Corrugated shipping container system

Abstract

The disclosure indicates that the compression strength of a corrugated shipping crate can be increased through the use of horizontal panels adhered to the inside surface of the vertically fluted outer walls of the crate. The panels can comprise a layer of horizontally fluted single layer of double wall or triple wall corrugated, and a layer of vertically oriented double or triple wall corrugated. The crates' outer walls can be vertically fluted 1100 weight corrugated or less. The double wall vertically fluted corrugated, can be corrugated board have a weight in the range from 500 to 1100 pounds.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described in conjunction with the accompanying drawings, in which:

FIG. 1 is a plan view of an embodiment showing a pre-folded C wall with three score lines dividing the wall into four sub-panels in accordance with an embodiment of the invention;

FIG. 2 is plan view of an embodiment showing three horizontal inner panels adhered to three wall sub-panels in accordance with an embodiment of the invention;

FIG. 3 is plan view of an embodiment showing three horizontal inner panels adhered to three wall sub-panels in a configuration that is the reverse of the configuration of FIG. 2. The C walls of FIGS. 2 and 3 are identical is plan view of an embodiment showing three horizontal inner panels adhered to three wall sub-panels in accordance with an embodiment of the invention;

FIG. 4 is a plan view of the embodiment of FIG. 2 folded to its C configuration in accordance with an embodiment of the invention;

FIG. 5 is a top view of two C walls of FIG. 6C being placed together to form the container of FIG. 7 in accordance with and embodiment of the invention;

FIG. 6 is a top cross sectional view of the two C walls of FIG. 5 adhered together to form a corrugated crate in accordance with and embodiment of the invention;

FIG. 7 is a perspective view of an embodiment showing an assembled crate, with upper and lower lids in accordance with and embodiment of the invention;

FIG. 8A is a plan view of an embodiment showing the wall panel of FIG. 2, in a folded form, for compact shipping in accordance with and embodiment of the invention;

FIG. 8B is a plan view of the folded wall of FIG. 6A, being opened to the configuration of FIG. 2 in accordance with and embodiment of the invention;

FIG. 9 is a perspective view of a partially assembled crate have having different length end sub-panels in accordance with and embodiment of the invention;

FIG. 10 is the fully assembled crate of FIG. 9 showing the different length end sub-panels in accordance with and embodiment of the invention;

FIG. 11 is a top view of a crate having a horizontal fluted panel affixed to two of the sub-panel walls in accordance with and embodiment of the invention;

FIG. 12 is a top view of a crate having a horizontal fluted panel affixed to three of the sub-panel walls and where two end flaps are open in a door like fashion in accordance with an embodiment of the invention; and

FIG. 13 is a top view of a crate having both horizontal and vertical fluted sections affixed to individual sub-panels.

DETAILED DESCRIPTION

It is advantageous to define several terms before describing the invention. It should be appreciated that the following definitions are used throughout this application.

Definitions

Where the definition of terms departs from the commonly used meaning of the term, applicant intends to utilize the definitions provided herein, unless specifically indicated otherwise.

As employed herein, the term “corrugate paper” and the term “corrugated board” are used interchangeably, and are inclusive of single, double and triple wall corrugated materials for shipping crates, as well known in the art.

As employed herein, the term “crate” refers to an enclosure of any size or shape formed from a base an end cap and a pair of panels. Typically, the base is a second end cap. A crate formed from two end caps and two J panels, or two “U” panels.

As employed herein, the term “overlap” refers to the side-by-side arrangement of a panel or sub-panel of a wall of a crate, and a sub-panel or panel of another wall of a crate. The term overlap is used interchangeably with the term “superjacent” meaning to lie over, upon, or overlying. FIG. 9 shows end panels of walls 902 and 900, superjacent with each other.

As employed herein, the term “J” panel refers to a panel having at least one corner turn, that is, an L shaped corner. The term is inclusive of a panel having two corner turns in the form of a “J” or a which, for simplicity, is referred to as a “U”. An inner subpanel is preferably longer than the other two panels, but the two arms of the U can be the long sides of a crate. Fold lines separate the three subpanels, and the two outer sub-panels are contiguous with the inner one or two sub-panels. A “J” crate can have two outer panels of unequal dimensions. Depending upon the dimensions of a crate, the base of the “J” can be the longer of the sidewalls of a crate. In a four-foot crate, there may be three panels of roughly the same length.

