Abstract:
A hanging display box with a carrying handle is made from a folding cardboard sheet. The cardboard sheet includes a display panel with a window, a substantially transparent plastic material covering the window and having flaps extending substantially beyond the display panel. A top wall attached to the display panel is connected to a hanger panel with an opening, and a bottom wall attached to the display panel is connected to a rear panel also having an opening, so that when the rear panel is folded adjacent the hanger panel, the openings align to form the carrying handle. Side walls attached to the display panel releasably fix the plastic material against the window such that, when the box is opened, the plastic material and cardboard are easily separated and recycled.

Description:
This application claims priority to provisional application No. 61/728,086, filed Nov. 19, 2012. 
    
    
     BACKGROUND 
     Folding boxes for use in retail sales, including hanging packaging created from a single sheet of folded cardboard, is known in the art. Typically such boxes comprises a cardboard sheet stamped out of a cardboard blank, which is then folded into a three-dimensional box-like shape, which may or may not have a folding lid for opening and closing. These boxes often have openings incorporated into the cardboard sheet for display or hanging purposes. 
     Examples of folding single sheet cardboard retail packaging are Sorrentino (U.S. Pat. App. 2012/0080511), Tanaka (U.S. Pat. No. 8,066,177) and Chen (U.S. Pat. No. 6,840,437). Sorrentino teaches a package folded from a single cardboard sheet, having a window disposed across two sides of the folded package. Tanaka teaches a package folded from a single cardboard sheet without a window, but having anchoring tabs adapted to connect the lid to the side of the box. Chen teaches a windowless package formed from a single cardboard sheet, with dividers incorporated into the completed package. 
     These types of packages have various drawbacks. For example, they may expose different sides of the cardboard sheet upon folding, and require printing both sides of the cardboard, thereby raising production costs. They are frequently not recyclable. And when folded, they do not provide a handle by which they may be easily carried. 
     Although the cardboard component of folding packages may be recyclable, packages having plastic windows are generally not since that portion is not recyclable. While biodegradable bioplastics are available, these plastics generally have a low melting temperature, and a tendency for the melting temperature to decrease further if heated repeatedly. Therefore, although a bioplastic may have an initial melting temperature of 150° or 160° Fahrenheit, if heated for vacuum forming, the resulting molded bioplastic may have a melting temperature of 130° F. or even 120° F. Since warehouse or transportation conditions may exceed 120° F., vacuum formed bioplastics are disfavored for packaging. 
     There is thus a need for a box used in retail packaging, formed of a single sheet of folded cardboard, that when folded, exposes only one side of the cardboard sheet thereby requiring only one sided printing, and which has a window with a high melting temperature, but which is biodegradable. And a built-in handle for carrying the box is advantageous. 
     SUMMARY 
     A hanging display box having a built-in carrying handle is made from a foldable cardboard sheet. The cardboard sheet is preferably a unitary blank, printed on only one side. The cardboard sheet has a display panel with a window, and a substantially transparent plastic material overlaying the window. While conventional materials, such as cellophane and similar plastics are contemplated for the transparent plastic material, the use of biodegradable bioplastics, for example PLA is specifically contemplated. 
     The transparent material preferably includes flaps extending substantially beyond the display panel. A top wall is attached to the display panel in a folding arrangement, and a hanger panel is attached to the top wall, also in a folding arrangement. The hanger panel has a first opening which will form part of the carrying handle. The openings in the hanger panel and the rear panel are preferably sized for grasping and for hanging the box on a peg. As such, the openings may be large and oblong to facilitate a user inserting fingers and carrying the box. 
     A bottom wall is also attached to the display panel in a folding arrangement, preferably on the opposite side of the display panel as the top wall, and a rear panel is attached to the bottom wall in a folding arrangement. The rear panel has a second opening which will also forms part of the carrying handle. Side walls are also attached to the display panel in a folding arrangement, and when folded into a side wall assembly, they releasably fix the plastic material to the display panel, covering the window. 
     When the rear panel is folded adjacent to the hanger panel to close the box, the first opening aligns with the second opening, together forming the carrying handle. In one embodiment, the rear panel includes opposing third flaps for engaging the fixed side wall assembly and enclosing the box. 
     Preferably, the side wall assemblies include first side flaps attached to the top wall and opposing second side flaps attached to the bottom wall. The side walls each include an outer panel and an inner panel attached to the outer panel in a folding arrangement. An anchor panel is attached to the inner panel, opposite from the outer panel and also in a folding arrangement, for anchoring the outer panel and inner panel over the first opposing side flaps and the second opposing side flaps, thereby forming a side wall assembly which is rigid. 
