INTEGRAL PACKING BOX

Abstract: A packing box (case/carton) constructed from sheet material, such as corrugated cardboard, comprises a base (10), side structure walls (12) and foldable flap members (1 and 2) with slits forming slots (3), tongues (4), or combined slot/tongues (3+4) and which incorporate creased bending lines (5), and/or slit bending lines (16 or 17), with creased and perforated bending lines (7) forming ledges (8), when folded with creased bending lines (13), and closure lide flaps (9). When flaps (1 and 2) are folded so that they are in contact with the article surface and engaged within the box, a thin walled structure is created within the void space between an article, less in height than the side structure wall height, and closure lid. This enables the article to be restrained from excessive movement or to enable the separation of articles during handling, transportation and storage.

Description: Description Integral Packing Box Technical Field This invention relates to a packing box (case/ carton) used for containing articles and is constructed from sheet material, such as corrugated cardboard, and which comprises a base, side wall structure and at least one hinged, foldable flap. The more common methods of packing levels of articles that will vary, from box to box, are by either the use of boxes specifically designed to suit the article level, or by using extraneous packing material to fill the void space between the article surface and closure lid. These methods of packing levels of articles that will vary, can be relatively expensive and relies upon the availability and storage of either a variety of box heights or bulky void filling material, otherwise packing may not be adequately achieved. Packing methods developed to reduce cost, to be more convenient in use and reduce packaging storage space, range from the use of technology, in the form of specialised equipment, to the redesign of the packing box, in the sense of incorporating a form of packing material. Background Art U.S. Patent No. 3,313,467 indicates a box formed into a rectangular shape from a piece of cardboard and comprises a base, side wall structure, and hinged, foldable flaps that are .scored with a plurality of lines and which are vertically slotted to enable packing levels of articles that will vary. When the article level is above the side wall structure height, the flap score lines are folded to correspond with the height, so that they are in contact with the article surface. When the article level is below the side wall structure height, opposing flaps are folded into square type sections, by manipulation of convenient score lines, so that one surface of the square section is in contact with the article surface. The remaining flaps are then folded to rest upon the top of the square sections. The flaps are secured into the article retaining position by the use of adhesive tape applied to the outer surface of the flaps and side wall structure. Disclosure of Invention According to the present invention, a packing box (case/ carton) comprising a base, a side wall structure and at least one flap, detachable or not, that will fold inside to engage the surface of the article contained within and engage with another part of the box, such that the article is restrained. The advantages being that if the article level is the same or less than the height of the side wall structure, the majority of the void between the article surface and top of the side wall structure and the void (if any) to at least one side of the article, will be filled. This enables the ' quantity of box height sizes to be reduced, the elimination, or at very least the reduction of, extraneous packing material placed by hand or specialised equipment. At any stage of packing, the article may be restrained in order to reduce the risk of damage between handling and checking or to enable the separation of articles. Where a closure lid is necessary for stacking purposes and additional security, as is normally required, this can be fixed by hand or machine methods prior to despatch for general handling, transportation and storage. Specific embodiment of the invention, of which there are three, will now be described by way of example with reference to the accompanying drawings. Although the three versions shown employ mutually engaging flaps, it is possible to achieve article restraining by engagement of flap to side wall structure or with additional material, by means of tongues formed in the flap sides or general plane being able to engage with slits formed in the wall sides at varying levels or additional material. The boxes herein provide for the most economical use of material and means of manufacturing presently found. Figure 1 shows the first embodiment for converting two pattern blanks of square boxes (which has four bottom flaps forming the base and two top flaps forming the closure lid) from sheet material, such as corrugated cardboard. (The pattern inversion formation is arranged to reduce waste). This first embodiment includes the following features:- Flap 1 with slots 3, creased bending lines 5 (shown dotted) and slit 6 with creased and perforated bending line 7 (shown dotted) which forms a ledge 8 when the flap is folded along creased bending line 13 between flap and side wall structure. Flap 2 with tongues 4, creased bending lines 5 (shown dotted) and slit 6 with creased and perforated bending line 7 (shown dotted) which forms ledge 8 when the flap is folded along creased bending line 13 between flap and side wall structure. Closure lid flaps 9. Base forming flaps 10- Fixing flange 11-- Side structure walls 12. General creased bending lines 13 (shown dotted). Figure 2 shows the initial box formation of the first embodiment by sealing fixing flange 11 onto side wall structure 12 after folding creased bending lines 13 between walls. Figure 3 shows base forming flaps 10 of the first embodiment that have been folded inwardly using creased bending lines 13, between side wall structure and flaps. The joint between the outer base flaps has been sealed with adhesive tape 14. Figure 4 shows the second embodiment of a box blank as described in figure 1 but, with differently shaped slots 3 and tongues 4 and which incorporates slits 16 which will enable the flaps 1 and 2 to fold. Figure 5 shows the third embodiment of a box blank as described