Bulk shipping box assembly with detachable pallet

[0001] This application claims the benefit of prior U.S. Provisional Patent Application Ser. No. 60/490,198, filed Jul. 25, 2003.

[0002] This invention relates to shipping containers for shipping products in bulk, and more particularly to a shipping box and detachable pallet for shipping relatively heavy and bulky items, such as automotive parts and the like.

[0003] Heavy duty boxes formed from one or more plies of corrugated cardboard are commonly used for shipping products in bulk. These boxes are frequently fastened to a pallet by staples or straps prior to filling the box with product. The end user must either have the container shipped to it in its set-up condition and already fastened on the pallet, or the end user must have the necessary stapling or strapping equipment available to set up the container in-house. In the former case, shipping the set-up container and pallet is expensive, and in the latter case, the assembly and set up requires added capital cost for equipment, is labor intensive, and presents safety issues for the end user and its employees. Also, because of the large size of a typical bulk box, it is difficult to reach into the box to apply staples. Moreover, the staples must penetrate both the box and the pallet, and strapping normally crushes the box. Both methods require hand tools to apply and remove the fasteners, and cause damage to both the box and the pallet, making re-use impractical.

[0004] Further, the boxes, with attached pallets, are commonly stacked on top of one another up to three pallets high. The side walls must have sufficient stacking strength to withstand the compressive load imposed on them. Conventional boxes of the type with which the present invention is concerned typically have a capacity of 500 pounds, i.e., they can safely be stacked three high when loaded with 500 pounds of product. However, some bulk products have greater weight than this, and although conventional boxes have a built-in safety factor, greater stacking strength is desirable.

[0005] Accordingly, there is need for a bulk shipping box and pallet assembly that can be manufactured and shipped to an end user in a knocked-down or flattened condition and then easily set up by the end user and fastened to a pallet, and easily detached from the pallet when desired, without requiring the use of hand tools or other equipment, and without causing damage to either the box or the pallet, whereby they are suitable for reuse. Further, there is need for a bulk shipping box having improved stacking strength.

[0006] The present invention comprises a bulk shipping box and blank for making the same, wherein the box has integral means for releasably attaching the box to a pallet without requiring the use of separate fasteners, and a shipping box and pallet assembly that can be manufactured and shipped to an end user in a knocked-down or flattened condition and then easily set up by the end user and fastened to a pallet, and detached from the pallet and knocked down to a flattened condition when desired, without requiring the use of hand tools or other equipment and without causing damage to either the box or the pallet. The box of the invention also incorporates a reinforcing insert that improves stacking strength.

[0007] As manufactured and shipped to the end user, the bulk shipping assembly of the invention comprises a box in a flattened tubular condition, a pallet, and a cover. The box includes integral slotted tabs that are engageable with the slats of the pallet to hold the box to the pallet without requiring the use of staples, strapping or other fasteners. The box can be quickly and easily erected by hand from the flattened condition to an open expanded condition, and then attached to the pallet by bending the slotted tabs and positioning the ends of a slat or slats of the pallet into the slots of the tabs to attach the box to the pallet. When it is desired to detach the box from the pallet and return it to its flattened condition, the tabs are flexed to disengage the pallet slats from the tab slots, and the box is unfolded to its flattened tubular condition. The box and pallet may then be reused, if desired.

[0008] More specifically, the box of the invention preferably is made from a single unitary blank of corrugated cardboard and has opposite side walls, opposite end walls, and bottom flaps that are foldable into closing relationship over the bottom of the box. Two opposed bottom flaps have die cuts in them defining attaching tabs that lie in the plane of the respective flap when the box is in its flattened condition, and that project downwardly from the bottom edge of the associated box side wall when the box is erected. The tabs include a first, outer panel that is a continuation of the associated side wall, and a second, inner panel that folds between the first panel and the pallet, forming a double thickness or double layer construction that is very strong and has sufficient rigidity to stay in locking engagement with the pallet slat during handling, and yet can be flexed and released from the pallet when desired. The tabs have one or more slots in at least the second, inner panel for receiving an extended end of at least one pallet slat when the box is erected and attached to the pallet.

[0009] In a first embodiment, a single slot is formed in each of the first and second panels of the attaching tabs, and when the second panel is folded inwardly of the first panel, the slots in the two panels are aligned for receiving the extended end of a pallet slat that forms part of the top deck of the pallet. This embodiment is designed for use with a pallet having only a few slats forming the top deck, with one of the slats lying on the centerline of the pallet, and the extended ends of that slat being engaged in the slots in both panels of the attaching tab.

[0010] In a second embodiment, two side-by-side slots are formed in each of the first and second panels for receiving the extended ends of two slats that form part of the top deck of the pallet. This embodiment is designed for use with pallets having a larger number of slats than in the first embodiment, wherein the two central slats lie on opposite sides of the pallet centerline, and extended ends of these two slats are engaged in the slots in both panels of the attaching tab.

