The present invention relates to containers with integrated support structures and methods for using the same. More particularly, the present invention relates to corrugated fiberboard containers provided with externally fixed support frames and methods for using the same.
Containers formed of corrugated fiberboard material (e.g., cardboard boxes) are used in many applications for shipping and/or storing one or more objects or items. Containers of this type are typically transported and stored in a generally flat, unfolded configuration, and are folded into containers at the time of use.
Containers of this type generally do not exhibit substantial stacking strength and shipping protection unless they are filled with other reinforcing material (e.g., dunnage). Dunnage adds extra weight and cost, and is a separate material from the container that must be stored prior to use, and can present recycling challenges depending upon the materials utilized.
The present invention provides devices that are reversibly foldable between a compact configuration and a container configuration. The compact configuration allows a large number of the devices to be shipped in a minimum amount of space. It also allows a large number of the devices to be stored in a minimum amount of space.
Devices according to the invention comprise a top, a front panel, a left panel, a rear panel, a right panel and a bottom. When in the container configuration, the top and bottom are spaced apart generally parallel to each other, the front panel and the rear panel are spaced apart generally parallel to each other, and the left panel and the right panel are spaced apart generally parallel to each other, thereby cooperating to define a closed containment cavity, which can be used to contain one or more items (e.g. for shipping and/or storage).
In one embodiment, a first support frame is fixed to an exterior face of the left panel, and a second support frame is fixed to an exterior face of the right panel. In other embodiments, third and fourth support frames are fixed to exterior faces of the front and rear panels.
In another embodiment, support beams are fixed to interior faces of front and rear top flaps, and support beams are fixed to interior faces of front and rear bottom flaps. These flaps, when folded inwardly, place ends of the support beams adjacent to interior faces of the panels on which the first and second support frames are fixed. The support frames and support beams thus cooperate to form a bracing and reinforcing structure.
In another embodiment, vertical strength is improved by one or more support beams fixed to interior faces of the front and rear panels. The ends of these support beams are adjacent to the aforementioned support beams fixed to interior faces of the flaps. In this manner, the support beams and support frames cooperate to define a cage, which provides high strength.
Devices according to the invention preferably consist substantially of corrugated fiberboard, which makes it lightweight and recyclable. However, devices can alternatively be constructed using other materials. It will be appreciated that the dimensions (e.g., length, width and height) of devices according to the invention is largely a matter of design choice, and will be determined in view of the item or items to be contained, cost and end use applications. Product specific devices are disclosed, such as containers for shipping one or more wine bottles.
The present invention also provides methods of using devices according to the invention. In one embodiment, the method comprises removing a device according to the invention from a stack of devices that in the compact configuration. The removed device is then reconfigured into the container configuration via a folding operation. The flaps to which support beams are affixed that are part of the bottom are folded inwardly until ends of the support beams are adjacent to interior faces of the sides of the device opposite the support frames, and then additional flaps, if present, are folded until their edges are aligned. Adhesive tape can be used to secure the bottom in this arrangement. Next, the device is inverted such that the interior cavity is exposed. One or more items or objects are placed within the interior cavity of the device. Additional packing material and dunnage may be added, if appropriate. The top is then closed by folding the flaps in the same manner as the bottom. Again, adhesive tape can be used to secure the top in a closed arrangement.
In accordance with another method of the invention, a device containing one or more items is received from a shipper. The top is opened, preferably by cutting adhesive tape used to secure the top in a closed arrangement. The contents within the interior cavity of the device are then removed. The device is then inverted, and the bottom is opened, again preferably by cutting adhesive tape used to secure the bottom in a closed arrangement. The device is then foldingly converted into the compact configuration for storage and reuse. In another embodiment, the device is recycled after the contents have been removed from the interior cavity.
The foregoing and other features of the invention are hereinafter more fully described below, the following description setting forth in detail certain illustrative embodiments of the invention, these being indicative, however, of but a few of the various ways in which the principles of the present invention may be employed.
