Abstract: The present invention is a method for forming a corrugated container having a double wall construction. A blank is formed of a pair of corrugated layers sandwiched between and adhered to adjacent flat layers and having a sufficient moisture content to enable the blank to be formed. The blank can include printed indicia, thermoresistant coatings, release coatings, and other coatings applied to the blank to enhance the utility of the container formed from the blank. The blank is then inserted into a thermoforming machine in which a pair of heated dies compress the blank into the desired container shape.

Abstract: An extremely thin, high flute density, printable, corrugated paperboard having a combined caliper thickness of about 0.040 inches or less includes a first flat paper liner about 0.0085 to 0.010 inches thick, a corrugated medium having a paper thickness of about 0.005 to 0.008 inches, with the flute dimensions including a cordal flute height of about 0.021 inches and a distance between flute crests of about 0.070 inches, and a second flat paper liner about 0.0065 to 0.01 inches thick, the composite paperboard product having about 181 flutes per linear foot. The process for manufacturing the corrugated paperboard includes novel steps for forming the flutes in a manner which will not cause wrinkling or tearing of the paper stock, and the application of a novel adhesive formulation having solid content of about 28.8 percent and a Steinhall viscosity of about 23 seconds.

Abstract: An apparatus for supporting an article in shock-isolating, spaced relation to the walls of a container is provided. A support wall and a plurality of lateral support members define a partial enclosure for receiving the article. Corner support members secure the support wall and the lateral support members in the configuration defining the enclosure. Spacer support members extend from the lateral support members to position the article receiving enclosure in spaced relation away from the walls, the top and the bottom of the container, to provide shock-isolation for protecting the article supported, capped and at least partially received by the apparatus.