Enhanced strength partition assembly with integral pad

Abstract

An enhanced strength partition assembly for using with a reusable palletized shipping box system, containing a plurality of individual compartments, i.e, a crate, formed from mated slotted transverse panels and slotted longitudinal panels. A system of exterior panels surrounding the interlocking panels to form the outside of the partition assembly. Alternatively, an exterior panel with an overlapping section surrounds the interlocking panels, secures to itself, and forms the outside of the partition assembly. Flaps extending from the lower edges of the exterior panels may be folded to form an integral layer pad for separating the partitions formed by the partition assembly from other sections of the palletized shipping box. Portions of the slotted panels are adhered to and extend over a greater area of the exterior panel to provide additional structural support.

What is claimed is: 
     
         1 . A partition assembly for use in a reusable palletized shipping box containing a plurality of individual compartments comprising:
 (a) a subassembly comprising:
 (i) at least one substantially parallel transverse panel, each transverse panel further comprising a partitioning section; a pair of folded tab sections extending from each side of the partitioning section; a pair of fold lines each located on a side edge shared by the partitioning section and the folded tab sections, said fold lines running the length of the shared edge; the partitioning section further comprising a series of slots extending upwardly from the bottom edge of the partitioning section to about the midpoint of the height thereof; 
 (ii) at least one substantially parallel longitudinal panel, each longitudinal panel further comprising a partitioning section; a pair of folded tab sections extending from each side of the partitioning section; a pair of fold lines each located on a side edge shared by the partitioning section and the folded tab sections, said fold lines running the length of the shared edge; the partitioning section further comprising a series of slots extending downwardly from the top edge of the partitioning section to about the midpoint of the height thereof; said transverse panel and said longitudinal panel being perpendicularly disposed with said transverse panel slots being placed within said longitudinal panel slots to create a series of individual compartments; and 
   (b) at least one exterior panel, each exterior panel being defined by a top edge, a bottom edge, and a pair of side edges; the exterior panel having at least 1 vertical fold line; wherein said folded tab sections of the transverse panel and the longitudinal panel are configured to extend vertically substantially the distance from the bottom edge of the exterior panel to the top edge of the exterior panel; and wherein said folded tab sections of the transverse panel and the longitudinal panel are configured to extend horizontally along the exterior panel substantially the distance formed by a said individual compartment; said exterior panel also comprising at least one flap extending downwardly from a bottom edge of said exterior panel, further defined by fold lines extending horizontally along the edge shared between the exterior panel and the bottom panel, where the combined area of all flaps is at least equal to the area formed by the lower surface of said subassembly.   
     
     
         2 . The partition assembly of  claim 1 , wherein said exterior panels comprise at least one tab and at least one recess at one side edge and corresponding mating tabs and recesses on the opposite side edge; said exterior panel tabs and recesses being mated. 
     
     
         3 . The partition assembly of  claim 2 , wherein said mated panel tabs and recesses of said exterior panels are adhesively joined to a transverse panel fold tab. 
     
     
         4 . The partition assembly of  claim 1 , where said exterior panel(s) are configured to surround said subassembly to form the outside surface of said assembly. 
     
     
         5 . The partition assembly of  claim 1 , where each folded tab section of each transverse panel and each longitudinal panel is adhesively joined to said exterior panel. 
     
     
         6 . The partition assembly of  claim 1 , formed from corrugated stock. 
     
     
         7 . The partition assembly of  claim 1 , wherein such transverse and longitudinal panels are arranged to enable the assembly to be folded substantially flat. 
     
     
         8 . The partition assembly of  claim 1 , wherein said exterior panels comprise at least one flap at one side edge, said flap overlaps a portion of an adjacent side edge and is secured to said adjacent side edge. 
     
