Abstract:
A box folded from a single cardboard sheet includes two handle members incorporated into the cardboard sheet. The box includes a first handle member removably attached near a top panel of the enclosure portion of the box, and a second handle member removably attached to the rear panel of the box. When the cardboard sheet is folded to assemble the box, the first handle member and second handle member come together in an overlaying configuration to form a box handle. Holes in the handle members form structure through which users may insert their fingers for carrying the box, and a perforated area, allows the handle to be easily separated from the box leaving a flap to overlay or be tucked in the box.

Description:
[0001]    This application is a continuation-in-part of, and claims the benefit of the priority filing date of application Ser. No. 13/869,867, filed on Apr. 24, 2013, which claims the benefit of the priority date of provisional application No. 61/638,156, filed on Apr. 25, 2012. 
     
    
     BACKGROUND 
       [0002]    Blister packaging for small electronics goods is well known. One type of such display packaging consists of a pair of corrugated cardboard sheets joined together with a clear PVC plastic insert showing the product, and is popular with manufacturers and consumers. Consumers can see the product when contemplating a purchase, and for manufacturers the double cardboard layer package is rugged for protecting the product during shipping, and the sealed edges provide tamper resistance. See, for example, Nazari, U.S. Pat. No. 7,726,480. 
         [0003]    There are environmental concerns with this popular type of packaging, however, as the cardboard and plastic portions are individually recyclable but must be separated for recycling. Even if designed to be separable, most consumers fail to make the effort. This is because the packaging is typically difficult to open and so consumers resort to using a knife or scissors to cut the plastic portion and extract the product, leaving the plastic and cardboard together upon disposal. Accordingly, a better package is needed for displaying the product in a tamperproof fashion and that is environmentally friendly, as well as inexpensive to make. 
         [0004]    Another issue with blister packaging for consumer products, having two sheets of corrugated cardboard and a clear plastic container sandwiched between them, is that this type of conventional packaging uses hot melt glue typically applied by hand and difficult to control due to the drying time and placement of the glue. Also, the corrugated sheets of the cardboard are visible on the side edges of the finished packaging which is aesthetically unappealing. 
         [0005]    Other conventional blister packaging uses one sheet of corrugated cardboard and one or two flat sheet of paper, adhered together by adhesive. Since only one cardboard sheet is used, this type of packaging sometimes lacks sufficient structural strength when multiple display packs are stood on their sides in a container. When the weight of the top package is supported directly by the packs in the bottom bundle, they must have sufficient structural strength and rigidity to prevent them from bending. 
         [0006]    Folding cardboard boxes are known in the art, including folding display cardboard boxes made of a single cardboard sheet. Displays of these types of packages may be stacked, but are typically hung on pegs or similar display structures for ease of installation and retrieval by users. One benefit of hanging packaging of this type is that a handle may be incorporated into the package, allowing a user to easily carry it after purchase, obviating the need for a bag. 
         [0007]    One example of this type of packaging was disclosed in U.S. patent application Ser. No. 13/869,867 for a Display Cardboard Folded Package with Periphery Sealed Edges, of which this application is a continuation-in-part. A manufacturing benefit of such packaging is that it can be easily constructed from a single cardboard sheet. Although formed by a single sheet, product packaging must be able to function as an attractive container for a product prior to purchase, and should ideally be able to serve as a container for a product for storage and other purposes alter purchase. 
         [0008]    Notably, the handle portion of this type of folding packaging, frequently becomes superfluous once the package is brought home from a store. Additionally, the handle makes the package difficult to manage since it presents a physical obstacle when trying to organize or arrange multiple packages tightly together. For this reason, there is a need for a folding display package made from a single sheet of cardboard, which has a handle for displaying and carrying the package, but which also may be removed to form a conventionally shaped box. 
       SUMMARY 
       [0009]    A package for a product includes a single sheet having one side with an image of the product printed thereon and an opposing blank side. The sheet is foldable into a shell having a rear opening, and the shell is sized to receive the product inside the shell through the opening. The shell has a front panel with an image of the product. The sheet further includes a top panel next to the shell, a rear panel to cover the shell, and the shell has outer edges adhered to outer edges of the rear panel, so that the product may be placed inside the shell and is sealed inside the package. The package has crushed edges around a majority of the perimeter of the package. 
