Mcfarland, William W. (Wooster, OH)
Wintringer III, Harry D. (Shelby, OH)

04/880285

08/03/1971

11/26/1969

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International Paper Company (New York, NY)

206/521

206/420, 206/592, 206/422

B65D5/50; B65D25/14

206/65,65F,46FR 229/14C

Reeves, Robert B.

Martin, Larry

This is a continuation-in-part of U.S. application, Ser. No. 744,267, filed on June 17, 1968 now U.S. Pat. No. 3,494,539, by W. W. McFarland and H. D. Wintringer, III.

What we claim is

1. In combination: P1 an outer carton having a bottom, opposed sidewall panels hingedly connected to said bottom along lines parallel to the corresponding opposed edges of the sidewall panels, P1 opposed end wall panels hingedly connected to said bottom along lines parallel to one another, perpendicular to said sidewall panel line forming a rectangular receptacle, P1 a first spacing means extending upwardly from the bottom of said rectangular receptacle, shaped substantially so as to successively touch consecutive wall panels, P1 a first packaging insert having hingedly connected opposed end flaps, said first packaging insert being deposited into said receptacle with the end flaps disposed downwardly, the first packaging insert resting upon the first spacing means, P1 a second packaging insert substantially identical to the first packaging insert and resting above the first packaging insert, P1 a second spacing means substantially identical to said first spacing means, positioned inversely to the first spacing means and situated above the second packaging insert, and P1 a top substantially identical to the bottom.

2. A combination according to claim 1 further comprising a spacer inserted substantially in the center of the outer carton extending upwardly from the bottom of said rectangular receptacle.

3. A combination according to claim 2 in which the first and second spacing means are shaped substantially as parallelograms are in two opposing vortices of the parallelograms such that each of close proximity to each of two opposing panels of the rectangular receptacle.

4. A combination according to claim 1 in which each spacing means has two troughs each at opposite vortices of the parallelogram, each of said troughs being in close proximity to each of the other opposing panels of the rectangular receptacle.

5. A combination according to claim 2 in which each spacing means has two troughs, one trough at each of the vortices opposite the sidewall panel and each one of the two other vortices in close proximity to the center of a respective one of the end wall panels of the container.

6. A combination according to claim 4 in which each of the packaging inserts is a rectangle having a plurality of apertures along the edges thereof.

7. A combination according to claim 6 in which each of the packaging inserts has an aperture substantially in the center thereof.

8. A combination according to claim 7 in which each of the packaging inserts has two opposed troughs situated substantially parallel to and midway between the end flaps, each capable of engaging one of the troughs located at each of the opposed vortices of the spacing means.

9. A combination according to claim 1 in which said outer container, said first and second spacer means and said first and second packaging inserts and said center spacer are paperboard.

10. A combination according to claim 9 in which said paperboard is corrugated and the strength lines along the end wall panels and sidewall panels of the rectangular receptacle run perpendicular to the top and bottom planes.

11. A combination according to claim 1 in which each end wall panel has an aperture, a distance X from the opposed free edges of the end wall panels and each sidewall panel has a tongue of length more than 2X, said tongue being capable of engaging the aperture in the end wall panel and further being capable of being doubled back on itself to form an edge interlock.

12. A combination according to claim 2 and which flanges are hingedly connected to the center spacer, in a substantially perpendicular orientation with respect to the plane of the center spacer to support and separate the upper half of the container structure, and so situated as to prevent any article from coming into contact with any portion of the outer carton.

13. In combination: P1 an outer carton having a bottom, P1 opposed sidewall panels hingedly connected to said bottom along lines parallel to the corresponding opposed edges of the sidewall panel, P1 opposed end wall panels hingedly connected to said bottom along lines parallel to one another and perpendicular to said sidewall panel lines forming a rectangular receptacle, P1 a first packaging insert spacer substantially shaped as a parallelogram extending upwardly from the bottom of said rectangular receptacle so that each of the two opposing vortices of the parallelogram is in close proximity to the center of one of the end wall panels of the container, P1 a first packaging insert having a plane portion, opposed end flaps hingedly connected along score lines of said plane portion, a plurality of apertures along two opposed edges of the plane portion, said first packaging insert being inserted into said receptacle and resting upon said first packaging insert spacer, P1 a second packaging insert substantially identical to said first packaging insert positioned inversely to the first packaging insert, P1 a second packaging insert spacer substantially identical to said first packaging insert spacer positioned inversely to the first packaging insert spacer and engaging said first packaging insert, and P1 a top substantially identical to said bottom.

