Patent Publication Number: US-6662947-B2

Title: Box for carrying bottles

Description:
FIELD OF THE INVENTION 
     The present invention is directed to a box, and, more particularly, to a box for carrying bottles. 
     BACKGROUND OF THE INVENTION 
     Boxes are typically formed of material, such as corrugated fiberboard, that is die cut into a sheet having a desired shape. Fold lines are scored on the sheet, demarcating separate walls, a top, a bottom, and closure flaps, thus forming a blank. The blank is then folded about the fold lines and the closure flaps are glued, male/female locked, or stapled to the walls, top and bottom, thereby forming a box. 
     U.S. Pat. No. 2,173,494 to Rous discloses a carton for carrying six bottles. Rous is limiting in that it does not provide for protection between the bottles during transport. U.K. Pat. No. 1,338,230 to Smallwood discloses a case for carrying 10 bottles. Smallwood is limiting in that a fastener, such as adhesive or staples, is required to retain the case in its assembled condition, and no protection is provided between the bottles. 
     In view of the foregoing it is an object of the present invention to provide a box that reduces or overcomes the aforesaid difficulties inherent in prior known boxes for carrying bottles. 
     BRIEF SUMMARY OF THE INVENTION 
     The principles of the invention maybe used advantageously to provide a simple and effective box for carrying bottles that is easy to assemble and disassemble, while at the same time providing protection for the bottles, and which is easy for an individual to carry. 
     In accordance with a first aspect, a blank of foldable material for forming a box includes a first wall panel, and a second wall panel foldable about a first wall fold line demarcating the first and second wall panels. A third wall panel is foldable about a second wall fold line demarcating the second and third wall panels. One side of a triangular top extends along a top edge of the second wall, and is foldable about a top fold line demarcating the top and the second wall. A plurality of apertures is formed in the top. One side of a triangular bottom extends generally along a bottom edge of the second wall and is foldable about a bottom fold line demarcating the bottom and the second wall. An insert includes a first panel, and a second panel adjacent the first panel and foldable about an insert panel fold line demarcating the first panel and the second panel. A slit in the first panel extends from the insert panel fold line through the first panel and back to the insert panel fold line to form a third panel foldable about the insert panel fold line. 
     In accordance with another aspect, a box formed from a blank of foldable material includes a first wall and a second wall adjacent the first wall. The second wall is folded about a first wall fold line demarcating the first and second walls to form a first box corner. A third wall adjacent the second wall is folded about a second wall fold line demarcating the second and third walls to form a second box corner. A triangular top extends along a top edge of the second wall and is folded about a top fold line demarcating the top from the second wall. A triangular bottom extends along a bottom edge of the second wall and is folded about a bottom fold line demarcating the bottom from the second wall. A plurality of apertures is formed in the top, with each aperture configured to receive a neck of a bottle. An insert has a plurality of panels folded from of a sheet of material, the insert being positioned between the first, second and third walls when the walls are folded about the wall fold lines. 
     In accordance with another aspect, a blank of foldable material for forming a box includes a first wall panel and a second wall panel. The second wall panel is foldable about a first wall fold line demarcating the first and second wall panels, to form a first box corner. A third wall panel is foldable about a second wall fold line demarcating the second and third wall panels. A pair of wall tabs extends from a side edge of the first wall panel. A wall closure flap is foldable about a wall closure flap fold line demarcating the wall closure flap and the third wall. A pair of wall tab slots extends generally along the wall closure flap fold line, with each wall tab slot configured to receive a respective wall tab. A triangular top has one side extending along a top edge of the second wall and is foldable about a top fold line demarcating the top and the second wall. A pair of top tabs is also included, with a first top tab projecting from a top edge of the first wall and a second top tab projecting from a top edge of the third wall. A pair of top closure flaps is included as well, with each top closure flap extending along one side of the top and foldable about a top closure flap fold line demarcating the top closure flap from the top. A pair of top slots is included, with each top slot extending generally along one of the top closure flap fold lines and configured to receive a top tab. A triangular bottom has one side extending generally along a bottom edge of the second wall and is foldable about a bottom fold line demarcating the bottom and the second wall. Also included is a pair of bottom tabs, with a first bottom tab projecting from a bottom edge of the first wall and a second bottom tab projecting from a bottom edge of the third wall. Also included is a pair of bottom closure flaps, with each bottom closure flap extending along one side of the bottom and foldable about a bottom closure flap fold line demarcating the bottom closure flap from the bottom. A pair of bottom slots is also included, with each bottom slot extending generally along one of the bottom closure flap fold lines and configured to receive a bottom tab. An insert includes a first panel and a second panel. The second panel of the insert is adjacent the first panel and folded about an insert panel fold line demarcating the first panel and the second panel. A slit in the first panel extends from the insert panel fold line through the first panel and back to the insert panel fold line to form a third panel foldable about the insert panel fold line. The insert is positioned between the first, second and third walls when the walls are folded about the wall fold lines. 
