Patent Application
20200324933
The present invention relates generally to a Corrugated Box Assembly with Combination Self-Locking Lid and Tab-Style Fold over tab and Method of Construction. More so, the present invention relates to a box assembly that lies flat as a box blank having two rectangular sidewalls, two square sidewalls, rectangular flaps, and square flaps; whereby the box blank constructs to a rectangular box defined by six faces and twelve edges; whereby at least one fold over tab extends longitudinally along the joint between the square sidewall and the rectangular sidewall; whereby the fold over tab adds a bulge to the outer surface of the box body, so as to help loose a stack of boxes; and further provides multiple stacking tabs extend from the top flaps to mate with corresponding stacking holes in an adjacent box assembly, so as to stabilize multiple boxes arranged in a stacked arrangement.
The following background information may present examples of specific aspects of the prior art (e.g., without limitation, approaches, facts, or common wisdom) that, while expected to be helpful to further educate the reader as to additional aspects of the prior art, is not to be construed as limiting the present invention, or any embodiments thereof, to anything stated or implied therein or inferred thereupon.
It is known in the art that corrugated boxes are used for storage and shipping. These boxes provide some measure of product protection by themselves but often require inner components such as cushioning, bracing and blocking to help protect fragile contents. The boxes are designed to protect potential damage to the contents. For example, boxes unitized into a unit load on a pallet do not encounter individual handling while boxes sorted and shipped through part of their distribution cycle as mixed loads or express carriers can receive severe forces that damage the boxes. Moisture and debris are also inhibited from the object while inside the box.
Generally, corrugated fiberboard is a material consisting of a fluted corrugated sheet and one or two flat linerboards. It is made on “flute lamination machines” or “corrugators” and is used in the manufacture of shipping containers and corrugated boxes. The corrugated medium and linerboard board both are made of kraft containerboard, a paperboard material usually over 0.01″ thick. These boxes are often stacked for stowage, transporting, or awaiting to be filled, even when fully constructed.
Other proposals have involved corrugated boxes. The problem with these containers is that they do not provide both a stacking tab and a fold over tab. Also, the structural integrity does not benefit from stacking tabs and fold over tabs that enhance structural integrity of the box when carrying loads or being stacked. Even though the above cited corrugated boxes meet some of the needs of the market, a Corrugated Box Assembly with Combination Self-Locking Lid and Tab-Style Fold over tab and Method of Construction, is still desired.
Illustrative embodiments of the disclosure are generally directed to a corrugated box assembly with combination self-locking lid and tab-style fold over tab and method of construction. The box assembly provides a storage and shipping box having a generally rectangular cross-section made up of sidewalls and flaps for packing and carrying objects. When fully assembled, the box forms a rectangular cross section defined by six faces and twelve edges with locking tongues and slots that intimately interlock to construct the box and form a self-locking lid; at least one fold over tab extending along the outer edge of the body of the constructed box to create a bulge for removing multiple boxes stacked into each other; and stacking tabs extending from the top flaps to mate with corresponding stacking holes in an adjacent box assembly, so as to stabilize multiple boxes arranged in a stacked arrangement,
Box assembly is defined by a unique sidewall construction that utilizes a box body having two rectangular sidewalls with bottom and top rectangular die-cut flaps that are hingedly connected by score lines formed in the blanks. The box body also has two square sidewalls with bottom and top square die-cut flaps hingedly connected by score lines formed in the blanks, and a fold over tab at the edge of one of the rectangular sidewalls. The sidewalls join at lateral edges to form an enclosed region defined by a rectangular cross section.
A lockable lid is hinged to the body of the box assembly. Two of the rectangular die-cut flaps and two of the square die-cut flaps engage together to form a lid. The square die-cut flaps have locking tongues defined by heel portions adapted to lock under corresponding and adjacent slots that form in the rectangular die-cut flaps, after swinging through the slots. Such locking is achieved by folding the locking tongues of the lid into intimate engagement with corresponding slots in the rectangular die-cut flaps of the box assembly.
At least one fold over tab extends from the edge of one of the rectangular sidewalls when the box body is in the blank, unconstructed configuration. When the box body is constructed, the fold over tab extends longitudinally along the joint between a square sidewall and a rectangular sidewall. The fold over tab has an adhesive, so that when folded over the joint between the square sidewall and the rectangular sidewall, the sidewalls of box are fastened together. The fold over tab adds a bulge to the outer surface of the box body, so as to help loose a stack of boxes.
Fold over join tab adds strength to the vertices and edges of the box assembly, eliminating the need for fastening mechanisms to reinforce the vertices and corners of the box assembly. Additionally, fold over tab is shaped for easy stacking of multiple boxes, and to allow a bulge to separate stacked boxes.
In addition to the fold over tab feature, the flaps at the lid of the box assembly have locking tongues defined by heel portions adapted to lock under corresponding and adjacent slots that form in the rectangular die-cut flaps, after swinging through the slots. Such locking is achieved by folding the locking tongues of the lid into intimate engagement with corresponding slots in the rectangular die-cut flaps of the box assembly. Further, the box assembly provides stacking tabs that help stabilize stacking of multiple box assemblies.
In some embodiments, a fully constructed embodiment of the box assembly may include a plastic or cardboard corrugated container that assembles to a generally polyhedron-shaped box, and that can be easily folded from a collapsed, flat sheet to an operational, three-dimensional container that is defined by 6 faces and 12 edges.
In one aspect, the box assembly, comprises:
One objective of the present invention is to provide a corrugated paper box fold over tabs and locking tongues construction with sufficient strength so as to be self-supporting and require no additional support means.
Another objective is to provide a polyhedron box having 6 faces and 12 edges when fully constructed.
Yet another objective is to provide multiple dimensions of sidewalls, so as to enhance the strength of the vertices and corners of the box; thereby eliminating the need for metallic staples and cloth tape to reinforce the vertices and corners of the box.
Yet another objective is to provide geometric corners that interlock with L-shaped slots to reinforce the vertices and corners of the fully constructed box, but also easily disengage for returning the box to the flat, sheet configuration.
Yet another objective is to provide a corrugated paper box structure which is adaptable to speedy assembly.
Yet another objective is to provide additional means to hold the corner structure exact when assembled.
Yet another objective is to furnish a box construction blank with simple peripheral configuration which enables like blank to be cut with but a minimum of scrap material.
Other systems, devices, methods, features, and advantages will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims and drawings.
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
Like reference numerals refer to like parts throughout the various views of the drawings.
The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper,” “lower,” “left,” “rear,” “right,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in
A corrugated box assembly 100 with combination self-locking lid and tab-style fold over tab is referenced in
As referenced in
However in other embodiments, the box assembly may form, without limitation, a hexagonal shape, a cube shape, a pyramid shape, a cylindrical shape. In any shape however, the self-locking lid and tab-style fold over tab 140 is utilized.
In some embodiments, box assembly 100 may include a plastic or cardboard corrugated container that assembles to a generally polyhedron-shaped box, and that can be easily folded from a collapsed, flat sheet to an operational, three-dimensional container that is defined by 6 faces and 12 edges.
The method 900 for assembly of box assembly 100 is relatively straight forward, as the sidewalls and flaps are folded inwardly to join at locking slots and tongues that interlock in intimate engagement to create a generally rectangular, upright box. Additionally, stacking tabs help stabilize stacking of multiple box assemblies. Further, the box assembly 100 can better support vertical and lateral loads, such as are present when many like boxes are stacked in a column, making box ideal for packaging and shipping heavy objects, fragile goods, and easily damaged produce, for example. And, as described above, box collapses to a flat box blank 102 when not operational for facilitated stowage and transporting.
Turning now to
In some embodiments, grab hole 142a-b that forms in square sidewalls 112a-b provides a surface area for gripping and carrying box. Grab hole 142a-b may have a curved shape that fits the hand. In one embodiment, square sidewalls 112a-b are disposed in a spaced-apart, parallel relationship from each other, and in a generally perpendicular relationship to rectangular sidewalls 104a-b. In one non-limiting embodiment, square sidewalls 112a-b have a length of about 11 11/16″, and a width of about 11″.
Box assembly 100 provides a unique sidewall construction that utilizes two different dimensions of sidewalls arranged in a generally rectangular shape with fold over tabs, which adds strength to the vertices and corners of box assembly 100. This helps reduce the need for fastening mechanisms, such as metallic staples and cloth tape to reinforce the vertices and corners of the box assembly 100.
In addition, box assembly provides a fold over tab 140 that is configured to help create a box assembly 100 with greater vertical and lateral support (
In one embodiment, fold over tab 140 is configured to fold over an outer corner edge of box assembly, extending longitudinally along the outer lateral edge of the constructed box assembly. The adhesive 158 on fold over tab serves to fasten the sidewalls of the box assembly together. Fold over tab 140 also creates an outer bulge that helps in separating multiple box assemblies stacked into each other. In one non-limiting embodiment, fold over tab 140 has a width of about 1⅝″.