     
         9 . A partition assembly for use in a reusable palletized shipping box containing a plurality of individual compartments comprising:
 (a) a series of substantially parallel transverse panels, each transverse panel further comprising a partitioning section; a pair of folded tab sections extending from each side of the partitioning section; a pair of fold lines each located on a side edge shared by the partitioning section and the folded tab sections, said fold lines running the length of the shared edge; the partitioning section further comprising a series of slots running upwardly from the bottom edge of the partitioning section to about the midpoint of the height thereof;   (b) a series of substantially parallel longitudinal panels, each longitudinal panel further comprising a partitioning section; a pair of folded tab sections extending from each side of the partitioning section; a pair of fold lines each located on a side edge shared by the partitioning section and the folded tab sections, said fold lines running the length of the shared edge; the partitioning section further comprising a series of slots running downwardly from the top edge of the partitioning section to about the midpoint of the height thereof; said transverse panels and said longitudinal panels being perpendicularly disposed with said transverse panel slots being placed within said longitudinal panel slots to create a series of individual compartments; and   (c) an exterior panel comprising at least four exterior panel sections defined by fold lines extending vertically along the exterior panels; two lower flaps each extending downwardly from a bottom edge of the adjoining exterior panel section, further defined by a fold line extending horizontally along the edge shared between the adjoining exterior section and bottom panel; where the lower flaps, when folded upwardly to contact the lower surfaces of said partitions, substantially cover the openings of all said partitions; an overlapping panel extending from, and in line with, the final exterior panel section, defined by a fold line extending vertically along the side edge shared between the overlapping panel and the adjoining exterior panel section; wherein said folded tab sections of the transverse panel are configured to extend vertically substantially the distance from the bottom edge of the exterior panel to the top edge of the exterior panel; and wherein said folded tab sections of the transverse panels are configured to extend horizontally along the exterior panel substantially the distance formed by a said individual compartment.   
     
     
         10 . The partition assembly of  claim 9 , wherein said adjoining exterior panels from which said lower flap extend are located on opposite faces of the partition assembly such that when said flaps are folded upwardly to contact the lower surfaces of said partitions, the lower edges of said lower flaps are substantially parallel with each other. 
     
     
         11 . The partition assembly of  claim 10 , wherein said lower flaps in combination, when folded upwardly to contact said lower surfaces of said partitions, cover substantially the entire said lower surface of said partitions. 
     
     
         12 . The partition assembly of  claim 9 , additionally comprising at least one upper panel, extending upwardly from an upper edge of an adjoining exterior panel section, further defined by a fold line extending horizontally along the edge shared between the adjoining exterior panel section and the upper section. 
     
     
         13 . The partition assembly of  claim 9 , wherein said panel tabs are adhesively joined to an exterior panel. 
     
     
         14 . The partition assembly of  claim 9 , wherein the overlapping panel is configured to overlap and be secured to the exterior panel. 
     
     
         15 . The partition assembly of  claim 9 , wherein such transverse and longitudinal panels are arranged to enable the assembly to be folded substantially flat. 
     
     
         16 . The partition assembly of  claim 9 , formed from corrugated stock. 
     
     
         17 . A partition assembly for use in a reusable palletized shipping box containing a plurality of individual compartments comprising:
 (a) a subassembly comprising:
 (i) at least one substantially parallel transverse panel formed from corrugated stock, each transverse panel further comprising a partitioning section; a pair of folded tab sections extending from each side of the partitioning section; a pair of fold lines each located on a side edge shared by the partitioning section and the folded tab sections, said fold lines running the length of the shared edge; the partitioning section further comprising a series of slots extending upwardly from the bottom edge of the partitioning section to about the midpoint of the height thereof; 
 (ii) at least one substantially parallel longitudinal panel formed from corrugated stock, each longitudinal panel further comprising a partitioning section; a pair of folded tab sections extending from each side of the partitioning section; a pair of fold lines each located on a side edge shared by the partitioning section and the folded tab sections, said fold lines running the length of the shared edge; the partitioning section further comprising a series of slots extending downwardly from the top edge of the partitioning section to about the midpoint of the height thereof; said transverse panels and said longitudinal panels being perpendicularly disposed with said transverse panel slots being placed within said longitudinal panel slots to create a series of individual compartments; and 
   (b) one exterior panel formed from corrugated stock and configured to surround said subassembly, said exterior panel being defined by a top edge, a bottom edge, and a pair of side edges; the exterior panel having at least 3 vertical fold lines forming four exterior panel sections; an overlapping panel extending from, and in line with, the final exterior panel section defined by a fold line extending vertically along the edge shared between the overlapping panel and the adjoining exterior panel section; wherein said overlapping panel is configured to overlap and be secured to an adjacent section of the exterior panel; wherein said exterior panel further comprising two lower flaps each extending downwardly from a bottom edge of the adjoining exterior panel section, further defined by a fold line extending horizontally along the edge shared between the adjoining exterior panel section and bottom panel; where the lower flaps, when folded upwardly to contact the lower surfaces of said partitions, substantially cover the openings of all said partitions; wherein said folded tab sections of the transverse panel and the longitudinal panel are configured to extend vertically substantially the distance from the bottom edge of the exterior panel to the top edge of the exterior panel; wherein said folded tab sections of the transverse panel and the longitudinal panel are configured to extend horizontally along the exterior panel substantially the distance formed by a said individual compartment; wherein said folded tab sections are adhesively joined to at least one of said exterior panels; and wherein said transverse and longitudinal panels are arranged to enable said assembly to be folded substantially flat.