Wiley v. RockTenn CP

8/2/2019 Wiley v. RockTenn CP

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FILEDU.S. DISTHICT COURTEASTERN DISTHICl AHKANSASIN THE UNITED STATES DISTRICT COURTAPR 16 2012EASTERN DISTRICT OF ARKANSAS

WESTERN DIVISION ~ A ~ E S W ~ A C K , CLERKy l..)l::PCLI.:.HTED WILEY PLAINTIFF

vs.ROCKTENN CP, LLC F/K/A SMURFIT-STONECONTAINER CORPORATION F/DBA SMURFIT-STONECONTAINER ENTERPRISES, INC.

COMPLAINT

DEFENDANT

Comes now the Plaintiff, Ted Wiley ("Wiley''), by and through his attorney, StanleyLaw Firm, and for his Complaint against the Defendant, RockTenn CP, LLC f/k/a Smurfit-Stone Container Corporation formerly d/b/a Smurfit-Stone Container Enterprises, Inc.

This case assigned to District J u d g e ~ ("RockTenn"), states: \ t \and to Magistrate Judge - , 0 VC .:ternal connecting flaps disposed 40about the lower perimeter of the box walls. Although thisdevice is self locking, experience has shown that the d e ~ i g n Thus a related object is to pro,ide a pallet box that whendeployed, is rugged enough for use with pallets in a relatively harsh industrial environment, hut which is flexible

45 enough to be quickly erected from a flat, folded, storagestate.

is rather hard to erect. Further, this type of design is notpractical to make on a standard industrial corrugator.SUMMARY OF THE INVENTION

This invention provides a foldably deployable, heavyduty pallet box for containing a variety of products that arenormally handled with palletized loads. My new container 50provides a bulk packaging solution that is readily capable ofreliably handling large loads of products such as debonedmeats, liquids and other bulky and heavy items. All can besafely handled aud constrained.Preferably, the container is made from two identical, but 55complementary blanks tha t form a single board that foldably

forms the desired pallet container. Preferably each blankcomprises various foldable panels and correspondingregions to which complementary panels are affixed. Alternatively, the board may comprise a larger, unitary blank GOcomprising similar complementary halves. when blanks areglued together in proper alignment, aud the box deployed, aspring effect occurs-larger loads tend to maintain the p i e ~ e s together aud preserve box integrity. Because of the flapconstructions, and the mode ofgluing during manufacturing, 65a strong aud resilient pallet box is provided. The larger thebox, the better the spring effect.

Another important object is to provide a heavy-duty palletbox of he character described that is safe for use in a typicalindustrial warehouse scenario.

Concurrently, au important object is to provide a palletbox that minimizes shipping costs and expenses.Another object is to provide a pallet box that is suitablefor the reliable transportation oflarge quantities of flowablesolids.Yet another important object is to provide a pallet box ofthe character described that does not have to be upside-downduring the unfolding and deployment process.Yet another object of my invention is to provide ageometric design for a pallet box that can safely employed

with a variety of sizes and weight-bearing capacities. It is afeature of my design that pallet loads of up to 2400 poundscan be safely constrained.These aud other objects aud advantages of the presentinvention, along with features of novelty appurtenantthereto, will appear or become apparent in the course of thefollowing descriptive sections.

Case 4:12-cv-00226-JLH Document 1 Filed 04/16/12 Page 31 of 34


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US 7,328,833 Bl5

BRJEF DESCRIPTION OF THE DRAWINGSIn the following drawings, which form a part of thespecification and which are to be construed in conjunctiontherewith, and in which like reference numerals have beenemployed throughout wherever possible to indicate likeparts in the various views:FIG. 1 is a top plan view of a preferred blank that is gluedto an identical, complementary blank to produce the preferred board;FIG. 2 is a bottom plan view of he preferred blank of FIG.1; PIG. 3 is a top plan view of a preferred, complementaryblank;FIG. 4 is a bottom plan view of the complementary blankof FIG. 3;FIG. S is a diagrammatic and isometric view showing apair of blanks aligned for proper assembly that are adaptedto be glued together to form the desired board;FIG. 6 is an isometric view of the assembled board,immediately after the complementary blanks are gluedtogether;FIG. 7 is an isometric view of the assembled boardshowing a subsequent fulding stage for assembly of thedesired foldable box;FIGS. 8 and 9 are isometric views showing subsequentfolding stages;FIG. 10 is an isometric view of the partially-assembledand flattened board as it appears immediately after thepartial folding steps of FIGS. 7-9;FIG.l l is an isometric view of he flattened board of FIG.10 with certain flaps partially folded before gluing;FIG. 12 is an isometric view of the flattened board ofPIGS. 10 and 11 showing all flaps glued, with the resultantboard disposed in a flat shipping or storage state;FIGS. 13-15 show are elevational views taken generallyfrom the position indicated by reference arrows 13-13 inFIG. 12, showing how the desired container is formed byunfolding the previous flat, constituent board;FIG. 16 is a top isometric view of he deployed container;FIG. 17 is a bottom isometric view of the deployedcontainer of PIG. 16; and,FIG. 18 is an enlarged fragmentary isometric view takengenerally from a position along line 18-18 of FIG. 17.

