edge 410a is positioned
outward of the
adjacent end of the side wall panel 378, and the riser tab second free edge
410b is
positioned outward of the score lines 384, 386 foldably connecting the side
wall roll over
panel 382 to the side wall panel 378. The riser tabs 410 function in much the
same way
as in the previous embodiment, extending across the corners of the lid 254 and
resting
on the corners of the base 252.
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[0055] Blank 370 has an end rim wall panel 420 foldably connected to top
wall panel
372 via a score line 422, and end wall panel 424 foldably connected to the end
rim wall
panel 420 via a score line 426, and an end wall roll over panel 428 foldably
connected
to the end wall panel 424 via a pair of closely spaced score lines 430, 432
(forming a
roll over edge therebetween). A flap 434 is foldably connected to each
opposite end of
the end rim wall panel 420 via a score line 436. A flap 438 is foldably
connected to
each opposite end of the end wall roll over panel 428 via a score line 440.
[0056] Blank 370 also has a header wall panel 450 foldably connected to the
opposite end of top wall panel 372 via a score line 452. Header wall panel 450
has a
first inward flap 456 foldably connected to each opposite end of the header
wall panel
450 via a score line 458, and a second outward flap 462 foldably connected to
each
opposite end of the header wall panel 450 via a score line 464. The free edge
468 of
header wall panel 450 is preferably inwardly curved to accommodate larger
bodies.
[0057] To assemble the lid 254 from the blank 370, the end rim wall panel
420, end
wall panel 424, and end wall roll over panel 428, and header wall panel 450
are folded
upwardly. Flaps 400, 434, 456, and 462 are folded inwardly, whereas flaps 438
are
folded outwardly. Flaps 434 and 456 are secured to inner surfaces of side rim
wall
panels 374 with hot melt glue. Side wall panels 378 are folded further
upwardly
positioning tabs 400 adjacent an inner surface of end wall panel 424 and tabs
462
adjacent an inner surface of side wall panels 378. Next the end wall roll over
panel 428
is folded inwardly against flaps 400 and end wall panel 424, placing flaps 438
adjacent
inner surfaces of side wall panels 378. Finally, side wall roll over panels
382, side rim
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wall roll over panels 388, and top wall roll over panels 392 are folded
inwardly against
the side wall panel 378, the side rim wall panel 374, and the top wall panel
372,
respectively. This causes risers 410 to "pop out" and extend across the
corners of lid
254. The free edges of the top wall roll over panels 392 are secured to the
top wall
panel 372 with hot melt glue.
[0058] Referring to Fig. 10, a plurality of containers 250 are illustrated
ready for
shipment. The geometry of various ones of the panels, flaps, and score lines
of the
blank 280 described above is selected so as to provide side walls 256 and end
walls
258 of base 252 which taper inwardly, by, for example, about 12 degrees, and
to
provide a depth of about 10.5 inches. This permits two bases 252 to be nested
for
shipment as illustrated, with the top base containing four fully erected lids
254, flipped
upside down and nesting in one another as illustrated. As in the prior
embodiment,
each base 252 contains it own unerected (i.e. flat) drip tray 120 that is
folded in half and
then folded in half again. The entire contents can be shipped in the same
standard
cardboard shipping box described above and measuring about 82.5 inches long by
about 29 inches wide by about 20.75 inches deep. At the shipping destination,
nothing
needs to be assembled; only tray 120 needs to be folded and placed into base
252.
[0059] Referring to Figs. 11A-11C, to trim the container 250 a big body
500, pillow
502, overthrow 504, and mattress 506 are provided. The big body 500 can be
attached
to the base with hook and loop fastener (not shown); the overthrow 504 simply
lies
across the head end of the foot end lid 254. Two sets of trim components can
be
placed in the top base 252 of the two nested bases 252 discussed above, for
shipment.
CA 02821816 2013-07-25
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[0060] The various embodiments of the invention shown and described are merely
for illustrative purposes only, as the drawings and the description are not
intended to
restrict or limit in any way the scope of the claims. Those skilled in the art
will
appreciate various changes, modifications, and improvements which can be made
to
the invention without departing from the spirit or scope thereof. The
invention in its
broader aspects is therefore not limited to the specific details and
representative
apparatus and methods shown and described. Departures may therefore be made
from
such details without departing from the spirit or scope of the general
inventive concept.
Accordingly, the scope of the invention shall be limited only by the following
claims and
their equivalents.
