Folding box construction

A one-piece blank construction for a flip-lid box includes a rectangular bottom panel, rectangular top panel, panels bridging between the bottom and top, and two flip-lid panels foldably connected to one of the components of the respective side walls. The overall "footprint" of the blank is small because the blank is approximately rectangular, thus effecting the maximum saving of material. The one-piece construction is easy to set up, cuts the wastage of material, and increases strength so as to allow a smaller material thickness to be utilized.

This invention relates to the construction of cardboard boxes and has to do 
particularly with the design of a blank for a such a box, which presents 
certain advantages. 
BACKGROUND OF THIS INVENTION 
Many items for sale on the market are packaged in a box known as a flip-lid 
box, this being a box with a rectangular top panel and two flip-lids 
constituted by rectangular flaps approximately the same size as the top 
panel, hingedly connected to opposed side edges of the top panel. These 
flip-lids are typically used to present more information about the 
contents of the box, i.e. more than could be applied using the box alone, 
without the flip-lids. 
In the industry concerned, it is typical to utilize 60" and 40" offset 
presses and die-cutting equipment. Designs of previous flip-lid boxes have 
required the more expensive 60" offset press and die-cutter, due to the 
design of the blank. Also, it has been necessary in the past to construct 
the flip-lid box from two components, which further increases the cost. 
GENERAL DESCRIPTION OF THIS INVENTION 
In view of the shortcomings of the current design for a flip-lid box 
construction, it is an aim of one aspect of this invention to provide a 
one piece blank design, which is such as to provide all parts of the final 
box, and moreover to permit the utilization of the less expensive 40" 
offset press and die-cutter. 
Furthermore, it is an aim of another aspect of this invention to provide 
only a single entry/closure feature, such that loading, closing and 
re-opening the package always occurs at the single closure. This results 
in a lower labour factor. 
The present design involves the elimination of the glue lap, and this 
reduces the material requirement by about 9%. 
It is an aim of a further aspect of this invention to provide an increase 
in the integral strength of side panel assemblies, by virtue of being 
attached to the flip-lids. This increase in integral strength permits a 
reduction in the boxboard thickness required to manufacture the cartons. 
Typically, the thickness can be reduced from 0.24" to 0.020". This is a 
decrease of approximately 17%. It has been determined that a 20% reduction 
in boxboard thickness, coupled with the 9% material reduction compared to 
previous carton styles, achieves an outstanding overall savings of about 
29%. 
More particularly, this invention provides a blank for a folding box, 
comprising: 
a rectangular bottom panel having a pair of opposed side edges and a pair 
of opposed end edges, 
a first rectangular end panel foldably connected to said bottom panel at 
one of said end edges thereof, thus defining a first fold-line, 
a rectangular top panel having a pair of opposed side edges and a pair of 
opposed end edges, the top panel being foldably connected to said end 
panel at an end edge of the top panel, thus defining a second fold-line 
remote from and parallel to said first fold-line, 
a second rectangular end panel foldably connected to the other end edge of 
the top panel, thus defining a third fold-line remote from and parallel to 
said second fold-line, 
a tuck flap foldably connected to said second end panel at a fourth 
fold-line remote from and parallel to said third fold-line; 
each of the opposed side edges of the top panel having a rectangular 
adhesion side wall foldably connected thereto, thus defining fifth and 
sixth fold lines, 
each side edge of the bottom panel having a rectangular adherent side wall 
foldably connected thereto, thus defining seventh and eighth fold-lines 
perpendicular to the first fold-line, 
first and second rectangular flip lid panels foldably connected to the two 
adherent side walls, respectively, at ninth and tenth fold-lines parallel 
with said seventh and eighth fold-lines, and connecting means for 
fastening each adhesion side wall to a respective adherent side wall such 
that each adherent side wall lies outwardly of its respective adhesion 
side wall. 