DETAILED DESCRIPTIONWilh initial reference directed now to FIGS. 1-6 of lheappended drawings, preferred complementary blanks 20, 21are illustrated. In the best mode blank 20 (PIGS. 1-2) isidentical to complementary blank 21 (FTGS. 3-4). Thepreferably identical, multi-component blanks 20, arecoupled together as described hereinafter and appropriatelyglued together to form a preferred board 22 (i.e., FIGS. S, 6)which may be stored in a compact, flat position (i.e., FIG.12) and lhereafler unfolded as in FIGS. 13-15 into lhe

deployed, polygonal pallet carton 27 of FIG. 16.For purposes of simplifying this discussion and the associated drawings and disclosure, all common parts of theillustrated blanks 20, 21 have been designated with similarreference numerals that dtifer only in their suffix. This topportions ofblank 20 (FIG. 1) have been given the suffix "A,"and the corresponding bottom portions (i.e., the same partsas they appear from the underside of the blank) have beengiven the suffix "B" in FIG. 2. Likewise, in FIG. 3 identicalstructural parts visible from the top complementary blank 21have been designated with the suffix "C"; those same parts

6visible from the underside of blank 21 have been designatedwith the reference numeral "D" (FIG. 4).

In the best mode the board 22 is formed from a pair ofidentical, complementary blanks 20 and 21 that are fitted andfastened together as hereinafter described. Alternatively, itwill be recognized that a single board comprising a pair ofhalves substantially identical with blanks 20, 21 may beemployed, but this approach results in a larger basic blankthat increases tooling costs. As used herein the term "blank"10 is thus intended to refer not only to the preferred two-piecemode, wherein board 22 comprises a pair of complementaryblanks, but to a single piece board or blank comprisingsymmetrical halves, each resembling a blank 20, or 21. Inany event, The blanks or boards are preferably die-cut from15 heavy-duty corrugated material, although other sheet-likecomponents like paperboard, cardboard or the like knovm tothose with skill in the art ca n be used. During assembly whena pair of blanks 20, 21 are glued together the resulting boards22 are fiat, and may be temporarily stored in a stacked20 relationship for volumetric efficiency. A single workman

may appropriately fold boards, and they need not be turnedupside-down during deployment.A preferred blank 20 comprises an upper generally rectangular region comprising separate, smaller rectangular25 panels: a gluing side panel 24A, an adjacent, central sidepanel 26A, and an adjacent, integral receiving side panel28A (FIG. 1). A vertical score l ine 30A divides and foldablyseparates panels 24A, l6A. A similar, spaced apart, scoreline 32A foldably separates adjacent panels 26A, 28A.30 Panels 24A, 26A, and 28A will form sides of the deployedand erected polygonal container 27 (FIG. 16) along withsimilar corresponding panels 24C, 26C, 28C of complementary blank 21 (FIGS. 3, 4). The top of blank 20 is designated

by the reference numeral 34A. A generally rectangular35 gluing flap 36A that is integral with and acljacent gluing sidepanel 24A is separated therefrom by vertical, double scorelines 38A The opposite terminal edge of the blank 20,bounding receiving panel 28A, has been designated by thereference numeral 40A, and in the best mode there is no flap40 there.

A trio of axially aligned, contiguous horizontal body scorelines 42A, 43A, and 44A respectively adjoin the bottoms ofpanel 24A, 26A, and 28A. A first, generally trapezoidalflange 46A is separated from the bordering side panel 24A45 by score line 42A. The bottom edge of flange 46A isdesignated generally by the reference numeral 47A. Flange

46A supports an outer, integral glue flap 48A that is separated by inclined, double score lines 49A. Similarly, there isa second generally trapezoidal, flange SOA separated from50 bordering receiving panel 28A by score line 44A. Thebottom of flange SOA is designated by the reference numeralS2A. The angled, outer edge of flange SOA is designated bylhe reference numeral 54A. As de:;cribed later in more detail,flanges from the various coupled-together blanks form rein-55 forcement shelves for bracing the bottom of the containerwhen erected. It should be noted that in the best mode there

is no glue flap formed along edge 54A of !lange 23SOA. Theflanges (i.e., 46A, 46B, 46C, 46D and SOA, SOB, SOC, andSOD) form a supporting shelf that reinforces the container60 bottom, as will later be described in conjunction with adescription of FIGS. 17-18.Importantly there is a relatively large, generally trapezoidal segment 60A formed at the panel bottom, beneath scoreline 43A and the integral, adjoining central panel 26A. The65 purpose of rapezoidal segments 60Al60B and 60C/60D is toform a heavy-duty bottom fur the pallet container, when lheblanks 20, 21 are coupled, and the resulting board is