Top rectangular flaps form a pair of top locking slots 124a, 124b, 124c, 124d utilized to intimately engage correlating top locking tongues 132a-d in the top square flaps 130a-b to construct the top portion of box assembly 100. The tongue and slot form an intimate relationship, where the tongue slides into the slot and remains affixed due to frictional forces and the weight of box assembly 100 and contents therein. This works to close the top of box assembly 100.
The interlocking slots 124a-d and tongues 132a-d also prevent tucking, as the flaps can be more easily accessed, and the packer does not have to put hands into the interior of the box to engage and disengage the flaps to a closed or open position. The flaps are easily accessed from the outside of the box assembly 100. In one non-limiting embodiment, top flaps have a width of about 4⅛″, and bottom flaps have a width of about 5″.
Looking now at
This unique interlocking mechanism serves to significantly increase the strength of box assembly 100 when fully assembled and closed. The interlocking mechanism also works to provide additional rigidity to sidewalls on each of the corners when the box assembly 100 is fully assembled, without utilizing additional support means.
Looking now at a bottom view of box assembly 100 in
In one non-limiting embodiment, the two bottom rectangular flaps 126a-b and the two bottom square flaps 136a, 136b form at least one air hole 144a, 144b, 144c, 144d, 144e, 144f, 144g, 144h. Air hole 144a-h can be useful for storing produce and other perishable items. Air holes may have circular, rectangular, elongated, ovular, or irregular shapes.
Looking back at
As
Further, as
In some embodiments, method 900 may include an initial Step 902 of providing a generally flat box blank, the box blank having: two rectangular sidewalls; two square sidewalls; four corner sidewalls, whereby the rectangular and square sidewalls joining at the lateral edges in an alternating arrangement to form an enclosed region defined by a rectangular cross section and four parallel outer edges; at least one elongated, L-shaped fold over tab, the fold over tab being longitudinally attached along the parallel outer edges; two die-cut top rectangular flaps hingedly connected by a top score line along the top edge of the rectangular sidewalls; two die-cut top square flaps hingedly connected by the top score line along the top edge of the square sidewalls; and two die-cut bottom square flaps hingedly connected by the bottom score line along the bottom edge of the square sidewalls.
Method 900 further comprises a Step 904 of folding the rectangular sidewalls towards each other, whereby the box assembly is partially formed. The sidewalls may fold along an indented crease or score line forming in the box blank. A Step 906 includes folding the square sidewalls towards each other, whereby the lateral edges of the rectangular and square sidewalls engage. A rectangular cross section forms at this point.
In some embodiments, a Step 908 comprises folding the fold over tab along the parallel lateral edges of the partially formed box assembly, whereby the adhesive helping to fasten the sidewalls together. The fold over tab is folded to extend longitudinally along the outer lateral edge of the constructed box assembly. The adhesive on the fold over tab, which may include glue, staples, a weld, and the like, serves to fasten the sidewalls of the box assembly together. The fold over tab also creates an outer bulge that helps in separating multiple box assemblies stacked into each other.
In some embodiments, a Step 910 may include folding the bottom rectangular flaps and the bottom square flaps inwardly. The bottom flaps come together to form a bottom portion of the box assembly. A Step 912 includes interlocking a bottom locking tongue from the bottom square flap with a corresponding and adjacent bottom locking slots from the bottom rectangular flap. The tongue and slot form an intimate relationship, where the tongue slides into the slot and remains affixed due to frictional forces and the weight of the box assembly and contents therein. In some embodiments, a Step 914 may include filling an enclosed region of the box assembly with an object.
In some embodiments, a Step 916 comprises folding the top rectangular flaps and the top square flaps inwardly. Method 900 may further comprise a Step 918 of interlocking a top locking tongue from the top square flap with a corresponding and adjacent top locking slots from the top rectangular flap, whereby the box assembly 100 is fully constructed and defined by six faces and twelve edges. A final Step 920 includes stacking multiple box assemblies, whereby a top stacking tabs intimately engage a bottom stacking hole in the sidewalls and flaps. This is effective in supporting boxes stacked on their flaps. However, when box assemblies are stacked into each other, fold over tab 140, which extends along the outer corner edge of assembled box, creates a bulge in the stacked boxes that allows for easy separation.
Although the process-flow diagrams show a specific order of executing the process steps, the order of executing the steps may be changed relative to the order shown in certain embodiments. Also, two or more blocks shown in succession may be executed concurrently or with partial concurrence in some embodiments. Certain steps may also be omitted from the process-flow diagrams for the sake of brevity. In some embodiments, some or all the process steps shown in the process-flow diagrams can be combined into a single process.
These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings.
Because many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalence.