     In order to construct the hanging display box and enclosing an item, a single cardboard material is provided, preferably printed only on one side. The cardboard material is stamped into a foldable sheet having a display panel, and a portion of the display panel is removed to form a window. A substantially transparent material is placed over the window, extending substantially beyond the display panel. Preferably the portion extending substantially beyond the display panel are flaps of transparent material. 
     The blank is folded to encapsulate the transparent material and form a shell. Specifically, a user may first form the shell by folding the top wall relative to the display panel, and folding the bottom wall in the same direction relative to the display panel. Flaps attached to the top wall and bottom wall are then brought into alignment and the side walls folded over them. 
     Once the shell is formed, an item is placed in the shell, and a rear panel is folded over the item to form the display box. When the rear panel is folded over, holes in the blank may be aligned to form a carrying handle. For securing the box in a closed configuration, the rear panel may be adhered to the shell to seal the display box. Once purchased, a user may open the box and remove the item, and as part of that process partially unfolding the blank and separating the substantially transparent material from the cardboard material. In this manner, the plastic and cardboard components of the box can be disposed of separately are thus easily recyclable. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a plan view of a first embodiment cardboard sheet adapted to be folded into a first embodiment folding box. 
         FIG. 2  is a perspective view of the first embodiment cardboard sheet partially folded into the first embodiment folding box. 
         FIG. 3  is a perspective view of a partially assembled first embodiment folding box. 
         FIG. 4  is a perspective view of an assembled first embodiment folding box in an open configuration. 
         FIG. 5  is a rear perspective view of the first embodiment folding box. 
         FIG. 6  is a front perspective view of the first embodiment folding box. 
         FIG. 7A  is a plan view of a second embodiment cardboard sheet adapted to be folded into a second embodiment folding box having a window. 
         FIG. 7B  is a plan view of a transparent sheet adapted to be incorporated into the second embodiment folding box having a window. 
         FIG. 8  is a perspective view of the second embodiment cardboard sheet partially folded into the second embodiment folding box. 
         FIG. 9  is a perspective view of a partially assembled second embodiment folding box. 
         FIG. 10  is a perspective view of an assembled second embodiment folding box in an open configuration. 
         FIG. 11  is a front perspective view of the second embodiment folding box. 
     
    
    
     REFERENCE NUMBERS 
       110 . folding box 
       112 . cardboard sheet 
       114 . display panel 
       116 . top side wall 
       118 . hanger panel 
       120 . opening 
       122 . side flap 
       124 . bottom side wall 
       126 . rear panel 
       128 . rounded side flap 
       130 . side wall panel 
       132 . outer panel 
       134 . inner panel 
       136 . anchoring panel 
       138 . printed side 
       210 . second embodiment folding box 
       212 . cardboard sheet 
       214 . display panel 
       216 . top side wall 
       218 . hanger panel 
       220 . opening 
       222 . side flap 
       224 . bottom side wall 
       226 . rear panel 
       228 . rounded side flap 
       230 . side wall panel 
       232 . outer panel 
       234 . inner panel 
       236 . anchoring panel 
       238 . window 
       310 . transparent sheet 
       312 . pane region 
       314 . flap members 
       316 . crease lines 
     DESCRIPTION 
     Referring to  FIG. 1 , a first embodiment folding box  110  includes a cardboard sheet  112  shown in an unfolded configuration. The cardboard sheet  112  has a display panel  114  which will serve as the front of the completed box  110 . A top side wall  116  is foldably attached to the display panel  114 , which will form the top of the box  110 . A hanger panel  118  having an opening  120  for grasping, or hanging and displaying the box  110  is foldably attached to the top side wall  116  opposite the display panel  114 . Two side flaps  122  are foldably attached to the remaining sides of the top side wall  116 . 
     Still referring to  FIG. 1 , a bottom side wall  124  is foldably attached to the display panel  114 . A rear panel  126  is foldably attached to the bottom side wall  124  opposite the display panel  114 . The rear panel  126  also includes an opening  120  for grasping, or hanging and displaying the box  110 . The openings  120  will align in the box  110 , forming a handle or hanging structure. In this manner, the box  110  can hang on a peg wall, or sit in a display or shelf, and when a user selects the box  110 , the hanging structure is useful as a handle for holding the box  110 . That is, the user may insert one or more fingers or his or her hand into the opening  120  and grasp the box  110  in this way for carrying it outside the store. The rear panel  126  includes two rounded side flaps  128  for anchoring the rear panel  126  in the box  110  foldably attached to the remaining sides of the rear panel  126 . Two side flaps  122  are also foldably attached to the remaining sides of the bottom side wall  124 . 
