METHOD OF FORMING CONTAINERS HAVING TOP FLANGE WITH GLUED CORNERS, SAME CONTAINERS, AND BLANKS FOR FORMING SAME

A method of forming a container from a blank includes applying an adhesive to an interior surface of side flange tabs of the blank, rotating the end panels of the blank inwardly towards a bottom panel, rotating side panels of the blank inwardly towards the bottom panel, and rotating the side flange panels of the blank outwardly into a parallel orientation to the bottom panel. The method further includes, after rotating the side flange panels, rotating end flange panels into a parallel orientation to the bottom panel and coupling the end flange tabs to the side flange tabs to form the container having a fully formed top flange.

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Description
CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 63/220,311 filed Jul. 9, 2021, U.S. Provisional Patent Application No. 63/309,805 filed Feb. 14, 2022 and to U.S. Provisional Patent Application No. 63/320,428 filed Mar. 16, 2022, all of which are entitled, “METHOD OF FORMING CONTAINERS HAVING TOP FLANGE WITH GLUED CORNERS, SAME CONTAINERS, AND BLANKS FOR FORMING SAME”, which are incorporated herein by reference in their entirety.

BACKGROUND

The field of the present disclosure relates generally to methods of forming containers, and, more particularly, to a container having a top flange with corners thereof that are glued during formation of the container, and methods for forming same.

Containers come in a variety of forms. Certain conventional containers, such as boxes, punnets, trays, etc., typically have an enclosed bottom portion with four sides. Some containers include a top portion or lid to close the container, while other containers have open tops. In some instances, containers are formed and are later filled with a product and then sealed with a film adhered across the top thereof, to close the container.

In some such instances, the containers are initially formed with they have an open top portion such that they can be later filled. Frequently, such containers are formed and stacked or nested with one another, and are transported to another location for filling and/or sealing. In some instances, containers include a flanged portion around their top rim, to which a sealing film is eventually adhered. In some known containers containing these flanged portions, the flange is not formed at the same time that the container is initially formed. Rather, formed containers with planar (unflanged) sidewalls are stacked and transported for filling; once filled, the flanges of the containers are folded outwards to form the sealing surface during the sealing process.

Other conventional containers may have the flange formed during initial formation of the container, but the flange is formed by merely folding the flange into place. That is, the flange is not set or glued in place.

These known containers may be weak and prone to disengagement of various portions of the flange with one another. Further, such containers may experience a poor seal, because the flange is prone to disengagement, or require a more robust seal, which can be complex, time-consuming, and/or expensive to produce. Further, when the containers are nested, they may become stuck together and present problems when the containers are to be separated to fill and/or seal.

Containers may be separated by human means or by machine as part of an automated packing process. Regardless of the method being used to fill the containers, difficulty may arise when the containers nest too tightly. When the flanges between each respective container rest directly on top of one another, it can be difficult, by machine or by hand, to separate the flanges and pull the containers apart. If the flanges are adequately spaced apart, it is easier to reliably separate the containers.

BRIEF DESCRIPTION

In one aspect, a method of forming a container from a blank is provided. The blank includes a bottom panel, two opposing side panels, two opposing end panels, a respective end flange panel extending from a top edge of each end panel and a respective end flange tab extending from each side edge of each end flange panel. The blank further includes a respective side flange panel extending from a top end of each side panel and respective side flange tabs extending from respective end edges of each side flange panel. The method includes applying an adhesive to an interior surface of the side flange tabs, rotating the end panels inwardly towards the bottom panel, rotating the side panels inwardly towards the bottom panel, and rotating the side flange panels outwardly into a parallel orientation to the bottom panel. The method further includes, after the rotating the side flange panels, rotating the end flange panels into a parallel orientation to the bottom panel and coupling the end flange tabs to the side flange tabs to form the container having a fully formed top flange.

In another aspect, a container is provided. The container includes a bottom panel, two opposing side panels coupled to the bottom panel along a respective first set of fold lines, and two opposing end panels coupled to the bottom panel along a respective second set of fold lines. The container further includes respective end flange panels extending from top edges of each end panel and in an orientation that is generally parallel to the bottom panel, respective end flange tabs extending from each side edge of each end flange panel, and respective side flange panels extending from top ends of each side panel in an orientation that is generally parallel to the bottom panel. The container further includes respective side flange tabs extending from respective end edges of each side flange panel, the side flange tabs each being coupled to a respective end flange tab to form a top flange of the container.

In yet another aspect, a method of stacking a first container on a second container is provided. The first container and second container are each formed from respective blanks having substantially the same size and shape. The blanks each include a bottom panel, two opposing side panels, and two opposing end panels. The blanks further include a respective end flange panel extending from a top edge of each end panel, a respective end flange tab extending from each side edge of each end flange panel, a respective side flange panel extending from a top end of each side panel, and respective side flange tabs extending from respective end edges of each side flange panel. The method includes forming the first container by applying an adhesive to an interior surface of the side flange tabs, rotating the end panels inwardly towards the bottom panel, rotating the side panels inwardly towards the bottom panel, rotating the side flange panels outwardly into a parallel orientation to the bottom panel, after rotating the side flange panels, rotating the end flange panels into a parallel orientation to the bottom panel, and coupling the end flange tabs to the side flange tabs to form the container having a fully formed top flange. The method further includes forming the second container and positioning the first container within a cavity of the second container such that a denesting assembly of one of the first container and the second container engages the other of the first container and the second container to space the top flange of the first container from a top flange of the second container.

In other aspects, containers formed using such methods and blanks for forming such containers are also provided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of an example blank of sheet material for forming a container in accordance with the present disclosure.

FIG. 2 is a perspective view of an example container formed from the blank shown in FIG. 1.

FIG. 3 is a side perspective view of a stack of a plurality of containers shown in FIG. 2.

FIG. 4 is a top plan view of another embodiment of a blank of sheet material for forming a container in accordance with the present disclosure.

FIG. 5 is a perspective view of an example container formed from the blank shown in FIG. 4.

FIG. 6 is a top plan view of another embodiment of a blank of sheet material for forming a container in accordance with the present disclosure.

FIG. 7 is a top plan view of another embodiment of a blank of sheet material for forming a container in accordance with the present disclosure.

FIG. 8 is a perspective view of an example container formed from the blank shown in FIG. 7.

FIG. 9 is a flow diagram of a method of forming a container from a blank in accordance with the present disclosure.

FIG. 10A is a top plan view of an example blank of sheet material for forming a container with denesting assemblies in accordance with the present disclosure.

FIG. 10B is an enlarged view of the region B of the blank sheet of material shown in FIG. 10A, showing one of the denesting assemblies of the blank.

FIG. 11 is a perspective view of an example container formed from the blank shown in FIG. 10A.

FIG. 12 is another perspective view of the container shown in FIG. 11.

FIG. 13 is another perspective view of the container shown in FIG. 11.

FIG. 14 is a perspective view of a stack of a plurality of containers shown in FIGS. 11-13.

FIG. 15 is a top plan view of another embodiment of a blank of sheet material for forming a container in accordance with the present disclosure.

FIG. 16 is a perspective view of an example container formed from the blank shown in FIG. 15.

FIG. 17 is a side perspective view of a stack of a plurality of containers shown in FIG. 16.

FIG. 18 is a top plan view of another embodiment of a blank of sheet material for forming a container in accordance with the present disclosure.

FIG. 19 is a perspective view of an example container formed from the blank shown in FIG. 18.

FIG. 20 is a side perspective view of a stack of a plurality of containers shown in FIG. 19.

 DETAILED DESCRIPTION

The following detailed description illustrates the disclosure by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the disclosure, describe several embodiments, adaptations, variations, alternatives, and make use of the disclosure, including what is presently believed to be the best mode of carrying out the disclosure.

Embodiments of the present disclosure provide a stackable container including a top flange. The container is constructed from a blank of sheet material using a machine and/or by hand. For example, the blank can be folded around a mandrel to form a container, or the container can be formed by hand and/or by another style of a tray forming machine. Alternatively, a folder/glue machine can be used to form the container. In one embodiment, the container is fabricated from a paperboard material. The container, however, may be fabricated using any suitable material, and therefore is not limited to a specific type of material. In alternative embodiments, the container is fabricated using cardboard, plastic, fiberboard, foam board, corrugated paper, and/or any suitable material known to those skilled in the art and guided by the teachings herein provided.

In an example embodiment, the container includes at least one marking thereon including, without limitation, indicia that communicates the product, a manufacturer of the product, and/or a seller of the product. For example, the marking may include printed text that indicates a product's name and briefly describes the product, logos and/or trademarks that indicate a manufacturer and/or seller of the product, and/or designs and/or ornamentation that attract attention. “Printing,” “printed,” and/or any other form of “print” as used herein may include, but is not limited to including, ink jet printing, laser printing, screen printing, giclée, pen and ink, painting, offset lithography, flexography, relief print, rotogravure, dye transfer, and/or any suitable printing technique known to those skilled in the art and guided by the teachings herein provided. In another embodiment, the container is void of markings, such as, and without limitation, indicia that communicates the product, a manufacturer of the product and/or a seller of the product.