Background of the Invention

This application relates to containers and more particularly to paperboard containers which facilitate rapid loading and allow injury-free storing and shipping of television picture tubes and similar fragile articles. Television picture tubes, especially the larger picture tubes, are bulky and fragile articles. Injury and a great deal of damage can result if these tubes are not handled properly or if they are broken or become damaged during handling, shipping, or storage.

Color picture tubes have a glass face, a glass or metal throat and a glass or metal neck. These tubes are built in a vacuum, thus creating a substantial risk that the glass may crack and an implosion results therefrom. This would cause the glass and metal to fly about the storage container and would result in considerable injury to other tubes and anyone who might be handling the container at such time. Most television tubes are built on a mass production basis and are then removed from the assembly line and shipped to the assembly area where they are mounted into the television sets themselves. It is imperative that these tubes be removed from the assembly line and packaged in as rapid a manner as possible while continuing to protect the handler of the container from injury.

It is unlikely that a tube when first built will be immediately shipped and then be assembled into a finished television set without some waiting period at either the assembly point or the manufacturing location. It is essential, therefore, to have a container which will protect the tubes during the storage period from the weight of other containers being placed thereon.

It is also important that the protection which is employed in manufacturing the container be inexpensive so as not to make the total manufacturing cost prohibitive. Since container weight, size of the container, labor and assembling of the container and other factors are involved in the total manufacturing cost which will be attributable to any individual unit, it is imperative that these costs be minimized so as to effectively protect the tube without substantially increasing the price.

Brief Summary of the Invention

The container includes an outer box or carton which is cut from a sheet of paperboard such that the top and bottom form rectangular receptacles and are substantially identical with regard to the relevant scoring, embossing and cutting. Within the bottom half of the box is a lower packaging insert which substantially divides the box into a center portion which is a parallelogram, and further arranged such that the edges of the parallelogram are in contact with the adjacent sides of the lower half of the outer container so as to divide the outer box into a series of four substantially triangular portions and one center portion substantially shaped as a parallelogram.

A packaging insert spacer having upstanding tabs which when placed in the carton engage the corresponding tabs of the packaging insert, is placed into the lower portion of the outer box. The packaging insert spacer also has upstanding tabs which are positioned along the opposite walls of the inner portion of the outer box.

A center spacer which substantially divides the parallelogram along one of its major axis is placed into the lower portion of the outer box, and is engaged there by so as to provide a spacing insert between the two center television tubes.

A second packaging insert spacer is then placed on the packaged tubes and a second packaging insert is placed thereon. The box is covered with a top which is identical to the bottom.

Each of the container parts is made from paperboard sheets such as corrugated paperboard. When the parts are cut the top and bottom plates are identical, the packaging insert spacer plates are identical and the packaging insert plates are identical. Such parts are cut, scored, embossed, and shipped to the manufacturing location where the tube is to be built. When a container is required, the appropriate blanks are removed from the storage area, folded along the prescored lines and fastened with appropriate means so as to form an assembled entity.

The invention is designed so that when the container is assembled the inner parts are in interlocking contact with one another and are in contact with the outer box so as to provide a double-walled supporting structure to prevent injury to the stored tube.

An object of this invention is to provide a container, the individual parts of which can be manufactured with a minimum expenditure of time and effort.

A further object of this invention is to provide a container for fragile articles which will protect these articles effectively without greatly increasing the cost of manufacture of these articles.

A still further object of this invention is to provide a container which can be loaded with a plurality of fragile articles simultaneously thereby reducing the labor time necessary in packaging the fragile articles.

A still further object of this invention is to provide a storage pallet for color television tubes to allow efficient and safe storage of the tube during the curing period.

Brief Description of the Drawings

The invention and further objects will be apparent and better understood from the following description of the preferred embodiment and the accompanying drawings in which:

FIG. 1 is a plane view of the container top and bottom blank.

FIG. 2 is a plane view of the packaging insert spacer blank.

FIG. 3 is a plane view of the packaging insert blank.

FIG. 4 is a plane view of the center spacer blank.

FIG. 5 is a perspective view of the bottom of the outer box with the packaging insert spacer, the packaging insert and the center spacer in position.

FIG. 6 is a perspective view of the assembled container with all insert spacers, inserts and the center spacer in position and with the top removed therefrom.