     Those skilled in the art will appreciate that preferred embodiments of the present invention can provide a box for carrying bottles that is easy to assembly and disassemble, provides a simple and efficient device for protecting the bottles from one another, as well as being easy to carry. These and additional features and advantages of the invention will be readily apparent and fully understood from the following detailed description of preferred embodiments, taken with reference to the appended drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a plan view of a box precursor in accordance with a preferred embodiment of the present invention. 
     FIG.  2 . is a perspective view of a box formed from the box precursor of FIG. 1, shown carrying three bottles. 
     FIG. 3 is an elevation view of a wall closure flap of the box precursor of FIG. 1 in its folded position. 
     FIG. 4 is an elevation view of a top closure flap of the box precursor of FIG. 1 in its folded position. 
     FIG. 5 is a plan view of the box of FIG.  2 . 
     FIG. 6 is an elevation view of a bottom closure flap of the box precursor of FIG. 1 in its folded position. 
     FIG. 7 is a plan view of an insert precursor for insertion in the box of FIG.  2 . 
     FIG. 8 is a perspective view of an insert formed from the insert precursor of FIG. 7, shown in its folded position as used when inserted into the box of FIG.  2 . 
     FIG. 9 is a perspective view of the insert of FIG. 8, shown in its folded position between three bottles. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As shown in FIG. 1, a box precursor or blank  2  in accordance with the present invention comprises a sheet that is die cut to a desired size. In a preferred embodiment, blank  2  is formed of corrugated fiberboard. Blank  2  may also be formed of folding carton, chip board, or any other material suitable for carrying the contents of the box such as, for example, bottles. Blank  2 , when folded, will form a box-shaped container  4  as seen in FIG.  2  and described more fully below. 
     The terms top, bottom and side, as used herein, are relative terms and refer generally to box  4  as illustrated in FIG. 2, with bottles protruding upwardly out of the box as seen here. It is to be appreciated that other orientations of box  4  are considered to be within the scope of the invention. For example, in one orientation where the user holds the box by its handle and the bottles protrude horizontally out of the box, the top and bottom would not refer to vertical directions, and in such a case could be considered to be end panels. 
     Blank  2  includes a first wall panel  6 , separated or demarcated from an adjacent second wall panel  8  by a first wall fold line  10 . A wall fold line, commonly referred to in the industry as a “score,” is a partially compressed region of blank  2  formed by scoring, which facilitates the folding of blank  2 . A third wall panel  12  is similarly demarcated from adjacent second wall panel  8  by a second wall fold line  14 . Wall fold lines  12 ,  14  form corners of a three-sided box  4 , as seen in FIG.  2 . 
     A pair of wall tabs  11  (tabs are commonly referred to in the industry as “male locks”) are formed along a side edge of first wall  6 , and are separated or demarcated from first wall panel  6  by a wall tab fold line  13 . In the illustrated embodiment, wall tabs  11  have rounded or radiused corners  9  that provide for easy insertion of wall tabs in slots  20 , described in greater detail below. In other preferred embodiments, corners  9  may be chamfered or otherwise modified to facilitate insertion of wall tabs  11  in slots  20 . In certain preferred embodiments, notches in wall tabs  11  at the juncture of wall tabs  11  and wall tab fold line  13  form barbs  15 . Barbs  15  maintain wall tabs  11  in their engaged position within slots  20 , as described in greater detail below. 
