Patent Application
20110204129
The present invention relates to a collapsible pack and, in particular, to a flat-pack box and also to a blank assembly formable into a collapsible pack.
Retail staff are under pressure to serve as many customers as possible, in as short a time as possible, and to focus their attention on the client they are serving at the same time. Likewise, businesses are under continual pressure to offer high quality products, which are well presented at the point of sale and/or to provide high quality packaging that is fit for purpose. Furthermore, there is often limited storage space in business premises, retail spaces and in the logistics chain on a product's journey from factory to consumer.
Typical boxes, lids and fitments require some form of transportation or storage. In addition, freight is charged by volumetric weight (volume and weight being used in the cost calculation), so shipping assembled boxes and packaging means paying for shipping the contents which may include a large volume of air in addition to the packaged products themselves. In order to overcome one or more of the drawbacks of known packaging, the invention proposes a re-foldable, flat-pack box which is simple and quick to erect.
This invention is such that the box may be assembled and disassembled quickly and easily without the need to use glue or adhesives during folding (or unfolding).
According to a first aspect, the present invention provides a collapsible pack comprising a base portion, a lid portion and an inner flap portion, the base portion comprising a bottom panel, opposing front and rear panels and opposing side walls wherein the front panel, rear panel and the side walls are each hingedly connected to the bottom panel, the lid portion comprising a top panel, and the inner flap portion comprising a rear panel, wherein the inner flap portion and the lid portion are each hingedly connected to the base portion rear panel.
In embodiments of the invention, the lid portion top panel is hingedly connected to the base portion rear panel.
During assembly of the pack, the inner flap portion rear panel is folded about the hinge line connecting same to the base portion rear panel so as to cover the base portion rear panel. In this way, in the erected pack, the inner flap portion rear panel reinforces the rear face of the pack giving further strength to the assembled pack.
In preferred embodiments, the inner flap portion rear panel is hingedly attached to the base portion rear panel. More specifically, the inner flap portion rear panel is hingedly attached to, or proximate to, an edge of the base portion rear panel. More specifically still, when hingedly attached proximate to an edge of the base portion rear panel, the inner flap portion rear panel is attached to the inner face of the base portion rear panel. In embodiments of the invention, the lid portion further comprises a side panel hingedly connected to the lid portion top panel. It is preferred that, in the fully assembled pack, the lid portion side panel will lie against the base portion front panel of the pack.
In embodiments of the invention, the inner flap portion further comprises a bottom panel hingedly connected to the inner flap portion rear panel. More specifically, the inner flap portion bottom panel is hingedly connected to a free edge of the inner flap portion rear panel, which free edge is opposite the edge of the inner flap portion rear panel hingedly connected to the base portion rear panel.
During assembly of the pack, the inner flap portion bottom panel is folded about the hinge line connecting same to the inner flap portion rear panel so as to lie against the base portion bottom panel. In this way, in the erected pack, the inner flap portion bottom panel reinforces the bottom face of the pack giving further strength to the assembled pack.
In embodiments of the invention, the pack further comprises a base portion inner front panel. More specifically, the base portion inner front panel is hingedly connected to the base portion front panel. During assembly of the pack, the base portion inner front panel is folded about the hinge line connecting same to the base portion front panel so as to lie against the base portion front panel. In this way, in the erected pack, the base portion inner front panel, when present, reinforces the front face of the pack giving further strength to the assembled pack.
In embodiments of the invention, the pack further comprises first, second, third and fourth pairs of base side wall flaps. More specifically, each pair of base side wall flaps depends from an edge of a base side wall of the pack. Even more specifically, a first base side wall flap of each pair of base side wall flaps depends directly from an edge of a base side wall and a second base side wall flap of each pair depends from the other base side wall flap of the same pair. In this way, each base side wall assembly will comprise two pairs of base side wall flaps depending from opposing edges of a base side wall.
Preferably, the second base side wall flap of each pair of base side wall flaps depends from the first base side wall flap of a pair along a diagonal hinge line between diagonally opposed vertices of the connected pair of base side wall flaps.
During assembly of the pack of the invention, the first, second, third and fourth pairs of base side wall flaps are folded about their respective hinge lines so as to lie on the inner surface of the base portion front and rear panels. In the assembled base portion, the base portion rear and front panels oppose one another and the base portion side walls oppose one another. The base side wall flaps are located at each corner of the assembled base portion, one pair of base side wall flaps at each corner.
In embodiments of the pack wherein a pair of base side wall flaps comprises a diagonal hinge line between diagonally opposed vertices of the connected pair of base side wall flaps, one of the pair depends from an edge of a base portion side wall and the other of the pair from the diagonal hinge line. During assembly, the base side wall flaps are folded about a hinge line connecting same to the edge of the base side wall inward of the base portion and one of the pair is attached to either the base portion rear panel or the base portion front panel. The pair of base portion side wall flaps is folded about the diagonal hinge line which, in turn, raises the base portion rear and/or front panels into position.
In embodiments of the invention, one of the pair of base portion side wall flaps is attached to either the base portion rear panel or the base portion front panel by a releasable mounting. More specifically, the releasable mounting may be a hook and eye fastening, a non-permanent adhesive, or the like. In alternative embodiments, the attachment is by permanent mounting such as permanent adhesive or the like.
