CORRUGATED CONTAINERS AND BLANKS FOR RECEIVING SEALS

Abstract

Corrugated containers with a seal and corresponding systems, blanks, and manufacturing methods are provided. An example corrugated container for receiving products therein includes a bottom panel and a plurality of wall panels extending therefrom. When the container is formed, the plurality of wall panels are folded with respect to the bottom panel and extend upwardly to form a receptacle with the bottom panel. The corrugated container further includes a plurality of flange flaps that each extend from one of the plurality of wall panels. When the container is formed, the plurality of flange flaps are folded away from an opening of the receptacle and define a rim for receiving a seal thereon (e.g., a top seal). The seal is formed of film and sized to fit over the opening of the container to contain the products within the receptacle. An eco-friendly product container is thus provided.

Description

BACKGROUND

Products, such as food products (e.g., fruits and vegetables), are often provided in plastic clamshells for display and purchase (e.g., at grocery stores). Some plastic clamshells may be transparent to enable viewing of the products, such as prior to purchase and handling of the product by the consumer. Notably, however, such plastic clamshells are undesirable due to their lengthy decomposition rates.

BRIEF SUMMARY

Example embodiments of the present disclosure generally relate to corrugated containers and, more particularly to corrugated containers designed to hold products and receive a seal thereon.

Embodiments of the present disclosure are directed to providing corrugated containers for receiving a seal (e.g., a top seal) thereon. In some embodiments, the corrugated containers may form receptacles with flange flaps that form a rim to receive a seal. In some embodiments, the flange flaps may be unsupported except as being foldably connected to one or more walls of the container (e.g., the flange flaps do not further connect to the container and/or fold over).

After forming the corrugated container, products (e.g., food products) may be placed therein and the seal can be applied to the flange flaps to, for example, contain, protect, and display the products therein. The seal may be formed of flexible film that is at least partially transparent to enable viewing of the products therethrough. Notably, the corrugated container has high structural strength and is biodegradable. Further, using existing corrugators and converting equipment to produce the integral corrugated blanks provides for ease of manufacturing and reduced costs.

Some food containers employ paperboard or molded pulp, but such containers may lack sufficient structure to protect the contained product during shipping/handling and/or to receive/hold a sufficient seal, often requiring extra support structure or folds/adhesive. In contrast, various embodiments provided herein include a blank for a corrugated container that provides sufficient rigidity and strength, such as due to the chosen liner (top or bottom) and/or the flute medium of the corrugated web product from which it is formed. This provides benefits over paperboard and molded pulp, such as reducing the number of folds required to achieve a desirable container form. To explain, due to having less strength, such paperboard or molded pulp containers require additional structural support around the opening of the container to hold any seal. In contrast, some embodiments herein provide single folded flange flaps (i.e., only one fold is required), as the structure of the corrugate (e.g., the extra strength from the chosen liner and/or fluted medium) provides the support necessary to receive and adhere the seal. Additionally, the fluted medium present in the bottom panel and wall panels provide extra padding during shipping and handling to protect the products contained therein. Further benefits include enabling ventilation holes and/or handles to be cut out during manufacturing while still maintaining desired strength of the overall corrugated container.

Various example corrugated containers provided herein are designed to hold food products, such as vegetables (e.g., cucumbers, peppers, mushrooms, garlic, carrots, beans, tomatoes, etc.) and/or fruit (e.g., strawberries, blueberries, raspberries, etc.). Some embodiments are designed to hold such products in their full (uncut) form. In some embodiments, however, one or more interior surfaces of the corrugated container may be coated and designed to hold and maintain cut form of products, such as cut vegetables, cut fruit, cut cheese, cut meats, among other things.

Corresponding systems, assemblies, and methods of manufacturing various example corrugated containers are also provided herein.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 shows a block diagram of an example corrugated container assembly manufacturing process, in accordance with some embodiments discussed herein;

FIG. 2 shows a top perspective view of an example corrugated container, in accordance with some embodiments discussed herein;

FIG. 3 shows a bottom perspective view of the example corrugated container shown in FIG. 2, in accordance with some embodiments discussed herein;

FIG. 4 shows a close-up view of a portion of the corrugated container shown in FIG. 2 with a seal applied, in accordance with some embodiments discussed herein;

FIG. 5 shows right perspective view of another example corrugated container with the seal applied, in accordance with some embodiments discussed herein;

FIG. 6 shows a top view of the example corrugated container shown in FIG. 5 with the seal applied, in accordance with some embodiments discussed herein;

FIG. 7A illustrates insertion of the example corrugated container shown in FIG. 2 into a seal guide feature in preparation for receiving a seal, in accordance with some embodiments discussed herein;

FIG. 7B illustrates sealing of a film on the flanges of the example corrugated container inserted into the seal guide feature, in accordance with some embodiments discussed herein;

FIG. 8 illustrates a layout of a blank for the example corrugated container shown in FIG. 2, in accordance with some embodiments discussed herein;

FIG. 9 illustrates a layout of a blank for another example corrugated container, in accordance with some embodiments discussed herein;

FIG. 10 shows an isometric view of another example corrugated container, in accordance with some embodiments discussed herein; and

FIG. 11 illustrates a flowchart of an example method of forming a corrugated container, inserting the product and applying the seal, and shipping the container assembly for use, in accordance with some embodiments discussed herein.

DETAILED DESCRIPTION

Some example embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all example embodiments are shown. Indeed, the examples described and pictured herein should not be construed as being limiting as to the scope, applicability or configuration of the present disclosure. Rather, these example embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like reference numerals refer to like elements throughout.

Notably, while some embodiments describe various positional qualifiers for various features, such as “top”, “bottom”, “front”, “back”, “side”, etc. embodiments described herein are not meant to be limited to such qualifiers unless otherwise stated. Along these lines, and as an example, a “front” wall may be a “side” wall depending on the container design/orientation. The directional qualifiers herein are generally used to aid in describing the disclosure in the context of the drawings and/or description but are not otherwise intended to be limiting.

While some embodiments describe a “user”, use of such a term herein is not meant to be limited to a person or a single person, as the “user” may be an end user, a consumer, a manufacturer, among other types of users along a supply chain in relation to the corrugated container. Further, when utilizing the word “user”, the actor(s) may be operating one or more machines/system that cause the intended function (e.g., forming the container or applying the seal).

