Wraparound Shipping Box Blank with System and Method of Forming Blank into a Shipping Case

• US 20140374303A1
• Filed: 06/21/2014
• Published: 12/25/2014
• Est. Priority Date: 06/21/2013
• Status: Active Grant

• Current Assignee: Greenone Logistics, LLC
• Original Assignee: Global Logistics Solutions Corp.
• Inventors: Martinez, Juan Carlos
• Granted Patent: US 9,896,234 B2
• Time in Patent Office: Days
• US Class Current: 206/508
• CPC Class Codes: B31B 50/734 interengaging tongues and slots
• CPC Class Codes: B65B 5/024 for making containers from preformed blanks
• CPC Class Codes: B65D 5/001 stackable
• 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 5/0281 the tubular body presenting double or multiple walls for thermal insulating purposes B65D81/3853
• CPC Class Codes: B65D 5/4266 Folding lines, score lines, crease lines

Abstract

A corrugated paperboard wraparound blank for forming a shipping case is provided, including five wall panels and four sets of end flaps connected via fold lines, at least two sets of stacking tabs, and at least two corresponding sets of receiving slots for receiving the stacking tabs. The wraparound blank is formed of a heavier material than a conventional blank, which would typically be difficult for automatic packaging equipment to form into a case, but the fold lines are creased with optional perforations or scoring. An optional modification aiding folding is presented for conventional case packers. The heavier fiberboard better supports and protects an inner product, such as cartons or paper bottles of liquids and reduces damage to the cap and neck. The heavier material in combination with the stacking tabs allows an increase in stacking height, thereby reducing transportation costs.

Claims

1. A shipping case blank 10A, comprising a single sheet comprising:

a front-wall panel 20 having a front longitudinal edge 25 and an opposing front longitudinal border, opposing right and left front lateral borders, at least two front stacking tabs 21, comprising at least a right front stacking tab 21 and a left front stacking tab 21, protruding from said front longitudinal edge 25, and at least two front-wall cutout opening edges 28 disposed along said front longitudinal border;

a right front end flap 22 connected to said front-wall panel 20 along a right first lateral fold line 26 at said right front lateral border of said front-wall panel 20;

a left front end flap 24 connected to said front-wall panel 20 along a left second lateral fold line 27 at said left front lateral border of said front-wall panel 20;

a base-wall panel 30 having opposing first and second base longitudinal borders, opposing right and left base lateral borders, at least two first base-wall cutout opening edges 33 disposed along said first base longitudinal border, and at least two second base-wall cutout opening edges 38 disposed along said second base longitudinal border, wherein said first base longitudinal border is connected to said front longitudinal border by a first longitudinal fold line 35;

wherein said at least two front-wall cutout opening edges 28 in combination with said at least two first base-wall cutout opening edges 33 define at least a front right and a front left receiving slot 29;

a third end flap 32 connected to said base-wall panel 30 along a right third lateral fold line 36 at said first base lateral border of said base-wall panel 30;

a fourth end flap 34 connected to said base-wall panel 30 along a left fourth lateral fold line 37 at said second base lateral border of said base-wall panel 30;

a back-wall panel 40 having opposing first and second back longitudinal borders, opposing first and second back lateral borders, at least two back-wall cutout opening edges 48 disposed along said first back longitudinal border, and at least two back stacking tabs 41, comprising at least a right back stacking tab 41 and a left back stacking tab 41, protruding from said second back longitudinal border;

wherein said back-wall panel 40 is connected to said base-wall panel 30 at first back longitudinal border by a third longitudinal fold line 45;

wherein said at least two back-wall cutout opening edges 48 in combination with said at least two second base-wall cutout opening edges 38 define at least a back right and a back left receiving slot 49;

a fifth end flap 42 connected to said back-wall panel 40 along a right fifth lateral fold line 46 at said first back lateral border of said back-wall panel 40;

a sixth end flap 44 connected to said back-wall panel 40 along a left sixth lateral fold line 47 at said second back lateral border of said back-wall panel 40;

an upper-wall panel 50 having opposing first and second upper-wall longitudinal borders, opposing first and second upper-wall lateral borders, at least two first upper-wall cutout opening edges 43 disposed along said first upper-wall longitudinal border, and at least two second upper-wall cutout opening edges 53 disposed along said second upper-wall longitudinal border;

wherein said upper-wall panel 50 is connected at said first upper-wall longitudinal border by a third longitudinal fold line 55 to said back-wall panel 40; and

wherein said at least two first upper-wall cutout opening edges 43 define the top edges of at least two back right and back left stacking tabs 41;

