Patent Application
20080173704
The present invention relates to packaging, and more particularly, to containers for packaging cut sheets of paper.
Corrugated containers for accommodating loose sheets of paper are well-known. The side walls of known containers are formed to substantially define the dimensions of the sheets of the paper packed therein to prevent movement of the loose sheets within the container, and thereby minimize damage to the edges of the sheets. Typically, such containers are provided with either a removable lid or a lid that is hingedly secured to the container to permit access to the paper through an open top. However, since there is little clearance between the sheets and the side walls, it is difficult to remove the paper without tilting or inverting the container to cause the paper to slide out through the open container top. This causes the edges of the paper sheets to misalign as they slide out from the container and sometimes results in folding and/or tearing of sheets, particularly the edges. Any damage to the paper edges can adversely affect the runability performance when it is loaded into a printing or photocopying device. In addition, if paper misalignment occurs, an operator of the printing/photocopying device must orderly stack the loose paper sheets, with all the edges of the sheets in alignment, so that the sheets can be properly loaded into the printing device.
In another configuration of a conventional paper container, access to the paper is provided by a side wall that is pivoted downwardly to expose one side of the paper stack. This requires using one hand to remove paper from the container, which limits the amount of paper a user can easily remove from the container in an orderly fashion.
In addition, current paper containers typically use a plastic strap and/or an adhesive strip to keep the container closed during shipping and handling. This structure requires additional expense and effort. In some cases, box cutters or scissors must be used to open the container to remove the paper.
Accordingly, there exists a need for a new and improved container for packaging cut sheets of paper.
It is therefore an object of the present invention to provide a container for shipping and/or storing a stack of paper that permits easy access to the paper for removing it from the container.
To such ends, and according to one representative embodiment, a container for containing a stack of paper comprises a bottom wall having opposed first and second edges. The bottom wall is dimensioned to support a stack of paper placed thereon. A first shell portion is pivotally connected at a bottom edge thereof to the first edge of the bottom wall, and a second shell portion is pivotally connected at a bottom edge thereof to the second edge of the bottom wall. The first and second shell portions are pivotable between a closed position for containing the stack of paper for shipping or storing, and open position, in which the top and at least two opposing sides of the stack are exposed. Advantageously, the shell portions, when opened, enable a user to easily remove the desired amount of paper from the container by grasping the paper on opposing sides of the stack.
In particular embodiments, the first shell portion comprises a main panel pivotally connected at a bottom edge thereof to the first edge of the bottom wall, a top panel extending from a top edge of the main panel, and first and second, spaced apart side panels. Each side panel extends from a respective side edge of the main panel, and is rigidly secured to the top panel and the main panel. Similarly, the second shell portion comprises a main panel pivotally connected at a bottom edge thereof to the second edge of the bottom wall, a top panel extending from a top edge of the main panel, and first and second, spaced apart side panels. Each side panel of the second shell portion extends from a respective side edge of the main panel, and is rigidly secured to its respective top panel and main panel. With this configuration, when the shell portions are closed, the top panels of the shell portions extend in an overlapping relationship relative to each other to serve as the top of the container, and the main panels extend upwardly from the bottom wall to serve as opposing side walls of the container. In addition, each side panel of the first shell portion extends in an overlapping relationship with an adjacent side panel of the second shell portion, thereby forming opposing side walls of the container extending between the main panels.
The container also may include first and second internal side walls, or panels, extending upwardly from respective edges of the bottom wall, each being positioned in a face-to-face relationship with an adjacent side of the stack. When the shell portions are closed, the internal side walls are positioned internal to the shell portions, and each side panel of the first shell portion extends in an overlapping relationship with an adjacent side panel of the second shell portion and an adjacent internal side wall. In this manner, the internal side walls serve to provide additional structural rigidity to the sides of the container formed by the overlapping side panels of the shell portions. Also, the internal side walls desirably are pivotally connected to the bottom wall so that when the shell portions are opened, the side walls can be pivoted downwardly away from the stack to expose all four sides of the stack.