The opposing base portion side walls are preferably hingedly attached to the base portion bottom panel. More specifically, the opposing base portion side walls are hingedly attached to, or proximate to, opposing side edges of the base portion bottom panel. When hingedly attached proximate to opposing side edges of the base portion bottom panel, the attachment is to the inner face of the base portion bottom panel.
In certain embodiments, the pack further comprises a second lid portion top panel. More specifically, the second lid portion top panel is hingedly connected to the base portion front panel. In these embodiments, the first and second lid portion top panels will abut one another in the assembled pack. In this way, the assembled pack has a split lid arrangement formed of two separate panels.
In particularly preferred configurations of the present invention, the lid and base portion panels are aligned as follows: lid portion side panel hingedly connected to lid portion top panel which is further hingedly connected to base portion rear panel which is further hingedly connected to base portion bottom panel which is further hingedly connected to base portion front panel.
In various embodiments, the base portion front panel may further be hingedly connected to a base portion inner front panel. In these embodiments, in the assembled pack, the base portion inner front panel lies over the base portion front panel at an inner surface thereof. In this way, the base portion inner front panel reinforces the front panel of the pack thereby giving further strength to the assembled pack.
In embodiments of the invention, the lid and the base portion panels share a common longitudinal axis in the collapsed (flat) pack. In embodiments of the invention wherein the pack comprises a cover layer, the base portion inner front panel may be commonly share the cover layer or, alternatively, may have a further cover layer of its own.
In certain embodiments, the inner flap portion panels are connected to one another along a hinge line. The inner flap portion rear panel and the inner flap portion bottom panel may be hingedly connected to one another along a common fold line formed in the material of the pack. More specifically, the inner lap portion rear panel and the inner flap portion bottom panel may be attached to one another along a hinge line. In alternative embodiments, the inner lap portion rear panel and the inner flap portion bottom panel may be covered by an inner flap cover layer. In this way, the inner lap portion rear panel and the inner flap portion bottom panel are hingedly connected to one another by the inner flap cover layer along a hinge line formed by the inner flap cover layer where the two separate panels abut one another.
It is preferred that the inner flap rear portion has substantially the same dimensions as the base portion rear panel and that the inner flap portion bottom panel and the base portion bottom panel are substantially the same dimensions. In this way, the inner flap serves to cover the hinge lines of the base portion of the pack, thereby providing a neat and high-quality product finish.
In preferred embodiments, the lid portion, base portion and incorporated inner flap portion are joined together as one piece, preferably by at least one cover layer.
Due to its rigid construction, during assembly of the pack from its fully collapsed position, the base portion of the pack is maintained in an erect set-up position. This allows the pack and lid to be re-used and re-folded, it frees the hands of the end-user, the quick assembly without glue or other adhesives means minimal time or effort is required for assembly or disassembly by the end user.
The rigidity of the pack construction allows the base portion of the box to be erected into a set-up position, whether or not the lid portion is in a closed or open position, whilst at the same time hiding the internal mechanism of the base of the pack by virtue of the inner flap portion. This provides a presentable and practical solution, and the pack is designed to minimise the amount of raw edges showing on the main faces as the folding panels cover the internal mechanism.
When used herein, the terms top, bottom, rear, front, side or the like, are not intended to define or to imply any specific orientation of the pack, rather the terms are used to assist the skilled artisan in their understanding of the present invention.
In the fully assembled position of the pack, it is preferred that the base and lid portions together form a parallelepiped box.
In embodiments of the invention, during assembly and also when the pack is fully assembled, the rear panel of the inner flap portion lies on the rear panel of the base portion and the inner flap portion bottom panel lies on the base bottom panel. In this way, the base portion is reinforced in strength when the inner flap portion is in position.
It is preferred that, in the collapsed (flat) position of the pack, the inner flap portion rear panel and bottom panel (if present) lie on the lid portion of the pack. In this way, the flat-pack orientation of the collapsible pack has a compact footprint which is easy and convenient to transport and is protected from damage occurring to the inner flap portion because of same lying within the footprint of the lid and base portion in the collapsed position of the pack.
In embodiments of the present invention, the panels of the base portion and the panels of the lid portion are each and all separate from one another.
In alternative embodiments, some or all of the panels of the base portion and/or some or all of the panels of the lid portion may be connected to one another. More specifically, one or more panels of the pack may be connected to one another along hinge lines.
In further alternative embodiments, some or all of the panels of the base portion and lid portion may be formed integrally with one another. More specifically, the panels may be integral with one another and delimited from one another by fold lines. The fold line may be creased, scored, perforated or otherwise defined in order to be hinge lines in the pack of the present invention.
In certain embodiments, the collapsible pack further comprises at least one cover layer.
It is preferred that the at least one cover layer is a flexible material. More specifically, the cover layer is a flexible paper-based material. In certain embodiments, the cover layer is a flexible laminated paper-based material.
It is further preferred that the at least one cover layer has an adhesive coating applied to one surface thereof. In this way, the cover layer can be adhered to one or more of the panels/walls/flaps of the pack.
