STACKABLE AND REUSABLE CONTAINERS AND RELATED METHODS
20260097881 ยท 2026-04-09
Inventors
Cpc classification
B65D5/0035
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
Reusable, stackable containers for produce and the like, along with related methods. In some implementations, a method for folding a sheet into a container may comprise folding a first rollover panel against a first panel, wherein the first panel is configured to define a first sidewall of the container. The first rollover panel may further be configured to define a reinforced upper portion of the first sidewall of the container. A second rollover panel may be folded against a second panel, wherein the second panel is configured to define a second sidewall of the container opposite from the first sidewall. The second rollover panel may be configured to define a reinforced upper portion of the second sidewall of the container.
Claims
1. A sheet for folding into a container, comprising: a first panel configured to define a sidewall of a container following a folding process; a first rollover panel configured to be folded against the first panel to define a reinforced upper portion of the sidewall of the container; a first slot formed in the first panel; a first end flap positioned at a first end of the first rollover panel; and a second slot formed in the first rollover panel, wherein the second slot is configured to be at least partially aligned with and adjacent to the first slot after the first rollover panel has been folded against the first panel, wherein the second slot is positioned and configured such that the second slot becomes at least partially aligned with the first slot only after the first rollover panel has been folded against the first panel, and wherein the aligned first and second slots are configured to receive a locking tab from an adjacent panel during the folding process.
2. The sheet of claim 1, further comprising a bottom panel configured to define a bottom of the container following the folding process, wherein the bottom panel comprises a plurality of partial openings formed along each peripheral edge of the bottom panel, wherein each of the plurality of partial openings connects with a corresponding partial opening of an adjacent panel such that a plurality of stacking tab openings are formed along each edge of the bottom of the container.
3. The sheet of claim 2, wherein each of the plurality of stacking tab openings is configured to receive a corresponding stacking tab of an adjacent container below such that the container can couple with an adjacent container using at least one stacking tab/stacking tab opening connection in either a column-stacked configuration or a cross-stacked configuration.
4. The sheet of claim 1, wherein the first rollover panel further comprises a locking flap configured to be folded through an opening in the first panel after the first rollover panel has been folded against the first panel to secure the first rollover panel against the first panel.
5. The sheet of claim 4, wherein the opening in the first panel comprises an elongated carrying opening.
6. The sheet of claim 5, wherein the locking flap is configured to be folded through the opening to define a handle that protrudes through the carrying opening.
7. The sheet of claim 1, wherein the sheet is configured to be folded into a container comprising an open top lacking any upper walls or upper wall portions.
8. A method for folding a sheet into a container, the method comprising the steps of: folding a first rollover panel against a first panel, wherein the first panel is configured to define a first sidewall of the container, and wherein the first rollover panel is configured to define a reinforced upper portion of the first sidewall of the container; folding a second rollover panel against a second panel, wherein the second panel is configured to define a second sidewall of the container, the second sidewall being positioned opposite from the first sidewall, and wherein the second rollover panel is configured to define a reinforced upper portion of the second sidewall of the container; folding up a pair of end flaps positioned on opposing ends of the first rollover panel, wherein a first pair of slots are formed along opposing ends of the first rollover panel adjacent to the pair of end flaps, wherein a second pair of slots are formed in the first panel, and wherein the step of folding the first rollover panel against the first panel results in a first slot of the first pair of slots being at least partially aligned with and adjacent to a first slot of the second pair of slots and a second slot of the first pair of slots being at least partially aligned with a second slot of the second pair of slots.
9. (canceled)
10. (canceled)
11. (canceled)
12. The method of claim 8, further comprising: inserting a first locking tab from a first adjacent panel through the first slot of the first pair of slots and the first slot of the second pair of slots; and inserting a second locking tab from a second adjacent panel opposite the first adjacent panel through the second slot of the first pair of slots and the second slot of the second pair of slots.
13. The method of claim 12, wherein the first locking tab extends from a third rollover panel, wherein the third rollover panel is configured to define a reinforced upper portion of a third sidewall of the container, and wherein the second locking tab extends from a fourth rollover panel, wherein the fourth rollover panel is configured to define a reinforced upper portion of a fourth sidewall of the container.