In addition, the container may be provided with a handle to facilitate carrying of the container. In one embodiment, the handle is coupled to the top panel of the first shell portion, and the top panel of the second shell portion is formed with a corresponding opening for receiving the handle. Thus, when the shell portions are closed, with the top panel of the second shell portion overlapping the top panel of the first shell portion, the handle extends upwardly through the opening. Advantageously, the handle in this configuration assists in retaining the shell portions in the closed position. Desirably, the handle is positioned to be at the geometric center of the top of the container when the container is closed to permit gravity-centered lifting and carrying of the container with one hand.
According to another representative embodiment, a container for containing one or more articles comprises a bottom wall, first and second shell portions connected in a pivotal manner to opposing edges of the bottom wall, and a handle coupled to one of the first and second shell portions. The shell portions are pivotal between a closed position in which the shell portions substantially enclose the articles and an open position in which the articles are exposed at least at two opposing sides of the container to facilitate removal of articles from the container.
According to still another representative embodiment, a container for containing one or more articles comprises a bottom and first and second side walls extending upwardly from respective edges of the bottom, with the first side wall being opposite the second side wall. In addition, first and second shell portions are connected in pivotal manner to respective edges of the bottom. The shell portions are pivotable toward each other to a closed position to contain the articles therebetween for shipping or storing the stack. The shell portions are also pivotable away from each other to cause the container to be open at two opposing sides of the container to facilitate removal of articles from the container.
A container for containing one or more articles, according to another representative embodiment, comprises a bottom, a first shell portion having a main panel connected in pivotal manner to a respective edge of the bottom, and a second shell portion having a main panel connected in pivotal manner to a respective edge of the bottom. Each shell portion has a top panel extending from a top edge of its respective main panel and first and second side panels extending from respective side edges of its respective main panel. The shell portions are pivotable toward each other to a closed position with the articles contained between the main panels, the top panels extending in an overlapping relationship relative to each other to cover the top of the articles, and each side panel of the first shell portion at least partially overlapping an adjacent side panel of the second shell portion and an adjacent side wall. The shell portions are also pivotable away from each other to cause the container to be open at the top and two opposing sides of the container to facilitate removal of articles from the container.
According to another representative embodiment, a blank for forming a container for containing paper comprises a bottom panel dimensioned to support a stack of paper, a first shell portion extending from an edge of the bottom panel, and a second shell portion extending from an edge of the bottom panel, opposite the first shell portion. The shell portions are configured such that, when the container is formed from the blank, the shell portions are pivotable relative to the bottom panel between a closed position for containing the stack of paper for shipping or storing and open position, in which at least two opposing sides of the stack are exposed to facilitate removal of paper from the container.
The foregoing and other features and advantages of the invention will become more apparent from the following detailed description of several embodiments, which proceeds with reference to the accompanying figures.
Referring to the drawings, a container according to one embodiment is indicated generally at 10 in
Of course, if desired, the container 10 could be used to store or ship articles other than paper, such as toys, produce, and various other articles. In one implementation, for example, one or more sides of the container 10 may include an opening or window covered by a transparent material (e.g., cellophane plastic) for use as a toy box. In another implementation, the container 10 can include an internal liquid-tight liner (such as used in boxes for storing and dispensing wine) so that the container can be used to hold liquids.
As shown in
As best shown in
As used herein, a portion of the container 10 that is “connected to” another portion of the container can mean that such portions are formed from a unitary blank and defined by a fold line in the blank (such as minor flap 46 and side flap 38), or that such portions are separately formed and subsequently directly or indirectly joined to each other.
The second shell portion 26 comprises a main panel 62, and a top panel 64 connected to the main panel 62 along fold line 66 extending along the top edge of the main panel 64. Two side flaps, or panels, 68, 70 are connected to the main panel 62 along fold lines 72, 74, respectively, extending along respective side edges of the main panel 62. Two minor flaps 76, 78 are connected to side flaps 68, 70, respectively, along fold lines 80, 82, respectively. The blank 12 is formed with cuts 84 and 86 to separate side walls 16, 18 from side flaps 68, 70, respectively.