In some embodiments, an interior and/or an exterior surface of the blank, and the resultant container, is coated or sealed. Such coating or sealing may make the container water resistant or resistant to bacteria. In other embodiments, the seal or coating may facilitate preserving a freshness of a product (e.g., a produce product) retained in the container. In any embodiment, such a coating or sealing may be applied to any section(s) of any surface(s) of the container.

In some embodiments, the container may include means of denesting the containers when they are in a stacked configuration. In some embodiments, a denesting assembly is located at a bottom corner. The denesting assembly may include a denesting tab, which, when folded inward, prevents the containers from sticking in the stacked configuration and provides a gap between the flanges of the stacked containers. In another embodiment, a denesting tab may be located at a top corner of the container, along the lower surface of the container flange. When the containers are stacked, the lower edge of the denesting tab of one container rests on top of the flange of the container below, therefore provides a spacing between the flanges. The spacing allows for easier gripping of the flange, by humans or by machine, and aids in the separation of the containers.

Referring now to the drawings, and more specifically to FIG. 1, depicted is a top plan view of an example embodiment of a blank 100 of sheet material. A container 200 (see FIG. 2) is formed from blank 100. Blank 100 has a first or interior surface 101 and an opposing second or exterior surface 103. Further, blank 100 defines a leading edge 102 and an opposing trailing edge 104. In one embodiment, blank 100 includes, in series from leading edge 102 to trailing edge 104, a first end panel 106, a bottom panel 108, and a second end panel 110 coupled together along preformed, generally parallel, fold lines 112 and 114, respectively.

More specifically, first end panel 106 extends from leading edge 102 to fold line 112, bottom panel 108 extends from fold line 112 to fold line 114, and second end panel 110 extends from fold line 114 to trailing edge 104. When container 200 is formed from blank 100, as described further herein, fold line 112 defines a bottom edge of first end panel 106 and a first end edge of bottom panel 108, and fold line 114 defines a second end edge of bottom panel 108 and a bottom edge of second end panel 110.

A first side panel 116 extends from a fold line at a first side edge 118 of bottom panel 108 to a fold line 120, and an opposing second side panel 122 extends from a fold line at a second side edge 124 of bottom panel 108 to a fold line 126. When container 200 is formed from blank 100, as described further herein, the fold line at first side edge 118 defines a bottom edge of first side panel 116 and a first side edge of bottom panel 108, and the fold line at second side edge 124 defines a second side edge of bottom panel 108 and a bottom edge of second side panel 122.

In the example embodiment, first end panel 106, second end panel 110, first side panel 116, and second side panel 122 include a plurality of cutouts 128 defined therein. In the example embodiment, cutouts 128 are leaf-shaped, and each of first end panel 106, second end panel 110, first side panel 116, and second side panel 122 have six cutouts. Alternatively, blank 100 may include any suitable number of cutouts 128 of any suitable shape and/or in any suitable location that enables blank 100 and/or container 200 to function as described herein. In yet other embodiments, one or more of panels 106, 110, 116, and 122 of blank 100 may have no cutouts 128.

First end panel 106 has a height H1, second end panel 110 has a height H2, first side panel 116 has a height H3, and second side panel 122 has a height H4. In the example embodiment, height H1 of first end panel 106, height H2 of second end panel 110, height H3 of first side panel 116, and height H4 of second side panel 122 are substantially the same. Further, bottom panel 108 has a length L1 and a width W1. In the example embodiment, length L1 is greater than width W1, such that bottom panel 108 is rectangular. In an alternative embodiment, width W1 is substantially equal to, or greater than, length L1.

In the example embodiment, side edges 170 of end panels 106, 110 and end edges 172 of side panels 116, 122 and are generally linear and extend at respective angles with respect to the bottom panel 108. In other words, in the example embodiment, side edges 170 of end panels 106, 110 are not parallel with side edges 118, 124 of bottom panel 108, and end edges 172 of side panels 116, 122 are not parallel with the end edges (at fold lines 112 and 114) of bottom panel 108.

Therefore, first end panel 106, second end panel 110, first side panel 116, and second side panel 122 each have a generally trapezoidal shape, in which panels 106, 110, 116, 122 taper outwardly as they extend away from bottom panel 108. That is, a respective width (not specifically shown) of end panels 106, 110 adjacent bottom panel 108 is less than a respective width (not specifically shown) of end panels 106, 110 opposite bottom panel 108. Likewise, a respective length (not specifically shown) of side panels 116, 122 adjacent bottom panel 108 is less than a respective length (not specifically shown) of side panels 116, 122 opposite bottom panel 108.

Alternatively, first end panel 106, second end panel 110, first side panel 116, second side panel 122, and/or bottom panel 108 may have any suitable shape and/or any suitable dimensions that enable blank 100 and/or container 200 to function as described herein.

Interior side panels 130, also referred to as glue panels, extend from each side edge of each end panel 106, 110, at respective fold lines 132. As such, blank 100 includes four interior side panels 130. Each interior side panels 130 has a respective free edge 178 opposing the respective fold line 132 from which the interior side panel 130 extends. In the example embodiment, free edge 178 includes a plurality of linear portions, such as four adjoining linear portions. In alternative embodiments, free edge 178 may be partially or fully arcuate, or may have any suitable shape that enables blank 100 and/or container 200 to function as described herein.

Additionally, a first end flange panel 134 extends from first end panel 106, and a second end flange panel 138 extends from second end panel 110. More particularly, first end flange panel 134 extends from leading edge 102 to a fold line 136 at a top edge of first end panel 106, and second end flange panel 138 extends from a fold line 140 at a top edge of second end panel 110 to trailing edge 104.

First end flange panel 134 and second flange panel 138 include first end flange tabs 142 and second end flange tabs 144, respectively. First end flange tabs 142 extend from a respective fold line 166 at each side edge of first end flange panel 134, and second end flange tabs 144 extend from a respective fold line 168 at each side edge of second end flange panel 138. In the example embodiment, each of first end flange tabs 142 and second end flange tabs 144 has, respectively, a free outside edge 146 that is generally arc shaped and a free inside edge 148 that is generally linear. As described further herein with respect to container 200, the shape of free outside edge 146 generally defines the shape of a corner 218 of the formed top flange 214 of container 200 (see FIG. 2), when container 200 is formed from blank 100. Therefore, in various alternative embodiments, first end flange tabs 142 and second end flange tabs 144 may have any suitable shape that enables blank 100 and/or container 200 to function as described herein.

A first side flange panel 150 extends from first side panel 116, and a second side flange panel 152 extends from second side panel 122. More particularly, first side flange panel 150 extends from fold line 120 to a free edge 154 (also referred to as a first side edge of blank 100), and second side flange panel 152 extends from fold line 126 to a free edge 156 (also referred to as a second side edge of blank 100).

First side flange panel 150 and second side flange panel 152 include first side flange tabs 158 and second side flange tabs 160, respectively. First side flange tabs 158 extend from each end edge of first side flange panel 150, and second side flange tabs 160 extend from each end edge of second side flange panel 152. In the example embodiment, each of first side flange tabs 158 and second side flange tabs 160 has, respectively, a free outside edge 162 that is generally arc shaped and a free inside edge 164 that is generally linear. As described further herein with respect to container 200, the shape of free outside edge 162 generally defines the shape of a corner 218 of the formed top flange 214 of container 200 (see FIG. 2), when container 200 is formed from blank 100. Therefore, in various alternative embodiments, first side flange tabs 158 and second side flange tabs 160 may have any suitable shape that enables blank 100 and/or container 200 to function as described herein.

In the example embodiment, first end flange tabs 142 and second end flange tabs 144 also each include a respective notch 184, defined between the inside edge 148 thereof and the side edge of the respective end flange panel 134/138 from which the end flange tab 142/144 extends. Likewise, first side flange tabs 158 and second side flange tabs 160 also each include a respective notch 186, defined between the inside edge 164 thereof and the end edge of the respective side flange panel 150/152 from which the side flange tab 158/160 extends. These notches 184, 186 improve the formation of container 200 formed from blank 100, as described further herein, by reducing interference between adjacent end flange tabs 142/144 and side flange tabs 158/160 when blank 100 is folded into container 200. Additionally, notches 184, 186 may facilitate folding and/or the joining or mating of respective flange panels and/or flange tabs.

In the example embodiment, side flange tabs 158, 160 are “deeper,” or extend further inward, toward bottom panel 108, than end flange tabs 142, 144. That is, side flange tabs 158, 160 have more extension in the horizontal direction (with respect to the view of FIG. 1) than the extension of end flange tabs 142, 144 in the vertical direction (with respect to the view of FIG. 1)

In the example embodiment, fold lines 166, 168 adjacent end flange tabs 142, 144 are generally aligned with side edges 170 of end panels 106, 110. That is, each end flange tab 142, 144 may be folded obliquely, with respect to the end flange panel 134/138 from which it extends. Additionally, fold lines 180, 182 adjacent side flange tabs 158, 160 are generally perpendicular to fold lines 120, 126. That is, each side flange tab 158, 160 may be folded substantially perpendicularly, with respect to the side flange panel 150/152 from which it extends. In other embodiments, each fold line 166, 168, 180, 182 of each flange tabs 142, 144, 158, 160 may have any orientation that enables blank 100 and/or container 200 to function as described herein.

