US20080169340A1 - Folded and glued display container having shelf elements - Google Patents

Abstract

A folded and glued container has panels defining a back panel and laterally opposite first and second sidewalls and one or more shelf panels attached to the back panel and extending laterally between the two sidewalls. The container is constructed as a compact folded and glued container that can be readily erected by the end user and provides one or more shelf or partition like structures formed in part by panels that are affixed, in addition to an integral die cut panel, when processing the container in a fold and glue machine line.

Description

FIELD OF THE INVENTION
• The invention relates to paperboard, corrugated craft and similar containers made in a fold and glue line and typically supplied in a collapsed or knocked-down-flat configuration that can be readily erected. According to one aspect, two or more separately integral pieces of stock are assembled and can be erected to form a tier of shelves.
BACKGROUND OF THE INVENTION
• Corrugated and paperboard containers are made from pieces of flat stock that are typically die cut into shapes that define various panels. The shapes are folded along strategic lines between the panels, and at least one overlapping strip or panel is typically glued, taped or otherwise affixed to another panel to form a closed perimeter. The various panels are intended to become the walls, top and/or bottom of a full or partial enclosure when folded into place. Often, the containers are supplied in a collapsed or flattened parallelogram state (known as knocked-down-flat or “KDF”), for efficient storage, handling and shipping. Before packing, the containers are opened out into a hollow form and the panels are folded to reside in orthogonal planes.
• Such containers can be more or less complicated. A simple version known as the regular slotted carton (RSC) has four side walls, each of which has a top and bottom flap. More complicated versions have doubled-over panels, reinforcing folded parts, inter-engaging tabs and slots and other features.
• Such containers advantageously are produced by feeding flat integral die cut sheets through a fold-and-glue machine, such as those available from Bobst Group, Inc. of Roseland, N.J., to apply adhesive and preliminarily to fold over select panels so that the panels are adhered in a KDF state for shipping or storage, ready to be erected into their final configuration by articulating the panels around adjoining folds. A simple RSC version is erected by pressing inwardly from diagonally opposite corners and folding the flaps inwardly by 90° from their adjoined panels. In relatively more complicated full or partial containers, various panels may need to be folded in appropriate directions in appropriate order. Various tabs may need to be inserted into respective slots and so forth.
• Containers as described can be used for displaying items or goods for the consumers at the point-of-sale location. Minimizing the effort and complication required to erect and set up the containers is an important factor for the viability and success of the particular container design. Thus, the number of parts required to erect or assemble the containers from their KDF configuration is an important element in the acceptability of the container design.
• Generally, a container design is most efficient if most or all of its panels, tabs and other parts are integral panels and extensions of panels cut from a single flat blank, i.e., integral parts of the same sheet of material. Separate discrete parts such as separate lids, inserted partitions, shelves, reinforcing inserts and the like require attention to inventory, manual assembly steps and other complications during the production, erection and set up of the container. Separate parts are not desirable.
• For these reasons, conventional KDF-type containers routinely are provided in a single piece flat blanks wherein all the panels necessary to construct or erect a container are members of a single sheet of stock material, cut out along an outline and scored or perforated at fold lines so as to provide all the necessary parts in an integral unit. The various seams are glued and the various folding connections between panels are cut, scored, compressed, etc.
• The die cut integral blanks, preferably preliminarily weakened along prospective fold lines, are processed through the fold and glue machine. Glue is applied at preselected surfaces that are to overlap at seams. Panels are folded around fold joints. The KDF container blanks are thus produced and assembled in a state ready to be packed and shipped. For more complicated container designs, for example including lids or inserts, the KDF container blanks may be accompanied by separate discrete parts, but they add cost and require time for inventory attention, assembly and other reasons.
• Because conventional KDF containers preferably are integral sheets, the panel layout design and general container complexity are limited. There is a need for ways to permit container designs to be made into complex structures, but without entailing complex parts and extensive assembly steps.
SUMMARY OF THE INVENTION
