Displayable produce container and method for making the same

• US 6,302,323 B1
• Filed: 10/20/2000
• Issued: 10/16/2001
• Est. Priority Date: 10/22/1999
• Status: Expired due to Term

• Current Assignee: Packaging Corporation of America
• Original Assignee: Packaging Corporation of America
• Inventors: Southwell, James D.
• Primary Examiner(s): Elkins, Gary E.
• Application Number:
  US09/693,800
• Time in Patent Office: 361 Days
• Field of Search: 229/164, 229/167, 229/168, 229/171, 229/174, 229/178, 229/915, 493/162, 493/177-182
• US Class Current: 229/164
• CPC Class Codes: B65D 5/0035 the ledges being located between side walls and doubled-over extensions B65D5/0025 takes precedence
• CPC Class Codes: Y10S 229/915 Stacking feature
• CPC Class Codes: Y10S 229/918 Corner construction
• CPC Class Codes: Y10S 229/919 Reinforced wall

Abstract

The present invention provides a stackable open-top container for use in shipping, storing and retail display of produce and other articles. The produce container contains a bottom wall, two side walls and two end walls. The ledges of the side walls of the present invention contain opposed concave curved scores. The produce container is formed by folding the side walls to the outside to achieve structural rigidity. The produce container of the present invention provides for full graphical coverage on all visible surfaces by use of a one-piece blank that is color coated/printed on only one side.

Claims

1. A stackable produce container, comprising a bottom wall, first and second opposing side walls, and first and second opposing end walls, each of said first and second side walls including a bowed inner side panel and an outer side panel hingedly connected to each other along a rigid concave-shaped ledge, and each of said first and second end walls including an inner end panel and an outer end panel hingedly connected to each other along a rigid transverse edge.

2. The produce container of claim 1, further comprising a first pair of minor end flaps extending from opposing ends of said inner end panels and a second pair of minor end flaps extending from opposing ends of the other of said inner end panels, one of said first pair of minor end flaps and one of said second pair of minor end flaps being captured between said inner side panel and said outer side panel of said first side wall, the other of said first pair of minor end flaps and the other of said second pair of flaps being captured between said inner side panel and said outer side panel of said second side wall.

3. The produce container of claim 2 further comprising a plurality of minor side flaps extending from opposing ends of said outer side panel, said plurality of minor side flaps forming the outer corrugation layer of said produce container adjacent the corners of said produce container.

4. The produce container of claim 3, further including a plurality of stacking tabs and a plurality of stacking receptacles.

5. The produce container of claim 2, wherein each of said end walls forms at least one small vent spaced along the lengths of said end walls adjacent said bottom wall, each of said first and second end walls further forming a respective large opening above said small vent.

6. A one-piece blank for forming a stackable produce container, comprising a central rectangular panel having a first pair of opposing edges and a second pair of opposing edges, a first inner side panel hingedly connected to one of said first pair of opposing edges, a second inner side panel hingedly connected to the other of said first pair of opposing edges, a first inner end panel hingedly connected to one of said second pair of opposing edges, a second inner end panel hingedly connected to the other of said second pair of opposing edges, a first outer side panel hingedly connected to said first inner side panel along a pair of curved score lines forming a first concave-shaped ledge, a second outer side panel hingedly connected to said second inner side panel along a second pair of curved score lines forming a second concave-shaped ledge, a first outer end panel hingedly connected to said first inner end panel, and a second outer end panel hingedly connected to said second end panel.

7. The one-piece blank of claim 6, further including a first pair of minor side flaps extending from opposing ends of said first outer side panel, a second pair of minor side flaps extending from opposing ends of said second outer side panel, a first pair of minor end flaps extending from opposing ends of said first inner end panel, and a second pair of minor end flaps extending from opposing ends of said second inner end panel.

8. A method of forming a stackable produce container, said method comprising the steps of:

providing a one-piece blank including a bottom wall having a first pair of opposing edges and a second pair of opposing edges, a first inner side panel being hingedly connected to one of said first pair of opposing edges along fold lines, a second inner side panel being hingedly connected to the other of said first pair of opposing edges along fold lines, a first inner end panel being hingedly connected to one of said second pair of opposing edges along fold lines, a second inner end panel being hingedly connected to the other of said second pair of opposing edges along fold lines, said first inner side panel being hingedly connected to a first outer side panel, said second inner side panel being hingedly connected to a second outer side panel, said first inner end panel being hingedly connected to a first outer end panel, said second inner end panel being hingedly connected to a second outer end panel, a first pair of minor side flaps extending from opposing ends of said first outer side panel, a second pair of minor side flaps extending from opposing ends of said second outer side panel, a first pair of minor end flaps extending from opposing ends of said first inner end panel, and a second pair of minor end flaps extending from opposing ends of said second inner end panel,

folding said inner side panels upward approximately 90 degrees relative to said bottom wall;

folding said inner end panels upward approximately 90 degrees relative to said bottom wall;

folding said first pair of minor end flaps and said second pair of minor end flaps approximately 90 degrees relative to said end walls in an inward direction so that each minor end flap is adjacent one of said inner side panels;

folding said first outer side panel in a downward and outward direction to form a first ledge and secure two minor flaps between said first outer side panel and said first inner side panel and folding said second outer side panel in an outward direction to form a second ledge and secure two minor flaps between said second outer side panel and said second inner side panel;

folding said first pair of minor side flaps and said second pair of minor side flaps approximately 90 degrees relative to said side walls in an inward direction so that each minor side flap is adhered to said end walls; and

folding said first outer end panel in a downward and outward direction to form a first end edge and folding said second outer end panel in a downward and outward direction to form a second end edge.

9. The method of claim 8, where said first outer end panel is attached to said first inner end panel and said second outer end panel is attached to said second inner end panel using adhesive.

10. The method of claim 8, where said first outer end panel is attached to said first inner end panel and said second outer end panel is secured to said second inner end panel using hand set locks.