Referring to
More specifically, the substrate 510 is divided into a number of different panels that define particular segments or regions of the substrate 510. A series of first panels 512 all fold in a first direction and include panels 520, 522, 524, and 526. Each of these panels 520, 522, 524, 526 is disposed adjacent another panel in the series and is separated from a next panel by one of the fold lines F1. As shown in
In the illustrated embodiment, each of the panels 520, 524 has a generally rectangular shape and the widths of the panels 520, 524 are preferably equal. In addition, the panels 522, 526 also have a generally rectangular shape, with the panel 522 being disposed between the panels 520, 524 and the panel 526 being formed on the other side of the panel 524. The panels 522, 526 have widths that are preferably equal to one another but are less than the width of the panels 520, 524.
Referring now to
On one side of each end panel 530, a flap 560 is provided. The flaps 560 are bounded along one margin at the fold lines F2 to the panel 522. The flap 560 thus folds about fold line F2 and is generally in the shape of a trapezoid in that it includes two non-parallel side edges 562. It will be appreciated from
The panel 522 is bounded at its ends by the flaps 560 and along its sides by panel 520 and 524. In other words, the panel 522 is disposed between the panels 520 and 524 and is joined thereto along fold lines F1.
On the other side of the panel 520 and the end panel 530, a first fastening panel 550 is formed and includes a main section 552 that extends between fold lines F2 and thus has a general rectangular shape and end sections 554 that extend from the fold lines F2 to the outer edge of the end panel 530. The end sections 554 thus extend the same distance from the fold lines F2 as the end panels 530; however, each end section 554 has a generally triangular shape, with the hypotenuse of the triangle being defined by an edge 556. The other two sides of the end section 554 are defined by the end edge 534 and the edge 532 that defines the fold line F2.
A free edge 558 of the fastening panel 550 and in particular, of the panel 520, represents a free edge that is used to construct and configure the substrate 510 into its sealed folded construction shown in
A pair of end panels 540 is also provided and is constructed to have a boundary along the fold lines F2 to the panel 524 which is located between panels 522 and 526 and is joined thereof along fold lines F1. The end panel 540 is defined by two parallel edges 542, one (inner edge) of which defines the fold line F2 and the other is an outer edge of the end panel 540. The end panel 540 has a trapezoid shape and is therefore, also defined by a pair of angled edges 544. The angled edges 544 are tapered inward toward the fold line F2 so as to cause the inner edge (the fold line F2) to have a lesser width than the outer edge 542.
In the embodiment of
As can be seen, a slit 561 separates the flap 560 and the adjacent panel 540 and therefore, permits folding of the flap 560. There is a gap between the other side edge 562 of the flap 560 and the adjacent panel 530 and therefore, there is no slit present in this location.
As illustrated in
On one side of each panel 540, a flap 570 is provided. The flaps 570 are bounded along one margin at the fold lines F2 to the panel 526. The flap 570 thus folds about fold line F2 and is generally in the shape of a trapezoid in that includes two non-parallel side edges 572 and an outer edge 574. It will be appreciated from
Similar to the flap 560, the flap 570 is defined by the pair of side edges 572 that are angled with respect to the fold lines F2 and outer edge 574, with one of the side edges 572 being formed by a slit or cut that also defines one of the edges 542 of the panel 540.
One the other side of the panel 526 and the flaps 570, a second fastening panel 590 is formed and includes a main section 592 that extends between fold lines F2 and extends from the fold line F1. The main section 592 can generally have a trapezoid shape and is defined by an inner edge 594 (fold line F1), an outer edge 596 that is parallel to the inner edge 594 and has a lesser length, and a pair of end edges 598 that extend between the inner edge 594 and the outer edge 596. The edges 598 are angled relative to the edges 594, 596.
The second fastening panel 590 is similar to and complementary to the first fastening panel 550 with the exception that the second fastening panel 590 does not include the end sections 554 that are present as part of the first fastening panel 550.
The outer edge 596 of the fastening panel 590 represents a free edge that is used to construct and configure the substrate 510 into its sealed folded construction shown in
As can be appreciated from
In accordance with a salient aspect of the present invention, the shirt box 500 can be configured in a partially assembled state in which a hollow central cavity for containing one or more shirts or one or more shirt and tie combinations is defined, yet which is collapsible into a generally flat state until such time that one or more shirts (or a shirt and tie combination) are to be inserted into the box. When the shirt box 500 is to be filled, it is brought to an uncollapsed state, the shirt is introduced into the hollow cavity, and the peripheral ends of the shirt box are bonded so as to define a substantially rectangular and sealed shirt box construction.