In the configuration illustrated by
In alternative embodiments, the side flaps 38, 40, 68, 70 can have other shapes and/or dimensions. For example, the side flaps 38, 40, 68 and 70 can be generally rectangular, with each side flap having a substantially constant width substantially equal to the width of side walls 16, 18. Alternatively, side flaps 38, 40, 68, and 70 can have straight, diagonally extending edges, instead of the rounded edges 58, 60, 90, and 92 shown in the illustrated embodiment. In another embodiment alternative, side flaps 68, 70 can be tapered from the top panel 64 to the bottom wall 14.
As shown in
To assemble the first shell portion 24, side flaps 38, 40 and top panel 34 are folded approximately 90° along their respective fold lines so that side flaps 38, 40 and top panel 34 extend substantially perpendicularly from the plane defined by main panel 32, as shown in
The second shell portion 26 is assembled in a similar manner by folding side flaps 68, 70 and top panel 64 approximately 90° along their respective fold lines so that side flaps 68, 70 and top panel 64 extend substantially perpendicularly from the main panel 62, as best shown in
Top panel 64 of the second shell portion 26 is formed with an opening 94 (
Handle 57 can be made from any of various materials. In particular embodiments, for example, handle 57 comprises a flexible strap made from a polymeric material, a piece of rope, or a piece of tape, although other suitable materials also can be used. Desirably, the handle 57 is designed to permit level stacking of containers. To this end, handle 57 may be made from a flexible material. Moreover, handle 57 may be substantially flat, i.e., having first and second major planar surfaces that extend substantially parallel to a surface defined by top panel 34 when container 10 is assembled and closed.
To package a paper stack 11 in the container 10, the stack is placed in the open container. For most paper, stack 11 is inserted such that the short ends of the stack are adjacent side walls 16, 18. The side walls 16, 18 are then folded, or pivoted, upwardly to be substantially perpendicular to the bottom wall 14 such that the side walls 16, 18 are in a face-to-face relationship with the short sides of the stack 11 (
As shown in
As mentioned above, bottom wall 14 in the illustrated configuration is dimensioned to substantially coincide with the dimensions of a paper stack 11 or perhaps multiples thereof. Thus, when the container 10 is closed, side walls 16, 18 abut the short sides of the paper stack 11 and main panels 32, 62 abut the long sides of the paper stack to substantially preclude the paper stack from shifting during shipping or handling of the container. With this arrangement, misalignment of the paper and damage to the edges of the paper caused during shipping or handling of container 10 can be substantially avoided. Although less desirable, in other embodiments, the container 10 could be dimensioned to provide spacing between the sides of the paper stack and inside surfaces of the container.
To keep shell portions 24, 26 from separating during shipping, an adhesive (e.g., glue) can be applied between side flaps 38 and 68, between side flaps 40 and 70, and/or between top panel 34 and top panel 64. Advantageously, the use of an adhesive between overlapping portions of container 10 allows the container to be easily opened without using any tools (e.g., a box cutter, scissors or equivalent devices), as further described below. In alternative embodiments, a plastic strap or an adhesive tape wrapped around the shell portions 24, 26 can be used in addition to, or instead of, an adhesive applied between adjacent portions of container 10 to keep the shell portions from separating during shipping.
Container 10 can be easily opened to gain access to the paper stacked inside by separating overlapping side flaps 38 and 68, overlapping side flaps 40 and 70, and overlapping top panels 34 and 64, and then pivoting the shell portions 24, 26 away from each other to fully expose two opposing sides of the paper stack 11 (as shown in
In an alternative embodiment, container 10 can be provided with score lines coinciding with fold lines 50, 52, 80, and 82 so that side flaps 38, 40 can be separated from top panel 34 and side panels 68, 70 can be separated from top panel 64. Once separated, side flaps 38, 40, 68, 70 and top panels 34, 64 can be folded downwardly to provide even greater access to the paper stack.