         [0010]    In various embodiments, the rear panel may extend to cover the top panel. The sheet s preferably made of corrugated cardboard, including a cut-out in the top panel corresponding to a cut-out the rear panel, for forming a handle for the package. Preferably the sheet includes a crushed area between the outer edges of the shell and the outer edges of the rear panel. 
         [0011]    To create the shell, the foldable sheet includes a first set of opposing side panels and a second set of opposing side panels adjoining a front panel, the front panel bearing an image of the product. The second set of opposing side panels includes tabs disposed distally from the front panel, and when the sheet is folded such that the tabs and the top panel align with the rear panel to form a common peripheral edge, an enclosure for the product is formed. 
         [0012]    To form the package, a single sheet of foldable material is provided and an image of the product printed on only one side of the sheet. The sheet is folded to create a shell sized to hold the product and a top panel, and folded to create a rear panel for enclosing the shell and covering the top panel. The outer edges of the rear panel are adhered to corresponding outer edges of the top panel and the outer edges of the shell, and the outer edges are crushed. A product may be inserted into the shell prior to the adhering the outer edges together, and adhesive may be applied between the rear panel and the top panel inward of the outer edges. To form a handle for hanging or carrying, holes may be formed in the top panel and correspondingly through the rear panel. 
         [0013]    In another embodiment, a box for a product is made from a single sheet of corrugated cardboard foldable into an enclosure with a rear opening. The enclosure is sized to receive the product through the rear opening, and the product may be arranged and visibly seen through a window formed in the box. The window can be of clear cellophane or a similar plastic material, or in some embodiments omitted altogether. The sheet of corrugated cardboard is also foldable into a rear panel for covering the rear opening, thereby forming a complete and sealable enclosure. 
         [0014]    For displaying the box in an attractive manner and to conveniently carry the box, a series of handle members are incorporated into the cardboard sheet. The enclosure includes a first handle member removably attached, near a top panel of the enclosure, and the rear panel includes a second handle member removably attached to the rear panel. When the cardboard sheet is folded, the first handle member and second handle member come together in an overlaying configuration to form a box handle. Holes in the handle members form a structure through which users may insert their fingers for carrying the box. 
         [0015]    The first handle member and second handle member are attached to the enclosure and rear panel, respectively, by a perforated area, allowing them to be easily separated. The first handle member is attached to the top of the box so that by pulling it away from the box, a clean line of separation is created at the edge of the enclosure. In contrast, the second handle member is attached to the rear panel so that when second handle is removed, a flap overhanging the enclosure is created. In this manner, when the handle is removed, the flap may be tucked into the enclosure so that no part of the cardboard sheet extends away from the box. 
         [0016]    In various embodiments, the outer edges between the first handle member and second handle member may be crushed and glued together. Also, the enclosure may be crushed at the edge of the window. Since the flap, once tucked into the enclosure, may make opening the rear panel difficult, the rear panel may include a finger hole for pulling open the package. 
         [0017]    To create the box with a removable handle, a single sheet of foldable material is first obtained. The sheet is preferably die-cut into a predetermined shape having fold lines for creating the enclosure, including various flaps for forming the enclosure in a desired shape, and a rear panel which may have side flaps. Using the flaps and fold lines, an enclosure and a roar panel are created. At this stage a product may be introduced into the box. 
         [0018]    A first handle member is attached to the enclosure, and a second handle member is attached to the rear panel. These handle members are overlaying, sized to have a common periphery, and when brought together form the completed handle. Ideally, holes formed in the handle members come together to form a single hole for accommodating a user&#39;s fingers. Preferably, the handle members are formed on top of the box for hanging and carrying. 