[0011] In a third embodiment, there are no slots in the first or outer panel, and the extended ends of the pallet slat engage in a slot in only the second or inner panel of the attaching tab. The inner panel can have only one slot, as in the first embodiment, or two slots as in the second embodiment. In this regard, it should be understood that a number of slots other than one or two could be employed in each of the embodiments, if desired or necessary for a particular application.

[0012] According to another aspect of the invention, a reinforcing insert is placed in the box in each of at least two opposite ends or sides to increase the stacking capacity of the box. The reinforcing insert is made from a flat piece of corrugated cardboard having creases or scores at its opposite ends defining panels that are folded over and laminated together to form a double thickness flap at each of the opposite ends of the insert. A central portion of the insert between the flaps is approximately the same width as the side or end of the box, and when the insert is placed in the box the central portion lies against an inner surface of the side or end wall, and the two flaps lie against adjacent walls. The dimensions of the insert are such that it has a tight fit in the box and extends the full height and width of the wall against which it is placed. However, when it is desired to return the box to its flattened condition, the inserts can be removed. With the inserts, the stacking strength of the box is increased from about 500 pounds to about 850 pounds. Although the insert is shown and described herein as being used in a box having attaching tabs for securing the box to a pallet, it should be understood that the insert could be used with other types of boxes.

[0049] The bulk shipping assembly of the invention is indicated generally at 10, and as seen best in FIGS. 1 and 2, comprises a box 11, cover 12, and pallet 13. This is the assembly that typically would be manufactured and shipped to an end user in the disassembled, knocked-down flattened condition shown in FIG. 2.

[0050] In a first embodiment of the box of the invention, illustrated in FIGS. 1–17, the box 11 has two opposed side walls 14 and 15, and two opposed end walls 16 and 17. With particular reference to FIG. 17, which shows a blank B₁ for erecting the first embodiment, the side and end walls are foldably connected to one another along adjacent side edges at fold lines 18, preferably creased. Opposed major bottom flaps 19 and 20 and opposed minor bottom flaps 21 and 22 are foldably attached along fold lines 23, also preferably creased, to bottom edges of respective opposite side and end walls. A glue flap 24 is foldably connected to one side edge of one of the side walls for use by the manufacturer in gluing up the box prior to its shipment to the end user. The bottom flaps are separated from one another by cuts 25 extending in alignment with the respective fold lines 18.

[0051] A pair of parallel, spaced apart first cuts 26 are made in each of the minor bottom flaps 21 and 22, perpendicular to the fold lines 23 and extending approximately midway into the respective flap. Second cuts 27 extend between the ends of the cuts 26, spaced from the fold line 23, and a pair of closely spaced score lines 28 extend between the cuts 26 spaced between the fold line 23 and cut 27. The cuts and score lines define first and second rectangular panels 29 and 30. It will be noted that the fold line 23 does not extend across the area between the cuts 26 of each pair, whereby the first panel 29 extends rigidly from the bottom edge of the respective end wall. Second panel 30 is foldably joined to the first panel and has a greater width than first panel 29, whereby when the second panel is folded about the score lines 28 into overlying relationship with first panel 29, the second panel extends at its free edge past the fold line 23. The first panel has a rectangular slot 31 formed therein, with one edge of the slot lying in substantial alignment with the score line 23, and the second panel has a rectangular slot 32 formed substantially in the center thereof. When the second panel is folded alongside the first panel, the slots 31 and 32 are in aligned registry with one another. To facilitate folding of the second panel about the score lines 28, small cut-outs 33 may be made in or between the score lines, and to facilitate grasping of the second panel to fold it about the score lines, a cut-out 34 may be made in the flap adjacent the free edge of the panel.

[0052] The outer side edges of the major bottom flaps 19 and 20 are cut away or recessed at 35 for a purpose explained below. If desired, relief cuts 36 may be made in the outer side edges of the minor bottom flaps 21 and 22 to provide clearance space when the box is erected.

[0053] Upon receipt by the end user of the assembly shown in FIG. 2, the flattened box 11 is placed in an upside down orientation, as shown in FIG. 3, and expanded to the open tubular configuration shown in FIG. 4. The major bottom flaps 19 and 20 are then folded inwardly and downwardly over the open bottom of the box, as shown in FIG. 5, followed by folding the minor bottom flaps 21 and 22 inwardly and downwardly over the previously folded major bottom flaps, as shown in FIG. 6. With further reference to FIG. 6, it will be noted that due to the rigid connection of the first panel 29 to the associated end wall, when the minor flaps are folded inwardly the panels 29 and 30 remain in an upright position generally coplanar with the end wall. To finish erecting the box, the second panels 30 are then folded inwardly and downwardly about the score lines 28, as shown in FIG. 7, and the free edge 36 of the second panel is pressed into the space provided between the associated end wall and adjacent edges of the inwardly folded major bottom flaps, as shown in FIGS. 8 and 9. This space is provided by the cuts 35 in the edges of the major bottom flaps, as described above. The completed erected box is shown in FIG. 10. The thus-folded panels form an attaching tab 38 for attaching the box to the pallet, as explained hereinafter.

