Two box container made of a composite blank and methods therefor

Abstract

A container includes a first blank having fold lines and a series of substantially rectangular panels hingedly connected to one another at the fold lines of the first blank, and a second blank having fold lines and a series of substantially rectangular panels hingedly connected to one another at the fold lines of the second blank. The first and second blanks are adhered to one another to form a composite blank that is spirally foldable to form the double-walled container, whereby the first blank forms an inner box of the container and the second blank forms an outer box of the container that surrounds the inner box. The first blank forming the inner box may be made of a material that is different in composition and/or thickness than the material used to form the second blank forming the outer box. The first and second blanks may also be made of similar materials.

1 . A container comprising: 
 a first blank including fold lines and a series of substantially rectangular panels hingedly connected to one another at the fold lines of said first blank;    a second blank including fold lines and a series of substantially rectangular panels hingedly connected to one another at the fold lines of said second blank;    said first and second blanks being adhered to one another to form a composite blank that is spirally foldable to form said container, wherein said first blank forms an inner box of said container and said second blank forms an outer box of said container that surrounds said inner box.    
     
     
         2 . The container as claimed in  claim 1 , wherein said first blank comprises a first material and said second blank comprises a second material that is different than said first material.  
     
     
         3 . The container as claimed in  claim 1 , wherein the first material of said first blank is sturdier than the second material of said second blank.  
     
     
         4 . The container as claimed in  claim 1 , wherein said first blank comprises a material selected from the group consisting of corrugated board, corrugated plastic and Styrofoam.  
     
     
         5 . The container as claimed in  claim 4 , wherein said corrugated board comprises a material selected from the group consisting of B, C, E and F flute corrugated board.  
     
     
         6 . The container as claimed in  claim 1 , wherein said inner box forms a protective liner for an object disposed within said container.  
     
     
         7 . The container as claimed in  claim 1 , wherein said second blank comprises paperboard.  
     
     
         8 . The container as claimed in  claim 7 , wherein said second blank comprises a material selected from the group consisting of PVC, PET G, A PET, R PET, polypropylene and assorted plastic materials.  
     
     
         9 . The container as claimed in  claim 1 , wherein the substantially rectangular panels of said first blank comprise in series a first sidewall, a rear wall, a second sidewall adapted to oppose the first sidewall and a front wall adapted to oppose the rear wall, and wherein the substantially rectangular panels of said second blank comprise in series an attachment flange, a front wall, a first sidewall, a rear wall adapted to oppose the front wall, and a second sidewall adapted to oppose the first sidewall.  
     
     
         10 . The container as claimed in  claim 9 , wherein the second sidewall of said first blank is adhered to the attachment flange of said second blank so that the front wall of said first blank is juxtaposed with the front wall of said second blank.  
     
     
         11 . The container as claimed in  claim 10 , wherein said first blank includes at least one upper end tab hingedly connected to an upper end of one of said first and second sidewalls for selectively closing an upper end of said inner box.  
     
     
         12 . The container as claimed in  claim 10 , wherein said first blank includes a first upper end tab hingedly connected to the upper end of said first sidewall and a second upper end tab hingedly connected to the upper end of said second sidewall.  
     
     
         13 . The container as claimed in  claim 10 , wherein said first blank includes at least one lower end tab hingedly connected to a lower end of one of said front and rear walls for selectively closing a lower end of said inner box.  
     
     
         14 . The container as claimed in  claim 13 , wherein said first blank includes the at least one lower end tab hingedly connected to the lower end of said front wall.  
     
     
         15 . The container as claimed in  claim 1 , wherein said second blank includes at least one top closure hingedly connected to an upper end thereof for selectively closing an opening at an upper end of said container and at least one bottom closure hingedly connected to a lower end thereof for selectively closing an opening at a lower end of said container.  
     
     
         16 . A container comprising: 
 a first blank made of a first material, said first blank including fold lines and a series of substantially rectangular panels hingedly connected to one another at the fold lines of said first blank;    a second blank made of a second material that is different than said first material, said second blank including fold lines and a series of substantially rectangular panels hingedly connected to one another at the fold lines of said second blank;    said first and second blanks being adhered to one another to form a composite blank that is spirally foldable to form said container, wherein said first blank forms an inner box of said container and said second blank forms an outer box of said container that surrounds said inner box.    
     
     
         17 . The container as claimed in  claim 16 , wherein the first material of said first blank is sturdier than the second material of said second blank.  
     
     
         18 . The container as claimed in  claim 16 , wherein said first blank comprises a material selected from the group consisting of corrugated board, corrugated plastic and Styrofoam.  
     
     
         19 . The container as claimed in  claim 18 , wherein said corrugated board comprises a material selected from the group consisting of B, C, E and F flute corrugated board.  
     
     
         20 . The container as claimed in  claim 16 , wherein said second blank comprises paperboard made of a material selected from the group consisting of PVC, PET G, A PET, R PET, polypropylene and assorted plastic materials.  
     
     
         21 . The container as claimed in  claim 16 , wherein the substantially rectangular panels of said first blank comprise in series a first sidewall, a rear wall, a second sidewall adapted to oppose the first sidewall and a front wall adapted to oppose the rear wall, and wherein the substantially rectangular panels of said second blank comprise in series a first sidewall, a front wall, a second sidewall adapted to oppose the first sidewall and a rear wall adapted to oppose the front wall.  
     
     
         22 . The container as claimed in  claim 16 , wherein said first blank includes tabs hingedly connected to upper and lower ends thereof for selectively covering upper and lower ends of said inner box; and wherein said second blank includes closures hingedly connected to upper and lower ends thereof for selectively closing upper and lower ends of said outer box.  
     
     
         23 . The container as claimed in  claim 22 , wherein said closures of said second blank cover said tabs of said first blank when said closures selectively close the upper and lower ends of said container.  
     
     
         24 . The container as claimed in  claim 16 , wherein said first blank comprises a material made of a first gauge and said second blank comprises a material made of a second gauge, wherein the first gauge is grater than the second gauge.