Containers with integrated support structures and methods for making and using the same

Abstract

A device that is reversibly foldable between a compact configuration and a container configuration. The device includes a top, a front panel, a left panel, a rear panel, a right panel, and a bottom. At least first and second support frames are fixed to exterior faces of the left and right panels. In some embodiments, the device includes a plurality of support beams affixed to flaps used form the top and bottom. Optionally, additional support beams are affixed to interior faces of the front and rear panels. The support beams and support frames cooperate to provide strength and support to the device. Devices according to the invention are stackable in both configurations. They are foldable into the compact configuration for shipping and storage, and are preferably made of substantially of corrugated fiberboard material, which makes them reusable and recyclable. Methods of using the devices are also disclosed.

What is claimed is: 
     
         1 : A device that is reversibly foldable between a compact configuration and a container configuration, said device comprising:
 a top;   a front panel;   a left panel;   a rear panel;   a right panel; and   a bottom;   wherein, when the device is in the container configuration, the top and bottom are spaced apart parallel to each other, the front panel and the rear panel are spaced apart parallel to each other, and the left panel and the right panel are spaced apart parallel to each other, thereby cooperating to define a closed containment cavity,   wherein a left side of the front panel is connected to a right side of the left panel along a first fold line,   wherein a left side of the left panel is connected to a right side of the rear panel along a second fold line,   wherein a left side of the rear panel is connected to a right side of the right panel along a third fold line,   wherein a left side of the right panel is connected to a right side of the front panel along a fourth fold line,   wherein the top comprises a front top flap extending from a top side of the front panel along a fifth fold line and a rear top flap extending from a top side of the rear panel along a sixth fold line,   wherein the bottom comprises a front bottom flap extending from a bottom side of the front panel along a seventh fold line and a rear bottom flap extending from a bottom side of the rear panel along an eighth fold line,   wherein a first support frame is fixed to an exterior face of the left panel,   wherein a second support frame is fixed to an exterior face of the right panel,   wherein a first support beam is fixed to an interior face of the front top flap,   wherein a second support beam is fixed to an interior face of the rear top flap,   wherein a third support beam is fixed to an interior face of the front bottom flap,   wherein a fourth support beam is fixed to an interior face of the rear bottom flap, and   wherein, when the device is in the container configuration, a first end of the first support beam is adjacent to an interior face of the left panel opposite the first support frame and a second end of the first support beam is adjacent to an interior face of the right panel opposite the second support frame,   wherein, when the device is in the container configuration, a first end of the second support beam is adjacent to the interior face of the left panel opposite the first support frame and a second end of the second support beam is adjacent to the interior face of the right panel opposite the second support frame,   wherein, when the device is in the container configuration, a first end of the third support beam is adjacent to the interior face of the left panel opposite the first support frame and a second end of the third support beam is adjacent to the interior face of the right panel opposite the second support frame,   wherein, when the device is in the container configuration, a first end of the fourth support beam is adjacent to the interior face of the left panel opposite the first support frame and a second end of the fourth support beam is adjacent to the interior face of the right panel opposite the second support frame, and   wherein, when the device is in the compact configuration, at least a portion of the front panel is coplanar with one of the left panel and the right panel.   
     
     
         2 : The device according to  claim 1 , wherein the device consists essentially of corrugated fiberboard and adhesives. 
     
     
         3 : The device according to  claim 2 , further comprising adhesive tape for securing the device in the container configuration. 
     
     
         4 : The device according to  claim 1 , wherein the top further comprises a left top flap extending from a top side of the left panel along a ninth fold line and a right top flap extending from a top side of the right panel along a tenth fold line, and wherein the bottom further comprises a left bottom flap extending from a bottom side of the left panel along an eleventh fold line and a right bottom flap extending from a bottom side of the right panel along an twelfth fold line. 
     
     
         5 : The device according to  claim 1 , further comprising a front support beam affixed to the interior face of the front panel and a rear support beam affixed to the interior face of the rear panel, wherein, when the device is in the container configuration, a first end of the front support beam is adjacent to the first support beam, a second end of the front support beam is adjacent to the third support beam, a first end of the rear support beam is adjacent to the second support beam, and a second end of the rear support beam is adjacent to the fourth support beam. 
     
     
         6 : The device according to  claim 1 , wherein the first support frame, the second support frame, the first support beam, the second support beam, the third support beam and the fourth support beam are each formed of an elongate structure comprising:
 a hollow outer portion formed of corrugated fiberboard sheet material; and   an accordion-folded inner support formed of corrugated fiberboard sheet material;   wherein the hollow outer portion has four outer surfaces that define a rectangle when viewed in cross-section transverse to a longitudinal axis of the elongate structure,   wherein the accordion-folded inner support is enclosed within the hollow outer portion, and   wherein the inner support includes a plurality of first spaced-apart peaks that contact a first inner surface of the hollow outer portion and a plurality of second spaced-apart peaks that contact an opposing second inner surface of the hollow outer portion.   
     
     
         7 : The device according to  claim 6 , wherein the hollow outer portion and the accordion-folded inner support are formed of separate and distinct pieces of corrugated fiberboard sheet material. 
     