In some embodiments, portions of flange tabs 142, 144, 158, 160 have reduced thickness, such that when container 200 is formed from blank 100, the corners 218 of flange 214 (see FIG. 2) formed from the coupled flange tabs have improved de-nesting characteristics. The thickness of the flange tabs 142, 144, 158, 160 may be reduced by scoring, compressing, crushing, and the like, of one or more portions of flange tabs 142, 144, 158, 160.

FIG. 2 is a perspective view of an example container 200 formed from blank 100 (shown in FIG. 1). Container 200 includes a bottom wall 202, first and second opposing end walls 204, 206, and first and second opposing side walls 208, 210. Generally, bottom wall 202 includes bottom panel 108 of blank 100, first end wall 204 includes first end panel 106, second end wall 206 includes second end panel 110, first side wall 208 includes first side panel 116 and two interior side panels 130 (one extending from each of first and second end panels 106, 110), and second end wall 210 includes second side panel 122 and two interior side panels 130 (one extending from each of first and second end panels 106, 110). End walls 204, 206, side walls 208, 210, and bottom wall 202 define a cavity 212 of container 200, for receiving and retaining product (not shown) therein.

In the example embodiment, due to the trapezoidal shape of panels 106, 110, 116, and 122, first and second end walls 204, 206 and first and second side walls 208, 210 extend obliquely away from bottom wall 202. Specifically, in one embodiment, each end wall 204, 206 and each side wall 208, 210 respectively forms an interior angle of more than about 90 degrees with respect to the bottom wall 202. That is, in the example embodiment, walls 204, 206, 208, 210 of the formed container 200 are generally angled outward (i.e., away) from bottom wall 202 of container 200. Therefore, the resulting container 200 is generally of a trapezoidal prism or a truncated pyramid shape. In alternative embodiments, however, end walls 204, 206 and side walls 208, 210 may form any angle with bottom wall 202 that enables blank 100 and/or container 200 to function as described herein.

Container 200 also includes a flange 214 extending from the top of each of first and second end walls 204, 206 and first and second side walls 208, 210. In the example embodiment, flange 214 extends outwardly, or away from cavity 212, and is bounded by a free edge 216 that includes both straight and arcuate segments; specifically, corners 218 of flange 214 are generally arcuate. In the example embodiment, flange 214 is oriented parallel to bottom wall 202. Due to the orientation of the walls of container 200, flange 214 is oriented oblique to first and second end walls 204, 206 and first and second side walls 208, 210. Alternatively, flange 214 may extend in any direction and have any suitable shape that enables blank 100 and/or container 200 to function as described herein.

Container 200 is formed by folding the various panels and tabs of blank 100 along respective fold lines. Specifically, each interior side panel 130 is rotated about fold line 132 towards interior surface 101 of each end panel 106, 110 such that each interior side panel 130 is substantially perpendicular to the respective end panel 106, 110. First end panel 106 and second end panel 110 are rotated about fold lines 112 and 114, respectively, towards interior surface 101 of bottom panel 108 to form first and second end walls 204, 206, respectively. In one embodiment, first and second end panels 106, 110 are rotated to form an angle of more than 90 degrees with respect to bottom panel 108. In alternative embodiments, however, first and second end panels 106, 110 may form any angle with bottom panel 108 that enables blank 100 and/or container 200 to function as described herein.

First side panel 116 is rotated about fold line 118 towards interior surface 101 of bottom panel 108 and into a face-to-face relationship with exterior surface 103 of two interior side panels 130. Likewise, second side panel 122 is rotated about fold line 124 towards interior surface 101 of bottom panel 108 and into a face-to-face relationship with exterior surface 103 of the other two interior side panels 130. In one embodiment, first and second side panels 116, 122 are rotated to form an angle of more than 90 degrees with respect to bottom panel 108. In alternative embodiments, however, first and second side panels 116, 122 are rotated and may form any angle with bottom panel 108 that enables blank 100 and/or container 200 to function as described herein.

In the example embodiment, an adhesive, in particular a hot-melt adhesive, is applied to end portions of interior surface 101 of first side panel 116 and second side panel 122. Accordingly, when these panels 116, 122 are rotated into face-to-face contact with interior side panels 130, the end portions of interior surface 101 of panels 116, 122 are respectively coupled and adhered to exterior surface 103 of interior side panels 130. Thereby, end walls 204, 206 and side walls 208, 210 are formed.

In alternative embodiments, the adhesive may be applied to interior surface 101 of interior side panels 130. In such instances, side panels 116, 122 may be rotated into position first, and end panels 106, 110 may thereafter be rotated, such that interior side panels 130 are coupled and adhered to exterior surface 103 of side panels 116, 122. In still alternative embodiments, interior side panels may instead extend from side panels 116, 122; in such instances, adhesive may be applied and panels 106, 110, 116, 122 rotated in any suitable order to form container 200.

In addition, substantially simultaneously to the forming of the walls of container 200 (e.g., within a same forming step), side flange panels 150, 152 are rotated outwardly (e.g., away from bottom wall 202) about fold lines 120, 126, respectively, until side flange panels 150, 152 are parallel to bottom wall 202. Side flange tabs 158, 160 are moved along with side flange panels 150, 152. That is, rotation of side flange panels 150, 152 results in simultaneous rotation of side flange tabs 158, 160 into the parallel orientation with respect to bottom wall 202.

In one example embodiment, the walls of container 200 are formed substantially simultaneously with the rotation of side flange panels 150, 152. Notably, however, the rotation of side flange panels 150, 152 may occur before or during the folding of end panels 106, 110 to form side walls 204, 206. In particular, side flange panels 150, 152 are folded such that end flange tabs 142, 144 and side flange tabs 158, 160 do not interfere at the corners of the partially formed container. Even more specifically, because end flange tabs 142, 144 are “shorter” or “shallower” than side flange tabs 158, 160 (e.g., the interior edge thereof extends less than the interior edge of side flange tabs 158, 160), the interior edge of end flange tabs 142, 144 does not “catch” on the folded-over side flange tabs 158, 160 as end panels 106, 110 are folded inwardly to form side walls 204, 206.

In a separate step (e.g., after a predetermined amount of time has passed, which may be milliseconds to seconds), end flange panels 134, 138 are rotated outwardly (e.g., away from bottom wall 202) about fold lines 136, 140, respectively, until end flange panels 134, 138 are parallel to bottom wall 202. End flange tabs 142, 144 are moved along with end flange panels 134, 138. That is, rotation of end flange panels 134, 138 results in simultaneous rotation of end flange tabs 142, 144 into the parallel orientation with respect to bottom wall 202. Moreover, this rotation of end flange panels 134, 138 couples exterior surface 103 of end flange tabs 142, 144 in a face-to-face relationship against interior surface 101 of side flange tabs 158, 160 (which are already in their final position, having been previously rotated).

Notably, in the example embodiment, adhesive, such as hot-melt adhesive, is applied to interior surface 101 of side flange tabs 158, 160 prior to the formation of container 200 (e.g., simultaneous with the application of adhesive to side panels 116, 122). Accordingly, when end flange panels 134, 138 are rotated subsequent to side flange panels 150, 152 being rotated, exterior surface 103 of end flange tabs 142, 144 is coupled against and adhered to interior surface 101 of side flange tabs 158, 160.

Thereafter, end flange panels 134, 138, side flange panels 150, 152, end flange tabs 142, 144, and side flange tabs 158, 160 are suitably oriented and secured to form flange 214. Flange corners 218 are formed at the overlap of corresponding end flange tabs 142, 144 and side flange tabs 158, 160. In the example embodiment, flange 214, also referred to as a “top flange,” is substantially flat or planar, and is more secure compared to conventional flanges that are not glued, or are not glued until the container is sealed. In at least some instances, where end flange tabs 142, 144 and/or side flange tabs 158, 160 feature a reduced thickness, the overall flange 214 may be even more desirably planar, which may in turn improve the sealing characteristics and/or rigidity of container 200.

Once formed, containers 200 are nested or stacked (see stack 300 of containers 200, shown in FIG. 3) for storage and/or transport thereof. In some instances, these containers 200 are ultimately used to retain a variety of objects. In some embodiments, a stack 300 of containers 200 is delivered to a filling location, at which individual containers 200 are retrieved from the stack 300. As described herein, flange corners 218 of container 200, including end flange tabs 142, 144 and/or side flange tabs 158, 160 that are embossed and/or feature reduced thickness, may improve the de-nesting characteristics of container 200.