14. The method of claim 8, wherein the sheet is configured to be folded into a container comprising an open top lacking any upper walls or upper wall portions.
15. A reusable container, comprising: a bottom panel defining a bottom for the container; a first pair of side panels defining, at least in part, a first pair of opposite sidewalls for the container; a first pair of rollover panels folded directly against respective upper portions of the first pair of side panels such that each rollover panel of the first pair of rollover panels is positioned directly against a respective upper portion of a corresponding side panel of the first pair of side panels to define reinforced upper portions for the first pair of side panels; a second pair of side panels defining, at least in part, a second pair of opposite sidewalls for the container; and a second pair of rollover panels folded directly against respective upper portions of the second pair of side panels such that each rollover panel of the second pair of rollover panels is positioned directly against a respective upper portion of a corresponding side panel of the second pair of side panels to define reinforced upper portions for the second pair of side panels.
16. The reusable container of claim 15, wherein the container comprises an open top lacking any upper walls or upper wall portions.
17. The reusable container of claim 16, wherein the container comprises a plurality of stacking tab openings along each bottom edge of the container such that the container can couple with an adjacent identical container using at least one stacking tab/stacking tab opening connection in either a column-stacked configuration or a cross-stacked configuration.
18. The reusable container of claim 15, further comprising a first pair of carrying openings defined by the first pair of side panels, wherein the first pair of carrying openings is configured to receive a corresponding pair of locking flaps foldably coupled with the first pair of rollover panels.
19. The reusable container of claim 18, further comprising a second pair of carrying openings defined by the second pair of side panels.
20. The reusable container of claim 18, wherein the pair of locking flaps defines a pair of handles protruding through the first pair of carrying openings.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The written disclosure herein describes illustrative embodiments that are non-limiting and non-exhaustive. Reference is made to certain of such illustrative embodiments that are depicted in the figures, in which:
[0024]
[0025]
[0026]
[0027]
[0028]
[0029]
DETAILED DESCRIPTION
[0030] It will be readily understood that the components of the present disclosure, as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the apparatus is not intended to limit the scope of the disclosure but is merely representative of possible embodiments of the disclosure. In some cases, well-known structures, materials, or operations are not shown or described in detail.
[0031] As used herein, the term substantially refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result to function as indicated. For example, an object that is substantially cylindrical or substantially perpendicular would mean that the object/feature is either cylindrical/perpendicular or nearly cylindrical/perpendicular so as to result in the same or nearly the same function. The exact allowable degree of deviation provided by this term may depend on the specific context. The use of substantially is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. For example, structure which is substantially free of a bottom would either completely lack a bottom or so nearly completely lack a bottom that the effect would be effectively the same as if it completely lacked a bottom.
[0032] Similarly, as used herein, the term about is used to provide flexibility to a numerical range endpoint by providing that a given value may be a little above or a little below the endpoint while still accomplishing the function associated with the range.
[0033] The embodiments of the disclosure may be best understood by reference to the drawings, wherein like parts may be designated by like numerals. It will be readily understood that the components of the disclosed embodiments, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the apparatus and methods of the disclosure is not intended to limit the scope of the disclosure, as claimed, but is merely representative of possible embodiments of the disclosure. In addition, the steps of a method do not necessarily need to be executed in any specific order, or even sequentially, nor need the steps be executed only once, unless otherwise specified. Additional details regarding certain preferred embodiments and implementations will now be described in greater detail with reference to the accompanying drawings.
[0034]
[0035] Sheet 100 comprises a plurality of panels configured to be folded with respect to one another during a folding/assembly process. More particularly, sheet 100 comprises a first panel 105 that, when folded/assembled, will become a bottom to a container and may therefore be referred to herein as a bottom panel. Similarly, sheet 100 comprises a second panel 110 configured to serve as a side wall, at least in part, of the container, a third panel 115 configured to serve as another side wall, at least in part, of the container opposite from second panel 110, a fourth panel 120 configured to serve as another side wall, at least in part, of the container perpendicular to the side walls formed by second panel 110 and third panel 115, and a fifth panel 126 configured to serve as another side wall, at least in part, of the container opposite from that formed by fourth panel 120.
