Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
REINFORCED POLYGONAL CONTAINERS AND
BLANKS OF SHEET MATERIAL FOR MAKING
THE SAME
BACKGROUND OF THE INVENTION
[0001/0002] The field of the invention relates generally to a blank and a
reinforced polygonal container formed from the blank and more particularly, to
a
blank for forming a reinforced polygonal container for transporting a product
stored
within the container.
[0003] Containers are frequently utilized to store and aid in
transporting products. These containers can be square, hexagonal, or
octagonal. The
shape of the container can provide additional strength to the container. For
example,
octagonal-shaped containers provide greater resistance to bulge over
conventional
rectangular, square or even hexagonal-shaped containers. An octagonal-shaped
container may also provide increased stacking strength.
[0004] In at least some known cases, a blank of sheet material is used
to form a container for transporting a product. More specifically, these known
containers are formed by a machine that folds a plurality of panels along fold
lines
and secures these panels with an adhesive. Such containers may have certain
strength
requirements for transporting products. These strength requirements may
include a
stacking strength requirement such that the containers can be stacked on one
another
during transport without collapsing. To meet these strength requirements, at
least
some known containers include reinforced corners or side walls for providing
-I-
CA 2740182 2017-08-09
CA 02740182 2011-05-13
80006-00971
additional strength including stacking strength. In at least some known
embodiments,
additional panels may be placed in a face-to-face relationship with another
corner
panel or side wall. However, it is difficult to form a container from a single
sheet of
material that includes multiple reinforcing panels along the corner and side
walls.
Accordingly, a need exists for a multi-sided reinforced container, also known
as a
mitered tray and/or a META Tray-8 (META Tray-8 is a registered trademark of
Smurfit-Stone Container Corporation located in Chicago. Illinois), formed from
a
single blank that can be easily formed at high-speeds.
BRIEF DESCRIPTION OF THE INVENTION
[0005] In one aspect, a blank of sheet material for forming a
polygonal container is provided. The blank includes a bottom panel, two
opposing
side panels, and two opposing end panels. Each side panel extends from a side
edge
of the bottom panel, and each end panel extends from an end edge of the bottom
panel. Each end panel includes at least one major stacking extension extending
from
a top edge thereof. The blank further includes a reinforcing panel assembly
extending
from a first side edge of a first end panel of the two end panels. The
reinforcing panel
assembly includes an inner end panel having a minor stacking extension
extending
from a top edge thereof The minor stacking extension is configured to align
with a
respective major stacking extension to form a stacking tab.
[0006] In another aspect, a polygonal container formed from a blank
of sheet material is provided. The container includes a bottom wall, two
opposing
side walls, and two opposing end walls. Each side wall emanates from a side
edge of
the bottom wall, and each end wall emanates from an end edge of the bottom
wall.
The container further includes a first corner wall extending between a first
end wall of
the two end walls and a first side wall of the two side walls. The first
corner wall is
formed from a first reinforcing corner assembly that includes a corner panel
and an
inner reinforcing corner panel at least partially overlying and attached to
the corner
panel. The container includes at least one stacking extending from a top edge
of at
least one end wall of the two end walls.
-2-
CA 02740182 2011-05-13
80006-00971
[0007] In yet another aspect, a method for forming a polygonal
container from a blank of sheet material is provided. The polygonal container
includes at least five sides. The blank includes a bottom panel, two opposing
side
panels each extending from a side edge of the bottom panel, two opposing end
panels
each extending from an end edge of the bottom panel, and a reinforcing panel
assembly extending from a first side edge of a first end panel of the two end
panels.
The reinforcing panel assembly includes a corner panel extending from the
first side
edge of the first end panel, a first reinforcing side panel extending from a
side edge of
the corner panel, a second reinforcing side panel extending from a side edge
of the
first reinforcing side panel, an inner reinforcing corner panel extending from
a side
edge of the second reinforcing side panel, and an inner end panel extending
from a
side edge of the inner reinforcing corner panel. A minor stacking extension
extends
from a top edge of the inner end panel, and a major stacking extension extends
from a
top edge of the first end panel. The method includes rotating the second
reinforcing
side panel toward an interior surface of the first reinforcing side panel
about a fold
line connecting the second reinforcing side panel and the first reinforcing
side panel.
The rotating aligns the first and second reinforcing side panels in a
substantially face-
to-face relationship, the corner panel and the inner reinforcing corner panel
in a
substantially face-to-face relationship, and the inner end panel and the first
end panel
in a substantially face-to-face relationship. The rotating further aligns the
minor
stacking extension and the major stacking extension in a substantially face-to-
face
relationship to form a stacking tab. The method further includes rotating the
first and
second reinforcing side panels toward an interior surface of the first side
panel about a
fold line connecting the second reinforcing side panel and the inner
reinforcing corner
panel and about a fold line connecting the first reinforcing side panel and
the corner
panel, rotating the corner panel and the inner reinforcing corner panel toward
the
interior surface of the first end panel about a fold line connecting the inner
reinforcing
corner panel and the inner end panel and about a fold line connecting the
corner panel
and the first end panel, and rotating the first end panel inward into a
substantially
perpendicular relationship with the bottom panel about a fold line connecting
the first
end panel and the bottom panel, the first end panel and inner end panel
forming a first
-3-
end wall of the polygonal container and the comer panel and the reinforcing
corner panel
forming a first comer wall of the polygonal container.
[0007a] Accordingly,
in one aspect there is provided a blank of sheet
material for forming a polygonal container, said blank comprising: a bottom
panel that
includes at least one bottom panel angled edge; two opposing side panels, each
side
panel extending from a side edge of the bottom panel; two opposing end panels,
each end
panel extending from an end edge of the bottom panel, each end panel
comprising at
least one major stacking extension extending from a top edge thereof; at least
one top
panel extending from a top edge of one of the two side panels, wherein the at
least one
top panel includes at least one top panel angled edge, such that upon
articulation of the
blank, the at least one top panel angled edge substantially aligns with the at
least one
bottom panel angled edge; and at least an outer reinforcing panel assembly and
at least
an inner reinforcing panel assembly extending from a first side edge of a
first end panel
of the two end panels, wherein the outer reinforcing panel assembly includes
an outer
corner panel and an outer reinforcing side panel, the outer comer panel having
a first
height, and the inner reinforcing panel assembly includes an inner reinforcing
side panel,
an inner reinforcing corner panel having a second height that is substantially
equal to the
first height, and an inner reinforcing end panel, wherein the outer corner
panel has a
width substantially equal to a width of the inner reinforcing comer panel and
the outer
reinforcing side panel has a width substantially equal to a width of the inner
reinforcing
side panel; the outer and inner reinforcing panel assemblies configured such
that upon
articulation of the blank, the respective outer comer and inner reinforcing
corner panels
and the respective outer and inner reinforcing side panels are disposed in
juxtaposed
face-to-face relation to one another, and the inner reinforcing end panel is
disposed in
juxtaposed face-to-face relation to one of the two opposing end panels, to
define, upon
articulation, the container having corresponding outer and inner octagonal
configurations.
[0007b] According to
another aspect there is provided a polygonal
container formed from a blank of sheet material, said container comprising: a
bottom
wall that includes at least one bottom wall angled edge; two opposing side
walls, each
side wall emanating from a side edge of the bottom wall; two opposing end
walls, each
end wall emanating from an end edge of the bottom wall; at least one top panel
extending from a top edge of one of the two side walls, wherein the at least
one top panel
includes at least one top panel angled edge, such that upon articulation of
the at least one
-4-
CA 2740182 2017-08-09
top panel to an orientation substantially parallel to the bottom wall, the at
least one top
panel angled edge substantially aligns with the at least one bottom wall
angled edge; at
least one stacking tab extending from a top edge of at least one end wall of
the two end
walls; and at least a first corner wall assembly comprising first inner and
first outer
reinforcing panel assemblies, wherein the first outer reinforcing panel
assembly includes
a first outer corner panel and a first outer reinforcing side panel, the first
outer corner
panel having a first height, and the first inner reinforcing panel assembly
includes a first
inner reinforcing side panel, a first inner reinforcing corner panel having a
second height
that is substantially equal to the first height, and a first inner reinforcing
end panel,
wherein the first outer corner panel has a width substantially equal to a
width of the first
inner reinforcing corner panel and the first outer reinforcing side panel has
a width
substantially equal to a width of the first inner reinforcing side panel; the
respective first
outer corner and first inner reinforcing corner panels overlying one another
in juxtaposed
face-to-face relation to form a first corner wall, the respective first outer
and first inner
reinforcing side panels overlying one another in juxtaposed face-to-face
relation to form
a first reinforcing side wall overlying an inner surface of a first of the two
opposing side
walls, and the first inner reinforcing end panel overlying and in juxtaposed
face-to-face
relation to one of the two opposing end panels to provide the container with
corresponding outer and inner octagonal configurations.
[0007e] According to
another aspect there is provided a method for
forming a polygonal container from a blank of sheet material, the method
comprising:
providing a blank including a bottom panel that includes at least one bottom
panel angled
edge, two opposing side panels each extending from a side edge of the bottom
panel, two
opposing end panels each extending from an end edge of the bottom panel, at
least one
top panel extending from a top edge of one of the two side panels wherein the
at least
one top panel includes at least one top panel angled edge, such that upon
articulation of
the blank, the at least one top panel angled edge substantially aligns with
the at least one
bottom panel angled edge, and outer and inner reinforcing panel assemblies
extending
from a first side edge of a first end panel of the two end panels, wherein the
outer
reinforcing panel assembly includes an outer corner panel extending from the
first side
edge of the first end panel, and an outer reinforcing side panel extending
from a side
edge of the outer corner panel, the outer corner panel having a first height,
and the inner
reinforcing panel assembly includes an inner reinforcing side panel extending
from a
side edge of the outer reinforcing side panel, an inner reinforcing corner
panel extending
-4a-
CA 2740182 2017-08-09
from a side edge of the inner reinforcing side panel, and an inner reinforcing
end panel
extending from a side edge of the inner reinforcing corner panel, the inner
reinforcing
corner panel having a second height that is substantially equal to the first
height, wherein
the outer corner panel has a width substantially equal to a width of the inner
reinforcing
corner panel and the outer reinforcing side panel has a width substantially
equal to a
width of the inner reinforcing side panel, and wherein a minor stacking
extension
extends from a top edge of the inner end panel and a major stacking extension
extends
from a top edge of the first end panel; rotating the inner reinforcing side
panel toward an
interior surface of the outer reinforcing side panel about a fold line
connecting the inner
reinforcing side panel and the outer reinforcing side panel, wherein said
rotating aligns
the outer and inner reinforcing side panels in a substantially face-to-face
relationship, the
outer corner and inner reinforcing corner panels in a substantially face-to-
face
relationship, and the inner reinforcing end panel and the first end panel in a
substantially
face-to-face relationship, and said rotating aligns the minor stacking
extension and the
major stacking extension in a substantially face-to-face relationship to form
a stacking
tab; rotating the outer and inner reinforcing side panels toward an interior
surface of the
first side panel about a fold line connecting the inner reinforcing side panel
and the inner
reinforcing corner panel and about a fold line connecting the outer
reinforcing side panel
and the outer corner panel; rotating the outer corner panel and the inner
reinforcing
corner panel toward the interior surface of the first end panel about a fold
line connecting
the inner reinforcing corner panel and the inner reinforcing end panel and
about a fold
line connecting the outer corner panel and the first end panel; and rotating
the first end
panel inward into a substantially perpendicular relationship with the bottom
panel about
a fold line connecting the first end panel and the bottom panel, the first end
panel and
inner reinforcing end panel forming a first end wall of the polygonal
container and the
outer corner panel and the inner reinforcing corner panel forming a first
comer wall of
the polygonal container, the polygonal container having corresponding outer
and inner
polygonal configurations.
-4b-
CA 2740182 2017-08-09
[0007d] According to another aspect there is provided a blank of
sheet material for forming a polygonal container, said blank comprising: a
bottom panel;
two opposing side panels, each side panel extending from a side edge of the
bottom
panel; two opposing end panels, each end panel extending from an end edge of
the
bottom panel, each end panel comprising at least one major stacking extension
extending
from a top edge thereof; and at least an outer reinforcing panel assembly and
at least an
inner reinforcing panel assembly extending from a first side edge of a first
end panel of
the two end panels, wherein the outer reinforcing panel assembly includes an
outer
comer panel and an outer reinforcing side panel, the outer comer panel having
a first
height and a first width, wherein the inner reinforcing panel assembly
includes an inner
reinforcing side panel, an inner reinforcing comer panel, and an inner
reinforcing end
panel, the inner reinforcing comer panel having a second height that is
substantially
equal to the first height and a second width that is substantially equal to
the first width,
and wherein upon articulation of the blank, the respective outer comer and
inner
reinforcing corner panels are disposed in juxtaposed face-to-face relation to
one another
to form a first comer wall of the polygonal container.
[0007e] According to another aspect there is provided a
polygonal
container formed from a blank of sheet material, said container comprising: a
bottom
wall; two opposing side walls, each side wall emanating from a side edge of
the bottom
wall; two opposing end walls, each end wall emanating from an end edge of the
bottom
wall; at least one stacking tab extending from a top edge of at least one end
wall of the
two end walls; and at least a first corner wall assembly comprising first
inner and first
outer reinforcing panel assemblies, wherein the first outer reinforcing panel
assembly
includes a first outer corner panel and a first outer reinforcing side panel,
the first outer
comer panel having a first height and a first width, wherein the first inner
reinforcing
panel assembly includes a first inner reinforcing side panel, a first inner
reinforcing
corner panel, and a first inner reinforcing end panel, the first outer corner
panel having a
second height substantially equal to the first height and a second width
substantially
equal to the first width, and wherein the respective first outer comer and
first inner
reinforcing comer panels overlie one another in juxtaposed face-to-face
relation to form
a first comer wall of the polygonal container.
