Abstract:
A shipping carton ( 10 ) is formed from a primary box ( 11 ) and an extension box ( 12 ) adapted to be joined together in a connected position. The primary box ( 11 ) may contain a base product while the extension box ( 12 ) provides room for optional items which may be purchased together with the base product. When joined together in the connected position, the combined boxes provide the unitary shipping carton ( 10 ) which accommodates both the base product and optional items. The extension box ( 12 ) includes at least two stabilizing tabs ( 16, 17 ). The stabilizing tabs ( 16, 17 ) extend from a connecting side ( 32 ) of the extension box ( 12 ) which is adapted to abut a side of the primary box ( 11 ) when the boxes are in the connected position. The stabilizing tabs ( 16, 17 ) function to stabilize the extension box ( 12 ) from lateral movement with respect to the primary box ( 11 ).

Description:
TECHNICAL FIELD OF THE INVENTION 
     This invention relates to product shipping cartons. More particularly, the invention relates to a shipping carton system which provides additional capacity for shipping various related products. The invention encompasses an extension box and a carton system which utilizes the extension box along with a primary box. The invention further encompasses a method for forming a unitary shipping carton. 
     BACKGROUND OF THE INVENTION 
     Many types of products may be customized for a particular consumer and then shipped directly to the consumer. For example, portable computers may be shipped with a number of different accessories such as power supplies, chargers, additional drives, and various software media along with hard copy manuals and documentation. The highly customizable nature of these types of products combined with the practice of shipping products directly to the consumer creates problems in the design of shipping cartons or packages for the products. Ideally, shipping cartons should be as compact as possible in order to save shipping costs and the cost of the carton itself. Also, minimizing shipping carton size is desirable for environmental reasons. 
     One solution to the shipping carton issue for highly customizable products is to design a single carton or box large enough to accommodate any configuration in which the product may be shipped. This solution is wasteful of the material used for the one-size-fits-all box, and wasteful of the material required inside the box for stabilizing the various configurations which may be shipped. 
     Another solution to the packaging problem is to have a different shipping carton for each different product configuration that could be ordered. This solution is, however, expensive both in terms of the number of cartons which must be designed and in terms of the number of cartons which must be held in inventory. Also, it may be difficult to match the appropriate shipping carton with a particular product configuration during or after the product is assembled. 
     Yet another solution for packaging highly customizable products for shipping is to use one small carton for the base product and then completely separate cartons for each optional item which may be purchased along with the base product. However, this solution raises the problem of shipping the resulting multiple cartons to the purchaser and may increase shipping costs. 
     SUMMARY OF THE INVENTION 
     It is an object of the invention to provide a shipping carton system and extension box which overcome the above-described problems and others associated with shipping highly customizable products, particularly computers and related products. Another object of the invention is to provide a method for forming a unitary shipping carton. 
     A shipping carton system according to the invention includes a primary box and an extension box adapted to be joined together in a connected position. The primary box is adapted to contain a base product while the extension box provides room for optional items which may be purchased together with the base product. When joined together in the connected position, the combined boxes provide a unitary shipping carton which accommodates both the base product and optional items. 
     The extension box includes at least two stabilizing tabs. The stabilizing tabs extend from a connecting side of the extension box which is adapted to abut a side of the primary box when the boxes are in the connected position. For example, the two stabilizing tabs may comprise first and second lateral stabilizing tabs which extend parallel to each other from the connecting side of the extension box. The stabilizing tabs may be adapted to extend into tab receiving slots formed on the primary box. Regardless of how the stabilizing tabs are captured on the primary box, the tabs function to stabilize the extension box from lateral movement with respect to the primary box. In the preferred form of the invention, a stabilizing tab is located on each side of the extension box which meets the primary box when the boxes are in the connected position. Also, at least one of the stabilizing tabs is preferably adapted to be captured under major flaps included on the primary box. 
     The extension box includes a container portion which may comprise a complete enclosure for optional items. Alternatively, the container portion may include an open area on the connecting side adapted to abut the primary box when the boxes are in the connected position. When an open area is included on the connecting side of the extension box, the extension box preferably includes at least one stop element. Each stop element presents a surface in the plane of the connecting side of the extension box, and abuts a side of the primary box when the boxes are in the connected position. In this position, each stop element helps resist forces tending to crush the extension box into the side of the primary box. 
