U.S. patent application number 10/177610 was filed with the patent office on 2003-12-25 for secure packaging and mailing container.
Invention is credited to Howard, David M..
Application Number | 20030234252 10/177610 |
Document ID | / |
Family ID | 29734447 |
Filed Date | 2003-12-25 |
United States Patent
Application |
20030234252 |
Kind Code |
A1 |
Howard, David M. |
December 25, 2003 |
Secure packaging and mailing container
Abstract
A mailing or shipping container, made of corrugated cardboard,
is formed from a single scored piece of corrugated cardboard that
when folded provides multiple layers of support at the corners of
the box providing extra strength for protection against crushing.
The container is constructed so as to permit folding in such a way
as to be self locking and has pressure sensitive adhesive means
applied to interior surfaces for sealing the container when folded.
The mailing or shipping container has added layers of cardboard at
the rear corners and added layers of cardboard at the front corners
to provided increased protection from crushing, depending on the
aspect ratio of the final assembled container. All layers are
foldably deployed and implemented from a single sheet blank of
substantially rectangular corrugated cardboard, by defining
suitable scores and cuts in the blank material.
Inventors: |
Howard, David M.; (Laguna
Beach, CA) |
Correspondence
Address: |
KEVIN W. KIRSCH, ESQ.
STRADLING YOCCA CARLSON & RAUTH
660 NEWPORT CENTER DRIVE
SUITE 1600
NEWPORT BEACH
CA
92660-6441
US
|
Family ID: |
29734447 |
Appl. No.: |
10/177610 |
Filed: |
June 19, 2002 |
Current U.S.
Class: |
220/62.1 |
Current CPC
Class: |
B65D 5/28 20130101; B65D
5/6658 20130101; B65D 5/5021 20130101; B65D 5/6652 20130101; B65D
5/22 20130101 |
Class at
Publication: |
220/62.1 |
International
Class: |
B65D 025/00; B65D
005/00 |
Claims
1. A robust and secure shipping container formed from a single
piece of foldable corrugated cardboard comprising: a main bottom
segment, said main bottom segment having side walls and a front
panel foldable over itself to form front walls, said folded front
walls defining a recess between said front walls; a main top
segment, connected to said main bottom segment, said main top
segment having side walls, said side walls having projecting tab
portions extending from the end of said side walls, said projecting
tab portions capable of fitting within said recess between said
folded front panels of said main bottom segment, said side walls
having a diagonal slit score whereby said projecting tab portions
are capable of moving upwardly and away from said side walls for
facilitating insertion of said projecting tab portions into said
space.
2. The foldable container of claim 1, wherein said front panel of
said main bottom panel further comprises: projections extending
from said front panel for fitting within corresponding slots in
said main bottom segment.
3. The container of claim 1, further comprising: an adhesive
material for substantially permanently fixing at least two of said
walls together in order to define a tamper-proof or tamper-evident
closure.
4. The container of claim 3 in which said adhesive material
comprises a pressure sensitive adhesive tape including a rubberized
adhesive, the adhesive tape disposed on an interior surface of two
side walls forming opposite sides of the container.
5. The container of claim 1, said container further comprising: at
least two layers of corrugated cardboard at two corners of said
container and at least four layers of corrugated cardboard at two
others corners of said container.
6. The container of claim 1, further comprising at least an
exterior kraft liner, the kraft liner including decorative graphic
indicia printed on its surface, and further including shipment data
graphic indicia fields printed at a conventional location on its
surface.
7. A foldable container formed from a single piece of folded
corrugated cardboard comprising: a main bottom segment, said main
bottom segment having side walls and a front panel foldable over
itself to form front walls, said folded front walls defining a
space between said front walls; a main top segment, connected to
said main bottom segment, said main top segment having side walls,
said side walls having projecting tab portions extending from the
end of said side walls, said projecting tab portions capable of
fitting within said space between said folded front panels of said
main bottom segment; at least two layers of corrugated cardboard at
two corners of said container and at least four layers of
corrugated cardboard at two other corners of said container; and
said side walls having a diagonal slit score whereby said
projecting tab portions are capable of moving upwardly and and away
from said side walls for facilitating insertion of said projecting
tab portions into said space.
