Patent Application
20080223911
The present invention relates generally to gift box containers for packaging an article or articles, and more particularly, but not exclusively, to a method of construction and assembly of double walled gift boxes.
Double walled gift boxes are known. Covers and bases are usually formed from relatively flexible paperboard blanks having decorative outer surfaces and flat, clean inner surfaces. Side and end walls are folded inward upon themselves to form double walls adhered together by adhesives. Inner portions of the walls are connected by creased gussets which are folded and tucked into junctions of the side and end walls. Glue strips connect inner and outer portions of the walls. Folded gussets are held in place by the glue strips.
Reinforcement of the double walled gift boxes with heavier sheets is sometimes useful. When larger, heavier sheets are added to boxes an alignment of the sheets to which the adhesive has been applied may become a problem; U.S. Patent Application Publication No. 2005/0092821 A1 discloses such a gift box. There is still a need for improved boxes and methods of construction which reduce defects while simplifying equipment and processes. It is known that when heavier sheets are secured with adhesive or other securing means, such adhesive or other securing means may break away during the construction or assembly process. It is therefore desirable to reduce or at least mitigate the problems of the prior art.
According to a first aspect of the present invention there is provided a package comprising a tray having a main panel with opposed side walls and opposed end walls hinged to said main panel, the package further comprising a stiffening sheet comprising a base panel having opposed side panels and opposed end panels hinged thereto, wherein at least one of said opposed end or side panels of the stiffening sheet comprises a securing tab defined at least in part by a weakened line of severance, said securing tab is secured to the tray and wherein the securing tab is severed from the stiffening sheet when the tray is erected from a flat collapsed form into a set up condition.
In the illustrative embodiments, the securing tab is separated from the stiffening sheet as a consequence of relative movement between the opposed end panels of the stiffening sheet and the outer side walls of the tray.
The securing tab may be struck from the end panel and may be defined in part by an aperture.
In certain embodiments, the end wall comprises a first panel and a second panel hinged together to form a double wall wherein said second panel comprises an engaging tab for engaging with said aperture to secure the package in said set up condition.
In certain embodiments, the base panel of the stiffening sheet is of smaller dimension than the main panel of the tray. The base panel of the stiffening sheet may alternatively be suspended above the main panel of the tray.
In certain embodiments, the base panel of the stiffening sheet is hinged along a first fold line to one of said opposed end panels and the main panel of the tray is hinged along a second fold line to one of said opposed end walls wherein said first and second fold lines are offset relative to one another.
According to a second aspect of the present invention there is provided a two part blank for forming a package the two part blank comprising a first blank for forming tray, the first blank having a main panel with opposed side walls and opposed end walls hinged to said main panel, the package further comprising a second blank for forming a stiffening sheet, the second blank comprising a base panel having opposed side panels and opposed end panels hinged thereto, wherein at least one of said opposed end or side panels of the stiffening sheet comprises a securing tab defined at least in part by a weakened line of severance, said securing tab being secured to the first blank and wherein the securing tab is severed from the second blank when the package is erected into a set up condition.
According to a third aspect of the present invention there is provided a securing device for use in a packaging apparatus for securing a first layer of the packing apparatus to a second layer of a packaging apparatus, comprising a first layer having a first panel and second panel hinged to the first panel by a first fold line, and a second layer having a third panel hinged to a fourth panel along a second fold line, wherein the first panel comprises a tab coupled to the first panel by a weakened line of severance said first layer being overlaid onto said second layer wherein said first layer is secured to the second layer by securing the tab to the third panel of the second layer, whereby in response to folding said first and third panels about their respective fold lines the tab separates from the first panel by tearing along the weakened line of severance.
In certain embodiments, the first and second fold lines are offset from one another.
In certain embodiments, the tab is struck from the third panel and defined in part by an aperture struck in part from the third panel.