a seventh end flap 52 connected to said upper-wall panel 50 along a right seventh lateral fold line 56 at said first upper-wall lateral border of said upper-wall panel 50;

an eighth end flap 54 connected to said upper-wall panel 50 along a left eighth lateral fold line 57 at said second upper-wall lateral border of said upper-wall panel 50;

wherein said first end flap 22, said second end flap 24, said third end flap 32, said fourth end flap 34, said fifth end flap 42, said sixth end flap 44, said seventh end flap 52, and said eighth end flap 54 are inwardly foldable to form opposing first and second end walls 75 to at least partially close the first and second ends of said shipping case 10; and

a lapping-wall panel 60 having a lapping-wall longitudinal border, a lapping-wall longitudinal edge, opposing first and second lapping-wall lateral edges, and at least two lapping-wall cutout opening edges 68 disposed along said lapping-wall longitudinal border;

wherein said at least two lapping-wall cutout opening edges 68 in combination with said at least two second upper-wall cutout opening edges 53 define at least a right and left channel slot 69;

wherein said lapping-wall panel 60 is connected to said upper-wall panel 50 at said lapping-wall longitudinal border at a fourth longitudinal fold line 65; and

wherein said first longitudinal fold line 35, said second longitudinal fold line 45, said third longitudinal fold line 55, said fourth longitudinal fold line 65, said first lateral fold line 26, said second lateral fold line 27, said third lateral fold line 36, said fourth lateral fold line 37, said fifth lateral fold line 46, said sixth lateral fold line 47, said seventh lateral fold line 56, and said eighth lateral fold line 57 comprise creases.

2. The shipping case 10 as recited in claim 1, wherein said creases include perforated cuts interposed with non-perforated sections.

3. The shipping case 10 as recited in claim 2, wherein:

said perforated cuts are between 3 and 15 mm in length; and

said non-perforated sections are between 3 and 15 mm in length.

4. The shipping case 10 as recited in claim 1, wherein:

the width at the base of said right front stacking tab 21 is from 5% to 25% of the width between said first lateral fold line 26 and said second lateral fold line 27; and

the width at the base of said left front stacking tab 21 is from 5% to 25% of the width between said first lateral fold line 26 and said second lateral fold line 27.

5. The shipping case 10 as recited in claim 1, wherein:

the width at the base of said right front stacking tab 21 is from 9% to 20% of the width between said first lateral fold line 26 and said second lateral fold line 27; and

the width at the base of said left front stacking tab 21 is from 9% to 20% of the width between said first lateral fold line 26 and said second lateral fold line 27.

6. The shipping case 10 as recited in claim 1, wherein:

said right front stacking tab 21 is inset a distance of 35 to 90 mm from said first lateral fold line 26; and

said left front stacking tab 21 is inset a distance of 35 to 90 mm from said second lateral fold line 27.

7. The shipping case 10 as recited in claim 1, wherein:

said first end flap 22 and said second end flap 24 extend laterally from said front-wall panel 20 a distance of from 50 to 100 mm;

said third end flap 32 and said fourth end flap 34 extend laterally from said base-wall panel 30 a distance of from 50 to 100 mm;

said fifth end flap 42 and said sixth end flap 44 extend laterally from said back-wall panel 40 a distance of from 50 to 100 mm; and

said seventh end flap 52 and said eighth end flap 54 extend laterally from said upper-wall panel 50 a distance of from 50 to 100 mm.

8. The shipping case 10 as recited in claim 1, wherein said wraparound blank 10A comprises c-flute, single wall, mid-heavy corrugated fiberboard paper.

9. The shipping case 10 as recited in claim 8, wherein said corrugated fiberboard paper has a minimum burst resistance test of at least 250 pounds per square inch.

10. The shipping case 10 as recited in claim 1, wherein said creases comprise indentations and scoring.

11. A shipping case 10, comprising a foldable wraparound blank 10A formed of a single sheet of corrugated fiberboard paper having a minimum burst resistance test of at least 250 pounds per square inch, said foldable wraparound blank 10A comprising:

a front-wall panel 20 having a front longitudinal edge 25 and an opposing front longitudinal border, opposing right and left front lateral borders, at least two front stacking tabs 21, comprising at least a right front stacking tab 21 and a left front stacking tab 21, protruding from said front longitudinal edge 25, and at least two front-wall cutout opening edges 28 disposed along said front longitudinal border;

a right front end flap 22 connected to said front-wall panel 20 along a right first lateral fold line 26 at said right front lateral border of said front-wall panel 20;

a left front end flap 24 connected to said front-wall panel 20 along a left second lateral fold line 27 at said left front lateral border of said front-wall panel 20;