In preferred embodiments, the at least one cover layer provides the hinge connections between adjacent panels/walls/flaps. In this way, the panels/walls/flaps of the pack may be repeatedly hinged with respect to one another thereby allowing the pack to be collapsed and assembled as required.
Preferably, the one or more of the panels of the base portion and the panels of the lid portion are connected by the cover layer. More specifically, the base portion bottom, front and rear panels, and the lid portion top panel, at least, are covered by the at least one cover layer. The connection lines between the panels provided by the cover layer form hinge lines between adjacent panels.
In embodiments of the invention, the inner flap portion further comprises a second cover layer. More specifically, the outer surface of the inner flap portion rear panel and, where present, the inner flap portion top panel, are covered by the second cover layer.
In embodiments of the invention, the inner flap portion rear panel is hingedly connected to the base portion rear panel by the second cover layer.
When the inner flap portion comprises a top panel, the second cover layer provides the hinged connection between the inner flap portion rear and top panels.
Where present, the first cover layer covers the external surface of the panels to which it is applied.
In embodiments of the invention, each panel is covered at least one cover layer. More specifically, each panel is covered on its outer and its inner surface by at least one cover layer. In this way, each panel is increased in strength by the presence of one or more covering layers applied to at least one of its surfaces. The cover layer(s) also serves to connect one or more of the panels of the pack together thereby forming a hingeable connection between adjacent panels.
The pack of the present invention can also be flat packed, saving valuable space in retail, home, business and logistics environments. The flat packed feature also requires less packaging for transportation (fewer export cartons) and is more secure for transportation—as ready-assembled boxes are more likely to be damaged in transit.
In embodiments of the invention, the pack may further comprise an insert. More specifically, the insert may be formed by an extension to or, as an additional panel attached to, one or more of the panels or walls of the pack. In certain embodiments, the insert is integrally formed with one or more of the panels of the pack. Alternatively, the insert may be hingedly connected to one or more of the panels of the pack.
In embodiments of the invention, the inner flap portion may be modified to provide an integrated insert for a contents or product(s) to be contained in the erect pack.
In further embodiments, one or both of the base side walls may comprise at least one additional panel forming an insert.
Alternatively, or in addition, the pack may further comprise a removable insert.
The insert of the pack may be configured to retain and/or support a product to be contained in the pack.
In embodiments of the invention, the pack comprises a closure member. The closure member is configured to maintain the pack in the closed position. The closure member may be a magnet and metallic element or, alternatively or in addition, may comprise a ribbon or string-like member.
The pack may comprise one or more carrying handles.
The pack may further comprise a window in a side wall thereof. Alternatively, or in addition, the pack may comprise a window in a lid and/or a base panel thereof.
According to a second aspect, the present invention provides a blank assembly erectable into a collapsible pack, the blank assembly comprising an outer blank having first and second major panels interconnected along hinge lines by a first minor panel and further having a second minor panel depending from the first major panel along a further hinge line; a first inner blank comprising a first minor panel; and a second and a third inner blank each comprising a first major panel and a first and a second minor panel depending from opposing edges of the major panel.
The outer blank may further comprise a third minor panel depending from the second major panel.
The outer blank may further comprise a fourth minor panel depending from the second minor panel along a further hinge line.
The outer blank may further comprise a fifth minor panel depending from the outer blank second minor panel along a further hinge line. In embodiments comprising both a fourth and a fifth minor panel, each depending from the second minor panel, it is preferred that the fifth minor panel depends from an edge of the second minor panel and that the fourth minor panel depends from the inner surface of the second minor panel proximate the edge thereof.
In embodiments of the invention, the inner blank further comprises a first major panel depending from the first minor panel of the inner blank along a hinge line.
In preferred embodiments, the first and second minor panels of the second and third inner blanks each comprise a diagonal fold line between diagonally opposing corners of the panels.
In embodiments of the pack and the blank assembly of the present invention, the panels, flaps and walls are formed of a rigid material. More specifically the rigid material may be a rigid cartonboard material. The rigid material provides strength to the pack and provides protection against crush forces for the contents of the assembled pack. The rigid material also allows the pack to be repeatedly collapsed and assembled for multiple re-use thereof.
The blank assembly according to the second aspect of the invention may be assembled into the collapsible pack of the first aspect of the invention.
More specifically, the major and minor panels of the blank assembly are folded about respective hinge lines to form the collapsible pack of the invention.
In embodiments of the invention, the major and minor panels of the blank assembly correspond to the panels, walls and flaps of the collapsible pack as shown in Table 1 below:—
The invention will now be described, by way of example only, with reference to the accompanying drawings, in which:—
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
Further, although the invention will be described in terms of specific embodiments, it will be understood that various elements of the specific embodiments of the invention will be applicable to all embodiments disclosed herein.
In the drawings, similar features are denoted by the same reference signs throughout.
