PIPELINER CONTAINER

Abstract

A container for the protection and dispensing of elongate coiled product, such as a collapsed pipeliner tube, has an arbor shaft supported in arbor holes made in opposed first and second base panels. A spindle of a product reel rotates on the arbor shaft. Handholes are made in the base panels outside of a product reel radius. A payout opening is made in a rectangular panel connecting the base panels together. End caps have sleeves that fit into the interior of the arbor shaft and flanges that mate to the base panel exterior surfaces.

Claims

1. A container for protecting and dispensing a coil of elongated flexible product, the container comprising: a carton with a first base panel, the first base panel being disposed in a first vertical plane and disposed at an angle to a horizontal axis; a second base panel of the carton disposed in a second vertical plane and disposed at an angle to the axis and to be axially displaced from the first base panel, the first and second base panels being similar polygons each with a plurality of sides and the carton being prismatic; a first arbor hole formed through the first base panel and disposed on the axis, the first arbor hole being circular and having an arbor hole diameter; a second arbor hole formed through the second base panel and disposed on the axis, the second arbor hole being circular and having the arbor hole diameter; the first and second base panels each having a plurality of sides and each having a closest side to the axis, a first radius measured between the axis and a closest point on the closest side of the first base panel, a second radius measured between the axis and a closest point on the closest side of the second base panel being equal to or less than the first radius; an arbor shaft disposed on the axis and supported by the first and second base panels, an outer surface of the arbor shaft being cylindrical and having an outer diameter selected to be closely received into the first and second arbor holes; a product reel having a spindle, an elongated, flexible product being coiled on the spindle, the spindle having an internal cylindrical surface with an inner diameter that is larger than the outer diameter of the arbor shaft, the spindle rotatably mounted on the arbor shaft, a third radius measured between the axis and an outer circumference of the product reel being less than the second radius; and the carton including a plurality of rectangular panels extending between corresponding sides of the first and second base panels, at least one of the rectangular panels being a dispensing panel, an opening in the dispensing panel formed for the dispensing therethrough of the product.

2. The container of claim 1, wherein the outer diameter of the arbor shaft is at least about 2 inches.

3. The container of claim 1, wherein a gross weight of the product reel is no more than about 29 pounds.

4. The container of claim 1, wherein the outer diameter of the arbor shaft is at least about 5 inches.

5. The container of claim 4, wherein a gross weight of the product reel is no more than about 46 pounds.

6. The container of claim 1, wherein the first and second base panels are constructed of cardboard, the cardboard having an ECT rating of at least 48.

7. The container of claim 1, wherein the arbor shaft is hollow.

8. The container of claim 6, wherein the arbor shaft has a first end disposed adjacent the first base panel and an opposed second end disposed adjacent the second base panel, the container further including first and second end caps for respective insertion in the first and second ends of the arbor shaft, the first and second base panels each having an external surface, the arbor shaft having an interior surface parallel to the axis, each end cap having an insertion portion adapted to be inserted into a respective end of the arbor shaft and a circumferential flange radially outwardly extending from the insertion portion, the circumferential flange of each end cap fitting to the external surface of a respective one of the first and second base panels.

9. The container of claim 7, wherein each end cap further has a central hole disposed on the axis, the central hole adapted to receive a connection rod for fastening the container to a transportation device for transporting the carton.

10. The container of claim 1, further comprising a first support sheet similar in size and shape to the first base panel and having a first support sheet arbor hole disposed on the axis and corresponding to the first arbor hole, the first support sheet disposed between the first base panel and the product reel; and a second support sheet similar in size and shape to the second base panel and having a second support sheet arbor hole disposed on the axis and corresponding to the second arbor hole, the second support sheet disposed between the second base panel and the product reel, the arbor shaft received in the first and second support sheet arbor holes, whereby the first and second support sheets each support a portion of a weight of the arbor shaft and a weight of the product reel.