Opening the illustrated container 10 does not destroy the integrity of the container structure. Consequently, the container can be reused for refilling, shipping, and/or storage. Although not required, shell portions 24, 26 can be provided with some structure useful for joining shell portions 24 and 26, such as a tab-and-slot locking mechanism to assist in retaining the shell portions in the closed position once the container has been initially opened and the adjacent surfaces of the shell portions are no longer adhesively secured to each other. Such a tab-and-slot locking mechanism may comprise a tab formed on one of the shell portions and a corresponding slot formed on the other shell portion. The tab is configured to be insertable into the corresponding slot when shell portions 24, 26 are pivoted to the closed position. The engagement of the tab and the slot assists in retaining the shell portions in their overlapping closed position.
Container 10 can be made from any suitable material, such as corrugated or non-corrugated fiberboard or polymeric materials, cardboard, or paperboard. Also, a moisture resistant coating can be provided on the inner surfaces of the container 10 to limit the ingress of moisture into the closed container. For example, a polymeric coating, such as HYDRABAN 1000AF™ manufactured by Michelman, Inc. of Cincinnati, Ohio, may be used to form the moisture resistant coating. Alternatively, a wax coating may be provided on the inner surfaces of the container, or a laminated liner, such as FIBER-LAM POLYCORR™ liner, manufactured by Fiber-Lam, Inc. of Doswell, Va., may be used.
Container 10 can be made using any convenient method. In one approach, for example, a unitary blank 12 (e.g., a cardboard blank) is cut using, for example, a machine having die cut capabilities (e.g., a rotary die cutter) to provide the configuration shown in
The moisture resistant coating, such as HYDRABAN 1000AF™, can be applied using conventional techniques, such as with a curtain coater or a doctor blade. In addition, the moisture resistant can be applied before or after the blank 12 is fabricated.
If desired, a removable, pressure sensitive label 98 can be provided on the outside of container 10, such as shown in
The configuration of container 10 is not limited to the illustrated embodiment. Accordingly, numerous modifications and alterations to the illustrated embodiment are possible. For example, in alternative embodiments, selected portions of the container 10 (e.g., side walls 16, 18 or shell portions 24, 26) can be separately formed and then subsequently joined to respective edges of the bottom wall 14 to form the container 10. In addition, selected portions of container 10 can be formed from two or more layers of material (e.g., two layers of fiberboard secured to each other using, for example, adhesive or mechanical fasteners) to provide additional structural rigidity to that portion of the container.
In another embodiment, container 10 can be configured with the side walls 16, 18 joined to the long sides of the bottom wall 14 and the shell portions 24, 26 joined to the short sides of the bottom wall 14. In this embodiment, when the container is closed, side walls 16, 18 abut the long sides of the paper stack and the main panels 32, 62 abut the short sides of the paper stack.
In still another embodiment, container 10 can be formed without side walls 16, 18. With this embodiment, side flaps 68, 70 can be positioned to abut adjacent sides of the paper stack 11 to prevent side-to-side shifting of the paper stack during shipping or handling of container 10.
In yet another embodiment, side walls 16, 18 can be rigidly secured to the bottom wall 14 in a substantially perpendicular relationship relative to the bottom wall 14. In this embodiment, side walls 16, 18 cannot be folded downwardly away from the stack.
In another embodiment, container 10 can be formed with one or two additional internal side walls positioned in a face-to-face relationship with the long sides of paper stack 11 and extending substantially perpendicularly to side walls 16, 18 to maintain side-to-side alignment of the paper sheets when the container is opened. Such side walls may be configured to be pivotable relative to the bottom wall, such as side walls 16, 18.
In another embodiment, side flaps 68, 70 can be permanently secured (e.g., using an adhesive or mechanical fasteners) to side walls 16, 18, respectively, so that shell portion 26 is permanently retained in the closed position. Shell portion 24 is pivotal downwardly and upwardly to open and close container 10, respectively.
