The present invention pertains to folded boxes. In particular, the present invention pertains to a box that is folded so as to maintain its specific volume from the initial collapsed state to its final folded state. The folded box contains substantially no open gaps.
There are many folded boxes and many methods for folding boxes disclosed in the prior art, many of which introduce open gaps into the folded box. As open gaps increase the volume of the folded box, they create inefficient use of space, especially shelf space of a display rack in a retail store.
There is a need for folding boxes more efficiently so as to maximize use of the shelf space.
In one aspect, the present invention pertains to a method of folding a box. The method comprises the steps of: (1) providing a collapsed box having an initial specific volume and an initial footprint; (2) folding the collapsed box forming at least two panels, the folded collapsed box having a final specific volume and a final footprint. The panels are substantially similar in size and are disposed on top of one another. The final specific volume of the folded collapsed box is substantially similar to the initial specific volume of the collapsed box and the final footprint is smaller than the initial footprint.
In another aspect, the present invention pertains to a method of folding a box. The method comprises the steps of: (1) providing a collapsed box having a first footprint; (2) folding the collapsed box forming at least two panels, the folded collapsed box having a final footprint. The panels are substantially similar in size and are disposed on top of one another. The folded collapsed box contains no open gaps.
One advantage of the present invention is that it yields a folded box that has the smallest footprint, for a given number of folds, while not increasing the volume of the folded box from its collapsed state. In this way, the inventive folded box can be displayed efficiently on a shelf because the greatest number of folded boxes can be displayed for a given display shelf.
As used herein, a “box” is a type of container formed from a plurality of joined sidewalls; typically four sidewalls are used and the box includes cover flaps and bottom flaps. A “collapsed box” is a formed container folded on its originally formed creases so as to have the sidewalls stacked on top of one another. An “originally formed crease” is one that made by the box manufacturer to create the sidewalls of the box. A collapsed box would typically have two layers of cardboard, either corrugated or non-corrugated disposed on one another, the first layer includes two sidewalls and the second layer includes the remaining two sidewalls. A “folded box” is the collapsed box folded so that its final footprint is smaller than its initial footprint. An “in-fold” is a fold in the side of the box so as to have the sidewalls touching or nearly touching one another. An illustration of an in-fold is described in German publication DE 3925490. An “open gap” is open space between the panels of the folded box and does not include the open gaps that are in a corrugated sheet of cardboard forming the box.
The invention can be further described with reference to the following figures, wherein:
The figures are idealized, are not drawn to scale, and are intended for illustrative purposes only.
The gaps between the bottom flaps of the box in
The folded boxes of the present invention are particularly suitable for display on a shelf in a retail store. In one aspect, the present invention pertains to a method of displaying folded box on the shelf. The method comprises the steps of: (1) providing a shelf having a defined volume determined by a surface area and a height of the shelf, (2) providing a plurality of collapsed boxes, each having an initial specific volume and an initial footprint; (3) folding each collapsed box forming at least two panels, each folded collapsed box having a final specific volume and a final footprint, wherein the panels are substantially similar in size and are disposed on top of one another, and wherein the final specific volume of the folded collapsed box is substantially similar to the initial specific volume of the collapsed box and the final footprint is smaller than the initial footprint; and (4) displaying the plurality of folded collapsed boxes on the shelf.
In another aspect, the a method of displaying a folded box on a shelf comprising the steps of: (1) providing a shelf having a defined volume determined by a surface area and a height of the shelf; (2) providing a plurality of collapsed boxes, each having an initial specific volume and an initial footprint; (3) folding the collapsed box so forming at least two panels, the folded collapsed box having a final footprint, wherein the panels are substantially similar in size and are disposed on top of one another; and wherein the folded collapsed box contains no open gaps; and (4) displaying the plurality of folded collapsed boxes on the shelf.
In both of the above-described steps, the method can further include a step of bundling the folded collapsed boxes together. The boxes can, but does not have to be of the same size, and if they are of different sizes, they most likely will have different footprints. The different size boxes can be bundled together to form even more efficient display of the boxes. The folded boxes can be displayed in any convenient manner at a retailer's selection.
The folded boxes are also particularly suited for shipping. In one aspect, the invention pertains to a method of shipping folded collapsed boxes. The method comprises the steps of: (1) providing a plurality of collapsed boxes each having an initial specific volume and an initial footprint; (2) folding the collapsed box forming at least two panels, the folded collapsed box having a final specific volume and a final footprint, wherein the panels are substantially similar in size and are disposed on top of one another and the final specific volume of the folded collapsed box is substantially similar to the initial specific volume of the collapsed box and the final footprint is smaller than the initial footprint; (3) bundling the folded collapsed boxes together; and (4) loading the bundled folded boxes into a transporter, such as a truck or rail cars.
In yet another aspect, the present invention pertains to a method for shipping a plurality of folded collapsed boxes comprising the steps of: (1) providing a plurality of collapsed boxes each having an initial first footprint; (2) folding the collapsed box forming at least two panels, the folded collapsed box having a final footprint, wherein the panels are substantially similar in size and are disposed on top of one another and the folded collapsed box contains no open gaps; (3) bundling the folded collapsed boxes together; and (4) loading the bundled folded boxes into a transporter.
This application claims priority to U.S. Provisional Application 60/736221, filed Nov. 14, 2005, which is incorporated by reference in its entirety.
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