11. The container of claim 1, wherein the product is a collapsed flexible polymer tube for lining pipes.

12. A container for dispensing flexible elongate product, the container comprising: a first prismatic base panel disposed in a first vertical plane; a second prismatic base panel disposed in a second vertical plane, the first and second base panels disposed at an angle to a horizontal axis, the first base panel being axially displaced from the second base panel, each of the first and second base panels having a vertical center line passing through the axis; an arbor shaft disposed on the axis and extending from the first base panel to the second base panel; a reel of flexible elongate product having a spindle, the spindle rotatably mounted on the arbor shaft, the reel having a radius, the reel disposed between the first and second base panels; a first hand hole formed in the first panel to be disposed outside of the radius, to a first side of a vertical center line of the first panel, and above the axis; and a second hand hole formed in the second panel to be disposed outside of the radius, to a second side of the vertical center line of the second panel, and above the axis; whereby a user may grasp the first panel through the first hand hole and the second panel through the second hand hole, a center of mass of the container being located vertically below the and horizontally between the first and second hand holes.

13. The container of claim 12, wherein a third hand hole is formed through the first base panel on the second side of the container relative to the vertical center line of the first panel, the third hand hole formed outside of the radius and above the axis, and wherein a fourth hand hole is formed through the second base panel on the first side of the container relative to the vertical center line of the second panel, the fourth hand hole being formed outside of the radius and above the axis.

14. A container for dispensing an elongate flexible product, the container comprising: a first base panel disposed in a first vertical plane; a second base panel disposed in a second vertical plane, the first and second vertical planes disposed on a horizontal axis to be axially displaced from each other; an arbor shaft extending between the first and second base panels and disposed on the axis, the arbor shaft having a cylindrical outer surface; a product reel having a spindle rotatably mounted on the arbor shaft so as to be disposed between the first and second base panels, an outer circumference of the product reel being disposed at or nearer than a first radius from the axis, the product as wound having a product thickness as measured in a radial direction relative to the axis; the first and second base panels each having a flat bottom side, a flat bottom panel connecting the bottom sides of the first and second base panels, all of the flat bottom panel being downwardly displaced from the axis by a distance that is greater than the first radius; the first and second base panels each having a front side, a front panel of the container extending between the front sides of the first and second base panels; and a payout opening formed in the front panel to be disposed below the axis and through which the product may be pulled out of the container and unwound from the reel, a vertical dimension of the payout opening being larger than the sum of the product thickness and a thickness of a human hand, whereby the human hand of a user may be inserted into the container and rotate the reel in a rotational direction downward and away from the payout opening, thereby rewinding the product onto the reel.

15. The container of claim 14, wherein the vertical dimension of the payout opening is selected from the range of about 5 to about 5 3/16 inches.

16. The container of claim 12, further comprising a payout opening door hinged to the front panel, the door adapted to close the payout opening.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Further aspects of the invention and their advantages can be discerned in the following detailed description as read in conjunction with the drawings of exemplary embodiments, in which like characters denote like parts and in which:

[0012] FIG. 1 is a top right perspective view of a container according to the invention, as containing a reel of pipeliner, an end of the pipeliner appearing at a payout door or opening;

[0013] FIG. 2 is a bottom left perspective view of the container shown in FIG. 1;

[0014] FIG. 3 is a schematic axial sectional view of a pipeliner container as housing a pipeliner reel;

[0015] FIG. 4 is a plan view of a first blank used to construct the container shown in FIGS. 1-3;

[0016] FIG. 5 is a plan view of a second blank used to construct the container shown in FIGS. 1-3 , an outer circumference of a cable reel to be housed in the container shown in broken line;

[0017] FIG. 6 is an exploded view of components of a pipeliner container prior to assembly;

[0018] FIG. 7 is a perspective view showing an early stage of assembling a pipeliner container, with a portion of a support sheet being broken away;

[0019] FIG. 8 is a perspective view showing a stage of assembling a pipeliner container after the stage shown in FIG. 7;

[0020] FIG. 9 is a perspective view showing a stage of assembling a pipeliner container after the stage shown in FIG. 8;

[0021] FIG. 10 is a perspective view showing a stage of assembling a pipeliner container after the stage shown in FIG. 9;

[0022] FIG. 11 is a perspective view of a first end cap for use with the container of the invention;

[0023] FIG. 12 is a perspective view of a second end cap for use with the container of the invention;

[0024] FIG. 13 is a perspective view of a pipeliner container in which a withdrawn length of pipeliner is being wound back onto the pipeliner reel by hand; and

[0025] FIG. 14 is an end perspective view of the container shown in FIG. 1, with a payout flap or door closed.

