Methods for creating multi-walled containers and articles produced there from

Abstract

Methods for making multi-walled containers from a single blank, preferably using a continuous process approach, and the resulting containers are disclosed. Various embodiments of the invention include, alone or in combination, intermediate panels formed from flap precursors that are in- or out-folded such that their distal ends are in proximate relationship to each other; outer flaps sized to overlap exposed edges of a container formed from the blank; stress relief features a joint corners to reduce stresses thereat. Methods for making select containers of the invention include folding and adhering the flap precursors to an inner panel, up-folding the inner panel/intermediate panel combination about a mandrel, and continuing to up-fold the outer panel until a container having a “use” position as a resting position is formed.

1 . A single blank for forming a multiple sidewall container, the blank defining a longitudinal direction from a first end to a second end, with the blank comprising:
 an inner panel forming inner sidewalls of the container when assembled, wherein the inner panel comprises a plurality of inner panel portions, each inner panel portion being contiguous with any adjacent inner panel portion and each inner panel portion comprising one inner sidewall of the container when assembled;   at least one pair of opposing middle flaps extending from the inner panel to a distal edge, wherein the sum of the lateral length of the pair of middle flaps from their intersection with the inner panel to the distal edge is equal to or less than the lateral length of the inner panel from the intersection of a first opposing middle flap to the intersection of a second opposing middle flap, and wherein each middle flap comprises a plurality of flap portions, each flap portion being contiguous with any adjacent flap portion and each opposing pair of flap portions comprising one middle sidewall of the container when assembled; and   an outer panel extending from the inner panel forming outer sidewalls of the container when assembled, wherein the outer panel comprises a plurality of outer panel portions, each outer panel portion being contiguous with any adjacent outer panel portion and each outer panel portion comprising an outer sidewall of the container when assembled,   wherein the at least one pair of opposing middle flaps are involuted to bring their respective distal edges into proximity with each other and with the inner panel, thereby forming intermediate sidewalls when the blank is assembled into the container.   
   
   
       2 . The blank of  claim 1  further comprising a glue tab at the first end of the blank and a glue tab at the second end of the blank wherein the first glue tab is adherable to the inner panel when the container is assembled and the second glue tab is adherable to the outer panel when the container is assembled. 
   
   
       3 . The blank of  claim 1  wherein the distal edges of the middle flaps are not linear. 
   
   
       4 . The blank of  claim 3  wherein the distal edges of the middle flaps are one of a repeating rectilinear, curvilinear, or a combination rectilinear and curvilinear design. 
   
   
       5 . The blank of  claim 1  wherein the distal edges of the middle flaps are complementary such that upon involution, the distal edge of one middle flap will substantially abut the distal edge of the opposing middle flap. 
   
   
       6 . The blank of  claim 1  wherein each middle flap portion is separated from an adjacent middle flap portion by a score. 
   
   
       7 . The blank of  claim 1  wherein each middle flap portion is separated from an adjacent middle flap portion by a slit, a slot or a gap. 
   
   
       8 . The blank of  claim 1  wherein each inner panel portion is separated from an adjacent inner panel portion by a score. 
   
   
       9 . The blank of  claim 1  constructed from a double liner corrugated material. 
   
   
       10 . The blank of  claim 1  wherein the lateral dimension of any inner panel portion is less than the lateral dimension of any outer panel portion. 
   
   
       11 . The blank of  claim 1  further comprising at least one pair of opposing end flaps extending from at least some outer panel portions wherein each end flap is separated from any adjacent end flap by one of a slot, a slit or a gap. 
   
   
       12 . The blank of  claim 11  wherein pairs of opposing end flaps extend laterally from each outer panel portion. 
   
   
       13 . The blank of  claim 11  further comprising a stress relief feature at an interface between an end flap and an outer panel portion. 
   
   
       14 . The blank of  claim 12  further comprising a stress relief feature at an interface between each end flap and each outer panel portion. 
   
   
       15 . The blank of  claim 11  wherein the longitudinal length of each end flap is one of greater or less than the longitudinal length of a corresponding outer panel portion from which it extends. 
   
   
       16 . The blank of  claim 1  wherein the resting position of a container formed from the blank is the same as the use position of a container formed from the blank. 
   
   
       17 . The blank of  claim 1  wherein the blank is derived from a web of double liner corrugated material. 
   
   
       18 . The blank of  claim 1  wherein the blank is derived from a continuous process beginning with a corrugator. 
   
   
       19 . The blank of  claim 13  wherein the stress relief feature comprises a hole defined at least in part by two adjacent end flaps and the outer panel. 
   
   
       20 . The blank of  claim 1  wherein one inner panel portion has a longitudinal length longer than any other inner panel portion.