Crush-tolerant container and blank and method for forming the same

Abstract

A blank for constructing a crush-tolerant container includes a first side panel, a bottom panel, a second side panel, and a top panel coupled together in series. At least one cutout and at least one bridge portion are defined along a first fold line between the top panel and the first side panel. The at least one bridge portion and the at least one cutout are configured to maintain the top panel in a plane spaced above a top edge of the first side panel when the container is formed and the top panel is not under a stacking load, and to allow the top panel to move downwardly such that at least a portion of the top panel is substantially co-planar with the top edge of the first side panel when the container is formed and the top panel is under the stacking load.

The invention claimed is: 
     
       1. A blank for constructing a crush-tolerant container, the blank comprising:
 a plurality of panels coupled together in series along substantially parallel fold lines, the plurality of panels including a first side panel, a bottom panel, a second side panel, and a top panel, and a glue flap extending from the top panel; and 
 at least one cutout and at least one bridge portion positioned along a first fold line between the top panel and the first side panel the glue flap, 
 wherein the at least one bridge portion is configured to maintain the top panel in a plane spaced above a top edge of the first side panel when the container is formed and the top panel is not under a stacking load, and 
 wherein the at least one bridge portion and the at least one cutout are configured to allow the top panel to move downwardly such that at least a portion of the top panel is substantially co-planar with the top edge of the first side panel when the container is formed and the top panel is under the stacking load; wherein the blank further comprises a plurality of end flaps, the plurality of end flaps including: 
 a first major end flap extending from a first end edge of the first side panel; and 
 a first minor flap extending from an end edge of the top panel; 
 wherein the first minor flap and the first major end flap are configured to be in face-to-face relationship with one another in a set-up container; 
 wherein the at least one cutout includes a first side edge disposed in the first side panel glue flap and offset a distance from the first fold line, wherein the first major end flap includes a first side edge, and wherein the first side edge of the at least one cutout is configured to be substantially aligned with the first side edge of the first major end flap in a set-up container. 
 
     
     
       2. The blank of  claim 1 , wherein the blank is formed from so corrugated cardboard including a plurality of flutes, and wherein the plurality of flutes are oriented parallel to a transverse axis of the blank such that the plurality of flutes on the first and second side panels are oriented vertically when the container is formed. 
     
     
       3. The blank of  claim 2 , wherein a major dimension of the at least one cutout is defined perpendicular to the plurality of flutes. 
     
     
       4. The blank of  claim 1 , wherein the at least one cutout is defined symmetrically about the first fold line. 
     
     
       5. The blank of  claim 1 , wherein the first major end flap includes internal flutes that are oriented vertically when the container is formed, and wherein the top panel is configured to engage the first major end flap to support the stacking load when the container is formed and the top panel is under the stacking load. 
     
     
       6. The blank of  claim 1 , wherein the plurality of panels further includes a glue flap extending from the top panel. 
     
     
       7. The blank of  claim 1 , wherein the plurality of panels further includes a glue flap extending from the first side panel. 
     
     
       8. A crush-tolerant container formed from a blank, the container comprising:
 a top wall and an opposing bottom wall; 
 two opposing side walls, wherein the top wall, the two side walls, and the bottom wall define a cavity; 
 and a first compression zone defined between the top wall and a first side wall of the two side walls, the first compression zone including a first cutout and at least a first bridge portion positioned along a first fold line between the top wall and the first side wall a glue flap, 
 wherein the first compression zone maintains the top wall in a first plane separated from a top edge of the first side wall by a compression depth when the top wall is not under a stacking load, and wherein the first compression zone is configured to enable displacement of the top wall toward the cavity by the compression depth when the top wall is under the stacking load; 
 further comprising two opposing end walls, wherein a first end wall of the two end walls includes a first major end flap that emanates from a first end edge of the first side wall, wherein the first major end flap includes internal flutes oriented vertically with respect to the bottom wall, and wherein upon displacement of the top wall by the compression depth, the top wall engages the first major end flap to support the stacking load; 
 wherein the first end wall further includes a first minor end flap that emanates from an end edge of the top wall, the first major end flap and the first minor end flap being secured to one another in a face-to-face relationship; 
 wherein the first cutout includes a first side edge disposed in the first side wall glue flap and offset a distance from the first fold line, and the first major end flap includes a first side edge substantially aligned with the first side edge of the first cutout, and wherein upon displacement of the top wall by the compression depth, the top wall engages the first side wall and the first major end flap substantially simultaneously. 
 