     Still referring to  FIG. 1 , two side wall panels  130 , are attached to the remaining sides of the display panel  114 . The side wall panels  130  each include an outer panel  132  foldably attached to the display panel  114 , an inner panel  134  foldably attached to the outer panel  132 , and anchoring panel  136  for holding the side wall panels  130  in position when folded, foldably attached to the inner panel  134 . 
     Referring to  FIGS. 2 and 3 , the first embodiment box  110  is shown in the initial stages of assembly. In order to assemble the first embodiment box  110 , the top side wall  116 , the bottom side wall  124 , and the side wall panels  130  are folded away from the indicia-bearing printed side (ref. no.  138  in  FIG. 6 ) of the display panel  114 , to create an enclosing space. The side flaps  122  of the top side wall  116  and bottom side wall  124  are brought into alignment with the junction of the display panel  114  and outer panels  132 , which may be creased, thereby allowing the inner panels  134  to fold over the side flaps  122 . Once the inner panels  134  fold over the side flaps  122 , anchoring the side flaps  122  in position, the anchoring panels  136  fold against the display panel  114 , ensuring that the outer panels  132  and inner panels  134  remain in position. In one preferred embodiment, an adhesive may be used to hold the anchoring panels  136  in position. 
     Referring to  FIG. 4 , an assembled first embodiment box  110  in an open configuration is shown. In order to close the box  110 , prior to sealing, an object to be held (not shown) is placed in the space bounded by the display panel  114 , top side wall  116 , bottom side wall  124 , and side wall panels  130 . Thereafter the rounded side flaps  128  of the rear panel  126  are folded to fit inside the box  110  and the rear panel  126  folded over the in the manner shown. Once the rear panel  126  is in place, the openings  120  will align forming a handle for hanging or holding the box  110 . The hanger panel  118  may adhere to an upper portion of the rear panel  126  in order to seal the box  110  prior to delivery or sale. Once the hanger panel  118  is adhered to the rear panel  126 , the openings  120  form a useful handle for carrying the box  110  or hanging it on display. 
     Referring to  FIGS. 5 and 6 , rear and front, respectively, perspective views of the assembled first embodiment box  110  are shown. When assembled, the blank side (not shown) of the cardboard sheet  112  is on the inside of the box  110 . In this manner, a cardboard sheet  112  may be printed on one side only, saving both production time and production costs. Referring to  FIG. 6 , a representation of an item (not shown) contained in the box  110  or other information may be placed on the printed side  138  of the display panel  114 . 
     Referring to  FIG. 7A , a second embodiment folding box  210  includes a cardboard sheet  212  in an unfolded configuration. The cardboard sheet  212  has a display panel  214  which will serve as the front of the completed box  210 . A top side wall  216  is foldably attached to the display panel  214 , which will form the top of the box  210 . A hanger panel  218  having an opening  220  for grasping, or hanging and displaying the box  210  is foldably attached to the top side wall  216  opposite the display panel  214 . Two side flaps  222  are foldably attached to the remaining sides of the top side wall  216 . 
     Still referring to  FIG. 7A , a bottom side wall  224  is foldably attached to the display panel  214 . A rear panel  226  is foldably attached to the bottom side wall  224  opposite the display panel  214 . The rear panel  226  also includes an opening  220  for grasping, or hanging and displaying the box  210 . The openings  220  will align in the box  210 , forming a handle or hanging structure. In this manner, the box  210  can hang on a peg wall, or sit in a display or shelf, and when a user selects a box, the hanging structure is useful as a handle for holding the box  210 . The rear panel  226  includes two rounded side flaps  228  for anchoring the rear panel  226  in the box  210  foldably attached to the remaining sides of the rear panel  226 . Two side flaps  222  are also foldably attached to the remaining sides of the bottom side wall  224 . 
     Still referring to  FIG. 7A , two side wall panels  230 , are attached to the remaining sides of the display panel  214 . The side wall panels  230  each include an outer panel  232  foldably attached to the back panel  214 , an inner panel  234  foldably attached to the outer panel  232 , and anchoring panel  236  for holding the side wall panels  230  in position when folded, foldably attached to the inner panel  234 . Therefore, the second embodiment box  210  is identical in structure and folding pattern to the first embodiment box  110 , except that the second embodiment box  210  includes a window  238  on the display panel  214  through which an item (not shown) held by the box  210  can be seen. 