Various example embodiments of the present disclosure provide corrugated containers for holding product, such as food products, and receiving a seal thereon. The seal may be formed of flexible film that is at least partially transparent to enable viewing of the products therethrough. Notably, example corrugated containers have high structural strength and are recyclable. Further, using existing corrugators to produce the integral corrugated blanks provides for ease of manufacturing and reduced costs.

Various example corrugated containers provided herein are designed to hold food products, such as vegetables (e.g., cucumbers, peppers, mushrooms, garlic, carrots, beans, tomatoes, etc.) and/or fruit (e.g., strawberries, blueberries, raspberries, etc.). In such a manner, an environmentally-friendly and relatively inexpensive container is provided that allows an end consumer to view and purchase food products that have been protected during assembly and shipping.

Some example corrugated containers are designed to hold food products in cut form (e.g., cut vegetables, cut fruit, cut cheese, cut meats, etc.). In such embodiments, one or more interior surfaces of the corrugated container may be coated to help protect the cut food from bacteria or other undesirable effects.

Example Corrugated Container Manufacturing Process

FIG. 1 illustrates an example corrugated container manufacturing process 100 to form one or more corrugated containers, insert the product, apply the seal, and ship the sealed container, according to various embodiments of the present disclosure. The manufacturing process 100 includes a number of phases. The process 100 may comprise a corrugation phase 110, a container blank forming phase 120, a container forming phase 130, an insert product phase 140, a seal forming phase 150, and a shipping phase 160. Although the phases are shown as distinct in the illustrated diagram, embodiments of the present disclosure are not meant to be so limiting as certain described processes within the phases may be performed in other phases, different described phases may be combined together, and/or phases and corresponding processes may be performed in a different order. Likewise, certain processes and/or phases may be performed in different locations and/or by different actors (e.g., the corrugated container manufacturer versus the food producer versus the customer, etc.).

In the corrugation phase 110, one or more corrugators may be used to form corrugated web product. Depending on the desired properties of the corrugated container, certain types of flute medium may be applied between two liners. In some embodiments, multiple layers of fluted medium may be applied between liners so as to form multi-layered corrugate. Different size corrugators may be used.

In the container blank forming phase 120, the corrugated container blank used to form the corrugated container may be formed, such as from the corrugated web product formed during the corrugation phase 110. In this regard, various processes may be performed on the corrugated web product to prepare the blank (e.g., an example blank 10 is shown in FIG. 8). For example, one or more cutting devices 125 may be used to cut out the blank from the corrugated web product. In some embodiments, additional features may be utilized, such as printing on the blank (e.g., to print a grower's logo or information about the intended product to be stored therein on a wall panel of the corrugated container blank). Such printing may occur, for example, via one or more printing devices 126, which may be before or after the blank is cut from the corrugated web product. In some embodiments, the blanks may be bundled up and shipped to a customer, such as a food producer (e.g., grower) of the intended product to be stored therein. In this way, the corrugated containers of the present disclosure may be easily shipped flat to a producer, thereby saving space and transportation costs in comparison to pre-formed containers.

In the container forming phase 130, the corrugated container may be formed (e.g., erected and glued together) such as by folding and/or connecting panels of the blank to form a walled receptacle with an opening (e.g., at the top) for receiving products therein. For example, one or more container forming machines/systems may form the corrugated container blank into a formed corrugated container. In this regard, one or more glue/folding devices 135 may be utilized to fold the various panels or flange flaps and apply glue and/or pressure as needed to form the corrugated container. In some embodiments, formation of the corrugated container may be manual or semi-manual. In some embodiments, formation of the corrugated container may occur by a food producer, by the corrugated manufacturer, or by another actor in the process 100 (such as a container former).

An example corrugator and various systems and devices that could be utilized with various embodiments of the present disclosure, such as in the corrugation phase 110, container blank forming phase 120, and container forming phase 130, are described further in U.S. Publication No. 2019/0018629, entitled “Digital Pre-Print Paper, Sheet, and Box Manufacturing Systems”, that application being owned by the Assignee of the present application and incorporated herein by reference.

In the insert product phase 140, product, such as food product described herein, may be inserted into the formed corrugated container. Such inserting of food product may be performed by one or more corresponding product handling devices/systems 145, such that product insertion may be automated or semi-automated, although manual insertion of food product is contemplated herein as well.

Once product is inserted into the corrugated container, the corrugated container may undergo sealing in the seal forming phase 150 to form a corrugated container assembly (e.g., corrugated container with seal applied). In the seal forming phase 150, a seal of, for example, flexible film may be sealed over the opening of the corrugated container to cover the product contained therein. Such sealing may occur via one or more sealing devices/systems 155, such that seal formation may be automated or semi-automated, although manual seal formation is also contemplated herein as well. As detailed further herein, the seal may be applied and sealed to the corrugated container via any application (e.g., cold application, hot application, pressure application, etc.) and may or may not use adhesive (e.g., glue). In some embodiments, the seal forming phase 150 may occur at the food producer, although other actors in the process 100 may perform the seal formation.

Once the corrugated container assembly is formed, it may be shipped (in the shipping phase 160), such as to a customer (e.g., a grocer, an end user, etc.) for use thereof (e.g., consumption, sale, etc.). In some embodiments, the corrugated container assembly may be packed with other corrugated container assemblies (or other items) and shipped accordingly. In some embodiments, a tray (e.g., a corrugated tray, a plastic tray, or other type tray) may be used to hold and ship a plurality of corrugated container assemblies. The tray may have a bottom portion with a wall that surrounds the corrugated container assemblies, and a removable top portion that can be secured to the bottom portion during shipping and removed such as for presentation of the corrugated container assemblies (and the products therein)—such as for display and individual purchase of the corrugated container assemblies (e.g., at a grocer). Upon arrival at the final destination, a user may remove, pierce, or peel back the top seal and remove the products from the container through the opening.