DETAILED DESCRIPTION

[0026] A container for dispensing a flexible, elongate product is shown generally at 100 in FIGS. 1 and 2. The container 100 includes a carton 102 that is formed as a prism. The carton 102 has a first base panel 104 disposed in a first vertical plane P1, and a second base panel 106 that is disposed in a second vertical plane P2 which in the illustrated embodiment is parallel to but axially spaced from the first vertical plane. Panels 104 and 106 are each disposed at an angle to a horizontal axis X, and may be disposed at right angles to axis X.

[0027] First and second base panels 104, 106 are similar in shape, and can be similar polygons, as shown. In the illustrated embodiment, the base panels 104, 106 are rectangles and more particularly are squares. In other embodiments, the base panels 104, 106 could be triangular, pentagonal, hexagonal or octagonal. A width and a height of the first base panel 104 is slightly more than a corresponding width and height of second base panel 106, by about two thicknesses of the cardboard stock from which the base panels 104 and 106 preferably are made.

[0028] Each of the base panels 104, 106 should have at least a straight bottom margin or corner, such as bottom margin 108 of base panel 104 and bottom margin 110 of base panel 106. The bottom margins 108 and 110, and the flat rectangular bottom panel 112 that extends between them, provide resistance to rotation of the entire carton 102 when product is paid out from the rotating reel contained therein (described below).

[0029] In the illustrated embodiment, the first base panel 104 has a vertically disposed left margin or corner 114 and a vertically disposed right margin or corner 116. A top margin or corner 118 joins the left margin 114 to the right margin 116. Similarly, the base panel 106 has a vertically disposed left margin or corner 120 and an opposed, vertically disposed right margin or corner 122. A top margin or corner 124 of the second base panel 106 joins its left margin 120 to its right margin 122.

[0030] The first base panel 104 has a vertical center line 160 that passes through axis X, and which divides panel 104 into a first side 162 and a second side 164. Similarly, the second base panel 106 has a vertical center line 208 that divides panel 106 into a first side 210 and a second side 212. If a vertical plane is drawn to contain axis X and center lines 160 and 208, sides 162 and 210 will be on one side of such a vertical axial plane, and sides 164 and 212 will be on the other side of such a vertical axial plane.

[0031] A radius R1 of first panel 104 is measured between axis X and the closest point of any of first panel margins 118, 116, 108 and 114. Since in the illustrated embodiment panel 104 is a regular polygon, a radius to the closest point on any of these margins will be the same. A radius R2 of second panel 106 is measured between axis X and the closest point of any of second panel margins 124, 122, 110 and 120. Since in the illustrated embodiment panel 106 is a regular polygon, a radius to the closest point on any of these second panel margins will be the same.

[0032] The prismatic carton 102 further includes a plurality of panels that extend between first base panel 104 and second base panel 106, the number of which is determined by the number of sides or margins of the polygonal base panels 104 and 106. In the illustrated embodiment there are four such panels. Front panel 126 extends between margin 114 of first base panel 104 and margin 122 of second base panel 106. Bottom panel 112 extends between margin 108 of first base panel 104 and margin 110 of the second base panel 106. A top panel 128 extends between margin 118 of first base panel 104 and margin 124 of second base panel 106. A back panel 130 extends between margin 116 of first base panel 104 and margin 120 of second base panel 106. In the illustrated embodiment these panels 126, 112, 128, 130 are much smaller in an axial direction than they are tall or wide, but their dimension in an axial direction will vary according the axial depth of the product reel housed by carton 102.

[0033] First base panel 104 has a first arbor hole 132 that is covered by a first end cap 134, both disposed on axis X. An upper left hand hole 136 is located in the upper left of panel 104, above axis X and outside of a radius (R3, FIG. 5) of a pipeliner reel (314, FIG. 3) contained therein. Similarly, a right hand hole 138 is located in an upper right region of panel 104, again above axis X and outside of the radius of the pipeliner reel contained therein. Left hand hole 136 is located within the first side 162 of panel 104, while right hand hole 138 is located within the second side of panel 164. Preferably the hand holes 136 and 138 are positioned to be close to top margin 118, such that the center of gravity of the container, located at axis X, will be below hand holes 136 and 138 by a maximum practicable distance. This makes container 100 more stable and easier to control when lifted by hand. Hand holes 136 and 138 are positioned outside of radius R3 so that there will be no interference between fingers inserted into the hand holes 136, 138 and the product reel housed in the carton 102.