Further, container 10 can be provided with additional handles and/or alternative handle configurations. For example, two or more handles can be coupled, or otherwise secured to, one or both of the top panels 34, 64. Alternatively, one or more handles can be coupled, or otherwise secured to, other portions of the container, such as the bottom wall 14, main panels 32, 62, side flaps 38, 40, or side flaps 68, 70.
In another embodiment, a handle is provided in the form of a flexible strap wrapped around the container so as to extend around the top, bottom, and two opposing sides of the container. Desirably, such a strap includes two handles integrally formed in the strap and is positioned to coincide with the lateral or longitudinal mid-line of the top of the container to permit gravity-centered lifting. Alternatively, handles can be integrally formed in top panels 34, 64.
As shown in
Blank 200 also has two side walls, or panels, 224, 226, foldable along fold lines 20, 22, respectively. A second shell portion 228 of blank 200 comprises top panel 230, and two side flaps, or panels 232, 234. Two minor flaps 236, 238 are connected to side flaps 232, 234, respectively, along fold lines 240, 242, respectively. Side panels 224, 226 are formed with edges 244, 246, respectively, which extend from a point adjacent side flaps 232, 234, respectively, in an outwardly tapered direction relative to side flaps 232, 234 to provide a clearance between side panels 224, 226 and side flaps 232, 234, respectively.
Although not required, in the illustrated embodiment, side flaps 232, 234 are formed with notches 248, 250, respectively, to facilitate rapid packaging of a stack of paper in the container 202 with a case packing machine. More specifically, notches 248, 250 are positioned to allow arms of a case packing machine to hold side panels 224, 226 against the sides of a stack of paper as shell portion 228 is folded upwardly around side panels 224, 226.
Top panel 230 desirably has a width w (
As discussed above, an exemplary use of the embodiments disclosed herein is for containing cut sheets of paper. In one specific construction, a container (e.g., container 10 or container 202) is dimensioned to contain 2 reams of paper and is constructed from a corrugated fiberboard blank having an inner liner, an outer liner, and a fluting material disposed between and adhesively secured to the inner and outer liners. In this construction, the inner liner comprises 35# paper, the corrugated material comprises 26# fluting, and the outer liner comprises 36# paper. In another construction, a container dimensioned to contain 3 reams of paper is constructed from a corrugated blank having a 56# inner liner, a 26# fluting, and a 36# outer liner. In another construction, a container dimensioned to contain 4 reams of paper is constructed from a corrugated blank having a 56# inner liner, a 26# fluting, and a 69# outer liner. In yet another construction, a container dimensioned to contain 5 reams of paper is constructed from a corrugated blank having a 56# inner liner, a 26# fluting, and a 36# outer liner.
The following examples are provided solely to illustrate certain features of working embodiments. A person of ordinary skill in the art will recognize that the scope of the invention is not limited to the illustrated features.
In this example, moisture absorption tests were performed on four different types of corrugated fiberboard, each having two paper liners and fluting material disposed between and adhesively secured to the liners. The material tested included the following: (1) corrugated fiberboard comprising a 38# first paper liner, a 23# fluting material, and a 56# second paper liner; (2) corrugated fiberboard comprising a 56# first paper liner, a 26# fluting material, and a 69# second paper liner; (3) corrugated fiberboard comprising a 36# first paper liner, a 26# fluting material, and a 35# second paper liner; (4) corrugated fiberboard comprising and a 36# first paper liner, 26# fluting material, and a 35# second paper liner with a X-300 moisture-resistant coating (available from Michelman, Inc.).
Multiple samples of each material measuring 2.5 inches in diameter were cut from sheets of each corrugated material and weighed. About 250 grams of calcium sulfate (CaSo4) were placed in each of multiple glass jars. Each sample was placed on top of an open jar and secured in place by a metal ring to create a hermetic seal. The samples were then placed in an incubator operating at 38° C.+/−2° C. and 78%+/−2% relative humidity. The samples were removed from the incubator and weighed after two, seven, and fifteen days. The initial weight of each sample and the weight after each time interval are provided in Tables 1a-1d below.