[0007f] According to another aspect there is provided a method
for
forming a polygonal container from a blank of sheet material, the blank
including a
bottom panel, two opposing side panels each extending from a side edge of the
bottom
-4c-
CA 2740182 2018-07-06
panel, two opposing end panels each extending from an end edge of the bottom
panel,
and outer and inner reinforcing panel assemblies extending from a first side
edge of a
first end panel of the two end panels, wherein the outer reinforcing panel
assembly
includes an outer corner panel and an outer reinforcing side panel, the outer
corner panel
having a first height and a first width, and the inner reinforcing panel
assembly includes
an inner reinforcing side panel, an inner reinforcing corner panel, and an
inner
reinforcing end panel, the inner reinforcing corner panel having a second
height that is
substantially equal to the first height and a second width that is
substantially equal to the
first width, and wherein a minor stacking extension extends from a top edge of
the inner
end panel and a major stacking extension extends from a top edge of the first
end panel,
the method comprising: rotating the inner reinforcing side panel toward an
interior
surface of the outer reinforcing side panel about a fold line connecting the
inner
reinforcing side panel and the outer reinforcing side panel, wherein said
rotating aligns
the outer corner and inner reinforcing corner panels in a substantially face-
to-face
relationship, and aligns the minor stacking extension and the major stacking
extension in
a substantially face-to-face relationship to form a stacking tab; rotating the
outer and
inner reinforcing side panels toward an interior surface of the first side
panel about a fold
line connecting the inner reinforcing side panel and the inner reinforcing
corner panel
and about a fold line connecting the outer reinforcing side panel and the
outer comer
panel; rotating the outer corner panel and the inner reinforcing comer panel
toward the
interior surface of the first end panel about a fold line connecting the inner
reinforcing
corner panel and the inner reinforcing end panel and about a fold line
connecting the
outer corner panel and the first end panel; and rotating the first end panel
inward into a
substantially perpendicular relationship with the bottom panel about a fold
line
connecting the first end panel and the bottom panel, the first end panel and
inner
reinforcing end panel forming a first end wall of the polygonal container and
the outer
corner panel and the inner reinforcing corner panel forming a first comer wall
of the
polygonal container.
[0007g] According to another aspect there is provided a blank of sheet
material for forming a polygonal container, said blank comprising: a bottom
panel; two
opposing side panels, each side panel extending from a side edge of the bottom
panel;
two opposing end panels, each end panel extending from an end edge of the
bottom
panel, each end panel comprising at least one major stacking extension
extending from a
top edge thereof; and a reinforcing panel assembly extending from a first side
edge of a
-4d-
CA 2740182 2018-07-06
first end panel of the two end panels, the reinforcing panel assembly
including at least an
outer corner panel, an outer reinforcing side panel, an inner reinforcing side
panel, and
an inner reinforcing corner panel, wherein a free bottom edge of the outer
corner panel is
collinear with a free bottom edge of the inner reinforcing corner panel, and
wherein upon
articulation of the blank, the outer corner panel and inner reinforcing corner
panel are
disposed in juxtaposed face-to-face relation to one another to form a first
corner wall of
the polygonal container.
[0007h] According to another aspect there is provided a
polygonal
Container formed from a blank of sheet material, said container comprising: a
bottom
wall; two opposing side walls, each side wall emanating from a side edge of
the bottom
wall; two opposing end walls, each end wall emanating from an end edge of the
bottom
wall, at least one stacking tab extending from a top edge of at least one end
wall of the
two end walls; and a first corner reinforcing assembly emanating from a first
side edge of
a first end wall of the two end walls, the first corner reinforcing assembly
comprising at
least an outer corner panel, an outer reinforcing side panel, an inner
reinforcing side
panel, and an inner reinforcing corner panel, wherein the outer corner panel
and inner
reinforcing corner panel are disposed in juxtaposed face-to-face relation to
one another
to form a first corner wall of the polygonal container, such that a bottom
edge of the
outer corner panel is coincident with a bottom edge of the inner reinforcing
corner panel.
[0007i] According to another aspect there is provided a method
for
forming a polygonal container from a blank of sheet material, the blank
including a
bottom panel, two opposing side panels each extending from a side edge of the
bottom
panel, two opposing end panels each extending from an end edge of the bottom
panel, at
least one major stacking extension extending from a top edge of each end
panel, and a
reinforcing panel assembly extending from a first side edge of a first end
panel of the
two end panels, the reinforcing panel assembly including at least an outer
comer panel,
an outer reinforcing side panel, an inner reinforcing side panel, and an inner
reinforcing
corner panel, wherein a free bottom edge of the outer corner panel is
collinear with a free
bottom edge of the inner reinforcing corner panel, the method comprising:
rotating the
inner reinforcing side panel toward an interior surface of the outer
reinforcing side panel
about a fold line connecting the inner reinforcing side panel and the outer
reinforcing
side panel, wherein said rotating aligns the outer corner panel and the inner
reinforcing
corner panel in a substantially face-to-face relationship; rotating the outer
and inner
reinforcing side panels toward an interior surface of the first end panel
about a fold line
-4e-
CA 2740182 2018-07-06
connecting the inner reinforcing side panel and the inner reinforcing corner
panel and
about a fold line connecting the outer reinforcing side panel and the outer
corner panel;
rotating the outer corner panel and the inner reinforcing corner panel toward
the interior
surface of the first end panel about a fold line connecting the outer corner
panel and the
first end panel; and rotating the first end panel inward into a substantially
perpendicular
relationship with the bottom panel about a fold line connecting the first end
panel and the
bottom panel, the first end panel at least partially forming a first end wall
of the
polygonal container and the outer corner panel and the inner reinforcing
corner panel
forming a first corner wall of the polygonal container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Figure 1 is a top plan view of a blank of sheet material
for
constructing a container according to a first embodiment of the present
invention.
[0009] Figure 2 is a perspective view of a container formed
from the
blank shown in Figure 1 in an open configuration.
[0010] Figure 3 is a perspective view of the container shown in Figure
2 in a closed configuration.
[0011] Figure 4 is a perspective view of a plurality of the
containers
shown in Figure 2 in a stacked configuration.
[0012] Figure 5 is a top plan view of a blank of sheet material
for
constructing a container according to a first alternative embodiment of the
present
invention.
[0013] Figure 6 is a perspective view of a container formed
from the
blank shown in Figure 5.
[0014] Figure 7 is top plan view of a blank of sheet material
for
constructing a container according to a second alternative embodiment of the
present
invention.
[0015] Figure 8 is perspective view of a container formed from
the
blank shown in Figure 7.
[0016] Figure 9 is a top plan view of a blank of sheet material
for
constructing a container according to a third alternative embodiment of the
present
invention.
-4f-
CA 2740182 2018-07-06
CA 02740182 2011-05-13
80006-00971
[0017] Figure 10 is a perspective view of a container that is partially
formed from the blank shown in Figure 9.
[0018] Figure 11 is a top plan view of a blank of sheet material for
constructing a container according to a fourth alternative embodiment of the
present
invention.
[0019] Figure 12 is a perspective view of a container that is formed
from the blank shown in Figure 11.
[0020] Figure 13 is a top plan view of a blank of sheet material for
constructing a container according to a fifth alternative embodiment of the
present
invention.
[0021] Figure 14 is a perspective view of a container that is formed
from the blank shown in Figure 13.
[0022] Figure 15 is a top plan view of a blank of sheet material for
constructing a container according to a sixth alternative embodiment of the
present
invention.
[0023] Figure 16 is a perspective view of a container that is formed
from the blank shown in Figure 15.
[0024] Figure 17 is a top view of a machine for forming a container
from a blank.
[0025] Figure 18 is a side view of the machine shown in Figure 17.
[0026] Figure 19 is a perspective view of a hopper station of the
machine shown in Figures 17 and 18.
[0027] Figure 20 is another perspective view of the hopper station
shown in Figure 19.
-5-
CA 02740182 2011-05-13
80006-00971
[0028] Figure 21 is a partial perspective view of a forming station of
the machine shown in Figures 17 and 18.
[0029] Figure 22 is a perspective view of an initial forming station of
the forming station shown in Figure 21.
[0030] Figure 23 is another perspective view of the initial forming
station shown in Figure 22.
[0031] Figure 24 is a perspective view of the forming station shown
in Figure 21.
[0032] Figure 25 is a perspective view of a secondary forming station
of the forming station shown in Figure 21.
[0033] Figure 26 is a perspective view of the secondary forming
station of the forming station shown in Figure 25.
[0034] Figure 27 is another perspective view of the secondary
forming station shown in Figure 25.
[0035] Figure 28 is a schematic cross-sectional view of the
secondary forming station shown in Figure 27.
[0036] Figure 29 is a perspective view of the secondary forming
station shown in Figure 25.
[0037] Figure 30 is a perspective view of a breaking station of the
forming station shown in Figure 25.
[0038] Figure 31 is a top perspective view of the breaking station
shown in Figure 30.
[0039] Figure 32 is a perspective view of the forming station shown
in Figure 21.
-6-
CA 02740182 2011-05-13
80006-00971
[0040] Figure 33 is a perspective view of the secondary forming
station and a compression station of the machine shown in Figures 17 and 18.
[0041] Figure 34 is a perspective view of the compression station
shown in Figure 33 without a blank positioned therein.
[0042] Figure 35 is a perspective view of the compression station
shown in Figure 34 with a blank positioned therein.
[0043] Figure 36 is a perspective view of the compression station
shown in Figure 35.
[0044] Figure 37 is a perspective view of an ejection station of the
machine shown in Figures 17 and 18.
DETAILED DESCRIPTION OF THE INVENTION
[0045] The following detailed description illustrates the disclosure
by way of example and not by way of limitation. The description clearly
enables one
skilled in the art to make and use the disclosure, describes several
embodiments,
adaptations, variations, alternatives, and use of the disclosure, including
what is
presently believed to be the best mode of carrying out the disclosure.
[0046] The present invention provides a stackable, reinforced
container formed from a single sheet of material, and a method and machine for
constructing the container. The container is sometimes referred to as a
reinforced
mitered tray or a reinforced eight-sided tray. The container may be
constructed from
a blank of sheet material using a machine. In one embodiment, the container is
fabricated from a cardboard material. The container, however, may be
fabricated
using any suitable material, and therefore is not limited to a specific type
of material.
In alternative embodiments, the container is fabricated using cardboard,
plastic,
fiberboard, paperboard, foamboard, corrugated paper, and/or any suitable
material
known to those skilled in the art and guided by the teachings herein provided.
-7-
CA 02740182 2011-05-13
80006-00971
[0047] In an example embodiment, the container includes at least one
marking thereon including, without limitation, indicia that communicates the
product,
a manufacturer of the product and/or a seller of the product. For example, the
marking may include printed text that indicates a product's name and briefly
describes
the product, logos and/or trademarks that indicate a manufacturer and/or
seller of the
product, and/or designs and/or ornamentation that attract attention.
"Printing,"
"printed," and/or any other form of "print" as used herein may include, but is
not
limited to including, ink jet printing, laser printing, screen printing,
giclee, pen and
ink, painting, offset lithography, flexography, relief print, rotogravure, dye
transfer,
and/or any suitable printing technique known to those skilled in the art and
guided by
the teachings herein provided. In another embodiment, the container is void of
markings, such as, without limitation, indicia that communicates the product,
a
manufacturer of the product and/or a seller of the product.
[0048] It should be understood that features included in one
embodiment can be used with other embodiments described herein. Further, any
of
the containers described herein can include handles defined through end and/or
side
walls thereof. Moreover, vent holes, such as vent holes 174 (shown in Figures
1, 5, 7,
and 9) can be defined through any suitable panel in any of the embodiments and
have
any suitable size, shape, orientation, and/or location that enable the below-
described
blanks and containers to function as described herein. Additionally, any of
the blanks
described herein can be formed into containers and/or loaded with a product
manually
and/or by using a machine, such as the machine described herein. Further,
different
embodiments described herein can vary in size and/or dimensions although
similar
labels are used for each embodiment. For example, although a depth is labeled
similarly throughout the description, each embodiment can have varying depths.
[0049] Referring now to the drawings, and more specifically to
Figure 1, which is a top plan view of an example embodiment of a blank 10 of
sheet
material. A container 200 (shown in Figures 2-4) is formed from blank 10.
Blank 10
has a first or interior surface 12 and an opposing second or exterior surface
14.
Further, blank 10 defines a leading edge 16 and an opposing trailing edge 18.
In one
-8-
CA 02740182 2011-05-13
80006-00971
embodiment, blank 10 includes, in series from leading edge 16 to trailing edge
18, a
first top panel 20, a first side panel 22, a bottom panel 24, a second side
panel 26, and
a second top panel 28 coupled together along preformed, generally parallel,
fold lines
30, 32, 34, and 36, respectively.
[0050] More specifically, first top panel 20 extends from leading
edge 16 to fold line 30, first side panel 22 extends from first top panel 20
along fold
line 30, bottom panel 24 extends from first side panel 22 along fold line 32,
second
side panel 26 extends from bottom panel 24 along fold line 34, and second top
panel
28 extends from second side panel 26 to trailing edge 18. Fold lines 30, 32,
34 and/or
36, as well as other fold lines and/or hinge lines described herein, may
include any
suitable line of weakening and/or line of separation known to those skilled in
the art
and guided by the teachings herein provided. When container 200 is formed from
blank 10, fold line 32 defines a bottom edge of first side panel 22 and a
first side edge
of bottom panel 24, and fold line 34 defines a second side edge of bottom
panel 24
and a bottom edge of second side panel 26. Further, when container 200 is
formed
from blank 10, fold line 30 defines a side edge of first top panel 20 and a
top edge of
first side panel 22, and fold line 36 defines a top edge of second side panel
26 and a
side edge of second top panel 28. In the exemplary embodiment, vent openings
38
are defined along fold lines 30, 32, 34, and 36; however, it should be
understood that
blank 10 includes any suitable number of vent openings 38 along any suitable
fold
line. Further, vent openings 38 can have any suitable size and/or shape that
enables
blank 10 and/or container 200 to function as described herein.
[0051] First side panel 22 and second side panel 26 are substantially
congruent and have a rectangular shape. Bottom panel 24 has an octagonal
shape.
More specifically, first side panel 22 and second side panel 26 have a width
W1.
Bottom panel 24 has a width W2, which is longer that width WI. Alternatively,
width
W1 is substantially equal to or longer than width W2. Further, in the
exemplary
embodiment, side panels 22 and 26 have a first height HI, and bottom panel 24
has a
first depth Di that is larger than first height HI. In an alternative
embodiment, height
H1 is substantially equal to or larger than depth DI. Alternatively, first
side panel 22,
-9-
CA 02740182 2011-05-13
80006-00971
second side panel 26, and/or bottom panel 24 have any suitable dimensions that
enable blank 10 and/or container 200 to function as described herein.
[0052] In the exemplary embodiment, bottom panel 24 may be
considered to be substantially rectangular in shape with four cut-off corners
or angled
edges 40, 42, 44, and 46 formed by cut lines. As such, the cut-off corner
edges 40,
42, 44, and 46 of otherwise rectangular bottom panel 24 define an octagonal
shape of
bottom panel 24. Moreover, each angled corner edge 40, 42, 44, and 46 has a
length
LI, and angled edges 40 and 44 and angled edges 42 and 46 are substantially
parallel.
