Stackable shipping and display box
An elongate, rectangular box (16, 60, 80) and method for packaging containers (C), wherein the box can be cross-stacked for stable stacking of the boxes, and optimizes utilization of pallet space. Containers (C) are placed in the box in diagonally offset relationship to one another in a parallelogram-shaped arrangement, and interior corner inserts (14,15, 61,62, 81,82) are placed in the boxes to form diagonal interior corner panels extending across two diagonally opposite corners of the box, defining an interior box shape closely conforming to the parallelogram-shaped arrangement of the containers. The inserts also define structure that supports one box on top of one another when the boxes are stacked. The box is especially suited for packaging four one-gallon containers.
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This application is a continuation-in-part of application Ser. No. 10/799,967, filed Mar. 12, 2004.
TECHNICAL FIELDThis invention relates to packaging, and more particularly to a stackable shipping and display box.
BACKGROUND ART Many products are shipped in cartons or boxes that enable the product to be displayed in the shipping box at the point of sale. These types of boxes are particularly suitable for products sold in club stores, where many products, e.g., juices, typically are packaged in one-gallon containers. Conventional boxes for handling one-gallon containers usually comprise full depth closed regular slotted containers (RSC's), although partial depth boxes or trays are sometimes used. A divider that extends between the containers normally is used in the partial depth trays to provide adequate strength. Further, conventional boxes for holding one-gallon containers are commonly designed for holding six containers, although some packages, such as those shown in
To facilitate handling, it is common practice to stack several layers of filled boxes on a pallet, and sometimes to stack two or more pallets high. Conventional square boxes are often column stacked, and typically require internal or external support to eliminate or reduce load on the bottles. Column stacking of the boxes is inherently unstable, and layer sheets, or slip sheets, may be employed between adjacent layers of boxes to improve the stability of the stacked boxes.
Moreover, the pallets used typically have dimensions of 48×40 inches, and the square boxes do not utilize the pallet space well, i.e., a plurality of the boxes placed in a layer either do not occupy the entire pallet space, or they overhang the pallet, depending upon how the boxes are oriented and how many are placed in a layer on the pallet. Conventional square boxes do not permit any arrangement of the boxes on a pallet that will result in the footprint of the area occupied by the boxes being substantially equal to the shape and area of the pallet. When conventional square boxes holding four one-gallon containers are placed on a conventional 48×40 inch pallet, often only nine boxes, or thirty-six one-gallon containers, can be accommodated in each layer of boxes without overhanging the edges of the pallet, depending upon the bottle diameter and/or footprint.
Applicant's prior copending application Ser. No. 10/799,967, discloses a shipping and display box that, when filled with containers of product, has a maximum desired weight, is configured to enable stable stacking of filled boxes, optimally utilizes pallet space, and places no load on the product containers, all without requiring the use of separate layer sheets, or separate internal or external pieces intended solely as reinforcements. The box in the prior application is designed for machine set-up, and except for the embodiment illustrated in
Accordingly, there is need for a stackable shipping and display box having the novel features of the box disclosed in prior copending application Ser. No. 10/799,967, but wherein the box can be set up by hand.
DISCLOSURE OF THE INVENTIONThe present invention comprises a box for shipping and displaying product, wherein the box can be set up by hand, has a desired case weight, is configured so that filled boxes can be stacked in stable interlocked relationship, optimally utilizes pallet space, and the product containers are not subjected to load when filled boxes are stacked on top of one another.
The box of the invention comprises a rectangular tray having predetermined length and width dimensions to hold a desired number of product containers in contiguous, side-by-side, diagonally offset relationship to one another. The diagonally offset placement of the containers results in interior spaces at two diagonally opposite corners of the box, and at least one separate insert is placed in the box, forming angled corner panels that extend into these spaces to contact the containers to help retain them in the box and to provide stacking support and prevent vertical loads on the containers. The tray and insert are each made from respective blanks of corrugated board that can be folded by hand.