[0036] Sheet 100 further comprises additional panels 125, 130, 135, 140, 145, and 150. As will be explained in greater detail below, panels 125 and 130 are configured to be positioned adjacent to and at least substantially parallel to panel 110 after folding. In the depicted embodiment, panels 125 and 130 are configured to be positioned at least parallel to panel 110 to collectively define a multi-layered sidewall of the container. Similarly, panels 135 and 140 are configured to be positioned adjacent to and at least substantially parallel to panel 115 to collectively define another multi-layered sidewall of the container.
[0037] Panel 110 comprises two stacking tabs, namely, stacking tab 112A and stacking tab 112B. As discussed in greater detail below, stacking tabs 112A and 112B are configured to be positioned within respective stacking tab openings defined along a bottom portion of an adjacent container panels to engage the containers together in a stacked configuration. Similarly, panel 115 comprises first stacking tab 117A and a second stacking tab 117B.
[0038] Each of the various stacking tabs 112A/112B and 117A/117B is positioned within a corresponding clearance aperture. More particularly, stacking tabs 112A and 112B are positioned within clearance apertures 113A and 113B, respectively. Similarly, stacking tabs 117A and 117B are positioned within clearance apertures 118A and 118B, respectively.
[0039] Each of these clearance apertures is formed within a respective rollover flap that is foldably coupled to a respective panel. More particularly, clearance apertures 113A and 113B are formed within a first rollover flap 111 and clearance apertures 118A and 118B are formed within a second rollover flap 116. Rollover flaps 111 and 116 are each configured to be folded over against their respective panels (panels 110 and 115, respectively) to expose their respective stacking tabs after folding them against such panels. Clearance apertures 113A, 113B, 118A, and 118B extend about the peripheries of their respective locking tabs other than along a base portion of the locking tabs at which the locking tabs protrude from and are connected with their respective panels.
[0040] Rollover flaps 111 and 116 further comprise locking tabs that extend in a different direction than the respective stacking tabs 112A/112B and 117A/117B of each such rollover flap. More particularly, in the depicted embodiment, rollover flap 111 comprises a first locking tab 114A that extends in a direction at least substantially perpendicular to stacking tabs 112A and 112B and second locking tab 114B that extends in an opposite direction to locking tab 114A, but also at least substantially perpendicular to stacking tabs 112A and 112B.
[0041] Similarly, rollover flap 116 comprises a first locking tab 119A that extends in a direction at least substantially perpendicular to stacking tabs 117A and 117B and a second locking tab 119B that extends in an opposite direction to locking tab 119A, but also at least substantially perpendicular to stacking tabs 117A and 117B.
[0042] As illustrated in the figures, locking tabs 114A/114B and 119A/119B each extends beyond a peripheral edge of its respective panel, and beyond a corresponding peripheral edge of its respective rollover flap. The functionality of these locking tabs will be discussed and be more apparent in connection with other figures below.
[0043] Panels 120 and 126 each comprises two slots formed at opposite ends of its respective panel. Thus, panel 120 comprises a first slot 122A positioned along a first peripheral edge of panel 120 and further comprises a second slot 122B positioned along a second peripheral edge of panel 120 opposite from the first peripheral edge. Similarly, panel 126 comprises a first slot 128A positioned along a first peripheral edge of panel 126 and further comprises a second slot 128B positioned along a second peripheral edge of panel 126 opposite from the first peripheral edge.
[0044] Each of these slots 122A, 122B, 128A, and 128B is configured to receive a corresponding locking tab from another panel, as discussed in greater detail below. In some embodiments, one or more (in some such embodiments, all) of these slots 122A, 122B, 128A, and 128B may comprise extended side cuts, as shown in
[0045] Each of panels 125, 130, 135, and 140 comprises another respective stacking tab. More particularly, panel 125 comprises stacking tab 127, panel 130 comprises stacking tab 132, panel 135 comprises stacking tab 137, and panel 140 comprises stacking tab 142. Each of these stacking tabs 127, 132, 137, and 142 may comprise a shape that is identical or at least substantially identical to that of stacking tabs 112A, 112B, 117A, and 117B, for reasons that will become apparent.
