Method and apparatus for making, shipping and erecting boxes

A cardboard box with four side panels, four bottom flaps and four top flaps. The box is made from a blank having a first height measured between the outermost edges of the top and bottom flaps. The flaps are rotated into abutting contact with the exterior surface of the panels thereby reducing the overall height of the box to the height of the panel. Adjacent pairs of top and bottom flaps are provided with living hinges that enable them to remain in this position when the box is collapsed. The collapsed box is shipped through the mail in this diminished size and then erected into a box of the same height as the panels.

BACKGROUND OF THE INVENTION

1. Technical Field

The invention relates generally to shipping and storage boxes. More particularly, the invention relates to cardboard boxes which are shipped in a flat configuration and are erected at the time of use. Specifically, the invention relates to a box in which the top and bottom flaps are retained in abutting contact with the side panels by living hinges when the box is shipped to a first consumer.

2. Background Information

Various types of boxes exist which may be manufactured of any flat material such as cardboard, and which are configured to efficiently fold into the final box shape. As people move about the country and the world, it becomes ever evident that the need for individuals to purchase and utilize storage and shipping boxes is ever increasing. Additionally, with the advent of e-commerce and more specifically the advent of online sites that permit people to purchase goods from remote sellers after bidding on the same over the Internet, there is a need for companies that conduct such e-commerce to send shipping boxes to their sellers for boxing up of the sold goods. However, presently known cardboard boxes, even when shipped, stored or displayed in a flattened, unassembled configuration tend to take up a significant amount of space. This is especially problematic if such flattened, unassembled boxes are to be forwarded to sellers through the regular postal service.

Cardboard cartons or boxes which are purchased in a flattened position and are assembled for manual loading generally include a plurality of flaps which extend upwardly into the air from a top edge of the sidewall panels. These flaps can be cumbersome to work around when loading the box. Various box configurations have been proposed in the prior art to try and deal with this problem. For example, U.S. Pat. No. 2,718,348 to Monfort, discloses a box having four sidewall panels joined together along four fold lines. The box includes top and bottom flaps that extend respectively outwardly from the top and bottom edges of those sidewall panels. Some of the top flaps are secured to each other by a bridging member on the respective fold line. The box is shipped in a first collapsed position where the top flaps and bottom flaps are coplanar with the sidewall panels and extend outwardly away from the top and bottom edges thereof. The bridging members between some of the top flaps are positioned on the folds that form the outer corners of the collapsed box. A pair of diametrically opposed folds fall intermediate these outer corners. The top flaps are not connected together by bridging members along these intermediate folds. When it is time for the box to be erected, it is manipulated into a second collapsed position where the folds with the bridging members are moved to a position intermediate the outer corners. When in this second position, the top flaps are not connected by bridging members at the outer corners. This arrangement permits the assembler to fold the top flaps downwardly from their shipping position into a position where the exterior surface of each flap is in abutting contact with the exterior surface of one of the sidewall panels. The box is then opened up and the bottom flaps are used to close the bottom opening of the box. The exterior surfaces of the top flaps remain in abutting contact with the exterior surfaces of the sidewall panels. Consequently, the top flaps do not interfere with the loading of goods into the box's interior. When the box is fully loaded, the bridging members are broken and the top flaps are rotated to a position where they may be used to close off access to the interior of the box.

U.S. Pat. No. 2,783,933 to Sharts discloses a similar arrangement where diametrically opposed folds include bridging members on the top flaps. Once again, the collapsed box is shipped with the top and bottom flaps coplanar with the sidewall panels and extending outwardly away from the top and bottom edges thereof. The bridging members are positioned on the folds that fall intermediate the outer corners of the collapsed box. The top flaps are not connected together by bridging members at the outer corners. Consequently, the box does not have to be moved from a first collapsed position to a second collapsed position, as was the case with the Montfort box, before folding the top flaps downwardly into abutting contact with the exterior surface of the sidewall panels. After purchasing the box, the consumer simply folds the top flaps from their shipping position into a loading position where the exterior surface of each of the top flaps is in abutting contact with the exterior surface of one of the sidewall panels. The box is opened up and the bottom flaps are rotated into a position where they close off access to the bottom of the box. The bridging members between some of the top flaps are broken once the box is loaded. The top flaps are then rotated out of contact with the exterior surfaces of the sidewall panels and into a position where they close off access to the box's interior.