According to a fourth aspect of the present invention there is provided a package comprising a securing device for use in a packaging apparatus for securing a first layer of the packing apparatus to a second layer of a packaging apparatus, comprising a first layer having a first panel and second panel hinged to the first panel by a first fold line, and a second layer having a third panel hinged to a fourth panel along a second fold line, wherein the first panel comprises a tab coupled to the first panel by a weakened line of severance said first layer being overlaid onto said second layer wherein said first layer is secured to the second layer by securing the tab to the third panel of the second layer, whereby in response to folding said first and third panels about their respective fold lines the tab separates from the first panel by tearing along the weakened line of severance.
According to a fifth aspect of the present invention there is provided a blank for forming a packaging apparatus comprising a securing device for securing a first layer of the packing apparatus to a second layer of a packaging apparatus, comprising a first panel and a second panel hinged wherein the first panel comprises a tab coupled to the first panel by a weakened line of severance said first panel being overlaid onto said second panel wherein said first panel is secured to the second panel by securing the tab to the second panel, whereby in response to relative movement between said first and second panels the tab separates from the first panel by tearing along the weakened line of severance.
According to a sixth aspect of the present invention there is provided a securing device for use in a package comprising a panel of foldable sheet material, wherein a securing tab is coupled to said panel by a frangible connection, wherein said panel is securable in position by securing means applied to the securing tab and wherein the securing tab is separable from said panel during subsequent processing of the panel.
One advantage of the present invention is that a first panel may be secured by a securing means to a second panel in order to ensure correct alignment of the first panel with respect to the second panel when the package is assembled, but the securing means is able to separate from the first panel during subsequent processing of the package, thereby reducing or preventing distortion of the package.
A further advantage of the present invention is that it allows a first blank to be overlaid and secured to a second blank, the first and second blanks being dimensioned differently such that in an assembled package a space between the first and second blank is provided, such that the first and second blanks may be processed together, e.g. fed through a straight line gluing operation, maintaining correct alignment relative to one another.
Exemplary embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings:
A preferred embodiment of the present invention is shown in
Inner side walls 16a, 16b, are hingedly connected outer side walls 14, 14b, respectively along respective fold lines 34a, 34b. Inner side walls 16a, 16b, each comprise a pair of tabs 26 hinged to opposed ends of the inner side walls 16a, 16b, along fold lines 27. The tabs 26 are disposed adjacent to the fold line 34a, 34b, separating the inner and outer side walls, 14a, 14b and 16a, 16b.
Outer end walls 18a, 18b are hinged to opposed ends of the main panel 12 along fold lines 36a, 36b respectively. Inner end walls 20a, 20b, are hinged to respective ones of said outer end walls 18a, 18b along fold lines 38a, 38b respectively. Inner end walls 20a, 20b, each comprise a tab 24 disposed centrally on the free edge 37 opposed the hinged edge defined by fold line 38a, 38b. The side edges of the inner end wall 20a, 20b comprise a recess portion 21 disposed adjacent to the fold line 38a, 38b.
The recess 21 is substantially similar in dimension to tab 26. The remaining portion of the side edge forms an engaging edge 22, such that in an assembled form the portion 22, engages beneath tab 26, between the outer side wall 18a, 18b, and the end edge 25, of the inner side wall 16a, 16b.
The end edge 25 of the inner side wall is offset from an end edge defined by fold line 31 of the outer side wall 14a, 14b; such that at least a portion of the inner side wall 16a, 16b is shorter in length than the outer side wall 14a, 14b. This arrangement provides a space between the end edge of the inner side wall 25, and the inside surface of the end walls 18a, 18b. This space is sufficient to accommodate the engaging edge 22 of the sides of inner end walls 20a, 20b such that the edge of the inner side wall 25 and engaging edge 22 form a complementary locking mechanism for securing the inner end walls 20a, 20b without the need for adhesive.
A first gusset panel 28 hinged to each side edge of outer end wall 18a, 18b along a fold line 38. A second gusset panel 30 is hinged to each of said first gusset panels 28 along a fold line 33 and to each end edge of the outer side panels 14a, 14b.