As employed herein, the term “scored” when used with respect to corrugated panels, is inclusive of an elongated crushing of the corrugated material to form a region about which subpanels can be folded to form an “L”, a “U” or a “J” shaped configuration.

As employed herein, the term “contiguous” refers to components that have been constructed integrally with an adjacent component, as for example, the subpanels of a panel having multiple parts. Contiguous subpanels are separated by score lines that facilitate the forming of corner folds and folds for storage and/or shipping of corrugated board to an assembly facility.

As employed herein, the term “single wall” refers to corrugated material that has one corrugated layer and two outer flats sheets.

As employed herein, the term “double wall” refers to corrugated material that has two corrugated layers separated by a flat sheet and two outer flats sheets.

As employed herein, the term “triple wall” refers to corrugated material that has three corrugated layers, with each layer being separated by a flat sheet and two outer flats sheets, thus providing four flat sheets and three corrugated sheets.

As employed herein, the designation of “1,300 weight paper”, indicates that 1,000 square feet of the paper from which the flutes are made and weighs 1,300 pounds. Similarly, the designation “1,100” indicates that 1000 square feet of the sheet material weighs that 1,100 pounds. It is noted that, by way of contrast, the weight of Kraft paper is based on paper weight, per 3,000 square feet.

As employed herein, the term “flute” refers to the layer of corrugated board that typically is used with two outer layers of flat sheets.

Description of Embodiments of the Invention

The invention relates to the design and manufacturing of cross core panel crates and a system of shipping these crates as folded corrugated panels, preferably on a skid, prior to assembly. The disclosed crates provide higher crush resistance than prior art crates at a lighter weight.

FIG. 1 illustrates the exterior face 112 of panel 110 that forms vertical walls of the cross core panel crate in the unfolded position, ready for assembly. The panel 110 is divided into four sub-panels, 120, 130, 140 and 150 by score lines 126, 136 and 146. Each crate is made up of two panels 110, each having four (4) sub-panels 120, 130, 140 and 150, created by three (3) score lines 126, 136, 146. The score lines 126 and 146 enable the sub-panel 110 to be folded into the C shape to form the crate, as described herein after. The center score line 136, in conjunction with the outer score lines 126 and 146, enables the panel 110 to be folded into the compact shipping formation as illustrated hereinafter in 8A and 8B.

FIGS. 2 and 3 illustrate the inner face 114 and 114 of the panels 110 and 110R that are used to form the crate. Score line 126 separates the contiguous sub-panels 122 and 132; score line 136 separates contiguous sub-panels 132 and 142R and score line 146 separates sub-panels 142 and 152. To provide the strength required for a shipping crate, horizontally fluted panels 134, 144, and 154 are adhered to the sub-panels 130, 140 and 150, respectively. The fluted panels 134, 144 and 154 are adhered proximate the center of the sub-panels 130, 140 and 150. The fourth panel 122 remains open and does not receive a fluted panel in order to provide the overlap with the second panel 110R.

As seen in FIG. 3, the second panel 110R forming the crate is illustrated. In most embodiments the first panel 110 and second panel 110R are identical, however it could be seen in some embodiments where irregular crates are required that the two panels could be dimensioned differently. The corresponding designations for the sub-panels in FIG. 3 on the interior surface 114R are 122R, 132R, 142R and 152R. Score line 126R separates the contiguous sub-panels 122R and 132R; score line 136R separates contiguous sub-panels 132R and 142R and score line 146R separates sub-panels 142R and 152R. As with the first sub-panel 110, three of the four sub-panels, 132R, 142R and 152R have horizontally fluted panels 134R, 144R and 154R, respectively, adhered at approximately the middle. It should be noted that the configuration of the horizontally fluted panels 154, 144, 134 and 154R, 144R, 134R in FIGS. 2 and 3, are actually identical. When the wall forming panel, indicated generally by arrow 110 in FIG. 2 is rotated 180 degrees, it is identical to wall forming panel 110R of FIG. 3. Accordingly, pair of the panels 110 and 110R is used to form a crate such as illustrated in FIG. 5.

In FIG. 4 panel 110 is illustrated in the folded position. As can be seen, the fluted panels 154, 144 and 134 face the interior of the crate. Sub-panel 150 is folded at score line 146 to form one end of the crate. Score line 136 is not folded once the panel 110 is being assembled into a crate and is only used for the shipping process that is described further hereinafter. Sub-panel 120 is folded at score line 126 to form the overlap end 160 to the crate.