Referring to the figures,
The collapsible pack has a base portion and a lid portion, together with an inner flap portion B. The base portion itself comprises a front panel A1, a bottom panel A2 and a rear panel A3 each hingedly connected to the adjacent panel along a hinge/fold line. Side walls D3 and E3 complete the main walls and panels of the base portion and are connected along respective fold/hinge lines to the bottom panel A2. Side walls D3 and E3 each have a pair of side wall flaps D1/D2, D4/D5, and E1/E2, E4/E5 respectively, depending from opposing edges thereof. One of each pair of side wall flaps D2, D4, E2, E4 depend directly from an edge of the side wall D3, E3. The second flap of each pair D1, D5, E1, E5 depend along a diagonal hinge line from the other flap of the same pair D2, D4, E2, E4. Side flaps D1 and E1 are each adhered to the front panel A1 of the base portion and side flaps D5 and E5 are each adhered to the rear panel A3 of the base portion. In the depicted embodiment, the base portion further comprises an inner front panel C1, depending from a free edge of the front panel A1 along a hinge line.
The lid portion comprises a top panel A4 connected to the base portion at an edge of the rear panel A3 along a hinge line. In the depicted embodiment, the lid portion further comprises a side panel A5 depending from the free edge of the lid top panel along a further hinge line.
The inner flap portion B comprises a rear panel B1 hingedly connected to the base portion rear panel A3. In the depicted embodiment, the inner flap portion also has a bottom panel B2 connected to the free edge of rear panel B1 along an interconnecting hinge line. Bottom panel B2 has a lifting tag X2 attached to a free edge of the panel B2 to facilitate its lifting from the bottom of the fully assembled pack.
Referring to
As with any component in the pack, the covering layer(s) can be printed with graphics and/or indicia, decorated or coloured. In this way, the covering layer serves to enhance the aesthetic features of the final pack.
Referring to
In much the same way, base portion inner front panel C1 is covered by cover layer X5, leaving joining panel Z2 to be adhered to the inner surface of base portion front panel A1, thus formed a hinged connection between the two panels proximate the free edge of the base portion front panel A1.
Also in much the same way, side walls D3 and E3 and their respective side wall flaps D1, D2, D3, D4 and E1, E2, E3, E4 are covered by further cover layers X6 and X7 leaving joining panels Z3 and Z4 to be adhered to the inner surface of the base portion bottom panel A2 thereby forming a hinged connection between the side walls and the bottom panel at opposing edges thereof. Joining panels Z3 and Z4 do not extend to the side wall flaps D1, D2, D3, D4 and E1, E2, E3, E4. The side wall flaps are hinged only to their respective side wall panel edges.
As depicted in
As depicted in
Panels C1, B1 and B2 each provide inner reinforcing panels for the assembled pack giving additional strength thereto.
In all of the depicted embodiments, grey board (a rigid paper based material) is used for the panels, and paper as the flexible covering layer material, to form a rigid, paper-wrapped, re-foldable one piece collapsible pack and lid. In this example, paper is used as the interconnecting cover layer material. In alternative embodiments, the panels can be made flexible and foldable through the use of materials that have been pre-cut, pre-creased, pre-folded, or by connecting the panels with a flexible material, which may be a thicker or thinner substrate, or may connect the panels along their entire edges to each other or along part of their abutting edges.
In the embodiment depicted in
The cover sheet of paper X3 that is laminated to the back of the two grey board panels is larger than the grey board panels, such that three of the edges of the paper layer X3 can be wrapped over the edge of the grey board as shown in
A separate covering sheet of paper (not shown) is then affixed to the other surface of the panels B1 and B2. One edge of the paper protrudes from the outline of the panels B1 and B2 so that it lies over the fourth edge of the bottom paper X3. These two sheets of paper can then be glued together. These panels B1 and B2 and the two paper sheets together form the integral panel, which is key to the function and assembly of the pack.
Panel C1 is also formed by wrapping a cover layer X5 of paper on the underside and on to the top surface of a piece of grey board. The construction is also such that a piece of excess paper protrudes from one edge of C1 to form joining panel Z2. The panel C1 is shown in
Panel C1 in the depicted embodiment is constructed of 1 panel piece only, however, this can be altered in size or structure and additional panels or parts may be added.
The next stage in the construction of the pack from the blank assembly is to add the side panels, as shown in
The side panels are then attached to the body of the pack by gluing the excess flaps of paper forming joining panels Z4 and Z3 to the inner surface of panel A2, as shown in
Panels D1 and D5, E1 and E5 are then glued to the top surface of the paper cover layer X8 that lines the inner surfaces of the pack, in this example, as illustrated in
The following steps as depicted in
The positions of the panels and the flexible joins between the individual panels making up the main parts of the collapsible pack are such that the pack can be folded into a setup position and easily disassembled into a flat pack position. In the depicted embodiment, the paper covering layer interconnecting material that wraps the grey board, is flexible, thus allowing movement at the joins and the panels to fold. The hinge line between D3 and A2 and, correspondingly the hinge line between E3 and A2, are flexible so that D3 and E3 can lie flat against the surface of A2 or fold upwards to a position at 90 degrees to the surface of A2. Similarly, the hinge line between panels C1 and A1 is flexible, as is the hinge line between the inner flap portion B and panel A. The hinge line between panels making up the body of the pack, A, namely A1, A2, A3, A4, A5, are also flexible, as are the panels making up the side panels D and E, with the exception of D1 and D5, E1 and E5 are they are glued to the inside surfaces of panels A1 and A3, in this example.
