Method of forming containers having top flange with glued corners, same containers, and blanks for forming same

Abstract

A method of forming a container from a blank includes applying an adhesive to an interior surface of side flange tabs of the blank, rotating the end panels of the blank inwardly towards a bottom panel, rotating side panels of the blank inwardly towards the bottom panel, and rotating the side flange panels of the blank outwardly into a parallel orientation to the bottom panel. The method further includes, after rotating the side flange panels, rotating end flange panels into a parallel orientation to the bottom panel and coupling the end flange tabs to the side flange tabs to form the container having a fully formed top flange.

What is claimed is: 
     
         1 . A container comprising:
 a bottom panel;   two opposing side panels coupled to the bottom panel along a respective first set of fold lines;   two opposing end panels coupled to the bottom panel along a respective second set of fold lines;   respective end flange panels extending from top edges of each end panel and in an orientation that is generally parallel to the bottom panel;   respective end flange tabs extending from each side edge of each end flange panel;   respective side flange panels extending from top ends of each side panel in an orientation that is generally parallel to the bottom panel; and   respective side flange tabs extending from respective end edges of each side flange panel, the side flange tabs each being coupled to a respective end flange tab to form a top flange of the container.   
     
     
         2 . The container of  claim 1 , wherein the two opposing side panels and the two opposing end panels each have a generally trapezoidal shape and the end panels and side panels each extend obliquely away from the bottom panel. 
     
     
         3 . The container of  claim 1 , wherein the bottom panel, two opposing side panels, and two opposing end panels collectively define a cavity of the container for receiving a product therein, the cavity further configured to receive a portion of an adjacent container therein to facilitate stacking the adjacent container within the container, and wherein the container further includes a denesting assembly configured to engage the adjacent container when received within the cavity of the container such that a flange of the adjacent container is spaced from the flange of the container. 
     
     
         4 . The container of  claim 3 , wherein the denesting assembly includes a denesting tab and a denesting cutout, the denesting tab being folded into the cavity. 
     
     
         5 . The container of  claim 4 , wherein the container further includes an interior side panel extending from a side edge of a first end panel of the two end panels, the denesting tab being coupled to the interior side panel and the end panel, wherein the denesting cutout is defined by the denesting tab, the bottom panel, and at least one of the side panels and the end panels. 
     
     
         6 . The container of  claim 4 , wherein the denesting tab is positioned at a bottom corner of the container, the bottom corner of the container being defined by the bottom panel, a first end panel of the two end panels, and a first side panel of the two side panels. 
     
     
         7 . The container of  claim 6 , wherein the container defines four bottom corners and includes four denesting assemblies positioned at each bottom corner. 
     
     
         8 . The container of  claim 3 , wherein the denesting assembly includes respective denesting tabs coupled to end edges of each side panel, the denesting tabs extending outward from the end edges and being coplanar with the respective side panels. 
     
     
         9 . The container of  claim 8 , wherein the container is configured to be received in a cavity defined in an adjacent container that has a substantially similar size and shape as the container, the denesting tab being sized to engage an adjacent flange of the adjacent container such that the flange of the container is spaced from the adjacent flange of the adjacent container when the container is received within the cavity of the adjacent container. 
     
     
         10 . A method of forming a container from a blank, the blank including a bottom panel, two opposing side panels, two opposing end panels, a respective end flange panel extending from a top edge of each end panel, a respective end flange tab extending from each side edge of each end flange panel, a respective side flange panel extending from a top end of each side panel, and respective side flange tabs extending from respective end edges of each side flange panel, the method comprising:
 applying an adhesive to an interior surface of the side flange tabs;   rotating the end panels inwardly towards the bottom panel;   rotating the side panels inwardly towards the bottom panel;   rotating the side flange panels outwardly into a parallel orientation to the bottom panel;   after said rotating the side flange panels, rotating the end flange panels into a parallel orientation to the bottom panel; and   coupling the end flange tabs to the side flange tabs to form the container having a fully formed top flange.   
     
     
         11 . The method of  claim 10 , wherein the bottom panel, two opposing side panels, and two opposing end panels collectively define a cavity of the container for receiving a product therein, the method further comprising:
 positioning a film on the top flange to extend over and cover the cavity; and   sealing the film against the top flange.   
     
     
         12 . The method of  claim 10 , wherein the two opposing side panels and the two opposing end panels each have a generally trapezoidal shape such that, after said rotating of the end panels and the side panels, the end panels and side panels each extend obliquely away from the bottom panel. 
     
     
         13 . The method of  claim 10 , wherein the bottom panel, two opposing side panels, and two opposing end panels collectively define a cavity of the container for receiving a product therein, the cavity further configured to receive a portion of an adjacent container therein to facilitate stacking the adjacent container within the container, and wherein the container further includes a denesting assembly configured to engage the adjacent container when received within the container such that a flange of the adjacent container is spaced from the fully formed flange of the container. 
     
     
         14 . The method of  claim 13 , wherein the denesting assembly includes a denesting tab and a denesting cutout, the method further comprises folding the denesting tab into the cavity. 
     
     
         15 . The method of  claim 14 , wherein the blank further includes an interior side panel extending from a side edge of a first end panel of the two end panels, the denesting tab being coupled to the interior side panel and the end panel, wherein the denesting cutout is defined by the denesting tab, the bottom panel, and at least one of the side panels and the end panels. 
     
     
         16 . The method of  claim 14 , wherein the denesting tab is positioned at a bottom corner of the container, the bottom corner of the container being defined by the bottom panel, a first end panel of the two end panels, and a first side panel of the two side panels, and wherein, when the denesting tab is folded into the cavity and the adjacent container is received within the cavity, the denesting tab is configured to engage an outer surface of the adjacent container. 
     
     
         17 . The method of  claim 16 , wherein the container defines four bottom corners and includes four denesting assemblies positioned at each bottom corner. 
     
     
         18 . The method of  claim 13 , wherein the denesting assembly includes respective denesting tabs coupled to end edges of each side panel, the denesting tabs extending outward from the end edges and being coplanar with the respective side panels. 
     
     
         19 . The method of  claim 18 , wherein the container is configured to be received in a cavity defined in an adjacent container that has a substantially similar size and shape as the container, the denesting tab being sized to engage an adjacent flange of the adjacent container such that the flange of the container is spaced from the adjacent flange of the adjacent container when the container is received within the cavity of the adjacent container. 
     
     
         20 . A method of stacking a first container on a second container, the first container and second container each being formed from respective blanks having substantially the same size and shape, the blanks each including a bottom panel, two opposing side panels, two opposing end panels, a respective end flange panel extending from a top edge of each end panel, a respective end flange tab extending from each side edge of each end flange panel, a respective side flange panel extending from a top end of each side panel, and respective side flange tabs extending from respective end edges of each side flange panel, the method comprising:
 forming the first container by:
 applying an adhesive to an interior surface of the side flange tabs; 
 rotating the end panels inwardly towards the bottom panel; 
 rotating the side panels inwardly towards the bottom panel; 
 rotating the side flange panels outwardly into a parallel orientation to the bottom panel; 
 after said rotating the side flange panels, rotating the end flange panels into a parallel orientation to the bottom panel; and 
 coupling the end flange tabs to the side flange tabs to form the container having a fully formed top flange; 
 forming the second container; and 
 positioning the first container within a cavity of the second container such that a denesting assembly of one of the first container and the second container engages the other of the first container and the second container to space the top flange of the first container from a top flange of the second container.