[0054] The pallet 13 is then picked up, inverted to an upside down orientation, and placed over the bottom of the box, as shown in FIG. 11. As seen best in FIG. 12, the slats 40 that form the top deck of the pallet have extended ends 41. In the particular pallet shown, there are three slats 40a, 40b and 40c that form the top deck, and the center slat 40b is aligned with the slots 31 and 32 formed in the first and second panels 29 and 30, respectively, which comprise inner and outer panels in the erected attaching tab. The pallet is then pushed toward one of the attaching tabs, until the extended end 41 of the slat 40b is engaged in the slots 31 and 32, as shown in FIG. 13. The opposite attaching tab is then flexed outwardly, as shown in FIG. 14, so that the extended end of the slat 40b on the other end of the pallet can be inserted into the slots 31 and 32 of that tab, thus completing attachment of the pallet to the box, as shown in FIG. 15. The assembled box and pallet are then placed in an upright position, as shown in FIG. 16, for receiving product.

[0055] To detach the box from the pallet, the process described above is simply reversed. That is, the box and attached pallet are placed in an upside down position, the attaching tabs are flexed outwardly to disengage the extended slat ends from the slots, the attaching tabs are unfolded, and the flaps are unfolded so that the box can be flattened.

[0056] A second embodiment of the invention is indicated generally at 50 in FIGS. 18–22. The box 11′ in this embodiment is made from a single unitary blank B₂ designed for use with a different pallet 13′, and is essentially the same as the first embodiment, except that two side-by-side slots 51 and 52 are formed in the first panel 29′, and two side-by-side slots 53 and 54 are formed in the second panel 30′, rather than the single slots provided in the first embodiment. Further, the small cut-outs 33 and 34, provided in the first embodiment, are omitted from this embodiment. The attaching tabs 55 in this embodiment thus have two side-by-side slots for receiving the extended ends 56 of a pair of adjacent slats 57 and 58 in the pallet 13′. In all other respects this embodiment is the same as the first embodiment, and assembly and disassembly are achieved in the same way.

[0057] A third embodiment of the invention is indicated generally at 60 in FIGS. 23–27. The box 11″ in this form of the invention is made from a single unitary blank B₃, and is essentially the same as embodiment two described above, except that the slots are omitted from the first, outer panel 29″, whereby when the pallet is attached to the box, the outer surface of the attaching tab 61 is smooth and unbroken. In all other respects, this embodiment is the same as embodiment two, described above, and assembly and disassembly are achieved in the same way.

[0058] FIG. 28 depicts the interior of a box 11, 11′ or 11″, and shows that the major bottom flaps 19 and 20 each extend half way across the bottom of the box so that the bottom is completely closed. The free edge 66 of the second, inner panel of the attaching tab is seen projecting up through the space defined by the cut-outs 35 in the adjacent side edges of the flaps 19 and 20. Except for the attaching tab and its associated structure, this inner box construction is generally the same as a conventional bulk box.

[0059] FIG. 29 depicts a box 11, 11′ or 11″ having a reinforcing insert 70 placed therein in accordance with another aspect of the present invention. It should be noted that while only one end of the box, and one insert, are shown in this figure, an insert preferably would be placed in each of two opposite sides or ends of the box. See FIG. 35. Further, although the insert 70 is shown as placed in a box 11, 11′ or 11″ according to the invention, it could equally as well be used in other types of boxes.

[0060] The insert 70 is made from a single flat piece or blank B₄ of corrugated cardboard having a series of three scores or crease lines 71, 72 and 73 at each end, defining first, second and third panels 74, 75 and 76, respectively, at the ends of the blank, and a center panel 77.

[0061] The distance between the scores or crease lines 73, and thus the width of the center panel 77, is approximately the same as the width of a box wall against which the insert is to be placed. A suitable adhesive is placed on the first and/or second panel, and the second panel 75 is folded onto the first panel 74 and adhesively laminated thereto, forming a double thickness hinged end or panel 78 on each end of the insert, and leaving the third panel 76 free, as depicted in FIG. 31. In use, the ends 78 are folded inwardly and an insert is pressed into place in each end or side of the box. The fit is snug to prevent displacement of the insert, and as seen best in FIG. 29, the height of the insert is the same as the height of the box.

[0062] Although the preferred embodiments illustrated and described herein pertain to rectangular boxes having four sides, it should be understood that the invention could be applied to other box configurations, such as octagonal.

[0063] Although particular embodiments of the invention are illustrated and described in detail herein, it is to be understood that various changes and modifications may be made to the invention without departing from the spirit and intent of the invention as defined by the scope of the appended claims.