U.S. Pat. No. 3,727,827 to Stice discloses a variable size container. Each of the adjacent pairs of the top and bottom flaps on Stice's box is connected together by a bridging member. The box is provided with a plurality of additional horizontal and vertical fold lines in various positions. This permits a variety of differently shaped and sized containers to be constructed from a single blank. The box is shipped to the end consumer in a collapsed position with the top and bottom flaps coplanar with the sidewall panels and extending outwardly away from the top and bottom edges thereof. In this instance, the top flaps are not folded downwardly into abutting contact with the exterior surface of the sidewall panels. Instead, the consumer folds the box along selected horizontal and vertical fold lines to make up the size and shape container they need. The bridging members that fall on the outer corners of the eventually constructed box are broken so that the top and bottom flaps can be rotated into a suitable position to close the box.

Rendall (U.S. Pat. No. 2,936,239) discloses a box with bridging members between each pair of top flaps. The box is shipped in a collapsed position with the top and bottom flaps coplanar with the sidewall panels. When the box reaches the consumer, they manipulate it into an open position and then rotate the bottom flaps to a position where they close off access to the bottom of the box. The top flaps may be left extending upwardly from the sidewall panels and the box may be used as an open top container. Alternatively, the bridging members between the top flaps may be broken and the top flaps may be rotated to close off the top of the box.

All of the above patents disclose that the box blank is shipped to the consumer in a position where the top and bottom flaps are coplanar with the sidewall panels and extend outwardly away from the top and bottom edges thereof. Consequently, the shipping size of all of these boxes is fairly large.

Therefore, the need exists in the art for a box which takes up less space when it is in a flattened, unassembled configuration and which is able to fit within the confines of a standard-size postal carrier's delivery bag, and which may be easily assembled by the user once received or purchased.

BRIEF SUMMARY OF THE INVENTION

The device of the present invention comprises a box that has four side panels, four bottom flaps and four top flaps. The box is made from a blank having a first height measured between the outermost edges of the top and bottom flaps. The flaps are rotated into abutting contact with the exterior surface of the panels thereby reducing the overall height of the box to the height of the panel. Adjacent pairs of top and bottom flaps are provided with living hinges that enable them to remain in this position when the box is collapsed. The collapsed box is shipped through the mail in this diminished size and then erected into a box of the same height as the panels. Thus, the box is of a height that is substantially equal to the height of a sidewall panel when in each of a shipping position, erected position and storage position.

A shipping label is applied to an interior surface of one of the top and bottom flaps and includes a shipping address for mailing of the collapsed box to a first consumer. When the box is fully erected, the shipping label is moved to an interior of the box as the one of the top and bottom flaps is rotated to close off access to the interior of the box. Additionally, the box includes a mailing label that is applied to an exterior surface of one of the panels, top and bottom flaps in a region that is not visible when the box is in a collapsed position. When the box is erected, the mailing label becomes visible and a mailing address of a second consumer made be written thereon. Similarly, a prepaid postage decal is applied to an exterior surface of one of the panels, top and bottom flaps in a region that is not visible when the box is in a collapsed position but becomes visible when the box is fully erected. The mailing label with the mailing address and the prepaid postage decal is used when the fully erected and loaded box is mailed on to a second consumer by the first consumer.

DETAILED DESCRIPTION OF THE INVENTION

The storage and shipping box of the present invention is indicated generally at the numeral1, and is shown specifically inFIGS. 1-12.FIGS. 1A and 1Bshow a blank2that is used to construct the box1. Blank2is a planar sheet of material that preferably is of a uniform thickness “T” (FIG. 3).FIG. 1Ashows the exterior surface “E” of blank2andFIG. 1Bshows the interior surface “I” of blank2. As is well-known in the art, blank2may be made of a variety of materials including corrugated cardboard, non-corrugated paperboard, or a variety of wax-coated products including paper and plastic.