     The method for forming a unitary shipping carton according to the invention includes connecting the primary box and extension box with the stabilizing tabs extending into the respective tab receiving slots formed on the primary box. Once the boxes are in the connected position, the method includes applying adhesive tape to secure the two boxes together. This step includes applying tape over a first side of the primary box, across a junction between the two boxes, and over a first side of the extension box. The tape applying step also includes applying tape across a second side of the primary box opposite the first side, across the junction between the two boxes, and across a second side of the extension box. 
     The shipping carton system according to the invention facilitates using a relatively small box for a base product, but allows various optional items to be packaged together with the base product and shipped in a unitary carton. The invention reduces carton materials and inventory. Also, the shipping carton system requires no special taping equipment. The unitary carton may be taped together using the same taping equipment used for the primary box. 
     These and other objects, advantages, and features of the invention will be apparent from the following description of the preferred embodiments, considered along with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an isometric view of a unitary shipping carton embodying the principles of the invention, with adhesive tape shown in phantom. 
     FIG. 2 is an exploded isometric view showing the primary box and extension box which make up the unitary carton shown in FIG.  1 . 
     FIG. 3 is an isometric view of the extension box from a perspective showing the connecting side of the box. 
     FIG. 4 is an isometric view similar to FIG. 2 but showing the extension box in the connected position prior to folding the major flaps of the primary box. 
     FIG. 5 is a plan view of a blank piece of carton material which may be folded into the extension box shown in FIG.  4 . 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIGS. 1 and 2, a unitary shipping carton  10  is formed from two separate boxes, a primary box  11  and an extension box  12 . FIG. 1 shows primary box  11  and extension box  12  in a connected position and taped together with adhesive tape  14  to form carton  10 . Boxes  11  and  12  may be made from any suitable material, and preferably corrugated cardboard or other suitable shipping carton material. Although not limited to any particular use, shipping carton  10  is suitable for shipping customizable products such as portable computers. The base product, that is, the portable computer itself (not shown) may be contained in primary box  11  along with any other components which are always shipped with the base product. Extension box  12  is suitable for containing optional accessories and documentation (not shown). 
     Although the form of the invention illustrated for purposes of example in the figures depicts primary box  11  as being larger than extension box  12  in order to accommodate a base product, the primary box need not be larger, and may in fact be smaller than the extension box. Regardless of the respective size of the two boxes, either box may be adapted to contain a base product and the other box may be adapted to contain optional items for that base product. Also, extension box  12  need not connect to a short side of primary box  11  shown in the illustrated example. Furthermore, the invention is not limited to rectangular shipping cartons. The primary and extension boxes, and the resulting unitary carton may be substantially any shape to fit the desired application. 
     Referring to FIGS. 2 and 3, extension box  12  includes a container portion shown generally at reference numeral  15  and a number of the stabilizing tabs. The illustrated form of the invention includes first and second lateral stabilizing tabs,  16  and  17 , respectively, along with a top stabilizing tab  18  and a bottom stabilizing tab  19 . Although the example of the invention shown in the drawings is preferred, other forms of the invention may include as few as two spaced apart stabilizing tabs. 
     When in the connected position shown in FIG. 1, each stabilizing tab  16 ,  17 ,  18 , and  19  cooperates with primary box  11  to prevent or resist lateral movement between the two boxes, that is, movement in the direction of arrows L shown in FIG.  1 . Primary box  11  preferably includes a separate tab receiving slot for receiving each stabilizing tab extending from extension box  12 . As shown in FIG. 2, the illustrated primary box  11  includes first and second lateral slots  22  and  23 , respectively, for receiving first and second lateral stabilizing tabs  16  and  17  in the connected position. Also, the major flaps  24  at the top of primary box  11  fold down to the top edge  25  of the primary box to define a top slot  26  for receiving top stabilizing tab  18 . Similarly major flaps  28  at the bottom of the primary box  11  fold down to a bottom edge  29  of the primary box to define a bottom slot  30  for receiving bottom stabilizing tab  19 . The connection between the two boxes  11  and  12  will be described further below with reference to FIGS. 1 and 4. 