The process of folding the collapsible pack into a set-up position is illustrated in
To assemble the pack from a flat/collapsed position, A1 and A3 are pushed towards each other by the end user either by holding onto the Lid (A4/A5) and inner front panel C1, or at some other location such that A1 and A3 lie at 90 degrees against the surface of the inner face of panel A2.
This motion will automatically fold D3 and E3 into a vertical (90 degree) position against the inner surface of A2, if the panels D1, D5, E1 and E5 have been affixed to A1 and A3 respectively as described in this example, otherwise the user will need to push these side panels in. The position of the panels is now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner surface of A2, thus forming the beginnings of the base structure of the pack. Due to the folding up of panels D3 and D4, the panels D1 and D2, D4 and D5, E1 and E2, E4 and E5 will all fold together such that their surfaces lie flat against each other, this processes is illustrated in FIG. 11, where D4 and D5, E4 and E5 are pushed towards each other as the box is set up.
Panel C1 is then folded over such that its inner surface lies flat against the inner surface of panel A1, as illustrated in
An integral feature of this flat packing, quick-fold erect, re-foldable one piece box & lid, the incorporated Panel B, is then folded over such that the inner surface of panel B1 lies flat against A3, as shown in
The Panel B2, is then be pushed down so that it lies flat against the panel A2. The length of the panels in this example are such that the base of panel C1 rests just above the base of the box, the length of panel B2 is such that the end of panel B2 pushes against C1. In this way, the pushing down of panel B2, or an incorporated panel added for this purpose, has the effect of holding panel C1 and B1 in place in their folded positions, hence holding the base of the box in a set up position. Thus, the base of the pack is now erected with A1, A3, D3 and E3 all at 90 degrees to the inner surface of A2 and held in place by the folding of the inner panels B and also C1 as described above. With the panels in this position, the bottom part of the box will remain erected whether or not the lid, comprised of A4 and A5, is opened or closed. This arrangement of panels making up B (in this example B1 and B2) and the folding of these panels is one of several variations of the invention demonstrating how the inner flap portion panel (or panels) holds the base of the box in an erect set-up position. There are alternative ways to hold the base of the box in a set up position, using an incorporated panel (or panels) without the panel B2 resting against the base of the box, or against C1, and examples of this will be described and illustrated hereinafter.
The panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the panel A5 folding over the outer surface of A1, as illustrated by
The pack has advantages over known pack constructions in that the base, lid and incorporated integral inner flap portion can be folded into a flat-packed position.
The following is a description of an alternative embodiment of the construction of a collapsible pack of the invention, described solely by way of example, in which the inner flap portion B is made of one panel. In this example, grey board (a rigid paper based material) is used for the panels, and paper as the flexible connecting material, to form a rigid paper wrapped re-foldable one piece box and lid. In this example, an alternative method of holding the box in an erect set up position shall be described, whereby the panels B and C are held in place by magnets.
b show an alternative example of the construction of a collapsible pack of the invention, made of panels wrapped with a cover layer of paper interconnecting material. This particular embodiment differs from that depicted in
The collapsible pack depicted in the embodiment is held in the erect position by magnets X11 (
a and 16a show how the pack maybe folded into a set up position by the user. In this example, the folding of the incorporated panels is such that B1 and C1 are held in place by magnets X11 (
a and 16b illustrate the assembled pack in an open position with the lid portion A4 and A5 being foldable to close the pack.
The following steps will now describe how the pack of
The process of folding into a set-up can easily be reversed to unfold the boxes back to a flat pack position.
To assemble from a flat position, base portion front panel A1 and rear panel A3 are pushed towards each other by the end user (either by holding onto the Lid (A4/A5) and end panel C1, or some other location) such that A1 and A3 lie at 90 degrees against the surface of the inner face of base portion bottom panel A2, as illustrated by
This motion will automatically fold side walls D3 and E3 into a vertical (90 degree) position against the inner surface of bottom panel A2. The position of the panels is now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner surface of A2, thus forming the beginnings of the base structure of the pack.
Inner front panel C1 is then folded over such that its inner surface lies flat against the inner surface of base front panel A1. The inner front panel C1, in its folded position, will cover the side wall flaps D1 and D2, E1 and E2, so that they lie underneath inner front panel C1 between C1 and A1. In this example, C1 is held in place by magnets X11 under the paper surface of panel C1 and by magnets correspondingly on the inside surface panel A1 (not shown).
The inner flap rear panel B1, is then folded over such that the inner surface of panel B1 lies flat against base portion rear panel A3, as shown in
Thus, the bottom part of the pack is now erected with A1, A3, D3 and E3 all at 90 degrees to the inner surface of A2 and held in place by the folding of the inner panel B1 and also C1 as described above, as illustrated by
In the depicted second alternative embodiment of a collapsible pack according to the invention, the panels are wrapped with a paper interconnecting material. In this particular example, the inner flap portion B is formed of two panels, rear panel B1 and bottom panel B2 and the lid portion can be opened in the centre of the pack, through the incorporation of a second lid top panel F1. Thus, the depicted embodiment differs from the embodiment shown in
The following steps will now describe how the pack in the above example can be folded and unfolded by the user.