The first and second fastening elements 551, 591 are designed to interlockingly mate together for permanently connecting the panel 590 to the panel 550. According to one embodiment and as illustrated, the fastening elements 551, 591 are in the form of an interlocking based structure or a crimped based structure where the two panels 550, 590 are securely connected to one another so as to form a closed box blank that and be stored flat prior to use. When the securement technique is an interlocking based structure, the elements 551, 591 when pressed together interlock with one another. The elements 551, 591 can thus be a snap-fit based system that interlocks with one another when mated together.
With further reference to
Preferably, the material of the substrate has a thickness so that, in combination with the fold lines F1 and F2, a stable, second state results in which the shirt boxes 500 can be stacked in great number, one upon another, to promote efficient shelf and display space usage.
In order to facilitate folding of the shirt box, in a preferred form, the end panels 530, 540, 580 can have chamfered corners adjacent their respective free ends. The chamfered corners reduce interference of one panel member with another as the box 500 is folded.
In the assembled, folded state, the angled sides of the trapezoidal shape box 500 are defined by panels 522, 526 and the top is defined by panel 524 and the bottom is defined by panel 520. In the assembled state, the ends of the box 500 are defined by the folded panels 530, 540 and flaps 560, 570. When the box 500 is fully assembled into the folded state of
In one embodiment of the present invention, the side edges of the partially folded, collapsed box 500 shown in
In the flat storage position (collapsed state) that allows a number of boxes 500 to be easily stacked on top of one another, the box 500 is folded about the fold line F1 between the panels 522, 524 so that the panel 524 is disposed above and lies across a portion of the panel 520 and a portion of the panel 522 and both panels 526, 590 lie above the panel 520. The outer edge 596 of the fastening panel 590 does not extend all the way to the fold line F1 that is formed between the panel 520 and the fastening panel 550. In this orientation, the flaps 570 lie above the end panel 530 but do not extend all the way to the outer edge of the end panel 530. Each end panel 540 is disposed over a portion of the end panel 530 and one flap 560. The outer edge 542 of the end panel 540 preferably overlies the outer edge 532 of the underlying end panel 530 in this folded construction. The outer edge of the underlying flap 560 does not extend to the fold line F2 that is defined by the overlying outer edges of the end panels 530, 540.
One angled edge 544 of the end panel 540 that is adjacent the flap 570 is disposed over the end panel 530, while the other angled edge 544 does not overlie any structure and is angled outwardly from the fold line F1 between the panels 522, 524 and therefore, the tip where the angled edges 544 and 584 intersect represents the furthest point of one side of the unassembled, folded, collapsed box 500.
In the folded, closed position of
To construct and assemble the box 500 into its normal condition for use as shown in
As the panel 524 continues to be raised and the panels 522, 526 pivot upwardly toward an axis that is normal to the panel 520, the end panels 540 are also raised and assume a position above the end panels 530, with the flaps 560, 570 being positioned between the end panels 530, 540. As the panel 524 is raised, the flaps 560, 570 move in direction that causes them to become more normal relative to the underlying panel 520. In this initial movement, the end sections 554 begin to pivot upwardly about the first end edge 534 (F1 fold line between the end section 554 and the end panel 530).
In this intermediate position, the end sections 554 are close to or even in a perpendicular orientation relative to the end panel 530 and the panel 522 can likewise be in position where the panel 522 is substantially perpendicular to the panels 520, 524 as shown in
To go from the intermediate position to the final, closed position of
As a result of folding the first fastening panel 550 in this manner into a position where it lies in the same plane as the panel 520, the two panels 522, 526 of the box 500 form and define the two angled sides of the trapezoid shaped box 500. The assembly of the box 500 is then completed by bending the flaps 560, 570 inwardly towards the interior compartment of the box 500 (e.g., folded over towards the panels 522, 526, respectively) and then the end panels 530, including the end sections 554, are folded up towards the folded flaps 560, 570 and brought into contact therewith to close off the interior compartment of the box 500. As shown, the combination of the end section 554 and the adjoining end panel 530 itself defines a trapezoid shaped end.
The final sealing of the box 500 is performed by folding down the end panel 540, at the fold line F2 between panels 540, 524 so as to fold the panel 540 over the folded end panel 530 so that the trapezoidal shaped end panel 540 lies over the complementary trapezoidal shaped end panel 530, with one angled edge 544 being generally aligned with and overlying the edge 556 associated with the end section 554 and the other angled edge 544 being aligned with and overlying the edge 536. The end flap 580 is then folded about the fold line F2 so as to position the end flap 580 on an underside (bottom surface) of the panel 520. To secure the end flap 580 to this underside surface of the panel 520, the removable strip of the double-sided tape member 600 is removed so as to expose the second side of the tape member 600, thereby exposing an adhesive surface which permits the engagement of the end panel 580 with the underside of the panel 520. Once the panels 580 have been adhesively joined by the tape member 600, the shirt box 500 is in the second state, namely, the assembled state, in which the hollow central cavity is sized to receive one or more shirts.