FIG. 5 illustrates the wall panel unit 110R folded and placed to interact with the panel 110. The two wall units 110 and 110R come together to form the crate with overlap panel 160 being adhered to the exterior 112R of sub-panel 150R and the overlap panel 160R being adhered to the exterior surface 112 of sub-panel 150R.

Glue, or any other convenient bonding agent adheres the horizontal fluted panels 154, 144,134, to the wall panels 110 and 110R. Similarly, glue, or any other bonding agent adheres horizontal fluted panels 154R, 144R and 134R to the wall panel 110R. Additionally, glue or any other convenient bonding agent is used to adhere the overlap panel 160 to the sub-panel 150R and the overlap panel 160R to the sub-panel 150. The method of adhering the horizontal fluted panels to a wall panel and the overlap panels to the wall panels is not narrowly critical. One skilled in the art can use any convenient method of securing the horizontal sub-panels to a wall panel.

While triple wall corrugated paper is a preferred material for the wall panels, such as 110 and 110R, double wall corrugated board can also be used.

FIG. 6 shows the flute orientation of wall panel 110 and wall panel 110R. The horizontal panels 134, 144, 154, 134R, 144R and 154R do not reveal their flutes because they are horizontal to the open top and bottom. Conversely, the flutes 180 of wall panel 110 are vertical, and thus are visible. Similarly, the flutes 180R of wall 110R are also visible.

Once the panels 110 and 110R are assembled, the crate is completed as illustrated in FIG. 7. The crate 700 shows the panel 120 overlapped by overlap panel 160R, with the opposing end (not shown) having panel 150 overlapped by overlap panel 160. As can also be seen here, the score lines 146 and 126 ar folded while center score line 136 remains unfolded. The base, or lower lid, 702 is dimensioned to receive the assembled panels 110 and 110R and provide the required lateral rigidity. Additional rigidity is provided by the top 706. In most embodiments the crate 700 will either be set upon a skid 510 that raises it from the ground. Alternatively, the crate 700 can be manufactured with feet as part of the lower lid 702.

In order to facilitate shipping, the panels 110 are folded into four equal sections as illustrated in FIGS. 8A and 8B. The ability to fold the panels 110 is enabled by the score lines 126, 136 and 146, which enables sub-panel 120 to lie adjacent to sub-panel 130; sub-panel 130 to lie adjacent to sub-panel 140 and sub-panel 140 to lie adjacent to sub-panel 150 as illustrated in FIG. 8A. Although the score line 136 is not used to bend the crate during assembly, it is critical to the ability to compactly ship the unassembled panels 110 on skids, within the top and bottom lids or in shipping crates. Upon reaching it destination is unfolded as illustrated in FIG. 6B, until it is once again in the configuration of FIG. 2. The fluted panels 134, 144, and 154 are shipped flat along with the panels 110 and can be assembled at the time of use.

An alternate embodiment of the shipping crate is illustrated in FIG. 9 wherein crate 900 has the end sub-panels 920 and 920R dimensioned shorter than the end sub-panels 950 and 950R. The remaining sub panels 930, 940 and 950 and the counterpart sub-panels 930R, 940R and 950R remain equal sizing and carry the horizontal fluted panels 934, 944, 954 and the counterpart horizontal fluted panels 934R, 944R, 954R. As with previous embodiments, the panels 910 and 901-R are folded at score lines 926R, 946R, 926 and 946. Score lines 936R and 936 (not shown) are not folded when assembled and are only used when the panels 110 are being shipped. The embodiment of FIG. 9 can also be folded and shipped flat as described heretofore.

The crate 900 in FIG. 10 has been assembled with the upper lid 986 and lower lid 988 in place. As seen in this embodiment the end sub-panel 920R is dimensioned to cover only a portion of the end sub-panel 950. As with prior embodiments, the score line 936, between sub-panels 940 and 930 is not folded. As described heretofore, the crate 900 is placed on a skid 900 or other structure to enable movement by forklift.

FIG. 11 shows an alternate embodiment in which single horizontal inner panels 1106 and 1106R spans the length of the interior of the sub-panels 1102, 1104, 1102R and 1104R and thus overlies the middle panels score lines 1136 and 1136R. In this embodiment the end sub-panels 1120, 1120R, 1130 and 1130R are substantially the same length.