wherein the width at the base of said right front stacking tab 21 is from 5% to 25% of the width between said first lateral fold line 26 and said second lateral fold line 27 fold line 27;

wherein the width at the base of said left front stacking tab 21 is from 5% to 25% of the width between said first lateral fold line 26 and said second lateral fold line 27;

wherein said right front stacking tab 21 is inset a distance of 35 to 90 mm from said first lateral fold line 26; and

wherein said left front stacking tab 21 is inset a distance of 35 to 90 mm from said second lateral fold line 27;

a base-wall panel 30 having opposing first and second base longitudinal borders, opposing right and left base lateral borders, at least two first base-wall cutout opening edges 33 disposed along said first base longitudinal border, and at least two second base-wall cutout opening edges 38 disposed along said second base longitudinal border, wherein said first base longitudinal border is connected to said front longitudinal border by a first longitudinal fold line 35;

wherein said at least two front-wall cutout opening edges 28 in combination with said at least two first base-wall cutout opening edges 33 define at least a front right and front left receiving slot 29;

a third end flap 32 connected to said base-wall panel 30 along a right third lateral fold line 36 at said first base lateral border of said base-wall panel 30;

a fourth end flap 34 connected to said base-wall panel 30 along a left fourth lateral fold line 37 at said second base lateral border of said base-wall panel 30;

a back-wall panel 40 having opposing first and second back longitudinal borders, opposing first and second back lateral borders, at least two back-wall cutout opening edges 48 disposed along said first back longitudinal border, and at least two back stacking tabs 41, comprising at least a right back stacking tab 41 and a left back stacking tab 41, protruding from said second back longitudinal border;

wherein said back-wall panel 40 is connected to said base-wall panel 30 at first back longitudinal border by a third longitudinal fold line 45;

wherein said at least two back-wall cutout opening edges 48 in combination with said at least two second base-wall cutout opening edges 38 define at least a back right and back left receiving slot 49;

a fifth end flap 42 connected to said back-wall panel 40 along a right fifth lateral fold line 46 at said first back lateral border of said back-wall panel 40;

a sixth end flap 44 connected to said back-wall panel 40 along a left sixth lateral fold line 47 at said second back lateral border of said back-wall panel 40;

an upper-wall panel 50 having opposing first and second upper-wall longitudinal borders, opposing first and second upper-wall lateral borders, at least two first upper-wall cutout opening edges 43 disposed along said first upper-wall longitudinal border, and at least two second upper-wall cutout opening edges 53 disposed along said second upper-wall longitudinal border; and

wherein said upper-wall panel 50 is connected at said first upper-wall longitudinal border by a third longitudinal fold line 55 to said back-wall panel 40;

a seventh end flap 52 connected to said upper-wall panel 50 along a right seventh lateral fold line 56 at said first upper-wall lateral border of said upper-wall panel 50;

an eighth end flap 54 connected to said upper-wall panel 50 along a left eighth lateral fold line 57 at said second upper-wall lateral border of said upper-wall panel 50;

wherein said first end flap 22, said second end flap 24, said third end flap 32, said fourth end flap 34, said fifth end flap 42, said sixth end flap 44, said seventh end flap 52, and said eighth end flap 54 are inwardly foldable to form opposing first and second end walls 75 to at least partially close the first and second ends of said shipping case 10; and

a lapping-wall panel 60 having a lapping-wall longitudinal border, a lapping-wall longitudinal edge, opposing first and second lapping-wall lateral edges, at least two lapping-wall cutout opening edges 68 disposed along said lapping-wall longitudinal border;

wherein said at least two lapping-wall cutout opening edges 68 in combination with said at least two second upper-wall cutout opening edges 53 define at least a right and left channel slot 69;

wherein said lapping-wall panel 60 is connected to said upper-wall panel 50 at said lapping-wall longitudinal border at a fourth longitudinal fold line 65; and

wherein said first longitudinal fold line 35, said second longitudinal fold line 45, said third longitudinal fold line 55, said fourth longitudinal fold line 65, said first lateral fold line 26, said second lateral fold line 27, said third lateral fold line 36, said fourth lateral fold line 37, said fifth lateral fold line 46, said sixth lateral fold line 47, said seventh lateral fold line 56, and said eighth lateral fold line 57 comprise perforated cuts interposed with non-perforated sections.

12. The shipping case 10 as recited in claim 11, wherein, upon forming said wraparound blank 10A into said shipping case 10:

said lapping-wall panel 60 is adhered to said front-wall panel 20; and

said at least two front stacking tabs 21 extend through said at least a front right and front left receiving slot 29.

