Materials for and method for manufacturing retail container and resulting retail container

• US 7,981,017 B2
• Filed: 07/14/2009
• Issued: 07/19/2011
• Est. Priority Date: 03/27/2009
• Status: Active Grant

• Current Assignee: GYRE Innovations, LLC
• Original Assignee: York Container Company
• Inventors: Laughman, Jamie L., Little, Troy
• Primary Examiner(s): Pickett; J. Gregory
• Assistant Examiner(s): DESAI, KAUSHIKKUMAR A
• Application Number:
  US12/502,659
• Publication Number:
  US 20100247272A1
• Time in Patent Office: 735 Days
• Field of Search: 206/509, 206/736, 229/915, 229/919, 229/122.32, 229/122, 229/33, 229/172, 229/164, 493/51, 493/79, 493/93, 493/84, 493/68, 493/69, 493/70
• US Class Current: 493/51
• CPC Class Codes: B31B 2105/00 Rigid or semi-rigid containers made by assembling separate sheets, blanks or webs
• CPC Class Codes: B31B 2105/0025 Making boxes by uniting two U-shaped blanks
• CPC Class Codes: B31B 2110/35 rectangular, e.g. square
• CPC Class Codes: B31B 50/14 Cutting, e.g. perforating, punching, slitting or trimming cutting window openings B31B50/83
• CPC Class Codes: B31B 50/20 Cutting sheets or blanks
• CPC Class Codes: B31B 50/88 Printing; Embossing
• CPC Class Codes: B65D 5/0015 the container being formed by folding up portions connected to a central panel
• CPC Class Codes: B65D 5/0075 Paper elements affixed to the container blank before or during erection
• CPC Class Codes: B65D 5/445 Reinforcements formed separately from the container

Abstract

In accordance with the invention, a method of manufacturing containers such as shipping, display and display ready packaging, for example, and resulting containers and associated preassemblies and blanks are provided, which, when utilized, result in preassemblies that are more easily and quickly assembled into fully assembled containers including a plurality of stacking shoulder provided at opposing ends of the containers.

Claims

1. A method of manufacturing a container, the method comprising:

cutting a primary blank including a plurality of lateral panels and at least one bottom panel configured to provide an exterior of the container;

cutting a plurality of supplementary blanks each including a plurality of major sections and at least one sub-section; and

affixing one of the major sections of each supplementary blank to the corresponding opposing lateral panel of the primary blank and the at least one sub-section of each supplementary blank to the at least one bottom panel of the primary blank,

wherein as the container is finally assembled, an exterior of the container is formed by the plurality of lateral panels and the at least bottom panel of the primary blank, and

wherein a plurality of stacking shoulders are formed automatically by movement of the primary blanks causing movement of the supplementary blanks at opposing lateral panels of an interior of the container, and the plurality of stacking shoulders are formed as part of the final assembly of the primary blank as the exterior of the container.

2. The method of claim 1, wherein the plurality of lateral panels of the primary blank include a front side panel, back side panel and first and second end panels.

3. The method of claim 2, wherein one of the major sections of each of the plurality of supplementary blanks is affixed to either a first end panel or a second end panel of the plurality of lateral panels of the primary blank.

4. The method of claim 1, wherein the supplementary blanks each includes a plurality of keys, each configured to be erected upon one of the stacking shoulders as the stacking shoulders are formed during final assembly of the primary blank as the exterior of the container.

5. The method of claim 1, wherein the container includes a plurality of keyhole apertures on the at least one lateral panel of the primary blank following final assembly of the primary blank as the exterior of the container.

6. The method of claim 1, wherein the primary blank is affixed to the supplementary blanks via application of an adhesive.

16. The method of claim 1, wherein the supplemental blanks each includes first and second major sections joined by a shoulder section, and the first major section is affixed to the lateral panel of the primary blank and the at least one sub-section extends from the second major section.

17. The method of claim 16, wherein the supplemental blanks each includes lateral sub-sections extending from a respective lateral edge of the second major section and the lateral sub-sections lie adjacent a corresponding adjacent lateral panel of final assembly of the primary blank.

18. The method of claim 16, wherein the first and second major sections of the supplemental blanks have a height greater than the height of the lateral panel to which the first major section is affixed.

19. The method of claim 16, wherein the first major section of the supplemental blanks has a height less than the height of the second major section and the height of the lateral panel to which the first major section is affixed.