     Referring to  FIG. 7B , a transparent sheet  310  is used to cover the window  238 . The transparent sheet  310  comprises a pane region  312 , and flap members  314  foldably attached to the pane region  312  along crease lines  316 . The flap members  314  preferably extend all the way across the outer panels  232 , top side wall  222 , and bottom side wall  224 . Ideally, the transparent sheet  310  comprises a polymer such as Polylactic Acid (PLA), or a similar transparent bioplastic. Since the transparent sheet  310  is releasable and easily separated from the box  210 , sorting them with similar materials for recycling is facilitated. 
     Currently, PLA and other bioplastics have low glass transmission temperatures (i.e., the temperature at which they change from a hard and relatively brittle state into a molten rubber-like state), and those glass transmission temperatures become even lower upon heating and re-heating. For this reason, heating and vacuum-forming PLA often results in a plastic unsuitable for use in hot environments such as warehouses, where temperatures routinely exceed 120° Fahrenheit. 
     Since PLA&#39;s initial glass transmission temperature is often in excess of 140°-150° Fahrenheit, an un-molded sheet of PLA resists melting and is better suited to high temperature environments. For this reason, the transparent sheet  310  is not vacuum formed for insertion into the cardboard sheet  210 , but rather is cut to shape, and crease lines  316  physically formed on the sheet and the flap members  314  folded without applying any heat during assembly. Although PLA is one contemplated material, other embodiments may include any type of plastic window, including Polyethylene terephthalate (PET), or other commonly used plastics. 
     Referring to  FIGS. 8 and 9 , the second embodiment box  210  and transparent sheet  310  are shown in the initial stages of assembly. Referring to  FIG. 8 , in order to assemble the second embodiment box  210 , the transparent sheet  310  is seated over the display panel  214 . Preferably, the pane region  312  of the transparent sheet  310  is the same size as the display panel  214 . Thereafter, the top side wall  216 , the bottom side wall  224 , and the side wall panels  230  are folded to form an enclosure in the manner shown. With the pane region  312  the same size as the display panel  214 , the flap members  314  will lay against the top and bottom side walls  216 / 224  and side wall panels  230 . 
     Referring to  FIG. 9 , the side flaps  222  of the top side wall  216  and bottom side wall  224  are brought into alignment with the crease formed at the junction of the display panel  214  and outer panels  232 , thereby allowing the inner panels  234  to fold over the side flaps  222 . In this manner, the outer panels  232  and side flaps  222  sandwich the flap members  314  holding the transparent sheet  310  in place. In an alternative embodiment, the flap members  314  may be sandwiched between the side flaps  222  and inner panels  234 , depending on the desired method of construction. Once the inner panels  234  fold over the side flaps  222 , anchoring the side flaps  222  and transparent sheet  310  in position, the anchoring panels  236  fold against the pane portion  312  of the transparent sheet  310 , ensuring that the outer panels  232  and inner panels  234  remain in position. In one preferred embodiment, an adhesive may be used to hold the anchoring panels  236  in position. 
     Referring to  FIG. 10 , an assembled first embodiment box  210  in an open configuration is shown. In order to close the box  210 , prior to sealing, an object to be held (not shown) is placed in the space bounded by the display panel  214 , top side wall  216 , bottom side wall  224 , and side wall panels  230 . Thereafter the anchoring panels  228  of the rear panel  226  are folded to fit inside the box  238  and the rear panel  226  folded over the in the manner shown. Once rear panel  226  is in place, the openings  220  will align forming a handle for hanging or holding the box  210 . The hanger panel  218  may adhere to an upper portion of the rear panel  226  in order to seal the box  210  prior to delivery or sale. Once the hanger panel  218  is adhered to the rear panel  226 , the openings  220  form a useful handle for carrying the box  210  or hanging it on display. 
     Referring to  FIG. 11 , a front perspective view of an assembled second embodiment box  210  is shown. When assembled, the pane region  312  of the transparent sheet  310  is shown, through which an item (not shown) contained in the box  210  or other display may be placed and viewable in the closed box  210 . Because the transparent sheet  310  has not been heated during assembly, the box  210  can withstand higher temperatures when stored, and while remaining 100% recyclable. 
     The foregoing description is sufficient in detail to enable one skilled in the art to make and use the invention. It is understood, however, that the detail of the preferred embodiments presented is not intended to limit the scope of the invention. For instance, recyclable bioplastics other than PLA may be used, and the shape of the box may be other than square or rectangular. Therefore equivalents thereof and other modifications which come within the scope of the invention as defined by the claims will become apparent to those skilled in the art upon reading this specification.