Self-locking stackable tapered container with partial top structure

• US 7,458,503 B2
• Filed: 07/25/2007
• Issued: 12/02/2008
• Est. Priority Date: 09/27/2002
• Status: Expired due to Term

• Current Assignee: International Paper Company
• Original Assignee: International Paper Company
• Inventors: Fry, Stanley L
• Primary Examiner(s): Elkins; Gary E
• Application Number:
  US11/881,108
• Publication Number:
  US 20070267470A1
• Time in Patent Office: 496 Days
• Field of Search: 229/112, 229/170, 229/916, 206/509
• 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 5/0035 the ledges being located between side walls and doubled-over extensions B65D5/0025 takes precedence
• CPC Class Codes: B65D 5/22 held erect by extensions of one or more sides being doubled-over to enclose extensions of adjacent sides
• CPC Class Codes: B65D 5/28 with extensions of sides permanently secured to adjacent sides, with sides permanently secured together by adhesive strips, or with sides held in place solely by rigidity of material
• CPC Class Codes: Y10S 229/918 Corner construction

Abstract

A stackable container for carrying produce. The container has tapered side walls or end walls to aid in the stacking of like containers. Also, the container has locking flaps that allow the container to be erected manually and without the need for fasteners. Further, at least one tapered wall of the container has a reinforcement flap that creates a partial top structure in the upper part of the container that helps prevent bulging of the walls. The reinforcement flap also creates doubled stacking tabs and diagonal corner posts that aid in the stacking of like containers.

Claims

1. A container formed from a blank, the container comprising:

a base panel;

two opposing side walls connected to the base panel at substantially a 90°

angle;

two opposing end walls connected to the base panel at an angle less than 90°

, the end walls having a width equal or less than the width of upper edges of the side walls, each end wall having an end flap connected to opposing sides of the end wall, each end flap having a lock recess disposed along a top edge of thereof;

locking flaps connected to the side walls by at least one pair of lock hinge assemblies, wherein each locking flap folds inwardly to sandwich adjacent said end flaps between the locking flap and an adjacent said side wall and further, wherein each locking hinge assembly locks into the lock recess of the adjacent end flap; and

a reinforcement flap connected to at least one of said end walls by at least one doubled stacking tab, wherein the reinforcement flap lies flush against an inner surface of the at least one of said end walls, wherein

the base panel further comprises at least one stacking slot cut into the base panel, the at least one stacking slot positioned to accept the at least one doubled stacking tab extending from an angled end wall of a sub-adjacent container;

the at least one stacking slot is positioned adjacent to the at least one end wall; and

the at least one end wall has a first thickness and further comprises a crushed area, the crushed area having a second thickness, the second thickness being less than the first thickness, wherein a bottom of the crushed area is adjacent to the at least one stacking slot.

2. The container according to claim 1, further comprising a tab flap disposed on the base panel adjacent to the at least one stacking slot, the flap having a contact edge disposed adjacent and parallel to the at least one stacking slot.

3. The container according to claim 1, wherein the end flap has a bottom edge that angles divergently upward from a bottom edge of an adjacent said end wall.

4. The container according to claim 1, wherein the reinforcement flap has corner flaps attached to opposing side edges thereof, and further wherein each corner flap extends diagonally towards an adjacent said locking flap.

5. The container according to claim 4, wherein the locking flap has at least one lock slot disposed along an outer edge thereof, a lock tab projects from a side edge of the corner flap and further, wherein the lock tab extends into said at least one lock slot.

6. The container according to claim 1, wherein a bottom tab projects from a bottom edge of at least one said end flap, at least one tab slot is disposed on the base panel adjacent to at least one of said side walls and further, wherein the bottom tab extends into the at least one tab slot.

7. A container formed from a blank, the container comprising:

a base panel;

two opposing side walls connected to the base panel at substantially a 90°

angle;

two opposing end walls connected to the base panel at an angle less than 90°

, the end walls having a width equal or less than the width of upper edges of the side walls, each end wall having an end flap connected to opposing sides of the end wall, each end flap having a lock recess disposed along a top edge of thereof;

locking flaps connected to the side walls by at least one pair of lock hinge assemblies, wherein each locking flap folds inwardly to sandwich adjacent said end flaps between the locking flap and an adjacent said side wall and further, wherein each locking hinge assembly locks into the lock recess of the adjacent end flap; and

a reinforcement flap connected to at least one of said end walls by at least one doubled stacking tab, wherein the reinforcement flap lies flush against an inner surface of the at least one of said end walls, wherein the reinforcement flap has corner flaps attached to opposing side edges thereof, and further wherein each corner flap extends diagonally towards an adjacent said locking flap.

8. The container according to claim 7, wherein the base panel further comprises at least one stacking slot cut into the base panel, the at least one stacking slot positioned to accept the at least one doubled stacking tab extending from an angled end wall of a sub-adjacent container.

9. The container according to claim 8, wherein the at least one stacking slot is positioned adjacent to the at least one end wall.

10. The container according to claim 9, further comprising a tab flap disposed on the base panel adjacent to the at least one stacking slot, the flap having a contact edge disposed adjacent and parallel to the at least one stacking slot.

11. The container according to claim 7, wherein the end flap has a bottom edge that angles divergently upward from a bottom edge of an adjacent end wall.

12. The container according to claim 7, wherein the locking flap has at least one lock slot disposed along an outer edge thereof, a lock tab projects from a side edge of the corner flap and further, wherein the lock tab extends into at least one lock slot.

13. The container according to claim 7, wherein a bottom tab projects from a bottom edge of at least one end flap, at least one tab slot is disposed on the base panel adjacent to the side wall and further, wherein the bottom tab extends into the at least one tab slot.