The rectangular shape of the boxes enables boxes in adjacent layers to be cross-stacked and interlocked for stable stacking, and the diagonally offset relationship of the containers in the box results in outer box dimensions that maximally utilize pallet space when the boxes are stacked on a pallet. These boxes can be placed on a conventional 48×40 inch pallet so that the footprint of the area occupied by a layer of boxes is substantially the same as the area of the pallet surface. With the invention, eleven boxes holding forty-four containers can be placed in a layer on a 48×40 inch pallet, although it should be understood that these numbers can vary, depending upon the bottle diameter and footprint. Boxes incorporating the invention can be stably stacked two or more pallets high and without imposing a vertical load on the containers.
Although the boxes could be configured to hold different numbers and sizes of containers and still incorporate the features of the invention, in the particular embodiments illustrated and described herein they are sized to hold four one-gallon containers. When loaded with four one-gallon containers of juice, for example, a package using the box of the invention has a case weight that is less than about 40 pounds.
Additionally, empty containers, e.g., bottles, can be inverted and placed upside down in the box by the bottle manufacturer for shipment to a facility for filling the bottles. The shape of the box, including the angled corner panels, securely holds the inverted empty bottles in place even when some of the side walls have a reduced height to define openings through which the bottles are visible.
The box of the invention is equally suitable for use with containers having a round cross-section or a non-round cross section, e.g., square.
BRIEF DESCRIPTION OF THE DRAWINGSThe foregoing, as well as other objects and advantages of the invention, will become apparent from the following detailed description taken in conjunction with the accompanying drawings, wherein like reference characters designate like parts throughout the several views, and wherein:
A conventional box of square shape designed for holding four one-gallon containers C is shown at 10 in
The invention solves this problem, as depicted somewhat schematically in
Inserts 14 and 15 are placed in the boxes to define a generally parallelogram-shaped box interior, as seen best in
A first embodiment of a box according to the invention is shown at 16 in
The inserts 14 and 15 placed in diagonally opposite corners of the tray form diagonally extending panels 23 and 24 across the corners. Containers C placed in the tray are supported in diagonally offset relationship by the rectangularly shaped tray and the inserts. The inserts also enable loaded boxes to be stacked on top of one another without imposing load on the containers.
The tray is erected by hand from a single blank B1 as shown in
First side wall panels 31 and 32 are each foldably joined along a first edge thereof to respective opposite side edges of the panel 22 by fold scores or creases 33, and second side wall panels 34 and 35 are foldably joined along a first edge thereof to a second edge of respective first side wall panels by closely spaced double scores or crease lines 36, 37. The second side wall panels 34 and 35 comprise roll-over panels, and a pair of tabs 38 and 39 on the outer edge of the roll-over panels engage in the slots 25 and 26 when the side wall panels are folded up and inwardly to form the side walls 18 and 19. It will be noted that the roll-over panels 34 and 35 are cut away at one end 40. These cut-outs form a space for accommodating an insert panel as described hereinafter.
To erect the tray 17 from the blank B1, the end wall panels 20 and 21 are first folded upwardly, with the flaps 28 and 29 being folded inwardly in general alignment with opposite side edges of the bottom panel 22. The first side wall panels 31 and 32 are then folded upwardly, and the second side wall panels 34 and 35 are folded inwardly and downwardly, capturing the flaps 28 and 29 between the first and second side wall panels, which form outer and inner side wall panels, respectively, in the erected container. The tabs 38 and 39 are then engaged in the slots 25 and 26 to hold the tray in assembled position.
The inserts 14 and 15 are identically constructed and a blank for forming the inserts is indicated at B2 in
The bendable tab 30 formed in an upper edge of each tray end wall is inserted through aligned openings 51 and 52 in the first and fifth panels 41 and 45 to hold the insert in its operative folded position and in the tray.
