REINFORCED POLYGONAL CONTAINERS AND BLANKS FOR MAKING THE SAME

• US 20140246484A1
• Filed: 05/09/2014
• Published: 09/04/2014
• Est. Priority Date: 05/07/2008
• Status: Active Grant

• Current Assignee: WestRock Shared Services, LLC (WestRock Company)
• Original Assignee: Rock-Tenn Shared Services, LLC (WestRock Company)
• Inventors: Smith, Kenneth Charles, Armstrong, Maureen Ann
• Granted Patent: US 9,764,524 B2
• Time in Patent Office: Days
• US Class Current: 229/108
• CPC Class Codes: B31B 2100/00 Rigid or semi-rigid containers made by folding single-piece sheets, blanks or webs
• CPC Class Codes: B31B 2100/0024 having all side walls attached to the bottom
• CPC Class Codes: B31B 2120/502 having integral corner posts or reinforcements
• CPC Class Codes: B31B 50/066 from above a magazine
• CPC Class Codes: B31B 50/07 by air pressure or suction
• CPC Class Codes: B31B 50/26 Folding sheets, blanks or webs
• CPC Class Codes: B31B 50/28 around mandrels, e.g. for forming bottoms
• CPC Class Codes: B31B 50/282 involving stripping-off formed boxes from mandrels
• CPC Class Codes: B31B 50/44 by plungers moving through folding dies
• CPC Class Codes: B31B 50/52 by reciprocating or oscillating members, e.g. fingers by plungers moving through folding dies B31B50/44
• CPC Class Codes: B31B 50/81 Forming or attaching accessories, e.g. opening devices, closures or tear strings
• CPC Class Codes: B65D 5/0015 the container being formed by folding up portions connected to a central panel
• CPC Class Codes: B65D 5/0025 the corner posts being formed as a prolongation of a doubled-over extension of the side walls
• CPC Class Codes: B65D 5/003 having ledges formed by extensions of the side walls B65D5/0045 and B65D5/0065 take precedence
• CPC Class Codes: B65D 5/4295 Ventilating arrangements, e.g. openings, space elements
• CPC Class Codes: B65D 5/443 Integral reinforcements, e.g. folds, flaps double walls B65D5/02
• CPC Class Codes: B65D 5/4608 Handgrip holes
• CPC Class Codes: B65D 5/48018 formed by folding extensions of side panels of a "cross-like" body blank B65D5/4801 takes precedence
• CPC Class Codes: B65D 5/6629 the lid being formed by two mating halves joined to opposite edges of the container body
• CPC Class Codes: B65D 5/6644 the lid-halves being held in closed position by local tabs or projections at the upper edge of opposite walls of the container body, e.g. by entering within slots provided in the lid-halves

Abstract

A blank of sheet material for forming a polygonal container is provided. The blank includes a bottom panel, two opposing side panels, two opposing end panels, 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, a 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 reinforcing corner panel. The corner panel and the reinforcing corner panel are configured, upon articulation of the blank, to be positioned into face-to-face relationship to form a corner wall of the container extending from a side edge of an end wall of the container to an end edge of a side wall of the container.

Claims

1. 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; 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 comprising;

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;

a 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 reinforcing corner panel,

wherein the corner panel and the reinforcing corner panel are configured, upon articulation of the blank, to be positioned into face-to-face relationship to form a corner wall of the container extending from a side edge of an end wall of the container to an end edge of a side wall of the container.

2. A blank in accordance with claim 1, wherein the reinforcing panel assembly is configured to be attached to an exterior surface of an adjacent side panel of the two side panels when the container is formed.

3. A blank in accordance with claim 1, wherein the corner panel has a first height, and the reinforcing corner panel has a second height that is less than the first height.

4. A blank in accordance with claim 3, wherein the reinforcing corner panel includes opposing top and bottom edges, and the difference between the first height and the second height is substantially equal to a thickness of the bottom panel such that the bottom edge of the reinforcing corner panel rests on the bottom panel when the container is formed.

5. A blank in accordance with claim 1, wherein the corner panel has a first height, and the end panel has a second height that is less than the first height such that the corner panel is positioned in face-to-face relationship with an outer edge of the bottom panel when the container is formed.

6. A blank in accordance with claim 1 further comprising a plurality of reinforcing panel assemblies, wherein one reinforcing panel assembly of the plurality of reinforcing panel assemblies extends from each side edge of each end panel of the two end panels.

7. A blank in accordance with claim 1 further comprising:

an inner reinforcing corner panel extending from a first side edge of a first side panel of the two side panels, the inner reinforcing corner panel configured to be coupled to an exterior surface of the reinforcing corner panel when the container is formed.

8. A blank in accordance with claim 7, wherein the inner reinforcing corner panel has a width that is one of equal to or less than a width of the reinforcing corner panel.