     As shown in FIG. 3, container portion  15  includes a connecting side indicated generally at reference numeral  32  adapted to abut a side  33  (FIG. 2) of primary box  11  when the boxes are in the connected position. Connecting side  32  includes an open area  34 . Other forms of the invention may include an extension box which forms a complete enclosure with no open side or area such as area  34 . However, open area  34  reduces the material required for extension box  12 . The container portion  15  of extension box  12  combines with side  33  of primary box  11  to form a complete enclosure for materials to be placed in the extension box. 
     In this preferred embodiment, stop elements  36  are included on extension box  12 . Each stop element  36  presents a surface lying in the plane of the connecting side  32  of extension box  12 . Stop elements  36  increase the structural rigidity of extension box  12  and also help prevent extension box  12  from being crushed into the primary box when a force is applied along line F in FIG.  1 . Other fold downs  37  on extension box  12  help increase structural rigidity of the box but do not necessarily provide the resistance to crushing provided by stop elements  36 . 
     Referring still to FIG. 3, the top side of extension box  12  comprises a lid  40  for the extension box which pivots about pivot connection  41 . Top tab  18  is positioned on the side of lid  40  opposite pivot connection  41  and extends from connecting side  32  when the lid is in the closed position shown in FIG.  3 . Also, top tab  18  preferably includes wings  42  which are adapted to cooperate with a receptacle feature  43  on primary box  11  as shown in FIG.  4 . FIG. 4 illustrates that the method for forming carton  10  includes first inserting the lateral and bottom stabilizing tabs  16 ,  17 , and  19  into their respective receiving slots  22 ,  23 , and  30  on primary box  11 . In this position in the illustrated form of the invention, the minor flaps  44  at the top of primary box  11  are closed and extension box lid  40  is closed to insert top tab  18  and wings  42  through receptacle feature  43  included on the minor flaps  44 . Wings  42  may then expand to hold tab  18  in the connected position. Major flaps  24  at the top of primary box  11  may then be closed to capture top stabilizing tab  18  as shown in FIG.  1 . Capturing at least one stabilizing tab with major flaps of the primary box helps provide a secure connection between the two boxes  11  and  12 . 
     Finally, carton  10  is sealed using a suitable sealing method, preferably the adhesive tape  14  shown in FIG.  1 . The preferred adhesive tape is applied over a first side or top of primary box  11 , across a junction  46  between the two boxes, and over the top side or lid  40  of extension box  12 . Adhesive tape is similarly applied over the bottom or second side of primary box  11 , across junction  46  between the two boxes, and over a bottom side of extension box  12 . Since boxes such as primary box  11  are commonly taped along the junction of the major flaps, tape  14  is also preferably applied along the junction of the major flaps at the top and bottom of the box as shown in FIG. 1, with the tape extending further over the top  40  of extension box  12  and somewhat over the end of the extension box. Generally, the same taping equipment used to tape primary box  11  alone can be used to tape the combined boxes  11  and  12  to form unitary shipping carton  10 . 
     The illustrated, preferred form of the invention utilizing tab receiving slots on the primary box  11 , has the advantage that the stabilizing tabs  16 ,  17 ,  18 , and  19  cooperate with the tab receiving slots simply by inserting each tab in the respective slot. No adhesive or other connecting material is required at the stabilizing tabs themselves. An alternative form of the invention does not require separate tab receiving slots  22  and  23 . In this alternate form of the invention, at least some of the stabilizing tabs may be connected to the primary box with adhesive, tape, or staples. This alternate embodiment of the invention is to be considered within the scope of the following claims unless otherwise indicated in the particular claim. 
     FIG. 5 shows a sheet of material from which the preferred extension box  12  may be formed. The sheet may be stamped out of a blank piece of material using suitable stamping equipment and includes a primary side or panel  50 , end panels  51 , a top forming lid  40 , and bottom  52 . Hand hold  53  may also be stamped out to provide a convenient location for holding the resulting carton  10  for lifting. Fold downs  54  are used to create stop elements  36  shown in FIG.  3 . Additional fold downs  37  may also be stamped out of the blank sheet of material. Once folded, fold downs  54  and  37  leave the lateral tabs  16  and  17 , top tab  18 , and bottom tab  19  extending from the connecting side  32  of extension box  11  as shown particularly in FIG.  3 . 
     The above described preferred embodiments are intended to illustrate the principles of the invention, but not to limit the scope of the invention. Various other embodiments and modifications to these preferred embodiments may be made by those skilled in the art without departing from the scope of the following claims.