In accordance with a specific feature of the present invention, blank2includes a plurality of foldlines that are used to erect box1. Blank2preferably is provided with two horizontally oriented and spaced-apart foldlines3and four vertically oriented and spaced-apart foldlines5. It will be understood, however, that other arrangements and numbers of foldlines3,5may be provided to construct boxes of different shapes to that shown inFIG. 1. Foldlines5divide blank2into a first panel4a, a second panel6a, a third panel4b, a fourth panel6b, and a connector panel7. Foldlines3form a top edge and bottom edge for each of the panels4athrough6band separate them from a top flap and a bottom flap, respectively. First panel4ahas a top edge8with a top flap21B extending outwardly away therefrom and a bottom edge10with a bottom flap22B extending outwardly away therefrom. It will be understood that top and bottom edges8,10are disposed along the spaced apart foldlines3. It should further be understood that top and bottom flaps21B,22B are substantially coplanar with first panel4abefore the construction of box1is initiated.

Second panel6ahas a top edge12with a top flap20A extending outwardly away therefrom and a bottom edge14with a bottom flap22A extending outwardly away therefrom. Top and bottom edges12,14are disposed along foldlines3and top and bottom flaps20A,22A are substantially coplanar with second panel6a.First panel4ais separated from second panel6aby a joint15that is disposed along one of foldlines5. It should be noted that a gap29exists between top flaps21B and20A and between bottom flaps22B and22A. These gaps29extend substantially from the foldlines3to the respective outermost edges2aor2bof blank2.

Third panel4bhas a top edge8with a top flap21A extending outwardly away therefrom, and a bottom edge10with a bottom flap23A extending outwardly away therefrom. Once again, top and bottom edges8,10are disposed along the spaced apart foldlines3and top and bottom flaps21AB,23A are substantially coplanar with third panel4b. Third panel4bis separated from second panel6aby a joint16that falls on another of foldlines5. In accordance with a specific feature of the present invention, top flaps20A,21A are partially separated from each other by a gap28while a hinge26connects a portion of the top flaps20A,21A together. Hinge26originates a distance outwardly away from foldline3and continues to the outermost edge2aof blank2. Similarly, a portion of bottom flap22A is separated from a portion of bottom flap23A by a gap28while a hinge24connects another portion of flaps22A,23A together. Hinge24originates a distance outwardly away from foldline3and continues to outermost edge2bof blank2.

Fourth panel6bhas a top edge12with a top flap20B extending outwardly away therefrom and a bottom edge14with a bottom flap23B extending outwardly away therefrom. Top and bottom edges12,14are disposed along foldlines3and top and bottom flaps20B,23B are substantially coplanar with fourth panel6b.Fourth panel6bis separated from third panel4bby a joint17that falls along another of vertical foldlines5. A gap29is defined between each of top flaps21A,20B and bottom flaps23A,23B. Gaps29extend substantially from the foldline3to the respective outermost edge2a,2bof blank2. Consequently, top flaps21A,20B are not connected to each other and bottom flaps23A,23B are not connected together.

As is apparent from a review of the present invention, hinges24-27may simply be manufactured of the same material and be integrally formed with blank2. In this instance, hinges24-27are of the same thickness “T” as the rest of the material used in blank2and therefore may need to be cut with a knife or other implement in order to break the same. It will be understood that hinges24-27could, alternatively, be manufactured out of material with a reduced thickness relative to the rest of the blank, or could be made with a fracture line formed therein to make breaking the hinge easier. It will further be understood that hinges24-27may all be of different lengths. This is accomplished by increasing or decreasing the length of gaps28.

Connector panel7has a top edge11and a bottom edge13that are disposed along the respective foldlines3. A top connector flap7A extends outwardly away from top edge11and a bottom connector flap7B extends outwardly away from bottom edge13. Top and bottom connector flaps7A,7B are substantially coplanar with connector panel7. Connector panel7is separated from fourth panel6bby a joint18that falls on another of foldlines5. In accordance with a specific feature of the present invention, a portion of top flap20B is separated from a portion of top connector flap7A by a gap28. A hinge27connects other portions of these flaps20B,7A together. Hinge27originates a distance outwardly from the associated foldline3and continues to the outermost edge2aof blank2. Similarly, a portion of bottom flap22B is separated from a portion of bottom connector flap7B by a gap28. A hinge25connects other portions of flaps22B,7B together. Hinge25originates a distance outwardly from the associated foldline3and continues to outermost edge2bof blank2.