     A flange or wall closure flap  16  extends along a side edge of third wall panel  12 , and is similarly separated or demarcated from third wall panel  12  by a wall closure flap fold line  18 . A pair of slots  26 , seen in FIG.  3  and commonly referred to in the industry as “female slots,” are formed generally along wall closure flap fold line  18 . As seen in FIG. 1, each slot  26  is formed by a plurality of slits formed in blank  2 . A slit  20  in wall closure flap  16  extends generally parallel and proximate to wall closure flap fold line  18 . A first end slit  22  extends from a first end of slit  20  to wall closure flap fold line  18 . A second end slit  24  extends from a second end of slit  20  to wall closure flap fold line  18 . Each slit  20  and its corresponding end slits  22 ,  24  form a slot  26 , as seen in FIG.  3 . Slots  26  receive wall tabs  11  when box  4  is assembled, and the engagement of wall tabs  11  in slots  26  serves to maintain the walls of box  4  in their folded state. In certain preferred embodiments, end slits  22 ,  24  extend at an angle with respect to wall closure flap fold line  18 . In the illustrated embodiment, end slits  22 ,  24  are angled outwardly from slit  20  toward the top and bottom of third wall panel, respectively, such that slot  26  has a generally trapezoidal shape. It is to be appreciated that more or less than two wall tabs  11  and corresponding slots  26  may be formed along first wall panel  6  and third wall panel  12 . 
     As seen in FIG. 1, a triangular end or top panel  28  extends along an edge (seen as an upper edge in the illustrated embodiment) of second wall panel  8 , and is demarcated from second wall panel  8  by a top fold line  30  extending along the length of the upper edge of second wall panel  8 . One or more cut outs or apertures  32  are formed in top panel  28 . As seen in FIG. 2, apertures  32  are seen to receive the necks  34  of bottles  36  carried within box  4 . In the illustrated embodiment, three bottles  36  are carried in box  4 , and, consequently, three apertures  32  are formed in top panel  28 . 
     A top tab  38  is formed along an edge (seen as an upper edge in the illustrated embodiment) of each of first wall panel  6  and third wall panel  12 . A first portion  40  of top tab  38  is formed by a pair of slits  42 , extending downwardly from the upper edge of the respective wall panel to a first top tab fold line  44  about which first portion  40  may be folded. A second portion  46  extends upwardly from the upper edge of its respective wall panel, and is separated or demarcated from first portion  40  by a second top tab fold line  48 . Top tab fold line  48  preferably extends just below and parallel to the upper edge of its respective wall panel. Slits  42  preferably extend generally parallel to one another and perpendicular to the upper edge of the respective wall panel. In the illustrated embodiment, second portion  46  has rounded or radiused corners  50  that provide for easy insertion of top tabs  38  in slots  62 , as further described below. In other preferred embodiments, corners  50  may be chamfered or otherwise modified to facilitate insertion of top tabs  38  in slots  62 . 
     A top flange or closure flap  52  extends along each side edge of top panel  28 , and is similarly separated or demarcated from top panel  28  by a top closure flap fold line  54 . A slit  56  is formed in top closure flap  52 , and extends generally parallel and proximate to top closure flap fold line  54 . A first end slit  58  extends from a first end of slit  56  to top closure flap fold line  54 . A second end slit  60  extends from a second end of slit  56  to top closure flap fold line  54 . Each slit  56  and its corresponding end slits  58 ,  60  form a slot  62 , as seen in FIG.  4 . Slots  62  receive respective top tabs  38  when box  4  is assembled as seen in FIG. 5, and serve to maintain top panel  28  of box  4  in its folded state. 
     Cut outs or apertures  64  are formed in top panel  28 , with each aperture opening into a corresponding slot  62 . Apertures  64  serve to provide access to top tabs  38  when top panel  28  is in its folded state, as seen in FIG. 5, allowing an individual to grasp top tabs  38  with a finger and release them from engagement with slots  62 . Such access to top tabs  38  facilitates disassembly of box  4 . In the illustrated embodiment, apertures  64  have a semi-circular shape. Other suitable shapes will become readily apparent to those skilled in the art, given the benefit of this disclosure. 
     In certain preferred embodiments, end slits  58 ,  60  extend at an angle with respect to top closure flap fold line  54 . In the illustrated embodiment, end slits  58 ,  60  are angled outwardly from slit  56  toward top closure flap fold line  54 , such that slot  62  has a generally trapezoidal shape, as seen in FIG.  4 . It is to be appreciated that more than one top tab  38  and corresponding slot  62  may be formed along first wall  6  and top closure flap  52 . 
     As seen in FIG. 1, a triangular end or bottom panel  63  extends along an edge (seen as a lower edge in the illustrated embodiment) of second wall panel  8 , and is demarcated from second wall panel  8  by a bottom fold line  65  extending along the length of the lower edge of second wall panel  8 . 