     
     
       9. The container of  claim 8 , wherein upon displacement of the top wall by the compression depth, the top wall engages the first side wall to support the stacking load. 
     
     
       10. The container of  claim 8 , wherein the first bridge portion deforms to enable displacement of the top wall toward the cavity by the compression depth. 
     
     
       11. The container of  claim 8 , further comprising a second compression zone defined between the first side wall and the bottom wall, the second compression zone including a second cutout and a second bridge portion, wherein the second compression zone maintains the bottom wall in a second plane separated from a bottom edge of the first side wall by the compression depth when the top wall is not under the stacking load, and wherein the second compression zone is configured to enable displacement of the first side wall towards the bottom wall by the compression depth when the top wall is under the stacking load. 
     
     
       12. The container of  claim 8 , wherein the two side walls include internal flutes oriented vertically with respect to the bottom wall. 
     
     
       13. A method for forming a crush-tolerant container from a blank,
 the blank including a plurality of panels coupled together in a series along substantially parallel fold lines, the plurality of panels including a top panel, a first side panel, a bottom panel, a second side panel, and a glue flap, 
 the blank also including at least one cutout and at least one bridge portion positioned along a first fold line between the top panel and the first side panel glue flap, 
 the method comprising:
 rotating the plurality of panels about the plurality of fold lines to form a plurality of walls of the container, such that the plurality of walls define a cavity, and such that the at least one bridge portion extends between a first side wall and a top wall of the plurality of walls; and 
 securing the glue flap to the top panel such that the at least one bridge portion extends between a top wall of the plurality of walls and the glue flap, wherein the at least one bridge portion maintains the top wall in a plane spaced above a top edge of the first side wall by a compression depth when the top wall is not under a stacking load, and the at least one bridge portion and the at least one cutout are configured to allow the top panel to move downwardly such that at least a portion of the top panel is substantially co-planar with the top edge of the first side panel when the top wall is under the stacking load; 
 
 wherein the blank further includes a first minor end flap extending from an end edge of the top panel and a first major end flap extending from an end edge of the first side panel,
 the method further comprising: rotating the first major end flap inwards towards the cavity, wherein the first major end flap includes internal flutes oriented vertically after said rotating, and wherein the top wall is configured to engage the first major end flap to support the stacking load when the top wall is under the stacking load; 
 rotating the first minor end flap inwards towards the cavity and into a face-to-face relationship with the first major end flap; and 
 securing the first minor end flap to the first major end flap, wherein the at least one cutout includes a first side edge disposed in the first side panel glue flap and offset a distance from the first fold line, and the first major end flap includes a first side edge substantially aligned with the first side edge of the at least one cutout. 
 
 
     
     
       14. An assembly of stacked crush-tolerant containers comprising:
 a first crush-tolerant container comprising:
 a top wall and an opposing bottom wall; 
 two opposing side walls, wherein the top wall, the two side walls, and the bottom wall define a cavity; and 
 a first compression zone defined between the top wall and a first side wall of the two side walls, the first compression zone including a first cutout and at least a first a bridge portion positioned along a first fold line between the top wall and the first side wall the glue flap; and 
 
 a second crush-tolerant container stacked vertically on top of the first container, wherein, under a load of the second container, the first compression zone of the first container enables displacement of the top wall toward the cavity of the first container by a compression depth; 
 wherein the first container further comprises: 
 two opposing end walls, 
 a first end wall of the two end walls including a first major end flap that emanates from a first end edge of the first side wall, the first end wall further including a first minor end flap that emanates from an end edge of the top wall, the first major end flap and the first minor end flap being secured to one another in a face-to-face relationship, 
 wherein the first major end flap includes a first side edge and the first cutout of the first container includes a first side edge disposed in the first side wall the glue flap and offset a distance from the first fold line, 
 wherein the first side edge of the first cutout is substantially aligned with the first side edge of the first major end flap, and wherein upon displacement of the top wall by the compression depth, the top wall engages the first side wall and the first major end flap substantially simultaneously to support the load of the second container. 
 