7. A container preassembly comprising:

a primary blank including a plurality of lateral panels and at least one bottom panel configured to provide an exterior of the container; and

a plurality of supplementary blanks each including a plurality of major sections and at least one sub-section,

wherein one of the major sections of each supplementary blank is affixed to a corresponding opposed lateral panel of the primary blank and the at least one sub-section of each supplementary blank is affixed to the at least one bottom panel of the primary blank such that, as the container is finally assembled, an exterior of the container is formed by the plurality of lateral panels and the at least one bottom panel of the primary blank, and

wherein a plurality of stacking shoulders are formed automatically by movement of the primary blanks causing movement of the supplementary blanks at opposing lateral panels of an interior of the container, and the plurality of stacking shoulders are formed as part of the final assembly of the primary blank as the exterior of the container.

8. The container preassembly of claim 7, wherein the plurality of lateral panels of the primary blank include a front side panel, back side panel and first and second end panels.

9. The container preassembly of claim 8, wherein one of the major sections of each of the plurality of supplementary blanks is affixed to either a first end panel or a second end panel of the plurality of lateral panels of the primary blank.

10. The container preassembly of claim 7, wherein the supplementary blanks each includes a plurality of keys, each configured to be erected upon one of the stacking shoulders as the stacking shoulders are formed during final assembly of the primary blank as the exterior of the container.

11. The container preassembly of claim 8, wherein the primary blanks includes a plurality of keyhole apertures on at least of the lateral panels of the primary blank following final assembly of the primary blank as the exterior of the container.

12. The container preassembly of claim 8, wherein the primary blank is affixed to the supplementary blanks via application of an adhesive.

20. The container preassembly of claim 7, wherein the supplemental blanks each includes first and second major sections joined by a shoulder section, and the first major section is affixed to the lateral panel of the primary blank and the at least one sub-section extends from the second major section.

21. The container preassembly of claim 20, wherein the supplemental blanks each includes lateral sub-sections extending from a respective lateral edge of the second major section and the lateral sub-sections lie adjacent a corresponding adjacent lateral panel of final assembly of the primary blank.

22. The container preassembly of claim 20, wherein the first and second major sections of the supplemental blanks have a height greater than the height of the lateral panel to which the first major section is affixed.

23. The container preassembly of claim 20, wherein the first major section of the supplemental blanks has a height less than the height of the second major section and the height of the lateral panel to which the first major section is affixed.

13. A plurality of blanks for a container preassembly, the plurality of blanks comprising:

a primary blank including a plurality of lateral panels and at least one bottom panel configured to provide an exterior of the container; and

a plurality of supplementary blanks each including a plurality of major sections and at least one sub-section,

wherein the primary blank is configured to mate with and be affixed to the supplementary blank so that one of the major sections of each supplementary blank is affixed to the corresponding opposed lateral panel of the primary blank and the at least one sub-section of each supplementary blank is affixed to the at least one bottom panel of the primary blank such that, as the container is finally assembled, an exterior of the container is formed by the plurality of lateral panels and the at least one bottom panel of the primary blank, and

wherein a plurality of stacking shoulders are formed automatically by movement of the primary blanks causing movement of the supplementary blanks at opposing lateral panels of an interior of the container, and the plurality of stacking shoulders are formed as part of the final assembly of the primary blank as the exterior of the container.

14. The plurality of blanks of claim 13, wherein the supplementary blacks each includes a plurality of keys, each configured to be erected upon one of the stacking shoulders as the stacking shoulders are formed during final assembly of the primary blank as the exterior of the container.

15. The plurality of blanks of claim 13, wherein the primary blank includes a plurality of keyhole apertures on at least one of the lateral panels of the primary blank following final assembly of the primary blank as the exterior of the container.

24. The plurality of blanks of claim 13, wherein the supplemental blanks each includes first and second major sections joined by a shoulder section, and the first major section is to be affixed to the lateral panel of the primary blank and the at least one sub-section extends from the second major section.

25. The plurality of blanks of claim 24, wherein the supplemental blanks each includes lateral sub-sections extending from a respective lateral edge of the second major section and the lateral sub-sections are configured to lie adjacent a corresponding adjacent lateral panel of final assembly of the primary blank.

26. The plurality of blanks of claim 24, wherein the first and second major sections of the supplemental blanks have a height greater than the height of the lateral panel to which the first major section is to be affixed.

27. The plurality of blanks of claim 24, wherein the first major section of the supplemental blanks has a height less than the height of the second major section and the height of the lateral panel to which the first major section is to be affixed.