Shipping container for use with prehung door and frame assembly

Abstract

A container is provided for shipping hardware such as door knobs, binges, framing wedges and the like with prehung door and frame assemblies. The container has a substantially rectangular configuration having a closed container portion and a jamb panel that extends from the top of the container that wraps around the outside of one of the jambs of the frame to secure the container to the prehung door and frame assembly. The depth of the container is less than the depth of the cavity side of the prehung door and frame assembly and the front wall of the container fits beneath or flush with the edge of the jamb on the cavity side of the frame.

What is claimed is: 
     
         1 . A combined container and jamb protector for use with a prehung door and frame assembly having a cavity side, said container comprising: a substantially rectangular container comprising a top, a bottom, a first side wall, a second side wall, a front wall and a back wall and a jamb panel extending from the container which wraps around the outside of a jamb of said frame to secure the container to said frame in said cavity side and to protect said jamb. 
     
     
         2 . The combined container and jamb protector of  claim 1  wherein said container has a depth equal to or less than the depth of said cavity. 
     
     
         3 . The combined container and jamb protector of  claim 1  wherein said jamb panel folds around the outside of the jamb and also onto the door side of the prehung door and frame assembly. 
         4 . The combined container and jamb protector of  claim 1  wherein the length of said jamb panel is greater than the length of said front wall. 
         5 . The combined container and jamb protector of  claim 1  wherein connected to the top edge of said jamb panel through a fold line is a second jamb panel that when folded perpendicular to said jamb panel and said container is placed at the corner of said frame said second jamb panel lays on a second jamb of said frame connected perpendicular to said jamb that the jamb panel is wrapped around. 
     
     
         6 . The combined container and jamb protector of  claim 1  formed by a single blank of foldable protective sheet material folded to define said container and said jamb panel. 
     
     
         7 . A container corner protector for a prehung door and frame assembly comprising:
 a container defined by a container first side wall, a container front waif a container back wall folded perpendicular to said container first side wall and running parallel to said container front wall and a second side wall folded perpendicular to said back wall and running parallel to said container first side wall and a container bottom having a width about equal to the container back wall and length equal to the width of the container first and second side walls which are about equal, a jamb panel connected through a fold line to said front wall, said container front wall having a width that is greater than the container back wall such that when the container first side wall is folded perpendicular to the container back wall a jamb channel is formed between the container second side wall and said jamb panel and a tie folded perpendicularly from the top of container front wall and running parallel to said container bottom;   a second jamb panel folded perpendicular to the top of said jamb panel and a fold under flap folded at 180 degrees from said second jamb panel and lying flat with the bottom of said second jamb panel to form an envelope, said second jamb panel forming a second jamb channel running perpendicular to and connecting with said jamb channel; and   a door side panel folded perpendicular to said jamb panel and running parallel to said container front wall and a door side tie folded perpendicular from the top of said door side panel said second tie running parallel to said container bottom, said tie and door side tie fitted into said envelope.   
     
     
         8 . The container corner protector of  claim 7  wherein said container bottom is folded perpendicular from the lower edge of said container front wall and includes a bottom flap folded perpendicular from the container bottom edge and running parallel to the container front wall and said bottom flap defines a key slot and said container back wall defines a locking key at the bottom that mates with said key slot. 
     
     
         9 . The container corner protector of  claim 7  wherein said container bottom is folded perpendicular from the lower edge of said container first side wall and includes a bottom flap folded perpendicular from the first side wall bottom edge and running parallel to the container second side wall and said bottom flap defines a key slot and said container second side wall defines a locking key at the bottom that mates with said key slot. 
     
     
         10 . The container corner protector of  claim 7  wherein said container bottom is folded perpendicular from the lower edge of said container second side wall and includes a bottom flap folded perpendicular from the second side wall bottom edge and running parallel to the container first side wall and said bottom flap defines a key slot and said container first side wall defines a locking key at the bottom that mates with said key slot. 
     
     
         11 . The container corner protector of  claim 7  wherein said tie and door side tie have a curved top edge. 
     
     
         12 . The container corner protector of  claim 7  wherein the top edge of said jamb panel defines a key slot and the top edge of said, fold under .flap defines a key that mates with said key slot. 
     
