Abstract:
A packaging article for protectively storing perishable paper products that includes protective materials that protect the packaging article and its contents from any of a number of threats including water damage, fire damage, mold, insects, bacteria, fungi and theft. The packaging article comprises a bottom wall, side walls and a closure that surround and define an interior cavity in which the paper products are stored or transported. Each of the bottom wall, side walls and closure are made from a plurality of layers. Protective materials are applied to one or more of the bottom wall, side walls and closures by either impregnating a paper or cardboard with a suitable chemical, applying a film thereover, spraying a coating thereover or sandwiching the protective material between two adjacent layers. Suitable chemicals that produce the desired properties include, but are not limited to wax, oil, plastic, polybrominated diphenyl ether, polybrominated biphenyl, brominated cyclohydrocarbons, boric acid and hydrogen peroxide. A radio frequency identification tag may also be received within the wall of the packaging article to protect the same against theft.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of U.S. patent application Ser. No. 11/703,966, filed Feb. 8, 2007, the entire specification of which is incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
     TECHNICAL FIELD 
       [0002]    This invention generally relates to storage and transportation materials. More particularly, the invention relates to mailing and storage boxes and envelopes. Specifically, the invention relates to boxes and envelopes that are made of a plurality of different layers that have protective materials incorporated therein or applied thereto to protect the article from a variety of different threats. 
       BACKGROUND INFORMATION 
       [0003]    Offices and individuals frequently need to store materials such as files and papers for long periods of time. Typically, these materials are placed in some sort of storage box for safekeeping. These boxes may take a variety of forms including plastic tubs or corrugated cardboard boxes with lids. Plastic tubs are convenient and protect the materials stored therein from dangers such as liquid exposure, but can be relatively expensive if large volumes of materials need to be stored. Cardboard boxes on the other hand are inexpensive and convenient, but they are vulnerable to dangers such as water damage, fire, insects and mold. 
         [0004]    There is therefore a need in the art for an improved corrugated cardboard box that is less vulnerable to threats that may damage the contents of the box. 
       SUMMARY OF THE INVENTION 
       [0005]    The device of the present invention comprises a packaging article for protectively storing perishable paper products that includes protective materials that protect the packaging article and its contents from any of a number of threats including water damage, fire damage, mold, insects, bacteria, fungi and theft. The packaging article comprises a bottom wall, side walls and a closure that surround and define an interior cavity in which the paper products are stored or transported. Each of the bottom wall, side walls and closure are made from a plurality of layers. Protective materials are applied to one or more of the bottom wall, side walls and closures by impregnating a paper or cardboard layer with a suitable chemical, applying a film thereover, spraying a coating thereover or sandwiching the protective material between two adjacent layers. Suitable chemicals that produce the desired properties include, but are not limited to wax, oil, plastic, polybrominated diphenyl ether, polybrominated biphenyl, brominated cyclohydrocarbons, boric acid and hydrogen peroxide. A radio frequency identification tag may also be received within the wall of the packaging article to protect the same against theft. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    The preferred embodiments of the invention, illustrative of the best mode in which applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims. 