 
     
     
       15. The assembly of stacked crush-tolerant containers of  claim 14 , wherein upon displacement of the top wall of the first container by the compression depth, the top wall of the first container engages the first side wall of the first container to support the load of the second container. 
     
     
       16. The assembly of stacked crush-tolerant containers of  claim 14 , wherein the first container further comprises a second compression zone defined between the first side wall and the bottom wall, the second compression zone including a second cutout and a second bridge portion, wherein, under the load of the second container, the second compression zone is configured to enable displacement of the first side wall towards the bottom wall by the compression depth when the top wall is under the stacking load. 
     
     
       17. A blank for constructing a crush-tolerant container, the blank comprising:
 a plurality of panels coupled together in series along substantially parallel fold lines, the plurality of panels including a first side panel, a bottom panel, a second side panel, and a top panel; and   at least one cutout and at least one bridge portion positioned along a first fold line between the bottom panel and the first side panel,   wherein the at least one bridge portion is configured to maintain the first side panel in a plane spaced above a bottom edge of the bottom panel when the container is formed and the top panel is not under a stacking load, and   wherein the at least one bridge portion and the at least one cutout are configured to allow the first side panel to move downwardly such that at least a portion of the first side panel is substantially co-planar with the bottom edge of the bottom panel when the container is formed and the top panel and first side panel are under the stacking load; wherein the blank further comprises a plurality of end flaps, the plurality of end flaps including:   a first major end flap extending from a first end edge of the first side panel; and   a first minor flap extending from an end edge of the bottom panel;   wherein the first minor flap and the first major end flap are configured to be in face-to-face relationship with one another in a set-up container;   wherein the at least one cutout includes a first side edge disposed in the first side panel and offset a distance from the first fold line, wherein the first major end flap includes a first side edge, and wherein the first side edge of the at least one cutout is configured to be substantially aligned with the first side edge of the first major end flap in a set-up container.    
     
     
       18. The blank of claim 17, wherein the blank is formed from corrugated cardboard including a plurality of flutes, and wherein the plurality of flutes are oriented parallel to a transverse axis of the blank such that the plurality of flutes on the first and second side panels are oriented vertically when the container is formed.  
     
     
       19. The blank of claim 18, wherein a major dimension of the at least one cutout is defined perpendicular to the plurality of flutes.  
     
     
       20. The blank of claim 17, wherein the at least one cutout is defined symmetrically about the first fold line.  
     
     
       21. The blank of claim 17, wherein the first major end flap includes internal flutes that are oriented vertically when the container is formed, and wherein the top panel is configured to engage the first major end flap to support the stacking load when the container is formed and the top panel is under the stacking load.  
     
     
       22. The blank of claim 17, wherein the plurality of panels further includes a glue flap extending from the top panel.  
     
     
       23. The blank of claim 17, wherein the plurality of panels further includes a glue flap extending from the first side panel.  
     
     
       24. A crush-tolerant container formed from a blank, the container comprising:
 a top wall and an opposing bottom wall;   two opposing side walls, wherein the top wall, the two side walls, and the bottom wall define a cavity;   and a first compression zone defined between the bottom wall and a first side wall of the two side walls, the first compression zone including a first cutout and at least a first bridge portion positioned along a first fold line between the bottom wall and the first side wall,   wherein the first compression zone maintains the first side wall in a first plane separated from a bottom edge of the bottom wall by a compression depth when the top wall is not under a stacking load, and wherein the first compression zone is configured to enable displacement of the top wall toward the cavity and the first side wall toward the bottom wall by the compression depth when the top wall and first side wall are under the stacking load;   further comprising two opposing end walls, wherein a first end wall of the two end walls includes a first major end flap that emanates from a first end edge of the first side wall, wherein the first major end flap includes internal flutes oriented vertically with respect to the bottom wall, and wherein upon displacement of the top wall by the compression depth, the top wall engages the first major end flap to support the stacking load;   wherein the first end wall further includes a first minor end flap that emanates from an end edge of the bottom wall, the first major end flap and the first minor end flap being secured to one another in a face-to-face relationship;   wherein the first cutout includes a first side edge disposed in the first side wall and offset a distance from the first fold line, and the first major end flap includes a first side edge substantially aligned with the first side edge of the first cutout, and wherein upon displacement of the top wall and the first side wall by the compression depth, the bottom wall engages the first side wall and the first major end flap substantially simultaneously.    
     