• A folded and glued container according to an embodiment comprises a plurality of panels defining a back panel and laterally opposite first and second sidewalls, each sidewall being joined to the back panel. One or more shelf panels are attached to the back panel and extend laterally between the two sidewalls. A facing panel is joined to each of the shelf panels. An inner facing panel is joined to each of the facing panels and a pair of facing supports are provided for supporting the facing panel in the erected state of the container. One facing support in each of pair of facing supports is joined to one of the sidewalls and the other facing support of the pair is joined to the other of the sidewalls. The container also can include longitudinally opposite top and bottom end walls joined to the back panel. In the erected state of the container, the top and bottom end walls may be attached to each of the sidewalls by one or more locking tabs.
• According to another embodiment, a folded and glued self-erecting container comprises a plurality of panels defining a back panel and laterally opposite first and second sidewalls. Each sidewall has an outer sidewall panel joined to the back panel and a plurality of inner sidewall panels joined to the outer sidewall panel. One or more shelf panels are attached to the back panel and extend laterally between the two sidewalls. The shelf panels are joined to inwardly folded bellows panels extending between the shelf panels and the outer sidewall panels such that when the sidewalls are erected from their knocked-down-flat configuration to an orientation perpendicular to the back panel, the shelf panels are raised from their knocked-down-flat configuration to form shelves between the two sidewalls. The shelf panels can function as shelves when the container is in an upright orientation or can also function as partitions when the container is laid down on its back panel.
• In certain embodiments, a facing panel is joined to each of the shelf panels for forming a facing structure for each shelf. The facing structure functions as a retaining wall raised along the front edge of each of the shelves to retain the items being held by the shelves. Alternatively, in a similar structure the facing structure is below the front edge of each shelf and stiffens the shelf while allowing items to be moved freely over the front edge of the shelf, without obstruction. An inner facing panel is joined to each of the facing panel and a pair of facing supports are provided for supporting each of the facing panels in the erected state of the container. One facing support of the pair of facing supports is joined to one of the outer sidewall panels and the other facing support of the pair of facing supports is joined to the other of the outer sidewall panels.
• In other embodiments, the folded and glued self-erecting container may further include top and bottom end walls, each of the top and bottom end wall panels are joined to inwardly folding bellows panels extending between them and the outer sidewall panels. When the sidewalls are erected from their knocked-down-flat configuration to an orientation perpendicular to the back panel, the top and bottom end wall panels are lifted automatically from their knocked-down-flat configuration. In some embodiments, one or both of the top and bottom end wall panels can be configured with facing panels and inner facing panels and corresponding facing supports provided along the outer sidewall panels allowing the top and/or bottom end walls to function as shelves.
• According to another embodiment, one or both of the top and bottom end walls can be provided with a facing panel and an inner facing panel and associated facing supports joined to the outer sidewall panels.
BRIEF DESCRIPTION OF THE DRAWINGS
• A number of additional objects and aspects are apparent from the appended description and the associated illustrations of preferred embodiments, wherein:
• FIG. 1 is a perspective view of an erected container according to one embodiment;
• FIG. 2 is a plan view of the die-cut blank for the container ofFIG. 1;
• FIG. 3 is a plan view of the KDF container blank for the container ofFIG. 1 that has been folded and glued from the die-cut blank ofFIG. 2;
• FIGS. 4aand4bare perspective views of interim stages in erecting the container ofFIG. 1;
• FIG. 4cis a longitudinal cross-sectional view of a shelf panel being assembled inFIG. 4b;
• FIG. 5ais a perspective view of a container according to another embodiment;
• FIG. 5bis a plan view of the KDF container blank for the container ofFIG. 5a;
• FIG. 6ais a perspective view of a container according to another embodiment;
• FIG. 6bis a plan view of the KDF container blank for the container ofFIG. 6a;
• FIG. 7ais a perspective view of a container according to another embodiment;
• FIG. 7bis a plan view of the die-cut blank for the container ofFIG. 7a;
• FIG. 7cis a perspective view of the KDF container blank for the container ofFIG. 7athat has been folded and glued from the die-cut blank ofFIG. 7b;
• FIG. 8ais a perspective view of a self-erecting container according to another embodiment;
• FIG. 8bis a plan view of the die-cut blank for the container ofFIG. 8a;
• FIG. 8cis a perspective view of the KDF container blank for the container ofFIG. 8athat has been folded and glued from the die-cut blank ofFIG. 8b;
