Patent Publication Number: US-2007108263-A1

Title: Crush-resistant box, box blank, and method of manufacture

Description:
BACKGROUND OF THE INVENTION  
      This invention relates generally to containers, and more particularly to boxes for crush-sensitive products.  
      Products such as self-adhesive bandages are often shipped and sold in small boxes made from cardboard or other sheet-like materials. These boxes, while lightweight and inexpensive, are often subject to crushing or deformation during the necessary handling when they are packed in large quantities in larger containers, shipped to stores, and stocked on shelves. Crushed or deformed boxes are unsightly and may damage the product contained inside. It is known to make boxes crush-resistant by using thicker materials throughout, or by making the entire box a double-paneled structure. However, this introduces undesired weight and cost to the box.  
     BRIEF SUMMARY OF THE INVENTION  
      Therefore, it is an object of the invention to provide a crush-resistant box.  
      It is another object of the invention to provide a box having some of the panels thereof reinforced.  
      It is another object of the invention to provide a crush-resistant box which provides clear access to the product contained therein.  
      It is another object of the invention to provide a box having a reclosable lid.  
      These and other objects are met by the present invention, which according to one aspect provides a blank for a box including a plurality of panels separated by a plurality of fold lines, the blank including: a plurality of outer panels adapted to be folded to define an outer enclosure, the outer panels including a pattern of fold lines and perforations defining a lid at one end of the outer enclosure, the lid moveable between an open position and a closed position; a plurality of inner panels adapted to be folded to lie inside of the outer enclosure such that at least some of the outer panels are reinforced by an underlying one of the inner panels; and at least one lock tab extending outwardly from the inner panels so as to contact the lid and retain the lid in a closed position.  
      According to another embodiment of the invention, the number of inner panels is one less than the number of outer panels.  
      According to another embodiment of the invention, a portion of the inner panels underlie the lid when the lid is in a closed position.  
      According to another embodiment of the invention, the inner panels include at least an inner front panel; and the outer panels include at least an outer front panel, wherein the inner front panel is adapted to be folded to reside against the outer front panel.  
      According to another embodiment of the invention, the inner front panel has a notch disposed at an upper end thereof therein for permitting access to an interior of the inner enclosure when the lid is in the open position.  
      According to another embodiment of the invention, the panels include, in sequence: a first inner side panel; an inner front panel; a second inner side panel; an outer rear panel; a first outer side panel; an outer front panel; and a second outer side panel.  
      According to another embodiment of the invention, the blank further includes a plurality of end flaps protruding from upper and lower ends of the outer panels.  
      According to another embodiment of the invention, at least one of the end flaps includes a hang tag having a hole formed therethrough, wherein the hang tag initially forms a continuous portion of the end flap and can be folded away from the end flap to provide access to the hole for hanging the blank thereby.  
      According to another embodiment of the invention, the hang tag is initially connected to the end flap by at least one tag perforation, and wherein at least one finger notch is provided in the end flap for facilitating breaking of the perforation.  
      According to another embodiment of the invention the blank is made from card board.  
      According to another embodiment of the invention, a box includes: a plurality of interconnected outer panels which define an outer enclosure wherein the outer panels define a lid at one end thereof which is moveable between an open position and a closed position; a plurality of interconnected inner panels disposed inside the outer enclosure, at least some of the inner panels being disposed in a reinforcing relationship adjacent corresponding ones of the outer panels; and at least one lock tab extending outwardly from the inner panels so as to contact the lid and retain the lid in a closed position.  
      According to another embodiment of the invention, one of the inner panels includes a lid tab defined by a tab perforation; and a free end of the lid tab is secured to the lid.  
      According to another embodiment of the invention, the lid is defined by at least one fold line cooperating with a plurality of perforations such that the lid initially forms an integral part of the outer panels and can be separated along the perforations to fold open about the fold line.  
      According to another embodiment of the invention, a portion of the inner panels underlie the lid when the lid is in a closed position.  
      According to another embodiment of the invention, the inner panels include at least an inner front panel; and the outer panels include at least an outer front panel, wherein the inner front panel resides adjacent the outer front panel in a reinforcing relationship so as to resist crushing of the box in a side-to-side direction.  
      According to another embodiment of the invention, the inner front panel has a notch disposed at an upper end thereof for permitting access to an interior of the inner enclosure when the lid is in the open position.  
      According to another embodiment of the invention, the outer enclosure includes opposed front and back outer panels connected by opposed outer side panels; and the inner panels include opposed inner side panels connected by an inner front panel.  
      According to another embodiment of the invention, the inner and outer panels are integrally formed from a single sheet-like blank.  
      According to another embodiment of the invention, the box further includes at least one foot extending downwardly from a bottom panel of the box so as to stabilize the box in a upright standing position.  
      According to another embodiment of the invention, the box further includes a plurality of top end flaps protruding from the top ends of the outer panels and folded together to form a top end panel; and a plurality of bottom end flaps protruding from the bottom ends of the outer panels and folded together to form a bottom end panel.  