FIG. 7 is a perspective view of one of the corner tab portions of the outer container showing the interlocking nature of the top and bottom of the outer container.

FIG. 8 is a cross-sectional view taken along 8--8 on FIG. 6.

FIG. 9 is a cross-sectional view taken along 9--9 of FIG. 6.

FIG. 10 is a cross-sectional view taken along 10--10 of FIG. 6.

FIG. 11 is a sequential view depicting the order in which the packaging insert spacers, packaging inserts, and center spacer are inserted into the outer carton.

Detailed Description of the Invention

Referring to FIG. 11, the container of the instant invention is made up of an outer carton erected from blanks generally designated 2 and 4, packaging insert spacers generally designated 6 and 8, packaging inserts generally designated 10 and 12 and a center spacer generally designated 14. All of the above elements are cut and scored or embossed from paperboard material such as corrugated paperboard and are folded and assembled in the manner hereinafter described.

Referring to FIG. 1, the outer carton blanks for the top and bottom, 2 and 4, are identical. The carton blanks 2 and 4 are embossed with a pair of parallel lines 22, 23 which extend from one edge of the blank to the opposite parallel edge of the blank across the face of the blank. A second set of lines, 20, 21, parallel to one another, are scored from line 22 to line 23 and are perpendicular to lines 22 and 23. Lines 20 and 21 terminate in the pair of slots 40, 42 and 41, 43 respectively.

The embossing and slotting results in the formation of sidewall panels 30 and 31 and end wall panels 32 and 33. End wall panels 32 and 33 each have two pairs of slots numbered 46A, 46B and 44A, 44B respectively. The sidewall panels terminate in side seam flaps 35 which, when the top and bottom are assembled, fold into the slots on the end wall panels, and then back on themselves. Sidewall panels 30 and 31 are scored upwardly and assembled such that the side seam flaps 35 will be inserted from the outside into the inside of the respective slots 44A, 44B; 46A, 46B of the end wall panels when said end wall panels are folded upwardly.

FIG. 2 depicts the packaging insert spacer blank. The packaging insert spacer is cut from a rectangular piece of paperboard. A center score line 225,226 is embossed on the packaging insert spacer, and divides said spacer in half lengthwise. Lines parallel to said centerline 225,226 are scored towards either end of the rectangular paperboard blank, specifically scorings 224 and 227. FInally the blank is scored in a lengthwise direction so as to divide the rectangular blank into three sections. A center rectangular section whose boundaries are the embossings 224, 227, 220--222, and 221--223 is cut in the blank.

THe center packaging spacer is assembled by folding downwardly along embossing 225,226 and thereby achieving a 90° angle between the resultant halves; folding along embossing 224 and 227 upwardly 90° so as to obtain a substantially W-shaped member, and then bending downwardly along line 221--223 and 220--222 thereby forming a central parallelogram with two troughs T and T'each of which will serve as an interlocking support, as will be hereafter described.

Referring next to FIG. 3, there is shown the packaging insert generally labeled 10 and 12. This insert is also cut from a sheet of paperboard. There are four arcuate members, in pairs of two, 350, 352 and 351, 353 which are situated opposite one another, in the plane of the sheet along two opposite edges. The packaging insert has a hole cut therein comprising two central arcuate portions 354 and 355 with a curvature in the direction opposite to the curvature of the pair of arcuate members on the corresponding side. The central arcuate members are connected by scored fold lines 326 and 327.

Near the other two edges of the packaging insert blank, are score lines 320 and 321 running from one outer edge of one at the arcuate member to the corresponding outer edge of the arcuate member opposite the first arcuate member, thereby forming a flap which can be folded downwardly.

Tabs 336 and 337 are located in the central portion of the packaging insert along the scored lines 326 and 327 respectively. THese flaps, when folded in a direction similar to that of the outer flaps 331 and 330, act as support structures within the box and are in contact with the bottom of the lower section of the carton.

Tabs are also cut and scored near the inner portion of the adjoining pairs of arcuate members. Score lines 322, 323, 324, and 325 allow flaps 332, 333, 334, and 335 respectively to be folded downwardly in the same direction as flaps 330, 331, 336, and 337. The resultant troughs T ₁ , T ₁ ', fit over the troughs T' resulting from bending along score lines 220, 221, 222, and 223 on the packaging insert spacer blank. The superposition of trough T ₁ , T ₁ ', and T-T' results in an interlock and dual support member so as to prevent any shifting in the respective inserts.