• FIG. 8dis a perspective view of the KDF container blank ofFIG. 8cthat is partially erected; and
• FIG. 8eis a perspective view of the KDF container blank ofFIG. 8cthat is further partially erected.
DETAILED DESCRIPTION
• As will be appreciated, terms such as “horizontal,” “vertical,” “left,” “right,” “up,” “down,” “top,” “bottom,” “front” and “back,” (etc.), used as nouns, adjectives or adverbs (e.g. “horizontally”, “rightward”, “upwardly”, “downwardly”, etc.) refer in this description to the orientation of the structure of the invention as it is illustrated in the particular drawing figure when that figure faces the reader. Such terms are not intended to limit the invention to a particular orientation. Similarly, the terms “longitudinal” and “lateral” generally refer to the orientation of surfaces or other structures relative to an axis of elongation or axis of rotation, as appropriate. The terms “integral”, “integrally connected” or “integrally joined” when used to describe the relationship between two or more structures means that the structures are comprised of a single piece of material.
• The terms “connected” and “interconnected”, when used to describe the relationship between two or more structures, mean that such structures are secured or attached either directly or indirectly through intervening structures and include movable connections such as pivoting connections. The term “operatively” means that the foregoing direct or indirect connections between such structures allow the structures to operate as described and intended by virtue of such connection.
• Lines representing fold lines are shown in the drawings by broken and solid lines that represent lines along which the material can be weakened or caused preferentially to fold by any of various means. For example, corrugated or other material can be compressed along a thin line defining a fold, or can be cut part way through along the line, or cut all or part way through the line at spaced intervals. Each of these and similar techniques form lines along which the material is folded or made readily foldable, in the knocked-down flat (“KDF”) blank and/or in the erected container.
• Portions of joints in which glued surfaces are exposed to view in the drawings and discussed in this description are sometimes shown in the relevant figures by “XXX” patterns, representing an area to which adhesive has been or will be applied. Areas where the glue on a rear face of a respective panel is relevant are at times shown in broken line “XXX” patterns, indicating an adhering surface on a side opposite from the side shown (i.e., the backside).
• FIG. 1 shows acontainer10 according to an embodiment in erected configuration. Thecontainer10 is a rectilinear container comprised of a plurality of panels, aback panel20 and laterally opposingsidewall panels30. Thecontainer10 also includes one ormore shelf panels60 that are attached to theback panel20. Theshelf panels60 extend between the sidewalls30 and provides partitions for the container or function as shelves for displaying items when the container is used in vertical orientation as shown. Each of theshelf panels60 include a facingpanel64 that is folded and oriented substantially perpendicular to theshelf panels60 to retain items that are placed on theshelf panels60. Thecontainer10 is erected from a folded and glued KDF container blank10bshown inFIG. 3.
• FIG. 2 shows a layout of a sheet of die-cut blank10aincludingshelf panels60 cut from a single flat blank sheet of stock material. The die-cut blank10acan be cut, for example, from a sheet of corrugated board, paperboard or other suitable sheet material. A number of thicknesses can be die cut in a single step. However, the die-cut blank10apreferably is cut out individually so that the blank can be scored or compressed along the fold lines, at the same time that the perimeter of the blank is cut from the sheet. The die-cut blank10ais then folded and glued by a fold-and-glue machine to form the KDF container blank10b.
• The fold-and-glue process may be carried out by fold-and-glue machines, such as those available from Bobst Group, Inc. of Roseland, N.J., apply adhesive to pre-selected areas of the die-cut blank and preliminarily fold over pre-selected panels.
• An aspect of the inventive product show is that for making KDF container blanks, such as the blank10b, for various embodiments of the invention, the fold-and glue machine is caused to glue and attach certain separate supplemental pieces such as theshelf panels60 to the integral main die-cut blanks10a. As described herein, the addition of supplemental pieces to a blank enables a number of advantageous aspects to be achieved while using the capabilities of the fold and glue machine to apply adhesive at strategic places and to fold over various panels and tabs to form a KDF structure ready to be erected.
• The die-cut blank10acomprises aback panel20,sidewall panels30 and facingsupports32 that are cut from a single sheet of stock material and thus are integrally joined. Theback panel20 and thesidewall panels30 are integrally joined across longitudinally extendingfold lines1f. Thesidewall panels30 and the facing supports32 are integrally joined along longitudinally extendingfold lines2f. The facing supports32 are provided with lockingtabs33 for engaging with theshelf panel60 when thecontainer10 is erected.