8. The container of claim 7, further comprising: an adhesive
material for substantially permanently fixing at least two of said
walls together in order to define a tamper-proof or tamper-evident
closure.
9. The container of claim 8 in which said adhesive material
comprises a pressure sensitive adhesive tape including a rubberized
adhesive, the adhesive tape disposed on an interior surface of two
side walls forming opposite sides of the container.
10. The container of claim 7, further comprising at least an
exterior kraft liner, the kraft liner including decorative graphic
indicia printed on its surface, and further including shipment data
graphic indicia fields printed at a conventional location on its
surface.
Description
FIELD OF THE INVENTION
[0001] The present invention relates, generally, to the field of
shipping and mailing containers and, more particularly, to secure,
crush-proof shipping and mailing containers that are easily and
efficiently assembled from a unitary, substantially rectangular
piece of substrate material.
BACKGROUND OF THE INVENTION
[0002] There have been a number of pre-formed shipping and mailing
containers that have been developed for use and sale in gift shops
and/or department stores for packaging gifts. These boxes are
typically formed from multiple pieces of rather thin cardboard
material and are generally stored and/or provided in a
substantially flat configuration. Boxes presented in this condition
permit the user to fold variously configured blanks in order to
create either the receptacle or cover portion of a gift box.
[0003] The United States Post Office and, more particularly, United
Postal Service and Federal Express, have standards that must be met
in order that boxes may be used for mailing or shipping. The boxes
must be able to withstand certain pressure and drop tests and be
fabricated from material having a particular minimum weight.
Cardboard gift boxes, of the type typically provided by gift and
department stores, do not meet these requirements and must be
further packaged in a suitable container.
[0004] Additionally, previously available pre-formed boxes do not
have any security means associated with their construction or
assembly in order to prevent the boxes from being accessed by
unauthorized persons. Typically, such boxes, when used as mailing
or shipping containers, must be covered in wrapping paper or
otherwise secured by application of adhesive tapes about their
circumference. The inconvenience and additional work required to
put conventional pre-formed boxes into suitable condition for
shipping or mailing makes them particularly unsuitable for use as
gift boxes, particularly when it is considered that these
conventional gift box sizes do not always fit comfortably within
the volumetric requirements of a suitable shipping container.
Additional expense and energy is often required to prepare a
pre-boxed gift for shipping or mailing. Accordingly, it should be
understood that there is a need for a shipping and/or mailing
container that is strong enough to meet shipping and mailing drop
and crush requirements as well as providing a degree of security in
the form of being tamper-evident, if not tamper-proof. Such boxes
should be able to support decorative prints on their exterior
surface so as to be visually appealing as well as structurally
sound.
SUMMARY OF THE INVENTION
[0005] It is one of the objects of the present invention to provide
a robust and secure shipping container that is reliable and more
convenient to use than conventional, flimsy two-part containers. It
is another object of the present invention to provide a robust and
secure shipping container that complies with United States Post
Office Regulations for mailing and with the crush, break and size
requirements of commercial international shipping concerns.
[0006] It is yet another object of the present invention to provide
a robust and secure shipping container that provides improved
protection for products within the box as well as provides added
security to the contents from unauthorized access by implementing a
tamper-proof and/or tamper-evident adhesive.
[0007] The present invention comprises of a robust and secure
shipping container made of corrugated cardboard, formed from a
single piece of corrugated cardboard. The robust and secure
shipping container is able to be folded such that there are
multiple layers of support at the corners of the container to
provide extra strength for protection against crushing. The
container is constructed to permit folding in such a way as to be
self-locking and has adhesive means applied to anterior surfaces
for sealing the container when folded. Pressure sensitive adhesive
tape is provided on the inside surfaces of the walls of the
container so that during assembly it is sealable and protected from
unauthorized persons or for use in mailing.