Alternatively, bottom panel 24 has any suitable shape that enables container
200 to
function as described herein. For example, bottom panel 24 may be in the shape
of a
rectangle having corners that are truncated by a segmented edge such that
bottom
panel 24 has more than eight sides. In another example, bottom panel 24 may be
in
the shape of a rectangle having corners that are truncated by an arcuate edge
such that
bottom panel 24 has four substantially straight sides and four arcuate sides.
In the
exemplary embodiment, each angled edge 40, 42, 44, and 46 includes a crushed
area
48 that facilitates forming container 200 from blank 10. More specifically,
crushed
area 48 enables corner walls 210, 212, 214, and/or 216 (shown in Figure 2) to
be
formed. Alternatively, blank 10 does not include crushed areas 48.
[0053] In the exemplary embodiment, first side panel 22 includes
two free side edges 50 and 52, and second side panel 26 includes two free side
edges
54 and 56. Side edges 50, 52, 54, and 56 are substantially parallel to each
other.
Alternatively, side edges 50, 52, 54, and/or 56 are other than substantially
parallel. In
the exemplary embodiment, each side edge 50, 52, 54, and 56 is connected to a
respective angled edge 40, 42, 44, or 46. Each side edge 50, 52, 54, and 56
may be
directly connected to a respective angled edge 40, 42, 44, or 46 or, as shown
in Figure
1, may be slightly offset from a respective angled edge 40, 42, 44, or 46 to
facilitate
forming container 200 from blank 10 by allowing clearance for a thickness of a
panel
that is directly or indirectly attached to first side panel 22 or second side
panel 26.
-10-
CA 02740182 2011-05-13
80006-00971
[00541 First top panel 20 and second top panel 28 are substantially
congruent and have a generally trapezoidal shape. More specifically, first top
panel
20 includes an angled edge 58 extending from an intersection 60 of fold line
30 and
free edge 50 toward an apex 62 and an angled edge 64 extending from an
intersection
66 of fold line 30 and free edge 52 toward an apex 68. A free side edge 70
extends
from apex 62 to leading edge 16, and a free side edge 72 extends from apex 68
to
leading edge 16. Similarly, second top panel 28 includes an angled edge 74
extending
from an intersection 76 of fold line 36 and free edge 54 toward an apex 78 and
an
angled edge 80 extending from an intersection 82 of fold line 36 and free edge
56
toward an apex 84. A free side edge 86 extends from apex 78 to trailing edge
18, and
a free side edge 88 extends from apex 84 to trailing edge 18.
[0055] Angled edge 58, free edge 50, angled edge 40, at least a
portion of free edge 70, and a bottom edge 90 define a cutout 92; angled edge
64, free
edge 52, angled edge 46, at least a portion of free edge 72, and bottom edge
90 define
cutout 94; angled edge 74, free edge 54, angled edge 42, at least a portion of
free edge
86, and bottom edge 90 define cutout 96; and angled edge 80, free edge 56,
angled
edge 44, at least a portion of free edge 88, and bottom edge 90 define cutout
98. In
addition, first and second top panels 20 and 28 have a depth D2 that is
smaller than
half of depth Di. In an alternative embodiment, depth D2 is substantially
equal to or
larger than half of depth DI. It should be understood that first side panel
22, second
side panel 26, bottom panel 24, and/or top panels 20 and/or 28 may have any
suitable
dimensions that enable blank 10 to function as described herein.
[0056] In the exemplary embodiment, first top panel 20 includes a
first locking slot 100 and a second locking slot 102 defined therethrough.
Similarly,
second top panel 28 includes locking slots 100 and 102. Each slot 100 and 102
is
located, shaped, and sized to receive a stacking tab 204 (shown in Figure 2)
when
container 200 is closed, as described in more detail below. In the exemplary
embodiment, a slit 104 extends from each slot 100 and/or 102 to enable
stacking tab
204 to be slid through slit 104 into a respective slot 100 or 102; however, it
should be
understood that any or all of slots 100 and/or 102 do not include slit 104. In
the
-11-
CA 02740182 2011-05-13
80006-00971
exemplary embodiment, each slot 100 and 102 is generally rectangularly shaped
with
one slightly arcuate edge 106, and slots 100 and 102 are substantially mirror
images
of each other.
[0057] A first end panel 108 extends from bottom panel 24 along a
fold line 110 to a free edge 112, and a second end panel 114 extends from
bottom
panel 24 along a fold line 116 to a free edge 118. Fold line 110 defines a
bottom edge
of first end panel 108 and an end edge of bottom panel 24, and fold line 116
defines a
bottom edge of second end panel 114 and an end edge of bottom panel 24. First
and
second end panels 108 and 114 are each generally rectangularly or square
shaped.
End panels 108 and 114 each have a depth D3 that is shorter than depth Di such
that
end panels 108 and 114 are narrower than bottom panel 24. In the exemplary
embodiment, end panels 108 and 114 each have a height H2 such that height H2
is
substantially equal to height HI. Alternatively, height H2 is other than equal
to height
HI. In the exemplary embodiment, fold line 110 extends between ends of angled
corner edges 40 and 42, and fold line 116 extends between ends of angled
corner
edges 46 and 44.
[0058] Each end panel 108 and 114 includes a pair of mirror image
stacking extensions 120 and 122. More specifically, each stacking extension
120 and
122 forms a portion of stacking tab 204 when container 200 is formed from
blank 10.
Each stacking extension 120 and 122 defines a notch 124 and has angled upper
corners 126 and 128. Notch 124 is sized to receive a portion of top panel 20
or 28
when container 200 is closed, as described in more detail below. Further, in
the
exemplary embodiment, each fold line 110 and 116 includes a pair of stacking
slots
130 defined by cut lines 132. Cut lines 132 include an upper portion 134 that
has a
shape that corresponds to a shape of an upper edge 136 of stacking tabs 204.
When
containers 200 are stacked as shown in Figure 4, stacking tabs 204 of a lower
container 200 are received within stacking slots 130 of an upper container
200. When
containers 200 are stacked, stacking tabs 204 do not extend into a cavity 224
of an
upper container 200, but rather are flush within stacking slots 130, as shown
in Figure
4.
-12-
CA 02740182 2011-05-13
80006-00971
[0059] Referring again to Figure 1, in the exemplary embodiment, a
reinforcing panel assembly 138 extends from side edges of each end panel 108
and
114. Each side edge is defined by a respective fold line ¨ 140, 142, 144, or
146. Fold
lines 140, 142, 144, and 146 are substantially parallel to each other.
Alternatively,
fold lines 140, 142, 144, and/or 146 are other than substantially parallel. In
the
exemplary embodiment, each reinforcing panel assembly 138 includes free bottom
edge 90. Further, each reinforcing panel assembly 138 is substantially similar
and
includes an outer reinforcing panel assembly 148 and an inner reinforcing
panel
assembly 150 connected to each other along a fold line 152. Fold line 152
defines a
side edge of outer reinforcing panel assembly 148 and a side edge of inner
reinforcing
panel assembly 150. Moreover, outer reinforcing panel assembly 148 includes a
corner panel 154 and a first reinforcing side panel 156; and inner reinforcing
panel
assembly 150 includes an inner reinforcing corner panel 158, a second
reinforcing
side panel 160, and an inner end panel 162. Each reinforcing panel assembly
138 is
configured to form a reinforcing corner assembly 202 (shown in Figure 2) when
container 200 is formed from blank 10. Further, first top panel 20 is
separated from
adjacent reinforcing panel assemblies 138 by side edges 70 and 72, and second
top
panel 28 is separated from adjacent reinforcing panel assemblies 138 by side
edges 86
and 88.
[0060] Outer reinforcing panel assembly 148 extends from an end
panel 108 or 114 along each of fold lines 140, 142, 144, and 146. Further,
inner
reinforcing panel assembly 150 extends from each outer reinforcing panel
assembly
148 along fold line 152. A notch 164 is formed along fold line 152 between
inner
reinforcing panel assembly 150 and outer reinforcing panel assembly 148;
although it
should be understood that notch 164 can be omitted. In the exemplary
embodiment,
inner reinforcing corner panel 158 and second reinforcing side panel 160 have
a width
W3, and outer reinforcing panel assembly 148 has a width W4, which is
substantially
equal to width W3. Further, in the exemplary embodiment, inner and outer
reinforcing panel assemblies 150 and 148 have a height H3 that is
substantially similar
to height H1 of first side panel 22 and second side panel 26. In an
alternative
-13-
CA 02740182 2011-05-13
80006-00971
embodiment, height H3 is other than equal to height HI. In the exemplary
embodiment, each outer reinforcing panel assembly 148 includes a fold line 166
that
divides each outer reinforcing panel assembly 148 into corner panel 154 and
first
reinforcing side panel 156. Fold line 166 defines an edge of corner panel 154
and a
side edge of first reinforcing side panel 156, and fold line 152 defines a
side edge of
first reinforcing side panel 156. In the exemplary embodiment, corner panel
154 and
first reinforcing side panel 156 are substantially rectangular.
[0061] Further, each inner reinforcing panel assembly 150 includes
fold lines 168 and 170 that divide each inner reinforcing panel assembly 150
into
second reinforcing side panel 160, inner reinforcing corner panel 158, and
inner end
panel 162. More specifically, second reinforcing side panel 160 extends from
first
reinforcing side panel 156 along fold line 152, inner reinforcing corner panel
158
extends from second reinforcing side panel 160 along fold line 168, and inner
end
panel 162 extends from inner reinforcing corner panel 158 along fold line 170
to a
free edge 172. Fold line 168 defines an edge of inner reinforcing corner panel
158
and a side edge of second reinforcing side panel 160, fold line 170 defines a
side edge
of inner reinforcing corner panel 158 and an edge of inner end panel 162, and
fold
line 152 defines a side edge of second reinforcing side panel 160. In the
exemplary
embodiment, corner panel 154 and inner reinforcing corner panel 158 are
substantially congruent, and first and second reinforcing side panels 156 and
160 are
substantially congruent. Further, free edge 172 is generally co-linear with
leading
edge 16 or trailing edge 18; however, free edge 172 can have any suitable
position
with respect to leading edge 16 and/or trailing edge 18 that enables blank 10
and/or
container 200 to function as described herein.
[0062] Each corner panel 154 and each inner reinforcing corner
panel 158 have a width W5 that is substantially equal to length Ll. In
addition, each
first reinforcing side panel 156 and second reinforcing side panel 160 have a
width
W6 that is larger than width W5. In an alternative embodiment, width W6 is
smaller
than or approximately equal to width W5. Further, in the exemplary embodiment,
each inner end panel 162 has a depth D4 that is equal to approximately half of
width
-14-
CA 02740182 2011-05-13
80006-00971
W3 of first and second end panels 108 and 114. When end panels 108 and/or 114
include vent holes 174, inner end panels 162 include corresponding vent holes
174
that are configured to align with vent holes 174 defined through end panels
108 and/or
114 when container 200 is formed from blank 10. In an alternative embodiment,
depth D4 is other than equal to approximately half of width W3.
[0063] In the exemplary embodiment, inner end panel 162 includes a
minor stacking extension 176 extending from a top edge 178 thereof Minor
stacking
extension 176 has a shape that at least partially corresponds to the shape of
stacking
extension 120 or 122 such that minor stacking extension 176 aligns with a
respective
stacking extension 120 or 122 to form a stacking tab 204. In the exemplary
embodiment, minor stacking extension 176 is substantially similarly shaped to
a
respective stacking extension 120 or 122, except minor stacking extension 176
includes a straight side edge 180 rather than forming notch 124. It should be
understood that minor stacking extension 176 has any suitable shape and
position that
enables blank 10 and/or container 200 to function as described herein.
Further, in the
exemplary embodiment, inner end panel 162 includes a notch 182 defined in
bottom
edge 90. Notch 182 is shaped to correspond to at least a portion of stacking
slot 130
defined in end panel 108 and/or 114. As such, when container 200 is formed
from
blank 10, inner end panel 162 does not obstruct stacking slot 130, and a lower
stacking tab 204 can fit within an upper stacking slot 130.
[0064] Figure 2 is a perspective view of container 200 that is formed
from blank 10 (shown in Figure 1). Figure 3 is a perspective view of container
200 in
a closed configuration. Figure 4 is a perspective view of a plurality of
containers 200
in a stacked configuration. Although container 200 is shown as being formed
without
a product to be contained therein, container 200 may also be formed having a
product
therein. Further, container 200 may include any suitable number of products of
any
suitable shape.
[0065] To construct container 200 from blank 10, in the exemplary
embodiment, each inner reinforcing panel assembly 150 is folded about fold
line 152
-15-
CA 02740182 2011-05-13
80006-00971
such that inner reinforcing panel assembly 150 and outer reinforcing panel
assembly
148 are in an at least partially overlying relationship, and such that inner
end panel
162 is in an at least partially overlying relationship with at least a portion
of first or
second end panel 108 or 114. More specifically, blank 10 is folded along fold
line
152 such that corner panel 154 and inner reinforcing corner panel 158 are
substantially aligned in an at least partially overlying relationship, first
and second
reinforcing side panels 156 and 160 are substantially aligned in an at least
partially
overlying relationship, and inner end panel 162 and at least a portion of
first or second
end panel 108 or 114 are substantially aligned in an at least partially
overlying
relationship. In the exemplary embodiment, inner end panel 162, a respective
end
panel 108 or 114, reinforcing side panels 156 and 160, and/or corner panels
154 and
158 are secured in the above-described relationships. For example, inner end
panel
162 may be adhered to a respective end panel 108 or 114, reinforcing side
panels 156
and 160 may be adhered together, and/or corner panels 154 and 158 may be
adhered
together.
[0066] Reinforcing panel assemblies 148 and 150 are rotated about
fold lines 140, 142, 144, and 146 and fold lines 170. Further, reinforcing
side panels
156 and 160 are rotated about fold lines 166 and 168 toward corner panels 154
and
158 before or after reinforcing panel assemblies 148 and 150 are rotated about
fold
lines 140, 142, 144, and 146 and fold lines 170. In the exemplary embodiment,
reinforcing panel assemblies 148 and 150 and reinforcing side panels 156 and
160 are
rotated such that reinforcing side panels 156 and 160 are substantially
perpendicular
to end panels 108 and 114. First and second end panels 108 and 114 are then
rotated
about fold lines 110 and 116, respectively, toward interior surface 12. A
reinforcing
corner assembly 202 is formed by corner panels 154 and 158, reinforcing side
panels
156 and 160, and inner end panel 162. When reinforcing corner assemblies 202
are
formed, minor stacking extension 176 aligns with a respective stacking
extension 120
or 122 to form a stacking tab 204. First end panel 108 with a pair of inner
end panels
162 forms a first end wall 206, and second end panel 114 with a pair of inner
end
panels 162 forms a second end wall 208. Each end wall 206 and 208 includes a
pair
-16-
CA 02740182 2011-05-13
80006-00971
of stacking tabs 204 extending from an upper edge thereof. Further, each pair
of
corner panels 154 and 158 forms one corner wall 210, 212, 214, or 216.