13. The shipping case 10 as recited in claim 11, wherein said corrugated fiberboard paper comprises a c-flute, single wall, mid-heavy fiberboard.

14. The shipping case 10 as recited in claim 11, wherein:

said perforated cuts are between 3 and 15 mm in length; and

said non-perforated sections are between 3 and 15 mm in length.

15. A method of forming a shipping case 10, comprising:

providing to a case packer multiple foldable wraparound blanks 10A, wherein each of said multiple foldable wraparound blanks 10A comprises;

a front-wall panel 20 comprising at least two front stacking tabs 21, at least two front-wall cutout opening edges 28 defining a first portion of at least two front receiving slots 29, and opposing right 22 and left 24 front-wall end flaps;

a base-wall panel 30 comprising at least two first base-wall cutout opening edges 33 defining a second portion of said at least two front receiving slots 29, at least two second base-wall cutout opening edges 38 defining a first portion of at least two rear receiving slot 49, and opposing right 32 and left 34 base-wall panel end flaps;

a back-wall panel 40 comprising at least two back-wall cutout opening edges 48 defining a second portion of said at least two rear receiving slots 49, at least two back stacking tabs 41, and opposing right 42 and left 44 back-wall panel end flaps;

an upper-wall panel 50 comprising at least two first upper-wall cutout opening edges 43, at least two second upper-wall cutout opening edges 49 defining the edges of a first portion of at least two channel slots 69, and opposing right 52 and left 54 upper-wall panel end flaps; and

a lapping-wall panel 60 comprising at least two lapping-wall cutout opening edges 68 defining a second portion of said at least two channel slots 69;

selecting a single wraparound blank 10A from said multiple foldable wraparound blanks 10A;

partially folding said single wraparound blank 10A;

wherein said base-wall panel 30 is positioned downward, said front-wall panel 20 extends upwardly, said back-wall panel 40 extends upwardly, and said stacking tabs 21 extend upwardly;

receiving a set of product containers into the partially folded said single wraparound blank 10A;

folding said upper-wall panel 50 downward in a manner to cause said at least two front stacking tabs 21 to extend upwardly and protrude through said two at least two channel slots 69 and in a manner to cause said at least two back stacking tabs 41 to extend upwardly;

applying hot melt adhesive to adhere said lapping-wall panel 60 to said front-wall panel 20; and

applying hot melt adhesive to adhere said opposing right 22 and left 24 front-wall end flaps, said opposing right 32 and left 32 base-wall panel end flaps, said opposing right 42 and left 44 back-wall panel end flaps, and said opposing right 52 and left 54 upper-wall panel end flaps to form the opposing end walls 75 of said shipping case 10.

16. The method of forming a shipping case 10 as recited in claim 15, wherein a left pressure plate 66 and a right pressure plate 77 of said case packer are cut in a manner that allows shipping case 10 to be folded with no adverse effect on said at least two front stacking tabs 21 or on said at least two back stacking tabs 41.

17. The method of forming a shipping case 10 as recited in claim 15, wherein a left pressure plate 66 of said case packer comprises a left rearward area 86 and a left forward area 96;

wherein a right pressure plate 77 of said case packer comprises a right rearward area 87 and a right forward area 97;

further comprising;

cutting a corner of said left rearward area 86 along left notch edge 80 to define a left notch;

cutting a corner of said right rearward area 87 along right notch edge 85 to define a right notch;

cutting a left U-shape cutout into said left forward area 96 along left U-shaped edge 12; and

cutting a right U-shape cutout into said right forward area 97 along right U-shaped edge 95.

18. The method of forming a shipping case 10 as recited in claim 17, wherein:

the width of said right U-shape cutout defined by said right U-shaped edge 95 is between 15 to 30 mm;

the width of said left U-shape cutout defined by said left U-shaped edge 12 is between 15 to 30 mm;

the depth of said right U-shape cutout defined by said right U-shaped edge 95 is between 40 to 80 mm;

the depth of said left U-shape cutout defined by said left U-shaped edge 12 is between 40 to 80 mm.

19. The method of forming a shipping case 10 as recited in claim 17, wherein:

the outer edge of said right U-shape cutout defined by said U-shaped edge 95 is 22 to 40 mm from the front edge of said right pressure plate 77; and

the outer edge of said left U-shape cutout defined by said U-shaped edge 12 is 22 to 40 mm from the front edge of said left pressure plate 66.

20. The method of forming a shipping case 10 as recited in claim 17, wherein:

said right notch defined by said right notch edge 85 is sized in width from 5 to 100 mm and in depth from 40 to 80 mm; and

said left notch defined by said left notch edge 80 is sized in width from 5 to 100 mm and in depth from 40 to 80 mm.