Plastic corrugated container with ultrasonically formed score lines
First Claim
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1. A plastic corrugated box comprising:
- a first side wall panel having a bottom portion and a first bottom flap extending from the bottom portion, the first side wall panel and the first bottom flap formed from a continuous sheet of material having a first outer layer, a second outer layer and a plurality of parallel flutes between the first outer layer and the second outer layer; and
,the first bottom flap separated from the bottom portion of the first side wall panel by a first ultrasonically formed score line in a portion of the continuous sheet of material across a corresponding portion of the plurality of parallel flutes, the score line having an indented first outer layer and a plurality of reshaped flute segments along the first score line.
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Abstract
A corrugated plastic box and a method for manufacturing a corrugated plastic box from a blank are provided. The method includes the steps of forming rounded edge seals on the perimeter edges of the blank, pre-sealing portions of the blank to form a plurality of areas in which major and minor flap slots and a glue tab are desired, ultrasonically scoring the blank to form a plurality of flap score lines, and cutting the blank through the plurality of pre-sealed flap slots and glue tab, leaving a sealed edge.
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Citations
20 Claims
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1. A plastic corrugated box comprising:
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a first side wall panel having a bottom portion and a first bottom flap extending from the bottom portion, the first side wall panel and the first bottom flap formed from a continuous sheet of material having a first outer layer, a second outer layer and a plurality of parallel flutes between the first outer layer and the second outer layer; and
,the first bottom flap separated from the bottom portion of the first side wall panel by a first ultrasonically formed score line in a portion of the continuous sheet of material across a corresponding portion of the plurality of parallel flutes, the score line having an indented first outer layer and a plurality of reshaped flute segments along the first score line. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. A plastic corrugated blank for forming a box comprising:
a generally rectangular single continuous portion of plastic corrugated material having a plurality of fold lines forming side edges of a plurality of side wall panels, the corrugated material having a first outer layer, a second outer layer and a plurality of flutes extending between the first outer layer and the second outer layer, the plastic corrugated material having a plurality of ultrasonically formed score lines, each score line forming an edge between one of the plurality of side wall panels and a flap connected to one of the plurality of side wall panels in the single continuous portion of plastic corrugated material, each score line having an indented first outer layer and a plurality of reshaped flute segments along each score line. - View Dependent Claims (19, 20)
Specification