• The one ormore shelf panels60, including as associated sub-parts, attachment flaps62, facingpanels64 andinner facing panels66, can be die cut from the same sheet of stock material, but these parts are cut as individual pieces and are not integrally joined to the die-cut blank10awhen processed in the fold and glue machine. Anattachment flap62 is joined to the rest of theshelf panel60 by afold line3f. A facingpanel64 is joined to theshelf panel60 by afold line4fand the inner facingpanel66 is joined to the facingpanel64 by afold line5f. The inner facingpanel66 is provided with one ormore locking tabs67 and theshelf panels60 are provided with corresponding lockingtab receiving slots65 for holding the shelf assemblies in their erected configuration.
• The KDF container blank10bis formed by gluing and attaching each of theshelf panels60 to theback panel20 portion of the die-cut blank10a. The fold-and-glue machine applies glue to the glue areas G marked by “XXX” of theback panel20 shown inFIG. 2. The fold-and-glue machine then picks up the one ormore shelf panels60, which are fed separately into the fold-and-glue machine as supplemental pieces, positions and attaches them to theback panel20 so that the attachment flaps62 of theshelf panels60 align with the glue areas G. The result is a KDF container blank10bshown inFIG. 3.
• Referring toFIGS. 4a-4c, interim stages of erecting thecontainer10 from the KDF container blank10bare illustrated. First, thesidewall panels30 and theshelf panels60 are folded up along thefold lines1fand3f, respectively, as shown inFIG. 4a. The facing supports32 are then folded inwards along thefold lines2f. A pair of facing supports32, one joined to each of the opposingsidewall panels30, is provided for each of the facingpanel60. The facingpanels64 are folded along thefold lines4ftowards the top of thecontainer10 as shown by the arrows A inFIG. 4b. As illustrated inFIG. 4c, which is a longitudinal cross-sectional view of ashelf panel60 in the final assembly configuration, theinner facing panels66 are then folded down behind the facing supports32 along thefold lines5funtil the lockingtabs67 provided along the edge of theinner facing panels66 are inserted into the lockingtab receiving slots65 provided on theshelf panels60. Folding the facingpanels64 and theinner facing panels66 in this manner captures the facing supports32 between the facingpanels64 and theinner facing panels66. Thelocking tab33 provided on the facingsupport32 is shown engaged into the lockingtab receiving slot65 along with thelocking tab67 of the inner facingpanel66. In this embodiment, the facing supports32 keep the facingpanels64 in upright position as shown inFIG. 1 and also provide the structural support for the shelves/partitions formed by theshelf panels60.
• Referring toFIGS. 5aand5b, in another embodiment, longitudinally opposite topend wall panel40 and bottomend wall panel50 are provided to add additional structural rigidity to an embodiment with respective back and side walls forming an open-faced container11.FIG. 5ashows a perspective view of thecontainer11 with the bottomend wall panel50 in fully assembled position and the topend wall panel40 in a partially assembled position.
• KDF container blank11bfor thecontainer11 is shown inFIG. 5b. The top and bottomend wall panels40,50 are integrally joined to theback panel20. The top and bottomend wall panels40,50 are configured with one ormore locking tabs42,52, respectively. End flaps34 extend from the longitudinally opposite ends of thesidewall panels30 to provide lockingtab receiving slots35. To complete the erection of the container, the end flaps34 are folded inwards alongfold lines6f. Then the top and bottomend wall panels40,50 are folded inwards alongfold lines7fand8f, respectively, and theirlocking tabs42,52 are folded and inserted into the lockingtab receiving slots35. If appropriate, the locations of the end flaps34, lockingtabs42,52, and the lockingtab receiving slots35 can be interchanged between thesidewall panels30 and theend wall panels40,50. The KDF container blank11bis similar to the KDF container blank10bwith the addition of the end flaps34, the top and bottomend wall panels40,50 and their associated lockingtabs42,52 and the lockingtab receiving slots35.
• Referring toFIGS. 6aand6b,container12 and its KDF container blank12baccording to another embodiment are illustrated. In this embodiment, one or both of the top and bottomend wall panels40,50 may be configured as shelves also. In the illustrated example of thecontainer12 shown inFIG. 6a, both the top and bottom end wall panels are illustrated in shelf configuration. The top and bottomend wall panels40,50 are provided with facingpanels64′ andinner facing panels66′ and corresponding facing supports32′ are provided on thesidewall panels30. The bottomend wall panel50 is configured similar to theshelf panels60 with the difference being that the bottomend wall panel50 is integrally joined to theback panel20 along thefold line8frather than being glued to it. And the topend wall panel40 is configured similar to theshelf panels60 with the difference being that the topend wall panel40 is integrally joined to theback panel20 along thefold line7f. But in this embodiment, thetop end31 of thesidewall panels30 are extended longitudinally to provide the facing supports32′ for the topend wall panel40. As with theshelf panels60, theinner facing panels66′ of the top and bottomend wall panels40,50 are provided with one ormore locking tabs67′ and corresponding number of lockingtab receiving slots65′ are provided. And as with the facing supports32, the facing supports32′ are provided with lockingtabs33′ for engaging with the lockingtab receiving slots65′ when thecontainer12 is in fully erected configuration.