FIG. 1Ashows that the blank2has a first height H1as measured between the outermost edges2aand2b. The panels are all of a second height H2as measured between top and bottom edges8,10and12,14. The second height H2is smaller than the first height H1.

FIG. 1Cshows an alternative blank2that may be used to form box1. The blank is substantially identical to the blank illustrated inFIGS. 1A and 1Bexcept that the connector flap7does not have flaps7A and7B connected thereto. Instead, connector flap7has beveled edges35,37and is of a height H2as measured between edges35,37. Additionally, the fourth panel6bis disposed adjacent the first panel4ainstead of being disposed between the third panel4band the connector panel7as was the case in the blank ofFIG. 1A. In this version of the blank, the fourth panel6bis separated from the first panel4aby a joint19. Furthermore, the flap20B is connected to flap21B by a hinge33and the flap22bis connected to the flap23B by a hinge31. The box constructed from this blank is substantially identical in external appearance to the box constructed from the blank shown inFIGS. 1A and 1B. It will be understood that other modifications may be made to blank2without departing from the scope of the present invention.

In accordance with the present invention, a shipping address label70preferably is applied to exterior surface “E” of blank2before construction of the box1begins. Label70preferably includes a plurality of spaced apart horizontal lines that a consumer may use to write a shipping address. Label70may be printed directly onto the exterior surface “E” of blank2or may be an adhesive type label that is applied onto exterior surface “E”.

In accordance with yet another specific feature of the present invention, a prepaid postage decal72is also applied to the exterior surface “E” of blank2. The prepaid postage decal72represents a flat rate for mailing the erected and loaded box through the mail. This flat rate is a pre-negotiated rate with a postal service of any particular country or countries and is dependent upon the dimensions of the box once erected and upon the maximum permissible weight of the box once loaded. Preferably, the flat rate is not dependent upon the delivery address of the loaded box if delivered within a pre-negotiated region. For example, the flat rate may be a rate negotiated with either or both of the postal services of the United States and Canada for delivery of a box of particular dimensions and maximum weight anywhere within North America.

Decal72may be printed directly onto the exterior surface “E” or may be an adhesive label that is applied thereto. Both of the label70and decal72preferably are applied in regions of the blank2that are adjacent one of the top and bottom edges8,10,12,14and which will be covered by one of the top and bottom flaps as will be hereinafter described when the blank2is folded.

When box1is erected, the panels and flaps are folded about these horizontal and vertical foldlines3,5as will be hereinafter described. In the erected box panels4aand4bcomprise a pair of opposed, substantially parallel and spaced apart sidewalls4and panels6aand6bcomprise a pair of opposed, substantially parallel and spaced apart endwalls6. The top flaps21B,20A,21A, and20B are folded inwardly toward each other to close off access to a top opening in the box. The bottom flaps22B,22A,23A, and23B are folded inwardly toward each other to close off access to a bottom opening in the box.

It will be understood that hinges24,25,26and27may be of any of a variety of lengths without departing from the spirit of the present invention, but are preferably between ½ and 2 inches in length. Furthermore, while hinges24,25,26and27are shown as being located proximate the outermost edges2a,2b, they may be spaced a distance inwardly away therefrom without departing from the spirit of the present invention.