The inserts are erected by hand from a single blank B2 (
A second embodiment of the invention is indicated generally at 60 in
A blank B4 for making a modified tray that could be used with the embodiment of
A further modified blank B5 that could be used with any of the inserts described herein is shown in
When four one-gallon containers C are placed in any of the embodiments of the box of the invention, they are oriented in nested, offset or staggered relationship as depicted in
The inserts and adjacent side and end wall portions define triangular reinforcing structures at two diagonally opposite corners of the box, lending stacking strength to the box and enabling boxes filled with containers to be stacked two or more pallets high without imposing load on the containers.
While particular embodiments of the invention have been illustrated and described in detail herein, it should be understood that various changes and modifications may be made to the invention without departing from the spirit and intent of the invention as defined by the scope of the appended claims.
Claims
1. A box for shipping and storing containers of product, said box
- comprising a rectangularly shaped tray having a greater length dimension than width dimension and having a bottom wall, opposite end walls, and opposite side walls disposed orthogonally to the end walls and defining an elongate interior space, the ratio of said length and width dimensions being such that when containers of product are placed in the tray they are constrained to a side-by-side, diagonally offset relationship to one another in a generally parallelogram-shaped arrangement.
2. A box as claimed in claim 1, wherein:
- angled interior corner panels extend diagonally across two diagonally opposite interior corners the tray, defining a generally parallelogram-shaped box interior; and
- said parallelogram-shaped arrangement of the containers therein conforms to the interior shape of the box, whereby the containers are closely constrained against movement in the box.
3. A package as claimed in claim 2, wherein:
- the angled interior corner panels comprise inserts placed in the tray.
4. A package as claimed in claim 3, wherein:
- the inserts define structure extending above the height of containers placed in the tray to support an upper box when boxes loaded with containers are stacked on top of one another.
5. A shipping and display box for containers of product, comprising:
- a box having a bottom wall, opposite end walls, and opposite side walls disposed orthogonally to the end walls to define an elongate rectangularly shaped box having four corners; and
- angled interior corner panels extending diagonally across two diagonally opposite corners of the box, defining a generally parallelogram-shaped interior space in the box, said interior space having a dimensional relationship to containers to be placed therein such that when a number of containers are placed in the box they are contstrained to a side-by-side parallelogram-shaped arrangement that conforms closely to the interior shape of the box, said elongate rectangular shape of the box enabling the boxes to be cross-stacked and interlocked with one another to produce a stable stack of the boxes.
6. A box as claimed in claim 5, wherein:
- the diagonally extending interior corner panels have a height that is at least as great as the height of containers placed in the box, whereby boxes filled with containers may be stacked on top of one another without imposing a load on the containers, said interior corner panels serving to support an upper box on a lower box and imparting stacking strength to the box as well as defining said parallelogram-shaped interior space that conforms closely to the parallelogram-shaped arrangement of containers placed therein.
7. A box as claimed in claim 6, wherein:
- said interior corner panels comprise separate inserts placed in the box.
8. A box as claimed in claim 7, wherein:
- said inserts each include a first panel extending parallel to and lying against an adjacent end wall, second and third panels extending parallel to and lying against respective opposite side walls, and a fourth panel extending from the third panel to adjacent the first panel and forming said diagonally extending interior corner panel.
9. A box as claimed in claim 8, wherein:
- said box is configured to closely conform to and hold four one-gallon containers disposed in said box in side-by-side diagonally offset relationship.
10. A box as claimed in claim 5, wherein:
- said box is formed from a single unitary blank of corrugated cardboard.
11. A box as claimed in claim 10, wherein:
- the side walls of said box comprise outer side wall panels and inner roll-over side wall panels;
- the end walls comprise an end wall panel having a flap on each of opposite ends thereof, said flaps being captured between the outer side wall panel and inner roll-over panel of respective adjacent side walls; and
- tabs on a lower edge of the roll-over panels engaged in slots in the bottom wall to hold the roll-over panels in place, and thus hold the box in erected position.
12. A box as claimed in claim 7, wherein:
- said box, including said bottom wall, side walls and end walls, is formed from a first blank of corrugated cardboard, and said inserts are formed from respective second and third blanks of corrugated cardboard.
13. A box as claimed in claim 8, wherein:
- said inserts each include a reversely folded fifth panel extending from the fourth panel toward the third panel, said fifth panel extending parallel to and lying against the first panel.