The open, empty, and de-nested containers 200 are then filled with a product (e.g., produce). A film 220 is placed across the top of container 200 and sealed against flange 214 to form a seal. Film 220 may be coupled and adhered to flange 214 using any suitable method or material (e.g., adhesive, heat-sealing, etc.).

As described elsewhere herein, flange 214 of container 200 provides structural advantages over flanges of similar containers. Namely, the application of adhesive to side flange tabs 158, 160 to couple end flange tabs 142, 144 to side flange tabs 158, 160 during the initial formation of container 200 increases both the structural integrity and sealing ability of container 200. Conventional containers may have a top flange, but, as described above, such conventional containers are not formed in the same way as container 200 (i.e., do not include a formed flange or do not apply adhesive to join flange tabs during initial container formation), and therefore container 200 provides improvements over known conventional containers.

The application of adhesive when coupling end flange tabs 142, 144 to side flange tabs 158, 160 reinforces and strengthens corners 218 of flange 214, thus enhancing the structural rigidity of container 200. For example, container 200 may be able to hold a greater weight of a product and/or more effectively prevent leakage of liquid. Such enhancement may also reduce the risk of structural failure of container 200 once filled and sealed. Additionally, such reinforcement facilitates improved sealing of container 200. Moreover, flange 214 may be substantially flatter than flanges of conventional containers. Such flanges 214 enables easier, faster, simpler, and/or more cost-effective (e.g., using less sealing material) application of a sealing film to seal container 200. These enhancements enable container 200 to function more effectively than other conventional containers.

FIG. 4 is a top plan view of an alternative blank 400 of sheet material for forming a container 500 (see FIG. 5). Blank 400 is substantially similar to blank 100 (shown in FIG. 1), except as noted below. As such, components common to blank 100 and blank 400 are labeled with the same reference symbols.

In one embodiment, blank 400 includes cutouts 402 extending from fold lines 112, 114, 118, 120, 124, 126, 136, 140 into each of first end panel 106, second end panel 110, first side panel 116, and second side panel 122. In this embodiment, cutouts 402 have a general rectangular shape adjacent to fold lines 112, 114, 118, 120, 124, 126, 136, 140 and a general semicircular shape at the opposing end. In the example embodiment, each end panel 106, 110 contains four cutouts 402 and each side panel contains five cutouts 402. In alternative embodiments, blank 400 may include any suitable number of cutouts 402 in any suitable location having any suitable shape that enables blank 400 and/or container 500 to function as described herein.

In one embodiment, blank 400 also includes interior side panels 430 having a different overall shape than interior side panels 130 of blank 100. Interior side panels 430 of blank 400 have free edge 178 opposing fold line 132, where free edge 178 includes a plurality of linear and curved portions. In particular, each free edge 178 includes a curved notch 404, such that, when container 500 is formed from blank, interior side edges 430 do not cover or otherwise interfere with cutouts 402 on side panels 116, 122. That is, curved notch 404 of interior side panels 430 keeps interior side panels 430 from overlapping with cutouts 402 in side panels 116, 122. In alternative embodiments, one or more of free edges 178 may have any suitable shape that enables blank 400 and/or container 500 to function as described herein.

Additionally, bottom panel 108 of blank 400 is smaller and squarer than bottom panel 108 of blank 100. In the example embodiment, similar to blank 100, blank 400 includes end flange tabs 142, 144 and side flange tabs 158, 160. However, in blank 400, fold lines 166, 168, 180, 182 that bound the flange tab are angled such that each flange tab 142, 144, 158, 160 can be folded perpendicular to its respective flange panel 134, 138, 150, 152. In other embodiments, fold lines 166, 168, 180, 182 may have any orientation that enables blank 400 and/or container 500 to function as described herein.

FIG. 5 is a perspective view of an example container 500 formed from blank 400 (shown in FIG. 4). Container 500 is substantially similar to container 200 (shown in FIG. 2), and is formed from blank 400 using a method similar to forming container 200 from blank 100. Container 500 may have different dimensions than container 200.

FIG. 6 is a top plan view of an alternative blank 600 of sheet material for forming a container. Blank 600 is substantially similar to blank 100 (shown in FIG. 1), except as noted below. As such, components common to blank 100 and blank 600 are labeled with the same reference symbols.

In one embodiment, blank 600 includes cutouts 602 extending along fold lines 112, 114, 118, 124, 120, 126, 136, and 140. Additionally, fold lines 604 between side panels 116, 122 and interior end panels 606 (described further herein) also have cutouts 602 extending therethrough. In the example embodiment, cutouts 602 have a general “stadium” shape. In alternative embodiments, blank 600 may include any suitable number of cutouts 602 having any suitable shape that enables blank 600 and/or any container formed therefrom to function as described herein.

In one embodiment, blank 600 also includes interior end panels 606 extending end edges of first side panel 116 and second side panel 122, along fold lines 604, rather than interior side panels 130 as in blank 100. As such, in the example embodiment, blank 600 includes four interior end panels 606. In the example embodiment, interior end panels 606 have a different overall shape than the interior side panels 130 of blank 100. In the example embodiment, interior end panels 606 have a free edge 608 opposing fold line 604, where free edge 608 includes a plurality of linear and/or curved portions. In alternative embodiments, one or more of free edge 608 may have any suitable shape that enables blank 600 and/or any container formed therefrom to function as described herein.

In the example embodiment, each end panel 106, 110 has notches 610 formed in the side edges thereof. In the example embodiment, once container 700 is formed from blank 600, notches 610 accommodate cutouts 602 in interior end panels 606 of blank 600. That is, when formed, notches 610 prevent end panels 106, 110 from overlapping cutouts 602 in interior end panels 606.

Additionally, blank 600 includes notches 612 formed in side panels 116, 122, between bottom edges of interior end panels 606 and fold lines 118/124. Notches 612 may facilitate folding and/or the joining or mating of respective flange panels and/or flange tabs.

In this example embodiment, end flange tabs 142, 144, and side flange tabs 158, 160 of blank 600 do not include notches 182/184 and are of a different general shape than the flange tabs in blank 100. In blank 600, each flange tab 142, 144, 158, 160 has a respective free edge 146 that includes curved and straight portions. Additionally, fold lines 166, 168, 180, 182 that bound each flange tab 142, 144, 158, 160 are angled such that each flange tab 142, 144, 158, 160 can be folded oblique to its respective flange panel 134, 138, 150, 152.

A container formed from blank 600 is formed in a similar manner as container 200, with interior end panels 606 of blank 600 folded in a similar manner to interior side panels 130 of blank 100, but coupled to end panels 106, 110 instead of side panels 116, 122.

FIG. 7 is a top plan view of an alternative blank 800 of sheet material for forming a container.

In the example embodiment, similar to blank 100, blank 800 includes a first end panel 802, a second end panel 804, a first side panel 806, a second side panel 808, and a bottom panel 810. First end panel 802, second end panel 804, first side panel 806, and second side panel 808 each have a general trapezoidal shape, and bottom panel 810 has a general rectangular shape with chamfered corners. Thus, in the example embodiment, bottom panel 810 has eight edges. Blank 800 also includes a first end flange panel 812, a second end flange panel 814, a first side flange panel 816, and a second side flange panel 818, as well as first end flange tabs 820, second end flange tabs 822, first side flange tabs 824, and second side flange tabs 826, similar to blank 100.

In the example embodiment, flange tabs 820, 822, 824, 826 of blank 800 have a different size and overall shape than the flange tabs of blank 100. In particular, flange tabs 820, 822, 824, 826 each have a respective free end edge 828 that includes a plurality of straight and/or curved lines. In the example embodiment, flange tabs 820, 822, 824, 826 also each include a respective notch 830 located on the respective inside edge 832 thereof. Flange tabs 820, 822, 824, 826 may have any suitable shape that enables blank 800 and/or container 900 to function as described herein.

In the example embodiment, blank 800 also includes corner panels 834 that extend from fold lines 836, at the chamfered or angled corners of bottom panel 810. Interior corner panels 838, also referred to as glue panels, extend from each side edge of each corner panel 834. As such, in the example embodiment, blank 800 includes eight interior corner panels 838. Each interior corner panel 838 extends from a side edge of a respective corner panel 834 at a fold line 840 (only one fold line 840 is labeled on FIG. 7 for clarity).

Corner panels 834 of blank 800 also each include corner flange panel 842. Each corner flange panel 842 extends from a respective fold line 844, at the top of the respective corner panel 834, to a free edge 845. Corner flange tabs 846 that extend from each end edge of each corner flange panel 842. In the example embodiment, corner flange tabs 846 are bounded by fold lines 848 respectively, as well as a free edge 849. In the example embodiment, corner flange tabs 846 also include a notch 850 defined in inside edges thereof. The fold lines 848 that bound each corner flange tab 846 are angled such that each corner flange tab 846 can be folded oblique to its respective corner flange panel 842. In other embodiments, fold lines 848 may have any orientation that enables blank 800 and/or container 900 to function as described herein.