[0046] As discussed in greater detail below, following assembly, stacking tabs 127, 132, 137, and 142 are configured to be positioned adjacent to and parallel with stacking tabs 112B, 112A, 117B, and 117A, respectively, so that a pair of respective stacking tabs can together fit within a corresponding slot and/or opening formed in an adjacent container to facilitate secure stacking.
[0047] Sheet 100 further comprises additional rollover panels 150 and 160, both of which are configured to form a reinforcement for a sidewall of a container, and therefore may be referred to herein as reinforcement panels. However, like panels 111 and 116, these panels are also specifically configured to be folded against their respective adjacent panels and may also alternatively be referred to herein as rollover panels.
[0048] Rollover panels 150 and 160 each comprises two respective end flaps. More particularly, panel 150 comprises a first end flap 152A at a first end a second end flap 152B at a second end opposite from the first end. Similarly, panel 160 comprises a first end flap 162A positioned at a first end and a second end flap 162B positioned at a second end opposite from the first end.
[0049] Each of these end flaps 152A, 152B, 162A, and 162B is configured to be folded relative to its respective rollover flap during the aforementioned folding process. Moreover, each of these end flaps 152A, 152B, 162A, and 162B is configured to fold along a respective fold line that is positioned adjacent to a respective slot. Thus, end flap 152A is positioned adjacent to slot 153A, end flap 152B is positioned adjacent to slot 153B, end flap 162A is positioned adjacent to slot 163A, and end flap 162B is positioned adjacent to slot 163B. As explained below, each of these slots 153A, 153B, 163A, and 163B is configured to be aligned, at least in part, with a corresponding slot from an adjacent panel to allow for a respective locking tab to extend through a respective pair of slots to secure the container in a folded configuration.
[0050] Rollover panels 150 and 160 each further comprises a respective locking flap that is configured to further facilitate a stable final configuration for the container. Thus, rollover panel 150 comprises a locking flap 155 and rollover panel 160 comprises a locking flap 165, both locking flaps 155/165 of which are foldably coupled to their respective rollover panel 150/160 at a central position thereon between the opposing end flaps.
[0051] Locking flaps 155/165 are, as explained in greater detail below, configured to be inserted through respective openings 175/185 in an adjacent side panel 120/126, respectively. As also explained further below, openings 175/185 may be configured to allow a user to insert a hand therethrough to lift/carry the container. Thus, openings 175/185 may be considered elongated carrying openings.
[0052] In addition, because locking flaps 155/165 are configured to extend through carrying openings 175/185, they may be configured to provide a more comfortable and/or functional surface for carrying the container and may therefore be considered to define handles for the container that protrude from and are coupled with a respective carrying opening.
[0053] In addition to carrying openings 175/185, additional elongated openings are formed in panels 110 and 115 to provide two other handles for carrying the container. Thus, panel 110 comprises an opening 190 and panel 115 comprises an opening 195 to provide a handle and/or carrying opening along each of the four sidewalls of the container. Both of these openings may comprise score lines along both opposing sides to allow for a flap to be bent, either inward or outward, to provide a more comfortable and/or stable handle.
[0054] As described below, panels adjacent to panels 110 and 115 may comprise elongated openings that are configured to be aligned, at least in part, with openings 190 and 195 so that, once folded, a suitable handle and/or carrying opening is maintained. Thus, panel 126 comprises an elongated opening 192B, panel 130 comprises an elongated opening 192A, panel 135 comprises an elongated opening 197B, and panel 140 comprises an elongated opening 197A.
[0055] Openings 192A, 192B, 197A, and 197B may have the same or at least substantially the same size and/or shape as openings 190 and 195. However, this need not be the case for effective functionality. In other words, if openings 192A, 192B, 197A, and/or 197B are larger in one or more dimensions that openings 190 and/or 195, the effective size of the handle/carrying opening that results may remain unchanged.
[0056] Vent openings may be formed in one or more of the various panels to allow for water and/or air circulation throughout the container. In some embodiments, the vent openings may be configured to allow for placement of a plurality of the containers in either column-stacked or cross-stacked configurations without impeding, or at least without unduly or substantially impeding, air flow through the vent openings. Moreover, openings, whether considered vent openings or otherwise, may be formed along one or more of what will become lower peripheral edges of the resulting container that facilitate desired stacking, preferably in either cross-or column-stacking configurations.