FIG. 12 shows an alternate embodiment in which a single horizontal panel 1202 spans the length of three of the sub-panels 1230, 1240, and 1250 of wall panel 1200, and two of the sub-panel score lines 1236 and 1246. The corresponding panel 1200R has three if the sub-panels 1230R, 124R, and 1250R spanned by single horizontal panel 1202R, covering score liens 1236R and 1246R. It should be noted that the sub-panels 1250 and 1220R can be left to open similar to a door to facilitate packing.

FIG. 13 illustrates a further embodiment of the invention that provides substantially increased crush resistance. In this embodiment the panel 1310 is divided into sub-panels 1320, 1330, 1340 and 1350 and its counterpart panel 1310R is divided into sub-panels 1320R, 1330R, 1340R and 1350R. As previously described, horizontal fluted panels 1334, 1344 and 1354 are adhered to sub-panels 1330, 1340, 1350 and horizontal fluted panels 1334R, 1344R and 1354R are adhered to sub-panels 1330R, 1340R, 1350R. The end sub-panels 1320 and 1320R are substantially the same length as the sub-panels 1350 and 1350R. In this embodiment, however, additional vertical flute panels 1338, 1348 and 1358 are adhered to horizontal fluted panels 1334, 1344 and 1354 on the inner surface. Additional vertical flute panels 1338R, 1348R and 1358R are also adhered to the interior surface of horizontal fluted panels 1334R, 1344R and 1354R.

It is recognized that materials other than corrugated paper board can be used based on current technology and future improvements in technology. Corrugated plastic is not preferred because of ecological reasons, but from a structural standpoint, corrugated plastic and paper are equivalents. Recyclable plastics are preferred to plastics that are not readily recycled.

It is highly preferable that the two corrugated wall units in the foregoing embodiments are essentially identical. This provides an economy in the manufacture of the units and an advantage in that only one type of unit needs to be stored. It also provides ease of assembling of the crate since there is minimal chance for error.

The corrugated material for the horizontal panels may be triple wall, e.g. 600, 750, 900, 1100, or 1300 weight triple wall, etc. The corrugated material can also be a double wall, e.g. 275, 350, 500, 750 weight double, etc.

Similarly, a crate can be formed from two 12 by 7 foot panels having two outer subpanels that are about 8×7 and an inner sub-panel that is about 4×7 to produce a crate that is 8×4×7 and having overlying outer panels. The long sides thus have two overlaying panels.

The panel dimensions are selected such that at least two panel units are employed to form a crate. At least one panel has two or three subpanels and no panel has more than three subpanels. That is, no panel can form more than three sides of the crate. Two panels having three subpanels can be used, or four panels with two subpanels can be used. The shortest of the three panels, can serve as a door to provide ease of access to the crate interior.

The compression resistance of crates can be tested by using r ASTM D4169/D642. Failure of crates tested under ASTM D4169/D642, occurs when the crate compresses to any extent. The tests are all run to failure and since the tests are run in twenty pounds increments, the compression prior to failure, that is, the maximum compression strength, is twenty pounds less than compression at failure.

Testing of the Compression Strength of Different Combinations of Corrugated Board

COMBINATION	# compression	Deflection	Notes
1-1300-1300 triple-triple	12960	2.16	27% more
wall			expensive
2-1100-1100 triple-triple	13500	2.08	4% stronger
wall
3-1300-500-1300	18060	1.72	18.3% more
TW-DW-TW			expensive
4-1100-500-1100 TW DW	22710	—	25.6% stronger
TW
5-1300-500 triple-double	11190	1.92″	24.7% more
			expensive
6-1100-500 triple-double	13950	2.30″	24.7% stronger

All tests were conducted with crates having the same crate design.

DW refers to double wall corrugated.

TW refers to triple wall corrugated.

The combination of Test 1 employs material that is 27% more expensive than the material of Test 2. Nevertheless, the combination of Test 2 is 4% stronger than the combination of Test 1.

The combination of Test 2 is 18.3% more expensive than the material of Test 4. Contrary to conventional wisdom the combination of Test 4 is 4% stronger than the combination of Test 3.

The combination of Test 5 is 24.7% more expensive than the material of Test 6. Contrary to conventional wisdom the combination of Test 6 is 4% stronger than the combination of Test 5.

In tests 1 and 2 the crate panels are all vertical/vertical.