[0034] As seen in FIG. 2, the second base panel 106 has an arbor hole 200 that is covered by a second end cap 202, both disposed on reel axis X. An upper left hand hole 204 is made in panel 106 so as to be disposed in the upper left corner of panel 106, so as to be outside of radius R3, and to be within side 212 of panel 106. Similarly, an upper right hand hole 206 is made in panel 106 in an upper right corner of panel 106, so as to be outside of radius R3, above axis X and within side 210 of panel 106. The horizontal spacing of hand hole 204 from center line 208 should about the same as the horizontal spacing of hand hole 136 from center line 160. The horizontal spacing of hand hole 206 from center line 208 should be about the same as the horizontal spacing of hand hole 138 from center line 160.

[0035] Each of the hand holes 136, 128, 204 and 206 may be made by providing a horizontal fold line downwardly spaced from top margin 118 or top margin 124, as the case may be, and cutting out a flap to downwardly depend from that fold line. The handle hole flap thus created may be folded inward to provide some cushioning to a hand inserted therein.

[0036] While in the illustrated embodiment four such hand holes 136, 138, 204 and 206 have been provided, in other embodiments only two such hand holes could be provided, at opposite horizontal ends or sides off the carton 102. If only two hand holes are provided, each should be on a different horizontal and on a different panel from the other one. Thus, in one embodiment, only hand holes 136 and 204 could be provided, or, alternatively, only hand holes 138 and 206 could be provided. This allows a user moving the container 100 to grasp and lift both panels 104, 106 at the same time, near opposite horizontal ends of the container, so that the reel axis X (and therefore the center of gravity of container 100) is horizontally midway between the hand holes and a considerable distance below them. This relationship between the position of the hand holes and axis X is best for stability and balance.

[0037] As seen in FIG. 1, front panel 126 has a payout or dispensing opening 140 disposed near bottom panel 112. Opening 140 may extend in an axial direction for the entire width of panel 126. In FIG. 1, an end 142 of a pipeliner 144 is seen protruding out of opening 140. The rest of pipeliner 144 is wound on a spindle 308 (FIG. 3). The pipeliner 144 is a flexible tube that is circular in cross section when it is used to line pipes, but in its condition as packaged and shipped, the pipeliner 144 is a collapsed tube or ribbon that is much wider than it is tall. A total thickness of pipeliner 144, as measured on a radius from axis X and as collapsed and wound, can be in the range of 5 in. to about 6 in. A single thickness of the pipeliner 144, as collapsed, may be about 3/16 in. The opening 140 has a vertical dimension that is much greater than a single thickness of the collapsed pipeliner ribbon 144. This is so a hand and an arm of a user may be inserted therein to rewind an unused portion the pipeliner back onto the reel contained in carton 102.

[0038] Payout opening 140 may have a door 146 that folds outwardly and downwardly around a score or fold line 148. A somewhat semicircular fastening tab 150 may downwardly extend from a horizontal upper edge 152 of the opening 140. Tab 150 cooperates with a concave fastening cutout 154 to reclose the door 146 (FIG. 14). Similar fastening tabs 156 may upwardly extend from lower edges of the hand holes 136, 138, 204, and 206, and these may cooperate with respective concave fastening cutouts 158 formed on the lower edges of the hand hole flaps.

[0039] As seen in FIG. 3, an arbor shaft 300 is disposed on axis X. In the illustrated embodiment, arbor shaft 300 is a hollow cylinder that may be spirally wound cardboard, may have a thickness of in. The needed strength or resistance to shear of arbor shaft 300 will vary according to the gross weight of the product reel 314 that it supports. An interior diameter of arbor shaft 300 may be about 5 inches.

[0040] The arbor shaft spans the interior of carton 102 and is closely received in arbor hole 132 of panel 104 and in arbor hole 200 of panel 106. While an internal surface of arbor shaft 300 may be other than cylindrical or in some embodiments may not be hollow or only partly so, the shaft 300 will have an outer cylindrical surface 302. The cylindrical surface 302 of the arbor shaft 300 is supported directly by edge 304 of arbor hole 132 and directly by edge 306 of arbor hole 200.