         [0019]    In order to make the handle removable, perforations are formed along as line between the enclosure and the first handle member, and along a line between the second handle member and rear panel. The perforations alone the second handle member are formed such that when removed, the second handle member leaves a flap overhanging the enclosure. In one embodiment, the perforations may end at the hole in the handle for ease of removal and to create a clean line. 
         [0020]    Preferably, once the product is inserted into the enclosure and the box closed, the handle members are adhered together. To aid in adhering the handle members together, an adhesive may be applied between the handle members, including around the peripheral edges of the handle members. In this manner, the peripheral edges of the handle may be crushed to form a tamper-resistant and attractive display package. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0021]      FIG. 1  is a plan view, flat pattern of the printed side of a cardboard sheet. 
           [0022]      FIG. 2  is a perspective view of the blank, side of the cardboard sheet. 
           [0023]      FIG. 3  is a perspective view of the cardboard sheet folded into a package. 
           [0024]      FIG. 4  is a partial cross-section view through the side of the package. 
           [0025]      FIG. 5  is a perspective front view of a box having a detachable handle. 
           [0026]      FIG. 6  is a perspective rear view of a box having a detachable handle. 
           [0027]      FIG. 7  is a perspective view of a box with a detachable handle in an open configuration. 
           [0028]      FIG. 8  is a perspective view of a box with a detachable handle, with the front tab being removed. 
           [0029]      FIG. 9  is a perspective view of a box with a detachable handle, with the rear tab being removed. 
           [0030]      FIG. 10  is a perspective front view of a box with the handle removed. 
           [0031]      FIG. 11  is a perspective rear view of box with the handle removed and a flap inserted into the enclosure to close the box. 
           [0032]      FIG. 12  is a perspective rear view of the box with the handle removed and a flap inserted over the top of the enclosure. 
       
    
    
     REFERENCE NUMERALS 
       [0000]    
       
           10 . Package 
           12 . Foldable Sheet 
           14 . Graphic Representation of a Product 
           18 . Tabs 
           20 . Cut-Out Portion 
           27 . Printed Side 
           24 . Top Panel 
           26 . Front Panel 
           28 . First Side Panel 
           30 . Second Side Panel 
           32 . Third Side Panel 
           34 . Fourth Side Panel 
           36 . Flap 
           40 . Indented Fold Lines 
           44 . Rear Panel 
           50 . Blank Side 
           52 . Peripheral Edge 
           54 . Crushed Area 
           110 . Box 
           112 . Handle 
           114 . Front Tab 
           116 . Rear Tab 
           118 . Hole 
           120 . Window 
           122 . Perforations 
           124 . Crease Line 
           126 . Top Panel 
           128 . Flap 
           130 . Sides 
           132 . Top Edge 
           134 . Finger Hole 
           136 . Enclosure 
           138 . Wall Portion 
           140 . Anchor Portion 
           142 . Lid Portion 
           144 . Central Panel 
           146 . Side Flaps 
           148 . Indicia 
       
     
       DESCRIPTION 
       [0071]      FIG. 1  is a plan view of a foldable sheet  12 , showing the printed side  22  of the foldable sheet. The foldable sheet  12 , which is preferably made of cardboard, but may be made of any substantially flat foldable material, includes a front panel  26  and four side panels  28 ,  30 ,  32  and  34 , referred to as first through fourth side panels, respectively. Flaps  36  are attached to the four side panels  28 ,  30 ,  32  and  34  to prevent gaps when the foldable sheet  12  is folded. In the illustrated embodiment, tour side flaps  36  are attached to opposite ends of the second side panel  30  and fourth side panel  34 , which are themselves on opposite sides of the front panel  26 . In other embodiments, the flaps  36  may be disposed on opposite sides of the first side panel  2 $ and third side panel  32 , or a single flap  36  may be disposed on each of the four side panels  28 ,  30 ,  32  and  34  as desired. 