This specification and the accompanying drawing figures are merely illustrative, and various modifications and changes can be made in the subject matter disclosed herein without departing from what is defined in the appended claims. All references to direction and position, unless otherwise indicated, refer to the orientation of structures and components as illustrated in the drawings, and should not be construed as limiting the claims appended hereto.
Various views of a first embodiment of a device 10 according to the invention are shown in
With reference to the aforementioned drawing figures, the device comprises a top 20, a front panel 30, a left panel 40, a rear panel 50, a right panel 60 and a bottom 70. When the device is in the container configuration, the top and bottom are spaced apart generally parallel to each other, the front panel and the rear panel are spaced apart generally parallel to each other, and the left panel and the right panel are spaced apart generally parallel to each other, thereby cooperating to define a closed containment cavity, which can be used to contain one or more items (e.g. for shipping and/or storage).
A left side 80 of the front panel is connected to a right side 90 of the left panel along a first fold line 100. A left side 110 of the left panel is connected to a right side 120 of the rear panel along a second fold line 130. A left side 140 of the rear panel is connected to a right side 150 of the right panel along a third fold line 160. And, a left side 170 of the right panel is connected to a right side 180 of the front panel along a fourth fold line 190.
The top comprises a front top flap 200 extending from a top side 210 of the front panel along a fifth fold line 220 and a rear top flap 230 extending from a top side 240 of the rear panel along a sixth fold line 250. The bottom comprises a front bottom flap 260 extending from a bottom side 270 of the front panel along a seventh fold line 280 and a rear bottom flap 290 extending from a bottom side 300 of the rear panel along an eighth fold line 310.
A first support frame 320 is fixed to an exterior face 330 of the left panel. A second support frame 340 is fixed to an exterior face 350 of the right panel. The support frames reinforce the panel to which they are affixed, and can serve as handles for carrying the device (particularly when heavily loaded).
A first support beam 360 is fixed to an interior face 370 of the front top flap. A second support beam 380 is fixed to an interior face 390 of the rear top flap. A third support beam 400 is fixed to an interior face 410 of the front bottom flap. A fourth support beam 420 is fixed to an interior face 430 of the rear bottom flap.
When the device is in the container configuration, a first end 440 of the third support beam is adjacent to an interior face 450 of the left panel opposite the first support frame and a second end 460 of the third support beam is adjacent to an interior face 470 of the right panel opposite the second support frame. When the device is in the container configuration, a first end 480 of the fourth support beam is adjacent to the interior face of the left panel opposite the first support frame and a second end 490 of the fourth support beam is adjacent to the interior face of the right panel opposite the second support frame. When the device is in the container configuration, a first end 500 of the first support beam is adjacent to the interior face of the left panel opposite the first support frame, and a second end 510 of the first support beam is adjacent to the interior face of the right panel opposite the second support frame. Similarly, when the device is in the container configuration, a first end 520 of the second support beam is adjacent to the interior face of the left panel opposite the first support frame and a second end 530 of the second support beam is adjacent to the interior face of the right panel opposite the second support frame.
Preferably, a front support beam 540 is affixed to an interior face 550 of the front panel and a rear support beam 560 is affixed to an interior face 570 of the rear panel. When the device is in the container configuration, a first end 580 of the front support beam is adjacent to the first support beam, and a second end 590 of the front support beam is adjacent to the third support beam. Similarly, a first end of the rear support beam 585 is adjacent to the second support beam, and a second end of the rear support beam is adjacent to the fourth support beam 595. When the device is configured in this manner, the support beams and support frames cooperate to define a cage, which supports and protects the cavity within the container from forces acting on the container. It will be appreciated that two or more front support beams and/or rear support beams can be utilized, if desired. If two or more support beams are used on a particular side, it is helpful (but not necessary) for such support beams to be distributed in a symmetrical manner so that the load is evenly distributed during stacking.