• In other embodiments, for better presentation of display items carried on the shelves, it may be desirable that the shelves in the container be disposed at a forward incline.FIGS. 7aand7billustrate an example of such acontainer13, configured withshelf panels60 that are inclined at an angle β. The incline angle for each shelf panel may be configured to a particular desired angle. As shown in the corresponding die-cut blank13ainFIG. 7b, thesidewall panels30 are configured to have the facing supports32 extend from thesidewall panels30 at the incline angle β. In this example, the topend wall panel40 is provided with lockingtabs42 that mate with the lockingtab receiving slots35 provided on the end flaps34 of thesidewall panels30 when thecontainer13 is in its erect configuration. The end flaps34 are provided at the top end of theside wall panels30 and are integrally joined to the side wall panels alongfold lines6f. The lockingtab receiving slots35 are provided along thefold lines6fto be in alignment with the lockingtabs42. As discussed previously, one or both of the top and bottomend wall panels40,50 may be configured to be a shelf. In the example illustrated inFIGS. 7aand7b, the bottomend wall panel50 is configured as such. The bottomend wall panel50 which is integrally joined to theback panel20 along thefold line8fhas a facingpanel54 integrally joined to it along thefold line4f. An inner facingpanel56 is integrally joined to the facingpanel54 along thefold line5f. And lastly, a shelf-formingextension panel58 is integrally joined to the inner facingpanel56 along thefold line9f. Also provided along thefold line9fare one ormore locking tabs57 and provided along thefold line4fare corresponding number of lockingtab receiving slots55.
• The die-cut blank13aincludes one ormore shelf panels60, including the associated sub-parts, attachment flaps62, facingpanels64 andinner facing panels66 that are die cut from the same sheet of stock material, but are cut as individual pieces and are not integrally joined to the die-cut blank13a. Theattachment flap62 is integrally joined to the rest of theshelf panel60 by afold line3f. The facingpanel64 is integrally joined to theshelf panel60 by afold line4fand the inner facingpanel66 is integrally joined to the facingpanel64 by afold line5f.
• A KDF container blank13bis formed by gluing and attaching each of theshelf panels60 to theback panel20 portion of the die-cut blank13a. The fold-and-glue machine applies glue to the glue areas G marked by “XXX” of theback panel20 shown inFIG. 7b. In this example, twoshelf panels60 are provided corresponding to the two sets of facing supports32a,32band32c,32d. The fold-and-glue machine then picks up the one ormore shelf panels60, which are fed separately into the fold-and-glue machine as supplemental pieces, positions and attaches them to theback panel20 so that the attachment flaps62 of theshelf panels60 align with the glue areas G. The result is a KDF container blank13bshown inFIG. 7cin perspective view.
• In erecting/assembling thecontainer13, thesidewall panels30 are folded inwards alongfold lines1f. The facing supports32a-fare then folded inwardly along thefold lines2f. Each of theshelf panels60 are erected by folding it outward along thefold lines3f. Then, the facingpanel64 is folded along thefold line4ftoward the top of the container. Theinner facing panels66 are then folded down behind the facing supports32a,32band32c,32dalongfold lines5funtil lockingtabs67 are inserted into the lockingtab receiving slots65. The sequence of folding the facingpanels64 andinner facing panels66 are similar to the steps shown inFIGS. 4band4cin reference to the corresponding panels incontainer10. In this embodiment, the facing supports32a-fkeep the facingpanels64 orthogonal to theshelf panels60 and provide structural support as well as functioning as a retaining wall for the shelf.
• To form the bottom shelf structure, the bottomend wall panel50 is folded towards the top of the container along thefold line8f. Next, the facingpanel54 is folded up towards the top of the container along thefold line4f. Next, the inner facingpanel56 is folded inwardly (i.e., towards the back panel20) over onto the facingpanel54 so that the corresponding pair of facing supports32eand32fare held between the facingpanel54 and the inner facingpanel56. The shelf-formingextension panel58 is then folded outwardly (i.e., away from the back panel20) along thefold line9finto an inclined position and the one ormore locking tabs59 of the shelf-formingextension panel58 are inserted into the corresponding lockingtab receiving slots25 cut into theback panel20. The lockingtabs57 engage into the lockingtab receiving slots55 of the bottomend wall panel50 after the facingpanel54 and the inner facingpanel56 are folded over the facing supports32eand32f. The outline of the lockingtabs57 are die cut so that when the shelf-formingextension panel58 is folded along thefold line9f, the lockingtabs57 protrudes.