     
         13 . A one-piece, planar, paperboard blank for forming the container corner protector of  claim 7 . 
     
     
         14 . A one-piece, planar, paperboard blank for forming a container corner protector for a prehung door and frame assembly comprising a plurality of rectangular panels connected by fold lines comprising:
 a container first side wall connected by a fold Sine to a container back wall, said container back wall defining a locking key extending from near the center of its lower edge along a fold line,   a second side wall connected by a fold line to said container back wall,   a container front wall connected to said container second side wall through a fold line,   a tie connected from the top of said container front wall by fold line,   a container bottom extending from the bottom edge of said container front wall through a fold line,   a bottom flap extending from the bottom edge of said container bottom through a fold line and a slot centrally formed along said fold line for receiving said locking key,   a jamb panel connected to said container front wall through a fold line,   a second jamb panel connected to the top of said jamb panel through a fold line,   a fold under flap connected to the top edge of the second jamb panel through a fold line,   a door side panel connected by a fold line to said jamb panel,   a door side tie connected to the top edge of said door side panel through a fold line, and   the bottom edge of the connected container first side wall, container back wall, container second side wall, container front wall and the fold line connecting the container front wall and the container bottom are aligned in a straight line.   
     
     
         15 . The blank of  claim 14  wherein the widths of the jamb panel and second jamb panel are about the same as width of the width of the jambs making up the frame of the prehung door and frame assembly and the length of the jamb panel and door side panel are about the same and said length is longer than the length of said container first side wall, container back wall and container second side wall by an amount at least as great as the thickness of the jambs of the frame of the prehung door and frame assembly such that when the blank is folded to make the corner protector container the additional length forms a jamb channel within the corner protector container. 
     
     
         16 . The blank of  claim 14  wherein said fold under flap that has a width slightly narrower than the width of the second jamb panel. 
     
     
         17 . The blank of  claim 14  wherein said fold under flap is connected to the second jamb panel through two parallel fold lines. 
     
     
         18 . The blank of  claim 14  wherein defined in the top edge of the fold under flap is a key and located along the fold line connecting the jamb panel with the second jamb panel is a key slot said key and said key slot mate when the blank is folded. 
     
     
         19 . The blank of  claim 14  wherein the outside edge of container first side wall, the fold line connecting said container first side wall to said container back wall and the fold line connecting container back wall to the container second side wall are about the same length and said fold line connecting said jamb panel to said door side panel and the outer edge of said door side panel are about the same length and said lengths of said fold line connecting said jamb panel to said door side panel are greater than said outside edge of container first side wall, the fold line connecting said container first side wall to said container back wall and the fold line connecting said container back wall to said container second side wall. 
     
     
         20 . The blank of  claim 14  wherein the length of said fold under flap is about the same as the length of the second jamb panel. 
     
     
         21 . The blank of  claim 14  wherein tie and door side tie have a rounded top edge. 
     
     
         22 . The blank of  claim 14  where in the container bottom has a width about equal to the width of the container back wall and less than the width of the container front wall and said container bottom has a length about equal to the width of the container first side wall the container second side wall which are about equal to each other. 
     
     
         23 . The blank of  claim 14  wherein a key slot is defined along the fold line that connects said jamb panel with said second jamb panel and a key formed along the top edge of the fold under flap. 
     
     
         24 . The blank of  claim 14  wherein the width of the jamb panel and the second jamb panel are about the same. 
     
     
         25 . A container corner protector for a prehung door and frame assembly comprising: the assembled blank of  claim 14 . 
     
     
         26 . A combined container and jamb protector for attachment to a prehung door and frame assembly comprising:
 a container defined by a container first side wall, a front waif a container back wall folded perpendicular to said container first side wall and running parallel to said container front wall and a second side wall folded perpendicular to said back wall and to said container front wall and running parallel to said container first side wall, a container bottom starting at the fold of the second side wall folded perpendicular to said container front wall having a width about equal to the container back wall and length equal to the width of the container first and side wails which are about equal, a container top starting about at the fold of the second side wall folded perpendicular to said container front wall having a width about equal to the container back wall and length about equal to the width of the container first and side walls which are about equal, said container front wall having a width that is greater than the container back wall such that when the container second side wall is folded perpendicular to the container back wall and to said container front wall a jamb channel is formed between the container first side wall and a jamb panel that is folded perpendicular to said front wall parallel to the second side wall, and   a door side panel folded perpendicular to said jamb panel and running parallel to said container front wall.   
     