The top preferably further comprises a left top flap 600 extending from a top side 610 of the left panel along a ninth fold line 620 and a right top flap 630 extending from a top side 640 of the right panel along a tenth fold line 650. Similarly, the bottom preferably further comprises a left bottom flap 660 extending from a bottom side 670 of the left panel along an eleventh fold line 680 and a right bottom flap 690 extending from a bottom side 700 of the right panel along an twelfth fold line 710.
In the embodiment illustrated in
The device preferably consists essentially of corrugated fiberboard and adhesives, which makes it lightweight and recyclable. However, it will be appreciated that the device can be constructed using other similar materials (e.g., corrugated plastic sheeting such as COROPLAST®). Adhesive tape 740 may be applied to the device to secure the device in the container configuration. The use of adhesive tape allows the device is to be reused. The adhesive tape can be cut with a knife to allow the flaps to be folded away. The device can be stored in the compact configuration and then folded back into the container configuration for use a shipping or storage container. The device can be re-sealed in the container configuration using adhesive tape once the flaps are folded back to the container configuration. The device is very durable, and can be used repeatedly.
The first support frame, the second support frame, the first support beam, the second support beam, the third support beam and the fourth support beam are each preferably formed of an elongate structure comprising a hollow outer portion formed of corrugated fiberboard sheet material and an accordion-folded inner support formed of corrugated fiberboard sheet material. Elongate structures of this type were previously disclosed by the inventor in International Application No. PCT/US2015/057956, filed Oct. 20, 2015, which was published as WO 2016/069843 A1, and is hereby incorporated by reference in its entirety as if fully rewritten herein.
In the embodiment illustrated in
In the illustrated embodiments, the support frames have mitered corners. But it will be appreciated that other configurations of the picture frame-like elements (e.g., straight-cut, ‘butt joint” corners) could also be utilized. The outer periphery of the support frames preferably extend to the outer edges of the panels on which they are affixed.
It will be appreciated that the dimensions (e.g., length, width and height) of the device is largely a matter of design choice, and will be determined in view of the item or items to be contained, cost and end use applications. Accordingly, the dimensions of the support beams, the thickness of the material used to fabricate the panels (etc.) can be varied within the spirit and scope of the invention.
In the embodiment illustrated in
The devices shown in
The present invention also provides methods of using devices according to the invention. In one embodiment, the method comprises removing a device according to the invention from a stack of devices that in the compact configuration. The removed device is then reconfigured into the container configuration via a folding operation. The flaps to which support beams are affixed that are part of the bottom are folded inwardly until ends of the support beams are adjacent to interior faces of the sides of the device opposite the support frames, and then additional flaps, if present, are folded until their edges are aligned. Adhesive tape can be used to secure the bottom in this arrangement. Next, the device is inverted such that the interior cavity is exposed. One or more items or objects are placed within the interior cavity of the device. Additional packing material and dunnage may be added, if appropriate. The top is then closed by folding the flaps in the same manner as the bottom. Again, adhesive tape can be used to secure the top in a closed arrangement.
In accordance with another method of the invention, a device containing one or more items is received from a shipper. The top is opened, preferably by cutting adhesive tape used to secure the top in a closed arrangement. The contents within the interior cavity of the device are then removed. The device is then inverted, and the bottom is opened, again preferably by cutting adhesive tape used to secure the bottom in a closed arrangement. The device is then foldingly converted into the compact configuration for storage and reuse. In another embodiment, the device is recycled after the contents have been removed from the interior cavity.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and illustrative examples shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
This application is a continuation of co-pending International Application PCT/US2018/033087, filed May 17, 2018, and claims priority to U.S. App. Ser. No. 62/507,304, filed May 17, 2017.
Number | Date | Country | |
---|---|---|---|
62507304 | May 2017 | US |
Number | Date | Country | |
---|---|---|---|
Parent | PCT/US2018/033087 | May 2018 | US |
Child | 16057318 | US |