     A bottom tab  66  is formed along an edge (seen as a lower edge in the illustrated embodiment) of each of first wall panel  6  and third wall panel  12 . A first portion  68  of top tab  66  is formed by a pair of slits  70 , extending upwardly from the lower edge of the respective wall panel to a first bottom tab fold line  72  about which first portion  68  may be folded. A second portion  74  extends downwardly from the lower edge of its respective wall panel, and is separated or demarcated from first portion  68  by a second bottom tab fold line  76 . Bottom tab fold line  76  preferably extends just above and parallel to the lower edge of its respective wall panel. Slits  70  preferably extend generally parallel to one another and perpendicular to the lower edge of the respective wall panel. In the illustrated embodiment, second portion  74  has rounded or radiused corners  78  that provide for easy insertion of bottom tabs  66  in slots  90  as further described below. In other preferred embodiments, corners  78  may be chamfered or otherwise modified to facilitate insertion of bottom tabs  66  in slots  90 . 
     A bottom flange or closure flap  80  extends along each side edge of bottom panel  63 , and is similarly separated or demarcated from bottom panel  63  by a bottom closure flap fold line  82 . A slit  84  is formed in bottom closure flap  80 , and extends generally parallel and proximate to bottom closure flap fold line  82 . A first end slit  86  extends from a first end of slit  84  to bottom closure flap fold line  82 . A second end slit  88  extends from a second end of slit  84  to bottom closure flap fold line  82 . Each slit  84  and its corresponding end slits  86 ,  88  form a slot  90 , as seen in FIG.  6 . Slots  90  receive bottom tabs  66  when box  4  is assembled, and serve to maintain bottom panel  63  of box  4  in its folded state. 
     Cut outs or apertures  92  are formed in bottom panel  63 , with each aperture opening into a corresponding slot  90 . Apertures  92  serve to provide access to bottom tabs  66  when bottom panel  63  is in its folded state as seen in FIG. 6, allowing an individual to grasp bottom tabs  66  with a finger and release them from engagement with slots  90 . Such access facilitates disassembly of box  4 , allowing an individual to easily access the bottles carried in the box. In the illustrated embodiment, apertures  92  have a semi-circular shape. Other suitable shapes will become readily apparent to those skilled in the art, given the benefit of this disclosure. 
     In certain preferred embodiments, end slits  86 ,  88  extend at an angle with respect to bottom closure flap fold line  82 . In the illustrated embodiment, end slits  86 ,  88  are angled outwardly from slit  84  toward bottom closure flap fold line  82 , such that slot  90  has a generally trapezoidal shape, as seen in FIG.  6 . It is to be appreciated that more than one bottom tab  66  and corresponding slot  90  may be formed along bottom panel  63  and bottom closure flap  80 . 
     As seen in FIGS. 1 and 2, a handle  94  is formed in box  4 . Handle  94  includes a first aperture  96  formed in first wall panel  6  and a second aperture  98  formed in second wall  8 . Apertures  96  and  98  are preferably oval, or racetrack shaped, with semi-circular ends connected by straight sides. A handle flap  100  is positioned within aperture  96 , and is separated or demarcated from first wall panel  6  by a handle flap fold line  102 . Similarly, a handle flap  104  is positioned within aperture  98 , and is separated or demarcated from second wall panel  8  by a handle flap fold line  106 . Handle flaps  100 ,  104  have the shape of a half oval, or half racetrack, with a long axis of the racetrack shaped apertures forming the straight sides of the flaps, which are the sides of the flaps remote from the handle flap fold lines  102 ,  106 . 
     When box  4  is in its assembled state, as seen in FIG. 2, handle flaps  100 ,  104  are bent into the interior of box  4  about handle flap fold lines  102 ,  106 , respectively, in overlapping fashion. The handle flaps thus provide a comfortable resting place for an individual&#39;s fingers extending through apertures  96 ,  98  of handle  94  when carrying box  4 . 