The process of folding into a set-up position is similar to that described in respect of
To assemble from a flat position, base portion front panel A1 and base portion rear panel A3 are pushed towards each other by the end user, either by holding onto the lid panels (A4/A5) and inner front panel C1, or some other location, such that base portion front panel A1 and base portion rear panel A3 lie at 90 degrees to the surface of the inner face of base portion bottom panel A2, as illustrated in
Base portion inner front panel C1 is then folded over such that its inner surface lies flat against the inner surface of base portion front panel A1. Base portion inner front panel C1, in its folded position, will cover the side wall flaps D1 and D2, E1 and E2, so that they lie underneath panel C1 between C1 and A1.
An integral feature of this flat packing, quick fold erect, re-foldable one piece base and lid, is that the inner flap Panel B, is then folded over such that the inner surface of inner flap portion rear panel B1 lies flat against base portion rear panel A3. The inner flap rear panel B1, in its folded position, will cover the side wall flaps D4 and D5, E4 and E5, so that they lie underneath panel B1 between B1 and A3.
The inner flap portion bottom panel B2, is then be pushed down so that it lies flat against the base portion bottom panel A2 as illustrated in
The lid top panels A4 and F1 can then be folded over the top of the erected bottom part of the box to act as a lid or cover, as illustrated in
The embodiment is an example of a pack with an integrated fitment or insert and integrated compartment. The number of panels used, cut-outs, panel dimensions and configuration can all be altered to hold a variety of products.
Panels D and E form the side walls of the collapsible pack as follows:—first pair of base side wall flaps D1/D2, base first side wall D3, second pair of base side wall flaps D4/D5, base inner side wall D6, third pair base side wall flaps E1/E2, second base side wall E3, fourth pair base side wall flaps E4/E5, retaining element top panel E6, retaining element side panel E7, retaining element bottom panel E8/E9.
The panels B, C, D and E in this example fold together to form an integral insert in the form of a retaining element, which will be described in more detail below.
The following steps will now describe how the pack in the above example can be folded and unfolded by the user.
The interconnecting material between the joins of the panels is flexible, allowing movement at the joins, and the panels to fold. The process of folding into a set-up position is illustrated step by step in
To assemble from a flat position, base portion front panel A1 and base portion rear panel A3 are pushed towards each other by the user, either by holding onto the panels of the lid (A4/A5) and end panel C, or some other location such that A1 and A3 lie at 90 degrees to the surface of the inner face of panel A2, as illustrated in
This motion will automatically fold D3 and E3 into a vertical (90 degree) position against the inner surface of A2. The position of the panels is now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner surface of A2, thus forming the beginnings of the base structure of the box. Due to the folding up of Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2, E4 and E5 will all fold together such that their surface lie flat against each other, as previously explained.
Panel B is folded over, as illustrated in
Panel C1 is then folded over such that its inner surface lies flat against the inner surface of panel A1, as illustrated in
The compartment defined by panels D6, E6, E7, E8 and E9 has a variety of functions and can be used to hold any product or may be left empty. In this example base inner bottom panel C2 has a recess cut in one side edge so that a cable or wire of an electrical product (or any other product) can be fed into the bottom compartment during packing, and the main body of the product held in the top part of the box for display, for example.
Base inner side wall panel D6 is then folded over. In this example, panel D6 has a “U”-shaped recess cut into it to receive an insert Y1 as illustrated in
The lid portion top panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the lid portion side panel A5 folding over the outer surface of base portion front panel A1, as illustrated by
The following is an example of a box with an integrated insert fitment incorporated into the side wall panels of the box.
The process of folding into a set-up position is illustrated step by step in
As with the other collapsible pack described previously, to assemble from a flat position, panels A1 and A3 are pushed towards each other by the end user (either by holding onto the Lid (A4/A5) and end panel C, or some other location) such that A1 and A3 lie at 90 degrees to the surface of the inner face of panel A2, as illustrated by
This motion will automatically fold side wall panels D3 and E3 into a vertical (90 degree) position against the inner surface of base portion bottom panel A2. The position of the panels is now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner surface of A2, thus forming the beginnings of the base structure of the box. Due to the folding up of Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2, E4 and E5 will all fold together such that their surface lie flat against each other, this processes is illustrated in
Base portion inner front panel C1 is then folded over such that its inner surface lies flat against the inner surface of base portion front panel A1, as illustrated in
A feature of this flat packing, quick fold erect, re-foldable one piece box & lid of this embodiment is that the inner flap portion Panel B, is then folded over such that the inner surface of inner flap rear panel B1 lies flat against base portion rear panel A3, as shown in
The inner flap portion bottom panel B2, is then be pushed down so that it lies flat against the base portion bottom panel A2 as illustrated in
The side wall panels D6, D7, D8 and D9 are then folded to form an insert fitment at one end of the inside of the box. On the opposite side of the box, retaining element panels E6, E7, E8, and E9 are also folded to form an insert fitment. The folding is illustrated by
The lid portion top panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the lid portion side panel A5 folding over the outer surface of base portion front panel A1, as illustrated by
The following is an alternative example of a box with an integrated fitment incorporated into the panels of the box.