Blank2is erected into a box1in the following manner. The planar sheet of material that comprises blank2is folded about each of the foldlines5. Blank2is folded along the foldline5between fourth panel6band connector panel7and the connector panel7is caused to overlap a portion of first panel4a. This causes connector flap7A to overlap a portion of top flap21B and causes bottom connector flap7B to overlap a portion of bottom flap22B. An adhesive or other securing mechanism is applied between the overlapped areas to fixedly secure connector flap7to first panel4a, top connector flap7A to top flap21B, and bottom connector flap7B to bottom flap22B. The blank2is then manipulated to fold along the appropriate foldlines5to form joints15and17(FIG. 2) and is oriented so that these joints15,17constitute the outermost corners of the blank2. In order to do this, box1is moved from the position shown inFIG. 1to the position shown inFIG. 2by rotating box1in the direction of Arrow A (FIG. 2) and by flexing joints15and17to have a 180° bend associated therewith. Joints16and18are moved to a substantially flat configuration. In this first folded position (FIG. 2), hinges24,25,26, and27are disposed in the region of the box that is intermediate the outer corners formed by joints15and17. It will be understood that gaps29are oriented along joints15,17and are therefore disposed along the outer corners when box1is in this first folded position. It should also be noted that at this pointFIG. 2illustrates the exterior surfaces of the box1, and most specifically the exterior surfaces of second panel6a, third panel4btogether with their top flaps20A/21A and bottom flaps22A/23A. If the box1were flipped over, then the exterior surfaces of the fourth panel6band the first panel4aand their associated flaps21B/22B and20B/23B would be seen.

Once the box1is in the position shown inFIG. 2, then the top flaps20A/21A, which are joined together by hinge26, and the top flaps20B/21B, which are joined together by hinge27, are rotated along Arrows B and C, respectively, until they are in the position shown inFIG. 3. Similarly, bottom flaps22A/23A, which are joined together by hinge24, and bottom flaps23B/22B, which are joined together by hinge25, are rotated in the direction of Arrows D and E, respectively, until they are moved into the position shown inFIG. 3. As these joined flaps20A/21A;20B/21B and22A/23A;23B/22B continue to be rotated, they will ultimately move to the position shown inFIG. 4. In this position, the exterior surfaces of each of the joined top flaps20A/21A and20B/21B abut the exterior surface of the associated first, second, third and fourth panels. Consequently, when box1is in the position shown inFIG. 4, the interior surfaces of the flaps20A/21A;22A,23A are visible. Similarly, if the box1were flipped over, the interior surfaces of flaps20B/21B and23B/22B would be visible.

Referring particularly toFIG. 4, box1is shown in a first collapsed position with first hinge24and second hinge26aligned along joint16and where the joint is substantially flattened so that the second panel6ais substantially coplanar with the third panel4b. It will be understood that, similarly, third hinge26and fourth hinge27are aligned along joint18which is also substantially flattened with the fourth panel6band first panel4abeing substantially coplanar with each other. As mentioned previously, in this first collapsed position, joints15and17include a 180° bend and constitute the outer corners of the collapsed box.

Box1is then moved from the first collapsed position (FIG. 4) into a second collapsed position (FIG. 5) by rotating box1in the direction of Arrow F. This causes the panels to move so that joints16and18are positioned at the outermost corners of box1. Each joint16,18has a 180° bend therein and each joint15and17is substantially flattened. By rotating the box along the direction of Arrow F, it can be seen that first hinge24and third hinge26are moved into a position where they have a 180° bend in them as they wrap around joint16. Second hinge25and fourth hinge27also are caused to have a 180° bend as they wrap around joint18. The forces supplied by hinges24-27assure that the top flaps20A/21A and20B/21B and the bottom flaps22A/23A and23B/22bare all held in abutting contact with the exterior surface of the associated panels4a-6b. Hinges24-27provide sufficient force to assure that the free ends of each of the top and bottom flaps adjacent gaps29are also held in abutting contact with the exterior surface of the associated panels4a-6b.

When box1is in this second collapsed position it is in a configuration that is suitable for shipping. Box1in this second collapsed position is of a reduced height relative to the original blank2. The overall height of box1when it is in each of the first and second collapsed positions is H2. In other words, the height of box1is substantially equal to the height H2of the panels4a-6balone. This is due to the fact that the top and bottom flaps have been folded into abutting contact with the exterior surface of the panels4a-6b. This arrangement allows the user to more easily ship the box1as it is of a diminished size relative to the original blank2. The overall thickness W of box1in the second collapsed condition is equal to the combined thickness of two abutting panels, such as4band6band two flaps, such as21A and20B. The diminished dimensions of box1in the second collapsed condition preferably are one that is suitable for easy insertion of the box into a standard postal mailbag. Additionally, the positioning of hinges24-27on the outermost corners presents a box configuration that does not have free edges that can snag or catch on other objects being shipped, mailed or carried in a mailman's bag. Additionally, the diminished dimensions of box1when in the first or second collapsed condition also makes it possible to store or display box1in a smaller space compared to previously known boxes in which the top and bottom flaps extend outwardly away from and coplanarly with the panels that form the sidewalls and endwalls thereof.