     
         8 : The device according to  claim 6 , wherein the hollow outer support and the accordion-folded inner support are integrally formed from one piece of corrugated fiberboard sheet material. 
     
     
         9 : The device according to  claim 6 , wherein at least a portion of the first peaks are adhesively joined to the first inner surface and/or at least a portion of the second peaks are adhesively joined to the second inner surface. 
     
     
         10 : The device according to  claim 5 , further comprising:
 a thirteenth fold line disposed in the front panel parallel to the first fold line, said thirteenth fold line being spaced apart from the first fold line a distance that is equivalent to a thickness of the front support beam; and   a fourteenth fold line disposed in the rear panel parallel to the third fold line, said fourteenth fold line being spaced apart from the third fold line a distance that is equivalent to a thickness of the rear support beam.   
     
     
         11 : The device according to  claim 1 , wherein both the first support frame and the second support frame are reinforced by corner gussets. 
     
     
         12 : A device that is reversibly foldable between a compact configuration and a container configuration, said device comprising:
 a top;   a front panel;   a left panel;   a rear panel;   a right panel; and   a bottom;   wherein, when the device is in the container configuration, the top and bottom are spaced apart parallel to each other, the front panel and the rear panel are spaced apart parallel to each other, and the left panel and the right panel are spaced apart parallel to each other, thereby cooperating to define a closed containment cavity,   wherein a left side of the front panel is connected to a right side of the left panel along a first fold line,   wherein a left side of the left panel is connected to a right side of the rear panel along a second fold line,   wherein a left side of the rear panel is connected to a right side of the right panel along a third fold line,   wherein a left side of the right panel is connected to a right side of the front panel along a fourth fold line,   wherein the top comprises a front top flap extending from a top side of the front panel along a fifth fold line and a rear top flap extending from a top side of the rear panel along a sixth fold line,   wherein the bottom comprises a front bottom flap extending from a bottom side of the front panel along a seventh fold line and a rear bottom flap extending from a bottom side of the rear panel along an eighth fold line,   wherein a first support frame is fixed to an exterior face of the left panel,   wherein a second support frame is fixed to an exterior face of the right panel, and   wherein, when the device is in the compact configuration, at least a portion of the front panel is coplanar with one of the left panel and the right panel.   
     
     
         13 : The device according to  claim 12 , wherein a third support frame is fixed to an exterior face of the front panel and a fourth support frame is fixed to an exterior face of the rear panel. 
     
     
         14 : The device according to  claim 12 , wherein the device consists essentially of corrugated fiberboard and adhesives, and wherein the device further optionally comprises adhesive tape for securing the device in the container configuration. 
     
     
         15 : A rectangular support frame formed of one or more elongate structures,
 wherein the rectangular support frame has four corners,   wherein the one or more elongate structures used to form the rectangular support frame comprise:   a hollow outer portion formed of corrugated fiberboard sheet material; and   an accordion-folded inner support formed of corrugated fiberboard sheet material;   wherein the hollow outer portion has four outer surfaces that define a quadrilateral when viewed in cross-section transverse to a longitudinal axis of the elongate structure,   wherein the accordion-folded inner support is enclosed within the hollow outer portion,   wherein the inner support includes a plurality of first spaced-apart peaks that contact a first inner surface of the hollow outer portion and a plurality of second spaced-apart peaks that contact an opposing second inner surface of the hollow outer portion, and   wherein each of the four corners is reinforced by a corner gusset.   
     
     
         16 : The rectangular support frame according to  claim 15 , wherein the quadrilateral is a trapezoid. 
     
     
         17 : A rectangular support frame formed of one or more elongate structures,
 wherein the rectangular support frame has four corners,   wherein the one or more elongate structures used to form the rectangular support frame comprise:   a hollow outer portion formed of corrugated fiberboard sheet material; and   an accordion-folded inner support formed of corrugated fiberboard sheet material;   wherein the hollow outer portion has four outer surfaces that define a quadrilateral when viewed in cross-section transverse to a longitudinal axis of the elongate structure,   wherein the accordion-folded inner support is enclosed within the hollow outer portion,   wherein the inner support includes a plurality of first spaced-apart peaks that contact a first inner surface of the hollow outer portion and a plurality of second spaced-apart peaks that contact an opposing second inner surface of the hollow outer portion, and   wherein the rectangular support frame is mounted to a wrapping panel provided with at least two fold lines, said wrapping panel being configured to wrap and thereby envelope the rectangular support frame such that the at least two fold lines align with a bottom left edge and a top left edge of the rectangular support frame.   
     
     
         18 : The rectangular support frame according to  claim 17  wherein the rectangular support frame defines an interior cavity configured to receive a single wine bottle and wherein the interior cavity of the rectangular support frame contains a U-shaped wine-bottle support provided with an opening for receiving a neck of the single wine bottle. 
     
     
         19 : The rectangular support frame according to  claim 17 , wherein the rectangular support frame has an interior cavity configured to receive three wine bottles side by side and wherein the interior cavity of the rectangular support frame contains dividers for separating the three bottles of wine from each other.