[0067] First side panel 22 is rotated about fold line 32 toward interior
surface 12, and second side panel 26 is rotated about fold line 34 toward
interior
surface 12. More specifically, first side panel 22 and second side panel 26
are rotated
to be substantially perpendicular to bottom panel 24, as shown in Figure 2.
Interior
surface 12 of first side panel 22 is secured to exterior surface 14 of two
adjacent first
reinforcing side panels 156, and interior surface 12 of second side panel 26
is secured
to exterior surface 14 of two adjacent first reinforcing side panels 156. In
the
exemplary embodiment, first side panel 22 and second side panel 26 are adhered
to
respective first reinforcing side panels 156. Alternatively, first side panel
22 and/or
second side panel 26 are otherwise attached to respective first reinforcing
side panels
156 using, for example, fasteners, a bonding material, such as glue or an
adhesive,
and/or any suitable method for attached the panels. In the exemplary
embodiment,
first side panel 22 and two pairs of reinforcing side panels 156 and 160 form
a first
side wall 218, and second side panel 26 and two pairs of reinforcing side
panels 156
and 160 form a second side wall 220.
[0068] When container 200 is formed, interior surface 12 of side
walls 218 and 220 is adjacent the side walls of the product. Further, height
H1 of side
walls 218 and 220 is sized to correspond to a height of the products within
container
200 such that height H1 is substantially equal to or greater than the height
of the
products. Bottom panel 24 forms a bottom wall 222 of container 200, and bottom
wall 222, side walls 218 and 220, end walls 206 and 208, and corner walls 210,
212,
214, and 216 define a cavity 224 of container 200. In the exemplary
embodiment,
bottom edges 90 of reinforcing corner assemblies 138 are substantially aligned
with
fold lines 32, 34, 110, and 116 and angled edges 40, 42, 44, and 46. In Figure
2,
container 200 has a configuration referred to herein as an "open
configuration."
[0069] Referring to Figure 3, to close container 200 and form a top
wall 226, first top panel 20 is rotated about fold line 30 toward cavity 224
such that
-17-
CA 02740182 2011-05-13
80006-00971
first top panel 20 is substantially perpendicular to first side panel 22 and
substantially
parallel to bottom panel 24. Further, second top panel 28 is rotated about
fold line 36
toward cavity 224 such that second top panel 28 is substantially perpendicular
to
second side panel 26 and substantially parallel to bottom panel 24. As top
panels 20
and 28 are rotated toward cavity 224, a stacking tab 204 is inserted through
each
locking slot 100 or 102. More specifically, a projection 228 of stacking tab
204 at
least partially defined by notch 124 can be slid through slit 104 and then
notch 124
can contact an edge of locking slot 100 or 102 once projection 228 is through
slit 104
and/or locking slot 100 or 102.
[0070] Referring to Figure 4, a plurality of closed containers 200 can
be stacked one on the other, and stacking tabs 204 of a lower container 200
are
received within stacking slots 130 of an upper container 200 to facilitate
preventing
movement of one container 200 with respect to the other container 200 while
stacked.
[0071] The above-described method to construct container 200 from
blank 10 may be performed using a machine, as described in more detail below.
The
machine performs the above-described method to continuously form container 200
from blank 10 as blank 10 is moved though the machine. In one embodiment, the
machine includes at least one plow or finger to at least partially rotate at
least one of
panels 162, 158, 108, 114, 22, and 26 and/or further form container 200 using
a
mandrel to complete rotating these panels. Alternatively, a product is placed
on
interior surface 12 of bottom panel 24 and container 200 is formed about the
product
manually and/or automatically.
[0072] Figure 5 is a top plan view of an example embodiment of a
blank 300 of sheet material. Blank 300 is essentially similar to blank 10
(shown in
Figure 1) and, as such, similar components are labeled with similar
references. More
specifically, blank 300 includes outer reinforcing corner panels 302, 304,
306, and
308. Further, blank 300 includes fold lines 310, 312, 314, and 316 rather than
free
side edges 50, 52, 54, and 56.
-18-
CA 02740182 2011-05-13
80006-00971
[0073] In the exemplary embodiment, first outer reinforcing corner
panel 302 extends from first side panel 22 along fold line 310 to a free edge
318.
Fold line 310 and free edge 318 define end edges of first outer reinforcing
corner
panel 302, and fold line 310 defines an end edge of first side panel 22. First
outer
reinforcing corner panel 302 is substantially rectangular shaped having a top
edge 320
and a bottom edge 322. Bottom edge 322, angled edge 40, and bottom edge 90
define
a removable cutout 324, and top edge 320, edges 58 and 70, and bottom edge 90
define a removable cutout 326. Further, first outer reinforcing corner panel
302 has
generally height H1 such that first side panel 22 and first outer reinforcing
corner
panel 302 have a generally equal height. In the exemplary embodiment, first
outer
reinforcing corner panel 302 has a slightly tapered bottom edge 322 such that
first
outer reinforcing corner panel 302 is slightly shorter at free edge 318 than
at fold line
310. Alternatively, outer reinforcing corner panel 302 has as substantially
constant
height without a tapered bottom edge 322. In the exemplary embodiment, top
edge
320 is substantially collinear with fold line 30, which defines the top edge
of first side
panel 22, and bottom edge 322 is generally collinear with fold line 32.
Further, first
outer reinforcing corner panel 302 has a width W7. Width W7 is substantially
equal to
length Li. Alternatively, width W7 is less than length LI.
[00741 Similarly, in the exemplary embodiment, second outer
reinforcing corner panel 304 extends from first side panel 22 along fold line
312 to a
free edge 328, third outer reinforcing corner panel 306 extends from second
side panel
26 along fold line 314 to a free edge 330, and fourth outer reinforcing corner
panel
308 extends from second side panel 26 along fold line 316 to a free edge 332.
In the
exemplary embodiment, second outer reinforcing corner panel 304, third outer
reinforcing corner panel 306, and fourth outer reinforcing corner panel 308
are each
substantially rectangular and have generally height H1 with taper bottom edge
322.
Alternatively, outer reinforcing corner panel 304, 306, and/or 308 has as
substantially
constant height without a tapered bottom edge 322. In the exemplary
embodiment,
top edge 320 of second outer reinforcing corner panel 304 is substantially
collinear
with fold line 30, bottom edge 322 of second outer reinforcing corner panel
304 is
-19-
CA 02740182 2011-05-13
80006-00971
generally collinear with fold line 32, top edge 320 of third outer reinforcing
corner
panel 306 is substantially collinear with fold line 36, bottom edge 322 of
third outer
reinforcing corner panel 306 is generally collinear with fold line 34, top
edge 320 of
fourth outer reinforcing corner panel 308 is substantially collinear with fold
line 36,
and bottom edge 322 of fourth outer reinforcing corner panel 308 is generally
collinear with fold line 34.
[0075] Further, bottom edge 322 of second outer reinforcing corner
panel 304, angled edge 46, and bottom edge 90 define a removable cutout 334;
bottom edge 322 of third outer reinforcing corner panel 306, angled edge 42,
and
bottom edge 90 define a removable cutout 336; and bottom edge 322 of fourth
outer
reinforcing corner panel 308, angled edge 44, and bottom edge 90 define a
removable
cutout 338. Similarly, top edge 320 of second outer reinforcing corner panel
304,
edges 64 and 72, and bottom edge 90 define a removable cutout 340; top edge
320 of
third outer reinforcing corner panel 306, edges 74 and 86, and bottom edge 90
define
a removable cutout 342; and top edge 320 of fourth outer reinforcing comer
panel
308, edges 80 and 88, and bottom edge 90 define a removable cutout 344.
[0076] Moreover, second outer reinforcing corner panel 304, third
outer reinforcing corner panel 306, and fourth outer reinforcing corner panel
308 each
have width W7. Alternatively, outer reinforcing corner panels 302, 304, 306,
and/or
308 may have any suitable dimensions that enable blank 10 to function as
described
herein. In the exemplary embodiment, outer reinforcing corner panels 304, 306,
and
308 have substantially constant width W7 from top edges 320 to bottom edges
322
such that outer reinforcing corner panels 304, 306, and 308 do not include
cutoff
corners and/or tapered top and/or bottom edges. Further, second, third, and
fourth
outer reinforcing corner panels 304, 306, and 308 are substantially congruent
to first
corner panel 302. Alternatively, corner panels 302, 304, 306, and/or 308 are
other
than congruent to each other.
[0077] Figure 6 is a perspective view of container 350 that is formed
from blank 300 (shown in Figure 5). Container 350 is essentially similar to
container
-20-
CA 02740182 2011-05-13
80006-00971
200 (shown in Figure 2) and, as such, similar components are labeled with
similar
references. Although container 350 is shown as being formed without a product
to be
contained therein, container 350 may also be formed having a product therein.
Further, container 350 may include any suitable number of products of any
suitable
shape.
[0078] To construct container 350 from blank 300 a method that is
substantially similar to the method for forming container 200 from blank 10 is
used.
However, to construct container 350, first outer reinforcing corner panel 302
is rotated
about fold line 310 toward interior surface 12 and secured to exterior surface
14 of
corner panel 154 extending from fold line 140 of first end panel 108. More
specifically, first outer reinforcing corner panel 302 is rotated such that
first outer
reinforcing corner panel 302 is oriented at oblique angle al to first side
wall 218.
Similarly, second outer reinforcing corner panel 304 is rotated about fold
line 312
toward interior surface 12 and secured to exterior surface 14 of corner panel
154
extending from fold line 144 of second end panel 114. More specifically,
second
outer reinforcing corner panel 304 is rotated such that second outer
reinforcing corner
panel 304 is oriented at oblique angle pl to first side wall 218.
[0079] In the exemplary embodiment, free edge 318 of first outer
reinforcing corner panel 302 is substantially aligned with fold line 140, and
free edge
328 of second outer reinforcing corner panel 304 is substantially aligned with
fold
line 144. Alternatively, first outer reinforcing corner panel 302 and/or
second outer
reinforcing corner panel 304 only partially overlap corner panels 154 such
that free
edges 318 and/or 328 are offset from fold lines 140 and/or 144, respectively.
First
outer reinforcing corner panel 302 forms a portion of first corner wall 352,
and second
outer reinforcing corner panel 304 forms a portion of second corner wall 354.
[0080] Third outer reinforcing corner panel 306 is rotated about fold
line 314 toward interior surface 12 and secured to exterior surface 14 of
corner panel
154 extending from fold line 142 of first end panel 108. More specifically,
third outer
reinforcing corner panel 306 is rotated such that third outer reinforcing
corner panel
-21-
CA 02740182 2011-05-13
80006-00971
306 is oriented at oblique angle 71 to second side wall 220. Similarly, fourth
outer
reinforcing corner panel 308 is rotated about fold line 316 toward interior
surface 12
and secured to exterior surface 14 of corner panel 154 extending from fold
line 146 of
second end panel 114. More specifically, fourth outer reinforcing corner panel
308 is
rotated such that fourth outer reinforcing corner panel 308 is oriented at
oblique angle
61 to second side wall 220. In the exemplary embodiment, free edge 330 of
third
outer reinforcing corner panel 306 is substantially aligned with fold line 142
of first
end panel 108, and free edge 332 of fourth outer reinforcing corner panel 308
is
substantially aligned with fold line 146 of second end panel 114.
Alternatively, third
outer reinforcing corner panel 306 and/or fourth outer reinforcing corner
panel 308
only partially overlap corner panels 154 such that free edges 330 and/or 332
are offset
from fold lines 142 and/or 146, respectively.
[0081] In the exemplary embodiment, third outer reinforcing corner
panel 306 forms a portion of third corner wall 356, and fourth outer
reinforcing corner
panel 308 forms a portion of fourth corner wall 358. Although outer
reinforcing
corner panel 302, 304, 306, and 308 are described as being positioned against
exterior
surface 14 of corner panel 154, reinforcing corner panel 302, 304, 306. and/or
308
may be positioned within cavity 224 adjacent to exterior surface 14 of inner
reinforcing corner panel 158, which defines an inner surface of the corner
walls.
Further, in the exemplary embodiment, crushed areas 48 facilitate formation of
corner
walls 352, 354, 356, and/or 358 by enabling outer reinforcing corner panels
302, 304,
306, and 308 to be rotated into position. Corner walls 352, 354, 356, and 358
each
include three layers of panels, and corner walls 210, 212, 214, and 216 (shown
in
Figure 2) each include two layers of panels.
[0082] Figure 7 is a top plan view of an example embodiment of a
blank 400 of sheet material. Blank 400 is essentially similar to blank 10
(shown in
Figure 1) and, as such, similar components are labeled with similar
references. In the
exemplary embodiment, blank 400 is dimensioned differently than blank 10 such
that
inner end panels 402 have a depth D5 that less than half of depth D3 of end
panels 108
-22-
CA 02740182 2011-05-13
80006-00971
and 114. As such, blank 400 includes reinforcing panel assembly 404 rather
than
reinforcing panel assembly 138 (shown in Figure 1).
[0083] Reinforcing panel assembly 404 extends from side edges of
each end panel 108 and 114 along fold lines 140, 142, 144, and 146. Each
reinforcing
panel assembly 404 includes a free bottom edge 406. Further, each reinforcing
panel
assembly 404 is substantially similar and includes outer reinforcing panel
assembly
148 and an inner reinforcing panel assembly 408 connected to each other along
fold
line 152. Outer reinforcing panel assembly 148 includes corner panel 154 and
first
reinforcing side panel 156; and inner reinforcing panel assembly 408 includes
inner
reinforcing corner panel 158, second reinforcing side panel 160, and inner end
panel
402. In the exemplary embodiment, each outer reinforcing panel assembly 148
includes fold line 166 that divides each outer reinforcing panel assembly 148
into
corner panel 154 and first reinforcing side panel 156. Further, each inner
reinforcing
panel assembly 408 includes fold lines 168 and 170 that divide each inner
reinforcing
panel assembly 408 into second reinforcing side panel 160, inner reinforcing
corner
panel 158, and inner end panel 402. More specifically, second reinforcing side
panel
160 extends from first reinforcing side panel 156 along fold line 152, inner
reinforcing corner panel 158 extends from second reinforcing side panel 160
along
fold line 168, and inner end panel 402 extends from inner reinforcing corner
panel
158 along fold line 170 to a free edge 410.