It is often appropriate to provide information such as assembly instructions or the like on a piece of packaging. In accordance with a specific feature of the present invention and referring toFIG. 6, it can be seen that a printer30may be utilized to print indicia32onto the interior surface “I” of at least one of the top and bottom flaps, such as top flap21A. Inasmuch as this printed indicia32is on the interior surface of top flap21A, when box1is fully erected and moved to the closed position as will be discussed hereinafter, the indicia will be moved to a position disposed in the interior of the box and will not detract from the appearance of the box exterior. It will be understood that instead of printing directly onto the folded blank2, an adhesive label containing the printed indicia32may be applied to the interior surface “I” of one of the top and bottom flaps.

It will be understood that if the printed indicia32is a shipping address then that address may be one that is selected from a computerized database of addresses of consumers to whom the folded blanks2are to be mailed.

In accordance with a specific feature of the present invention, the printed indicia32preferably, but not exclusively, includes a shipping address for a consumer. This shipping address enables the post office or a shipping company to ship the box when in a second collapsed condition (FIG. 6) to a remote consumer.

In accordance with another specific feature of the present invention, it is possible to ship a number of boxes together when in the second collapsed position. This is illustrated inFIG. 6Awhere three folded blanks2are shown in the second collapsed position. The folded blanks are stacked one on top of the other and are banded together by restraining straps80. A single shipping label, in the form of indicia32, is applied to one of the flaps on an outermost blank2. Although not illustrated herein, it will be understood that one or more restraining straps80may also be applied around a single folded blank2in a position that will ensure the top and bottom flaps do not separate from the exterior surface “E” of panels4a-6b. This strap80will ensure that no loose corners of the top and bottom flaps become damaged as the folded blank is shipped.

Referring toFIG. 7, the folded blank2, having been received or purchased by the consumer in the second collapsed position, may now be erected into a position where it is ready for use. The erection of box1is accomplished as follows. Firstly, the folded blank2is moved from the second collapsed position back to the first collapsed position, i.e., blank2is rotated from the position shown inFIG. 7along the direction indicated by Arrow G to the position shown inFIG. 8. This causes hinges24-27, which were disposed at the outer corners of the blank inFIG. 7to be moved away from the outer corners and to a position where they are disposed intermediate the outer corners. In this first collapsed position, flaps20A and21A remain in abutting contact with the exterior surface “E” of the associated panels4a-6b. Bottom flaps22B,22A,23A,23B are then rotated downwardly in the direction of Arrows H and I as shown inFIG. 8to where they once again extend coplanarly with and outwardly away from panels4a-6b. Box1is then moved to a partially erected state (FIG. 9) with top flaps21B,20A,21A,20B remaining in abutting contact with the exterior surface “E” of the panels4a-6band with the hinges26and27intact. Hinges24and25on bottom flaps22B,22A,23A,23B are broken apart (FIG. 9). This permits the bottom flaps22B,22A,23A,23B to be rotated in the direction of Arrows J inwardly toward each other and so as to close off the bottom opening of box1(FIG. 10). A suitable sealing mechanism, such as an adhesive or staples is then applied to bottom flaps22B,22A,23A,23B to fix them in place relative to each other. Box1is now in a loadable condition where any desired articles34may be introduced into the cavity defined by panels4a-6band bottom flaps22B,22A,23A and23B. Box1may be loaded with articles goods34while top flaps21B,20A,21A,20B remain positioned in abutting contact with the exterior surface “E” of panels4a-6b. Top flaps21B,20A,21A and20B remain in this position as they are held there by hinges26and27.