In the example embodiment, similar to blank 100, first end panel 802, second end panel 804, first side panel 806, and second side panel 808 include a plurality of cutouts 852 defined therein. Specifically, first and second end panels 806, 808 each include three cutouts 852 located near fold lines 854, 856, and first and second side panels 806, 808 each include four cutouts 852 located near fold lines 858, 860. Alternatively, blank 800 may include any suitable number of cutouts 852 of any suitable shape and/or in any suitable location that enables blank 800 and/or container 900 to function as described herein.

In some embodiments, portions of flange tabs 820, 822, 824, 826, 846 have reduced thickness, such that when the container 900 is formed from the blank 800, the corners 918 of flange 914 (see FIG. 8) formed from the coupled flange tabs have improved de-nesting characteristics. The thickness of the flange tabs 820, 822, 824, 826, 846 may be reduced by scoring, compressing, crushing, and the like, of one or more portions of the flange tabs.

FIG. 8 is a perspective view of an example eight-sided container 900 formed from blank 800 (shown in FIG. 7). Container 900 includes a bottom wall 902, first and second opposing end walls 904, 906, first and second opposing side walls 908, 910, and four angled corner walls 920. Generally, bottom wall 902 includes bottom panel 810 of blank 800, first end wall 904 includes first end panel 802 and two interior corner panels 838, second end wall 906 includes second end panel 804 and two interior corner panels 838, first side wall 908 includes first side panel 806 and two interior corner panels 838, second end wall 910 includes second side panel 808 and two interior corner panels 838, and each corner wall 920 includes one of corner panels 834. End walls 904, 906, side walls 908, 910, corner walls 920, and bottom wall 902 define a cavity 912 of container 900, for receiving and retaining product (not shown) therein. Like container 200, the walls of container 900 are oriented obliquely, at angles of more than 90 degrees, with respect to bottom wall 902. In the example embodiment, bottom wall 902 of container 900 has a general rectangular shape with straight chamfered corners. Thus, bottom wall 902 of container includes eight sides. Alternatively, container 900 may have any suitable shape and or dimensions enable blank 800 and/or container 900 to function as described herein.

Container 900 also includes a flange 914 extending from the top of walls 904, 906, 908, 910, 920. In the example embodiment, flange 914 extends outwardly, or away from cavity 912, and is bounded by a free edge 916 that includes both straight and arcuate segments; specifically, corners 918 of flange 914, formed by corner flange panels 842, are generally arcuate. In the example embodiment, flange 914 is oriented parallel to bottom wall 902. Due to the orientation of the walls of container 900, flange 914 is oriented oblique to walls 904, 906, 908, 910, 920. Alternatively, flange 914 may extend in any direction and have any suitable shape that enables container 900 to function as described herein.

Container 900 is formed by folding the various panels and tabs of blank 800 along respective fold lines. Specifically, corner panels 834 are rotated inwardly (towards bottom panel 810) about fold lines 836, and interior corner panels 838 are rotated inwardly (towards the respective corner panel 834) about fold lines 840. First side panel 806 is rotated about fold line 858 towards an interior surface of bottom panel 810, and second side panel 808 is rotated about fold line 860 towards the interior surface of bottom panel 810. Each of first side panel 806 and second side panel 808 is coupled to two respective interior corner panels 834 using an adhesive, such as holt-melt adhesive, to form side walls 908, 910. First end panel 802 is rotated about fold line 854 towards the interior surface of bottom panel 810, and second end panel 804 is rotated about fold line 856 towards the interior surface of bottom panel 810. Each of first end panel 802 and second end panel 804 is coupled to two respective interior corner panels 838 using an adhesive, such as hot-melt adhesive, to form end walls 904, 906. First side panel 806, second side panel 808, first end panel 802, and second end panel 804 may be rotated about fold lines 858, 860, 854, 856, respectively, and attached to interior corner panels 838 in any order that enables blank 800 and/or container 900 to function as described herein.

In addition, substantially simultaneously to the forming of the walls of container 900 (e.g., within a same forming step), end flange panels 812, 814 and side flange panels 816, 818 are rotated outwardly (e.g., away from bottom wall 902), until flange panels 812, 814, 816, 818 are parallel to bottom wall 902. This rotation of flange panels 812, 814, 816, 818 results in simultaneous rotation of flange tabs 820, 822, 824, 826 into the parallel orientation with respect to bottom wall 202.

In a separate step (e.g., after a predetermined amount of time has passed, which may be milliseconds to seconds), corner flange panels 842 are rotated outwardly about fold lines 844, until corner flange panels 842 are substantially parallel to bottom panel 810. Rotation of corner flange panels 842 results in simultaneous rotation of corner flange tabs 846 into the parallel orientation with respect to bottom wall 202. Moreover, this rotation of corner flange panels 842 also couples corner flange tabs 846 in an overlapping relationship with end and side flange tabs 820, 822, 824, 826 (which are already in their final position, having been previously rotated).

Notably, in the example embodiment, adhesive, such as hot-melt adhesive, is applied to the interior surface of end and side flange tabs 820, 822, 824, 826 prior to the formation of container 900. Accordingly, when corner flange panels 842 are rotated subsequent to end and side flange panels 812, 814, 816, 818 being rotated, the exterior surface of corner flange tabs 846 is coupled against and adhered to the interior surface of corresponding end and side flange tabs 820, 822, 824, 826.

When formed using the method described herein, container 900 includes the same advantages as container 200. Specifically, flange 914, also referred to as a “top flange,” is substantially flat or planar, and is more secure compared to conventional flanges that are not glued, or are not glued until the container is sealed. In at least some instances, where any flange tabs 820, 822, 824, 826 and/or 846 feature a reduced thickness, the overall flange 914 may be even more desirably planar, which may in turn improve the sealing characteristics and/or rigidity of container 900.

Once formed, containers 900 are nested or stacked for storage and/or transport thereof. In some instances, these containers 900 are ultimately used to retain a variety of objects. In some embodiments, a stack of containers 900 is delivered to a filling location, at which individual containers 900 are retrieved from the stack. As described herein, flange corners 918 of container 900, including flange tabs 820, 822, 824, 826 and/or 846 that are embossed and/or feature reduced thickness, may improve the de-nesting characteristics of container 900.

The open, empty, and de-nested containers 900 are then filled with a product (e.g., produce). A film (not shown) is placed across the top of container 900 and sealed against flange 914 to form a seal. The film may be coupled and adhered to flange 914 using any suitable method or material (e.g., adhesive, heat-sealing, etc.). As described elsewhere herein, flange 914 of container 900 provides structural advantages over flanges of similar conventional containers. Namely, the application of adhesive to end and side flange tabs 820, 822, 824, 826 to couple corner flange tabs 846 to end and side flange tabs 820, 822, 824, 826 during the initial formation of container 900 increases both the structural integrity and sealing ability of container 900. Conventional containers may have a top flange, but, as described above, such conventional containers are not formed in the same way as container 900 (i.e., do not include a formed flange or do not apply adhesive to join flange tabs during initial container formation), and therefore container 900 provides improvements over known conventional containers.

The application of adhesive when coupling end and side flange tabs 820, 822, 824, 826 to corner flange tabs 846 reinforces and strengthens corners 918 of flange 914, thus enhancing the structural rigidity of container 900. For example, container 900 may be able to hold a greater weight of a product and/or more effectively prevent leakage of liquid. Such enhancement may also reduce the risk of structural failure of container 900 once filled and sealed. Additionally, such reinforcement facilitates improved sealing of container 900. Moreover, flange 914 may be substantially flatter than flanges of conventional containers. Such flanges 914 enables easier, faster, simpler, and/or more cost-effective (e.g., using less sealing material) application of a sealing film to seal container 900. These enhancements enable container 900 to function more effectively than other conventional containers.

FIG. 9 is a flow diagram of a method 1000 of forming a container from a blank. In some embodiments, the blank includes a bottom panel, two opposing side panels, two opposing end panels, a respective end flange panel extending from a top edge of each end panel, a respective end flange tab extending from each side edge of each end flange panel, a respective side flange panel extending from a top end of each side panel, and a respective side flange tab extending from each end edge of each side flange panel. Method 1000 includes applying 1002 hot-melt adhesive to an interior surface of the side flange tabs, rotating 1004 the end panels inwardly towards the bottom panel, and rotating 1006 the side panels inwardly towards the bottom panel. Method 1000 also includes rotating 1008 the side flange panels outwardly into a parallel orientation to the bottom panel, and after rotating 1008, rotating 1010 the end flange panels into a parallel orientation to the bottom panel. Method 1000 also include coupling 1012 the end flange tabs to the side flange tabs to form the container having a fully formed top flange.

In some embodiments, the blank further includes a respective interior side panel extending from each side edge of each end panel. In some such instances, method 1000 further includes applying hot-melt adhesive to a portion of an interior surface of the side panels, rotating the interior side panels inwardly, after said rotating the interior side panels, performing the rotating 1008, and coupling the side panels to the interior side panels.

Method 1000 may include additional, fewer, and/or alternative steps, including steps disclosed elsewhere herein.