[0084] Free edge 410 is generally co-linear with leading edge 16 or
trailing edge 18; however, free edge 410 can have any suitable position with
respect
to leading edge 16 and/or trailing edge 18 that enables blank 400 and/or
container 450
to function as described herein. In the exemplary embodiment, notch 182 is
defined
in inner end panel 402 along free edge 410 by bottom edge 406 and edge 70, 72,
86,
or 88. Notch 182 is shaped to correspond to at least a portion of stacking
slot 130
defined in end panel 108 and/or 114. As such, when a container 450 (shown in
Figure
8) is formed from blank 400, inner end panel 402 does not obstruct stacking
slot 130,
and a lower stacking tab 452 (shown in Figure 8) can fit within an upper
stacking slot
130.
-23-
CA 02740182 2011-05-13
80006-00971
[0085] In the exemplary embodiment, inner end panel 402 includes a
minor stacking extension 412 extending from a top edge 414 thereof. Minor
stacking
extension 412 has a shape that at least partially corresponds to the shape of
stacking
extension 120 or 122 such that minor stacking extension 412 aligns with a
respective
stacking extension 120 or 122 to form a stacking tab 452. In the exemplary
embodiment, minor stacking extension 412 is substantially similarly shaped to
a
respective stacking extension 120 or 122, except minor stacking extension 412
is
defined by straight free edge 410. It should be understood that minor stacking
extension 412 has any suitable shape and position that enables blank 400
and/or
container 450 to function as described herein.
[0086] Each reinforcing panel assembly 404 is configured to form a
reinforcing corner assembly 454 (shown in Figure 8) when container 450 is
formed
from blank 400. Further, first top panel 20 is separated from adjacent
reinforcing
panel assemblies 404 by side edges 70 and 72, and second top panel 28 is
separated
from adjacent reinforcing panel assemblies 404 by side edges 86 and 88.
[0087] Figure 8 is a perspective view of container 450 that is formed
from blank 400 (shown in Figure 7). Container 450 is essentially similar to
container
200 (shown in Figure 2) and, as such, similar components are labeled with
similar
references. Although container 450 is shown as being formed without a product
to be
contained therein. container 450 may also be formed having a product therein.
Further, container 450 may include any suitable number of products of any
suitable
shape. To construct container 450 from blank 400 a method that is
substantially
similar to the method for forming container 200 from blank 10 is used.
[0088] Figure 9 is a top plan view of an example embodiment of a
blank 500 of sheet material. Blank 500 is essentially similar to blank 300
(shown in
Figure 5) and blank 400 (shown in Figure 7) and, as such, similar components
are
labeled with similar references. More specifically, blank 500 is similar to
blank 400
and includes outer reinforcing corner panels 302. 304, 306, and 308, as shown
and
described with respect to Figure 5. Further, blank 500 includes fold lines
310, 312,
-24-
CA 02740182 2011-05-13
80006-00971
314, and 316 rather than free side edges 50, 52, 54, and 56 (shown in Figure
7), as
shown and described with respect to Figure 3.
[0089] In the exemplary embodiment, in addition to cutouts 324,
334, 336, and 338. blank 500 includes cutouts 502, 504, 506, and 508. More
specifically, angled edge 58, top edge 320, and bottom edge 406 define a first
cutout
502; angled edge 64, top edge 320, and bottom edge 406 define a second cutout
504;
angled edge 74, top edge 320, and bottom edge 406 define a third cutout 506;
and
angled edge 80, top edge 320, and bottom edge 406 define a fourth cutout 508.
[0090] Figure 10 is a perspective view of a container 550 that is
partially formed from blank 500 (shown in Figure 9). Container 550 is
essentially
similar to container 350 (shown in Figure 6) and container 450 (shown in
Figure 8)
and, as such, similar components are labeled with similar references. Although
container 550 is shown as being formed without a product to be contained
therein,
container 550 may also be formed having a product therein. Further, container
550
may include any suitable number of products of any suitable shape. To
construct
container 550 from blank 500 a method that is substantially similar to the
method for
forming container 350 from blank 300 and forming container 450 from blank 400
is
used.
[0091] Figure 11 is a top plan view of a blank 600 of sheet material
for constructing a container according to a fourth alternative embodiment of
the
present invention. Blank 600 is essentially similar to blank 10 (shown in
Figure 1)
and, as such, similar components are labeled with similar references. In the
exemplary embodiment, blank 600 includes top shoulder panels 602 and 604
rather
than top panels 20 and 28 (shown in Figure 1). As such, blank 600 includes
reinforcing panel assemblies 606 rather than reinforcing panel assemblies 138
(shown
in Figure 1).
[0092] A reinforcing panel assembly 606 extends from side edges of
each end panel 108 and 114 along fold lines 140. 142, 144, and 146. Each
reinforcing
panel assembly 606 includes a free bottom edge 608. Further, each reinforcing
panel
-25-
CA 02740182 2011-05-13
80006-00971
assembly 606 is substantially similar and includes outer reinforcing panel
assembly
148 and an inner reinforcing panel assembly 610 connected to each other along
fold
line 152. Outer reinforcing panel assembly 148 includes corner panel 154 and
first
reinforcing side panel 156; and inner reinforcing panel assembly 610 includes
inner
reinforcing corner panel 158, second reinforcing side panel 160, and inner end
panel
612. In the exemplary embodiment, each outer reinforcing panel assembly 148
includes fold line 166 that divides each outer reinforcing panel assembly 148
into
corner panel 154 and first reinforcing side panel 156. Further, each inner
reinforcing
panel assembly 610 includes fold lines 168 and 170 that divide each inner
reinforcing
panel assembly 610 into second reinforcing side panel 160, inner reinforcing
corner
panel 158, and inner end panel 612. More specifically, second reinforcing side
panel
160 extends from first reinforcing side panel 156 along fold line 152, inner
reinforcing corner panel 158 extends from second reinforcing side panel 160
along
fold line 168, and inner end panel 612 extends from inner reinforcing corner
panel
158 along fold line 170 to a free edge 614.
[0093] Free edge 614 is generally co-linear with leading edge 16 or
trailing edge 18: however, free edge 614 can have any suitable position with
respect
to leading edge 16 and/or trailing edge 18 that enables blank 600 and/or
container 650
(shown in Figure 12) to function as described herein. In the exemplary
embodiment,
notch 182 is defined in inner end panel 612 along bottom edge 608. Notch 182
is
shaped to correspond to at least a portion of stacking slot 130 defined in end
panel
108 and/or 114. As such, when container 650 is formed from blank 600, inner
end
panel 612 does not obstruct stacking slot 130, and a lower stacking tab 652
(shown in
Figure 12) can fit within an upper stacking slot 130.
[0094] In the exemplary embodiment, end panels 108 and 114 each
include first stacking extensions 616 and 618 that are mirror images of
stacking
extensions 120 and 122 (shown in Figure 1). More specifically, each first
stacking
extension 616 and 618 includes a notch 620 defined nearer a fold line 140,
142, 144,
or 146 than a center of end panel 108 and/or 114. Further, in the exemplary
embodiment, inner end panel 612 includes a second stacking extension 622
extending
-26-
CA 02740182 2011-05-13
80006-00971
from a top edge 624 thereof. Second stacking extension 622 has a shape that
corresponds to the shape of first stacking extension 616 or 618 such that
second
stacking extension 622 aligns with a respective first stacking extension 616
or 618 to
form a stacking tab 652. In the exemplary embodiment, second stacking
extension
622 is substantially similarly shaped to a respective first stacking extension
616 or
618 and includes notch 620. It should be understood that second stacking
extension
622 has any suitable shape and position that enables blank 600 and/or
container 650 to
function as described herein.
[0095] Figure 12 is a perspective view of container 650 that is
formed from blank 600 (shown in Figure 11) and is in a closed position.
Container
650 is essentially similar to container 200 (shown in Figure 2) and, as such,
similar
components are labeled with similar references. Container 650 may include any
suitable number of products of any suitable shape. To construct container 650
from
blank 600 a method that is substantially similar to the method for forming
container
200 from blank 10 is used, except for forming a top wall 654. More
specifically, top
wall 654 is formed by rotating top shoulder panels 602 and 604 about
respective fold
lines 30 and 36. Leading edge 16 or trailing edge 18 is inserted into a notch
656
defined by each stacking tab 652. Notches 656 secure top shoulder panels 602
and
604 in position to form top wall 654.
[0096] Figure 13 is a top plan view of an example embodiment of a
blank 700 of sheet material. Blank 700 is essentially similar to blank 300
(shown in
Figure 5) and blank 600 (shown in Figure 11) and, as such, similar components
are
labeled with similar references. More specifically, blank 700 is similar to
blank 600
and includes outer reinforcing corner panels 302, 304, 306, and 308, as shown
and
described with respect to Figure 5. Further, blank 700 includes fold lines
310, 312,
314, and 316 rather than free side edges 50, 52, 54, and 56 (shown in Figure
11), as
shown and described with respect to Figure 3.
[0097] Figure 14 is a perspective view of a container 750 that is
formed from blank 700 (shown in Figure 13). Container 750 is essentially
similar to
-27-
CA 02740182 2011-05-13
80006-00971
container 350 (shown in Figure 6) and container 650 (shown in Figure 12) and,
as
such, similar components are labeled with similar references. Although
container 750
is shown as being formed without a product to be contained therein, container
750
may also be formed having a product therein. Further, container 750 may
include any
suitable number of products of any suitable shape. To construct container 750
from
blank 700 a method that is substantially similar to the method for forming
container
350 from blank 300 and forming container 650 from blank 600 is used.
[0098] Figure 15 is a top plan view of an example embodiment of a
blank 800 of sheet material. Blank 800 is essentially similar to blank 300
(shown in
Figure 5) and, as such, similar components are labeled with similar
references. More
specifically, blank 800 includes outer reinforcing corner panels 302, 304,
306, and
308. Further, blank 800 includes fold lines 310, 312, 314, and 316. However,
in an
alternative embodiment (not shown), blank 800 may not include outer
reinforcing
corner panels 302, 304, 306, and 308.
[0099] In the exemplary embodiment, a reinforcing panel assembly
138 extends from side edges of each end panel 108 and 114. Each reinforcing
panel
assembly 138 is substantially similar and includes an outer reinforcing panel
assembly
148 and an inner reinforcing panel assembly 150 connected to each other along
a fold
line 152. Fold line 152 defines a side edge of outer reinforcing panel
assembly 148
and a side edge of inner reinforcing panel assembly 150. Moreover, outer
reinforcing
panel assembly 148 includes a corner panel 154 and a first reinforcing side
panel 156;
and inner reinforcing panel assembly 150 includes an inner reinforcing corner
panel
158, a second reinforcing side panel 160, and an inner end panel 162. Each
reinforcing panel assembly 138 is configured to form a reinforcing corner
assembly.
[00100] Each end panel 108 and 114 includes a pair of mirror image
stacking extensions 120 and 122. Each stacking extension 120 and 122 defines a
notch 124. Notch 124 is sized to receive a portion of top panel 20 or 28 when
container 850 (shown in Figure 16) is closed, as described in more detail
below.
Further, in the exemplary embodiment, bottom panel 24 includes stacking slots
-28-
CA 02740182 2011-05-13
80006-00971
configured to receive the stacking tabs of an adjacent container when the
containers
are stacked as shown in Figure 4.
[00101] In the exemplary embodiment, inner end panel 162 includes
a minor stacking extension 176 extending from a top edge 178 thereof. Minor
stacking extension 176 has a shape that corresponds to the shape of stacking
extension
120 or 122 such that minor stacking extension 176 aligns with a respective
stacking
extension 120 or 122 to form a stacking tab 204 when inner reinforcing panel
assembly 150 is folded onto outer reinforcing panel assembly 148 and end panel
108
or 114. In the exemplary embodiment, minor stacking extension 176 is
substantially
similarly shaped to a respective stacking extension 120 or 122 and includes a
similar
notch.
[00102] In the exemplary embodiment, first top panel 20 and second
top panel 28 each include a pair of locking assemblies 802 positioned at each
end of
the top panels. Each locking assembly 802 includes a locking slot 804 and a
rotatable
locking panel 806. Locking panels 806 are partially defined by a cut-line 808
that
borders inner end panel 162. Thus, each inner end panel 162 includes a removed
portion, which partially defines locking panel 806 and corresponds with
stacking slot
130 to further facilitate stacking of multiple containers. In operation, after
side walls
218, 220 and end walls 206, 208 are formed with the reinforcing corner
assemblies,
top panels 20 and 28 are rotated downwardly to a position that is
substantially parallel
to bottom panel 24. Locking panels 806 are rotated downwardly such that
locking
panels 806 are adjacent to (i.e., in a face-to-face relationship) an external
surface of
end panels 108 or 114. By rotating locking panels 806 downwardly, each locking
slot
804 is increased in size and receives stacking tab 204. Each stacking tab 204,
with the
help of notches 124, is configured to receive a portion of top panel 20 or 28
when
container 850 is closed. Thus, stacking tabs 204 are used to help hold or lock
top
panels 20 and 28 in the closed position. In addition, when stacking tabs 204
are
inserted into locking slots 804, stacking tabs 204 are adjacent to locking
panels 806
such that locking panels 806 are held in the rotated position. In the rotated
position,
each locking panel 806 is adjacent to an external surface of end panel 108 or
114, and
-29-
CA 02740182 2011-05-13
80006-00971
is adjacent to respective stacking tab 204. The respective stacking tab 204
maintains
or holds locking panel 806 in the rotated position.
[00103] Figure 16 is a perspective view of container 850 that is
formed from blank 800 (shown in Figure 15). Container 850 is essentially
similar to
container 350 (shown in Figure 6) and, as such, similar components are labeled
with
similar references. Although container 850 is shown as being formed without a
product being contained therein, container 850 may also be formed having a
product
therein. Further, container 850 may include any suitable number of products of
any
suitable shape.
[00104] To construct container 850 from blank 800 a method that is
substantially similar to the method for forming container 350 from blank 300
is used.
For example, reinforcing corner assembly 202 is formed by corner panels 154
and
158, reinforcing side panels 156 and 160, and inner end panel 162. When
reinforcing
corner assemblies 202 are formed, minor stacking extension 176 aligns with a
respective stacking extension 120 or 122 to form a stacking tab 204. First end
panel
108 with a pair of inner end panels 162 forms a first end wall 206, and second
end
panel 114 with a pair of inner end panels 162 forms a second end wall 208.
Each end
wall 206 and 208 includes a pair of stacking tabs 204 extending from an upper
edge
thereof. Further, each pair of corner panels 154 and 158 forms one corner wall
210,
212, 214, or 216.