     As seen in FIGS. 7-8, an insert  108  is formed of a sheet of material. Insert  108  may be formed of, for example, corrugated fiberboard, folding carton, chip board, or any other material suitable for providing protection between bottles within the box. Insert  108  includes a first insert panel  110 , and a second insert panel  112  separated or demarcated from first insert panel  110  by an insert panel fold line  114 . A third insert panel  116  is formed as a part of first insert panel  110  by a slit  117  that extends from insert panel fold line  114  through first insert panel  110  and back to insert panel fold line  114 . Slit  117  includes a first portion  118  that is spaced from and generally parallel to insert panel fold line  114 . A second portion  120  extends from a first end of first portion  118  to insert panel fold line  114 . Second portion  120  is joined to first portion  118  by rounded corner  121 . A third portion  122  extends from a second end of first portion  118  to insert panel fold line  114 . Third portion  122  is joined to first portion  118  by rounded corner  124 . In use, insert panels  110  and  112  are folded toward one another until they are approximately 120° apart. Third insert panel is then folded about insert panel fold line  114  away from first panel  110  and toward second panel  112  until it is approximately 120° from first insert panel  110  and second insert panel  112 . Insert  108  fits between three bottles  36 , as seen in FIG. 9, providing protection for the bottles from one another as they are carried in box  4 . Notches  126  having rounded corners  128  are formed in the corners of first insert panel  110  and second insert panel  112 , and facilitate the insertion of insert  108  between bottles  36 , or the insertion of bottles  36  into box  4  between the respective panels of insert  108 . Insert  108  is advantageously formed from a single sheet of material, die-cut into its proper shape, thereby easing manufacture of the insert, and, consequently, reducing the costs associated with its manufacture. 
     As noted above, blank  2  may be formed of corrugated fiberboard. In certain preferred embodiments the direction of the corrugation runs generally perpendicular to wall fold lines  10  and  14 , providing for easier scoring of the wall fold lines. Similarly, in certain preferred embodiments the direction of corrugation of insert  108  is generally perpendicular to insert fold line  114 . However, it is to be appreciated that the direction of corrugation of blank  2  and insert  108  may extend in any direction. 
     To form box  4  from blank  2 , first wall panel  6  and second panel  8  are folded toward one another about first wall fold line  10 , and third panel  12  and second panel  8  are folded toward one another about second wall fold line  14 . Wall closure flap  16  is then folded in toward first wall panel  6 . Wall tabs  11  are folded in toward wall closure flap  16  and third wall panel  12  and inserted into respective slots  26 . At this point, the three walls of the box have been formed, with adjacent walls spaced apart at an angle of approximately 60°. The engagement of barbs  15  with wall closure flap  16  prevents wall tabs  11  from inadvertently coming out of slots  26 , thereby ensuring that box  4  retains its shape and the bottles remain in the box. 
     Top closure flaps  52  are then folded inwardly about top closure flap fold lines  54  toward the walls. Top panel  28  is folded downwardly toward the walls about top closure flap fold lines  54  such that top closure flaps  52  are received between the walls, and top closure flap fold lines  54  are adjacent and generally parallel to the top edges of first and third wall panels  6 ,  12 . Top tabs  38  are then inserted into slots  62 , thereby retaining top panel  28  in its use position. Three bottles  36  are then placed in box  4 , with necks  34  of bottles  36  protruding through and received by apertures  32 . Insert  108  is positioned between the panels, one of first, second and third panels  110 ,  112 ,  116  extending between each of adjacent bottles in box  4 . It is to be appreciated that insert  108  can be placed in box  4  before any bottles  36  are placed in the box, or after one or two bottles are placed in the box. 
     Bottom closure flaps  80  are then folded inwardly about bottom closure flap fold lines  82  toward the walls. Bottom panel  63  is folded upwardly toward the walls about bottom fold line  65  such that bottom closure flaps  80  are received between the walls, and bottom closure flap fold lines  82  are adjacent and generally parallel to the bottom edges of first and third wall panels  6 ,  12 . Bottom tabs  66  are then inserted into slots  90 , thereby retaining bottom  63  in its use position. Handle flaps  100 ,  104  are then folded in toward the interior of box  4 , and the box can then easily be carried by an individual. 
     Removal of bottles  36  from box  4  is accomplished by first removing bottom tabs  66  from slots  90 . By inserting a finger into an aperture  92 , an individual can easily grasp a bottom tab  66  and slide it out of a corresponding slot  90 . Once bottom tabs are free of slots  90 , bottom  63  can be unfolded about bottom fold line  63 , allowing access to bottles  36 . Box  4  may then be completely disassembled by removing top tabs  38  from top slots  62 , unfolding top  28  about top fold line  30 , removing wall tabs  11  from wall slots  26  and unfolding the wall panels. Box  4  can be assembled again at any time in the manner described above. 
     While the invention has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described systems and techniques that fall within the spirit and scope of the invention as set forth in the appended claims. 
     In light of the foregoing, those skilled in the art will readily understand that various modifications and adaptations can be made without departing from the scope and spirit of the invention as defined in the appended claims.