FIG. 10A is a top plan view of an alternative blank 1100 of sheet material for forming a container 1200 (see FIG. 11). Blank 1100 is substantially similar to blank 100 (shown in FIG. 1), except as noted below. As such, components common to blank 100 and blank 1100 are labeled with the same reference symbols.

In one embodiment, blank 1100 includes cutouts 1102 defined within the first end panel 106 and second end panel 110. In the example embodiment, each end panel 106, 110 contains four cutouts 1102. In alternative embodiments, cutouts may also be defined within the first side panel 116 and the second side panel 122. Blank 1100 may include any suitable number of cutout 1102 in any suitable location having any suitable shape that enables blank 1100 and/or container 1200 to function as described herein.

In the example embodiment, blank 1100 includes an interior side panel 1104 having a different overall shape than interior side panels 130 of blank 100. Interior side panels 1104 of blank 1100 each include a free edge 178 opposing fold line 132 and substantially parallel to fold line 132. Free edges 178 each extend along the length of respective fold lines 132 an each terminates transversely at an end edge 172 of the side panel 116, 122.

Additionally, bottom panel 108 of blank 1100 is smaller and squarer than bottom panel 108 of blank 1100. In the example embodiment, four denesting assemblies 1105 are included, located at each corner of the bottom panel 108. An alternative embodiment may include any suitable number of denesting assemblies 1105. For example, only one denesting assembly 1105 may be located at one corner of the bottom panel 108. Blank 1100 may include any number of denesting assemblies 1105 that enable blank 1100 and/or container 1200 to function as described herein.

FIG. 10B depicts an enlarged view of the region B of the blank 1100 shown in FIG. 10A. The denesting assembly 1105 includes a denesting tab 1106 and a denesting cutout 1118. The denesting tab 1106 includes a first triangular section 1108 defined in the interior side panel 1104, a second triangular section 1110 defined in the end panel 106, 110, side fold lines 1112, center fold line 1122, bottom fold lines 1124, a first teardrop shaped lobe 1116, and a second teardrop shaped lobe 1117. The triangular sections 1108, 1110 are defined by side fold lines 1112 which extend from a point 1114 along fold line 132 (shown in FIG. 10A) and extend outward at acute angles, center fold line 1122, and bottom fold lines 1124. Teardrop shaped lobes 1116, 1117 are adjacent to the triangular sections 1108, 1110 and extend into the denesting cutout 1118. The bottom fold lines 1124 is located between the triangular sections 1108, 1110 and the teardrop shaped lobes 1116, 1117. The denesting cutout 1118 is an empty space of the blank where there is no sheet material. The denesting cutout 1118 is located at a corner of the bottom panel 108 and further extends at an angle across a corner of the side panel 116, 122.

FIG. 11 is a perspective view of an example container 1200 (shown in FIG. 11) formed from blank 1100 (shown in FIG. 10A). Container 1200 is substantially similar to container 200 (shown in FIG. 2), and is formed from blank 1100 using a method similar to forming container 200 from blank 100. Container 1200 may have different dimensions than container 200 and further includes denesting assemblies 1105. In addition to the method described for forming container 200 from blank 100, an additional step is required to forming container 1200 from blank 1100. As the panels 106, 110, 116, and 122 are folded upward to form the container 1200, the denesting tab 1106 is folded along the fold lines 1112, 1122, 1124 into the cavity 1220 (as shown in FIG. 12) of the formed container 1200. The denesting assemblies 1105, and in particular, each of the fold lines 1112, 1122, 1124 and the cutout 1118 cooperate to allow for the denesting tabs 1106 to be bent inward toward the cavity 1220. The denesting cutout 1118 further includes an arched edge 1120 providing clearance for the teardrop shaped lobes 1116, 1117 of the denesting tab 1106 to be bent inward toward cavity 1220. As a result, the denesting tabs 1106 on the formed container 1200 each extend into the cavity 1220 at an acute angle with reference to the starting position.

FIG. 12 is another perspective view of the container 1200 (shown in FIG. 11) formed from blank 1100 (shown in FIG. 10A). Container 1200 includes a bottom wall 1210, first end wall 1212, second end wall 1214, first side wall 1216, and second side wall 1218. Bottom wall 1210 includes bottom panel 108 of blank 1100, first end wall 1212 includes first end panel 106, second end wall 1214 includes second end panel 110, first side wall 1216 includes first side panel 116 and two interior side panel 1104 (one extending from each of first and second end panels 106, 110), and second side wall 1218 includes second side panel 122 and two interior side panel 1104 (one extending from each of first and second end panels 106, 110). The walls form a cavity 1220.

Container 1200 also includes a flange 1222 extending from the top of each of first and second end walls 1212, 1214 and first and second side walls 1216, 1218. In the example embodiment, flange 1222 extends outwardly, or away from cavity 1220.

FIG. 13 is another perspective view of the container 1200 (shown in FIG. 11) formed from blank 1100 (shown in FIG. 10A).

FIG. 14 is a perspective view of a stack 1300 of a plurality of containers 1200, wherein the containers are nested or stacked for storage and/or transport thereof. The extended denesting tab 1106 ensures that the containers 1200 do not get stuck together when nested in a stack 1300 and provides a nearly equal spacing 1302 between the flange 1222 of each container 1200. The spacing 1302 between the flange 1222 allows for a worker or a machine to grab an individual container 1200 and prevents the container from becoming stuck to another container in the stack 1300.

FIG. 15 is a top plan view of an alternative blank 1400 for forming a container 1500 (see FIG. 16). Blank 1400 is substantially similar to blank 100 (shown in FIG. 1), and blank 1100 (shown in FIG. 10A), except as noted below. As such, components common to blank 100, blank 1100 and blank 1400 are labeled with the same reference symbols.

Blank 1400 includes a bottom panel 108, first end panel 106, second end panel 110, first side panel 116, second side panel 122, and interior side panels 130 projecting outwards from opposed sides of first end panel 106 and second end panel 110. In one embodiment, blank 1400 includes cutouts 1402 defined within the first end panel 106 and second end panel 110. In the example embodiment, each end panel 106, 110 contains four cutouts 1402. In alternative embodiments, cutouts may also be defined within the first side panel 116 and the second side panel 122. Blank 1400 may include any suitable number of cutouts 1402 in any suitable location having any suitable shape that enables blank 1400 and/or container 1500 to function as described herein.

FIG. 15 further depicts an enlarged view of a denesting tab 1404 (alternatively referred to as a “denesting assembly” in the embodiment of FIG. 15). Blank 1400 includes four denesting tabs 1404, located at the upper or top corners of the side panels 116, 122 (i.e., adjacent flange panels 150), although other embodiments may include any suitable number of denesting tabs. The denesting tab 1404 extends outwardly from end edge 172 and along fold line 120 of the first side flange panel 150. The denesting tab 1404 includes a curved edge 1406 along the first side flange tab 158 and a lower edge 1408 which is approximately perpendicular to end edge 172.

FIG. 16 is a perspective view of an example container 1500 formed from blank 1400 (shown in FIG. 15). Container 1500 is substantially similar to container 200 (shown in FIG. 2) and container 1200 (shown in FIG. 11), and is formed from blank 1400 using a method similar to forming container 200 from blank 100, apart from the differences described below. Container 1500 may have different dimensions that container 200 and further includes denesting tabs 1404. Container 1500 includes a bottom wall (not shown), a first end wall 1502, a second end wall (not shown), a first side wall 1504, and a second side wall (not shown). Bottom wall (not shown) includes bottom panel 108 of blank 1400, first end wall 1502 includes first end panel 106, second end wall (not shown) includes second end panel 110, first side wall 1504 includes first side panel 116 and two interior side panels 130 (one extending from each of first and second end panels 106, 110), and second side wall (not shown) includes second side panel 122 and two interior side panel 130 (one extending from each of first and second end panels 106, 110). The walls form a cavity 1506. Container 1500 further includes a flange 1508 projecting out from the top of each of the first end wall 1502, second end wall (not shown), first side wall 1504, and second side wall (not shown).

The denesting tabs 1404 are positioned adjacent to the flange 1508 and project outwards from the side walls 1504, beyond the end walls 1502 and in the same plane as side walls 1504. In the example embodiment, when assembled into the container 1500, at least one denesting tab 1404 is provided at each corner of the container 1500. The denesting tab 1404 extends within a profile of the flange 1508 and does not extend beyond a peripheral outer edge 1512 of the flange 1508. A notch 1510 is formed between curved edge 1406 and the flange 1508.

FIG. 17. is a perspective view of a stack 1600 of a plurality of containers 1500, showing the containers 1500 as nested or stacked for storage and/or transport thereof. The lower edge 1408 of the denesting tab 1404 is in contact with the top surface of the flange 1508 and a space 1602 is defined between each flange 1508. A force is translated through the lower edge 1408 of the desnesting tab 1404 of one container 1500 to the flange 1508 of the container 1500 below. The space 1602 is essentially equal between each flange 1508 and is maintained by the denesting tabs 1404.