[00105] First side panel 22 is rotated about fold line 32 toward
interior surface 12, and second side panel 26 is rotated about fold line 34
toward
interior surface 12. More specifically, first side panel 22 and second side
panel 26 are
rotated to be substantially perpendicular to bottom panel 24. Interior surface
12 of
first side panel 22 is secured to exterior surface 14 of two adjacent first
reinforcing
side panels 156, and interior surface 12 of second side panel 26 is secured to
exterior
surface 14 of two adjacent first reinforcing side panels 156. In the exemplary
embodiment, first side panel 22 and second side panel 26 are adhered to
respective
first reinforcing side panels 156. In the exemplary embodiment, first side
panel 22
-30-
CA 02740182 2011-05-13
80006-00971
and two pairs of reinforcing side panels 156 and 160 form a first side wall
218, and
second side panel 26 and two pairs of reinforcing side panels 156 and 160 form
a
second side wall 220. Bottom panel 24 forms a bottom wall 222 of container
850, and
bottom wall 222, side walls 218 and 220, end walls 206 and 208, and corner
walls
210, 212, 214, and 216 define a cavity 224 of container 850.
[00106] To close container 850 and form a top wall 852, first top
panel 20 is rotated about fold line 30 toward cavity 224 such that first top
panel 20 is
substantially perpendicular to first side panel 22 and substantially parallel
to bottom
panel 24. Further, second top panel 28 is rotated about fold line 36 toward
cavity 224
such that second top panel 28 is substantially perpendicular to second side
panel 26
and substantially parallel to bottom panel 24. With respect to blank 800, top
panels
20 and 28 include locking assemblies 802.
[00107] As top panels 20 and 28 are rotated toward cavity 224,
rotatable locking panels 806 are rotated downwardly to increase the size of
each
locking slot 804 such that a stacking tab 204 can be inserted into each
locking slot
804. Stacking tabs 204 are configured to receive at least a portion of top
panel 20 or
28 to hold top panel 20 or 28 in the closed position.
[00108] When locking panels 806 are rotated downwardly, locking
panels 806 are adjacent to (i.e., in a face-to-face relationship) an external
surface of
end walls 206 or 208. In addition, when stacking tabs 204 are inserted into
locking
slots 804, stacking tabs 204 are adjacent to locking panels 806 such that
locking
panels 806 are held in the rotated position. The respective stacking tab 204
maintains
or holds locking panel 806 in the rotated position.
[00109] Figure 17 is a top view of a machine 900 for forming a
container from a blank. Figure 18 is a side view of machine 900. Blank 10 and
container 200 are illustrated as being formed using machine 900; however, it
will be
understood that any of the above-described blanks can be formed into a
respective
container using machine 900. As used herein, the terms "downward," "down," and
variations thereof refer to a direction from a top 902 of machine 900 toward a
surface
-31-
CA 02740182 2011-05-13
80006-00971
or floor 904 on which machine 900 is supported, and the terms "upward," "up,"
and
variations thereof refer to a direction from floor 904 on which machine 900 is
supported toward top 902 of machine 900. Further, as used herein, "operational
control communication" refers to a link, such as a conductor, a wire, and/or a
data
link, between two or more components of machine 900 that enables signals,
electric
currents, and/or commands to be communicated between the two or more
components. The link is configured to enable one component to control an
operation
of another component of machine 900 using the communicated signals, electric
currents, and/or commands.
[00110] In the exemplary embodiment, machine 900 includes a
hopper station 906, a forming station 908, and an ejection station 910. More
specifically, hopper station 906, forming station 908, and ejection station
910 are
connected by a transport system 912, such as any suitable conveyor(s) and/or
motorized device(s) configured to move blank 10 and/or container 200 through
machine 900. In the exemplary embodiment, hopper station 906 is configured to
store
a stack 914 of blanks 10 in a substantially vertical orientation. More
specifically,
blanks 10 are stored with interior surface 12 facing in a downstream direction
A of the
machine 900 and exterior surface 14 facing away from the downstream direction
A, or
in an upstream direction.
[00111] Forming station 908 is generally aligned with and
downstream of hopper station 906 and includes any suitable number and/or
configuration of components, such as plows, arms, actuators, plungers and/or
other
devices for forming container 200 from blank 10. In the exemplary embodiment,
components of forming station 908 are in communication with a control system
918.
Control system 918 is configured to control and/or monitor components of
forming
station 908 to form container 200 from blank 10. In the exemplary embodiment,
control system 918 includes computer-readable instructions for performing the
methods described herein. In one embodiment, an operator can select which
blank 10,
300, 400, 500, 600, 700, and/or 800 (shown in Figures 1, 5, 7, 9, 11, 13, and
15) is
being manipulated by machine 900 using control system 918, and control system
918
-32-
CA 02740182 2011-05-13
80006-00971
performs the corresponding method using the components of forming station 908.
Control system 918 is also configured to automatically adjust positions of
arms,
plows, and/or other devices described herein that are used for forming
container 200.
Thus, when a user selects a container for forming, machine 900 will
automatically
adjust its forming elements for the various containers.
[00112] In the exemplary embodiment, control system 918 is shown
as being centralized within machine 900, however control system 918 may be a
distributed system throughout machine 900, within a building housing machine
900,
and/or at a remote control center. Control system 918 includes a processor 920
configured to perform the methods and/or steps described herein. Further, many
of
the other components described herein include a processor. As used herein, the
term
"processor" is not limited to integrated circuits referred to in the art as a
processor, but
broadly refers to a controller, a microcontroller, a microcomputer, a
programmable
logic controller (PLC), an application specific integrated circuit, and other
programmable circuits, and these terms are used interchangeably herein. It
should be
understood that a processor and/or control system can also include memory,
input
channels, and/or output channels.
[00113] In the embodiments described herein, memory may include,
without limitation, a computer-readable medium, such as a random access memory
(RAM), and a computer-readable non-volatile medium, such as flash memory.
Alternatively, a floppy disk, a compact disc-read only memory (CD-ROM), a
magneto-optical disk (MOD), and/or a digital versatile disc (DVD) may also be
used.
Also, in the embodiments described herein, input channels may include, without
limitation, sensors and/or computer peripherals associated with an operator
interface,
such as a mouse and a keyboard. Further, in the exemplary embodiment, output
channels may include, without limitation, a control device, an operator
interface
monitor, and/or a display.
[00114] Processors described herein process information transmitted
from a plurality of electrical and electronic devices that may include,
without
-33-
CA 02740182 2011-05-13
80006-00971
limitation, sensors, actuators, compressors, control systems, and/or
monitoring
devices. Such processors may be physically located in, for example, a control
system,
a sensor, a monitoring device, a desktop computer, a laptop computer, a PLC
cabinet,
and/or a distributed control system (DCS) cabinet. RAM and storage devices
store
and transfer information and instructions to be executed by the processor(s).
RAM
and storage devices can also be used to store and provide temporary variables,
static
(i.e., non-changing) information and instructions, or other intermediate
information to
the processors during execution of instructions by the processor(s).
Instructions that
are executed may include, without limitation, machine control commands. The
execution of sequences of instructions is not limited to any specific
combination of
hardware circuitry and software instructions.
[00115] In the exemplary embodiment, ejection station 910 is
configured to eject container 200 from forming station 908. More specifically,
in the
exemplary embodiment, ejection station 910 includes an exit conveyor 922 for
conveying formed containers from an exit 924 of forming station 908 to an end
926 of
exit conveyor 922. Exit conveyor 922 is part of transport system 912.
[00116] During operation of machine 900 to form container 200
from blank 10, stack 914 of blanks 10 is placed within hopper station 906.
Transport
system 912 removes one blank 10 from stack 914 and transfers blank 10 to
forming
station 908. Transport system 912 transfers blank 10 through the components of
forming station 908. The components of forming station 908 perform the method
for
forming container 200 from blank 10. Within forming station 908, blank 10 is
folded
into a partially formed container 928. Partially formed container 928 is
formed into
container 200 within forming station 908, and a subsequent blank 10 is
transferred
from hopper station 906 into forming station 908. As such, containers 200 are
formed
continuously by machine 900. After container 200 is formed in forming station
908,
transport system 912 transfers container 200 to ejection station 910 for
ejection from
machine 900.
-34-
CA 02740182 2011-05-13
80006-00971
[00117] Figures 19-37 show perspective views of machine 900.
Arrow A shows a direction of movement of blank 10 and/or container 200 through
machine 900. Further, the head of arrow A indicates a "downstream" or
"forward"
direction and the tail of arrow A indicates an "upstream" or "backward"
direction.
The term "front" as used herein with respect to movement through machine 900
refers
the downstream end of blank 10, and the term "rear' as used herein with
respect to
movement through machine 900 refers the upstream end of blank 10. Figure 19
shows a perspective view of hopper station 906 having a generally vertically
oriented
blank 10 therein. Figure 20 shows a perspective view of hopper station 906 and
forming station 908 wherein blank 10 is being transported from hopper station
906 to
station 908 using transport system 912. Figure 21 shows a perspective view of
forming station 908 with blank 10 being placed into a substantially horizontal
position
by transport system 912.
[00118] Figure 22 shows a perspective view of forming station 908
with blank 10 being placed onto transport system 912 with inner reinforcing
panel
assemblies 150 rotated substantially perpendicular to the remainder of blank
10.
Figure 23 shows a more close-up view of forming station 908 with blank 10
placed
onto transport system 912 with inner reinforcing panel assemblies 150 rotated
substantially perpendicular to the remainder of blank 10. Figure 24 shows a
perspective view of blank 10 being transported from an initial forming station
of
forming station 908 though a first gluing station to a secondary forming
station of
forming station 908 with inner reinforcing panel assemblies 150 rotated
substantially
perpendicular to the remainder of blank 10.
[00119] Figure 25 is a perspective view of the secondary forming
station of forming station 908. Figure 26 shows a perspective view of blank 10
being
further formed within the secondary forming station of forming station 908.
Figure
27 shows a perspective view of blank 10 having reinforcing corner assemblies
202
formed within the secondary forming station of forming station 908. Figure 28
shows
a schematic cross-sectional view of blank 10 being formed into container 200
within
the secondary forming station of forming station 908. Figure 29 shows a
perspective
-35-
CA 02740182 2011-05-13
80006-00971
view of a downstream end of the secondary forming station. Figure 30 is a
perspective view of a breaking station of forming station 908. Figure 31 is a
top
perspective view of the breaking station.
[00120] Figure 32 shows a perspective view of partially formed
container 928 as it moves downstream from the secondary forming station of
forming
station 908. Figure 33 shows a perspective view of the secondary forming
station and
a compression station of forming station 908. Figure 34 shows a perspective
view of
the compression station without partially formed container 928 positioned
therein.
Figure 35 shows a perspective view of partially formed container 928 within
the
compression station of forming station 908. Figure 36 shows a perspective view
of
partially formed container 928 within the compression station of forming
station 908.
Side support rails, as described in more detail below, are not shown in Figure
36.
Figure 37 shows a perspective view of formed container 200 on exit conveyor
922.
[00121] Referring to Figures 1. 2, and 17-37, machine 900 is
substantially symmetrical about a longitudinal axis 934 that extends from a
rear end
936 of machine 900 to a front end 938 of machine 900. As a container 200 is
formed
using machine 900, blank 10 moves along longitudinal axis 934 from rear end
936 to
front end 938.
[00122] Referring to Figures 19-21, hopper station 906 includes a
hopper 940, a feed mechanism 942, a transfer arm 944, and upper suction device
946.
Hopper 940 is configured to support stack 914 of blanks 10 in a substantially
vertical
position on feed mechanism 942. Feed mechanism 942 is part of transport system
912, and includes, in the example embodiment, a conveyor belt mechanism for
transporting blanks 10 downstream toward transfer arm 944. Blanks 10 within
hopper
940 are in an unformed, substantially planar state. Hopper 940 is further
configured
to facilitate maintaining alignment of blanks 10 within machine 900 such that
an
individual blank 10 may be transported from hopper station 906 and precisely
placed
within forming station 908.
-36-
CA 02740182 2011-05-13
80006-00971
[00123] As shown in Figures 20-36, forming station 908 includes an
initial forming station 950, a first gluing station 952, a secondary forming
station 954,
a second gluing station 956, and a compression station 958. Referring to
Figures 20-
24, initial forming station 950 includes a drive system 970, a lower suction
device
972, a pusher plate 974, stationary folding plows 976, moveable folding plows
978,
side plates 980, support rails 982, and outer side rails 984. Outer side rails
984 extend
the length of machine 900 are used to help guide the outer side edges of blank
10 as
blank 10 moves through machine 900.
[00124] As shown in Figures 21-24, first gluing station 952 includes
drive rollers 1000 and a first gluer 1002. As explained below in detail, drive
rollers
1000 are part of transport system 912 and are used to help transport blank 10
from
initial forming station 950 past first gluer 1002. First gluer 1002 includes a
plurality
of glue sprayers that apply hot glue or any other type of adhesive to certain
panels of
blank 10. Specifically, first gluer 1002 applies glue to portions of each
corner panel
154, each first reinforcing side panel 156, and first and second end panels
108 and
114. In an alternative embodiment, first gluer 1002 applies glue to a portion
of at
least some of these panels. First gluing station 952 also includes photo-eyes,
sensors,
proximity switches and other location detectors for detecting a location of
blank 10
within gluing station 952. Location data is provided to control system 918,
and
control system 918 controls when glue sprayers are turned on and off to
properly
apply glue to blank 10. In the exemplary embodiment, first gluer 1002 includes
a
plurality of glue modules are each separately controllable by control system
918. As
such, any suitable number of glue modules are activated depending on a size
and/or
placement of blank 10.
[00125] In Figures 25-33, secondary forming station 954 is
downstream from initial forming station 950 and first gluing station 952.
Secondary
forming station 954 helps form reinforcing corner assemblies 202 on each blank
10
that passes through machine 900. Secondary forming station 954 includes a push
lug
1040, a stop lug 1042, a servo-mechanical system 1044 (also known as a servo
drive),
a servo chain 1046, rotating folder arms 1048, male forming members 1050,
female
-37-
CA 02740182 2011-05-13
80006-00971
forming members 1052, and inner side rails 1054. In the example embodiment,
servo
drive 1044 is controlled by control system 918. Servo drive 1044 drives servo
chain
1046 which includes at least one push lug 1040 coupled to servo chain 1046.
Accordingly, servo drive 1044 drives servo chain 1046 around a first and
second
sprocket such that each push lug 1040 attached to servo chain 1046 rotates
from an
upstream location within secondary forming station 954 to a downstream
location
within secondary forming station 954. Push lug 1040 is configured to engage
blank
at trailing top edge 112 or 118 of blank 10. Push lug 1040 pushes blank 10
into a
forming position by pushing blank 10 until the opposing leading top edge 118
or 112
of blank 10 contacts stop lug 1042.
[00126] Stop lug 1042 is positioned downstream of push lug 1040.