Example Corrugated Containers and Assemblies

An example corrugated container 10 that accomplishes such advantages is shown in FIG. 2. FIGS. 2-3 show an example formed corrugated container 10, and FIGS. 4-6 show an example formed corrugated container assembly including a corrugated container 10, 10″ and a top seal or film 50. With reference to FIGS. 2-6, the corrugated container 10 comprises a plurality of wall panels folded into walls. In some embodiments, the container 10 may include eight walls (e.g., faces): a front wall 32, a back wall 36, two opposing side walls 22, 26, and four diagonal opposing connector walls 73, 75, 77, 79. In this regard, the corrugated container 10 is formed of a bottom panel 12 and a plurality of wall panels 22, 26, 32, 36, 72, 74, 76, 78. Further, the illustrated corrugated container 10 includes a plurality of flange flaps 23, 27, 33, 37, 73, 75, 77, 79 and side flaps 82, 84, 86, 88. Corresponding panels (e.g., a bottom panel 12 and a plurality of wall panels 22, 26, 32, 3672, 74, 76, 78), corresponding flange flaps (e.g., flange flaps 23, 27, 33, 37, 73, 75, 77, 79), and corresponding side flaps (e.g., side flaps 82, 84, 86, 88) can be seen in the corrugated container blank form shown in FIG. 8 (with a similar alternative blank form shown in FIG. 9). As shown in FIG. 8, the side flaps 82, 84, 86, 88 may be attached to any of the wall panels depending on the desired container design.

To form the container 10 shown in FIG. 2, the side flaps 82, 84, 86, 88 may be attached to the side wall panels 22, 26 (although other wall panels can be used depending on the arrangement of the container blank 10). The attachment of the side flaps may be made using adhesive, for example, although additional or alternative attachment means may be utilized (e.g., tape, staples).

Notably, the example illustrated container 10 is just one example corrugated container and is shown for explanatory purposes only, as other corrugated container designs are contemplated herein. For example, instead of having 8 wall panels, more or less wall panels could be utilized. Additionally or alternatively, other shapes of containers are contemplated, such as a rectangular cross-section for the opening, a square cross-section for the opening (or other shapes). An example alternative corrugated container 310 is shown in FIG. 10. Notably, the corrugated container 310 includes similar features to the corrugated container 10 as described herein, but includes only four wall panels 322, 326, 332, 336 and four flange flaps 323, 327, 333, 337. The bottom panel 312 and the wall panels 322, 326, 332, 336 form a receptacle with a rectangular cross-section for receiving products therein. As described in greater detail herein, the flange flaps 323, 327, 333, 337 may fold outwardly to support placement of a seal for the receptacle thereon. One of ordinary skill in the art in light of the description herein will appreciate that a corresponding blank may be formed.

Returning to FIGS. 2-3, some of the plurality of wall panels 22, 26, 32, 36 are integrally attached with and extend from the bottom panel 12. For example, with reference to FIG. 8, front wall panel 32 is attached at its first end 32a to a first end 12a of the bottom panel 12. A fold line 13a may be formed therebetween. In some embodiments, a crushing action may be pre-formed (such as during the container blank forming phase 120 or the container forming phase 130) to encourage or aid in forming a fold along the fold line 13a (and/or other fold lines shown and described herein). To explain, in some embodiments, the flute medium that provides the rigidity and strength may be directional, such that the flute medium defines differing strength characteristics depending on its direction. In this regard, in some embodiments, the corrugated container blank may be crushed at certain points (e.g., fold line, areas, etc.) to weaken the strength characteristics of the corrugate at those points, such as to encourage the desired effect (e.g., folding along a certain line). Notably, this directional strength of the flute medium provides advantages as contemplated herein, but also requires design and thought regarding fold lines and other desired features used by various embodiments herein. For example, some embodiments of the present disclosure contemplate utilizing a single integral piece of corrugated web product for the corrugated container blank (e.g., shown in FIG. 8). However, as can be viewed, the fold lines run in any desired direction, and the flute medium runs in one consistent direction. Thus, some of the fold lines may work with the direction of the flute medium for ease of folding, whereas other fold lines may prove more difficult to fold (and, thus, in some embodiments, pre-crushing may be applied to enable easier formation of the desired corrugated container). As used herein, the formation of a “fold line” is not meant to be limited, as any formation process is contemplated, such as using scoring, weakness lines or areas, perforations, crushing, etc.

In some embodiments (not shown), the corrugated container may be formed from multiple blanks. For example, the container may be erected from a blank for the wall panels that is then connected (e.g., glued, stapled, interlocked, folded, attached) to a bottom made from a different blank. As another example, the container may be formed from a single blank and then reinforced (e.g., at the bottom) using another piece of corrugated web product or other material configured to attach to the formed container.

Returning to FIG. 8, as illustrated, the remaining wall panels 22, 26, 36 are also attached to the bottom panel 12 at respective portions of the bottom panel 12 with corresponding fold lines therebetween.

In some embodiments, the front wall panel 32, the back wall panel 36, and the side wall panels 22, 26 may extend from a bottom panel 12, as shown in FIG. 8. Two of the connector wall panels 72, 74 may extend out from the front wall panel 32 and the other two connector wall panels 76, 78 may extend out from the opposing back wall panel 36. Other forms are contemplated, such as container designs where more than four wall panels extend from the bottom panel 12 and/or where two or more connector wall panels extend from the side wall panels 22, 26, for example. In this way, the formed corrugated containers may take the shape of various polyhedrals depending on the desired design. In this regard, one of ordinary skill in the art in light of the description herein will appreciate that other shaped corrugated containers are contemplated.

With reference back to FIGS. 2-3, when the corrugated container 10 is formed, the plurality of wall panels 22, 26, 32, 36 are folded with respect to the bottom panel 12 and extend upwardly to form a receptacle 15 with the bottom panel 12 for receiving the products therein. Further, when the corrugated container 10 is formed, the plurality of wall panels 22, 26, 32, 36, 72, 74, 76, 78 further define an opening 15a for receiving the products therethrough. As used herein, the term “upwardly” or other similar directional term is not meant to be limiting as it is not meant to denote an exact direction and, unless otherwise stated, could encompass variations (e.g., substantially upwardly, generally upwardly, etc.). Likewise, the directionality of the term is meant for explanatory purposes, as other directions are contemplated in various embodiments. In some embodiments, when the container 10 is formed, the wall panels 22, 26, 32, 36, 72, 74, 76, 78 may form an angle with respect to the bottom panel 12, wherein the angle may be in the range of about 80° to about 170°. In some embodiments, the wall panels 22, 26, 32, 36, 72, 74, 76, 78 may form an obtuse angle with respect to the bottom panel 12, wherein the obtuse angle may be in a range of about 91° to about 150°, such that the opening 15a of the container is wider than the bottom panel 12.

