Wraparound plastic corrugated case

Abstract

A plastic corrugated case is provided. The case is made of at least one extruded sheet having, in an unfolded state, an extrusion direction and a transverse direction perpendicular to the extrusion direction. The sheet has a cross-sectional profile parallel to the transverse direction, the cross-sectional profile having a first section, and a second section different from the first section.

1 . A plastic corrugated case, comprising: 
 at least one extruded sheet having, in an unfolded state, an extrusion direction and a transverse direction perpendicular to the extrusion direction, 
 the sheet having a cross-sectional profile parallel to the transverse direction, the cross-sectional profile having 
 a first section, and  
 a second section different from the first section.  
 
   
   
   
       2 . The case of  claim 1 , wherein the sheet further comprises: 
 a first panel; and    a second panel attached to the first panel,    wherein a cross-section of at least one of the panels is partially the first section and partially the second section.    
   
   
       3 . The case of  claim 2 , wherein the second panel attaches to the first panel along a fold line.  
   
   
       4 . The case of  claim 3 , wherein the fold line is parallel to the extrusion direction and is part of the cross-sectional profile.  
   
   
       5 . The case of  claim 3 , wherein the fold line is parallel to the transverse direction.  
   
   
       6 . The case of  claim 3 , wherein the first section is a corrugated cross-section.  
   
   
       7 . The case of  claim 6 , wherein the second section is a corrugated cross-section that is stronger than the first section.  
   
   
       8 . The case of  claim 6 , wherein the second section is solid.  
   
   
       9 . The case of  claim 2 , wherein the cross-sectional profile has a protrusion that, when the sheet is in a folded state, forms a corner brace between the first panel and the second panel.  
   
   
       10 . The case of  claim 2 , wherein the cross-sectional profile has a protrusion that, when the sheet is in a folded state, forms a structural rib on one of the first panel or the second panel.  
   
   
       11 . The case of  claim 3 , wherein the entire case is formed from one piece of the extruded sheet.  
   
   
       12 . A one piece plastic corrugated case having, in an unfolded state, an extrusion direction, the case comprising: 
 a bottom panel having a cross-sectional profile perpendicular to the extrusion direction;    a front panel attached to the bottom panel and having a cross-sectional profile perpendicular to the extrusion direction;    a back panel attached to the bottom panel and having a cross-sectional profile perpendicular to the extrusion direction;    a right side panel attached to at least one of the front panel, the back panel or the bottom panel and having a cross-sectional profile perpendicular to the extrusion direction;    a left side panel attached to at least one of the front panel, the back panel or the bottom panel and having a cross-sectional profile perpendicular to the extrusion direction; and    a top panel attached to at least one of the front panel, the back panel, the right side panel or the left side panel and having a cross-sectional profile perpendicular to the extrusion direction,    wherein the case is, in the unfolded state, a single piece of plastic, and    at least one of the cross-sectional profiles changes along a direction perpendicular to the extrusion direction.    
   
   
       13 . The case of  claim 12 , wherein, in the unfolded state, 
 the right side panel comprises a front right side panel attached to the front panel, and a back right side panel attached to the back panel; and    the left side panel comprises a front left side panel attached to the front panel, and a back left side panel attached to the back panel.    
   
   
       14 . A method of producing a plastic corrugated case, the method comprising: 
 extruding a first sheet having, in an unfolded state, an extrusion direction and a transverse direction perpendicular to the extrusion direction, 
 the extrusion causing the first sheet to have a cross-sectional profile parallel to the transverse direction, the cross-sectional profile having 
 a first section, and  
 a second section different from the first section;  
 
   folding the first sheet to form at least a part of the case; and    attaching portions of the first sheet to other portions of the first sheet or to portions of a second sheet to maintain the case in a folded state.    
   
   
       15 . The method of  claim 14 , wherein the first sheet is extruded to further comprise: 
 a first panel; and    a second panel attached to the first panel,    wherein a cross-section of at least one of the panels is partially the first section and partially the second section.    
   
   
       16 . The method of  claim 15 , wherein the first sheet is extruded such that the second panel attaches to the first panel along a fold line.  
   
   
       17 . The method of  claim 16 , wherein the fold line is parallel to the extrusion direction and is part of the cross-sectional profile.  
   
   
       18 . The method of  claim 16 , wherein the first section is extruded as a corrugated cross-section.  
   
   
       19 . The method of  claim 18 , wherein the second section is extruded as a corrugated cross-section that is stronger than the first section.  
   
   
       20 . The method of  claim 18 , wherein the second section is a solid extrusion.