in figure 1 but, of rectangular shape and with combined slot/ tongues 3+4 (slot/ tongues being integral in configuration requiring no slot striping during manufacture), leading tongues 4 and slit cuts 17 which orm a shape that will enable the flaps 1 and 2 to fold in order to produce a type of gusset plate reinforcement that will provide resistance to flap folding of 90 degrees or less along the fold line- (This provides for greater rigidity of the formed corner and reduces side movement of the flaps when engaged. It also assists the flaps in absorbing kinetic energy should the box be subjected to shock loading) . The closure lid flaps 9 have creased and perforated lips 18 which can be folded to form a beam rein orcement after engagement with slit cuts 19 when closed. This gives the closure lid greater resistance against deformation of shape, once ■ sealed, if subjected to external forces caused through stacking.. Figure 6 shows how the slit cuts 17 are determined by geometry and sized according to the ratio between the elements forming the overall gusset shape. Figure 7 shows a cross section through the first embodiment of the box which is partly filled with article(s) forming a relatively level surface and before engagement of flaps. Figure 8 shows a cross section through the first embodiment of the box as in figure 7 and flap 1 has been folded to make contact with the article surface. Figure 9 shows a cross section through the first embodiment of the box as in figures 7 and 8, and after flap 2 has been folded to make contact with the article surface to engage the tongues and slots. Figure 10 shows a cross section through the first embodiment of the box as in figures 7,8 and 9, and after sealing of the closure lid by means of adhesive tape. Figure 11 shows a cross section through the first embodiment of the box after completing the packing as described in figures 7, 8 and 9 but, with article(s) of a non uniform height and after sealing the closure lid by means of adhesive tape. Figure 12 shows a cross section through the second embodiment of the box and the method of engaging the lower flap tongue with the upper flap slot/ tongue. Figure 13 shows a cross section through the second embodiment of the box as in figure 12 and the flaps in the article retaining position with the closure lid sealed with adhesive tape. Figure 14 shows a cross section through the third embodiment of the box and the method of engaging the lower flap tongue with the upper flap slot/ tongue. Figure 15 shows a cross section through the third embodiment of the box as in figure 14 and the flaps in the article retaining position with the closure lid lip engaged with the corresponding slits and sealed with adhesive tape. Design Guidance:- The type of base forming flaps and closure lid flaps used do not affect the principle of article restraining. The size of flaps to box depth should be considered carefully and it is recommended that high boxes, containing only a small number of articles, are not used. Under circumstances where this will occur, a more shallow box can be used in order to provide more adequate protection of the article(s). A shallow height box also reduces the weight to surface area, enabling a thinner material thickness to be used. The length of the flaps should ideally be the width of a square box and the width of a rectangular box, although any length is possible provided the ratio of flap length/ material thickness is considered. Advised ratio of length/ thickness for flaps should be around 65:1, although experimentation is recommended to find the desired flap strength for the material being used to form the box and for the type of article being packed. The ratio may increase or decrease accordingly. Using the above ratio, 5.5 mm double wall, corrugated cardboard would require flaps 357 mm long (i.e.. box width). The following table l.A gives an example of void depth range for case widths, material thickness (based on the above ratio), the tongue width ranges (based on dividing the packing flap by 8 or 10 equal spaces from outer edge to creased perforated bending line 7), and the size of the ledge 8 (formed between creased and perforated bending line 7 and crease line 13). TABLE l.A Using the above information the following recommendations for sizes should be considered * - Positioning of flap creased bending lines 5 and straight slit cuts 16 to coincide with tongue widths. Slit cuts 17 to be formed as in Figure 6. (Spaces between tongues should be the same width as the tongue). Bending lines 5 in the flap containing slots should correspond exactly- Slot sizes:- Advised length is determined by multiplying the flap length by a factor of between 0.25 (for smaller boxes) to 0.28 (for larger boxes). The slots should be centrally placed, and 15 mm wide for the box herein described. Width will depend upon final configuration of slot used and for straight slots 2.7 x*material thickness. On longer boxes it may be necessary to use two sets of slots (side by side), which should be ratio spaced across the flap box length (taken as parallel to the box length) as follows ■ - l/4x W space, l/6x W slot, l/6x W space, l/6x W slot, l/4x W space:- where W = width of packing flap. Tongue sizes:- Advised length is determined the same as described for slot length and centrally placed to correspond. Width can be sized according to table l.A. On longer boxes it may be necessary to employ the use of two sets of tongues to the ratios previously described for slots. Any combination of, number of, shapes, and sizes of slots and tongues can be used, but various combinations may suit varying criteria- For example: - it depends upon the type of article being packed and the type of material the box is constructed from. Referring to the drawn figures 1,2,3,4,5,6,7, 8,9, 10,11, 12, 13, 14,and 15 after converting the box pattern and initially forming the box, as described in figures 1,2,3,4,and 5, the following packing procedure takes place: - Figure 8 shows flap 1, with slots 3, pushed into the box so that a creased bending line 5 folds to form an L shaped flap with one leg resting roughly parallel to and in contact with the article surface 15 and one leg roughly parallel to the adjacent wall structure. The ledge 8 is formed at the same time between creased and perforated bending line 7 and creased bending line 13. Figure 9 shows