     
       25. The container of claim 24, wherein upon displacement of the top wall by the compression depth, the top wall engages the first side wall to support the stacking load.  
     
     
       26. The container of claim 24, wherein the first bridge portion deforms to enable displacement of the top wall toward the cavity by the compression depth.  
     
     
       27. The container of claim 24, further comprising a second compression zone defined between the first side wall and the top wall, the second compression zone including a second cutout and a second bridge portion, wherein the second compression zone maintains the top wall in a second plane separated from a top edge of the first side wall by the compression depth when the top wall is not under the stacking load, and wherein the second compression zone is configured to enable displacement of the top wall towards the first side wall by the compression depth when the top wall is under the stacking load.  
     
     
       28. The container of claim 24, wherein the two side walls include internal flutes oriented vertically with respect to the bottom wall.  
     
     
       29. A method for forming a crush-tolerant container from a blank,
 the blank including a plurality of panels coupled together in a series along substantially parallel fold lines, the plurality of panels including a top panel, a first side panel, a bottom panel, a second side panel, and a glue flap,   the blank also including at least one cutout and at least one bridge portion positioned along a first fold line between the bottom panel and the first side panel,   the method comprising:
 rotating the plurality of panels about the plurality of fold lines to form a plurality of walls of the container, such that the plurality of walls define a cavity; and 
 securing the glue flap to the top panel such that the at least one bridge portion extends between a bottom wall and a first side wall of the plurality of walls, wherein the at least one bridge portion maintains the first side wall in a plane spaced above a bottom edge of the bottom wall by a compression depth when the top wall and first side wall are not under a stacking load, and the at least one bridge portion and the at least one cutout are configured to allow the first side panel to move downwardly such that at least a portion of the bottom panel is substantially co-planar with the bottom edge of the first side panel when the top wall and first side wall are under the stacking load; 
   wherein the blank further includes a first minor end flap extending from an end edge of the top panel and a first major end flap extending from an end edge of the first side panel,
 the method further comprising: rotating the first major end flap inwards towards the cavity, wherein the first major end flap includes internal flutes oriented vertically after said rotating, and wherein the bottom wall is configured to engage the first major end flap to support the stacking load when the top wall is under the stacking load; 
 rotating the first minor end flap inwards towards the cavity and into a face-to-face relationship with the first major end flap; and 
 securing the first minor end flap to the first major end flap, wherein the at least one cutout includes a first side edge disposed in the first side panel and offset a distance from the first fold line, and the first major end flap includes a first side edge substantially aligned with the first side edge of the at least one cutout.  
   
     
     
       30. An assembly of stacked crush-tolerant containers comprising:
 a first crush-tolerant container comprising:
 a top wall and an opposing bottom wall; 
 two opposing side walls, wherein the top wall, the two side walls, and the bottom wall define a cavity; and 
 a first compression zone defined between the top wall and a first side wall of the two side walls, the first compression zone including a cutout and a bridge portion positioned along a first fold line between the bottom wall and the first side wall; and 
   a second crush-tolerant container stacked vertically on top of the first container, wherein, under a load of the second container, the first compression zone of the first container enables displacement of the top wall toward the cavity of the first container by a compression depth;   wherein the first container further comprises:
 two opposing end walls, 
 a first end wall of the two end walls including a first major end flap that emanates from a first end edge of the first side wall, the first end wall further including a first minor end flap that emanates from an end edge of the top wall, the first major end flap and the first minor end flap being secured to one another in a face-to-face relationship, 
 wherein the first major end flap includes a first side edge and the cutout of the first container includes a first side edge disposed in the first side wall and offset a distance from the first fold line, 
 wherein the first side edge of the cutout is substantially aligned with the first side edge of the first major end flap, and wherein upon displacement of the top wall by the compression depth, the bottom wall engages the first side wall and the first major end flap substantially simultaneously to support the load of the second container.  
   
     
     
       31. The assembly of stacked crush-tolerant containers of claim 30, wherein upon displacement of the top wall and the first side wall of the first container by the compression depth, the first side wall of the first container engages the bottom wall of the first container to support the load of the second container.  
     