         [0072]    Still referring to  FIG. 1 , the first side panel  2 $ and third side panel  32  each have a tab  18  affixed opposite the front panel  26 . The second side panel  30  has a rear panel  44  affixed opposite the front panel  26 , and the fourth side panel  34  has a top panel  24  affixed opposite the front panel  26 . Preferably, the foldable sheet  12  may be creased, or otherwise constructed such that the front panel  26 , side panels  28 ,  30 ,  32  and  34 , flaps  36 , tabs  18 , rear panel  44  and top panel  24  tend to fold along predetermined indented fold lines  40 , which govern the shape of a package (not shown) formed from the foldable sheet  12 . 
         [0073]      FIG. 2  shows a perspective view of the blank side  50  of the foldable sheet  12  in preparation for folding. In order to form a package lot shown), the side panels  28 ,  30 ,  32  and  34  are folded relative to the front panel  26  to have a shell-like appearance, with the flaps  36  folded inward of the side panels  28 ,  30 ,  32  and  34 , as shown. The rear panel  44  may then be folded over to engage the tabs  18  and top panel  24 . In this manner, the blank side  50  of the foldable sheet  12  always forms the interior of a package (not shown), while the printed side  22  of the foldable sheet  12  always forms the exterior of a package. 
         [0074]      FIG. 3  is a perspective view of the foldable sheet  12  fully assembled into a sealed package  10  with a graphic representation of a product  14 . When the foldable sheet  12  is folded together to form a package  10 , the shell-like structure formed by the front panel  26 , side panels  28 ,  30 ,  32  and  34 , the tabs  18  and the top panel  24  form a uniform peripheral edge  52 . The peripheral edge  52  may be characterized as an area extending from the extreme edge of the foldable sheet  12  approximately a half an inch inward from the extreme edge. Additionally, cut-out portions  20  on the sheet  12  (shown in  FIGS. 1 and 2 ) may align to form a handle for hanging or carrying the package  10 . Since the printed side  22  of the sheet  12  is on the exterior of the package  10 , it may show graphics  14 , including images of items enclosed by the package  10 . 
         [0075]      FIG. 4  shows a cross section view through the side of the package  10  of  FIG. 3 . Once a product (not shown) is packaged inside an assembled package  10 , a crushed area  54  may be formed inward of the peripheral edge  52 . The crushed area  54  may comprise an adhesive (not shown) to facilitate sealing of the package  10 , and the adhesive may also extend beyond the crushed area  54  depending on the amount of adhesion desired. By heat seal coating the crushed area  54  prior to applying heat and pressure, the peripheral edge  52  may sealed to provide a tamper-resistant package  10  along with an attractive peripheral edge  52  of minimal thickness. 
         [0076]    Typically adhesive (not shown) should be strong enough so the package  38  will stay sealed in transit and while hanging on a peg (not shown), but weak enough so that it can be opened by a consumer. Additionally, a variety of sealants are contemplated, including heat seal, cold seal, glue, etc. Preferably, the foldable sheet  10  is entirely made of recyclable and recycled cardboard. With a graphic  14 , including a photograph or image of the product printed on the package  10 , customers can see what they&#39;re buying before the purchase occurs. 
         [0077]    Referring to  FIGS. 5-11 , another embodiment of the folding package is shown having a removable handle. 
         [0078]    Referring to  FIG. 5 , a box  110  formed from a single Sheet: of cardboard includes a handle  112  formed from a front tab  114  and a rear tab  116 . The front tab  114  and rear tab  116  are complimentary and arranged in an overlaying pattern, so that when the box  110  is assembled, a hole  118  for accommodating a user&#39;s fingers (not shown) is formed. The handle  112  is also adapted to allow the box  110  to be hung so that items (not shown) contained in the box  110  can be seen through a window  120  incorporated into the box. Also visible in  FIG. 1  are a series of perforations  122  that allow a user to remove the front tab  114 , disposed along a crease line  124  between the front tab  114  and top panel  126  of the box  110 . In one embodiment, the peripheral edge formed by the front tab  114  and rear tab  116  may be crushed to present a tamper resistant and attractive appearance. 
         [0079]    Referring to  FIG. 6 , the box  110  is shown from behind so that the rear tab  116  is visible. In this view, perforations  122  along the rear tab  116  show where the rear tab  116  is removed from the box  110 . Notably, perforations  122  on the rear tab  116  do not run along a crease line  124  (see,  FIG. 1 ). Rather, the perforations  122  on the rear tab  116  form a pattern for creating a flap  128 . 