[0008] In the preferred embodiment, the containers of the present
invention have graphics for a suitable occasion, such as for
Christmas or a Birthday, and a mailing label printed on the
appropriate upper portion of the container so that the container
itself can be used directly as the mailing or shipping container
without the need for additional wrapping paper.
DESCRIPTION OF THE DRAWINGS
[0009] These and other features, aspects and advantages of the
present invention will be more fully understood when considered
with respect to the following specification, pended claims and
accompanying drawings wherein:
[0010] FIG. 1 is a plan view of one embodiment of a material blank
suitable for forming a secure shipping container of the present
invention;
[0011] FIG. 2 is a plan view of a second embodiment of a material
blank suitable for forming a secure shipping container according to
the present invention;
[0012] FIG. 3 is a plan view of a third embodiment of a material
blank suitable for forming a secure shipping container according to
the present invention.
[0013] FIGS. 4-8 are semi-schematic perspective views of the
folding operations required to assemble the secure shipping
container of FIG. 1;
[0014] FIGS. 9-14 are semi-perspective views of the folding
operations required to assemble the exemplary secure shipping
container of FIG. 2;
DESCRIPTION OF THE INVENTION
[0015] Referring now to the exemplary embodiment of FIG. 1, there
is depicted a plan view of a material blank indicated generally at
10, used in formation of an exemplary embodiment of a secure
shipping container according to the present invention. The material
blank 10 is formed from a corresponding stamping dye that presses
against a single, unitary piece of cardboard, and which cuts out
the perimeter of the blank and forms the scores, holes, and other
geometric forms on the blank in a manner well understood in the art
of box making. The scores 14 are depressions in the material blank
10 and are conventionally formed by projections on the dye that
press into the corrugated cardboard blank sufficiently to form a
score or fold line 14, but not pressed sufficiently into the blank
so as to cut all the way through the material. Rather, a score
compresses the material and forms a weakened line, along which the
material may be folded. Cuts 15 are formed by sharpened depressions
on the dye that cut all the way through the material of the blank.
A slit score 17 is formed by sharpened depressions in the dye that
cut through only one layer of corrugated cardboard material, but
not all the way through.
[0016] In this regard, corrugated cardboard suitably comprises an
outer smooth layer of paper, commonly termed the kraft liner, an
interior corrugated or wrinkled layer, referred to in the trade as
the medium, and a third layer (commonly an outer or exterior layer)
also termed a kraft layer or liner. As will be understood by those
having skill in the art, the thickness of the interior layer (the
corrugated layer) is known as the fluting. Characteristically, the
size of the fluting, i.e., its thickness or more appropriately the
height of the periodic corrugations can vary depending upon the
strength requirements for the final material.
[0017] Returning now to the exemplary embodiment of FIG. 1, the
material blank 10 suitably comprises two segments, a top segment 16
for forming the top and rear portions of a shipping container and a
bottom segment 18 for forming the bottom and front portions of the
container. The top segment 16 further comprises a generally
rectangular portion 19 including side folds 20 and 22 formed
parallel to one another which define rectangular side segments 21
and 23 which, when folded, form side walls 24 and 26 for the top
segment. The ends of the rectangular side segments have cuts 27 and
29 and 31 and 33 which, in combination, define end tabs 35 and 37.
End tabs 35 and 37 include folds 39 and 41 which define their plane
of rotation.
[0018] The side segments include, at ends opposite from the tabs 35
and 37, an arcuate cut forming semicircular tabs 44 and 36 and a
closure flap 48. Three parallel and horizontal folds 50, 52 and 54
extending along the length of the upper and lower portion of the
top segment and which, when folded, form the rear 55, top 19, and
flap 48 of the completed secure shipping container.
[0019] Side panels 24 and 26 include a slit score 17 formed at a
diagonal to and extending from the juncture of semicircular tabs 44
and 46 and flap 48, respectively.
