Nestable container with uniform stacking features
View Patent ↗Various embodiments of flanged containers that can be stacked in a nested relationship are disclosed so as to provide uniform spacing between the containers to facilitate reliable denesting thereof. The flanges and/or sidewalls of the containers may be provided with features that facilitate alignment and uniform spacing of the nested containers so that a denesting apparatus can reliably denest the containers. Other containers include sidewalls divided into two sections that serve to stabilize stacked container.
1. A method of forming a nestable paperboard container, the method comprising:
obtaining a die set for forming the container, the die set comprising a forming punch and a forming die, at least one of the forming punch and the forming die comprises features for forming a denesting feature of the container, features for forming a sidewall of the container, and features for forming a flange of the container;
placing a blank between the forming punch and the forming die; and
forming the container from the blank by moving at least one of the forming punch and the forming die relative to the other of the at least one of the forming punch and the forming die,
wherein forming the container from the blank comprises forming the denesting feature of the container, forming the sidewall of the container, and forming the flange of the container, the denesting feature comprising an inner peripheral portion of the flange that is thicker than an outer portion of the flange, the inner peripheral portion of the flange extending from a perimeter of the sidewall, the inner peripheral portion of the flange comprising a first surface and the outer portion of the flange comprising a second surface, the first surface being offset from the second surface, and the first surface being an uppermost surface of the container.
2. The method of claim 1 , wherein forming the flange comprises forming the inner peripheral portion to extend along a majority of the perimeter of the sidewall.
3. The method of claim 1 , wherein the forming punch comprises a protrusion and the forming die comprises a central recess, and forming the container comprises moving the protrusion into the central recess to form the container having a base and the sidewall extending from the base.
4. The method of claim 3 , wherein the features for forming the flange comprise cooperating surfaces of the forming punch and the forming die, the cooperating surfaces being located laterally outward from the protrusion and the central recess.
5. The method of claim 3 , wherein the forming punch comprises a flange recess and the forming die comprises a flange shoulder, the flange recess and the flange shoulder being located laterally outward from the protrusion of the forming punch and the central recess of the forming die.
6. The method of claim 5 , wherein the features for forming the denesting feature comprise a denesting feature recess formed in the forming punch.
7. The method of claim 6 , wherein the denesting feature recess is adjacent the flange recess.
8. The method of claim 6 , wherein the denesting feature recess has a greater thickness than the flange recess.
9. The method of claim 8 , wherein the flange recess extends from the denesting feature recess to a peripheral edge of the die set so that the flange in the container formed from the blank comprises a peripheral edge of the container.
10. The method of claim 8 , wherein the denesting feature recess at least partially forms an upper portion of the sidewall adjacent the flange, the upper portion of the sidewall being thicker than a lower portion of the sidewall.
11. The method of claim 1 , wherein the blank comprises laminated paperboard.
12. The method of claim 11 , wherein forming the container comprises forming a plurality of pleats, wherein forming the plurality of pleats comprises selectively gathering the laminated paperboard.
13. The method of claim 12 , wherein the blank has score lines for forming the pleats.
14. The method of claim 1 , wherein the container is one of a plate or a tray.
15. The method of claim 1 , wherein forming the denesting feature and forming the flange further comprise positioning the first surface to extend directly from an inner surface of the sidewall so that the first surface is nonparallel with the inner surface.
16. The method of claim 1 , wherein the denesting feature further comprises an upper portion of the sidewall that is thicker than a lower portion of the sidewall, the inner peripheral portion of the flange extending directly from the upper portion of the sidewall.