In tests 3 and 4, the triple layered corrugated is vertical.

In all tests the 500 double wall horizontal panels have flutes that are horizontally relative to the vertical flutes of the wall panels.

The tests were conducted by an independent testing laboratory.

The test results show that the horizontal/vertical fluting of tests 5 and 6 are stronger than the triple wall crates of test 1 and 2. The unusual results are attributed to the use of the horizontal fluting to keep the vertical fluting from bowing.

The use of horizontally fluted panels adhered to the vertically oriented wall panel, provides a less expense, as well as a higher crush strength crate.

The higher crush strength of the 1100 triple wall compared to 1300 triple wall is attributed to the lighter weight material being less likely to bow. The lighter weight paper seems to relax and maintain unbowed. Perhaps the 1100 was easier for the 500 DW horizontal fluting to keep from bowing. The explanation for the unusual results is presented only for guidance and general knowledge but is not a part of the inventions described herein The results are unusual, contrary to common logic, and therefore an explanation of the tests showing the reverse of what would be expected is not a limitation of the invention Other explanations may come to light in the future.

All documents, patents, journal articles and other materials cited in the present application are herein incorporated by reference.

Broad Scope of the Invention

While illustrative embodiments of the invention have been described herein, the present invention is not limited to the various preferred embodiments described herein, but includes any and all embodiments having equivalent elements, modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the present disclosure. The limitations in the claims (e.g., including that to be later added) are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive. For example, in the present disclosure, the term “preferably” is non-exclusive and means “preferably, but not limited to.” In this disclosure and during the prosecution of this application, means-plus-function or step-plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation: a) “means for” or “step for” is expressly recited; b) a corresponding function is expressly recited; and c) structure, material or acts that support that structure are not recited. In this disclosure and during the prosecution of this application, the terminology “present invention” or “invention” may be used as a reference to one or more aspect within the present disclosure. The language present invention or invention should not be improperly interpreted as an identification of criticality, should not be improperly interpreted as applying across all aspects or embodiments (i.e., it should be understood that the present invention has a number of aspects and embodiments), and should not be improperly interpreted as limiting the scope of the application or claims. In this disclosure and during the prosecution of this application, the terminology “embodiment” can be used to describe any aspect, feature, process or step, any combination thereof, and/or any portion thereof, etc. In some examples, various embodiments may include overlapping features. In this disclosure, the following abbreviated terminology may be employed: “e.g.” which means “for example”.

Claims

1- A substantially rectangular crate having four exterior side panels, said four side panels being formed of a single rectangular length of corrugated material, said material being at least 800 weight triple layer corrugated paper, a plurality of inner panels adhered to the interior surface of said exterior panels, said interior panels being 700 or less corrugated paper.

2- The crate of claim 1, said exterior side panels being triple wall corrugated paper having a weight of at least 1100.

3- The crate of claim 1, wherein the flutes in the outer layer run vertically, and the flutes in the inner panels run horizontally.

4- The crate of claim 1, wherein said four exterior side panels are double wall or triple wall, vertically oriented corrugated, and the inner panel are double wall horizontally oriented corrugated.

5- The crate of claim 1, said exterior side panels being triple wall corrugated paper having a weight of about 1100 pounds.

6- The crate of claim 1, said interior side panels being double wall corrugated paper having a weight of 500 pounds.

7- The crate of claim 5, said exterior side panels being double wall corrugated paper having a weight of 500 pounds.

8- A substantially rectangular crate having four exterior side panels, said four side panels being formed of a single rectangular length of corrugated material, said material exterior side panels having vertical flutes, a plurality of inner panels adhered to the interior surface of said exterior panels, said interior panels having horizontal flutes.

9- The crate of claim 8, said exterior side panels being triple wall corrugated paper having a weight in the range from 900 to 1200.

10- The crate of claim 8, said exterior side panels being triple wall corrugated paper having a weight on the order of about 1100 pounds.

11- The crate of claim 8, said interior side panels being double wall corrugated paper having a weight on the order of about 500 pounds.

12- The crate of claim 10, said exterior side panels being double wall corrugated paper having a weight of 500 pounds.

13- A substantially rectangular crate having four exterior contiguous side panels, said four side panels being formed of a single rectangular length of corrugated material, said material being at least 800 weight triple layer corrugated paper, a plurality of inner panels adhered to the interior surface of said exterior panels, said interior panels being 700 or less corrugated paper.