           [0007]      FIG. 1  is a perspective view of a corrugated cardboard box known in the prior art; 
           [0008]      FIG. 2  is a cross-sectional top view through line  2 - 2  of  FIG. 1 ; 
           [0009]      FIG. 3  is a perspective view of a corrugated cardboard box in accordance with the present invention; 
           [0010]      FIG. 4  is a cross-sectional top view of a first embodiment of a side wall taken through line  4 - 4  of  FIG. 3 ; 
           [0011]      FIG. 4A  is a cross-sectional, top view of a second embodiment of the side wall of the storage box of  FIG. 3 ; 
           [0012]      FIG. 4B  is a cross-sectional top view of a third embodiment of the side wall of the storage box of  FIG. 3 ; 
           [0013]      FIG. 4C  is a cross-sectional top view of a fourth embodiment of the side wall of the storage box of  FIG. 3 ; 
           [0014]      FIG. 5  is a cross-sectional top view of a fifth embodiment of the side wall of the storage box of  FIG. 3 ; 
           [0015]      FIG. 6  is a cross-sectional top view of a sixth embodiment of the side wall of the storage box of  FIG. 3  and showing the incorporation therein of a security tag; 
           [0016]      FIG. 7  is a perspective view of a mailing envelope in accordance with the present invention; 
           [0017]      FIG. 8  is a cross-sectional top view of the mailing envelope taken through line  8 - 8  of  FIG. 7  and showing the structure of the front wall of the envelope; 
           [0018]      FIG. 8A  is a cross-sectional top view of a second embodiment of the front wall of the envelope; 
           [0019]      FIG. 8B  is a cross-sectional top view of a third embodiment of the front wall of the envelope; and 
           [0020]      FIG. 9  is a cross-sectional top view of a fourth embodiment of the front wall of the envelope showing the incorporation therein of a security tag. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]      FIGS. 1 and 2  show a corrugated cardboard box  10  known in the prior art. Box  10  has a bottom wall (not shown) and four side walls  12  that define an interior cavity  14  for holding a plurality of files or papers  16 . A lid  18  is provided for closing off access to cavity  14 . Lid  18  may take any one of a number of different forms, such as four panels as shown in  FIG. 1 , or a single panel (not shown) or a completely separate lid unit (not shown). The bottom wall, side walls  12  and lid  18  are all made from corrugated cardboard. As shown in  FIG. 2 , the side wall  12  comprises two planar sheets  20 ,  22  which sandwich a corrugated cardboard sheet  24  thereinbetween. The cardboard used in box  10  is vulnerable to water damage, fire damage, may permit mold to grow thereon if it is subjected to high moisture environments and is susceptible to paper-eating insets such as silverfish and the like. 
         [0022]      FIGS. 3-5  show a storage box in accordance with the present invention and generally indicated at  50 . Box  50  is similarly formed to box  10  in that it has a bottom wall (not shown), side walls  52  that surround and define an interior cavity  54  for holding a plurality of files or papers  56  therein. A lid  58  is provided for closing off access to cavity  54 . Lid  58  shown in  FIG. 3  comprises four panels that are secured together with an adhesive tape of the like. It will be understood by those skilled in the art that the shape, size and configuration of box  50 , as shown in the attached drawings, is by way of illustration only. Any shape, size and configuration of the box and lid may be used without departing from the spirit of the present invention. 
         [0023]    In accordance with a specific feature of the present invention, each of the bottom wall, side walls  52  and lid  58  of box  50  are manufactured from a corrugated cardboard that has been specially treated with one or more of several protective materials as will are hereinafter described. 
         [0024]    Referring to  FIG. 4 , there is shown a portion of side wall  52  comprising a first and a second planar sheet  60 ,  62  of cardboard which sandwich a corrugated sheet  64  of cardboard thereinbetween. It will be understood by those skilled in the art, that the bottom wall, side walls  52  and lid  58  of box  50  may be made up from any number of a plurality of planar and corrugated sheets that are layered and bonded together to form a unitary member of the required strength, without departing from the spirit of the present invention. The following illustrations show a box wall  52  made from two planar sheets and one corrugated sheet for the sake of clarity only.  FIG. 4  illustrates a first embodiment of the side wall  52  in which one or more of sheets  60 ,  62  and  64  are impregnated with a protective material as will be hereinafter described. 
         [0025]      FIG. 4A  shows a second embodiment of side wall  152  that includes layer of protective material  166  therein. In this instance, layer  166  is applied over second sheet  162  and, because second sheet  162  forms the exterior surface of side wail  152 , protective layer  166  forms the external surface of the storage box. 
         [0026]    Referring to  FIG. 4B , there is shown a third embodiment of a side wall of the box, being generally indicated at  252 . Side wall  252  comprises first and second planar sheets  260 ,  262  of cardboard which sandwich a corrugated layer  264  thereinbetween. Protective layer  266  is applied over first sheet  260  and thus forms the interior surface of the box in accordance with the present invention. 