As shown in FIG. 8, in some embodiments, the front wall panel 32, the back wall panel 36, and the side wall panels 22, 26 may widen as they extend from the bottom panel 12. The container design may enable the formed container 10 and receptacle 15 to widen toward the opening 15a. This widening may enable easier product filling of/removal from the formed container and/or more pleasant presentation of the products contained therein.

Some embodiments may include container blanks with a tubular form, in which the wall panels are already connected and/or united as one continuous panel with folds and/or corners. In these embodiments, the bottom 12 may be formed by multiple bottom panels extending from the wall panels. Additionally or alternatively, the bottom panel extending from one of the wall panels in a tubular container blank may include bottom flaps for folding and attaching to one or more wall panels to form the receptacle 15.

In some embodiments, when the corrugated container is formed, a plurality of flange flaps may extend outwardly from the opening to define a rim, such as to receive a seal thereon. For example, one or more flange flaps may fold outwardly from their corresponding wall panel with respect to the opening. In some embodiments, the flange flaps may only require a single fold to form the rim. In such a regard, in some embodiments, the flange flaps may be otherwise unsupported such that there is no additional connection to the container or additional fold of the flange flaps. In some embodiments, during manufacturing of the container blank 10, the various flange flaps may be perforated or otherwise scored to make folding with respect to the corresponding wall panels easier.

When formed, the flange flaps 23, 27, 33, 37, 73, 75, 77, 79 may be folded such that they are generally parallel with the bottom 12 and extend away from the opening 15 formed by the corresponding wall panels 22, 26, 32, 36, 72, 74, 76, 78. In particular, as shown in FIG. 2, when folded, a front flange 33 may extend from the front wall 32 and away from the opening 15a; a back flange 37 may extend from the back wall 36 and away from the opening 15a; two side flanges 23, 27 may extend from the two opposing side walls 22, 26, respectively, and away from the opening 15a; and four diagonal flanges 73, 75, 77, 79 may extend from the four diagonal opposing connector walls 72, 74, 76, 78, respectively, and away from the opening 15a.

Further, the flange flaps may be relatively small in width compared to, for example, the corresponding dimension of the wall panels (e.g., width or length depending on shape of the wall panels). For example, the flange flaps may only extend from about 0.125 inches to about 0.75 inches from the opening, as not much surface area of the flange flaps is needed to receive and hold a seal thereon. In this regard, since the flange flaps are formed of corrugated web product (e.g., with flute medium between the liners), the flange flaps are rigid enough to receive and hold a seal.

In some embodiments, the width of the flange flaps may extend from the opening about 5% to about 25% of the corresponding dimension of the wall panel from which the flange flap extends. In this way, a shorter flange may be easier to self-support—that is, the weight of the flange flap itself may not require any support beyond its single fold and/or perforated connection to the wall panel from which the flange flap extends. In this way, the container may save on material since a shorter, unsupported flange may not require additional complicated folds, structures, adhesives in order to maintain an orientation generally parallel to the bottom of the container, when formed. For example, when the container is formed, the flange flaps may form an angle with the wall panels, wherein the angle is within a range from about 90° to about 150°.

By forming a rim around the opening, the flange flaps therefore can form a structure that is configured to receive and hold the seal over the opening to contain the products stored in the receptacle. The upward-facing surfaces of the various flange flaps 23, 27, 33, 37, 73, 75, 77, 79, when folded, may act as a rim for sealing. Thus, in some embodiments, a longer flange flap width may be used in order to provide a greater surface area for maximizing the sealing opportunity and/or ensuring closure of the container. Further optimization of the widths of the various flange flaps may be applied depending on the size and configuration of the wall panels of a given container.

In the illustrated embodiment, with reference to FIGS. 2-3, when the corrugated container 10 is formed, a plurality of flange flaps 23, 27, 33, 37, 73, 75, 77, 79 may extend outwardly from opening 15a to define a rim, such as to receive a seal thereon. With reference to FIG. 8, as an example, the flange flap 33 may extend from a second end 32b of the front wall panel 33 (e.g., the second end 32b may be opposite the first end 32a—which is attached to the bottom panel 12). The flange flap 33 may include a first end 33a attached to the second end 32b of the front wall panel 32 at a fold line 34a. As noted above, in some embodiments, the fold line 34a may be pre-crushed to encourage folding thereon. The flange flap 33 may also define a second end 33b and side edges 33c, 33d. As shown in FIG. 8, the flange flap 33 may define a width extending between the first end 33a and the second end 33b that is about 0.25 inches. In some embodiments, this width between the first end 33a and the second end 33b may range from about 0.125 inches to about 0.75 inches, for example. This flange width range may allow the flange flap 33 to maintain an orientation generally parallel to the bottom 12 (e.g., horizontal) via the connections to the wall panel 32 across the fold line 34a, while providing sufficient surface area to obtain an appropriate (e.g., durable, yet peelable or removable) connection, joint, or bond with the seal 50 (e.g., film). In some embodiments, the flange flaps may remain unfolded until the seal is applied (e.g., right before or during application of the seal).

In some embodiments, the flange flaps may form a non-continuous rim around the opening, such that there may be spacing between consecutive flange flaps. In this regard, it may not be necessary to have a continuous rim surrounding the opening to still receive and hold an appropriate seal. As shown in FIG. 2, for example, the flange flap 27 includes a side edge 27c that is spaced apart from a side edge 79d of an adjacent flange flap 79—thereby forming a space or gap 47 therebetween. In some embodiments, one or more flange flaps may be omitted from corresponding wall panels. For example, one or more flange flaps (e.g., flange flaps 73, 75, 77, 79) may be omitted and still a proper seal could be applied to the corrugated container 10.

