Methods for creating multi-walled containers and articles produced there from

Abstract

Methods for making multi-walled containers from a single blank, preferably using a continuous process approach, and the resulting containers are disclosed. Various embodiments of the invention include, alone or in combination, intermediate panels formed from flap precursors that are in- or out-folded such that their distal ends are in proximate relationship to each other; outer flaps sized to overlap exposed edges of a container formed from the blank; stress relief features a joint corners to reduce stresses thereat. Methods for making select containers of the invention include folding and adhering the flap precursors to an inner panel, up-folding the inner panel/intermediate panel combination about a mandrel, and continuing to up-fold the outer panel until a container having a “use” position as a resting position is formed.

Description

BACKGROUND OF THE INVENTION[0001]Large format containers, generally referred to as “bins”, are used to hold a variety of materials, usually for transport but also for retail display. Because more than 95% of all products in the US are shipped in corrugated boxes, and because of the cost advantages associated with this form of packaging, most bins are constructed from corrugated paperboard. But while about 90% of all corrugated paperboard is single wall, the relatively large dimensions of bins in conjunction with the nature of the goods being placed in the bins require the additional strength provided by multiple wall construction.[0002]The prior art is replete with various methods for establishing a desired level of sidewall burst strength, bottom crush resistance and vertical load capacity for bins. Some solutions employ the use of double or triple wall corrugated paperboard as the starting material, while others rely upon layering walls or nesting boxes. Each of these approaches, ...

AI Technical Summary

Benefits of technology

[0004]Embodiments of the invention in one respect are directed to methods for creating a multi-walled container (and resulting articles) from a corrugated material with minimal intentional waste, wherein the container is formed from a single sheet or preferably a continuous web of corrugated material, such as single wall corrugated board, or double wall corrugated board. Because embodiments of the invention create a multi-walled container from a single sheet or web of material (as opposed to using inserts or a box-within-a-box design), it is possible, as well as desirable, to create the container in a single operation, which advantageously lends itself to a continuous process. Moreover, a continuous process will usually dispense with the need to manage container blanks. Additionally, multi-walled containers are usually large, e.g., from approximately 40″ in width / side. At this scale, conventional container blanks would be very large, approaching 30 feet in length. If embodiments of the invention were formed using traditional construction methodologies, e.g., one apparatus manufactures the blanks, the blanks are then moved to storage, and then moved to a box making machine, storage, transport and handling of such large format blanks would present a formidable challenge. By using a continuous process wherein a web or constant source of material is fed into a box making machine, all material handling requirements that would otherwise be associated with conventional blank-based box making procedures can be eliminated.

Problems solved by technology

If embodiments of the invention were formed using traditional construction methodologies, e.g., one apparatus manufactures the blanks, the blanks are then moved to storage, and then moved to a box making machine, storage, transport and handling of such large format blanks would present a formidable challenge.

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