Notches 340 and 341 are cut in the packaging insert blank so as to run from the body of the blank into tabs 336 and 337 respectively. These notches serve as an interlock with the center spacer as will be here below discussed.

Referring next to FIG. 4, center spacer 14 is cut from a paperboard sheet and is scored along a center fold line 420. Notches are cut in the ends parallel to the score line a short distance in from the edges perpendicular to the score line, these notches being 441, 442, 443, and 444. A plurality of tabs generally designated 431, 432, 433, and 434 are cut and folded along score lines 421, 422, 423, 424 so as to provide a pair of spacing elements which will prevent the center spacer from descending beyond a certain level and will act as rigid supports for the structure which will be placed upon the previously inserted packaging insert spacers and packaging inserts.

Notches 446, 447, 448, and 449 are cut in a direction perpendicular to the scored centerline 420. When the center spacer is folded in half along the fold line 420 it will result in a double-strength, double-thickness sheet with support and spacing flanges 431, 432, 433, and 434 hingedly connected to the vertical ends, and notches in the horizontal end so as to engage and securely interlock with notches 340 and 431 of packaging inserts 10 and 12.

After they are cut from the sheet paperboard, the various parts of the container are flat and may be shipped to and stored at the place where the containers are to be used. Thus, a minimum of space is needed in shipping and storing the containers themselves. This is not to imply that the containers cannot be shipped in an assembled fashion to the point where the containers are to be used.

Referring now to FIGS. 1, 2, 3, 4, and 5 to erect the container, the outer carbon blanks 2 and 4 are folded upwardly along fold lines 20, 21, 22, and 23. This will result in the formation of two sidewall panels 30, 31 and two end wall panels 32, 33. Side seam flaps 35 are then inserted into the corresponding notches 44A, 44B and 46A, 46B. It will be noticed that there is a double inner scoring on each one of the side seam flaps. This is to allow a bending back of the side seam flap so that squared end A of each side seam flap 35 can be passed through the respective slits 48, 49, 50, and 51 thereby effecting a bendback seal. Each sidewall panel engages and is securely interlocked with a corresponding end wall panel.

Next, packaging insert spacers generally labeled 6 and 8 are bent as hereinbefore discussed. When assembled, packaging insert spacer 6 is inserted into the bottom section of the outer carton. The troughs are adjacent to the end wall panels and the fold lines 225 and 266 each are adjacent to one of the end wall panels. The resultant configuration will be a series of four triangles around the periphery of the lower portion of the container with a parallelogram inscribed in the center thereof as can best be seen in FIG. 5.

Packaging insert 10 is then assembled by folding downwardly along score lines 320 and 321 and then by folding downwardly along score lines 326 and 327 and finally folding downwardly along lines 322, 323, 324, and 325. This will result in a structure having two end flaps 330 and 331 which will each be contiguous with an end wall panel and two center supports 336 and 337 which will act as support and engaging means for the center spacer. The troughs T ₁ , T ₁ ' created by the folding downwardly of flaps 332 and 334, and 333 and 335 will be superimposed upon and engaged the troughs T-T', formed by bending along lines 220 and 221, and 222 and 223 of the packaging insert spacer.

Center spacer 14 is assembled by folding along score line 420 such that the resultant halves are brought parallel and in contact with one another. Notches 441 and 442 are aligned with one another and 444 and 445 are aligned with one another. Tabs 431, 432, 433, and 434 are then folded along score lines 421, 422, 423, and 424 respectively in an outward direction such that the tab 431 is folded in the direction opposite to tab 432, and tab 433 is folded in a direction opposite to tab 434. This will result in the formation of two support flanges, one on either end of the center spacer. The center spacer 14 is then inserted into the lower portion of the outer carton such that the notch formed by aligning 441, 442 is inserted into either notch 340 or 341 and the notch created by notches 444 and 445 is inserted into the other corresponding notch (either 341 or 340). When properly assembled the two support flanges will rest on the top surface of the lower packaging insert 10 and will prevent the center spacer from descending beyond a predetermined depth. They will also serve to separate the upper packaging insert spacer from the lower packaging insert spacer as is hereinbelow discussed.

The upper packaging insert spacer is identical to the lower packaging insert spacer, therefore the assembly procedure for the upper sections is identical to that for the lower sections.