In some embodiments, one or more flange flaps may define a length that is less than a corresponding dimension of its corresponding wall panel. In this regard, various dimensions and configurations of flange flaps are contemplated by example embodiments of the present disclosure. For example, with reference to FIG. 8, the flange flap 33 includes a length (e.g., between side edges 33c and 33d) that is less than a corresponding dimension of a corresponding second end 32b of the attached front wall panel 32 (e.g., the width of the second end 32b is defined between side edges 32c and 32d of the front wall panel 32). In some embodiments, a flange length of each of the flange flaps 23, 27, 33, 37, 73, 75, 77, 79 may range from about 80% to about 100% of the corresponding dimension at the flange flap extension point (e.g., fold line 34a between wall panel 32 and flange flap 33) of each of the corresponding wall panels 22, 26, 32, 36, 72, 74, 76, 78, respectively, from which the flange flaps extend. For example, as shown in FIG. 8, the flange lengths of the flange flaps 23, 27 extending from the side wall panels 22, 26, respectively, may be approximately the same as the length of the side wall panels 22, 26 at the point at which the flange flaps 23, 27 begin to extend (e.g., the widest length of the side wall panels 22, 26).

Additionally, as shown in FIG. 8, the flange flaps (e.g., flange flaps 37, 79) extending from the wall panels (e.g., rear wall panel 36 and one of the wall panels 78), may include a gap (e.g., space 47) between the flange flaps. This gap may be created by the flange flaps having a flange length less than the corresponding dimension of the wall panels, from which the flange flaps extend, at the point the flange flaps begin. For example, one of the flange flaps (e.g., flange flap 75) that extends from one of the wall panels (e.g., wall panel 74) may have a flange length of about 1.2 inches; whereas, the corresponding dimension (e.g., width) of the wall panel (e.g., wall panel 74) at the point right before the flange flap begins may be about 1.4 inches (e.g., about 80%). As another example, the width of the front wall panel 32 at the point right before the flange flap 33 begins (e.g., the width at the side 32b) may be about 2 inches, while the length of the flange flap 33 may be about 1.8 inches (e.g., about 90%). The flange flaps may be centered relative to the wall panel from which they extend, however other positions are possible. For example, in some embodiments (not shown), side flaps (e.g., side flaps 82, 84, 86, 88) of the container 10 may include flange flaps spanning a partial width/length of the side flaps, extending away from the bottom panel, and positioned to one side of the side flap (e.g., toward flange flaps 73, 75, 77, 79). In such embodiments, the flange flaps of the side flaps may fold over wall panels (e.g., wall panels 22, 26) to which the side flaps are attached when the container is formed, thus providing support for some of the flange flaps.

FIG. 9 illustrates another example corrugated container blank 10′ that forms a slightly different corrugated container 10′ when formed. In this regard, the flange flaps may define even less of a length than the flange flaps in FIG. 8. For example, the flange flap 33′ may define a length between side edges 33c′ and 33d′ that is less than the length of flange flap 33 between side edges 33c and 33d (shown in FIG. 8). As shown in FIG. 9, in some example embodiments, the container blank 10′ may include narrower flange flaps 23′, 27′, 33′, 37′, 73′, 75′, 77′, 79′ with flange lengths that only extend to about 60% to about 70% of the corresponding dimension of the corresponding wall panels 22′, 26′, 32′, 36′, 72′, 74′, 76′, 78′, respectively, from which the flange flaps extend. For example, the side panel 26′ may be about 4.625 inches long, while the flange length of the side flange flap 27′ may be about 3 inches long (e.g., about 70%). Making the flange lengths smaller may help save on corrugate material and/or adhesive.

In some embodiments (not shown), the flange flaps may widen and/or be cut wider than the wall panels, from which the flange flaps extend. In these embodiments, the flanges may overlap one or more other flanges to form a continuous (or at least partially continuous) rim around the opening 15a when the container 10 is formed. This may enable the top seal 50 to be completely sealed around the rim of the container 10.

One of ordinary skill in the art (in view of this disclosure) will appreciate that the wall panels may define different shapes, such as the trapezoidal shape of the front wall panel 32 versus the rectangular shape of the wall panel 72 shown in FIG. 8. Similarly, different shapes are contemplated for the flange flaps and the bottom panel—such as needed to form the desired corrugated container shape.

In some embodiments, the corrugated container may include additional panels or features that enable its formation into the desired shape. For example, with reference to FIG. 8, the corrugated container 10 includes wall panels 72, 74, 76, 78 that are not directly attached to the bottom panel 12 and, instead, are attached to the sides of the front wall panel 32 and the back wall panel 36. Further, the corrugated container 10 includes side flaps 82, 84, 86, 88 that extend from respective such wall panels 72, 74, 76, 78 and enable formation of the corrugated container such as by adhering or attaching the side flaps 82, 84, 86, 88 to the side wall panels 22, 26 (e.g., consider FIG. 8 and FIG. 2, for example). Such adhering or attaching may occur, for example, during the corrugated container forming phase 130.

The container design may include various holes cut from the container panels giving access to the receptacle 15 inside. These holes may have various or multiple purposes, including access and/or display ports for the products stored therein, handling, transport, and/or processing aids, cover receptacles, and/or vents, for example. In some embodiments, the corrugated container may include one or more ventilation features, such as formed for open air access for the products stored in the corrugated container even after the seal is applied (e.g., shown in FIGS. 5 and 6). Such ventilation may enable the products to stay fresher longer and/or may enable washing of the products while they are contained within the corrugated container.

In some embodiments, the one or more ventilation features may be formed through at least one of the plurality of wall panels. For example, the ventilation feature may be a cut-out formed in the one of the wall panels (e.g., connector wall panel 72) completely surrounded by the connector wall panel. In some embodiments, a ventilation feature may be formed from a combination of cut-outs in the bottom 12 and the side walls 22, 26, as seen in FIG. 6. In some embodiments, the opposing front and back walls 32, 36 may include ventilation features, such as the round cut-outs 67 seen in FIG. 6. The ventilation features may allow for material savings, temperature control of the stored products, and/or convenient handling of the containers 10. For example, with reference to FIGS. 2 and 8, an elongated slot-shaped ventilation feature 65 is pre-cut from both side wall panels 22, 26 (although embodiments of the present disclosure contemplate other forms of removal, such as using lines of weakness to enable removal of the ventilation feature). The feature 65 may act as a vent and/or handle, as described below.