[0041] A reel spindle 308 is mounted on the arbor shaft 300 and rotates on arbor shaft 300 about axis X. The reel spindle 308 has an inner cylindrical surface 309 with a diameter that is slightly larger than an outer diameter of arbor shaft 300, and in the illustrated embodiment is in the range of about 5 13/16-5 inches. Reel spindle 308 may be made up of spirally wound cardboard. An outer surface 311 of the reel spindle 308 is cylindrical in the illustrated embodiment, but could be otherwise.

[0042] Elongate flexible product, such as a pipeliner 144, is wound onto reel spindle 308. As wound, pipeliner 144 may have a width, measured in an axial direction, of about 5-6 inches. The length (in an axial direction) of reel spindle 308 may be about the same as the width of the compressed pipeliner 144 wound on it. The gross weight of a complete, unused reel 314 may be as much as 46 pounds and still be successfully supported on panels 104 and 106, or alternatively on panels 104 and 106 and support sheets 316 and 318. In the illustrated embodiment, a portion of the gross weight of arbor shaft 300 and product reel 314 308 is borne by each of support sheets 316 and 318.

[0043] A support sheet 316 may be disposed adjacent to and inwardly of first base panel 104 and axially outwardly of spindle 308. Support sheet 316 may have the size and shape of first base panel 104 and may have a first support sheet arbor hole 317 that is disposed on axis X and which may have the same diameter as first arbor hole 132. Support sheet 318 may have the size and shape of second base panel 106 and may have a second support sheet arbor hole 319 that is disposed on axis X and may have the same diameter as second arbor hole 200.

[0044] Alternatively, support sheets 316 and 318 may be replaced with washers (not shown) that are not as extensive in size as support sheets 316 and 318, but have a circular radial margin and freely rotate on arbor shaft 300 and mitigate against any portion of reel 314 impinging on the interior surfaces of panels 104 and 106.

[0045] Panels 104 and 106 are selected to be strong enough to support the combined weight of arbor shaft 300 and a reel 314 with a complete and unused length of product on it, or, alternatively, are strong enough to support some of that combined weight, with support sheets 316 and 318 supporting the rest. In the illustrated embodiment, panels 104 and 106 are 5-ply cardboard, and may have an edge crush test (ECT) rating of at least 48, with a Mullen or burst test rating of at least 225 #. Support sheets 316 and 318 may be 3-ply B/C cardboard and may have an edge crush test (ECT) rating of at least 48. The needed strength of panels 104 and 106 and sheets 316 and 318 will vary directly with the weight of the arbor shaft 300 and product reel 314; each combination of panel 104 and sheet 316, and panel 318 and sheet 318, must support half of this weight without tearing or buckling.

[0046] But arbor holes 132 and 200, and corresponding support sheet arbor holes 317 and 319, have radii that are large. The larger these radii are, the more will be the length of the semicircular lower half of edges 304, 306, 317 and 319. The weight of the arbor shaft 300 and cable reel 314 is therefore distributed over a larger surface than would be the case if the arbor shaft 300 were replaced with a relatively small-diameter solid bar. A larger horizontal cross section of panels 104, 106 and sheets 316, 318 is thereby made available to bear the columnar load imposed by shaft 300 and reel 314. As this weight becomes more widely distributed, the resistance to tear at the edges 304, 306, and the corresponding edges of holes 317 and 319, will increase, as will the resistance to the buckling of walls 104, 106 and sheets 316 and 318. Increasing the radius of the external surface of arbor shaft 300 may therefore permit a reduction in the needed compressive strength of the cardboard making up panels 104, 106 and sheets 316, 318 for any given gross weight of the reel 314 and arbor shaft 300.

[0047] The outer diameter of the arbor shaft 300, and the maximum gross weight of the product reel 314, are related to each other. In a first, larger embodiment, an outer diameter of the arbor shaft 300 may be about 5 in., while the maximum gross weight may be about 46 pounds. In a second, smaller embodiment, the outer diameter of the arbor shaft 300 may be 2 in., while the maximum gross weight of the product reel 314 may be about 29 pounds. As the size of the arbor holes is increased, the distribution of the weight of the product reel 314 is wider, and therefore the total amount of weight of the product reel 314 may be greater.