14. A box as claimed in claim 8, wherein:
- said inserts each include a fifth panel extending from the fourth panel toward the second panel, said fifth panel extending parallel to and lying against an adjacent end wall of the box.
15. A box as claimed in claim 14, wherein:
- a notch is formed in an upper edge of the insert at the juncture of the fourth and fifth panels, and a tab on an upper end edge of the first panel is engaged in the notch to hold the insert in operative folded relationship.
16. A box as claimed in claim 13, wherein:
- aligned openings are formed through the first and fifth panels of the insert, and a tab is formed in an adjacent end wall of the box, said tab being engaged in the openings to hold the insert in operative folded position and to hold it in the box.
17. A box as claimed in claim 15, wherein:
- an opening is formed through the first panel, and a tab is formed on the adjacent end wall, said tab being engaged in the opening to hold the insert in the box.
18. A blank for forming an elongate, rectangular box having a bottom wall, opposite end walls, and opposite side walls, comprising:
- an elongate, rectangular center panel that forms said bottom wall in an erected box;
- opposite end panels foldably connected along a first edge to opposite ends of the center panel for forming said end walls in an erected box;
- a flap foldably connected to each of opposite ends of the end panels;
- a first side wall panel foldably connected at a first edge thereof to each of the opposite side edges of the center panel;
- a second side wall panel foldably connected at a first edge to a second edge of the first side wall panel, said second side wall panel comprising a roll-over panel and having tabs projecting from a second edge thereof, and one end edge of each said roll-over panel having a cut out; and
- slots in said center panel at opposite side edges thereof for receiving said tabs on said roll-over panel when a box is erected from said blank, and said flaps on the end panels being captured between the first side wall panel and the roll-over panel when a box is erected from said blank.
19. A blank for forming an insert to be placed in a corner of a box to form a stacking support to support one box on top of another when they are stacked, and to form an interior diagonally extending corner panel in a box, said blank comprising:
- a first rectangular panel adapted to lie against an end wall of a box;
- a second rectangular panel foldably joined to a first edge of the first panel and adapted to lie against an adjacent first side wall of a box;
- a third rectangular panel foldably joined to a second edge of the first panel and adapted to lie against an adjacent second side wall opposite the first side wall; and
- a fourth rectangular panel foldably joined to the third panel and adapted to extend diagonally from the third panel to the first panel to form with the first and third panels a triangularly shaped structure when the blank is operatively folded and placed in a box.
20. A blank as claimed in claim 19, wherein:
- a fifth rectangular panel is foldably joined to said fourth panel, said fifth panel being foldable toward said third panel to lie against said first panel when said blank is operatively folded and placed in a box.
21. A blank as claimed in claim 19, wherein:
- a fifth rectangular panel is foldably joined to said fourth panel, said fifth panel being foldable toward said second panel to lie against an end wall of a box when said blank is operatively folded and placed in a box.
22. A method of packaging containers in boxes to optimize utilization of pallet space on which said boxes are stacked, and to enable the boxes to be cross-stacked and interlocked with one another to produce a stable stack, comprising the steps of:
- folding a first blank of corrugated cardboard to form a tray having an elongate rectangular shape with side walls and end walls disposed orthogonally to one another;
- folding second and third blanks of corrugated cardbord to form first and second inserts having opposite side panels, an end panel, and a diagonal panel extending from one side panel to the end panel;
- placing the inserts in opposite ends of the tray to provide diagonally extending corner panels in diagonally opposite corners of the tray; and
- placing a predetermined number of containers in the tray in side-by-side, diagonally offset relationship to one another in a substantially parallelogram-shaped arrangement.
23. A method as claimed in claim 22, wherein:
- the containers are one-gallon containers, and four of the containers are placed in the box.
Type: Application
Filed: Oct 1, 2004
Publication Date: Sep 15, 2005
Applicant:
Inventor: Charles Weimer (Danielson, CT)
Application Number: 10/957,567