         [0027]    Referring to  FIG. 4C , there is shown a fourth embodiment of a side wall for the box, being generally indicated at  352 . Side wall  352  comprises first and second planar sheets  360 ,  362  of cardboard which sandwich a corrugated layer  364  thereinbetween. A first protective layer  366  is applied over sheet  362  and a second protective layer  368  is applied over sheet  360 . The protective layers  366 ,  368  therefore form both the exterior and interior surfaces of the box. 
         [0028]    Referring to  FIG. 5 , there is shown a fifth embodiment of a side wall for the box, being generally indicated at  452 . Side wall  452  comprises first and second planar sheets  460 ,  462  of cardboard which sandwich a corrugated layer  464  thereinbetween. A protective layer  466  is applied over second sheet  462  and another planar sheet of cardboard  470  is applied over protective layer  466 . Thus, protective layer  466  is sandwiched between two layers of untreated cardboard. 
         [0029]    Referring to  FIG. 6 , there is shown a sixth embodiment of a side wall for the storage box, being generally Indicated at  552 . Side wall  552  comprises first and second planar sheets  560 ,  562  of cardboard which sandwich a corrugated layer  564  thereinbetween. A protective layer  566  is applied over second sheet  562 . In accordance with another specific feature of the present invention, side wall  552  further incorporates an RFID (Radio Frequency Identification) tag  580 . Tag  580  is sandwiched between corrugated layer  564  and planar sheet  562 . Tag  580  may be used to rapidly locate a particular storage box. Tag  580  may also be used as a security device to set off an entryway alarm if the box is removed from a storage facility by unauthorized personnel. In this way, tag  580  is incorporated as a protective material against the threat of theft. 
         [0030]    In accordance with one of the specific features of the present invention, one or more layers of the bottom wall, side walls  52  and lid  58  of box  50  include protective materials that impart improved protective properties to the storage box  50 . In a first instance, shown in  FIG. 4 , any or all of sheets  60 ,  62  and  64  may be impregnated with a protective material. Thus, any and all of sheets  60 ,  62  and  64  constitute a protective layer of box  50 . 
         [0031]    With reference to  FIGS. 4A-6 , the protective layer will be referred to in the following description as layer  66  for the sake of clarity, but it will be understood that any and all of the protective layers  66 ,  68  through to  466  includes one or more protective materials that impart improved protective properties to the storage box. Protective layer  66  may be one of a planar or corrugated sheet of cardboard that is impregnated with the protective material. Alternatively, protective layer  66  may comprise a film that is bonded onto a planar sheet of cardboard. Furthermore, protective layer  66  may constitute a separate thin film. Finally, protective layer  66  may constitute a powder or liquid coating that is sprayed or otherwise deposited onto one of the sheets in the box. 
         [0032]    The protective layer  66  may constitute cardboard that is impregnated with a chemical that renders that layer water impervious or water repellant. The chemical may render the layer fire resistant or fire retardant. The chemical may be a fungicide that prevents mold from growing, or a pesticide that kills insects such as silverfish or that repels such insects because of an odor or taste associated therewith. A wide variety of chemicals are known to produce these properties, but have not been previously applied to corrugated cardboard or have not been applied in combination with each other to cardboard. So, for instance, a wide variety of chemicals and chemical components may be used for these purposes. These include, but are not limited to, a wax, or an oil may be impregnated into the layer, or a plastic film may be used to create a water repellant or resistant layer. Chemicals such as aluminum hydroxide and diammonium phosphate, polybrominated diphenyl ether, polybrominated biphenyl or brominated cyclohydrocarbons can be sprayed or otherwise applied to a one of the layers  60 ,  62  or a separate cardboard sheet in order to create a fire retardant layer. Boric acid or hydrogen peroxide may be used in layer  66  to act as a pesticide or fungicide. So, for example, in  FIG. 4 , one or more of sheets  60 ,  62  and  64  may be impregnated with a suitable insecticide to repel insects such as silverfish from box  50 . Or, in  FIG. 4A , layer  166  of a suitable fire-retardant chemical may be applied over the outer sheet  162  of the box. Or, in  FIG. 4B , a fungicide may be applied as layer  268  over the interior sheet  260  of the box. Or, in  FIG. 4C , layer  366  may be a suitable water repellant and layer  368  may be a fire retardant. Or, in  FIG. 5 , a fire-retardant layer  466  may be sandwiched between two sheets  462 ,  470  of cardboard. 