[0020] The bottom segment 18 similarly includes a pair of parallel
folds 60 and 62 along the sides which form, when folded, the side
walls 64 and 66. Extending from the side walls, cuts 68 and 70 are
provided which form tabs 72 and 74. The forming dye cuts out
triangular segments 76 and 78 between tabs 72 and 74 and the
interior front wall 90 in order to promote ease of assembly and
folding.
[0021] The bottom segment 18 further includes three parallel folds
80, 82 and 84 which extend transversely from side to side. When
folded, these parallel folds define the bottom 86, front 88 and
interior front 90 walls of the completed secure shipping container.
The interior front wall 90 is slightly shorter in width than the
front wall 88 and includes a pair of extending tabs 92 and 94 that
are designed to be press fit into corresponding slots 96 and 98 in
the bottom of the container for holding the interior front wall 90
in place without requiring use of adhesives, staples, or other
securing device.
[0022] Adhesive strips 100 and 102, having removable non-adhesive
covers, are provided along a side of each of the side walls 24 and
26 of the upper side walls of the container. Adhesive strips 100
and 102 are preferably comprised of a rubberized adhesive material
and are positioned so as to cover not only the side walls 24 and
26, but also the slit scores 17 that allow the container to be
easily assembled. The adhesive material is preferably a rubberized
adhesive, such that its bonding strength is substantial,
particularly to the materials which comprise the kraft liner of the
container. The adhesive material must bond with the kraft liner in
such a manner that the liner itself will be defaced or destroyed if
the side walls 24 and 26 are attempted to be pulled away from their
facing side wall components 64 and 66.
[0023] Utilizing such an adhesive, and positioning the adhesive to
cover the slit score 17, as well as extending substantially to the
outer edge of side walls 24 and 26, ensures that the container is
not only strong, but also secure against tampering. Making the
container tamper-evident or tamper-proof, in this fashion, allows
the container to be used as a primary shipping or mailing
container. No further wrapping nor packaging need be done in order
to make the article ready for transit.
[0024] Turning now to FIG. 2, there is depicted a second exemplary
embodiment of a secure shipping container in accordance with the
invention, which is also formed from a single, unitary piece of
corrugated cardboard material. The corrugated cardboard material
suitably comprises an outer smoother layer of paper, termed the
kraft liner, an interior corrugated layer, referred to in the trade
as the medium, and a third layer, the exterior layer, also termed
the kraft liner. The material blank depicted in the exemplary
embodiment of FIG. 2 is suitably formed from a corresponding
stamping dye that presses against the unitary piece of cardboard
material, cuts out the perimeter of the material and forms the
scores, holes and other cuts in the blank as was described above in
connection with the exemplary embodiment of FIG. 1.
[0025] The embodiment of FIG. 2 also comprises to segments, a
segment that will be used to form the top of the completed
container and a second segment that is used to form the bottom, or
holder portion of the completed container. The portion forming the
bottom or holder of the container suitably comprises generally
rectangular surfaces denoted A, A', B, B', C, C', D, E, F, F', G
and H. The surfaces are separated and/or delineated by cuts or
scores and define the bottom, front, back and sides of the holder
portion of the container as well as closure flaps and
reinforcements. The surface D defines the bottom of the container
and is separated from the front and back faces (E and H,
respectively) by scores or creases 130 and 132. The side flaps, A,
B, C and F, are also delineated from the front, back and bottom
surfaces by elongated scores 133 and 134 and are separated from one
another by cuts.
[0026] Locking slots 137 and 138 are formed midway along the cut
separating surfaces B and C, which function to receive and secure
locking tabs 135 and 136 disposed along the top surface of a
closure flap A and A'. In this regard, it should be noted that the
closure flap A and A' is separated from side surfaces B and B' by
scores 139 and 140, as opposed to being separated therefrom by a
cut.
[0027] With regard to the portion that forms the top of the
container, it suitably comprises a top surface I which is
delineated from the back of the container by a score 150. A closure
lip is formed by surfaces M and N, which are delineated from one
another and from the container top surface by scores 152 and 154.
The sides of the top are formed by surfaces K and L which, when
assembled, define an overhang or lip about the entire periphery of
the container cover.