[0048] End caps 134, 202 are inserted into the respective axial ends of arbor shaft 300. End caps 134, 202 may be molded of plastic. Each end cap 134, 202 has an insertion portion 320 whose external surface is closely received into the interior of arbor shaft 300. The insertion portions may be cylindrical. An external diameter of insertion portion 320 may be about 5 in. Insertion portion 320 may be chamfered at its inner axial end in order to facilitate its insertion into a respective axial end of arbor shaft 300. End caps 134, 202 further have a radially interior cylindrical wall 322 that is disposed around axis X. An internal diameter of wall 322 may be 1.5 inches. The wall 322 defines a central hole 324 that may receive a connection rod or pole for fastening the container 100 to a hand truck and/or to a vehicle or other transport apparatus.

[0049] End caps 134, 202 further have an annular portion 326 with an internal surface 328 that mates to the external surface of either panel 104 or panel 106. An outer diameter of the annular portion 326 should be substantially larger than the diameter of arbor holes 200, 132, and may for example be about 7 inches. The end caps 134, 202 act to lock the arbor shaft 300 and reel 314 in place to the base panels 104 and 106 and support sheets 316 and 318, and therefore to the entire carton 102.

[0050] The carton 102 may be assembled from two blanks 400 and 500, illustrated in their condition prior to folding and assembly in FIGS. 4 and 5. FIGS. 4 and 5 show the respective surfaces 310, 312 of blanks 400 and 500, respectively, that will be inwardly facing when assembled into carton 102. In FIGS. 4 and 5, solid lines are cut lines, while broken lines are fold or score lines. A structure with an a suffix in FIG. 4 will often correspond to a structure with the same character but a b suffix in FIG. 5, and both a and b structures may further correspond to a feature having the same character, without a suffix, of carton 102 as assembled. For example, an outer bottom rectangular flap 112a of blank 400, in FIG. 4, corresponds to an inner bottom rectangular flap 112b of blank 500, in FIG. 5. After assembly of blank 400 to blank 500, flap 112a will be in a parallel plane to and immediately interior to flap 112b, and both will constitute the bottom panel 112 seen in FIG. 2.

[0051] A first blank 400 includes first panel 104, which is made up with a single thickness of multiple-ply cardboard. A score or fold line 108a separates panel 104 from outer bottom rectangular flap 112a. A score or fold line 116a is the boundary between panel 104 and outer back rectangular flap 130a. A score or fold line 118a is the boundary between panel 104 and outer top rectangular flap 128a. And a score or fold line 114a is the boundary between panel 104 and outer front rectangular flap 126a.

[0052] Outer back rectangular flap 130a has protruding tabs 402a and 404a that extend outwardly from a straight blank margin 120a and which respectively fold around score lines 408 and 410. Outer top rectangular flap 128a has protruding tabs 412a and 414a that extend outwardly from a straight blank margin 124a and which respectively fold around score lines 418 and 420. Outer front rectangular flap 126a has protruding tabs 422a and 424a which extend outwardly beyond a straight blank margin 122a and which respectively fold around score lines 426 and 428. And outer bottom rectangular flap 112a has protruding tabs 430a and 432a which extend outwardly beyond a straight blank margin 110a and which respectively fold around score lines 434 and 436.

[0053] A score or fold line 438a divides outer back rectangular flap 130a from a corner clap 440a. At the other (top) end, a score or fold line 442a divides outer back rectangular flap 130a from a corner flap 444a. Similarly, a fold line 446a divides outer front rectangular flap 126a from a corner flap 448a. And, at the other (top) end, a fold line 450a divides outer front rectangular flap 126a from a corner flap 452a.

[0054] Blank 500 includes panel 106 and many structures that, after assembly, mate with or end up adjacent corresponding structures in blank 400. Notably, panel 106 is surrounded on its four sides by inner rectangular flaps 130b, 112b, 126b and 128b. As assembled, each of these inner rectangular flaps will be positioned immediately to the interior of outer rectangular flaps 130a, 112a, 126a and 128a, respectively, and will thereby constitute rectangular panels 130, 112, 126 and 128, each with two thicknesses of the cardboard stock used to form blanks 400 and 500.