      According to another embodiment of the invention, at least one of the end flaps includes a hang tag having a hole formed therethrough, wherein the hang tag initially forms a continuous portion of the end flap and can be folded away from the end flap to provide access to the hole for hanging the blank thereby.  
      According to another embodiment of the invention, the hang tag is initially connected to the end flap by at least one tag perforation, and wherein at least one finger notch is provided in the end flap for facilitating breaking of the perforation.  
      According to another embodiment of the invention, a method of forming a box includes: providing a blank; folding the blank to define a plurality of inner panels; and folding the blank to define a plurality of outer panels enclosing the inner panels, wherein at least some of the inner panels lie adjacent the outer panels in reinforcing relationship thereto; wherein the outer panels include a pattern of fold lines and perforations defining a lid moveable between an open position and a closed position; and at least one lock tab extends outwardly from the inner panels so as to contact the lid and retain the lid in a closed position.  
      According to another embodiment of the invention, the method further includes securing at least two of the outer panels together.  
      According to another embodiment of the invention, the method further includes securing at least one of the inner panels to one of the outer panels.  
      According to another embodiment of the invention, the outer panels are folded to form opposed front and back outer panels connected by opposed outer side panels; and the inner panels are folded to form opposed inner side panels connected by an inner front panel. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The invention may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which:  
       FIG. 1  is a front view of a box blank constructed according to the present invention;  
       FIG. 2  is a rear view of the blank of  FIG. 1 ;  
       FIG. 3  is a perspective view of the blank of  FIG. 1  before a folding process;  
       FIG. 4  is a perspective view of the blank of  FIG. 1  after a first fold is completed;  
       FIG. 5  is a perspective view of the blank of  FIG. 1  after a second fold is completed;  
       FIG. 6  is a perspective view of the blank of  FIG. 1  after a third fold is completed;  
       FIG. 7  is a perspective view of the blank of  FIG. 1  after interior panels thereof have been completely folded;  
       FIG. 8  is a perspective view of the blank of  FIG. 1  showing exterior panels thereof being folded over interior panels thereof;  
       FIG. 9  is a perspective view of a partially completed box formed from the blank of  FIG. 9  with its top and bottom ends open;  
       FIG. 10  is a perspective view of the box of  FIG. 9  showing a step of closing the bottom end thereof;  
       FIG. 11  is a perspective view of the box of  FIG. 9  with its bottom end closed;  
       FIG. 12  is a perspective view of the box of  FIG. 9  with an open top end and a closed bottom end;  
       FIG. 13  is a perspective view of the box of  FIG. 12  showing a step of closing the bottom end thereof;  
       FIG. 14  is a perspective view of the box of  FIG. 9  with its top and bottom ends closed;  
       FIG. 15  is a perspective view of the box of  FIG. 14  with a lid shown in an open position;  
       FIG. 16  is a view taken along lines  16 - 16  of  FIG. 14 ;  
       FIG. 17  is a front view of the box of  FIG. 14 ;  
       FIG. 18  is a front view of an alternative box blank constructed according to the present invention; and  
       FIG. 19  is a perspective view of a completed box formed from the blank of  FIG. 18 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      Referring to the drawings wherein identical reference numerals denote the same elements throughout the various views,  FIG. 1  illustrates an exemplary blank  10  for a crush-resistant box. The blank  10  is constructed of a generally planar, sheet-like material which is separated into a plurality of panels by a plurality of fold lines  12 . It should be noted that the fold lines  12  may represent physical areas of weakness prone to folding, for example by having been scored or pre-folded, or they may simply be virtual lines along which folds take place during a manufacturing process, described below. Any material which will not tear and which can be folded may be used for the blank. Non-limiting examples of suitable materials include paper, cardboard, plastic, fabrics, and sheet metal. In the illustrated example the blank  10  is constructed from coated cardboard  
      The blank  10  includes, in left to right order with reference to  FIG. 1 , inner panels  14  comprising a first inner side panel  14 A, an inner front panel  14 B, and a second inner side panel  14 C. A lid tab  16  is disposed at an upper end of the second inner side panel  14 C and connected to the remainder of the second inner side panel  14 C by a tab perforation  18 . The inner front panel  14 B has a notch  20  formed therein. Left and right lock tabs  22 A and  22 B are defined by cut patterns in the inner panels  14 .  
      Continuing left to right, the blank  10  includes outer panels  24  comprising a outer rear panel  24 A with first top and bottom end flaps  26 A and  28 A, a first outer side panel  24 A with second top and bottom end flaps  26 A and  28 B, an outer front panel  24 C with third top and bottom end flaps  26 C and  28 C, and a second outer side panel  24 D with fourth top and bottom end flaps  26 D and  28 D. A lid fold line  30  and a pattern of lid perforations  32  are disposed across portions of the outer rear panel  24 A, first outer side panel  24 B, outer front side panel  24 C, and second outer side panel  24 D to define a lid  34 . It should be noted that the particular arrangement of the panels is not critical to the present invention. For example, while the illustrated blank  10  is adapted to form a box having four sides, it could also be adapted for a greater or lesser number of sides.  