     
       32. The assembly of stacked crush-tolerant containers of claim 30, wherein the first container further comprises a second compression zone defined between the first side wall and the top wall, the second compression zone including a second cutout and a second bridge portion, wherein, under the load of the second container, the second compression zone is configured to enable displacement of the top wall towards the first side wall by the compression depth when the top wall is under the stacking load.  
     
     
       33. A blank for constructing a crush-tolerant container, the blank comprising:
 a plurality of panels coupled together in series along substantially parallel fold lines, the plurality of panels including a first side panel, a bottom panel, a second side panel, and a top panel; and   at least one cutout and at least one bridge portion positioned along a first fold line between the top panel and the second side panel,   wherein the at least one bridge portion is configured to maintain the top panel in a plane spaced above a top edge of the second side panel when the container is formed and the top panel is not under a stacking load, and   wherein the at least one bridge portion and the at least one cutout are configured to allow the top panel to move downwardly such that at least a portion of the top panel is substantially co-planar with the top edge of the second side panel when the container is formed and the top panel is under the stacking load; wherein the blank further comprises a plurality of end flaps, the plurality of end flaps including:
 a first major end flap extending from a first end edge of the second side panel; and 
 a first minor flap extending from an end edge of the top panel; 
 wherein the first minor flap and the first major end flap are configured to be in face-to-face relationship with one another in a set-up container; 
   wherein the at least one cutout includes a first side edge disposed in the second side panel and offset a distance from the first fold line, wherein the first major end flap includes a first side edge, and wherein the first side edge of the at least one cutout is configured to be substantially aligned with the first side edge of the first major end flap in a set-up container.    
     
     
       34. The blank of claim 33, wherein the blank is formed from corrugated cardboard including a plurality of flutes, and wherein the plurality of flutes are oriented parallel to a transverse axis of the blank such that the plurality of flutes on the first and second side panels are oriented vertically when the container is formed.  
     
     
       35. The blank of claim 34, wherein a major dimension of the at least one cutout is defined perpendicular to the plurality of flutes.  
     
     
       36. The blank of claim 34, wherein the at least one cutout is defined symmetrically about the first fold line.  
     
     
       37. The blank of claim 34, wherein the first major end flap includes internal flutes that are oriented vertically when the container is formed, and wherein the top panel is configured to engage the first major end flap to support the stacking load when the container is formed and the top panel is under the stacking load.  
     
     
       38. The blank of claim 34, wherein the plurality of panels further includes a glue flap extending from the top panel.  
     
     
       39. The blank of claim 34, wherein the plurality of panels further includes a glue flap extending from the first side panel.  
     
     
       40. A crush-tolerant container formed from a blank, the container comprising:
 a top wall and an opposing bottom wall;   two opposing side walls, wherein the top wall, the two side walls, and the bottom wall define a cavity; and   a first compression zone defined between the top wall and a second side wall of the two side walls, the first compression zone including a first cutout and at least a first bridge portion positioned along a first fold line between the top and the second side wall,   wherein the first compression zone maintains the top wall in a first plane separated from a top edge of the second side wall by a compression depth when the top wall is not under a stacking load, and wherein the first compression zone is configured to enable displacement of the top wall toward the cavity by the compression depth when the top wall is under the stacking load;   further comprising two opposing end walls, wherein a first end wall of the two end walls includes a first major end flap that emanates from a first end edge of the second side wall, wherein the first major end flap includes internal flutes oriented vertically with respect to the bottom wall, and wherein upon displacement of the top wall by the compression depth, the top wall engages the first major end flap to support the stacking load;   wherein the first end wall further includes a first minor end flap that emanates from an end edge of the top wall, the first major end flap and the first minor end flap being secured to one another in a face-to-face relationship;   wherein the first cutout includes a first side edge disposed in the second side wall and offset a distance from the first fold line, and the first major end flap includes a first side edge substantially aligned with the first side edge of the first cutout, and wherein upon displacement of the top wall by the compression depth, the top wall engages the second side wall and the first major end flap substantially simultaneously.    
     
     
       41. The container of claim 40, wherein upon displacement of the top wall by the compression depth, the top wall engages the second side wall to support the stacking load.  
     