The process of folding into a set-up position is illustrated step by step in
The base portion of the pack is assembled in the same way as described in respect of previous embodiments.
Panel B is folded over, as illustrated in
Panel C1 is then folded over such that its inner surface lies flat against the inner surface of panel A1, as illustrated in
The panels C2 and C4 have a number of slots cut out of them to hold products. In this example, C2 has 3 slots to hold 3 bottles. To hold the bottles more securely, the panel C2 has small retaining panels (C6, C7, C8, C9, C10 and C11) attached to each side of the 3 bottle slots, as illustrated in
The lid top panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the lid side panel A5 folding over the outer surface of base front panel A1. To keep the lid closed on the box when in an erected position, A5 can be attached to the outer surface of panel A1 through the use of magnets, clips, cuts, additional parts, ribbons, ties or other method.
In this example, an alternative insert fitment has been incorporated into the inner flap portion panels B, and this example shows an alternative way the integral incorporated panels can fold to hold the box in a set up position.
The sixth alternative embodiment is an example of a box, which in its fully assembled form is a cube shaped pack, with an integrated insert fitment. This example also describes an alternative construction, in that side wall flaps D1 and D5 are not attached to the inside surface of base portion front and rear panels A1 and A3 respectively.
The process of folding into a set-up position is illustrated step by step in
To assemble from a flat position, base portion panels A1 and A3 are pushed towards each other by the end user (either by holding onto the Lid (A4/A5) and end panel C, or some other location) such that A1 and A3 lie at 90 degrees to the surface of the inner face of panel A2, as illustrated in
This motion will automatically fold side wall E3 into a vertical (90 degree) position against the inner surface of bottom panel A2. As D1 and D5 are not glued to the inner surface of A2 and A3 respectively, panel D3 will need to be pushed in by the user, so that it is at 90 degrees to the surface of A2, as illustrated by
The position of the panels is now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner surface of A2, thus forming the beginnings of the base structure of the box. Due to the folding up of Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2, E4 and E5 will all fold together such that their surface lie flat against each other, this processes is illustrated in
Then, Panel C is folded over, as illustrated in
Panel B1 is then folded over such that its inner surface lies flat against the inner surface of panel A3, as illustrated in
In this example, panel B2 has a circular hole cut in the centre to hold a candle.
The panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the panel A5 folding over the outer surface of A1, as illustrated by
The following is an alternative example of a box with an integrated internal compartment incorporate into the panels that form the box.
The process of folding into a set-up position is illustrated step by step in
As in previous examples, to assemble from a flat position, A1 and A3 are pushed towards each other by the end user (either by holding onto the Lid (A4/A5) and end panel C, or some other location) such that A1 and A3 lie at 90 degrees against the surface of the inner face of panel A2, as illustrated by
This motion will automatically fold D3 and E3 into a vertical (90 degree) position to the inner surface of A2. The position of the panels is now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner surface of A2, thus forming the beginnings of the base structure of the box. Due to the folding up of Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2, E4 and E5 will all fold together such that their surface lie flat against each other, this processes is illustrated in
Panels D6, D7, D8, D9 and D10 are then folded to form a compartment, as illustrated by
Then, Panel C is folded over, as illustrated in
Panel C1, whose width has been adjusted for this purpose, also covers panel D10 and hence holds the internal compartment in place.
Panel B, is then folded over such that the inner surface of panel B1 lies flat against A3, as shown in
The Panel B2, is then be pushed down so that it lies flat against the panel A2 as illustrated in
The panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the panel A5 folding over the outer surface of A1. The box is now divided, by the incorporated internal panels into a larger and smaller compartment.
The following is an alternative example of a box with incorporated internal panels. This example of the construction of the box is designed to hold a wallet.
The process of folding into a set-up position is illustrated step by step in
To assemble from a flat position, A1 and A3 are pushed towards each other by the end user (either by holding onto the Lid (A4/A5) and end panel C, or some other location) such that A1 and A3 lie at 90 degrees against the surface of the inner face of panel A2, as illustrated in
This motion will automatically fold D3 and E3 into a vertical (90 degree) position to the inner surface of A2. The position of the panels is now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner surface of A2, thus forming the beginnings of the base structure of the box. Due to the folding up of Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2, E4 and E5 will all fold together such that their surface lie flat against each other, this processes is illustrated in
Then, Panel C is folded over, as illustrated in
Inner flap portion rear panel B1, and inner portion side flaps B2 and B3, which depend from the side edges of rear panel B1, are then folded over. This arrangement would hold the product, in this example, a wallet in place in the box. The surfaces, as with any part of the box, could be printed on to improve the aesthetic appeal of the product, as well as printing text on the surface.
The lid portion top panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the lid portion side panel A5 folding over the outer surface of base front panel A1, as illustrated by
The following is an alternative example of a box, with an integrated divider, which forms two separate compartments, to hold a product such as shoes.