         [0080]    The flap  128  pattern preferably includes two sides  130  that encroach into the rear tab  116 , and a top edge  132  running substantially the length of the rear tab  116 . Also, in one embodiment, the bottom of the hole  118  is incorporated into the flap  128  pattern, avoiding the need for perforations  122  along the entire flap  128 . Also shown in  FIG. 6  is a finger hole  134 , which is created by a circular perforated area and may be punched out and used as a manner of opening and closing the box  110  once the front tab  114  and rear tab  116  are removed. 
         [0081]    Referring to  FIG. 7 , the box  110  is shown in an open configuration. In this view, the single panel construction of the box  110  is evident. An enclosure  136  of the box  110  is formed by a series of wall portions  138  and anchor portions  140 , and includes the window  120 . The front tab  114  is attached to the enclosure  136  along a common edge bearing perforations  122  in this manner, when the front tab  114  is removed along the perforations  122 , the enclosure of the box  110  remains intact. 
         [0082]    Still referring to  FIG. 7 , the box  110  includes a lid  142 . The lid  142  includes a central panel  144  hingedly attached to the enclosure  136  thereby forming a rear opening. The central panel  144  also includes side flaps  146  and the rear tab  116  is incorporated into it between them. Also visible on the central panel  144  are the perforations  122  that allow the rear tab  116  to be removed by a user. As shown, the perforations  122  are arranged to create a flap  128  which remains after the rear tab  116  is removed. After removal, the flap  128  may be creased relative to the remaining portion of the lid  142  to create a hinged connection for tucking the flap  128  into the closed box  110 . 
         [0083]    Referring to  FIGS. 8 and 9 , a user adapting the box to a handle-less configuration is shown. In order to remove the handle  112 , a user preferably holds the box  110  in one hand and tears off the front tab  114  along the perforation  122 . Removing the from tab  114  creates a clean break along the crease line  124  between the front tab  114  and top panel  126  of the enclosure  136 . Once the front tab  114  is removed, the user then tears off the rear tab  116  along the perforation  122 . Removing the rear tab  116  creates a flap  128 , which can be folded and tucked into the box  110 . Also, to aid in removing, the rear tab  116 , the perforations may run into the handle  112 , thereby creating a portion that simply pulls away from the box  110 . Also removal of the tabs may be done in any order, or simultaneously as desired. 
         [0084]    Referring to  FIG. 10 , a front view the box  110  with the handle (not shown) removed is shown. Once the front tab  114  (not shown) and rear tab  116  not shown) are removed, the flap  128  remains as a portion of the central panel  144 , which is visible through the window  120 . Referring to  FIG. 11 , with the front tab  114  and rear tab  116  removed, the flap  128  may be folded relative to the central panel  144  and tucked into the box  110 . With the flap  128  and side flaps  146  (not shown) tucked into the box, they hold the central panel  144  against the enclosure  136 , thereby creating a traditional six-sided box, which is suitable for convenient storage and stacking with other, similarly sized boxes.  FIG. 12  shows an alternative embodiment wherein the flap  128  is folded over the enclosure. To hold the box closed in this embodiment, the flap  128  may include an adhesive (not shown). 
         [0085]    In order to open the box, a user may puncture the central panel  144  with a finger to create a finger hole  134  at the perforations  122 . In this manner the box may be easily opened and closed for future use. In one embodiment, the box  110  may have indicia  148  printed on its exterior. Since the box  110  is foldable from a single sheet of cardboard, it may be printed on a single side, avoiding the expense of printing on both sides. 
         [0086]    The foregoing description of the preferred embodiment of the Invention is sufficient in detail to enable one skilled in the art to make and use the invention. It is understood, however, that the detail of the preferred embodiment presented is not intended to limit the scope of the invention, in as much as equivalents thereof and other modifications which come within the scope of the invention as defined by the claims will become apparent to those skilled in the art upon reading this specification.