# US 8,464,894 B2 · Injection-molded composite construct and tool for forming construct > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,464,894 B2 - Document ID: US8464894B2 - Status: Granted - Kind: B2 - Application number: 12/822,591 - Filed: 2010-06-24 - Published: 2010-12-09 - Granted: 2013-06-18 - Earliest claimed: 2007-12-28 - Assignees: Graphic Packaging International, Inc. - Applicants: Brian R. O'Hagan; Phil Netzer; Bruce Barnard; Peter W. Blaas; Kevin J. Hjort - Inventors: Brian R. O'Hagan; Phil Netzer; Bruce Barnard; Peter W. Blaas; Kevin J. Hjort - Web page: https://patentgrep.com/patent/US8464894B2 ## CPC - B29C 45/14475: {Joining juxtaposed parts of a single article, e.g. edges of a folded container blank} - B29C 45/0046: {Details relating to the filling pattern or flow paths or flow characteristics of moulding material in the mould cavity} - B29C 45/2602: {Mould construction elements} - B29D 22/003: {Containers for packaging, storing or transporting, e.g. bottles, jars, cans, barrels, tanks} - B65D 5/209: {the adjacent edges of folded-up portions being joined by moulding seams in situ} - B29K 2105/20: Inserts - B29K 2711/12: Paper, e.g. cardboard - B29L 2031/712: {Containers; Packaging elements or accessories, Packages (closures therefor B29L2031/56; ink or toner cartridges B29L2031/7678; squeeze tubes B29L2023/20; suitcases B29L2031/7418)} - B29L 2031/7162: {Boxes, cartons, cases} - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - B65D: CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract A structure is injection molded onto a group of panels to form a container. The container has a tray and an injection-molded feature. The tray has a plurality of side panels that extend at least partially around, and at least partially define, a cavity of the container. The tray has a plurality of multi-part flanges with at least one of the multi-part flanges including a lower flange portion and an upper flange portion. The injection-molded feature has band that is injected molded onto the lower flange portion and the upper flange portion. An injection-molded strip extends along and at least partially defines the corner of the container. The strip extends downward from the inner portion of the band in the elongate corner of the container. A tool is also disclosed for forming the container. ## Claims ### Claim 1 A container comprising a tray and an injection-molded feature, the tray comprising: a base panel; a plurality of side panels that extends upwardly from the base panel and extends at least partially around and at least partially defines a cavity of the container; a plurality of multi-part flanges, wherein multi-part flanges of the plurality of multi-part flanges respectively extend outwardly from upper edges of side panels of the plurality of side panels, and wherein at least one of the multi-part flanges includes a lower flange portion that extends outwardly from the upper edge of the respective side panel, an intermediate portion that extends upwardly from an outer edge of the lower flange portion, and an upper flange portion that extends outwardly from the intermediate portion; and the injection-molded feature comprising a band that is injection-molded onto both an upper surface of the upper flange portion, and an upper surface of the lower flange portion, the band comprising an elongate portion that extends outwardly from an edge of the upper flange portion, the elongate portion is an outer portion of the band and the band comprises an inner portion adjacent the upper edge of the respective side panel, the inner portion having a greater cross-sectional area than the outer portion, the side panels at least partially define an elongate corner of the container, the container further comprises an injection-molded strip that extends along and at least partially defines the corner of the container, the strip extends downward from the inner portion of the band in the elongate corner of the container and has a first upper inner corner connecting the inner portion and a second upper inner corner connecting the inner portion, the first upper inner corner has a radius of curvature that is larger than the radius of curvature of the second upper inner corner. ### Claim 2 (depends on 1) The container of claim 1 wherein the inner portion is above the upper surface of the lower flange portion. ### Claim 3 (depends on 2) The container of claim 2 wherein the outer portion is above the upper surface of the upper flange. ### Claim 4 (depends on 1) The container of claim 1 wherein the band comprises a flat upper surface, the flat upper surface of the band comprises an upper surface of the inner portion and an upper surface of the outer portion of the band. ### Claim 5 (depends on 1) The container of claim 1 wherein the elongate portion comprises an outer edge of the container, the outer edge of the container extends around the perimeter of the container. ### Claim 6 (depends on 1) The container of claim 1 wherein the strip is adjacent to the inner surface of the side panels in the elongate corner of the container. ### Claim 7 (depends on 1) The container of claim 1 wherein the elongate corner of the container comprises a gap that is defined between at least a portion of an edge of each of the side panels, the strip covers the gap. ### Claim 8 (depends on 1) The container of claim 1 wherein the upper flange comprises a retention portion at the elongate corner of the container, the retention portion being formed by overlapped corner tabs of the side panels. ### Claim 9 (depends on 6) The container of claim 6 wherein the band and the strip comprise an injection-molded structure. ### Claim 10 A blank for forming a container having an injection-molded feature, the blank comprising: a base panel; at least two side panels foldably connected to the base panel, each of the at least two side panels have a respective side panel free edge; a first flange portion foldably connected to a respective one of the at least two side panels and a second flange portion foldably connected to a respective one of the at least two side panels, each of the first flange portion and the second flange portion extends along the length of a respective one of the at least two side panels; a gap is defined between the at least two side panels with the side panel free edge of each of the at least two side panels diverging from a junction of the side panel free edges so the gap becomes wider farther from the junction, the first flange portion has a first corner tab and the second flange portion has a second corner tab, the first corner tab and the second corner tab have a respective corner tab edge that intersects a respective side panel free edge and projects inward to narrow a width of the gap at the outermost edge margin of the blank, the first corner tab and the second corner tab being shaped to facilitate forming the injection-molded feature. ### Claim 11 (depends on 10) The blank of claim 10 wherein the first corner tab has a first length in a longitudinal direction of the blank and the second corner tab has a second length in the lateral direction of the blank. ### Claim 12 (depends on 11) The blank of claim 11 wherein the first length and the second length are substantially equal. ### Claim 13 (depends on 10) The blank of claim 10 wherein the first corner tab and the second corner tab are configured so that the at least a portion of the first corner tab and at least a portion of second corner tab are in an overlapping relationship with respect to one another when the blank is erected into a construct in which the gap is at least partially maintained. ### Claim 14 (depends on 10) A construct erected from the blank of claim 10 and including the injection-molded feature, wherein: the blank has been erected so that the gap has been at least partially maintained, and the first corner tab and the second corner tab are in an overlapping relationship with respect to one another; and a portion of the frame covers the gap.