The process of folding into a set-up position is illustrated step by step in
The base portion of the pack is folded (
Panel B, is then folded over such that the inner surface of panel B1 lies flat against A3, as shown in
The Panel B2, is then be pushed down so that it lies flat against the panel A2 as illustrated in
The panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the panel A5 folding over the outer surface of A1, as illustrated by
The process of folding into a set-up position is illustrated step by step in
Side wall panel E3 has a rectangle cut out portion and a clear substrate (e.g. PVC) is glued to the back of the cut out to act as a window panel.
The panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the panel A5 folding over the outer surface of A1.
Various alternative embodiments of the collapsible pack of the invention are shown in
Various other changes and modifications are envisaged, such as for example, there are a number of ways in which an insert may be integrated into a pack according to the invention, including altering the size, shape and number of panels, adding flaps, parts, cuts or interlocks to create an integrated insert. Some additional examples of alternatives for integrated inserts include fitments made using more incorporated integral panels, flaps, interlocks, cut outs, slots, holes and slits. In these examples, the fitment can also be flat packed, and is directly connected to the panels of the pack.
More panels can be incorporated, or part of the panels may be altered in size or structure, on the pack. Further panels, or parts, can also be incorporated to the existing panels and flaps which may also be changed in size and or structure.
This invention can also be made by altering the panel B2 or incorporating more panels, flaps, parts, cuts or interlocks so that the invention is held together in an erect set up position without the need for the panel B2 to touch or lie flat against the inner surface of the panel.
The base and lid could also be lined on the inside or the outside with material for decorative purposes or to protect the contents when in a set-up position. The base and lid could be lined with fabric material, for example.
The panels making up the compartment may be integrated with inner flap panel B2, as an extension of panel B2 or it may be incorporated to the other panels that make up the box and lid, or new panels or flaps incorporated to the box. Additional incorporated panels may act as an integrated compartment when folded in the set-up position. More panels can be integrated to form a combination of compartments and fitments. Alternative methods for holding the lid closed are also envisaged. Examples include the use of magnets, ribbons, studs clips, locks, Velcro and straps, or the like.
The collapsible pack of the invention is re-foldable so that it may be assembled and disassembled repeatedly by a user. The pack may be used to contain many different and varied products such as footwear, bottles, clothing, jewelry, wallets or the like. In this way, the pack is multifunctional and has the advantage that, in its collapsed form it is capable of flat-packing and also a quick fold erect process.
The one piece box and lid incorporating an integral internal panel or panels in the form of an inner flap portion allows the base of the box to be held erected in a set up position by the folded incorporated integral internal panels whether or not the attached lid is open or closed, without the use of additional glue, adhesives, tape, clip, or other fastener.
The pack is preferred to have a folding lid, folding side walls and incorporated integral internal folding panels, in which the lid, integral internal panels and side walls are attached to the main body of the box, and all are foldable such that the structure folds to form a fully covered complete box with attached lid (and not a box comprised of a separate lid and base parts).
Furthermore, the box can be assembled from the flat pack position to the set-up position and the box can be disassembled and returned to the flat pack position, without the use of adhesives, double sided tape, tape, or other fastener to hold it in the set-up position.
In preferred embodiments, the lid, side walls, base and internal panels are made flexible and foldable through the use of materials that have been pre-cut, pre-creased, pre-folded, or through by connecting the panels making up the sides and parts of the box with a flexible material, which may be a thicker or thinner substrate, or may connect the panels totally to each other or in part.
The box, lid and integral panels can be of varying dimensions, proportions, and sizes.
Further, any part of the box, lid or integral panels may have a window, slot, cut out or panel or may have part of the material replaced by a different material which is clear, see-through or not see-through to act as a window, or adornment or decoration, or access to the product.
A carrying mechanism, handle or part by which the box can be carried may be added to any of the internal or external panels, including but not limited to a ribbon, string, plastic, paper or metal handle affixed to the box.
When the lid is in a closed arrangement, the lid can be held in position by magnets, a ribbon, a clip, a slotting method, or other such method for securing the position of the lid of the box when in a set-up arrangement, or the lid can be left open and unattached.
The internal inner flap portion panels hold the box in an erect set up position by a fold erect mechanism of internal panels or by engaging frictionally, via slots or cuts in either flap, via a clip, or magnet, or by altering the shape of the panels or by interlocking between panels of the box, including more incorporated panels.
The internal flaps or panels may act as a fitment/insert. The internal flaps may have additional panels, flaps or material attached to them to support a product as a fitment, or to act as an adornment or decoration.
The internal flaps may have panels attached to them, or material cut out from them or the size or shape alerted in order to support a product as a fitment, or to act as an adornment or decoration.
The internal flaps may have additional panels, flaps or material attached to form a compartment or multiple compartments.
Part or all of the materials may be lined or coated with fabric or other materials, or various materials are used to make up the parts of the box.
The integral inner flap panel or panels may be fixed permanently in a set up position the use of additional glue, adhesives, tape, clip, or other fastener, or interlocking, clips or other method for permanently holding the box in a set-up position.
| Number | Date | Country | Kind |
|---|---|---|---|
| 0812777.1 | Jul 2008 | GB | national |
| 0813412.4 | Jul 2008 | GB | national |
| 12212668 | Sep 2008 | US | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/GB2009/050835 | 7/13/2009 | WO | 00 | 4/8/2011 |
