Patent Publication Number: US-6209783-B1

Title: Reinforced cardboard box for storage and shipping of elongated items and rolled documents

Description:
FIELD OF INVENTION 
     The invention pertains to a cardboard box construction. More particularly, the invention relates to a box construction adapted for storage and shipping of items that must be protected from crushing, folding or bending forces. 
     BACKGROUND OF THE INVENTION 
     Various types of cardboard boxes, tubes and containers have been devised to protect elongated articles and rolled documents during shipment. 
     U.S. Pat. No. 2,075,679, issued to Weber, describes an elongated double-paneled container formed of cardboard having an edge closure that is sealed with adhesive tape. U.S. Pat. No. 3,249,284, issued to Wood, discloses a paperboard wrap-around package with a joint in the middle of one side. The joint includes a series of interlocking hooks and slots. U.S. Pat. No. 1,449,468, issued to Walter, describes a heavy-weight box or tube formed of fiberboard for shipping heavy metal bars such as automobile bumpers. The container includes a flap extension and metal bands for securing closure. U.S. Pat. No. 4,236,740, issued to Sorenson et al., illustrates a paperboard file storage box formed from a single blank of cardboard. The file storage box includes a pair of reinforcing panels on either end that are secured to the box ends with tab elements that project through mating openings in end flaps that fold over the reinforcing panels. 
     An effective design for a shipping container for such items must necessarily be a compromise of various factors. It is an objective of the present invention that the container provide the required degree of protection from the forces encountered in transfeiring the container from one destination to another by means of automated package handling systems, trucks, automobiles and aircraft. It is a further objective that the container be light in weight to prevent excessive shipping costs. It is yet a further objective of the invention that the container is economical to produce and simple to assemble. It is a still further objective that the container provide a simple and effective means of being sealed and later opened. 
     While features disclosed in the prior art satisfy some of the objectives of the present invention, none of the inventions found include all of the requirements identified. 
     SUMMARY OF THE INVENTION 
     The present invention addresses all of the deficiencies of prior art reinforced cardboard boxes and satisfies all of the objectives described above. A reinforced cardboard box for storage and shipping of elongated items and rolled documents may be formed from a single blank of cardboard material comprising the following components. 
     A rectangular bottom panel having a pair of first and second opposed, parallel elongated side edges, the side edges defining the length of the panel and terminating in first and second opposed, parallel end edges. A pair of abutting bottom end panels that are joined to one of the opposed end edges of the bottom panel. A first side panel is joined to the first opposed edge of the bottom panel. The first side panel has a pair of first and second opposed, parallel edges coinciding in length with the length of the side edges of the bottom panel. 
     A second side panel is joined to the second opposed edge of the bottom panel. The second side panel has a pair of first and second opposed, parallel edges coinciding in length with the length of the side edges of the bottom panel. A pair of outer side end panels, each having an inner surface and an outer surface, are foldably joined to an end of the second side panel. The outer side end panels have a tab opening at the juncture of the outer side end panel with the second side panel. 
     A pair of inner side end panels, each having an inner surface and an outer surface, that are foldably joined to one of the outer side end panels. The inner side end panels have a bendable tab element extending outwardly beyond the distal end of the panel. Each of the tab elements is sized, shaped and located to engage tab openings at the juncture of one of the outer side end panels with the second side panel. The tab openings are engaged when the outer side end panel is folded upwardly and the inner side end panel is folded downwardly over an end of the abutting bottom end panel. 
     A pair of receiving pockets are formed between the inner surface of the outer side end panels and the inner surface of the inner side end panel when the inner side end panel is folded over the outer side end panel. 
     A first top panel forms a first portion of a top closure. The first top panel has a first pair and a second pair of opposed, parallel edges, the first pair being of an elongated length. A first, elongated parallel edge is joined to an elongated edge of the first side panel. 
     A pair of rounded closing end panels, each being joined to the second pair of opposed, parallel edges of the first top panel at a score line. The score line allows the closing end panel to be folded inwardly at a right angle to the first top panel. The rounded closing end panels are adapted to be received in the receiving pockets. 
     A second top panel forms a second portion of the top closure. The second top panel has a first pair and a second pair of opposed, parallel edges, the first pair being of an elongated length. A first elongated, parallel edge is joined to an elongated edge of the second side panel. The second top panel has a plurality of tab openings at the juncture of the second side panel and the second top panel. 
     Each of the inner side end panels has a first and second pair of opposed, parallel edges. The first pair of parallel edges includes the bendable tab element and the juncture between the inner side end panel and the outer side end panel. The second pair of parallel edges is normal to the first pair of parallel edges and includes a first edge and a second edge. The second edge is collinear with the juncture between the second side panel and the second top panel. 
     A reinforcing rib panel is joined to an elongated edge of the second top panel. The rib panel has a plurality of bendable tab elements extending from its distal edge. The tab elements are sized, shaped and disposed to engage the openings in the second top panel when the rib panel is folded inwardly toward the second top panel. 
     A pair of top reinforcing extensions are provided, each having a first edge collinear with the juncture of the second side panel and the second top panel and a parallel second edge. A third edge is normal to the first edge and is collinear with the distal end of the inner side end panel with a fourth edge parallel to the third edge. Each of the extensions is joined to the second edge of the second pair of opposed, parallel edges of the inner side end panels. The extensions are further foldable inwardly from the inner side end panels to provide a means for constraining the second top panel in orthogonal orientation to the second side panel when the second top panel is folded inwardly and the rib panel is folded over the reinforcing extension. 
     In variation of the invention a closing member extends from a second elongated edge of the first pair of opposed parallel edges of the first top panel. The closing member has a score line spaced from and parallel to the second edge of the first top panel, the score line is located to coincide with the juncture of the second top panel and the second side panel. 
     The second top panel includes a closing member opening. The closing member opening is sized, shaped and located to accommodate the closing member that is joined to the first top panel. The portion of the member extending beyond the score line is located within the box when assembled. 
     In yet another variation of the invention, a reinforced cardboard box for storage and shipping of elongated items and rolled documents further comprises the following components. A pair of enlarged, rounded closing end panels that are foldably joined to one of the second pair of parallel edges of the first top panel. Each of the closing end panels has a length at its joined edge approximately equal to twice the distance between the first pair of parallel edges of the first top panel. 
     A first reinforcing triangular panel is provided that extends, at an acute angle, from the distal end of the joined edge of the enlarged rounded closing panel to the distal edge of the first pair of parallel edges of the first top panel. A pair of triangular relief notches are formed at the second pair of parallel edges of the second top panel. The relief notches are sized, shaped and located to receive the first reinforcing triangular panels of the first top panel when the box is closed. 
     In a further variation of the invention, a reinforced cardboard box for storage and shipping of elongated items and rolled documents further comprises the following components. A pair of second reinforcing triangular panels that are joined to the second edges of the top reinforcing extension and foldably joined to the second edge of the second pair of opposed parallel edges of the inner side end panels. 
     In still another variation of the invention the first and second top reinforcing extensions each have first and second opposed, parallel side edges and third and fourth opposed, parallel end edges, normal to the first and second edges. The first top reinforcing extension is foldably joined at its fourth edge to the distal edge of the first abutting end panel and the second top reinforcing extension is foldably joined at its third edge to the distal edge of the second abutting end panel. 
     To assemble the reinforced cardboard box, first and second abutting end panels are folded inwardly from the bottom panel. Next, the second side panel is folded inwardly from the bottom panel. Then, the first and second outside end panels are folded inwardly from the second side panel and the first and second inner side end panels are folded inwardly from the first and second outer side end panels and over the first and second abutting end panels. This allows the first and second bendable end tab elements to engage the first and second end tab openings. 
     Next, the first and second top reinforcing extensions are folded inwardly from the first and second abutting end panels. Then, the second top panel is folded inwardly from the second side panel and the reinforcing rib panel is folded over the first and second top reinforcing extensions and inwardly from the second top panel. This allows the side tab elements to engage the side tab openings in the second side panel, thereby securing bottom panel, second side panel and second top panel in orthoganal relation to one another to form an open-topped elongated container. 
     To form the closed container, the first and second rounded closing end panels are folded inwardly from the first top panel. Next, the first side panel is folded inwardly from the bottom panel and the first top panel is folded inwardly from the first side panel. Then, the first and second rounded closing end panels are received in the first and second receiving pockets, forming a closed elongated container. The first and second top panels may be secured with tape. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a plan view of the preferred embodiment of the invention; 
     FIG. 1 a  is a partial plan view of a second embodiment of the invention, said embodiment lacking the enlarged, rounded closing end panels; 
     FIG. 2 is a perspective view of one end of the FIG. 1 embodiment; 
     FIG. 3 is a perspective view of one end of the FIG. 1 embodiment illustrating the bottom panel folded at a right angle to the second side panel and the abutting end panel folded at a right angle to the bottom panel; 
     FIG. 4 is a perspective view of one end of the FIG. 1 embodiment illustrating the inner side end panel folded over the abutting end panel and the top reinforcing extension folded at a right angle to the inner side end panel; 
     FIG. 5 is an extended perspective view of one end of the FIG. 1 embodiment illustrating the reinforcing rib panel folded over the top reinforcing extension and the rounded closing end panel folded at a right angle to the first top panel; 
     FIG. 6 is a perspective view of one end of the FIG. 1 embodiment illustrating the rounded closing end panel inserted into the receiving pocket and the closing member inserted into the closing member opening; 
     FIG. 7 is a perspective view of one end of the FIG. 1 embodiment illustrating the finished box rotated to rest upon the back panel and the top panels secured with packing tape; 
     FIG. 8 is a plan view of a third embodiment of the invention, said embodiment lacking the closing member and closing member opening and having the first and second top reinforcing members foldably joined to the first and second abutting end panels; 
     FIG. 9 is a perspective view of one end of the FIG. 8 embodiment illustrating the first abutting end panel folded inwardly from the bottom panel; 
     FIG. 10 is a perspective view of one end of the FIG. 8 embodiment illustrating the bottom panel folded at a right angle to the second side; 
     FIG. 11 is a perspective view of one end of the FIG. 8 embodiment illustrating the first top reinforcing extension folded inwardly from the first abutting end panel and the first outer side end panel folded inwardly from the second side panel and the first inner side end panel folded inwardly from the first outer side end panel and over the first abutting end panel; 
     FIG. 12 is a perspective view of one end of the FIG. 8 embodiment illustrating the first rounded closing end panel folded inwardly from the first top panel and the second top panel folded inwardly from the second side panel and the reinforcing rib panel folded inwardly from the second top panel and over the first top reinforcing extension; 
     FIG. 13 is a perspective view of one end of the FIG. 8 embodiment illustrating the closed container with the first rounded closing end panel inserted into the first receiving pocket; and 
     FIG. 14 is a perspective view of one end of the FIG. 8 embodiment illustrating the finished box rotated to rest upon the back panel and the top panels secured with packing tape. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1 illustrates a die-cut blank for a reinforced cardboard box  10  for storage and shipping of elongated items and rolled documents. As shown in FIGS. 1-5, the invention comprises the following components. 
     A rectangular bottom panel  14  having a pair of first  18  and second  22  opposed, parallel elongated side edges, the side edges  18 ,  22  defining the length of the panel  14  and terminating in first  26  and second  30  opposed, parallel end edges. A pair of abutting bottom end panels  34 ,  38  that are joined to one of the opposed end edges  26 ,  30  of the bottom panel  14 . A first side panel  42  is joined to the first opposed edge  18  of the bottom panel  14 . The first side panel  42  has a pair of first  46  and second  50  opposed, parallel edges coinciding in length with the length of the side edges  18 ,  22  of the bottom panel  14 . 
     A second side panel  54  is joined to the second opposed edge  22  of the bottom panel  14 . The second side panel  54  has a pair of first  58  and second  62  opposed, parallel edges coinciding in length with the length of the side edges  18 ,  22  of the bottom panel  14 . A pair of outer side end panels  66 ,  70 , each having an inner surface  74  and an outer surface  78 , are foldably joined to an end  82  of the second side panel  54 . The outer side end panels  66 ,  70  have a tab opening  86  at the juncture  90  of the outer side end panel  66 ,  70  with the second side panel  54 . 
     A pair of inner side end panels  94 ,  98  are provided, each having an inner surface  102  and an outer surface  106 , that are foldablyjoined to one of the outer side end panels  66 ,  70 . The inner side end panels  94 ,  98  have a bendable tab element  110  extending outwardly beyond the distal end  114  of the panel  94 ,  98 . Each of the tab elements  110  is sized, shaped and located to engage tab openings  86  at the juncture  90  of one of the outer side end panels  66 ,  70  with the second side panel  54 . The tab openings  86  are engaged when the outer side end panel  66 ,  70  is folded upwardly and the inner side end panel  94 ,  98  is folded downwardly over an end  118  of the abutting bottom end panel  34 ,  38 . 
     As shown in FIGS. 2-4, a pair of receiving pockets  122  are formed between the inner surface  74  of the outer side end panel  66 ,  70  and the inner surface  102  of the inner side end panel  94 ,  98  when the inner side end panel  94 ,  98  is folded over the outer side end panel  66 ,  70 . 
     As shown in FIGS.  1  and  5 - 7 , a first top panel  126  forms a first portion  130  of a top closure  134 . The first top panel  126  has a first pair  138  and a second pair  142  of opposed, parallel edges, the first pair  138  being of an elongated length. A first elongated, parallel edge  146  is joined to an elongated edge  46  of the first side panel  42 . 
     As shown in FIG. 1 a,  a pair of rounded closing end panels  150 ,  154 , each being joined to the second pair  158 ,  162  of opposed, parallel edges of the first top panel  126  at a score line  166 . The score line  166  allows the closing end panel  150 ,  154  to be folded inwardly at a right angle to the first top panel  126 . The rounded closing end panels  150 ,  154  are adapted to be received in the receiving pockets  122  (FIG.  5 ). 
     As shown in FIGS.  1  and  5 - 7 , a second top panel  158  forms a second portion  162  of the top closure  134 . The second top panel  158  has a first pair  166  and a second pair  170  of opposed, parallel edges, the first pair  166  being of an elongated length. A first elongated, parallel edge  174  is joined to an elongated edge  58  of the second side panel  54 . The second top panel  158  has a plurality of tab openings  178  at the juncture  182  of the second side panel  54  and the second top panel  158 . 
     As shown in FIGS. 1-5, each of the inner side end panels  94 ,  98  have a first  202  and second  206  pair of opposed, parallel edges. The first pair of parallel edges  202  includes the bendable tab element  110  and the juncture  210  between the inner side end panel  94 ,  98  and the outer side end panel  66 ,  70 . The second pair of parallel edges  206  is normal to the first pair  202  of parallel edges and includes a first edge  214  and a second edge  218 . The second edge  218  is collinear with the juncture  182  between the second side panel  54  and the second top panel  158 . 
     A reinforcing rib panel  222  is joined to an elongated edge  226  of the second top panel  158 . The rib panel  222  has a plurality of bendable tab elements  230  extending from its distal edge  234 . The tab elements  230  are sized, shaped and disposed to engage the openings  178  in the second top panel  158  when the rib panel  222  is folded inwardly toward the second top panel  158 . 
     A pair of top reinforcing extensions  238 ,  242  are provided, each having a first edge  246 ,  250  collinear with the juncture  182  of the second side panel  54  and the second top panel  158  and a parallel second edge  254 ,  258 . A third edge  298 ,  300  is normal to the first edge  246 ,  250  and is collinear with the distal end  114  of the inner side end panel  94 ,  98  with a fourth edge  302 ,  304  parallel to the third edge  298 ,  300 . Each of the extensions  238 ,  242  is joined to the second edge  218  of the second pair  206  of opposed, parallel edges of the inner side end panels  94 ,  98 . The extensions  238 ,  242  are further foldable inwardly from the inner side end panels  94 ,  98  to provide a means for constraining the second top panel  158  in orthogonal orientation to the second side panel  54  when the second top panel  158  is folded inwardly and the rib panel  222  is folded over the reinforcing extension  238 ,  242  (FIGS.  4 - 5 ). 
     In a variation of the invention a closing member  186  extends from a second elongated edge  192  of the first pair  138  of opposed, parallel edges of the first top panel  126 . The closing member  186  has a score line  190  spaced from and parallel to the second edge  192  of the first top panel  126 , the score line  190  is located to coincide with the juncture  194  of the second top panel  158  and the second side panel  54 . 
     The second top panel  158  includes a closing member opening  198 . The closing member opening  198  is sized, shaped and located to accommodate the closing member  186  that is joined to the first top panel  126 . The portion of the member  186  extending beyond the score line  190  is located within the box  10  when assembled (FIGS.  6 - 7 ). 
     In a variation of the invention, illustrated in FIGS. 1-5, a reinforced cardboard box for storage and shipping of elongated items and rolled documents  10  further comprises the following components. A pair of enlarged, rounded closing end panels  150   a,    154   a  that are foldably joined to one of the second pair of parallel edges  142  of the first top panel  126 . Each of the closing end panels  150   a,    154   a  has a length at its joined edge  262 ,  266  approximately equal to twice the distance between the first pair of parallel edges  138  of the first top panel  126 . 
     A first reinforcing triangular panel  270 ,  272  is provided that extends, at an acute angle, from the distal end  274  of the joined edge of the enlarged rounded closing panel  150   a,    154   a  to the distal edge  278  of the first pair  138  of parallel edges of the first top panel  126 . A pair of triangular relief notches  282 ,  286  are formed at the second pair  170  of parallel edges of the second top panel  158 . The relief notches  282 ,  286  are sized, shaped and located to receive the first reinforcing triangular panels  270 ,  272  of the first top panel  126  when the box  10  is closed. 
     In a further variation of the invention, illustrated in FIGS. 1-5, a reinforced cardboard box for storage and shipping of elongated items and rolled documents  10  further comprises the following components. A pair of second reinforcing triangular panels  290 ,  294  that are joined to the fourth edges  302  of the top reinforcing extension  238 ,  242  and foldably joined to the second edge  218  of the second pair  206  of opposed parallel edges of the inner side end panels  94 ,  98 . 
     In still another variation of the invention illustrated in FIGS. 8-14, the first  239  and second  243  top reinforcing extensions each have first  240 ,  241  and second  244 ,  245  opposed, parallel side edges and third  247 ,  248  and fourth  251 ,  252  opposed, parallel end edges, normal to the first  240 ,  241  and second  244 ,  245  edges. The first  239  top reinforcing extension is foldably joined at its fourth  251  edge to the distal edge  35  of the first  34  abutting end panel and the second  243  top reinforcing extension is foldably joined at its third  248  edge to the distal edge  39  of the second  38  abutting end panel. 
     To assemble the reinforced cardboard box  12 , as shown in FIG. 9, first  34  and second  38   f  abutting end panels are folded inwardly from the bottom panel  14 . Next, as shown in FIG. 10, the second side panel  54  is folded inwardly from the bottom panel  14 . Then, as shown in FIG. 11, the first  66  and second  70  outside end panels are folded inwardly from the second side panel  54  and the first  94  and second  98  inner side end panels are folded inwardly from the first  66  and second  70  outer side end panels and over the first  34  and second  38  abutting end panels. This allows the first  111  and second  112  bendable end tab elements to engage the first  87  and second  88  end tab openings. 
     Next, the first  239  and second  243  top reinforcing extensions are folded inwardly from the first  34  and second  38  abutting end panels. Then, as shown in FIG. 12, the second top panel  159  is folded inwardly from the second side panel  54  and the reinforcing rib panel  223  is folded over the first  239  and second  243  top reinforcing extensions and inwardly from the second top panel  159 . This allows the side tab elements  231  to engage the side tab openings  179  in the second side  54  panel, thereby securing bottom panel  14 , second side panel  54  and second top panel  159  in orthoganal relation to one another to form an open-topped elongated container. 
     To form the closed container  12 , as shown in FIGS. 12-14, the first  150  and second  154  rounded closing end panels are folded inwardly from the first top panel  127 . Next, the first side panel  42  is folded inwardly from the bottom panel  14  and the first top panel  127  is folded inwardly from the first side panel  42 . Then, the first  150  and second  154  rounded closing end panels are received in the first and second receiving pockets  122 , forming a closed elongated container  12 . The first  127  and second  159  top panels may be secured with tape  160  as shown in FIG.  14 .