The space 1602 prevents the flanges 1508 from contacting each other directly. In some instances, the flanges 1508 may have excess glue from the process of forming the container 1500. Preventing the flanges from coming into contact prevents any excess glue from causing the containers 1500 to stick together in a stacked configuration. In other instances, the space 1602 may prevent the containers 1500 from becoming compressed and becoming stuck together. Once the containers have compressed, it may result in additional friction between the surfaces of the containers 1500, making it more difficult to separate the containers 1500. Further, the sizing of the space 1602 can be selected to provide adequate clearance for a worker or machine to pull an individual container 1500 from the stack 1600.

FIG. 18 is a top plan view of an alternative blank 1700 for forming a container 1800 (see FIG. 19).

In the example embodiment, similar to blank 800, blank 1700 includes a first end panel 1702, a second end panel 1704, a first side panel 1706, a second side panel 1708, and a bottom panel 1710. The bottom panel 1710 has a generally rectangular shape with chamfered corners, giving it eight edges in the example embodiment. Blank 1700 also includes a first end flange panel 1712, a second end flange panel 1714, a first side flange panel 1716, and a second side flange panel 1718.

Blank 1700 also includes corner panels 1720 that extend from fold lines 1722 of the chamfered corners of bottom panel 1710. Interior corner panels 1724 extend from each side edge 1726 of each corner panel 1720. Each corner panel 1720 further includes a corner flange tab 1728 which includes a curved outer edge 1730 and additionally forms a notch 1732 on the inside edge adjacent to the corner panel 1720. The corner flange tabs 1728 may have any suitable shape that enables blank 1700 and/or container 1800 to function as described herein. Fold lines 1734 are defined between the interior corner panels and each of the first and second end panels 1702, 1704 and the first and second side panels 1706, 1708.

Each of the first and second end panels 1702, 1704 and the first and second side panels 1706, 1708 further includes denesting tabs 1736 located on either side of each respective panel 1702, 1704, 1706, 1708. The denesting tabs 1736 are substantially similar to the denesting tabs 1404 (shown in FIG. 15), in that they are provided adjacent to the flange panels 1712, 1714, 1716, 1718. However, unlike the blank of FIG. 15, which includes four denesting tabs 1404, in the example embodiment, eight denesting tabs are included, though other embodiments could include any suitable number of denesting tabs. The denesting tabs 1736 extend out away from the respective panel 1702, 1704, 1706, 1708 and along flange panels 1712, 1714, 1716, 1718. An indent 1738 is defined along a bottom edge 1740 of the denesting tab 1736.

FIG. 19 is a perspective view of an example eight-sided container 1800 formed from blank 1700 (shown in FIG. 18). Container 1800 is substantially similar to container 900 (shown in FIG. 8), and is formed from blank 1700 using a method similar to forming container 900 from blank 800. Container 1800 may have different dimensions that container 900 and further includes denesting tabs 1736. Container 1800 includes a bottom wall (not shown), first and second end walls 1802, 1804, first and second side walls 1806, 1808, and four corner walls 1810. Bottom wall (not shown) includes bottom panel 1710. First end wall 1802 includes first end panel 1702 and two interior corner panels 1724. Second end wall 1804 includes second end panel 1704 and two interior corner panels 1724. First side wall 1806 includes first side panel 1706 and two interior corner panels 1724. Second side wall 1808 includes second side panel 1708 and two interior corner panels 1724. End walls 1802, 1804, side walls 1806, 1808, and corner walls 1810 form a cavity 1812. Container 1800 also has a flange 1814 extending from the top of walls 1802, 1804, 1806, 1808, 1810. The flange 1814, extends outward from the cavity 1812.

Container 1800 includes denesting tabs 1736 which extend out from each end of each wall 1802, 1804, 1806, 1808 in the plane of the respective wall 1802, 1804, 1806, 1808 at an acute angle with regard to the corner walls 1810. The denesting tabs 1736 do not extend beyond the plane 1816 defined by the edge of the flange 1814.

FIG. 20 is a perspective view of a stack 1900 of a plurality of containers 1800, wherein the containers 1800 are nested or stacked for storage and/or transport thereof. The bottom edge 1740 of each denesting tab 1736 rests along the top surface of the flange 1814. This creates a spacing 1902 between each flange 1814 of each container 1800. The spacing 1920 is essentially equal between each container 1800 and is defined by the height of the denesting tab 1736. The space 1902 provides adequate clearance between containers 1800 to allow for separating of the containers 1800 by a worker or machine.

Further aspects of the present disclosure are provided by the subject matter of the following clauses:

A method of forming a container from a blank, the blank including a bottom panel, two opposing side panels, two opposing end panels, a respective end flange panel extending from a top edge of each end panel, a respective end flange tab extending from each side edge of each end flange panel, a respective side flange panel extending from a top end of each side panel, and respective side flange tabs extending from respective end edges of each side flange panel, the method comprising: applying an adhesive to an interior surface of the side flange tabs; rotating the end panels inwardly towards the bottom panel; rotating the side panels inwardly towards the bottom panel; rotating the side flange panels outwardly into a parallel orientation to the bottom panel; after said rotating the side flange panels, rotating the end flange panels into a parallel orientation to the bottom panel; and coupling the end flange tabs to the side flange tabs to form the container having a fully formed top flange.

The method according to any preceding clause, wherein the bottom panel, two opposing side panels, and two opposing end panels collectively define a cavity of the container for receiving a product therein, the method further comprising: positioning a film on the top flange to extend over and cover the cavity; and sealing the film against the top flange.

The method according to any preceding clause, wherein the two opposing side panels and the two opposing end panels each have a generally trapezoidal shape such that, after said rotating of the end panels and the side panels, the end panels and side panels each extend obliquely away from the bottom panel.

The method according to any preceding clause, wherein the bottom panel, two opposing side panels, and two opposing end panels collectively define a cavity of the container for receiving a product therein, the cavity further configured to receive a portion of an adjacent container therein to facilitate stacking the adjacent container within the container, and wherein the container further includes a denesting assembly configured to engage the adjacent container when received within the container such that a flange of the adjacent container is spaced from the fully formed flange of the container.

The method according to any preceding clause, wherein the denesting assembly includes a denesting tab and a denesting cutout, the method further comprises folding the denesting tab into the cavity.

The method according to any preceding clause, wherein the blank further includes an interior side panel extending from a side edge of a first end panel of the two end panels, the denesting tab being coupled to the interior side panel and the end panel, wherein the denesting cutout is defined by the denesting tab, the bottom panel, and at least one of the side panels and the end panels.

The method according to any preceding clause, wherein the denesting tab is positioned at a bottom corner of the container, the bottom corner of the container being defined by the bottom panel, a first end panel of the two end panels, and a first side panel of the two side panels, and wherein, when the denesting tab is folded into the cavity and the adjacent container is received within the cavity, the denesting tab is configured to engage an outer surface of the adjacent container.

The method according to any preceding clause, wherein the container defines four bottom corners and includes four denesting assemblies positioned at each bottom corner.

The method according to any preceding clause, wherein the denesting assembly includes respective denesting tabs coupled to end edges of each side panel, the denesting tabs extending outward from the end edges and being coplanar with the respective side panels.

The method according to any preceding clause, wherein the container is configured to be received in a cavity defined in an adjacent container that has a substantially similar size and shape as the container, the denesting tab being sized to engage an adjacent flange of the adjacent container such that the flange of the container is spaced from the adjacent flange of the adjacent container when the container is received within the cavity of the adjacent container.

A container comprising: a bottom panel; two opposing side panels coupled to the bottom panel along a respective first set of fold lines; two opposing end panels coupled to the bottom panel along a respective second set of fold lines; respective end flange panels extending from top edges of each end panel and in an orientation that is generally parallel to the bottom panel; respective end flange tabs extending from each side edge of each end flange panel; respective side flange panels extending from top ends of each side panel in an orientation that is generally parallel to the bottom panel; and respective side flange tabs extending from respective end edges of each side flange panel, the side flange tabs each being coupled to a respective end flange tab to form a top flange of the container.

The container according to any preceding clause, wherein the two opposing side panels and the two opposing end panels each have a generally trapezoidal shape and the end panels and side panels each extend obliquely away from the bottom panel.

The container according to any preceding clause, wherein the bottom panel, two opposing side panels, and two opposing end panels collectively define a cavity of the container for receiving a product therein, the cavity further configured to receive a portion of an adjacent container therein to facilitate stacking the adjacent container within the container, and wherein the container further includes a denesting assembly configured to engage the adjacent container when received within the cavity of the container such that a flange of the adjacent container is spaced from the flange of the container.

The container according to any preceding clause, wherein the denesting assembly includes a denesting tab and a denesting cutout, the denesting tab being folded into the cavity.

The container according to any preceding clause, wherein the container further includes an interior side panel extending from a side edge of a first end panel of the two end panels, the denesting tab being coupled to the interior side panel and the end panel, wherein the denesting cutout is defined by the denesting tab, the bottom panel, and at least one of the side panels and the end panels.