A further complementary locking mechanism is formed in part by tab 24 and in part by aperture 46 struck from stiffener sheet 10, as shown in
Stiffener sheet 10, shown in
A tab 60 is formed in trapezoidal opposed end panels 44a, 44b. Tab 60 is defined in part by aperture 46 and in part by a weakened line 61. Aperture 46, is struck in part from trapezoidal opposed end panel 44a, 44b and in part from main panel 40.
In the illustrative embodiment, the opposed end panels are trapezoidal in shape, although it will be appreciated by those skilled in the art that alternative shapes may be used.
Furthermore, whereas in the illustrative embodiment the tab 60 is struck from the trapezoidal opposed end panel 44a, 44b; it will be appreciated that alternative configurations could be employed without departing from the scope of the invention.
In the exemplary embodiment stiffening sheet 10 is dimensioned such that main panel 40 is smaller that main panel 12 of the tray forming blank 20. This allows tray forming blank 20 to be readily folded about the stiffening sheet 10 without the stiffening sheet initiating the folding process and provides a mechanism for securing the stiffening sheet to the tray forming blank whist further processing is carried out.
Turning now to the construction of the tray of the double walled gift box from the blanks shown in
Outer side walls 14a, 14b are then folded inwardly about fold lines 48a, 48b inwardly to lie in overlapping relationship with the base panel 40 of the stiffening sheet 10.
In consequence of folding outer side walls 16a, 16b into overlapping relationship with base panel 40 gusset panels 28 are folded into an overlapping relationship with outer end walls 18a, 18b and gusset panels 30 are folding into an overlapping relationship with trapezoidal opposed end panel 44a, 44b.
Optionally, gusset panels 28 are secured to outer end walls 18a, 18b by Glue G applied to gusset panels 28 as shown in
In an alternative method of assembly the package may be assembled starting from the partially assembled tray illustrated in
When gusset panels 28 are not secured to the outer end walls 18a, 18b the assembly process may include the further steps of folding the outer end walls and the outer side walls separately and of folding and tucking the gusset panels 28 into position.
Turning to
Once the outer end walls 18a, 18b and outer side walls 14a, 14b are substantially perpendicular to the base panel 40, the inner end walls 20a, 20b are folded inwardly of the tray 1, see
The engaging edges 22 of the inner end walls 20a, 20b engage the edges 25 of the inner side walls 16a, 16b to complete assembly of the tray 1, as shown in
Optionally, the tabs 24 and 22 may be removed and inner end walls 20a, 20b may be secured by glue or other bonding agent.
It is envisaged that the tray 1 may be assembled either by hand or automatically such as by a machine.
By providing tab 60 with a weakened line 61 the stiffening sheet 10 can be secured to the tray forming blank 20 by securing the tab 60 to the tray whilst being the tray is assembled and shipped in a flat collapsed form. A flat collapsible blank has the advantage of being readily shipped and distributed; the provision of tabs 60a allows a tray to be assembled from the flat collapsed form in a controlled and predictable manner without tearing or deformation.
When the flat collapsed tray 2 is assembled into a set up condition the weakened line of severance 61 coupling each tab 60 to a respective opposed end panel 44a, 44b breaks thereby separating the opposed end panels 44a, 44b of the stiffening sheet 10 from the outer end walls 18a, 18b of the tray forming blank 20. The breaking action is achieved as a consequence of the finite thickness of the sheet material which forms the tray forming blank 20 and that forming the stiffening sheet 10. This breaking action can be enhanced by offsetting the fold line 50a,50b between the opposed end panel 44a, 44b and the main panel 40 of the stiffening sheet 10 from the fold line 36a,36b hinging the outer end wall 18a, 18b and the main panel 12 of the tray forming blank 20.
This offsetting may be achieved by configuring the main panel 40 of the stiffening sheet 10 such that it is shorter in dimension between its opposed end panels 44a, 44b than the dimension of the main panel 12 of the tray forming blank 20 between its opposed outer end walls 18a, 18b.