[0028] Suitably, and in accordance with the invention, rubberized
adhesive material is applied to the container top side walls K and
K' in a manner that substantially covers the side walls. The
adhesive material includes removable non-adhesive covers such that
the adhesive material can be exposed after the container is
assembled and ready for shipping. The adhesive material is
rubberized and has a bonding strength to kraft liner such that once
the container top side walls K and K' are pressed against the
outside surface of the bottom portion sides C and C', the adhesive
material forms a tamper-proof or tamper-evident seal between the
container top and container bottom.
[0029] It should also be noted that integrity of the assembled
container is promoted by providing various locking tabs and the
corresponding locking slots in appropriate locations about the
container. As wall segments are folded over one another, and it is
desired to keep a particular wall segment in place, so as to secure
the container folds, a locking tab is press fit into a
corresponding locking slot in order to secure that particular
surface from further deflection.
[0030] Referring to FIGS. 4 and 5, the assembly of the exemplary
secure shipping container of FIG. 1, will be described in
conjunction with the plan view illustration of FIG. 1. As shown in
FIGS. 4 and 5, the tabs 72, 74 are folded along fold lines 116, 118
and the side wall panels of the bottom 64, 66 are folded along
folds or scores 60 and 62 until the side walls 64, 66 are
perpendicular to the bottom 86. The tabs 72, 74 are folded so that
they are perpendicular to both the side walls 64, 66 and the bottom
86. The front wall segment 88 is then folded upwardly until it is
also perpendicular to the bottom 86. The interior front wall 90 is
then folded along scores 82, 84 so that it overlaps the tabs 72 and
74. The tabs 92 and 94 engage and fit within slots 96 and 98 in the
bottom, thereby holding the front 88, 90 and side walls 64, 66
securely.
[0031] Referring to FIGS. 6 and 7, the top side walls 21, 23 and
the tabs 35 and 37 are then folded along the score lines 20, 22 and
39, 41 until the side walls 21, 23 are perpendicular to the top
segment 19, and the tabs 35, 37 are perpendicular to both the sid
walls 21, 23 and the top 19. The top segment 19 is then folded
along score lines 52 and 54 so that the tabs 35 and 37 are flush
along the rear wall 55. The side walls 21 and 23 of the top 16 are
positioned so as to overlap the side walls 64, 66 of the bottom 86.
The top flap 48 is then folded along score line 50 and fitted
within the bottom 86 so that it is flush against the interior front
wall 90. The folds having been creased, the container defines an
interior volume suitable for receiving an object to be shipped. The
container is reopened and the object to be shipped is placed within
the container.
[0032] Referring now to FIG. 8, once the shipping item is in place,
the side walls 21 and 23 are then bent along slit score lines 17
and the ends 44, 46 of the side walls 21, 23 are folded along slit
score lines 17 and folds 120, 122 for insertion into the space
formed between the front wall 88 and the interior front wall 90 of
the bottom 86. The finger slots 54 and 56 permit the easy opening
of the gift box B. By inserting fingers under the finger slots 54,
56 the tabs 44 and 46 may be pulled out and the gift box
opened.
[0033] With regard to assembly, and with reference to FIGS. 9-14,
the assembly of the exemplary embodiment of a shipping container
described in connection with FIG. 2 will be described in
conjunction with the plan view illustration of FIG. 2. As depicted
in the figures, the side surfaces of the bottom portion, A, A', B,
B', C and C', are rotated upwardly about 90.degree. along the major
scores 133 and 134 so as to be perpendicular to surfaces D, E, G
and H. Next, bottom reinforcement surfaces C and C' are rotated, or
bent, an additional 90.degree. such that they align to score 130
between the bottom surface D and the back surface H of the
container. The surfaces which form the front of the container,
i.e., surfaces D, E, F, F' and G are folded upwardly approximately
90.degree. along score 130, such that the interior face of the
bottom surface D lies against the exterior faces of the bottom
reinforcement surfaces C and C'. To complete the rectangular prism,
the container front face E is folded upwardly an additional
90.degree. along score 132 such that it is perpendicular to the
bottom surface D.