       FIGS. 3-9  illustrate the steps involved in forming box  36  from the blank  10 . The inner side panels  14 A and  14 C are folded so the inner rear panel  14 B overlies the outer rear panel  24 A and the first inner side panel  14 C mates with the first outer side panel  24 B. The first inner side panel  14 C is then secured to the first outer side panel  24 B. Examples of suitable means for securing the two panels include adhesives, fasteners such as staples, interconnecting tabs and slots, and depending on the material used for the blank, sonic welding or heat bonding. As shown in  FIG. 7 , the blank  10  may be folded upward so that the inner panels  14  define an inner enclosure.  
      As shown in  FIG. 8 , the outer panels  24  are folded so that they overlie the inner enclosure forming an outer enclosure, and the second outer side panel  24 D mates with the second inner side panel  14 C. The second outer side panel  24 D is secured to the second inner side panel  14 C. Examples of suitable means for securing the two panels include adhesives, fasteners such as staples, interconnecting tabs and slots, and depending on the material used for the blank, sonic welding or heat bonding. The resulting partially completed box  36  with the ends open is shown in  FIG. 9 .  
      The exact sequence in which the various panels are folded and secured is not of particular importance. For example, to reduce the cost of shipping, the blank  10  may be folded and secured into a flat shape without the three-dimensional volume shown in  FIG. 9 . When it is desired to use the blank  10 , it is then “broken” or folded open by hand or by machine to form the open-ended box  36  shown in  FIG. 9 . Furthermore, the folding and securing processes may take place simultaneously or near-simultaneously, for example using a known type of folding and gluing machine.  
      To complete the box  36 , the bottom end flaps  28 A- 28 D are folded inward and secured together, using the securing means described above, to form a bottom end panel  38 , as shown in  FIGS. 10 and 11 . The box  36  is then ready to be loaded with a product (not shown) such as bandages. In some cases the product may be loaded first and then the bottom closed afterwards. The bottom end of the box  36  may optionally include one or more downwardly-extending feet  39  which help the box  36  stand upright on a display shelf.  
      After the product is loaded into the box  36 , the top end is closed off by folding the top end flaps  26 A- 26 D inward and securing them together, using the securing means described above, to form a top end panel  40 , as shown in  FIGS. 12 and 13 .  
      The completed and closed box  36  is shown in  FIG. 14 . The box  36  encloses the desired product and protects the product from damage caused by shipping and handling. In particular, the first and second outer side panels  24 B and  24 D and the outer front panel  24 C are all reinforced. In effect, these panels each form a double thickness so as to resist crushing of the box  36  in either fore-and-aft or side-to-side directions, as shown in  FIG. 16 . Upper portions of the outer front panel  24 C, outer rear panel  24 A, and outer side panels  24 B and  24 D form the completed lid  34  which is retained in a closed position by virtue of the intact lid perforations  32 .  
      When is it desired to access the product, the box  36  is broken along the lid perforations  32 , and the lid tab  16  is separated at the inner perforation  18 , so the lid  34  can be moved to an open position about a “live hinge” formed by the lid fold line  30 , as shown in  FIG. 15 . The cut-down notch  20  in the inner front panel  14 B is generally aligned with the outer front panel  24 C so as to provide access to view and retrieve the product inside the box. The lid  34  may then be reclosed back down over the inner panels  14 . The box  36  retains its reinforced properties to protect the remaining product from crushing. In the closed position, the lock tabs  22 A and  22 B engage the interior surfaces of the lid  34  to retain it until it is intentionally reopened by a user.  
       FIG. 18  illustrates an alternative box blank  110  which incorporates a hang tab. The blank  10  is substantially identical in construction to the blank  10  and its construction and use are substantially the same. The blank  110  includes a plurality of inner panels  114 , a plurality of outer panels  124 , and a plurality of end flaps  126 . At least one of the end flaps  126 , in this case end flap  126 C includes an optional hang tab  125  which is attached to the remainder of the end flap  126 C by a pair of tag perforations  127 . A center hole  129  suitable for accepting a standard shelf hook (not shown) extends through the hang tab  125 . The end flap  126 C may include one or more finger notches  131  to ease use of the hang tab  125 .  
      The blank  110  may be assembled into a box  136  which is substantially identical to the box  36 . The hang tab  125  initially forms a continuous part of the end flap  126 C, and the box  136  may be stocked on a shelf without using the hang tag  125 . When it is desired to use the hang tag  125 , the tag perforations  127  are broken and the hang tag  125  is folded upwards, exposing the center hole for hanging the box  136  by a standard shelf hook. Although the end flap  126 C is separated by this action, the underlying end flap  126 C continues to provide a complete closure for the box  136 .  
      The foregoing has described a crush-resistant box, and a blank and a method for making such a box. While specific embodiments of the present invention have been described, it will be apparent to those skilled in the art that various modifications thereto can be made without departing from the spirit and scope of the invention. Accordingly, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation, the invention being defined by the claims.