It also allows provision of a double walled tray having a stiffening sheet wherein in an assembled form the stiffening sheet is effectively suspended by the securing means between the inner side walls and the opposed side panel. In the illustrative embodiment, this is achieved using adhesive. The suspension of the stiffening sheet as described may provide an additional cushioning benefit which protects articles placed within the gift box.
The embodiments shown in
The embodiments shown in
The relative movement in the embodiments of
The relative movement required to separate the tabs 160, 260 is opposite to that of the illustrative embodiment. This may be achieved by providing the sheet 110, 210 as an external sheet rather than as an internal sheet according to the illustrative embodiment. The tab 160, 260 could therefore be provided in the tray for forming the blank rather than in the stiffening sheet. Of course this may be undesirable in packaging intended to be used a gift box since the broken tab 160, 260 may be visible unless further packaging is used. It is also envisaged that the present invention could be used in other forms of packaging and is not limited to gift boxes.
Turning now to
Alternatively it is envisaged that glue may be applied to stiffener sheet 310 such that the inner side walls 316a, 316b are secured to the inner sheet only by securing tab 360. It is envisaged that other securing means may be employed in alternative configurations provided that the side and end walls of inner liner 310 are capable of movement relative to the side or end walls of tray blank 320. Optionally, panels 328 may be secured to opposed end walls 344a, 344b of the inner liner 310, by application of glue or other bonding agent. The constructed package may then be assembled into a tray as described previously.
In this way, means is provided for securing the inner liner 310 to the tray forming blank 320 whilst the package is constructed.
It will be appreciated that a gift box may be created by assembling of a first tray for forming a base and a second tray for forming a cover, wherein the base and cover are dimensioned such that one may fit within the other in a setup condition. In alternative embodiments the gift box may only comprise a top cover or base having a tray according to the present invention, the other of said top cover or base being provided by other means known in the art.
The entire box may be formed with conventional cutting, adhesive laying, and folding equipment. The stiffening sheet is cut and scored in a single operation and is placed in a single step. The initial perpendicular folding of the ends and sides insures precise alignment of the stiffener. No special provision is required for the precise aligning of detached parts when they are juxtaposed or are glued in place. No separate requirements for special aligning, placing, and bonding steps are present.
The bending of the sides along scores in the stiffening sheet automatically aligns and precisely positions the central panel of the stiffening sheet with respect to the main panel of the tray sheet as the side and end panels of the tray sheet are bent upward. The stiffening sheet is automatically locked in position by the inward folding and gluing of the outer side panel halves which would otherwise contact the inner surfaces of the inner side panel halves of a double walled box tray.
Savings result from no increases in the steps to handle the outer sheet when forming a double walled tray and no requirements to spread adhesive over the large main panel of the tray-forming sheet. Further increased savings result from not requiring precision placement equipment for aligning two large panels after gluing. The invention has the added advantage of reducing rejects from misaligned glued panels. Speed of production may be increased by the elimination of need for precise alignment before adhering large panels. Additional savings result from reduction of adhesive requirements, elimination of added adhesive requirements, and elimination of precision aligning and positioning equipment. The look and feel of the finished box may be enhanced by not requiring adhesive under the main panels.
While the invention has been described with reference to specific embodiments, modifications and variations of the invention may be constructed without departing from the scope of the invention, which is defined in the following claims.
It will be appreciated that whilst the invention described herein is directed to a double walled tray for a gift box, the present invention may be employed in any packaging system comprising two blanks in which a first blank is to be secured to a second blank pending further processing of the two blanks.
It is envisaged that in yet further embodiments of the invention that the securing tab may be replaced with an alternative fixing device capable of providing means for securing the inner liner to the outer tray while the package is constructed and/or processed, without departing from the scope of the present invention. The fixing device being separable from either the inner liner or the outer tray in a controlled manner, upon application of a predetermined force, or alternatively a forced applied in a specific direction, such that the inner liner is capable of movement relative to the outer tray.