In some embodiments, the ventilation features and/or the handle feature may be removable and defined by one or more series of perforations (e.g., weak points, cuts, scores, etc.). These perforations may help a user with removal of a cut-out, such as through separation of the cut-out from the front wall along the line of perforations, to form the ventilation feature and/or handle feature. In this way, the container 10 may be customizable to various uses and/or products. Though referred to as ventilation features or handle features, various formed openings or holes may provide any desired functionality, such as a machine processing aid, an access hole, among many other things).

FIGS. 5-6 illustrate an example circular ventilation feature 67 removed from the front and back wall panels 32″ and 36″. While the above examples include certain shapes, any shape of ventilation feature is contemplated. Notably, a benefit of using corrugated web product to form the container 10, 10″ is that the wall panels (or other panels) still maintain the desired strength and rigidity even with removal of a portion thereof for the ventilation feature.

In some embodiments, the one or more ventilation features may be formed based on the design of the container blank, such as by defining the shapes of one or more panels or flaps accordingly. For example, with reference to FIGS. 2 and 8, a rectangular-shaped ventilation feature 66 is formed after formation of the container 10 due to the relative sizes and positioning of the wall panels 72, 74, 76, 78 and bottom panel 12. In some embodiments, the connector wall panels 72, 74, 76, 78 may be cut such that one or more ventilation features 66 allow the receptacle 15 access to the open air, as shown in FIG. 2. In the depicted embodiment, the ventilation features 66 are created by the length of the connector walls 72, 74, 76, 78 not reaching all the way to the bottom 12. Alternative forms are contemplated. Referring to FIG. 8, it can be seen that, for example, wall panel 72 includes a side edge 72a that is spaced apart from a corresponding edge 32a of the wall panel 32 (e.g., the side edge 72a is not flush with edge 32a at the fold line 13a such that when the side flap 82 is attached to the side wall panel 26, ventilation feature 66 is formed, as shown in FIG. 2).

In some embodiments, one or more handles may be formed into the corrugated container. For example, similar to some of the ventilation features, holes in the container may be formed that are designed to act as handles for use, such as during transportation of the corrugated container/corrugated container assembly (e.g., with or without the seal applied). In some embodiments, one or more of the walls may include a handle feature. For example, the side walls 22, 26 may each include a handle feature (e.g., an access point for handling 65) for conveniently gripping the container 10. Similar to the ventilation feature, the handle feature may be cut-out from one or more of the wall panels during formation of the container blank 10.

In some embodiments, one or more features may be added to the corrugated container, such as separately-attached features (e.g., handles, straps, etc.) or features printed thereon. For example, as noted herein, one or more printing devices may be configured to print features on the panels. Example printed features include markings (e.g., for use during the manufacturing process 100), customer logos, barcodes, product information, etc. In some embodiments (not shown), one or more external handles may be added to the container 10.

In some embodiments, the container 10 (or portions thereof) may be formed of single-walled corrugate. However, in some embodiments, the container 10 (or portions thereof) may be formed of double-walled corrugate to add strength thereto, such as may be beneficial for shipping and/or handling. In some embodiments, the container 10 (or portions thereof) may be formed of additional layers of corrugate (e.g., triple-walled corrugate, or more), such as may be beneficial for further increased strength. In some embodiments, the container 10 (or portions thereof) may be formed of other types of material, such as cartonboard, microflute corrugate, etc.

As noted herein, some embodiments of the present disclosure are designed to hold uncut food products, such as vegetables (e.g., cucumbers, peppers, mushrooms, garlic, carrots, beans, tomatoes, etc.) and/or fruit (e.g., strawberries, blueberries, raspberries, etc.). However, in some embodiments, the corrugated containers may be designed to hold food products in cut form (e.g., cut vegetables, cut fruit, cut cheese, cut meats, etc.). In such embodiments, one or more interior surfaces of the corrugated container may be coated to help protect and/or preserve the cut food, such as from bacteria, prevent the cut food from absorbing the fibers from the container or other undesirable effects. For example, the interior surface of one or more of the bottom panel 12, the wall panels 22, 26, 32, 36, 72, 74, 76, 78, and side flaps 82, 84, 86, 88 may be at least partially coated with a coating substance that may be, for example, designed to protect the cut food products contained therein. In some embodiments, all of the panels except for the flange flaps may be coated with wax or another coating. The flange flaps may be left uncoated to enable better sealing of the film 50 to the corrugate. Alternatively, the corrugate product may be entirely coated and an additional coat and/or other processing may be applied to just the flange flaps in order to enable sealing of the film 50 to the rim. In some embodiments, the coating may be applied as spot coating during a printing phase.

The corrugated container 10 may be configured to receive a seal, such as on the flange flaps. The seal may be sized to fit over the opening of the corrugated container, and may adhere and/or attach to the rim (formed by the flange flaps) so as to contain the products within the receptacle. In some embodiments, the seal may be formed of a flexible film that may be adhered and/or attached to the flange flaps through various application methods alone or in combination, such as via cold application, hot application, pressure, among others. In some embodiments, adhesive or other attachment features (e.g., staples, tape, shrinking, etc.) may be applied along with the film to cause the seal to form. FIG. 4 illustrates an example seal 50 applied over the opening 15a of the corrugated container 10. As shown, the seal 50 includes edge portions 55 that are adhered to and/or attached to the flange flaps forming the rim (e.g., flange flaps 23, 33). In some embodiments, adhesive may be pre-applied to the flange flaps prior to positioning the film thereover for sealing. Notably, only a small surface area of the flange flaps is required to enable formation of a proper seal, such as due to the strength provided by using corrugated web product to form the flange flaps.

In some embodiments, the film is at least partially transparent to enable viewing of the products contained in the receptacle. For example, with reference to FIGS. 5-6, the seal 50 is formed of a transparent film that enables of viewing into the container 10″. Example films usable with various embodiments of the present disclosure include various polymer films, such as plastic wrap, cling wrap, etc. Notably, while some example embodiments describe the seal as a film, other seal types are contemplated by various embodiments, such as various lids or glass or other material. In some embodiments, the seal 50 may be clear or transparent film. In other embodiments, the seal 50 may be an opaque cover made from paper, cardboard, paper board, etc. The seal 50 may include printing and/or aesthetic designs for describing and/or advertising the products retained within the container 10.