Furthermore, this invention provides a method for setting up a box, 
utilizing a blank which comprises: 
a rectangular bottom panel having a pair of opposed side edges and a pair 
of opposed end edges, 
a first rectangular end panel foldably connected to said bottom panel at 
one of said end edges thereof, thus defining a first fold-line, 
a rectangular top panel having a pair of opposed side edges and a pair of 
opposed end edges, the top panel being foldably connected to said end 
panel at an end edge of the top panel, thus defining a second fold-line 
remote from and parallel to said first fold-line, 
a second rectangular end panel foldably connected to the other end edge of 
the top panel, thus defining a third fold-line remote from and parallel to 
said second fold-line, 
a tuck flap foldably connected to said second end panel at a fourth 
fold-line remote from and parallel to said third fold-line; 
each of the opposed side edges of the top panel having a rectangular 
adhesion side wall foldably connected thereto, thus defining fifth and 
sixth fold lines, 
each side edge of the bottom panel having a rectangular adherent side wall 
foldably connected thereto, thus defining seventh and eighth fold-lines 
perpendicular to the first fold-line, 
first and second rectangular flip lid panels foldably connected to the two 
adherent side walls, respectively, at ninth and tenth fold-lines parallel 
with said seventh and eighth fold-lines, and 
connecting means for fastening each adhesion side wall to a respective 
adherent side wall such that each adherent side wall lies outwardly of its 
respective adhesion side wall, 
the method comprising the steps: 
applying the connecting means to the blank such that it will connect 
together each adhesion side wall and its respective adherent side wall, 
and 
folding the top panel over so that it overlies the bottom panel but is 
spaced above the bottom panel, while correcting the adherent and adhesion 
side walls together in parallel, overlapped relation.

DETAILED DESCRIPTION OF THE DRAWINGS 
Attention is first directed to FIG. 1, which shows a blank 10 for a folding 
box. Specifically, the blank 10 includes a rectangular bottom panel 12 
having a pair of opposed side edges 14, 16, and a pair of opposed end 
edges 18 and 20. 
A first rectangular end panel 22 is foldably connected to the bottom panel 
12 at the end edge 20, whereby the end edge becomes a first fold-line 20. 
A rectangular top panel 24 is foldably connected to the end panel 22 at a 
second fold-line 26 which is remote from and parallel to the first fold 
line 20. A second rectangular end panel 28 is foldably connected to the 
top panel 24 at a third fold line 30 remote from and parallel to the 
second fold line 26. 
A tuck flap 32 is foldably connected to the second end panel 28 at a fourth 
fold line 44 remote from and parallel to the third fold line 30. 
The top panel 24 has a pair of opposed side edges 46, 48, which are 
parallel with and aligned with the side edges 14, 16, respectively, of the 
bottom panel, each top panel side edge 46, 48 having a rectangular 
adhesion side wall 50, 52, respectively, foldably connected thereto, thus 
defining fifth and sixth fold lines coinciding with the side edges 46, 48 
respectively. 
Each side edge 14, 16 of the bottom panel 12 has a rectangular adherent 
side wall 54, 56, respectively, foldably connected thereto, thus defining 
seventh and eighth fold lines perpendicular to the first fold line at the 
end edge 20 of the bottom panel 12. Thus the side edges 14 and 16 of the 
bottom panel 12 are coincident with the seventh and eighth fold lines. 
Rectangular flip-lid panels 58, 60 are foldably connected to the two 
adherent side walls 54, 56, respectively, at ninth and tenth fold lines 
62, 64, respectively, which are parallel with the seventh and eighth fold 
lines (14, 16). 
As illustrated, the blank 10 further comprises a third flip-lid panel 66 
congruent with the first flip-lid panel 58 and foldably connected thereto 
at an eleventh fold line 68 which constitutes an edge of the first 
flip-lid panel 58. Likewise, a fourth flip-lid panel 70 is congruent with 
the second flip-lid panel 60, and is foldably connected thereto at a 
twelfth fold line 72 which constitutes an edge of the second flip-lid 
panel 60. 
As shown in FIG. 1, the first rectangular end panel 22 has opposed end 
edges 74 which are perpendicular to the first and second fold lines 20, 
26. Each of the end edges 74 has an end edges stabilizing flap 76 foldably 
secured thereto. 
Furthermore, each adhesion side wall 50, 52 has an end edge 78 which is 
parallel to and collinear with the third fold line 30. Furthermore, a side 
wall stabilizing flap 80 is foldably secured to with respective adhesion 
side wall 50, 52. 
As based seen in FIG. 1, each of the stabilizing flaps 80 has a sloping 
partial wall 82. 
As best seen in FIG. 3, the blank includes adhesive means 100 for adhering 
each adhesion side wall 50, 52 to the corresponding adhesion side wall 54, 
56, respectively. In FIG. 3, the adhesive means takes the form of two 
double-sided adhesive tapes located on each adhesion side wall 50, 52. In 
the blank shown in FIG. 1, the tapes are located on the underside of the 
adhesion side walls 50, 52, which will become apparent below, where the 
process of setting up the box is described. 
