Containers with tapered sidewalls and stacking tabs

• US 7,677,434 B2
• Filed: 12/19/2005
• Issued: 03/16/2010
• Est. Priority Date: 03/19/2002
• Status: Active Grant

• Current Assignee: International Paper Company
• Original Assignee: International Paper Company
• Inventors: Fry, Stanley L.
• Primary Examiner(s): Mai; Tri M
• Application Number:
  US11/303,898
• Publication Number:
  US 20060091194A1
• Time in Patent Office: 1,548 Days
• Field of Search: 229/174, 229/112, 229/164, 229/918, 229/919, 229/917, 229/191, 229/169, 229/170, 229/175
• US Class Current: 229/174
• CPC Class Codes: B65D 5/0015 the container being formed by folding up portions connected to a central panel
• CPC Class Codes: B65D 5/2047 trapezoidal, e.g. to form a body with diverging side walls B65D5/2033 takes precedence
• CPC Class Codes: Y10S 229/915 Stacking feature

Abstract

A stackable container has a bottom panel, upstanding sidewalls, upstanding end walls, and an open top. According to one aspect of the invention, narrow reinforcing flaps are attached to the upper edge of at least one of the side and end walls, defining a stacking ledge and reinforcing the walls against outward bulge. The reinforcing flaps extend over only a small portion of the height of the side or end wall, and corner post flaps extend from opposite ends of the reinforcing flaps, extending diagonally across interior corners of the container. According to another aspect, the side and/or end walls lean inwardly, defining a narrower footprint at the top of the container than at the bottom. In a specific embodiment one of the walls leans in more than the other. According to a further aspect, an indexing and aligning tab extends upwardly from an upper edge of the container, and a complementary notch is formed in a lower edge for receiving the tab when the containers are stacked. According to a still further aspect, stacking tabs extend upwardly from the upper edge of the container, and slots are formed in the bottom panel for receiving the tabs when containers are stacked. Locking flaps extend into the slots to frictionally engage and hold the tabs.

Claims

1. A container comprising a base panel, a pair of opposing sidewalls, a pair of opposing end walls, and an open top, said container having an interior space and formed from a single unitary blank, wherein:

the sidewalls and end walls each have an upper edge;

a relatively narrow reinforcing flap is foldably joined to the upper edge of at least one of said pair of opposing sidewalls and said pair of opposing end walls, said reinforcing flap having a width from a top edge to a bottom edge thereof that extends over only a minor portion of the height of the associated side wall, said reinforcing flap is joined to the upper edge of one of said sidewalls;

a central portion of the upper edge of the opposite sidewall is recessed over a major portion of the length thereof, leaving relatively short upper edge portions at opposite ends of said opposite sidewall;

short reinforcement pieces are foldably attached to said short upper edge portions, said short reinforcement pieces having a width from an upper edge to a lower edge thereof that is greater than the width of said reinforcing flap from an upper edge to a lower edge thereof;

a small corner post flap is foldably joined to each of opposite ends of said reinforcing flap, said corner post flap being substantially rectangular and having a width from a top edge to a bottom edge thereof that is substantially the same as the width of the associated reinforcing flap and extending diagonally across interior corners of the container at the upper edges of the sidewalls and end walls, in spaced relation to the base panel; and

said container is reinforced by said narrow reinforcing flap and said small corner post flaps, leaving the interior space below said narrow reinforcing flap and small corner post flaps free of additional reinforcing structure, thereby resulting in greater interior space and requiring use of less material in the construction of the container.

2. The container according to claim 1, wherein:

at least one stacking tab extends upwardly from the upper edge of at least one of said pair of opposing sidewalls and said pair of opposing end walls; and

at least one slot is cut into the base panel, said at least one slot being positioned to accept said at least one stacking tab of an adjacently stacked container.

3. A stackable container as claimed in claim 2, wherein:

said at least one of said pair of sidewalls and said pair of end walls subtend an acute angle with the base panel, whereby said at least one of said sidewalls and said end walls lean inwardly.

4. A stackable container as claimed in claim 3, wherein:

said at least one stacking tab extends upwardly from the upper edge of said sidewalls at the same angle therewith.

5. The container according to claim 2, wherein:

a said reinforcing flap is attached in overlapping relationship to an upper inner surface of each of said pair of opposing sidewalls to form a ledge, the reinforcing flap further comprising at least one reinforcement tab and said at least one corner post flap, wherein the at least one reinforcement tab lies flush against the at least one stacking tab, and the corner flap extends at a diagonal away from the first at least one sidewall toward one of the opposing end walls.

6. A stackable container as claimed in claim 1, wherein:

said reinforcing flap is on each of said sidewalls.

7. A stackable container as claimed in claim 6, wherein:

said sidewalls subtend an acute angle with said base panel.

8. A stackable container as claimed in claim 1, wherein:

one of said pair of sidewalls and said pair of end walls subtend an acute angle with the base panel, whereby said one of said pair of sidewalk and said pair of end walls lean inwardly; and

at least one stacking tab extends upwardly from the upper edge of said one of said pair of sidewalls and said pair of end walls at the same angle therewith.

9. A stackable container as claimed in claim 1, wherein:

side flaps are foldably joined to opposite ends of each said sidewall, said side flaps having upper and lower edges; and

an aligning tab on one of the upper and lower edges and a complemental aligning notch on the opposite edge, the aligning tab on one container being received in the aligning notch in an adjacent stacked container to align the containers.