Some example films used in conjunction with various example embodiments can be formed from a variety of polymers, coatings, and adhesives across a variety of manufacturing methods. As examples, but not limited to, coextruded, extrusion laminated, extrusion coated, monolayer, monolayer coated, multilayer laminated, or multilayer adhesive films could all be candidates for use.

Embodiments of the present disclosure contemplate many different ways to create a seal with various example corrugated containers described herein. For example, depending on the characteristics of the seal, different techniques can be applied to cause an effective seal to be formed. In some embodiments, a sealing device 155 can be used to apply an example film to the flange flaps to form a container assembly (although manual seal formation is also contemplated). For example, a film (e.g., a high tack film) could be applied directly over the flange flaps without a support structure positioned below the flange flaps (e.g., an example support structure is described with respect to FIGS. 7A-7B).

FIGS. 7A-B illustrate some other example processes for applying an example seal to example corrugated containers, such as those described herein. Such processes may occur during the seal forming phase 150. In this regard, the described processes may be performed using or in conjunction with one or more sealing device(s) 155.

With reference to FIG. 7A, prior to applying the seal, the formed corrugated container 10 may be inserted into a seal guide feature 90. The seal guide feature 90 may include a cut-out 92 that is sized to receive and hold a formed corrugated container 10. In this regard, in some embodiments, the flange flaps may be positioned adjacent a support surface 91 that is configured to provide support to the flange flaps during application of the seal (such as described with respect to FIG. 7B). In the illustrated embodiment, as an example, the flange flap 27 is designed to fit on top of a portion 92c of the support surface 91 and flange flap 33 is designed to fit on top of another portion 92a of the support surface 91.

Turning to FIG. 7B, once the corrugated container 10 is inserted into the seal guide feature 90, the flange flaps will be positioned between the support surface 91 of the seal guide feature 90 and a press device 95. The film 50 can be positioned over the flange flaps and opening. In some embodiments, an adhesive may be applied to one or more flange flaps (or the film) before the film is positioned over the flange flaps. With the film 50 in position, the pressing device 95 may be operated to press down (e.g., along arrow D) to cause a pressing surface 96 to apply the film 50 to the flange flaps (e.g., flange flap 27). In some embodiments, the film 50 may be provided from a roll and may be cut before or after application to form a proper size for use as a seal to cover the opening.

Notably, utilizing the seal guide feature 90 applies a resistive force against the bottom of the flange flaps as the pressing force is applied by the pressing device 95 to the top of the flange flaps. This helps in proper formation of the seal. In some embodiments, the rigidity of the flange flaps (such as from the flute medium) aids in maintaining the desired form factor and strength during and after application of the seal. In contrast to fold-over flaps (e.g., flaps configured to fold all the way over such that they are parallel to a wall panel from which they extend) that may simply double or otherwise increase the thickness of a rim of a container, the flange flaps may be folded such that they are parallel (e.g., horizontal) to the bottom of the container.

FIGS. 7A-B illustrate just one example sealing method and corresponding sealing device 95, as others are contemplated herein.

Example Flowchart(s)

Embodiments of the present disclosure provide methods and systems for forming a corrugated container, inserting the product and applying the seal, and shipping the container assembly for use, according to various embodiments described herein. In this regard, associated systems and methods for manufacturing, shipping, and forming example corrugated container and corrugated container assembly designs described herein are contemplated by some embodiments of the present disclosure. Such systems and methods may include various machines and devices, including for example container forming devices (e.g., for folding, gluing, and/or taping containers, among other things) and/or corrugators. In this regard, known corrugators utilize web product (e.g., liner) and flute medium to form corrugated web product (which may be formed into any number of layered corrugate, such as conventional corrugate (liner, flute medium, liner) or double-walled corrugate (liner, flute medium, liner, flute medium, and liner)). The formed corrugated web product may then be cut (e.g., scored, sliced, perforated, etc.) as needed to form the corrugated container blank. An example corrugator is further described in U.S. Publication No. 2019/0016081, which was filed Jul. 12, 2018, and entitled “Controls for Paper, Sheet, and Container Manufacturing Systems”, the contents of which is incorporated by reference herein in its entirety.

Various examples of the operations performed in accordance with some embodiments of the present disclosure will now be provided with reference to FIG. 11. In this regard, FIG. 11 illustrates a flowchart according to an example method for forming a corrugated container, inserting the product and applying the seal, and shipping the container assembly for use according to an example embodiment 200. The operations illustrated in and described with respect to FIG. 11 may, for example, be performed by, with the assistance of, and/or under the control of one or more of a user or a machine for performing the operation (e.g., a corrugator for forming the corrugated container blanks, a container-forming machine for forming the container or portions thereof, a product handling machine for inserting the product into the container, a sealing device for applying a seal to the corrugated container, etc.).

Operation 202 may comprise forming the corrugated web product, and operation 204 may comprise forming the container blank. As noted above, such operations may be performed by various known machines/devices, such as a corrugator.

Operation 206 may comprise forming the corrugated container, which may occur, for example, using a container forming device and/or manually via a user. Operation 208 may comprise inserting the product into the corrugated container, which may occur, for example, using a product handling device and/or manually via a user. Operation 210 may include applying the seal to the flange flaps to cover the opening of the corrugated container. This may be completed by, for example, a sealing device and/or manually via a user.

Operation 212 may comprise shipping the corrugated container assembly and providing the corrugated container assembly (with seal applied and product inside) for use at operation 214.

CONCLUSION

Many modifications and other embodiments set forth herein may come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the embodiments of the present disclosure are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the present disclosure. Moreover, although the foregoing descriptions and the associated drawings describe example embodiments in the context of certain example combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative embodiments without departing from the scope of the present disclosure. In this regard, for example, different combinations of elements and/or functions than those explicitly described above are also contemplated within the scope of the present disclosure. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A corrugated container for receiving products therein, the corrugated container comprising: a bottom panel;a plurality of wall panels, wherein: each of the plurality of wall panels extends from the bottom panel, andwhen the container is formed, the plurality of wall panels are folded with respect to the bottom panel and extend upwardly to form a receptacle with the bottom panel for receiving the products therein, andwhen the container is formed, the plurality of wall panels further define an opening for receiving the products therethrough; anda plurality of flange flaps, wherein: each of the plurality of flange flaps extends from one of the plurality of wall panels, andwhen the container is formed, the plurality of flange flaps are folded with respect to the plurality of wall panels away from the opening and define a rim for receiving a seal thereon,wherein the seal is formed of film and configured to at least partially cover the opening of the container, wherein the seal is configured to at least one of adhere or attach to the rim.