9. A blank in accordance with claim 1 further comprising:

a second reinforcing panel assembly extending from a second side edge of the first end panel;

a third reinforcing panel assembly extending from a first side edge of a second end panel of the two end panels; and

a fourth reinforcing panel assembly extending from a second side edge of the second end panel, each reinforcing panel assembly comprising a corner panel extending from a respective side edge of a respective 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, a 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 reinforcing corner panel, each reinforcing panel assembly configured to be coupled to an exterior surface of said side panels when the container is formed.

10. A blank in accordance with claim 1 further comprising a support panel extending from a side edge of the inner end panel.

11. A polygonal container formed from a blank of sheet material, said container comprising:

a bottom panel;

two opposing side panels, each side panel emanating from a side edge of the bottom panel;

two opposing end panels, each end panel emanating 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 comprising;

a corner panel extending from the first side edge of the first end panel, a first outer reinforcing side panel extending from a side edge of the corner panel, a first inner reinforcing side panel at least partially overlying the first outer reinforcing side panel, and a reinforcing corner panel positioned in face-to-face relationship with the corner panel, the corner panel and the reinforcing corner panel forming a corner wall extending between the first end panel and a first side panel of the two side panels.

12. A polygonal container in accordance with claim 11 further comprising a first inner end panel extending from a side edge of the reinforcing corner panel, the first inner end panel at least partially overlying the first end panel.

13. A polygonal container in accordance with claim 11, wherein at least a portion of the reinforcing panel assembly is attached to an exterior surface of the first side panel.

14. A polygonal container in accordance with claim 13 wherein the first inner reinforcing side panel is adhered to the exterior surface of the first side panel.

15. A polygonal container in accordance with claim 11 wherein the corner panel has a first height and the reinforcing corner panel has a second height that is less than the first height.

16. A polygonal container in accordance with claim 15, wherein the reinforcing corner panel includes opposing top and bottom edges, and the difference between the first height and the second height is substantially equal to a thickness of the bottom panel such that the bottom edge of the reinforcing corner panel rests on the bottom panel.

17. A polygonal container in accordance with claim 11 wherein the corner panel is in a face-to-face relationship with an outer edge of the bottom panel.

18. A polygonal container in accordance with claim 11, wherein the reinforcing corner panel has a width that is one of equal to or less than a width of the corner panel.

19. A polygonal container in accordance with claim 11, further comprising:

a second reinforcing panel assembly extending from a second side edge of the first end panel, wherein at least a portion of the second reinforcing panel assembly is attached to an exterior surface of an adjacent second side panel of the two side panels;

a third reinforcing panel assembly extending from a first side edge of a second end panel of the two end panels, wherein at least a portion of the third reinforcing panel assembly is attached to an exterior surface of the adjacent first side panel of the two side panels, and

a fourth reinforcing panel assembly extending from a second side edge of the second end panel, wherein at least a portion of the fourth reinforcing panel assembly is attached to an exterior surface of the adjacent second side panel of the two side panels.

20. A polygonal container in accordance with claim 11 wherein the first reinforcing panel assembly further comprises:

a first inner end panel extending from a side edge of the reinforcing corner panel, the first inner end panel at least partially overlying the first end panel; and

a support panel extending from a side edge of the first inner end panel, the support panel forming a portion of a first support wall extending from the first end panel into a cavity of said container.

21. A method for forming a polygonal container from a blank of sheet material, the polygonal container including at least five sides, 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, and a reinforcing panel assembly extending from a first side edge of a first end panel of the two end panels, wherein 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, a 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 reinforcing corner panel, said method comprising:

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, said rotating aligning the first and second reinforcing side panels in a substantially face-to-face relationship, the corner panel and the 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;

rotating the first side panel inwardly into a substantially perpendicular relationship with the bottom panel;

rotating the first end panel inwardly into a substantially perpendicular relationship with the bottom panel, the first end panel and inner end panel forming a first end wall of the polygonal container;

rotating the corner panel and the reinforcing corner panel toward the interior surface of the first end panel, the corner panel and the reinforcing corner panel forming a first corner wall of the polygonal container;

rotating the first and second reinforcing side panels toward the interior surface of the first end panel about a fold line connecting the second reinforcing side panel and the reinforcing corner panel and about a fold line connecting the first reinforcing side panel and the corner panel; and

attaching the first side panel to one of the first and second reinforcing side panels to form a first side wall of the container.

22. A method in accordance with claim 21, wherein attaching the first side panel to one of the first and second reinforcing side panels comprises attaching an exterior surface of the second reinforcing side panel to an exterior surface of the first side panel.

23. A method in accordance with claim 21, wherein the blank includes an inner reinforcing corner panel extending from a side edge of the first side panel, said method further comprising attaching an exterior surface of the inner reinforcing corner panel to an interior surface of the reinforcing corner panel, wherein the reinforcing corner panel, the corner panel, and the inner reinforcing corner panel form the first corner wall.

24. A method in accordance with claim 21, wherein the reinforcing corner panel includes opposing top and bottom edges, said method further comprising positioning the bottom edge of the reinforcing corner panel in face-to-face relationship with an interior surface of the bottom panel.

25. A method in accordance with claim 24, further comprising positioning the corner panel in face-to-face relationship with an outer edge of the bottom panel.