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US 7,328,833 Bl7unfolded. Segment 60A has a first outer inclined edge 62Athat is cut away from adjoining flange 50A, 1 and a second,spaced-apart, inclined edge 64A that is cut away fromadjoining flange 46A. A generally rectangular bottom glueflap 68A is formed adjacent score line 70A at the bottom oftrapezoidal segment 60A. In the best mode, the glue flap 68Ahas an inclined edge 72A, a spaced apart vertical edge 73A,and a bottom edge 74A extending between edges 72A and73A. The length of glue flap 68A (i.e., correspondinggenerally to score line 70A in FIG. 1) is approximately one 10halfof the length of he bottom of rapezoidal segment 60A.Importantly, there is a relie f cut 78 A bordering glue flap 68A

8the trapezoidal segments 60A/60B and 60C/60D is hexagonal in the preferred embodiment, i.e., the number of facetsof the hexagon equals the number of sides of the deployedcontainer. Importantly, a pair of spaced apart reinforcementshelves 94 are disposed beneath to bottom 88 of thedeployed container 27 (these are best viewed in FIGS. 17and 18 where they appear at the top of the views.) Thesetwin spaced-apart r ~ i n f u r c e m e n t shelves result from thecoupled-together trapezoidal flanges 46A/46B that matewith flanges SOC/SOD, and from flanges 46c/46D that matewith flanges 50A/SOB. As the pallet is loaded, downwardpressure may tend to push down and deform bottom 88;however, when deflected, th e bottom 88 contacts the shelves94 that distribute pressure, reinforce the container, an d tendto maintain its proper geometry and shape.From the foregoing, it will be seen that this invention iswell adapted to obtain all the ends and objects herein setforth, together with other advantages inherent to the structure.

at the bottom left of segment 60A(i.e., as viewed in fiG. 1).The relief cut 78A is bounded by an offset alignment tab 80Aoccupying the extreme left bottom region of he trapezoidal 15segment 60A. There is a small, approximately rectangularglue reception region above relief cut 78A that has beengenerally designated by the reference numeral 79A. Reception region 79A will be glued to flap 68C on the complementary blan k 21 in assembly. It will be understood that certa in featnres and subcombi-20 nations are ofutility and may be en1ployed without referenceto other features and subcombinations. This is contemplatedby and is within the scope of the claims.Turning now to FIGS. 5 ami 6, assembly of the desiredboard 22 starts by positioning a pair of complimentaryblanks 20 and 21 substantially as illustrated. In FIG. S, blank20 is oriented substantially as seen in FIG. 1, but blank 21is turned upside down from the position illustrated in FIG. 253. This orientation is assumed for purposes of illustration, asother starting orientations for blanks 20, 21 could be used.

For example, blank 20 could be positioned on top of theFigure or at the bottom as oriented generally in FIG. S, witheither surface "A" or "B" facing the viewer, and blank 21 30would be positioned accordingly). The first step in assembling board 22 is to mate the complen1entary trapezoidal,bottom-forming segments 60A, 60C by moving themtogether as represented of arrows 53 (FlU. 5). When thisoccurs, 79A flange 68C (more particularly the bottom flangeside 68D nul seen in FIG. S) will be glued to region 79A on 35flange 60A. Similarly, the underside of flap 68A (morespecifically 68B) will be glued to glue receptive region 79Con trapezoidal bottom-forming segment 60C. A hexagonalcontainer bottom, generally designated by the referencenumeral 88 (FIGS. 13-15) results. Bottom 88 comprises the 40trapezoidal segments 60N60B and 60C/60D as discussedearlier.

Once the bottom 88 is constructed as aoresaid, it is foldedinto a flat position, as in the sequence of FIGS. 7-10. Bottom88 forms a triangular cross section with its apex projecting 45towards the viewer in FIGS. 8 and 9. Finally the two blanks20, 21 are pressed together, and bottom 88 (FIGS. 13-1S)will be flatly folded and nested together, projecting into theinterior as in FIG. 10, wi th lrdpezuidal segment 60B touching the surface of trapezoidal segment 60D. At this time 50gluing flap 36B is turned over and glued to panel 28D (i.e.,the underside panel of blan k 21), as indicated sequentially inFIGS. 10-12. Similarly, glue panel36C/36D (FIGS. 10-12)is folded over and glued to the edge region of surface 28B.The flange glue flap 48B (FIG. 11) is folded over glued toflange SOD (i.e., surface 48A thereof s glued to flange SOD). 55C-!mcurrently glue flap 48C is glued to flange SOH, formingthe configuration of FIG. 12. These construction steps needbe performed only approximately in order. Different portions of the blanks could be glued together in differentsequences. Completion of these gluing steps yields a flatly 60folded container 27 that is constructed in accordance withthe best mode of the invention.