• According to another aspect of the invention, the shelf structures formed by the supplemental pieces glued to the main die-cut blank by the fold-and-glue machine can be configured to be self-erecting. For example, referring toFIGS. 8a-8e, a self-erectingcontainer100 is illustrated.FIG. 8ashows a perspective view of the fully erected self-erectingcontainer100. The self-erectingcontainer100 comprises aback panel120 and laterally oppositesidewalls130, and longitudinally oppositetop end wall140 and abottom end wall150. Thecontainer100 also includes one ormore shelf panels160c,160dthat are attached to theback panel120. Theshelf panels160c,160dextend between thesidewalls130 and function as shelves for displaying items when thecontainer100 is used in vertical orientation as shown or provide partitions for the container when the container is used in horizontal orientation. Each of theshelf panels160c,160dmay be provided with a facingpanel164 that is oriented substantially perpendicular to theshelf panels160c,160dthat function as retaining wall for the shelves. In this embodiment, thebottom end wall150 is also provided with a facingpanel154 similar to the facingpanels164 of theshelf panels160c,160d. The number of shelf panels provided in a given container may vary depending on the number of shelves desired.
• Referring toFIG. 8b, a die-cut blank100afor thecontainer100 is shown. The die-cut blank100aincludesshelf panels160c,160dthat may be cut from the same blank sheet of stock material as the main section of the die-cut blank. As with the die-cut blanks for the other embodiments, the die-cut blank100acan be cut, for example, from a sheet of corrugated board, paperboard or other suitable sheet material. The die-cut blank100ais folded and glued by a fold-and-glue machine to form the KDF container blank100bshown inFIG. 8c.
• The die-cut blank100acomprises theback panel120,outer sidewall panels137 integrally joined to theback panel120 along fold lines f1 and a plurality ofinner sidewall panels139 integrally joined to theouter sidewall panel137 along fold lines f10. Provided in between theinner sidewall panels139 are facingsupports132 that are integrally joined to theouter sidewall panel137 by fold lines f2. The number of facing supports along each of theouter sidewall panel137 will depend on the number of shelves the particular embodiment of the container has. In thecontainer100 illustrated here, three shelves are provided (two from theshelf panels160c,160dand the third from the bottom end wall panel150), thus, there are three facingsupports132 are provided along each of theouter sidewall panels137 forming three pairs of facing supports. The facing supports132 are provided with lockingtabs133 for engaging with theshelf panels160c,160dand the bottomend wall panel150 when thecontainer100 is fully erected.
• The topend wall panel140 is integrally joined to theback panel120 along fold line f7. The bottomend wall panel150 is provided longitudinally opposite from the topend wall panel140 and is integrally joined to theback panel120 along fold line f8. The top and bottomend wall panels140,150 are integrally joined to theouter sidewall panels137 by inwardly folding bellowspanels170a,170b, respectively. Thebellows panels170a,170binclude glue regions G4, G5, respectively for gluing and bonding thebellows panels170a,170bto theouter sidewall panels137. The topend wall panel140 may further include areinforcement flap142 integrally joined to the top end wall panel along fold line f11. By gluing the glue region G3 and folding thereinforcement flap142 over onto the region G3, the structural rigidity of thetop end wall140 can be improved by increasing its thickness.
• The bottomend wall panel150 is provided with a facingpanel154 that is integrally joined to it along fold line f4 and aninner facing panel156 is integrally joined to the facingpanel154 along fold line f5. Along the edge of the inner facingpanel156 are one ormore locking tabs157 for engaging the lockingtab receiving slots155 provided on the bottomend wall panel150 along the fold line f4 when the container is fully erected.
• One ormore shelf panels160c,160d, including their sub-parts are die cut from the same sheet of stock material as the main portion of the die-cut blank (the portion with the back panel120), but are provided as individual supplemental pieces and are not integrally joined to the main portion of the die-cut blank when fed into a fold-and-glue machine. The fold-and-glue machine will glue and attach theshelf panels160c,160dto the main portion of the die-cut blank to form a KDF blank100b. Each of theshelf panels160c,160dare configured similar to theshelf panels60 of thecontainer10.