[0055] In particular, inner back rectangular flap 130b is divided from panel 106 by score or fold line 120b. Flap 130b and blank 500 have a straight outer margin 116b. Two slots 404b and 402b are located along score line 120b and will respectively receive tabs 404a and 402a when the carton 102 is assembled. One end of inner back rectangular flap 130b is divided from a corner flap 444b by a fold line 442b. The other, opposed end of inner back rectangular flap 130b is divided from a corner flap 440b by a score line 438b.

[0056] An inner bottom rectangular flap 112b is divided from panel 106 by a score line 110b. Flap 112b has a straight outer margin 108b. Two slots 430b and 432b are positioned along score line 110b and, in an assembled condition, will respectively receive tabs 430a and 432a.

[0057] An inner front rectangular flap 126b is divided from panel 106 by a fold line 122b. Two slots 422b and 424b are disposed on the fold line 122b, and, in an assembled condition, will respectively receive tabs 422a and 424a. Flap 126b and blank 500 have a straight outer margin 114b. A bottom end of front flap 126b is divided from a corner flap 448b by a fold line 446b. A top end of flap 126b is divided from a corner flap 452b by a fold line 450b. A cutout 140b lines up with and helps define payout opening 140 and, in use, will be selectively covered up by door 146.

[0058] A top inner rectangular flap 128b is divided from panel 106 by a fold line 124b. Slots 412b and 414b are disposed along the fold line 124b and, in an assembled condition, will respectively receive tabs 412a and 414a. Flap 128b and blank 500 have a straight outer margin 118b.

[0059] Each of slots 404b, 402b, 430b, 432b, 424b, 422b, 414b and 412b have an opening thickness sufficient to admit their respective associated tabs 404a, 402a, 430a, 432a, 424a, 422a and 412a. Each of tabs 404a, 402a, 430a, 432a and 412a may be barbed so that they will stay in an inserted condition once inserted into their respective slots.

[0060] As previously stated, in both its vertical and horizontal dimensions, panel 106 is about, or a little less than, two cardboard thicknesses smaller than panel 104. Nonetheless, and as shown in FIG. 5, a diameter of the contained product reel 314, a circumference of which is shown at 502, is less than both the width and height of panel 106. Said another way, radius R3 is always smaller than radii R1 or R2. This ensures that product reel 314 will be able to freely rotate on arbor shaft 300 inside of carton 102. Of course, as product is paid out of opening 140, the radius of the product reel 130 will get smaller.

[0061] FIGS. 6-10 illustrate steps in the assembly of a container 100. The parts of container 100, in an unassembled condition, are shown in FIG. 6. These parts include blank 400, blank 500, product reel 314, which in turn is formed by winding a flexible long product such as pipeliner 144 on a reel spindle 308, an arbor shaft 300, two support sheets 316 and 318, and two end caps 134 and 202.

[0062] As seen in FIG. 6, the support sheet 316 has a hand hole 600 that after assembly will register with hand hole 136, and a hand hole 602 that after assembly will register with hand hole 138. Similarly, the support sheet 318 has a hand hole 604 that after assembly will register with hand hole 204, and a hand hole 606 that after assembly will register with hand hole 206. The hand hole flaps 158 (FIG. 1) made out of panels 104 and 106 maybe folded inwardly to abut the upper edges of hand holes 600-606, making the hand holes 136, 138, 204, 206 more comfortable for the user.

[0063] To begin, end cap 134 is placed on a horizontal surface with insertion portion 320 end-up. The interior cylindrical surface of arbor shaft 300 is slid onto the insertion portion 320. Next, the arbor hole 132 of blank 400 is fitted onto shaft 300. This is followed by sliding on support sheet 316. At this point, the partial assembly has the appearance shown in FIG. 7.