     
         27 . The container of  claim 26  including a bottom flap folded perpendicular from the bottom edge of said container bottom and running parallel to the container front wall and said bottom flap defines a key slot and said lower edge of said container back wall defines a locking key at the bottom that mates with, said key slot and a top flap folded perpendicular from the top edge of said container top running parallel to the container front wall and said top flap defines a key slot and the top edge of said container back wall defines a locking key at the top that mates with said key slot and a top flap. 
     
     
         28 . A one-piece, planar, paperboard blank for forming the container of  claim 26 . 
     
     
         29 . A one-piece, planar, paperboard blank for forming a container and jamb protector for a prehung door and frame assembly comprising a plurality of rectangular panels connected by fold lines comprising:
 a container first side wall connected by a fold line to a container back wall;   a container second side wall connected to the second side of the container back wall by a fold line:   a container front wall connected to said container second side wall by a fold line said container front wall having a width wider than said container back wall;   a container bottom extending from the bottom edge of the container front wall and connected by a fold line;   a container top extending from the top edge of the container front wall and connected thereto by a fold line;   a jamb panel connected to the container front wall by a fold line, and   a door side panel connected to said jamb panel through a fold line.   
     
     
         30 . The blank of  claim 29  wherein said back wall has a first locking key extending from near the center of its lower edge along a fold line and a second locking key extending from near the center of upper edge along a fold line of said back wall. 
     
     
         31 . The blank of  claim 29  including a bottom flap extending from the bottom edge of container bottom through a fold line defining a key slop centrally located along said fold line for receiving the locking key extending from said lower edge of said back wall when forming the container and a top flap extending from the top edge of the container top through a fold line lap and defining a key slot centrally formed along said fold line for receiving the locking key extending from near the center of the upper edge of said back wall when forming the container embodiment, said container bottom has a width about equal to the width of the container back wall and less than the width of container front wall and container bottom has a length and the container top has a length about equal to the width of the container first side wall which has a width about the same as the container second side wall, and said bottom flap and the top flap have about the same width as the container bottom and the container top and a length no longer than the length of the container bottom and container top. 
     
     
         32 . The blank of  claim 29  wherein the width, of the front wall from the fold line where it connects to the second side wall and the fold line where it connects to said jamb panel is greater than the back wall thereby when the container is folded into shape the additional length forms a jamb channel in the container between the second side wall and the jamb panel. 
     
     
         33 . The blank of  claim 29  wherein the outside edge of container first side wall, the fold line connecting said container first side wall to said container back wall and the fold line connecting container back wall to the container second side wall, the fold line connecting the front wall to the back wall and the fold line connecting the front wall to said jamb panel are the same length. 
     
     
         34 . A one-piece, planar, paperboard blank for forming a combined container and jamb protector for a prehung door and frame assembly comprising a plurality of rectangular panels connected by fold lines comprising:
 a container first side wall connected by a fold line a to a container back wall;   a container second side wall connected to said container back wall;   a container front wall connected to said container second side wall said container front wall having a width greater than the width of said container back wall;   a container bottom extending through a fold line from the bottom of said first side wall;   a container top extending through a fold line from the top of said second side wall;   a jamb panel extending through a fold line from said container front wall; and   a door side panel extending through a fold line from said jamb panel.   
     
     
         35 . The blank of  claim 34  comprising:
 a bottom flap extending through a fold line from the bottom edge of said container bottom and a key slot located centrally along said fold line; 
 a top flat extending through a fold line from the top edge of said container top and a key slot located centrally along said fold line; 
 a locking key extending from the bottom edge of said second wall that mates with said key slot located in said container bottom; and 
 a locking key extending from the top edge of said first side wall that mates with said key slot located in said container top. 
 
     
     
         36 . A combined container and jamb protector for use with a prehung door and frame assembly comprising the assembled blank of  claim 35 .