flap 2, with tongues 4, pushed into the box so that a creased bending line 5 folds to form an L shape flap with one leg resting roughly parallel to and in contact with flap 1 and the article surface 15 and one leg roughly parallel to the adjacent wall structure. The ledge 8 is formed at the same time between creased and perforated bending line 7 and creased bending line 13. Tongues 4 are then engaged into slots 3, by pushing them down and in, so that they create a tension that will try and push the vertical leg of the flaps 1 and 2 against the adjacent sides of the box. The flaps are now in the article retaining position. Figures 10 and 11 show the closure lid resting on ledges 8 and sealed with adhesive tape 14. Figure 12 shows flap 1 and flap 2 positioned as described in figures 8 and 9, with both flaps then folded upwards so that leading tongue 4 of flap 1 can be engaged with a convenient slot 3 of flap 2. -10- Figure 13 shows the flaps as engaged in figure 12 and then pushed back down to the article retaining position creating tension between the flaps; so that they try and push against the adjacent sides of the box. The closure lid is shown resting on ledges 8 and sealed with adhesive tape 14. Figure 14 shows flaps 1 and 2 positioned as described in figures 8 and 9, except that the slits 17 automatically create a gusset plate with between the fold of the flap forming the corner of the L shape. Both flaps are then folded upwards, as described in figure 12, so that leading tongue 4 of flap 1 can be engaged with a convenient slot/ tongue 3+4 of flap 2. Since both flaps are identical either one can be on the bottom or top. Figure 15 shows the flaps as engaged in figure 14 and then pushed back down to the article retaining position creating tension between the flaps; so that they try and push against the adjacent sides of the box. The closure lid is shown resting on ledges 8 (not shown) with lip 18 engaged with slits 19 and sealed with adhesive tape 14. In figures 12, 13, 14, and 15, the leading tongue 4 of the upper flap 2 can be engaged into a convenient slot 3 (figure 12 and 13) or tongue 3+4 (figure 14 and 15) of the lower flap 2 if sufficient tension between flaps does not appear to have been achieved. Alternatively the flaps can be disengaged and another slot position can be engaged as originally described to increase tension. to unpack, the tape seal 14 in figures 10,11,13 and 15 is broken and a convenient slot hole is used as a finger, pull to disengage the flaps.

Claims: Clai s 1. A packing box comprising a base, a side wall structure and at least one flap, the flap having an edge connected with the side wall structure and a free edge and being arranged to fold, in one sense of rotation, into the box about its connection with the side wall structure, characterised in that the flap has at least one line of weakness between the said edges about which it yields, generally in the other sense of rotation of the edges relative to one another, when the flap engages the surface of an article contained within the box, such that the flap is foldable between an open position in which the article is held within the box, the said one flap being held in the article retaining position by its engagement with another part of the box. 2. A packing box as claimed in claim 1 including a pair of generally opposed flaps which both have lines of weakness and are foldable into article retaining positions to engage the surface of articles stored within the box, each flap having means for engaging the other flap in the respective article retaining positions. 3. A packing box as claimed in claim 2 in which each flap has a plurality of lines of weakness between the edge connected with the side wall structure and the free edge, the lines of weakness extending generally parallel to the connection between the side wall structure and the flap. 4. A packing box as claimed in claim 2 in which the lines of weakness on one flap are coincident with the means for engaging the other flap. 5. A packing box as claimed in claim 3 in which the means for engaging a series of slits or openings between the said edges of the flap which slits or openings will be engaged by projections formed in the opposite flap when the flaps are in the article retaining positions, the height of the upper surface of the article within the box determining the election of the opening and projection for engagement. 6- A packing box as claimed in claim 5 in which the slits define the -pro ections, which projections are deformable out of the general plane of one flap to enter a slit in the other flap. 7. A packing box as claimed in claim 6 in which the projections are tongues defined by the slits in the flaps. 8. A packing box as claimed in claim 2 in which slits providing intermittent lines of weakness, will deform into shapes providing resistance to folding the flap to angles of 90 degrees or less along the said lines of weakness. 9. A Packing box as claimed in claim 1 in which at least one flap is detachable to engage the surface of an article contained within the box such that the flap is held in the article retaining position by the flap engagement with another part of the box. 10- A packing box as claimed in claim 1 in which at least one flap will engage with material added to the box, such that the article within the box is held in a retaining position within the box. 11. A packing box as claimed in claim 1 comprising at least one lid connected with the side wall structure which lid is foldable over the flap in the article retaining position to close the box. 12. A packing box as claimed in claim 8, including mutually opposed lids having depending lips which are receivable in a slot in the flap in the closed position of the lids. 13. A packing box as claimed in claim 1 in which the flap is foldable *about both its connection with the side wall structure and a further fold region of the flap such that the flap projects into the box in the article retaining position spaced from the side wall structure. 14. A packing box as claimed in claim 1 which is constructed from unitary cut and scored blank of sheet material.

Inventors: BOOTH RICHARD, DHOOMA JOSE ANDRES, BOOTH, RICHARD, DHOOMA, JOSE, ANDRES
Applicants: BOOTH RICHARD, DHOOMA JOSE ANDRES, BOOTH, RICHARD, DHOOMA, JOSE, ANDRES
Application year: 1993
Main classification: B65D5
IPC codes: B65D5