     
       42. The container of claim 40, wherein the first bridge portion deforms to enable displacement of the top wall toward the cavity by the compression depth.  
     
     
       43. The container of claim 40, further comprising a second compression zone defined between the second side wall and the bottom wall, the second compression zone including a second cutout and a second bridge portion, wherein the second compression zone maintains the bottom wall in a second plane separated from a bottom edge of the second side wall by the compression depth when the top wall is not under the stacking load, and wherein the second compression zone is configured to enable displacement of the second side wall towards the bottom wall by the compression depth when the top wall is under the stacking load.  
     
     
       44. The container of claim 40, wherein the two side walls include internal flutes oriented vertically with respect to the bottom wall.  
     
     
       45. A method for forming a crush-tolerant container from a blank,
 the blank including a plurality of panels coupled together in a series along substantially parallel fold lines, the plurality of panels including a top panel, a first side panel, a bottom panel, a second side panel, and a glue flap,   the blank also including at least one cutout and at least one bridge portion positioned along a first fold line between the top panel and the second side panel,   the method comprising:
 rotating the plurality of panels about the plurality of fold lines to form a plurality of walls of the container, such that the plurality of walls define a cavity, and such that the at least one bridge portion extends between a second side wall and a top wall of the plurality of walls; and 
 securing the glue flap to the top panel, wherein the at least one bridge portion maintains the top wall in a plane spaced above a top edge of the second side wall by a compression depth when the top wall is not under a stacking load, and the at least one bridge portion and the at least one cutout are configured to allow the top panel to move downwardly such that at least a portion of the top panel is substantially co-planar with the top edge of the second side panel when the top wall is under the stacking load; 
   wherein the blank further includes a first minor end flap extending from an end edge of the top panel and a first major end flap extending from an end edge of the second side panel,
 the method further comprising: rotating the first major end flap inwards towards the cavity, wherein the first major end flap includes internal flutes oriented vertically after said rotating, and wherein the top wall is configured to engage the first major end flap to support the stacking load when the top wall is under the stacking load; 
 rotating the first minor end flap inwards towards the cavity and into a face-to-face relationship with the first major end flap; and 
 securing the first minor end flap to the first major end flap; wherein the at least one cutout includes a first side edge disposed in the second side panel and offset a distance from the first fold line, and the first major end flap includes a first side edge substantially aligned with the first side edge of the at least one cutout.  
   
     
     
       46. An assembly of stacked crush-tolerant containers comprising:
 a first crush-tolerant container comprising:
 a top wall and an opposing bottom wall; two opposing side walls, wherein the top wall, the two side walls, and the bottom wall define a cavity; and a 
 first compression zone defined between the top wall and a second side wall of the two side walls, the first compression zone including a first cutout and at least a first bridge portion positioned along a first fold line between the top wall and the second side wall; and 
   a second crush-tolerant container stacked vertically on top of the first container, wherein, under a load of the second container, the first compression zone of the first container enables displacement of the top wall toward the cavity of the first container by a compression depth;   wherein the first container further comprises:
 two opposing end walls, 
 a first end wall of the two end walls including a first major end flap that emanates from a first end edge of the second side wall, the first end wall further including a first minor end flap that emanates from an end edge of the top wall, the first major end flap and the first minor end flap being secured to one another in a face-to-face relationship, 
 wherein the first major end flap includes a first side edge and the first cutout of the first container includes a first side edge disposed in the second side wall and offset a distance from the first fold line, 
 wherein the first side edge of the first cutout is substantially aligned with the first side edge of the first major end flap, and wherein upon displacement of the top wall by the compression depth, the top wall engages the second side wall and the first major end flap substantially simultaneously to support the load of the second container.  
   
     
     
       47. The assembly of stacked crush-tolerant containers of claim 46, wherein upon displacement of the top wall of the first container by the compression depth, the top wall of the first container engages the second side wall of the first container to support the load of the second container.  
     
     
       48. The assembly of stacked crush-tolerant containers of claim 46, wherein the first container further comprises a second compression zone defined between the second side wall and the bottom wall, the second compression zone including a second cutout and a second bridge portion, wherein, under the load of the second container, the second compression zone is configured to enable displacement of the second side wall towards the bottom wall by the compression depth when the top wall is under the stacking load.