Packaging insert 12 is positioned so that notches 341 and 340 engage the upper notches formed in the center spacer by 448, 449 and 446, 447. The troughs formed by bending along lines 322, 324 and 323, 325 on the upper packaging inserts will be positioned directly over the troughs formed by the scoring and bending along the same lines of the lower packaging inserts. However, wherein the first packaging insert had its troughs facing downwardly, the second packaging insert will have its troughs facing upwardly.

An upper packaging insert spacer is placed in the partially assembled inner container such that the troughs on the packaging insert spacer formed by the folding along lines 220, 221 and 222, 223 will engage and be seated securely in the upwardly facing troughs of the upper packaging insert. The container in the illustrative embodiment is for six picture tubes.

It must be understood that the container can be suitably enlarged to receive a greater number of picture tubes. For example, by using top and bottom outer sections which are twice as long and inserting therein double-packaging insert spacers and double-packaging inserts as well as double center spacers, twelve tubes can be packaged.

Referring to FIG. 11, the lower section of the outer container is assembled. The lower packaging insert spacer is inserted therein such that each trough is in edge contact with one sidewall panel. Next, the lower packaging insert is placed into the lower portion of the outer carton such that its troughs are in intimate and contiguous contact with the troughs of the packaging insert spacer. Flaps 330 and 331 will be in close proximity to the end wall panels 32, 33. The center spacer 14 is positioned into the packaging insert such that the notches formed by 441, 442, and 444, 445 interlock with notches 340 and 341.

The partially assembled container is now ready to be filled with fragile articles, specifically, color picture tubes. Four color tubes are placed in the four outer arcuate members such that the screen face is pointed outwardly and the electron guns are pointed towards one another and towards the centerline of the box. Two television tubes are placed in the center portion formed by the two arcuate members and divided by the center spacer. The screens of these two television picture tubes are facing one another and are separated by the center spacer. Their electron guns point outwardly and the electron guns are pointed towards one another and towards the centerline of the box. Two television tubes are placed in the center portion formed by the two arcuate members and divided by the center spacer. Their electron guns point outwardly such that they lie in the line formed by the superimposed troughs as can be seen in FIGS. 8, 9, and 10. The overall configuration of the box is such that no television picture screen is at any time touching any outer wall. Each screen is removed a predetermined amount from the sidewalls and the top and bottom so as to be relatively isolated from any area which might impinge on said tube screens thereby causing injury to the glass.

The tubes are loaded into the lower pallet consisting of the lower portion of the container 2, packaging insert spacer 6, packaging insert 10 and center spacer 14. The upper packaging insert 12 is then placed into position such that notches 340 and 341 interlock with the notches formed by 448, 449 and 446, 447. The upper packaging insert spacer is then placed on top of the packaging insert so that the troughs of the packaging insert spacer are situated within the troughs of the packaging insert. The upper portion of the outer container is finally placed on the entire assembled container with the six picture tubes inside. The container is then banded to secure the top to the bottom to make the various constituent elements of the assembled container relatively immobile with respect to one another.

Color picture tubes have a two-piece gun assembly which is sealed onto the throat of the tube with an epoxy resin. This epoxy resin must cure for approximately three to five days before the tube can be tested to make sure that the seal is tight and that the tube is functioning properly. Color tubes must be packaged and stored in a way which occupies the minimum amount of protection. By placing six tubes in the container as hereinabove described, it becomes possible to use the container as a pallet due to the rigid side members and the reinforced corners and supports formed by the packaging insert spacer, packaging inserts, and center spacer.

After the tubes have been placed in the box and stored for a sufficient period to allow the epoxy to cure, the boxes are removed from the storage area and opened. The portion of the outer container as well as the upper packaging insert spacer, the upper packaging insert and the center spacer are removed and are inverted so as to form a bottom pallet. The upper portion of the outer carton becomes the lower portion, the upper packaging insert spacer becomes the lower packaging insert and the center spacer is turned upside down. This allows the operator of the conveyor line to take the six tubes from the container and place them in baskets where they will be shuttled to the various inspection points and while so doing a second operator can be removing six television tubes which have been tested and place them in the former upper portion of the container. Because the conveyor system is timed so that the same number of tubes will always be on the conveyor line, the six tubes placed on the conveyor inspection system will make up for the six tubes which are removed. By the time one operator has finished unloading the original container, the top section of the original container will be filled with six new tubes ready to be shipped to the final assembly area. At this point the lower portion will be inverted and will be placed over the former upper portion. The carton will be resealed, marked, and shipped to the assembly plant where the finished television set will be assembled.

The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed.