BOX WITH DISPENSING FLAP

Abstract

A blank (10) for a box includes: a sheet of material defining a plurality of panels separated by a plurality of fold lines (32), the plurality of panels defining an enclosure which includes: a top panel (38) including first perforation lines (46) defining a zipper tear-open element (14); and a back wall (16) including second perforation lines (48) defining a dispensing flap (50).

Description

BACKGROUND OF THE INVENTION

This invention relates generally to packaging, and more particularly to boxes suitable for storage and dispensing.

It is known to store and ship retail products in boxes made from fibrous materials such as paper, chipboard, or corrugated cardboard.

It also is known to manufacture boxes having removable portions which can be used to dispense the product inside.

One problem with such boxes is that they typically contain plastic which is an environmentally questionable material.

BRIEF SUMMARY OF THE INVENTION

This problem is addressed by a box having an integral dispensing flap.

According to one aspect of the technology described herein, a blank for a box comprises: a sheet of material defining a plurality of panels separated by a plurality of fold lines, the plurality of panels defining an enclosure which includes: a top panel including first perforation lines defining a zipper tear-open element; and a back wall including second perforation lines defining a dispensing flap.

According to another aspect of the technology described herein, a box comprises: a plurality of interconnected panels which define an enclosure surrounding an interior space, the plurality of panels including: a top panel including first perforation lines defining a zipper tear-open element; and a back wall including second perforation lines defining a dispensing flap.

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 top plan view of a flat box blank for an exemplary box;

FIG. 2 is a perspective view of a box assembled from the blank of FIG. 1, in an open condition ready to be filled with product;

FIG. 3 is a perspective view of the box of FIG. 2, completely closed;

FIG. 4 is a left side elevational view of the box of FIG. 3;

FIG. 5 is a right side elevational view of the box of FIG. 3;

FIG. 6 is a bottom plan view of the box of FIG. 3;

FIG. 7 is a top plan view of the box of FIG. 3;

FIG. 8 is a rear elevational view of the box of FIG. 3;

FIG. 9 is a front elevational view of the box of FIG. 3; and

FIG. 10 is a perspective exploded view of the box of FIG. 3 in combination with an internal tray.

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 box blank 10, which may be cut (e.g., by die-cutting, laser cutting, water jet cutting, etc.) from sheet stock according to a predetermined pattern.

The blank 10 may be made from any sheet stock or sheet-like material that is capable of being formed in a predetermined shape (e.g. by cutting) and folded, including, for example, paper or other fibrous materials, cardboard, card stock, chip board, plastic, or sheet metal. For the purpose of avoiding the introduction of non-biodegradable materials in the environment, it is preferred to avoid plastics and metals. One example of a suitable material for such boxes is a product made from cellulosic fiber commercially known as “U-board” or “chipper”, which is a thin, single-layer material. Another common material is double-walled cardboard with a fluted spacer positioned between two outer layers, commonly referred to as “corrugated” cardboard.

In the illustrated example, the blank 10 defines a first top flap 12 with a tear-open element referred to as a “zipper” 14, a back wall 16 with first side flaps 18, a bottom wall 20 with bottom tabs 22, a front wall 24 with second side flaps 26, and a second top flap 28 with top tabs 30. As noted that directional terms such as “front”, “back”, “top”, or “bottom” are used merely for purposes of convenient explanation and do not require any particular orientation of the components described. For example, a component described as being on the “top” of an object may be on the “bottom” if the object is inverted. Similarly, special structural features described as being present on any one of the sides or faces of the inventive box may be implemented on other sides or faces.

These elements are demarcated by fold lines 32 which may be marked by printing. Alternatively, the fold lines 32 may represent physical areas of weakness prone to folding, defined for example by scoring, crimping, pre-folding, or partially cutting. Alternatively, they may simply be virtual lines along which folds take place during a manufacturing process.

The blank 10 may be assembled by folding it along the fold lines 32, and secured together by means such as friction, interlocking of tabs, adhesives, fasteners, or combinations thereof, to form a box 34 (FIG. 3).

More specifically, the blank 10 is folded into a rectangular sleeve shape as shown in FIG. 2. The first top flap 12 is secured to the second top flap 28 and overlies the second top flap 28. In one example these two elements are joined with adhesive.

In the sleeve form, the first side flaps 18, the bottom tabs 22, the second side flaps 26, and the top tabs 30 are unfolded and extend laterally outward, exposing a large pass-through opening.

The sleeve may be flattened to collapse the back wall 16 against the front wall 24 for the purposes of compact storage or handling.

When the sleeve is to be filled, it is put in the open configuration shown in FIG. 2. It may then be loaded with product (not shown) in the direction of the arrow “P”.

Once loaded, the first side flaps 18, the bottom tabs 22, the second side flaps 26, and the top tabs 30 are folded down and secured together, for example with adhesive, forming the complete box 34 as seen in FIG. 3.

The box 34 is generally a parallelepiped shape when assembled and is used to store products therein. Stated another way, box 34 forms a complete six-sided enclosure with a hollow interior space 35.

When assembled, the front wall 24 and the back wall 16 are parallel and spaced apart from each other.

The side flaps 18, 26 and the bottom tabs 22 and the top tabs 30 are secured together to collectively define side panels 36 which are parallel and spaced apart from each other.

The top flaps 12, 28 are secured together to collectively define a top panel 38. The top panel 38 defines the zipper 14.

More specifically, referring to FIG. 7, the first top flap 12 includes a distal portion 40 interconnected to a proximal portion 42 via a tear strip 44. The proximal portion 42 is joined to the back wall 16 at a fold line 32. During assembly of the box 34, only the distal portion 40 is secured to the second top flap 28, e.g., using adhesive. The tear strip 44 is demarcated from the distal and proximal portions 40, 42 via first perforations 46. These represent lines of relative weakness permitting easy tearing. They may be formed, for example, by deep scoring, partially cutting, or punching a series of small holes or slots. The first perforations 46 may have various shapes such as linear or sawtooth.

When the tear strip 44 is pulled away along the first perforations 46, the distal and proximal portions 40, 42 are disconnected from each other. The proximal portion 42 and the second top flap 28 are thus disconnected from each other and free to fold open so that the product inside the box 34 can be removed.

Referring to FIG. 8, the back wall 16 includes second perforation lines 48 defining a dispensing flap 50. The dispensing flap 50 comprises first and second parallel end edges 52, 54, interconnected by side edges 56. In the illustrated example, the dispensing flap 50 is generally rectangular. However, it will be understood that any size or shape of dispensing flap 50 that will fit on the back wall 16 may be used.

In the illustrated example, the first end edge 52 and the side edges 56 are defined by the second perforations 48. The second end edge 54 is defined by a fold line. In use, the perforated edges would be broken and the dispensing flap 50 folded open along the second end edge 54 to remove product from the box 34. The dispensing flap 50 can then be re-closed. One or more of the perforated edges may be provided with a finger tab 58. This serves both as an access point to start tearing the perforations and as a locking element to hold the dispensing flap 50 closed between uses.

Alternatively, all four edges of the dispensing flap 50 could be defined by perforations so it can be completely removed.

Optionally, as seen in FIG. 10, a tray 60 may be provided which fits closely in the interior space 35 of the box 34. The tray 60 may be made from sheet stock as described above. In the illustrated example, it is generally an open-topped parallelepiped shape with a flat bottom 62. Instead of loading products directly into the box 34 as described above, the product may be loaded into the tray 60 which may then be loaded into the box 34 prior to the flaps being closed and sealed as described above. Subsequently, when the zipper 14 is opened, top flaps 12 and 28 may be folded back to allow the tray 60 to slide out of the end of the box 34. The user may then retrieve some or all of the product and push the tray 60 back into the box 34. The box 34 may incorporate one or the other of the dispensing flap 50 and the tray 60, or both of these features simultaneously.

Compared to the prior art, the box 34 has the benefit of providing secure storage for product along with easy access. It may be made without any nonrecyclable or environmentally damaging materials.

The foregoing has described a storage and dispensing box. All of the features disclosed in this specification, and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends, or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

1. A blank (10) for a box, comprising: a sheet of material defining a plurality of panels separated by a plurality of fold lines (32), the plurality of panels defining an enclosure which includes:a top panel (38) including first perforation lines (46) defining a zipper tear-open element (14); anda back wall (16) including second perforation lines (48) defining a dispensing flap (50).

2. The blank (10) of claim 1, wherein the dispensing flap (50) comprises first and second parallel end edges (52, 54), interconnected by side edges (56).

3. The blank (10) of claim 2, wherein the dispensing flap (50) is generally rectangular.

4. The blank (10) of claim 1, wherein the plurality of panels includes: a first top flap (12) defining a portion of the top panel (38),a back wall (16) adjoining the first top flap (12), the back wall (16) including a pair of laterally-extending first side flaps (18);a bottom wall (20) adjoining the back wall (16);a front wall (24) adjoining the bottom wall (20), the front wall (24) including a pair of laterally-extending second side flaps (26); anda second top flap (28) adjoining the front wall (24), the second top flap (28) defining a portion of the top panel (38).

5. The blank (10) of claim 4, wherein the bottom wall (20) includes a pair of laterally-extending bottom tabs (22).

6. The blank (10) of claim 4, wherein the second top flap (28) includes a pair of laterally-extending top tabs (30).

7. The blank (10) of claim 1 wherein the fold lines (32) comprise physical areas of weakness prone to folding.

8. The blank (10) of claim 1 wherein the sheet of material is made from cellulosic fiber.

9. A box (34), comprising: a plurality of interconnected panels which define an enclosure surrounding an interior space (35), the plurality of panels including: a top panel (38) including first perforation lines (46) defining a zipper tear-open element (14); anda back wall (16) including second perforation lines (48) defining a dispensing flap (50).

10. The box (34) of claim 9, wherein the dispensing flap (50) comprises first and second parallel end edges (52, 54), interconnected by side edges (56).

11. The box (34) of claim 10, wherein the dispensing flap (50) is generally rectangular.

12. The box (34) of claim 9, wherein the plurality of panels includes: a first top flap (12) defining a portion of the top panel (38),a back wall (16) adjoining the first top flap (12), the back wall (16) including a pair of laterally-extending first side flaps (18);a bottom wall (20) adjoining the back wall (16);a front wall (24) adjoining the bottom wall (20), the front wall (24) including a pair of laterally-extending second side flaps (26); anda second top flap (28) adjoining the front wall (24), the second top flap (28) defining a portion of the top panel (38).

13. The box (34) of claim 12, wherein the bottom wall (20) includes a pair of laterally-extending bottom tabs (22).

14. The box (34) of claim 12, wherein the second top flap (28) includes a pair of laterally-extending top tabs (30).

15. The box (34) of claim 9, further comprising a tray (60) having an open-topped parallelepiped shape positioned in the interior space (35) of the box (34).

16. The box (34) of claim 10, wherein the first end edge (52) and the side edges (56) are defined by the second perforation lines (48), and the second end edge (54) is defined by a fold line.

17. The box (34) of claim 16, wherein the first end edge (52) and the side edges (56) include a finger tab (58).