[0034] Next, and just as the front surface is being rotated, side
reinforcement surfaces F and F' are folded 90.degree. inwardly
along scores 133 and 134 such that as surface E becomes parallel to
bottom surface D, the outside faces of side reinforcement surfaces
F and F' lay against the inside faces of side portions B and B',
respectively. Side closure surfaces A and A' now fold downwardly,
sweeping through about 180.degree., such that their inside faces
lay against the inside faces of side reinforcement surfaces F and
F', respectively. As this operation is completed, locking tabs 135
and 136 press into lock slots 137 and 138 which are now disposed at
the right angle corner between bottom reinforcement surfaces C and
C' and side surfaces B and B'. In so doing, the outer edges of
closure surfaces A and A', adjacent lock slots 135 and 136 press
against the crease which is adjacent lock slots 137 and 138 and pin
the container together by material pressure.
[0035] The final step in completing the holding portion of the
container involve folding lock surface G inward along scores 140
and 141, approximately 90.degree., thereby protruding lock tab 142
in an outward direction, away from the direction of the fold, in
order to form a projecting tongue which will engage a corresponding
locking tab when the box top is secured.
[0036] The top or cover portion of the container is assembled in
substantially similar manner, with front reinforcement surfaces L
and L' rotated upwardly along scores 155 and 156. Side pieces K and
K' are then rotated upwardly along corresponding scores 151 and
153, thereby positioning the inside edges of front reinforcement
surfaces L and L' (defined by cuts 157 and 158, respectively, along
the major score 152 which separates the container top surface I
from the container front surface M. The container front assembly
(comprising surfaces M and N) is folded upward along score 152 and
the locking surface N is then folded approximately 180.degree. over
the reinforcement flaps L and L' until locking tabs 172 and 173
engage corresponding locking slots 170 and 171 thereby securing the
folded material in place.
[0037] In this regard, it should be noted that the front edge of
locking surface N is cut in a manner that forms two locking tabs or
protrusions 172 and 173 that extend beyond the straight edge of the
surface. The cut between locking tabs 172 and 173 is displaced away
from the surface's straight front edge such that as the locking
surface is folded over and locking tabs 172 and 173 engage
corresponding lock slots 170 and 172, the displaced edge 177 is
also displaced from score 152 in order that a lock slot is defined
in the region between lock slots 170 and 171. As the container
cover is closed over the container bottom, locking tab 142 of lock
surface G engages the lock slot created by displaced edge 177 of
lock surface N, thereby fitting the container together.
[0038] At this time, or just before the container cover is closed
over the container bottom, the non-adhesive material is removed
from the adhesive strips on the container top side members K and K'
and, after the cover is closed over the bottom, pressure is applied
to the outside surfaces of side members K and K' thereby sealing
the container against tampering or entry.
[0039] It should be mentioned that the container top portion need
not be assembled after the body portion. Indeed, FIGS. 9-12
illustrate the folding operations of the body portion, while FIGS.
13 and 14 illustrate the folding operations of the top (lid)
portion, without regard to sequence. The operations associated with
FIGS. 13 and 14 may certainly be carried out prior to the
operations associated with FIGS. 9-12.
[0040] It should further be noted that the exemplary embodiments of
FIGS. 1 and 2 define a shipping or mailing container that has a
substantially empty square or rectangular body receptacle. In
accordance with practice of principles of the invention, it should
be understood that the methodology of container formation and
assembly also supports interior detail that is disposed within the
receptacle in order to customize the container to hold various
articles. This interior detail is also formed from the same unitary
piece of cardboard material and is simply manipulated into place by
folding the material along predefined scores. An example of such
interior detail might be a tray or nest that is configured to hold
a certain number of golf ball four-packs, for example. Since the
dimension of golf ball four-packs are well understood, and
substantially the same from manufacturer to manufacturer, one need
only provide a nest or tray with a certain rectangular dimension in
order to customize the container as a golf ball gift box, for
example.