Attention is directed to FIG. 2, which shows the blank 10 at the start of 
the set-up procedure. In FIG. 1, the top panel 24, the adhesion side walls 
50, 52, the bottom panel 12, the adherent side wall 54, 56 and the 
rectangular flip-lid panels 58 and 60 are all in the flattened condition. 
However, the stabilizing flaps 76 have been raised to an upright position, 
and the third and fourth flip-lid panels 66 and 70 are in the midst of 
being folded to lie in surface contact and overlapping relationship with 
the respective flip-lid panels 58 and 60. 
As seen in FIG. 3, the flip-lid panels 66 and 70 are now in overlapping, 
surface-contacting relation with the flip-lid panels 58 and 60, 
respectively. In FIG. 3, the top panel 24 has been rotated through almost 
180.degree., so that the end panel 22 is more or less upright with respect 
to the bottom panels 12, and the adhesion side walls 50, 52 are in the 
process of being folded downwardly. It is pointed out again that FIG. 3 
shows the double sided tape 100, but the tape is not visible in FIG. 1, 
because FIG. 1 shows the opposed face of the top panel 24. 
Assuming that the double sided tape 100 (or whatever adhesive is being 
utilized) is ready to come into contact with the adherent side walls 54 
and 56, the adhesion side walls 50 and 52 are pushed into an upright 
position, capturing the stabilizing flaps 76. The adhesion side walls 50 
and 52 will then be lined up with the side edges 14, 16 of the bottom 
panel 12 (not visible in FIG. 3). When this occurs, the adherent side 
walls 54 and 56 can be folded upwardly and inwardly so that they fully 
overlap and adhere to the respective adhesion side walls 50, 52. This will 
raise the fold lines 62, 64 to be coincident with the side edges of the 
top panel 24, these being identified by the numerals 46 and 48 in FIG. 4. 
In FIG. 4, the second end panel 28 and the tuck flap 32 are shown bent 
upwardly at an angle, thereby to open the far end of the box (as pictured 
in FIG. 4), in order that the product may be inserted or removed. 
To complete the box for shipping or storage, the flip-lids 58/66 and 60/70 
are folded across the top of the top panel 24. This is pictured in FIG. 5, 
with the outermost flip-lid 58/66 having only a further 20.degree. or so 
to rotate in order to bring it into flat contact with the flip-lid 60/70. 
It is pointed out that the flip lids in the illustrated embodiment, each 
being constituted of two layers of boxboard, may be stiffer or heavier 
than is required in a given application. In such a case, the flip-lids 66 
and 70 may simply be omitted. 
It should also be indicated that double-side tape 100 is only one modality 
for adhering together the adhesion side walls and the adherent side walls. 
Obviously, it would be possible to use liquid glue, heat-activated 
adhesives, or other means of securing two flat panels in surface contact 
with each other. 
It will be seen that this invention offers a single piece construction 
requiring a minimal amount of gluing, allowing the box to function as a 
multipanel advertising medium, reusable software storage box and retail 
packaging (as one of many examples). It is a significant advantage that 
only a single piece of boxboard is required. Previous constructions 
utilizing two pieces were complex and required 60" offset press and 
die-cutting equipment to yield a similar product. The closure involving 
the end panel 28 and tuck flap 32 is such that only one entry/closure 
feature is required in order to load, close and re-open the package. This 
cuts labour costs during packaging. The flip-lids are created within the 
single piece construction, eliminating the glue lap. This has reduced the 
material requirement by about 9%. The adhering side panel assemblies 
attached to the flip-lids substantially increase the strength of the box. 
As mentioned earlier, boxboard thickness can be reduced with this design, 
typically from 0.24" to 0.020". 
A previously mentioned, the package can be produced on single pass 40" 
printing equipment. The one-piece construction has reduced waste by 17%, 
has reduced the amount of square inches required to make the box by 9%, 
and has permitted the overall thickness of the carton material to be 
reduced. Because of the unique construction, the integrity of the carton 
has been increased. 
While one embodiment of this invention has been illustrated in the 
accompanying drawings and described hereinabove, it will be evident to 
those killed in the art that changes and modifications may be made therein 
without departing from the essence of this invention, as set forth in the 
appended claims.