[0057] For example, the embodiment depicted in
[0058] Additionally, stacking openings 193 and 194 may be positioned along the folding edges of bottom panel 105 to what will eventually become the peripheral edges of the bottom of the container. These openings 193/194 may, as discussed in greater detail below, be configured to receive corresponding stacking tabs from a container stacked therebelow, again, preferably in both column and one or more cross-stacking configurations.
[0059] In preferred embodiments, the spacing between openings 193 and/or 194 may correspond with the spacing between stacking tabs, such as the spacing between tabs 112A and 112B and between tabs 117A and 117B, may the same, or at least substantially the same, to allow for this stacking flexibility. Preferably, the spacing between these openings formed along fold lines about the bottom panel 105 are all the same, or at least substantially the same, as the spacing between the aforementioned stacking tabs, including the spacing between openings 194 adjacent to panels 110 and 115 and openings 193 adjacent to panels 120 and 126.
[0060]
[0061] As also shown in
[0062]
[0063] Although not shown in
[0064]
[0065]
[0066] As shown in this figure, the container 100 comprises an open top lacking any upper walls or upper wall portions. In addition, the container 100 comprises sidewalls comprising reinforced upper portions along each sidewall thereof. Container 100 also comprises carrying openings along each side of the container. Two of the sidewalls comprise carrying openings that are defined, at least in part, by respective locking flaps 155/165. The other two sidewalls comprise carrying openings that are defined, at least in part, by bendable/flap portions positioned adjacent to openings 190 and 195. Container 100 further comprises a plurality of stacking tab openings along each bottom edge of the container 100 such that the container 100 can couple with an adjacent identical container using at least one stacking tab/stacking tab opening connection in either a column-stacked configuration or a cross-stacked configuration.
[0067] In certain preferred embodiments, the structure and/or materials of the sheet 100 may further be configured to allow for the container 100 to be used multiple times. In certain preferred embodiments, the sheet 100 may therefore comprise a corrugated plastic material.
[0068] As also shown in
[0069]
[0070]
[0071] As also shown in
[0072] Similarly, in preferred embodiments, the distance between one of the stacking tabs and the edge of the container may be about half of the distances A and/or B. In this manner, the distance between a first stacking tab and an adjacent stacking tab of an adjacent container in a side-by-side configurationdistance Dmay be the same or at least substantially the same as the distances A, B, and/or C.
[0073]
[0074] The second layer reverses this configuration. In other words, the front row comprises containers 100B in an end-to-end configuration and the back row comprises containers 100A in a side-by-side configuration. This configuration alternates back and forth between each adjacent layer in the stack. As also shown in this figure, the distance between adjacent stacking tabs along the width of a containerdistance Cmatches the distance between adjacent stacking tab openings along the length of the containerdistance B.
[0075] Similarly, the distance between adjacent stacking tab openings along the length of the containeragain, distance Bis equal or at least substantially equal to the distance between one stacking tab of a first container and an adjacent stacking tab of an adjacent containerdistance D. This allows the containers to be placed in column or cross-stacked configurations without sacrificing stability.
[0076] As also shown in
[0077] It will be understood by those having skill in the art that changes may be made to the details of the above-described embodiments without departing from the underlying principles presented herein. In addition, any suitable combination of various embodiments, or the features thereof, is contemplated.
[0078] Any methods disclosed herein may comprise one or more steps or actions for performing the described method. The method steps and/or actions may be interchanged with one another. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment and/or implementation, the order and/or use of specific steps and/or actions may be modified.
[0079] Throughout this specification, any reference to one embodiment, an embodiment, or the embodiment means that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the quoted phrases, or variations thereof, as recited throughout this specification are not necessarily all referring to the same embodiment.
[0080] Similarly, it should be appreciated that in the above description of embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any claim require more features than those expressly recited in that claim. Rather, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment.
[0081] Those having skill in the art will therefore appreciate that many changes may be made to the details of the above-described embodiments without departing from the underlying principles of the invention. The scope of the present invention should, therefore, be determined only by the following claims.