Stop lug 1042 is configured to precisely stop blank 10 so that blank 10 can be
further
formed within secondary forming station 954, and move downwardly out of the
path
of blank 10 so that, after secondary forming, blank 10 is able to move further
downstream within machine 900. More specifically, in the exemplary embodiment,
a
stop lug 1042 is positioned on each side of servo chain 1046, and stop lugs
1042
move upward from below servo chain 1046 to above servo chain 1046 to stop
blank
10 at an appropriate position. Stop lugs 1042 can be movably coupled to inner
side
rails 1054 and width-wise adjustable through adjustment of a width of inner
side rails
1054. Stop lugs 1042 are moveable upstream and downstream with respect to
inner
side rails 1054 for length-wise adjustment. As such, positions of stop lugs
1042 are
adjustable depending on a size of blank 10.
[00127] Rotating folder arm 1048 is mounted on each side of
secondary forming station 954 proximate to inner side rails 1054. Folder arm
1048 is
configured to rotate inwardly toward blank 10 from a starting position to a
folding
position, and then outwardly to return to the starting position. In rotating
between the
starting position and the folding position, folder arm 1048 contacts a portion
of inner
reinforcing panel assemblies 150 to fold inner reinforcing panel assemblies
150 from
the substantially perpendicular position to a nearly flat position wherein
inner
reinforcing panel assemblies 150 overlie respective outer reinforcing panel
assemblies
-38-
CA 02740182 2011-05-13
80006-00971
148 and end panels 108 and 114. As folder arm 1048 folds inner reinforcing
panel
assemblies 150, a portion of inner reinforcing panel assemblies 150 contacts a
respective male forming member 1050 causing reinforcing panel assemblies 150
to
bend along fold lines 168 and 170. The pre-bending of fold lines 168 and 170,
sometimes referred to as "pre-breaking," facilitates forming reinforcing
corner
assemblies 202, as explained below in greater detail.
[00128] After folder arm 1048 folds inner reinforcing panel
assemblies 150, folder arm 1048 rotates back to the starting position so that
male
forming members 1050 and female forming members 1052 are able to move together
and form reinforcing corner assemblies 202, as shown in Figure 28. More
specifically, each male forming member 1050 has an outer surface that is
shaped like
an inside surface of one of reinforcing corner assemblies 202, and each female
forming member 1052 has an outer surface that is shaped like an outside
surface of
one of the reinforcing corner assemblies 202. Thus, when male forming members
1050 and female forming members 1052 move toward each other, each female
forming member 1052 interfaces with the outside of blank 10 and each male
forming
member 1050 interfaces with the inside of blank 10 such that outer reinforcing
panel
assemblies 148 and end panels 108 and 114 are glued to a respective inner
reinforcing
panel assembly 150. In addition, the outer profiles of male forming members
1050
and female forming members 1052 form corner walls 210, 212, 214, and/or 216 of
each corner assembly 202.
[00129] After forming reinforcing corner assemblies 202, male
forming members 1050 and female forming members 1052 move away from each
other. Inner side rails 1054 are positioned to contact first reinforcing side
panel 156
on each reinforcing corner assembly 202 to maintain the overall angle of
reinforcing
corner assembly 202 at substantially 90 degrees. In other words, inner side
rails 1054
help prevent the formed reinforcing corner assemblies 202 from springing back
out of
a perpendicular position. Further, stop lug 1042 moves out of the travel path
of
partially formed container 928 such that partially formed container 928 can be
further
moved downstream within machine 900.
-39-
CA 02740182 2011-05-13
80006-00971
[00130] As shown in Figures 29-34, machine 900 includes a
breaking station 955 positioned between forming members 1050 and 1052 and
compression station 958. Breaking station 955 is configured to rotate
reinforcing side
panels 156 and 160, after reinforcing side panels 156 and 160 are joined
together by
forming members 1050 and 1052, to be at an acute angle (an angle of less than
approximately 90 degrees) with respect to interior surface 12 of end panels
108 and/or
114. Breaking station 955 includes a miter plate 1061 and a guide bar 1060. In
the
exemplary embodiment, miter plate 1061 is substantially parallel to
longitudinal axis
934 and oriented at an angle corresponding to an angle between corner panels
154 and
158 and end panels 108 and/or 114. Guide bar 1060 tapers inward toward miter
plate
1061 and over a top edge of miter plate 1061 at a downstream end of breaking
station
955. Guide bar 1060 is configured to force reinforcing side panels 156 and 160
to
rotate with respect to corner panels 154 and 158 and break at least fold lines
166 and
168. In the exemplary embodiment, reinforcing corner assembly 202 is
positioned
between miter plate 1061 and guide bar 1060 as partially formed container 928
is
transported downstream from secondary forming station 954 past second gluing
station 956. As such, breaking station 955 facilitates preventing reinforcing
corner
assembly 202 from un-forming as partially formed container 928 is transferred
into
compression station 958.
[00131] Referring to Figure 32, second gluing station 956 includes a
second gluer 1062 positioned adjacent each guide bar 1060. Push lug 1040
pushes
partially formed container 928 through second gluing station 956 to
compression
station 958. Second gluer 1062 includes a plurality of glue sprayers that
apply hot
glue or any other type of adhesive to certain panels of blank 10.
Specifically, second
gluer 1062 applies glue to portions of exterior surface 14 of first
reinforcing side
panels 156. Second gluing station 956 also includes photo-eyes, sensors,
proximity
switches and other location detectors for detecting a location of partially
formed
container 928 within gluing station 956. Location data is provided to control
system
918, and control system 918 controls when glue sprayers are turned on and off
to
properly apply glue to partially formed container 928. In the exemplary
embodiment,
-40-
CA 02740182 2011-05-13
80006-00971
second gluer 1062 includes a plurality of glue modules are each separately
controllable by control system 918. As such, any suitable number of glue
modules are
activated depending on a size and/or placement of blank 10. In the exemplary
embodiment, guide bars 1060 are positioned to direct each reinforcing corner
assembly 202 away from second gluers 1062 as partially formed container 928
passes
through machine 900 such that an appropriate distance is maintained between
second
gluers 1062 and exterior surface 14 of the respective first reinforcing side
panel 156 to
ensure a proper amount and placement of glue on the panel.
[00132] As shown in Figures 33-36, compression station 958, also
referred to as a plunger station, includes a pusher arm 1080 positioned just
downstream of second gluing station 956. In the exemplary embodiment, pusher
arm
1080 includes a pair of vertically-oriented bars 1082 coupled to a pair of
vertically-
oriented rotatable bars 1084 that are rotatable in the downstream direction
but not in
the upstream direction. In other words, rotatable bars 1084 allow partially
formed
container 928 to move downstream, but act as pusher arms after partially
formed
container 928 passes downstream of rotatable bars 1084. Rotatable bars 1084
are
configured to engage a rear edge of partially formed container 928 as
partially formed
container 928 is ejected from second gluing station 956. When rotatable bars
1084
engage the rear edge, pusher arm 1080 transfers partially formed container 928
from
second gluing station 956 into compression station 958. Pusher arm 1080 is a
component of transport system 912.
[00133] Further, in the exemplary embodiment, compression station
958 includes a plunger 1100, two side panel plows 1102, two pairs of end panel
plow
assemblies 1104, a plurality of corner pushers 1106, a stop plate 1108, and
support
bars 1109. Stop plate 1108 is adjustable upstream and downstream with respect
to a
frame of machine 900. As such a position of stop plate 1108 is selectable
based on
the size of blank 10. In the exemplary embodiment, support bars 1109 are
substantially parallel to longitudinal axis 934 and facilitate preventing glue
from
being removed and/or displaced with respect to first reinforcing side panels
156.
More specifically, support bars 1109 are positioned to contact glued first
reinforcing
-41-
CA 02740182 2011-05-13
80006-00971
side panels 156 to push reinforcing side panels 156 and 160 to be at a
substantially
right angle with respect to a respective side panel 22 or 26. Support bars
1109 are
adjustable depending on a size of blank 10 and/or partially formed container
928. In a
particular embodiment, support bars 1109 are positioned to contact a first
reinforcing
side panels 156 near fold line 152, above glue. Because support bars 1109
retain a
position of reinforcing corner assemblies 202 within compression station 958,
support
bars 1109 prevent the glue from being removed from and/or displaced from
exterior
surface 14 of first reinforcing side panels 156 as reinforcing corner
assemblies 202 are
rotated into position with end panels 108 and 114.
[00134] Compression station 958 can include an adjustable stop (not
shown) positioned at a downstream end of compression station 958 for stopping
movement of partially formed container 928 through compression station 958.
End
panel plows 1104 and side panel plows 1102 define a plunger opening 1110 that
extends from top ends of side panel plows 1102 and end panel plows 1104 to
exit
conveyor 922. More specifically, plunger 1100 has a shape that corresponds to
a
cross sectional shape of container 200. In the exemplary embodiment, plunger
1100
corresponds to end walls 206 and 208 and side walls 218 and 220 of container
200.
Plunger 1100 is open at corner walls 210, 212, 214, and 216. Alternatively,
plunger
1100 may also include walls at corner walls 210, 212, 214, and/or 216.
[00135] In the exemplary embodiment. plunger 1100 includes at
least four upright plates 1120 and 1122 coupled to a vertical actuator 1124.
More
specifically, side wall upright plates 1120 extend substantially parallel to
longitudinal
axis 934 and are oriented substantially vertically, and end wall upright
plates 1122 are
substantially perpendicular to side wall upright plates 1120 and longitudinal
axis 934
and are oriented substantially vertically. Upright plates 1120 and 1122 are
configured
to prevent over-rotation of side panels 22 and 26 and end panels 108 and 114
into
cavity 224 (shown in Figure 2) of container 200. Vertical actuator 1124, which
is
driven by drive system 970, is configured to move plunger 1100 between a first
position, also referred to as a top position, and a second position, also
referred to as a
bottom position. Control system 918 is in operational control communication
with
-42-
CA 02740182 2011-05-13
80006-00971
vertical actuator 1124 for controlling movement of plunger 1100 between the
first
position and the second position.
[00136] Compression station 958 includes a rear pair 1130 of end
panel plows 1104 and a front pair 1132 of end panel plows 1104. Each end panel
plow 1104 is moveable with respect to machine 900 and is configured to
upwardly
rotate an end panel 108 or 114 to be substantially perpendicular to bottom
panel 24.
More specifically, front pair 1132 is configured to fold a front end panel 108
or 114,
and rear pair 1130 is configured to fold a rear end panel 108 or 114. Each end
panel
plow 1104 includes an angled outer surface, a top surface, an angled inner
surface,
and a vertical plate. As used with respect to end panel plows 1104 and side
panel
plows 1102, the term "inner" refers to a direction toward plunger opening
1110, and
the term "outer" refers to a direction away from plunger opening 1110. In the
exemplary embodiment, the top surface of plow 1104 is substantially parallel
to
longitudinal axis 934 and extends between the angled outer surface and the
angled
inner surface. The vertical plate extends into plunger opening 1110 to at
least
partially define plunger opening 1110.
[00137] Each end panel plow assembly 1104 includes a frame having
a pair of end panel plows coupled thereto. Front pair 1132 of end plows 1104
is
configured to rotate inwardly toward plunger opening 1110 and outwardly away
from
plunger opening 1110. As such, front pair 1132 of end plows 1104 move between
a
first position, also referred to as an outer position, and a second position,
also referred
to as a forming position. Rear pair 1130 of end plows 1104 are also configured
to
rotate, but could be stationary if so desired. Control system 918 is in
operational
control communication with each end panel plow assembly 1104 for controlling
rotation between the outer position and the forming position. In the exemplary
embodiment, a sensor determines when partially formed container 928 is
positioned
over plunger opening 1110. End panel plow assemblies 1104 are moved to the
forming position when the sensor determines partially formed container 928 is
positioned over and/or within plunger opening 1110, and end panel plow
assemblies
1104 are moved to the outer position after plunger 1100 has been retracted
from
-43-
CA 02740182 2011-05-13
80006-00971
plunger opening 1110. As such, container 200 is secured within plunger opening
1110 by end panel plow assemblies 1104 in the forming position, and container
200 is
released from plunger opening 1110 onto exit conveyor 922 when end panel plow
assemblies 1104 are in the outer position. Although two end panel plows 1104
are
described in the example embodiment, it should be understood that any suitable
number of end panel plows may be used to fold end panels 108 or 114.
[00138] In the exemplary embodiment, each side panel plow 1102
includes a substantially horizontal upper surface, an angled inner surface,
and a
substantially vertical inner wall. Angled inner surfaces are configured to
rotate side
panels 22 and/or 26 inwardly toward plunger opening 1110 and/or plunger 1100.
The
vertical inner walls at least partially define plunger opening 1110. Side
panel plows
1102 also include glue rollers 1140 that are positioned on both sides of each
side
panel plow 1102. Glue rollers 1140 facilitate attaching and adhering side
panels 22
and 26 to adjacent first reinforcing side panel 156 as plunger 1100 moves
partially
formed container 928 through plunger opening 1110.
[00139] A corner pusher 1106 is positioned at each corner of plunger
opening 1110. Each comer pusher 1106 is coupled to an actuator that moves one
of
the corner pushers 1106 between a first position, also referred to as an outer
position,
and a second position, also referred to as an inner position. As such,
horizontal
actuator moves corner pusher 1106 toward and away from plunger opening 1110.
Control system 918 is in operational control communication with each actuator
for
controlling corner pushers 1106. In the exemplary embodiment, a sensor
determines
when partially formed container 928 is positioned over plunger opening 1110,
and
corner pushers 1106 are moved to the second position when the sensor
determines
partially formed container 928 is positioned over and/or within plunger
opening 1110.
In one embodiment, corner pushers 1106 are only moved to the inner position
when a
blank having outer reinforcing corner panels, such as blank 300 and/or 500, is
being
formed into a container using machine 900.
-44-
CA 02740182 2011-05-13
80006-00971
[00140] Referring to Figures 36 and 37, exit conveyor 922 extends
through a bottom 1112 of compression station 958 to receive containers 200
from
forming station 908. More specifically, exit conveyor 922 continuously runs
while
machine 900 is being operated to form containers 200. Alternatively, exit
conveyor
922 is operated intermittently when a container 200 is positioned within
bottom 1112
of compression station 958. In the exemplary embodiment, container 200 is
secured
within plunger opening 1110 by end panel plow assemblies 1104 and/or corner
pushers 1106 over exit conveyor 922. As such, when end panel plow assemblies
1104
are rotated to outer position and/or corner pushers 1106 are moved to outer
positions,
container 200 is released from plunger opening 1110 onto exit conveyor 922.
Control
system 918 is in operational control communication with exit conveyor 922 for
control thereof. Top panels 20 and 28 remain unfolded with respect to a
respective
side panel 22 or 26, and container 200 is ejected from machine 900 in the open
configuration.