FIG. 11shows that at this stage, indicia32are still visible as the interior surface “I” of top flap21A upon which the indicia are printed still faces outwardly. Once box1is fully loaded, hinge26and hinge27are broken and top flaps21B,20A,21A,20B are rotated inwardly toward each other in the directions of Arrows K and into the closed position as shown inFIG. 12. When this occurs, the interior surface “I” of top flaps21B,20A,21A,20B is disposed within the interior of box1and indicia32are no longer visible. Thus, the exterior appearance of box is not marred by the indicia32once box1is closed.

As is evident from the above description and method of operation, box1may be shipped and stored in a relatively small space limited to only to the height H2of panels4a-6band to the thickness “W” (FIG. 5) and length L of body2when in the second collapsed position (FIG. 5or6). As is also apparent and in accordance with one of the primary features of the invention, a portion of the interior surface of box1may be easily printed with directions or information assuring that when the box is in the closed position, there is no information on the exterior of the box to get in the way of further shipping or packaging. Thus, the folded box1, shown inFIG. 6, can be shipped to a consumer with the shipping address printed as indicia32on the interior surface “I” of one of the flaps. But, once the box1is fully erected, loaded and closed, it may be shipped to a second consumer at a remote location without indicia32being visible. The shipping address that constituted indicia32is no longer visible since the flap containing said indicia has been folded so that the exterior surface of that flap is now visible instead of the interior surface thereof. This removes the likelihood of any confusion as to which is the correct address for delivery of the loaded box. Once the box1is fully loaded with articles, the first consumer may write the mailing address of the second consumer onto the mailing label70applied to the exterior surface “E” of one of the panels.

While it has been illustrated herein that the blanks2are printed with the indicia32when in the second folded position, it should be understood that such indicia32may be printed on the blank2prior to it be folded (i.e. when it is in the position shown inFIG. 1B) or when the blank2is in the first folded position (FIG. 4). Preferably, shipping label70and decal72are applied to blank2when it is still a planar sheet (FIG. 1A).

FIG. 1Ashows that the distance between the outermost edges2a,2bof blank is the first height identified as H1and the distance between the two horizontal fold lines3is identified as the height H2, with H2being smaller than H1. As seen fromFIGS. 5 and 12, the height of both the shipped box (FIG. 5) and the erected box (FIG. 12) is H2, i.e., the height of the panels4a-6b. This is in contrast to previously known erectable boxes where the height of the shipped box would be the equivalent of the height H1and the height of the previously known erected box would be the equivalent of the height H2. The present inventor has therefore found a way to reduce the overall size of a shipping box to substantially the same height as the erected box and not substantially the height of the blank as was previously the case. This arrangement reduces the mailing cost for collapsed boxes sent through the regular mail as the postage rates are at least partially determined by the overall dimensions of the article shipped.

There is thus disclosed a method of shipping products comprising:

mailing a collapsed box10through the mail to a first location at a non-flat postage rate;

erecting the collapsed box10at the first location;

loading the products34to be shipped into the erected box34; and

mailing the loaded box34to a remote second location at a flat postage rate.

The steps of mailing the collapsed box34and mailing the loaded box34each further include the step of inserting the box into a standard size mail carrier's bag (not shown).

The step of mailing a collapsed box10as previously disclosed is preceded by the steps of providing a box34that has four side panels4,6, each panel having a top edge8,12and a bottom edge10,14with a top flap20,21extending outwardly from the top edge and a bottom flap22,23extending outwardly from the bottom edge; and wherein each panel4,6is of a first height H2as measured between the top and bottom edges thereof. When the box10is collapsed for mailing it has a height that is equal to the first height H2.

Furthermore, the step of collapsing the box10includes the steps of folding the top flaps20,21downwardly into contact with an exterior surface of the side panels4,6; folding the bottom flaps22,23upwardly into contact with the exterior surface of the side panels4,6; and moving the box10to a collapsed condition where a hinge26,27that connects two adjacent top flaps or a hinge24,25that connects two adjacent bottom flaps together is disposed on an outermost corner of the box10.

The step of mailing the collapsed box to the first location is preferably further preceded by the step of applying a flat-rate postage decal72to one of the side panels4,6of the box10prior to collapsing the box for mailing.

The step of mailing the box10to a second location further includes the step of applying a mailing label32to an outwardly facing interior surface of one of the folded top and bottom flaps20,21,22,23.