It will be appreciated that the area of the end section 554 and the end panel 530 is about equal to the area of the end panel 540 which, unlike the end panel 530 does not include a fold line F1 since these two structures mate together as described herein. In addition, the bottom of the box 500 is defined by the panel 520 and the first fastening panel 550, while the top of the box 500 is defined by the panel 524.
The fold lines F1 and F2 can be continuous or discontinuous, but preferably are continuous and more preferably comprise score lines in the substrate 520.
The set of first panels of the shirt box 500 thus includes a bottom panel 520, a top panel 524 and a pair of side panels 522, 526 that extend between the bottom and top panels 510, 524, each of the first and second side panels 522, 526 being formed at an angle other than 90 degrees with respect to the top panel 524 and the bottom panel 520. In the collapsed box, one side panel 522 lies adjacent and in the same plane as the bottom panel 520, while the other side panel 526 lies above the bottom panel 520 and in a different plane. The first fold line is formed between the first fastening panel 550 and the bottom panel 520 that is part of the first set of panels, wherein in the collapsed box 500, the first fastening panel 550 is folded over the bottom panel 520, while in the assembled state, the first fastening panel 550 and the bottom panel 520 lie at least substantially in the same plane.
It will be appreciated that the box 500 is constructed to receive and display one or more shirts. For example, when displaying two shirts, the shirts are arranged side by side and one shirt can at least partially overlie the other shirt so that both collars of the shirts are spaced apart and fully visible. It is also possible for one or more of the shirts to include a tie as described above with reference to previous embodiments.
Now referring to
The shirt 710, along with the attached bow tie 720 and cuff links 716, occupy a first section of the central cavity of the box 500, while a cummerbund 730 is disposed in and occupies a second section of the central cavity that is adjacent the first section. The cummerbund 730 can be folded so that its folded length is about the same as the length of the folded shirt 710. As is well known, the cummerbund 730 has a pair of free ends or straps 732, 734 that are releasably attached to one another, as by a hook or buckle type mechanism. In one aspect of the invention, a support structure 740, such as a piece of cardboard, is provided to support the folded cummerbund 730 and help locate and confine the cummerbund 730 to the second section of the box 500. The support structure 740 thus has a length that is about the same as the length of the folded shirt 710. The folded cummerbund 730 can be further secured to the support structure 740 by any number of different means, including, the use of a clip or the like (this further ensures that the cummerbund 730 will not move excessively relative to the support structure 740). By placing the cummerbund 730 in the second section of the box next to the folded shirt 710 in the first section, the consumer can view the cummerbund 730 directly next to the folded shirt 710. The consumer can thus view the complete tuxedo shirt arrangement prior to purchase to select the desired tuxedo shirt design.
In one aspect of this embodiment, one of the panels 540 contains a hanger 750 that has a hook member 752 to permit the box 500, with the tuxedo shirt arrangement 700 contained therein for display to the consumer. The hanger 750 includes a body portion 754 from which the hook member 752 extends and the hanger 750 is preferably attached to the panel 540 by securely attaching an underside of the body portion 754 to the outer face of the panel 540. The hanger 750 can be attached using any number of different techniques, including using an adhesive (e.g., glue or cement) or by otherwise bonding or welding the hanger 750 to the panel 540.
It will also be appreciated that the tuxedo arrangement 700 does not have to include the cummerbund 730 and support structure 740 but instead, the shirt box 500 can contain only the folded shirt 710, along with the bow tie 720 and cuff links 716.
As with the earlier embodiment, the shirt box 500 can be formed with hole 90 in one of the panels that forms the box 500. Hole 90 is positioned such that the outline of the hole overlies a portion of the shirt or the tuxedo arrangement. This arrangement provides access to the garments inside the shirt box 500 so that consumers can touch and feel the garments yet does not compromise the structural integrity of the box 500. It will be appreciated that the shape and size of the hole 90 are not critical and the hole 90 is therefore not limited to having an oval shape.
While the invention has been described in connection with certain embodiments thereof, the invention is capable of being practiced in other forms and using other materials and structures. Accordingly, the invention is defined by the recitations in the claims appended hereto and equivalents thereof.