         [0033]    It will be understood by those skilled in the art that one or more or all of these and other chemical compounds may be applied to the cardboard in one or more layers in order to protect the box from one or more of water, fire, insects and mold. Furthermore, any other chemical or substance may be applied to the interior or exterior of box  50 , or may be impregnated into the cardboard layers thereof in order to give the materials thereof the protective qualities that are desired. 
         [0034]      FIGS. 7-9  illustrate a mailing envelope in accordance with the present invention and being generally indicated at  700 . Envelope  700  comprises a pouch  702  and a flap  704 . Flap  704  includes an adhesive layer  706  over which a protective paper cover (not shown) is applied. The paper cover is removed from layer  706  when the envelope  700  has been stuffed and is to be closed. Flap  704  is folded over into abutting contact with wall  710  and adhesive layer  706  secures flap  704  to wall  710 . Preferably, both the pouch  702  and flap  704  incorporate protective materials therein. The protective materials are applied therein to secure the envelope  700  against threats such as fire, water, insects, mold, fungi, bacteria and theft. 
         [0035]    In accordance with one of the specific features of the present invention, walls  710  and  712  are manufactured from a plurality of layers. One or more of those layers include materials that impart protective properties to envelope  700 . Walls  710  and  719  may be integrally formed or may be secured together in some suitable manner. Walls  710  and  712  surround and define an interior cavity  714  into which the articles to be mailed are placed. 
         [0036]      FIG. 8  shows a first embodiment of the structure of wall  710 . Wall  710  comprises a first layer  716 , a second layer  718  and a third layer  720 . First layer  716  may be manufactured from any material, such as a paper or cardboard product. Second layer  718  is applied onto a first surface of first layer  716 . Second layer  718  is manufactured from a plastic blister-type material and is thus waterproof. Second layer  718  additionally provides cushioning for the articles retained within the cavity  714 . Third layer  720  is applied to a second surface of first layer  716 . Third layer  720  is provided to protect first layer  716  from a different threat to that of second layer  718 . So, for instance, third layer  720  may include a fungicide or a fire-retardant material. As previously described in relation to the storage box, if first layer  716  is a paper product, a protective material may be impregnated directly into that layer. Second and third layers  718 ,  720  may be applied as a film or sprayed onto first layer  716 . The structure of wall  710  is shown by way of illustration only. Any suitable layering of different materials may be utilized to protect the articles within pouch  702  from a variety of different threats such as water damage, fire damage, mold, bacteria, fungi, insects and theft. 
         [0037]      FIG. 8A  shows a second embodiment of a possible structure of the envelope wall, said wall being generally indicated at  810 . Wall  810  again is made up from a first layer  816 , a second waterproof blister-type layer  818  and a third layer  820 . In this instance, third layer  820  is applied onto second layer  818  instead of onto the first layer  816 . Third layer  820  may include a fire-retardant that protects the blister type second layer  818  from melting. 
         [0038]      FIG. 8B  shows a third embodiment of the possible structure of the envelope wall, being generally indicated at  910 . Again, wall  910  comprises a first layer  916 , a plastic blister-type material second layer  918  applied to a first surface of first layer  916 , a third layer  920  applied to a second surface of first layer  916 , and a fourth layer  922  applied to a second surface of the second layer  918 . Again, each one of the first, second, third and fourth layers  916 - 922  provides protection against a different threat. 
         [0039]    Finally,  FIG. 9  shows a fourth embodiment of the structure of the envelope wall being generally indicated at  1110 . The structure of wall  1110  is substantially identical to that of the first embodiment  710  thereof, with the exception that the wall includes a pouch  1112  that surrounds and retains an RFID tag  1114  therein to protect envelope  700  from the threat of theft. 
         [0040]    As with the storage box, the protective layers in envelope  700  may be impregnated into the material of the layer, applied as a film, applied as a spray coating or may be sandwiched between the various layers within envelope  700 . 
         [0041]    In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. 
         [0042]    Moreover, the description and illustration of the invention are an example and the invention is not limited to the exact details shown or described.