[00141] During operation of machine 900, a method for forming a
container 200 from blank 10 is performed. It should be understood that the
method
may be used to form any suitable container, such as containers 350, 450, 550,
650,
750, and/or 850 (shown in Figures 6, 8, 10, 12, 14, and 16), using machine
900. In
the exemplary embodiment, the method is performed by control system 918
sending
commands and/or instructions to components of machine 900. Processor 920
within
control system 918 is programmed with code segments configured to perform the
method. Alternatively, the method is encoded on a computer-readable medium
that is
readable by control system 918. In such an embodiment, control system 918
and/or
processor 920 is configured to read computer-readable medium for performing
the
method.
[00142] Referring to Figures 17-37, drive system 970 includes a
motor, gears, a chain and sprockets that cause much of transport system 912 to
move.
For example, drive system 970 causes transfer arm 944 to rotate to a position
where
upper suction device 946 comes into contact with a first blank 10 stored
within hopper
940. First blank 10 being the most downstream blank housed within hopper 940.
-45-
CA 02740182 2011-05-13
80006-00971
More specifically, upper suction device 946 comes into contact with interior
surface
12 of first blank 10 such that upper suction device 946 becomes releasably
coupled to
first blank 10. Transfer arm 944, still being driven by drive system 970,
rotates with
blank 10 coupled thereto such that blank 10 is placed in a substantially
horizontal
position with exterior surface 14 of blank 10 facing downwardly toward support
rails
982. Thus, transfer arm 944 moves blank 10 from hopper 940 to initial forming
station 950.
[00143] While transfer arm 944 moves blank 10 into a substantially
horizontal position within initial forming station 950, lower suction device
972 moves
upwardly from below support rails 982 to engage exterior surface 14 of blank
10.
Thus, blank 10 is essentially transferred with a "handshake" from upper
suction
device 946 to lower suction device 972. Lower suction device 972 then pulls
blank
downwardly onto support rails 982. As blank 10 is placed on support rails 982,
stationary folding plows 976 and moveable folding plows 978 engage inner
reinforcing panel assemblies 150 at each corner of blank 10, causing each
inner
reinforcing panel assembly 150 to rotate about 90 degrees with respect to
outer
reinforcing panel assembly 148 such that each inner reinforcing panel assembly
150 is
substantially perpendicular to bottom panel 24 of blank 10. Feed mechanism 942
pushes stack 914 forward to position the next blank 10 to be removed from
hopper
940 by transfer arm 944.
[00144] Blank 10 is moved from initial forming station 950 to
secondary forming station 954 through first gluing station 952. More
specifically,
blank 10 is transported forward into secondary forming station 954 using
pusher plate
974 and/or drive rollers 1000. For example, pusher plate 974 is moved in a
substantially horizontal direction from a rear position to a forward position
and blank
10 is slid forward into forming station 954 along support rails 982. Moveable
folding
plows 978 follow the motion of blank 10 to retain the position of rear inner
reinforcing panel assemblies 150. As blank 10 is transported forward. rear
inner
reinforcing panel assemblies 150 are transferred from moveable folding plows
978 to
stationary folding plows 976 to retain the position of inner reinforcing panel
-46-
CA 02740182 2011-05-13
80006-00971
assemblies 150. Further, drive rollers 1000 contact a leading end panel 108 or
114
and/or bottom panel 24 as blank 10 is transferred from initial forming station
950 to
first gluing station 952. Once drive rollers 1000 engage blank 10, pusher
plate 974
retracts to the rear position.
[00145] As blank 10 is transported through first gluing station 952,
adhesive is applied to interior surface 12 of corner panels 154, first
reinforcing side
panels 156, and/or end panels 108 and/or 114 using first gluer 1002. More
specifically, sensors within first gluing station 952 detect a position of
blank 10 with
respect to first gluer 1002 to control first gluer 1002 to properly apply the
adhesive.
As the trailing top edge 112 or 118 of blank 10 exits first gluing station
952, push lug
1040 engages trailing top edge 112 or 118 to move blank 10 through secondary
forming station 954. More specifically, using sensors and/or other devices,
control
system 918 controls servo drive 1044 to position push lug 1040 adjacent
trailing top
edge 112 or 118. Servo drive 1044 then controls movement of blank 10 through
secondary forming station 954 using push lug 1040. In the exemplary
embodiment,
push lug 1040 moves blank 10 through secondary forming station 954 until
leading
top edge 112 or 118 is adjacent to, or in contact with, stop lug 1042. Push
lug 1040
and stop lug 1042 are configured to properly position blank 10 within
secondary
forming station 954.
[00146] Within secondary forming station 954, reinforcing corner
assemblies 202 are formed using male forming member 1050 and female forming
member 1052. More specifically, in the exemplary embodiment, folder arm 1048
rotates from the starting position to the folding position to fold interior
surface 12 of
inner reinforcing panel assemblies 150 into face-to-face relationship with
interior
surface 12 of a respective outer reinforcing panel assembly 148. When folder
arms
1048 are at the folding position, inner reinforcing panel assemblies 150 are
not in
contact with outer reinforcing panel assemblies 148; however, in some
embodiments,
inner reinforcing panel assemblies 150 can be rotated into contact with outer
reinforcing panel assemblies 148 by folder arms 1048. In the exemplary
embodiment,
as inner reinforcing panel assemblies 150 are rotated by folder arms 1048,
inner end
-47-
CA 02740182 2011-05-13
80006-00971
panels 162 and inner reinforcing corner panels 158 are slightly rotated about
fold lines
168 and/or 170 by coming into contact with male forming member 1050. As such,
folder arms 1048 and male forming members 1050 pre-break inner reinforcing
panel
assemblies 150 along fold lines 168 and 170. Once inner reinforcing panel
assemblies
150 are positioned with respect to outer reinforcing panel assemblies 148
and/or end
panels 108 and/or 114, folder arms 1048 retract to the starting position.
[00147] When folder arms 1048 have retracted, male forming
members 1050 move downward toward blank 10 and female forming members 1052
move upward toward blank 10. Male forming members 1050 contact the inner, or
upper, surface of blank 10 and female forming members 1052 contact the outer,
or
lower, surface of blank 10. When male and female forming members 1050 and 1052
compress toward each other with blank 10 therebetween, corner panels 154 and
158
are rotated about fold lines 170 and 140, 142, 144, or 146 and reinforcing
side panels
156 and 160 are rotated about fold lines 166 and 168. Further, when male and
female
forming members 1050 and 1052 move together, at least inner end panel 162 is
adhered to a respective end panel 108 and 114. Alternatively or additionally,
reinforcing side panels 156 and 160 are adhered together and/or corner panels
154 and
158 are adhered together by male and female forming members 1050 and 1052.
When reinforcing corner assemblies 202 are formed by male and female forming
members 1050 and 1052, partially formed container 928 is formed from blank 10.
Male forming members 1050 move upward and female forming members 1052 move
downward to release partially formed container 928. As partially formed
container
928 is released, inner side rails 1054 contact first reinforcing side panel
156 to
maintain a position of reinforcing corner assembly 202 with respect to the
remainder
of blank 10.
[00148] Stop lug 1042 moves out of the path of partially formed
container 928, and push lug 1040 moves partially formed container 928 into
compression station 958 through breaking station 955 and second gluing station
956.
As partially formed container 928 is moved through breaking station 955,
reinforcing
side panels 156 and 160 are rotated to be at an acute angle to end panel 108
and/or
-48-
CA 02740182 2011-05-13
80006-00971
114 by guide bars 1060 and miter plates 1061. While partially formed container
928
is transported through breaking station 955 and second gluing station 956,
second
gluer 1062 applies adhesive to first reinforcing side panels 156, as described
above.
Pusher arm 1080 engages trailing top edge 112 or 118 of blank 10 to move
partially
formed container 928 into compression station 958 and over plunger opening
1110.
Because reinforcing corner assemblies 202 have been over-broken, reinforcing
corner
assemblies 202 do not un-form during transport to and/or through compression
station
958. Further, as partially formed container 928 is transported to compression
station
958, support bars 1109 maintain positions of reinforcing corner assemblies 202
to
prevent glue on first reinforcing side panels 156 from being removed and/or
displaced.
[00149] Plunger 1100 moves downward from the upper position
toward the lower position to contact interior surface 12 of bottom panel 24
using
vertical actuator 1124. Plunger 1100 pushes bottom panel 24 into and through
plunger opening 1110. End panel plows 1104 and side panel plows 1102 are in
the
forming position as partially formed container 928 is pushed through plunger
opening
1110. End panel plows 1104 fold end panels 108 and 114 to be perpendicular to
bottom panel 24 and side panel plows 1102 fold side panels 22 and 26 to be
perpendicular to bottom panel 24 as bottom panel 24 is forced downward. As end
panels 108 and 114 are rotated, reinforcing corner assemblies 202 are also
rotated into
position. In a particular embodiment, support bars 1109 contact exterior
surface 14 of
first reinforcing side panels 156 to prevent the glue from being removed from
first
reinforcing side panels 156 as reinforcing corner assemblies 202 are moved
into
position.
[00150] Further, glue rollers 1140 press interior surface 12 of side
panels 22 and 26 into contact with adhesive on first reinforcing side panels
156 as
partially formed container 928 is moved downward. Glue rollers 1140 apply a
force
to side panels 22 and/or 26 adjacent to first reinforcing side panels 156 as
plunger
1100 forces bottom panel 24 downward. Side panels 22 and 26 are forced into
-49-
CA 02740182 2011-05-13
80006-00971
contact with the adhesive on first reinforcing side panels 156 by glue roller
1140 and
plunger 1100.
[00151] Corner pushers 1106 are actuated to contact corner walls
210, 212, 214, and/or 216 when bottom panel 24 reaches the bottom of plunger
opening 1110. When machine 900 forms a container from blank 300 and/or 500,
corner pushers 1106 move toward each outer reinforcing corner panel 302, 304,
306,
and 308 (shown in Figures 5 and 9) and apply a force to exterior surface 14
thereof.
The applied force secures outer reinforcing corner panels 302, 304, 306, and
308 to
respective corner panels 154, which has adhesive applied thereto in second
gluing
station 956. In the exemplary embodiment, adhesive is applied to interior
surface 12
of at least one outer reinforcing corner panel 302, 304, 306, and/or 308
and/or exterior
surface 14 of corner panel 154. Corner pushers 1106 are controlled to rotate
interior
surface 12 of outer reinforcing corner panel 302, 304, 306, and/or 308 toward
exterior
surface 14 of corner panel 154 and to press outer reinforcing corner panel
302, 304,
306, and/or 308 into contact with corner panel 154 to secure outer reinforcing
corner
panel 302, 304, 306. and/or 308 to a respective corner panel 154 using the
adhesive.
[00152] Container 200 is then formed from blank 10. At any suitable
time during formation of container 200 from blank 10, a second blank 10 may be
removed from hopper 940 to form a second container 200. As such, the method
may
be performed to continuously form containers 200 using machine 900. After
container 200 is formed, end panel plows 1104, side panel plows 1102, and/or
corner
pushers 1106 secure container 200 within plunger opening 1110. Plunger 1100
retracts upwardly out of cavity 224 of container 200 to the upper position,
end panel
plows 1104, side panel plows 1102, and/or corner pushers 1106 move to outer
positions. As such, container 200 is released from plunger opening 1110 to
fall
downward to exit conveyor 922. Exit conveyor 922 transports container 200 from
plunger opening 1110 and/or forming station 908. More specifically, exit
conveyor
922 extends from ejection station 910 into the bottom of compression station
958 for
receiving container 200 from plunger 1100 and transferring container 200 from
forming station 908 to ejection station 910. When machine 900 forms a
container
-50-
CA 02740182 2011-05-13
80006-00971
having top panels, the container is ejected from machine 900 without the top
panels
rotated into position such that the container is configured to have a product
placed
therein. Container 200 can then be filled with a product and transported to a
machine
that folds top panels 20 and 28 and secures container 200 in the closed
position. The
machine can also tape container 200 in the closed position.
[00153] The above-described blanks and containers provide a
reinforcing polygonal container. More specifically, the embodiments described
herein provide an octagonal container having reinforced corner walls, side
walls, and
end walls for storing and/or transporting a product therein. Further, the
embodiments
described herein provide a polygonal container having a top wall. More
specifically,
the top wall may be formed from top panels emanating from the end walls of the
container. The top wall may be a full top wall covering substantially the
entire cavity
of the container or may be a partial top wall, such as top shoulders, that
allows access
to the cavity of the container when the top wall is formed. Moreover, the
embodiments described herein include an outer reinforcing panel to provide
further
support to the containers. Embodiments not including the outer reinforcing
panel may
be preferable when printing is to be applied to the exterior of the container.
Additionally, the blanks and containers described herein may include a support
wall
for additional support of the container when, for example, the containers are
stacked.
The support wall may also act as a partition or divider for the cavity of the
container.
[00154] The containers described herein include stacking tabs that
limit movement between stacked containers and secure the top panels to the end
walls. More specifically, the stacking tabs extend through locking slots
defined
through the top panels and fit within stacking slot defined in end walls of an
upper
container. The stacking tabs are formed with a double thickness of material to
provide strength to the stacking tabs.
[00155] The machine described herein facilitates forming containers
from the above-described blanks. More specifically, the machine more quickly
and
easily forms the containers, as compared to a person manually forming the
containers
-51-
CA 02740182 2011-05-13
80006-00971
from the blanks. As such, the machine facilitates producing many containers in
a
shorter time period, as compared to manual construction of the containers.
Further,
the above-described machine facilitates automating the method for forming a
container from a blank such that cost and time for producing a container is
reduced as
compared to manually forming the containers.
[00156] Exemplary embodiments of a container formed to contain a
product therein and blanks for making the same are described above in detail.
The
blanks and the container are not limited to the specific embodiments described
herein,
but rather, components of the blanks and/or the container may be utilized
independently and separately from other components described herein. For
example,
the blanks may also be used in combination with other types of product, and is
not
limited to practice with only the cylindrical products, as described herein.
Rather, the
exemplary embodiment can be implemented and utilized in connection with many
other container applications.
[00157] Although specific features of various embodiments of the
invention may be shown in some drawings and not in others, this is for
convenience
only. In accordance with the principles of the invention, any feature of a
drawing
may be referenced and/or claimed in combination with any feature of any other
drawing.
[00158] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person skilled in
the art to
practice the invention, including making and using any devices or systems and
performing any incorporated methods. The patentable scope of the invention is
defined by the claims, and may include other examples that occur to those
skilled in
the art. Such other examples are intended to be within the scope of the claims
if they
have structural elements that do not differ from the literal language of the
claims, or if
they include equivalent structural elements with insubstantial differences
from the
literal language of the claims.
-52-