• Each of theshelf panels160c,160dhas anattachment flap162 integrally joined to the shelf panel along a fold line f3. A facingpanel164 is integrally joined to each of the shelf panels along a fold line f4 and aninner facing panel166 is joined to the facingpanel164 along a fold line f5. Theinner facing panel166 is provided with one ormore locking tabs167 and the shelf panels are provided with corresponding lockingtab receiving slots165 for holding the shelf assemblies in their erected configuration. Additionally, in this self-erecting embodiment, theshelf panels160c,160dare each provided with a pair ofbellows panels170c,170d, respectively.
• Referring toFIG. 8c, a KDF blank100bconstructed from the die-cut blank100aby a fold-and-glue machine is shown. The fold-and-glue machine applies glue to the glue areas G6 and G7 and attaches theshelf panels160cand160dto theback panel120 of the main portion of the die-cut blank. For example, theshelf panel160cis attached by aligning the areas G6′ and theattachment flap162 to the corresponding glued areas G6 and G1, respectively, on theback panel120. Similarly, theshelf panel160dis attached by aligning the areas G7′ and theattachment flap162 to the corresponding glued areas G7 and G2, respectively, on theback panel120. The glue areas G4 of thebellows panel170ais then glued and the top end wall panel is folded over along the fold line f7, thus, attaching the glued areas G4 to theouter sidewall panels137. The glue areas G5 of thebellows panel170bis then glued and the bottomend wall panel150 is folded over along the fold line f8, thus, attaching the glued areas G5 to theouter sidewall panels137.
• As shown inFIG. 8c, the topend wall panel140, theshelf panels160c,160d, and the bottomend wall panel150 are joined to inwardly foldedbellows panels170a,170c,170d,170b, respectively, extending between these panels and theouter sidewall panels137. By the operation of the inwardly folded bellows panels, when theouter sidewall panels137 are erected from their KDF configuration to an orientation perpendicular to theback panel120, theshelf panels160c,160dand the top and bottomend wall panels140,150 are raised from their KDF configuration so that the topend wall panel140 forms a top end wall and theshelf panels160c,160dand the bottomend wall panel150 form shelves between the two sidewalls.
• FIG. 8dshows a partially erected KDF blank100bin which theouter sidewall panels137 are in fully vertical configuration and the top and bottomend wall panels140,150 and theshelf panels160c,160d, in turn, have been fully raised automatically by the operation of the associated inwardly foldedbellows panels170a,170b,170c,170d. Next, each of theinner sidewall panels139 are folded down inwards along the fold lines f10, as shown by the arrows B, until the lockingtabs139tof theinner sidewall panels139 are inserted into the lockingtab receiving slots129 provided in theback panel120. As shown inFIG. 8e, when theinner sidewall panels139 are folded down and locked as described, theinner sidewall panels139 capture the folded bellowspanels170a,170b,170c,170dbetween theinner sidewall panels139 and theouter sidewall panels137. This secures the top and bottomend wall panels140,150 and theshelf panels160c,160din the erected configuration.
• Further referring toFIG. 8e, next, the facing supports132 are folded inwards along the fold lines f2 as shown by the arrows C.The facing panels164 and154 are folded along the fold lines f4 towards the top of thecontainer100 and theinner facing panels166 and156 are then folded down behind the facing supports132 along the fold lines f5 until the lockingtabs167 and157 provided along the edges of theinner facing panels166 and156 are inserted into the corresponding lockingtab receiving slots165 and155 provided on theshelf panels160c,160dand the bottomend wall panel150. Folding the facingpanels164,154 and theinner facing panels166,156 in this manner captures the facing supports132 between the facingpanels164,154 and the associated inner facingpanels166,156. The facing supports132 keep the facingpanels164,154 in their erected position.
• In another embodiment, a facingpanel164 can be joined to each of the shelf panels160 for forming a facing for each shelf. Such facings function as retaining walls along the front edges of the shelves. An inner facingpanel166 is joined to each of the facingpanel164 and a pair of facingsupports132 are provided for supporting each of the facing panels in the erected state of the container. One facingsupport132 of the pair of facing supports is joined to one of theouter sidewall panels130 and the other facing support of the pair of facing supports is joined to the other of theouter sidewall panels130.
• The invention having been disclosed in connection with the foregoing variations and examples, additional variations will now be apparent to persons skilled in the art. The invention is not intended to be limited to the variations specifically mentioned. For example, in some other embodiments, the containers disclosed herein, both the self-erecting type as well as the non-self-erecting type, may be modified so that the shelf structures do not have the facing panels. In another example, the topend wall panel140 of thecontainer100 may be replaced with another shelf panel similar to theshelf panels160cand160dso that the top end of thecontainer100 is another shelf. Accordingly reference should be made to the appended claims rather than the foregoing discussion of preferred examples, to assess the scope of the invention in which exclusive rights are claimed.