2. The corrugated container of claim 1, wherein the bottom panel, the plurality of wall panels, and the plurality of flange flaps are formed of an integral piece of corrugated web product.

3. The corrugated container of claim 1, wherein a flange width of one of the plurality of flange flaps is within about 5% to 25% of a corresponding dimension of the wall panel from which the flange flap extends.

4. The corrugated container of claim 3, wherein the corresponding dimension of the wall panel is within about 1.5 to 3.5 inches.

5. The corrugated container of claim 1, wherein, when the container is formed, one or more consecutive ones of the plurality of flange flaps are configured to define a space therebetween such that the rim is not continuous around the opening.

6. The corrugated container of claim 1, wherein, when the container is formed, the plurality of flange flaps form a discontinuous rim.

7. The corrugated container of claim 1, wherein at least one of the plurality of flange flaps defines a length that is less than a corresponding dimension of an end of the corresponding one of the plurality of wall panels from which the one of the plurality of flange flaps extends, wherein the flange flap folds about the end.

8. The corrugated container of claim 1, wherein the receptacle is defined by an interior surface of the bottom panel and an interior surface of each of the plurality of walls, wherein the interior surface of the bottom panel and the interior surface of each of the plurality of walls includes a coating adapted to preserve cut food products contained within the receptacle.

9. The corrugated container of claim 1, wherein, when the container is formed, the plurality of flange flaps are folded away from the opening to be parallel with the bottom panel to define the rim.

10. A blank for a corrugated container for receiving products therein, the blank comprising: one or more bottom panels;a plurality of wall panels, wherein, when the container is formed, the plurality of wall panels: are folded with respect to the one or more bottom panels and extend upwardly to form a receptacle with the bottom panel for receiving the products therein, anddefine an opening configured to receive the products therethrough; anda plurality of flange flaps, wherein: each of the plurality of flange flaps extends from one of the plurality of wall panels, andwhen the container is formed, the plurality of flange flaps are folded with respect to the plurality of wall panels away from the opening and define a rim for receiving a seal thereon,wherein the seal is formed of film and configured to at least partially cover the opening of the container and at least one of adhere or attach to the rim.

11. The blank of claim 10, wherein the blank is formed of an integral piece of corrugated web product.

12. The blank of claim 10, wherein a width of one of the plurality of flange flaps extending from the one of the plurality of wall panels is between 0.125 in. to 0.75 in.

13. The blank of claim 10, wherein, when the container is formed, one or more consecutive ones of the plurality of flange flaps are configured to define a space therebetween such that the rim is not continuous around the opening.

14. The blank of claim 10, wherein at least one of the plurality of flange flaps defines a length that is less than a corresponding dimension of the one of the plurality of wall panels from which the one of the plurality of flange flaps extends

15. The blank of claim 10, wherein the blank further defines one or more ventilation features formed through at least one of the plurality of wall panels such that the products stored in the container have open-air access.

16. The blank of claim 10, wherein the plurality of wall panels includes at least four wall panels.

17. The blank of claim 10, wherein the seal is at least partially transparent.

18. The blank of claim 10, wherein the seal includes printing thereon.

19. The blank of claim 10, wherein at least one of the plurality of wall panels includes printing thereon.

20. A method of making a sealable container comprising: forming corrugated web product; andcutting out a blank from the corrugated web product, wherein the blank can be formed into a container for receiving products therein, the blank comprising: a plurality of wall panels, wherein, when the container is formed, the wall panels are folded with respect to at least one bottom panel to define a plurality of walls that define an opening configured to receive the products, wherein: when folded with respect to the one of the plurality of wall panels, the at least one bottom panel defines a bottom of the container, andwhen the container is formed, the bottom and plurality of walls define a receptacle for storing the products therein, anda plurality of flange flaps, wherein: each of the plurality of flange flaps extends from one of the plurality of wall panels, andwhen folded with respect to the plurality of walls away from the opening, the plurality of flange flaps define a rim for receiving a seal thereon, andwherein the seal is formed of film and configured to at least partially cover the opening of the container and at least one of adhere or attach to the rim.

21. The method of claim 20, further comprising: cutting out a ventilation hole in at least one of the plurality of wall panels of the blank from the corrugated web product.

22. The method of claim 20, further comprising: erecting the container from the blank.

23. The method of claim 20, further comprising: inserting the products into the receptacle of the container;positioning the film over the opening of the container; andsealing the film to the rim of the container with the products stored therein.

24. The method of claim 23, wherein sealing the film to the rim of the container comprises: fitting the container, when formed, into a seal guide feature such that the rim rests on a support structure; andapplying pressure to the film and rim.

25. The method of claim 23, wherein sealing the film to the rim of the container comprises applying heat and pressure to the film and the rim.

26. The method of claim 23, wherein sealing the film to the rim of the container comprises applying an adhesive between the film and the rim.

27. An assembly for presenting products stored therein to consumers, the assembly comprising: a corrugated container for storing products therein, the corrugated container comprising: a bottom panel defining a bottom of the container;a plurality of wall panels folded with respect to the bottom panel to define a plurality of walls extending upward from the bottom, wherein: the plurality of walls define an opening at a top of the container, andthe plurality of walls define a receptacle with products stored therein, anda plurality of flange flaps, wherein: each of the plurality of flange flaps extends from one of the plurality of wall panels, andthe plurality of flange flaps are folded with respect to the plurality of walls away from the opening and define a rim for receiving a seal thereon; anda film defining the seal that is sized to fit over the opening of the container and is sealed to the rim of the container.

28. The assembly of claim 27, wherein the bottom panel, the plurality of wall panels, and the plurality of flange flaps are formed of an integral piece of corrugated web product.

29. The assembly of claim 27, wherein the film is at least partially transparent.