The container according to any preceding clause, wherein the denesting tab is positioned at a bottom corner of the container, the bottom corner of the container being defined by the bottom panel, a first end panel of the two end panels, and a first side panel of the two side panels.

The container according to any preceding clause, wherein the container defines four bottom corners and includes four denesting assemblies positioned at each bottom corner.

The container according to any preceding clause, wherein the denesting assembly includes respective denesting tabs coupled to end edges of each side panel, the denesting tabs extending outward from the end edges and being coplanar with the respective side panels.

The container according to any preceding clause, wherein the container is configured to be received in a cavity defined in an adjacent container that has a substantially similar size and shape as the container, the denesting tab being sized to engage an adjacent flange of the adjacent container such that the flange of the container is spaced from the adjacent flange of the adjacent container when the container is received within the cavity of the adjacent container.

A method of stacking a first container on a second container, the first container and second container each being formed from respective blanks having substantially the same size and shape, the blanks each including a bottom panel, two opposing side panels, two opposing end panels, a respective end flange panel extending from a top edge of each end panel, a respective end flange tab extending from each side edge of each end flange panel, a respective side flange panel extending from a top end of each side panel, and respective side flange tabs extending from respective end edges of each side flange panel, the method comprising: forming the first container by: applying an adhesive to an interior surface of the side flange tabs; rotating the end panels inwardly towards the bottom panel; rotating the side panels inwardly towards the bottom panel; rotating the side flange panels outwardly into a parallel orientation to the bottom panel; after said rotating the side flange panels, rotating the end flange panels into a parallel orientation to the bottom panel; and coupling the end flange tabs to the side flange tabs to form the container having a fully formed top flange; forming the second container; and positioning the first container within a cavity of the second container such that a denesting assembly of one of the first container and the second container engages the other of the first container and the second container to space the top flange of the first container from a top flange of the second container.

Example embodiments of containers and blanks for making the same are described above in detail. The containers and blanks are not limited to the specific embodiments described herein, but rather, components of the blanks and/or the containers may be utilized independently and separately from other components described herein.

Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

This written description uses examples to disclose various embodiments, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

1. A container comprising:

a bottom panel;
two opposing side panels coupled to the bottom panel along a respective first set of fold lines;
two opposing end panels coupled to the bottom panel along a respective second set of fold lines;
respective end flange panels extending from top edges of each end panel and in an orientation that is generally parallel to the bottom panel;
respective end flange tabs extending from each side edge of each end flange panel;
respective side flange panels extending from top ends of each side panel in an orientation that is generally parallel to the bottom panel; and
respective side flange tabs extending from respective end edges of each side flange panel, the side flange tabs each being coupled to a respective end flange tab to form a top flange of the container.

2. The container of claim 1, wherein the two opposing side panels and the two opposing end panels each have a generally trapezoidal shape and the end panels and side panels each extend obliquely away from the bottom panel.

3. The container of claim 1, wherein the bottom panel, two opposing side panels, and two opposing end panels collectively define a cavity of the container for receiving a product therein, the cavity further configured to receive a portion of an adjacent container therein to facilitate stacking the adjacent container within the container, and wherein the container further includes a denesting assembly configured to engage the adjacent container when received within the cavity of the container such that a flange of the adjacent container is spaced from the flange of the container.

4. The container of claim 3, wherein the denesting assembly includes a denesting tab and a denesting cutout, the denesting tab being folded into the cavity.

5. The container of claim 4, wherein the container further includes an interior side panel extending from a side edge of a first end panel of the two end panels, the denesting tab being coupled to the interior side panel and the end panel, wherein the denesting cutout is defined by the denesting tab, the bottom panel, and at least one of the side panels and the end panels.

6. The container of claim 4, wherein the denesting tab is positioned at a bottom corner of the container, the bottom corner of the container being defined by the bottom panel, a first end panel of the two end panels, and a first side panel of the two side panels.

7. The container of claim 6, wherein the container defines four bottom corners and includes four denesting assemblies positioned at each bottom corner.

8. The container of claim 3, wherein the denesting assembly includes respective denesting tabs coupled to end edges of each side panel, the denesting tabs extending outward from the end edges and being coplanar with the respective side panels.

9. The container of claim 8, wherein the container is configured to be received in a cavity defined in an adjacent container that has a substantially similar size and shape as the container, the denesting tab being sized to engage an adjacent flange of the adjacent container such that the flange of the container is spaced from the adjacent flange of the adjacent container when the container is received within the cavity of the adjacent container.

10. A method of forming a container from a blank, the blank including a bottom panel, two opposing side panels, two opposing end panels, a respective end flange panel extending from a top edge of each end panel, a respective end flange tab extending from each side edge of each end flange panel, a respective side flange panel extending from a top end of each side panel, and respective side flange tabs extending from respective end edges of each side flange panel, the method comprising:

applying an adhesive to an interior surface of the side flange tabs;
rotating the end panels inwardly towards the bottom panel;
rotating the side panels inwardly towards the bottom panel;
rotating the side flange panels outwardly into a parallel orientation to the bottom panel;
after said rotating the side flange panels, rotating the end flange panels into a parallel orientation to the bottom panel; and
coupling the end flange tabs to the side flange tabs to form the container having a fully formed top flange.

11. The method of claim 10, wherein the bottom panel, two opposing side panels, and two opposing end panels collectively define a cavity of the container for receiving a product therein, the method further comprising:

positioning a film on the top flange to extend over and cover the cavity; and
sealing the film against the top flange.

12. The method of claim 10, wherein the two opposing side panels and the two opposing end panels each have a generally trapezoidal shape such that, after said rotating of the end panels and the side panels, the end panels and side panels each extend obliquely away from the bottom panel.

13. The method of claim 10, wherein the bottom panel, two opposing side panels, and two opposing end panels collectively define a cavity of the container for receiving a product therein, the cavity further configured to receive a portion of an adjacent container therein to facilitate stacking the adjacent container within the container, and wherein the container further includes a denesting assembly configured to engage the adjacent container when received within the container such that a flange of the adjacent container is spaced from the fully formed flange of the container.

14. The method of claim 13, wherein the denesting assembly includes a denesting tab and a denesting cutout, the method further comprises folding the denesting tab into the cavity.

15. The method of claim 14, wherein the blank further includes an interior side panel extending from a side edge of a first end panel of the two end panels, the denesting tab being coupled to the interior side panel and the end panel, wherein the denesting cutout is defined by the denesting tab, the bottom panel, and at least one of the side panels and the end panels.

16. The method of claim 14, wherein the denesting tab is positioned at a bottom corner of the container, the bottom corner of the container being defined by the bottom panel, a first end panel of the two end panels, and a first side panel of the two side panels, and wherein, when the denesting tab is folded into the cavity and the adjacent container is received within the cavity, the denesting tab is configured to engage an outer surface of the adjacent container.

17. The method of claim 16, wherein the container defines four bottom corners and includes four denesting assemblies positioned at each bottom corner.

18. The method of claim 13, wherein the denesting assembly includes respective denesting tabs coupled to end edges of each side panel, the denesting tabs extending outward from the end edges and being coplanar with the respective side panels.

19. The method of claim 18, wherein the container is configured to be received in a cavity defined in an adjacent container that has a substantially similar size and shape as the container, the denesting tab being sized to engage an adjacent flange of the adjacent container such that the flange of the container is spaced from the adjacent flange of the adjacent container when the container is received within the cavity of the adjacent container.

20. A method of stacking a first container on a second container, the first container and second container each being formed from respective blanks having substantially the same size and shape, the blanks each including a bottom panel, two opposing side panels, two opposing end panels, a respective end flange panel extending from a top edge of each end panel, a respective end flange tab extending from each side edge of each end flange panel, a respective side flange panel extending from a top end of each side panel, and respective side flange tabs extending from respective end edges of each side flange panel, the method comprising:

forming the first container by: applying an adhesive to an interior surface of the side flange tabs; rotating the end panels inwardly towards the bottom panel; rotating the side panels inwardly towards the bottom panel; rotating the side flange panels outwardly into a parallel orientation to the bottom panel; after said rotating the side flange panels, rotating the end flange panels into a parallel orientation to the bottom panel; and coupling the end flange tabs to the side flange tabs to form the container having a fully formed top flange; forming the second container; and positioning the first container within a cavity of the second container such that a denesting assembly of one of the first container and the second container engages the other of the first container and the second container to space the top flange of the first container from a top flange of the second container.
Patent History
Publication number: 20240308722
Type: Application
Filed: Jul 11, 2022
Publication Date: Sep 19, 2024
Inventors: Tom J. WHATLING (Harleston), Alyssa J. SCHERER (Duluth, GA), John VALENCIA (Johns Creek, GA)
Application Number: 18/577,956
Classifications
International Classification: B65D 5/20 (20060101); B65D 5/00 (20060101); B65D 5/28 (20060101); B65D 5/42 (20060101); B65D 77/20 (20060101);