Claims (12)

1. A folded and glued container comprising:

a plurality of panels defining a back panel and laterally opposite first and second sidewalls, each sidewall being joined to the back panel;

one or more shelf panels attached to the back panel and extending laterally between the two sidewalls;

a facing panel joined to each of said shelf panels;

an inner facing panel joined to each of said facing panels; and

a pair of facing supports provided for supporting each of said facing panels in the erected state of the container, one facing support of said pair of facing supports being joined to one of said sidewalls and the other facing support of said pair of facing supports being joined to the other of said sidewalls.

2. The container ofclaim 1, further comprising longitudinally opposite top and bottom end walls joined to the back panel.

3. The container ofclaim 2, wherein the top end wall attaches to each of the sidewalls by one or more locking tabs.

4. The container ofclaim 2, wherein the bottom end wall attaches to each of the sidewalls by one or more locking tabs.

5. The container ofclaim 2, further comprising:

a facing panel joined to the top end wall;

an inner facing panel joined to said facing panel of said top end wall; and

an additional pair of facing supports provided for supporting said top end wall's facing panel in the erected state of the container, one facing support of said additional pair of facing supports being joined to one of said sidewalls and the other facing support of said additional pair of facing supports being joined to the other of said sidewalls.

6. The container ofclaim 2, further comprising:

a facing panel joined to the bottom end wall;

an inner facing panel joined to said facing panel of said bottom end wall; and

an additional pair of facing supports provided for supporting said bottom end wall's facing panel in the erected state of the container, one facing support of said additional pair of facing supports being joined to one of said sidewalls and the other facing support of said additional pair of facing supports being joined to the other of said sidewalls.

7. The container ofclaim 2, wherein said pairs of facing supports joined to said sidewalls extend from the sidewalls at an incline to hold said one or more shelf panels at said incline and said container further comprising:

a shelf-forming extension panel joined to the bottom end wall's inner facing panel and attachable to the back panel by at least one locking tab for forming a shelf at said incline.

8. A folded and glued container comprising:

a plurality of panels defining a back panel and laterally opposite first and second sidewalls, each sidewall having an outer sidewall panel joined to the back panel, and a plurality of inner sidewall panels joined to the outer sidewall panel; and

one or more shelf panels attached to the back panel and extending laterally between the two sidewalls, the shelf panels being joined to inwardly folded bellows panels extending between the shelf panels and the outer sidewall panels such that when the sidewalls are erected from a knocked-down-flat configuration to an orientation perpendicular to the back panel, the shelf panels are raised from a knocked-down-flat configuration to form shelves between the two sidewalls.

9. The container ofclaim 8, further comprising:

a facing panel joined to each of said shelf panels;

an inner facing panel joined to each of said facing panels; and

a pair of facing supports provided for supporting each of said facing panels in the erected state of the container, one facing support of said pair of facing supports being joined to one of said outer sidewall panels and the other facing support of said pair of facing supports being joined to the other of said outer sidewall panels.

10. The container ofclaim 8, further comprising:

longitudinally opposite top and bottom end walls joined to the back panel;

inwardly folded bellows panels extending between the top and bottom end walls and the sidewalls connecting the sidewalls to the top and bottom end walls such that when the top and bottom end walls are pulled upwardly, the sidewalls are erected from a knocked-down-flat configuration to said orientation perpendicular to the back panel.

11. The container ofclaim 10, wherein the bottom end wall comprises a facing panel joined to the bottom end wall panel;

an inner facing panel joined to said facing panel; and

a pair of facing supports provided for supporting said facing panel in the erected state of the container, one facing support of said pair of facing supports being joined to one of said outer sidewall panels and the other facing support of said pair of facing supports being joined to the other of said outer sidewall panels.

12. A folded and glued container comprising:

a plurality of panels defining a back panel, longitudinally opposite top and bottom end walls joined to the back panel, and laterally opposite first and second sidewalls, each sidewall having an outer sidewall panel joined to the back panel, and a plurality of inner sidewall panels joined to the outer sidewall panel;

one or more shelf panels attached to the back panel and extending laterally between the two sidewalls, the shelf panels being joined to inwardly folded bellows panels extending between the shelf panels and the outer sidewall panels such that when the sidewalls are erected from a knocked-down-flat configuration to an orientation perpendicular to the back panel, the shelf panels are raised from a knocked-down-flat configuration to form shelves between the two sidewalls;

a facing panel joined to each of said shelf panels;

an inner facing panel joined to each of said facing panels;

a pair of facing supports provided for supporting each of said facing panels in the erected state of the container, one facing support of said pair of facing supports being joined to one of said outer sidewall panels and the other facing support of said pair of facing supports being joined to the other of said outer sidewall panels; and

inwardly folded bellows panels extending between the top and bottom end walls and the sidewalls connecting the sidewalls to the top and bottom end walls such that when the top and bottom end walls are pulled upwardly, the sidewalls are erected from a knocked-down-flat configuration to said orientation perpendicular to the back panel.

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