Turning to FIGS. 13-16, the folded, flat container 27 iserected by squeezing sideways, generally as indicated in thedirection of arrows 100, 101 (FIG. 13. Additional pressure 65and deflection r e s u l t ~ in the hexagonal, deployed container27 (FIGS. 15, 16). It is seen that the bottom 88 formed from

As many possible embodiments may be made of theinvention without departing from the scope thereof; it is tobe understood that all matter herein set forth or shown in theaccompanying drawings is lo be interprt:led as illuslmliveand not in a limiting sense.

Vlhat is claimed is:1. A heavy duty, knockdown container that is transformable between a flat, compact orientation for storage andshipping and a deployed configuration for containing goods,the container formed from a pair of substantially identicalcomplementary blanks that are coupled to one another,wherein each blank comprises:a generally rectangular gluing side panel having a top, apair of sides and a bottom;an integral, generally rectangular central side panel adjacent said gluing side panel, the central side panelhaving a top, a pair of sides and a bottom;a folding line defined between said central side panel andsaid gluing side panel;an integral receiving side panel adjacent said central sidepanel, the receiving side panel having a top, a pair ofsides and a bottom;a second folding line defined between said central sidepanel and said receiving side panel;a generally rectangular gluing flap foldably defined adjacent said gluing side panel for attaching the gluing sidepanel on a first blank to the receiving side panel on acomplementary blank;a generally lmpezuidal segment fuldably coupled to saidcentral side panel at the bottom thereo f for mating witha similar trapezoidal segment of the complementaryblank to form a foldable polygonal bottom of saidcontainer, the trapezoidal segment comprising a bottomglue flap, a spaced apart relie f slot, and a glue reception

region proximate the relie f slot that foldably mates withthe bottom glue flap on the trapezoidal segment of acomplementary blank;a first, generally trapezoidal flange foldably disposed atthe bottom of said gluing side panel which contiguously borders and is separated from said trapezoidalsegment, the first trapezoidal flange comprising anintegral, adjacent, foldable flange glue flap; and,a second, generally trapezoidal flange foldably disposedat the bottom of said receiving side panel which contiguously borders and is separated from said trapezoidal



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US 7,328,833 Bl9

segment for coupling to th e foldable flange glue flap ofa first trapezoidal flange associated with a gluing sidepanel of a complementary blank thereby forming afoldable shelf disposed beneath the container bottomfor reinforcing the container bottom when the container 5is deployed.

2. The container as defined in claim 1 further comprisingan alignment tab disposed adjacent the relief slot of eachtrapezoidal segment.3. A heavy duty, hexagonal container that is transformable 10between a flat, compact orientation for storage an d shippingand a deployed configuration for containing goods, thecontainer formed from a pair of substantially identicalcomplementary die-cut blanks that are coupled to oneanother, wherein each blank comprises: 15a generally rectangular gluing side panel having a top, apair of sides and a bottom;an integral, generally rectangular central side panel adjacent said gluing side panel, the central side panelhaving a top, a pair of sides and a bottom; 20a folding line defined between said central side panel andsaid ghring side panel;

an integral receiving side panel adjacent said central sidepanel, the receiving side panel ha"ing a top, a pair ofsides and a bottom; 25a second folding line defined between said central sidepanel and said receiving side panel;a generally rectangular gluing flap foldably defined adjacent said gluing side panel for attaching the gluing sidepanel on a first blank to the receiving side panel on a 30complementary blank;

10a generally trapezoidal segment foldably coupled to said

central side panel at the bottom thereoffor mating witha similar trapezoidal segment of the complementaryblank to form a foldable polygonal bottom of saidcontainer, the trapezoidal segment comprising a bott omglue flap, a spaced apart relief slot, and a glue receptionregion proximate the relief slot that foldably mates withthe bottom glue flap on the trapezoidal segment of acomplementary blank;

a first, generally trapezoidal flange foldably disposed atthe bottom of said gluing side panel which contiguously borders but is separated from said trapezoidalsegment, the first trape7nidal flange comprising anintegral, adjacent, foldable flange glue flap; and,

a second, generally trapezoidal flange foldably disposedat the bottom of said receiving side panel which contiguously borders but is separated from said trapezoidalsegment for coupling to the foldable flange glue flap ofa first trapezoidal flange associated with a gluing sidepanel of a complementary -blank thereby fomring afoldable sh elf disposed beneath the container bottomforreinforcing the container bottom when the containeris deployed.

4. The container as defined in claim 1 further comprisingan alignment tab disposed adjacent the relief slot of eachtrapezoidal segment.

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Wiley v. RockTenn CP

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