[0041] In the exemplary embodiment of FIG. 23, an exemplary golf
ball container is illustrated which is also formed of a corrugated
cardboard blank defined by a corresponding stamping dye that
presses against a single, unitary piece of cardboard, and cuts out
the perimeter of the blank, forming the scores, holes and other
cuts, as described above. The corrugated cardboard material
suitably comprises a smooth outer kraft liner, an interior
corrugated layer or medium, and an inside kraft liner.
[0042] With regard to the third exemplary embodiment, the top or
cover portion, indicated generally at 180, is formed with
substantially similar surfaces, scores and cutouts as the top or
cover portion of the second exemplary embodiment. Accordingly,
corresponding surfaces and scores are indicated with the same
reference numerals as those denoted in connection with the second
exemplary embodiment. Further, the container bottom surface B.sub.1
is surrounded by side surfaces S.sub.1, S.sub.2, S.sub.3, and
S.sub.4, each of which are separated from the bottom surface by a
corresponding fold line or score. The front and back side surfaces
S.sub.1 and S.sub.2 terminate to either side by inwardly folding
flaps F.sub.1, F.sub.2, F.sub.3 and F.sub.4. As the side surfaces
are folded upwardly, the securing flaps are rotated through
90.degree. such that they are perpendicular to their associated
side surface and parallel to the next, 90.degree. side surface.
Securing tabs T.sup.1 and T.sub.2 are then folded over the flaps
and their associated side surfaces S.sub.3 and S.sub.4 until
locking tabs 182 and 183 engage lock slots 184 and 185, thereby
securing the bottom of the container.
[0043] An interior nest, indicated generally at 186, is suitably
formed with three extension leg flaps L.sub.1, L.sub.2 and L.sub.3
disposed along three of the sides of the nest center. The fourth
side suitably comprises the front container surface F.sub.2, with
each of the extension legs having substantially the same width as
the container front surface F.sub.2, such that as the extension
legs are folded inward and the nest is tucked into the bottom
receptacle of the container, extension legs L.sub.1, L.sub.2 and
L.sub.3 lay against the container side walls and their width
suspends the nest in the center of the container receptacle.
[0044] The next is stamped or cut-out in order to define an
interior dimension suitable to receive whatever article is designed
to be placed therein. In the case of a golf ball nest, diagonal
side cuts may be made in the nest material such that the side cuts
may be folded down as a golf ball four-pack is placed within. The
flaps designed by the side cuts exert a slight side pressure
against the golf ball four-pack, thereby retaining the pack within
the nest against movement.
[0045] If it is desired to have any of the shipping containers
secured to prevent unauthorized opening or when used as a mailing
box, prior to folding the top over the bottom, the adhesive
covering would be removed from the pressure sensitive adhesive
tapes and then the remaining steps performed as indicated above.
Once assembled, the sides, proximate the tapes, are pressed
inwardly, pressing the adhesive against the bottom side walls and
creating a secured container. The pressure sensitive adhesive or
other suitable gluing means could be positioned at other locations
to secure the container, but positioning the adhesive along the
side walls is preferred, since this orientation allows for a
tamper-evident, or tamper-proof seal to be formed.
[0046] The user would now write in the name and address of the
person to whom the container would be mailed on the mailing label
provided. There would be no need to wrap the container for mailing
or gift giving.
[0047] In the preferred embodiment, the assembled container may be
any dimension. Where the completed container is thin (has a low
profile or aspect ratio) the side walls may be fabricated with a
single folded thickness of material. Conversely, where the aspect
ratio or profile is large (a tall container) foldable reinforcement
surfaces are deployed to give the container a double-wall
construction, thereby strengthening the container for crush
resistance. In the exemplary embodiments of the invention, the
blank medium is E fluting, 200 pound test, and the kraft liners are
provided as 42 kraft. In larger boxes, or containers with a higher
aspect ratio, B fluting which is a higher medium could be used
instead of E fluting.
* * * * *