[0064] Next, the spindle 308 of the product reel 314 is slid onto arbor shaft 300, followed by the other support sheet 318. Next, or at some point prior to this, the blank 500 is or has been folded into a five-sided box as seen in FIG. 8. The inner rectangular panels 130b, 112b, 126b and 128b are folded around their respective fold lines 120b, 110b, 122b and 124b until each of panels 130b, 112b, 126b and 128b are at right angles to panel 106. During this process, corner flaps 444b, 440b, 448b and 452b are folded around their respective fold lines 442b, 438b, 446b and 450b. In the condition seen in FIG. 8, corner flaps 440b and 448b are disposed inwardly of inner bottom rectangular flap 112b, and corner flaps 444b and 452b are disposed inwardly of inner top rectangular flap 128b.

[0065] Blank/box 500 is then inverted and its arbor hole 200 is placed on arbor shaft 300. In FIG. 9, outer corner flaps 448a, 452a, 444a and 440a have begun to be folded upward around their respective fold lines 446a, 450a, 442a and 438a.

[0066] As seen in FIG. 10, front exterior flap 126a is folded upward around its fold line 114a. While mostly not visible in FIG. 10, at or near this time, back exterior rectangular flap 130a is folded upward around its fold line 116a. After these folding steps have occurred, corner flaps 452a and 444a will be adjacent to the outer surface of inner top rectangular flap 128b, and corner flaps 448a and 440a will be adjacent to the outer surface of inner bottom rectangular flap 112b.

[0067] Assembly of container 100 is completed by (1) folding outer top rectangular flap 128a upward around its fold line 118a, (2) inserting tab 412a into slot 412b and inserting tab 414a into slot 414b, (3) folding outer bottom rectangular flap 112a upwardly around its fold line 108a, and (4) inserting tab 432a into slot 432b and inserting tab 430a into slot 430b. The various panels and flaps of container 100 may be stapled and/or taped to keep them in an assembled condition.

[0068] FIG. 11 is a perspective view of one embodiment of end cap 134, which can be identical to end cap 202. The insertion portion 320 is a hollow cylinder with an internal cylindrical wall 1100. Portion 320 has an external cylindrical surface 1102 that axially inwardly extends from inner annular surface 328 until it meets frustoconical surface 1104. Frustoconical surface 1104 joins surface 1102 to interior surface 1100. Surface 1104 is angled or chamfered to aid its insertion into an end of the arbor shaft 300.

[0069] The inner cylindrical wall 322 is held in place by a plurality of radial vanes 1106, which may be eight in number and which are angularly spaced apart from each other. Each vane 1106 inwardly extends from cylindrical surface 1100 to wall 322.

[0070] Another form of an end cap is shown at 1200 in FIG. 12. End cap 1200 has an insertion portion or plug 1202 that axially inwardly extends from annular inward surface 328. Plug 1202 has an external cylindrical surface 1204 that axially inwardly extends from annular inward surface 328 until it meets frustoconical surface 1206, which serves as an angled transition to an inner face 1208. A bore 1210 is defined by a cylindrical surface 1212 and extends completely through annulus 326 and plug 1202 along axis X. Frustoconical surface 1206 aids in the insertion of plug 1202 into an end of the arbor shaft 300.

[0071] In FIG. 13, a length of pipeliner 144 has been pulled out of the dispensing opening 140 of container 100. But sometimes the length of flexible linear product pulled out of container 100 turns out to be in excess of what is needed. In this instance, it is possible to return the unused length to the interior of container 100. A user 1300 may insert his hand and part of his arm 1302 through opening 140, which is dimensioned with this in mind. The user 1300 then pushes the product reel downward and (in this view) clockwise, away from opening 140, causing the pipeliner 144 to rewind onto the reel 314. As seen in FIG. 14, and at the conclusion of recovering unused product, the payout door 146 may be swung up and its cutout 154 reengaged to fastening tab 150, storing the product until its next use.

[0072] In summary, a container for a reel of flexible elongate product, such as pipeliner, has been shown and described. A spindle of the product reel rotates on an arbor shaft which in turn is supported by the carton walls and support sheets. The base panels are provided with hand holes for easy human transport of the container. A rod fits through axial end caps and permits the affixation of the container to a hand truck or other transport means. A payout door is dimensioned large enough to admit a user's hand, which may therefore rewind dispensed but unused product.

[0073] While illustrated embodiments of the present invention have been described and illustrated in the appended drawings, the present invention is not limited thereto but only by the scope and spirit of the appended claims.