In this example, drop, compression and vibration tests were conducted on three differently sized containers 202 made from corrugated fiberboard containing respective stacks of paper. The first container had a length of 12″, a width of 9″, and a height of 11⅜″, and weighed 26.4 lbs. (with paper). The second container had a length of 12″, a width of 9″, and a height of 7⅛″, and weighed 15.7 lbs. (with paper). The third container had a length of 12″, a width of 9″, and a height of 5″, and weighed 10.9 lbs. (with paper). The shell portions of the containers were glued together to retain the containers in their closed positions during testing.
Testing was conducted in accordance with the ASTM D4169 Standard Practice for Performance Testing of Shipping Containers and Systems, Distribution Cycle 3, Assurance Level II. In addition, testing was conducted at 73.4+/−2° C. and 50%+/−2% relative humidity.
In a first test, the containers were dropped from the platen of a LAB free fall drop tester (the first container was dropped from a height of 13″ and the second and third containers were dropped from a height of 15″). Each container was dropped once on its top, once on each bottom edge, once on a bottom corner, once on a diagonally opposite bottom corner, and once on its bottom.
In a second test, each container was placed on the bottom platen of a Tinius Olsen Compression Tester. To apply a load to each container, the top platen was operated to move downwardly at a speed of ½ inches per minute. The tester applied loads of 1,569 lbs., 1,556 lbs., and 1,572 lbs. to the first, second, and third containers, respectively.
In a third test, the containers were placed on the table of a TMI rotary vibration machine in their normal upright shipping position. The machine was activated and the speed was increased to about 250 rpm. The containers were vibrated at this frequency for 30 minutes. Each container was then re-positioned so as to lie on a respective side wall, vibrated for 15 minutes at 250 rpm, re-positioned again so as to lie on a respective end wall, and vibrated again for 15 minutes at 250 rpm.
In a fourth test, the containers were placed in their normal upright position on the table of a MTS 840 vibration machine. Fences were placed around the containers to prevent the containers from vibrating off the table (the fences did not restrict vertical motion of the containers). The containers were subjected to the “Random” test option for 20 minutes. Each container was then re-positioned so as to lie on a respective side wall, vibrated for 20 minutes, re-positioned again so as to lie on a respective end wall, and vibrated again for 20 minutes.
In a fifth test, the containers were dropped from the platen of the free fall drop tester (as in the first test, the first container was dropped from a height of 13″ and the second and third containers were dropped from a height of 15″). In this test, each container was dropped once on a vertical edge, once on a side face, once on an adjacent end face, once on a top corner, once on an adjacent top edge, and finally once on its bottom from twice the specified height (i.e., 26″ for the first container and 30″ for the second and third containers).
After subjecting the containers to the foregoing tests, each container showed signs of wear and tear, but the integrity of each container was unaffected.
In this example, several containers containing paper placed were subjected to various conditions in a temperature chamber to demonstrate the moisture transfer rate (MVTR) capabilities of the containers. The types of containers used in this example included a container having a construction similar to container 202 of
The containers were placed in a temperature chamber, which was operated to cool to 45° F. from ambient at 60% relative humidity over 8 hours, soak at 45° F. and 60% relative humidity for 4 hours, warm to 104° F. at 90% humidity over 8 hours, and then soak at 104° F. and 90% relative humidity for 4 hours.
The present invention has been shown in the described embodiments for illustrative purposes only. The present invention may be subject to many modifications and changes without departing from the spirit or essential characteristics thereof. We therefore claim as our invention all such modifications as come within the spirit and scope of the following claims.
The present application is a continuation of U.S. application Ser. No. 10/655,643, filed Sep. 5, 2003, which claims the benefit of U.S. Provisional Application No. 60/417,109, filed on Oct. 8, 2002, both of which applications are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 60417109 | Oct 2002 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10655643 | Sep 2003 | US |
| Child | 12077757 | US |
