U.S. patent application number 13/054120 was filed with the patent office on 2011-08-25 for collapsible pack with inner flap.
Invention is credited to Timothy Conroy.
Application Number | 20110204129 13/054120 |
Document ID | / |
Family ID | 39722184 |
Filed Date | 2011-08-25 |
United States Patent
Application |
20110204129 |
Kind Code |
A1 |
Conroy; Timothy |
August 25, 2011 |
COLLAPSIBLE PACK WITH INNER FLAP
Abstract
A collapsible pack and associated blank assembly, comprising a
base portion, lid portion and an inner flap portion, the base
portion comprising a bottom panel (A2), opposing front (A1) and
rear (A3) panels and opposing side walls (D3,E3) wherein the front
panel, rear panel and the side walls are each hingedly connected to
the bottom panel, the lid portion comprising a top panel, and the
inner flap portion comprising a rear panel, wherein the inner flap
portion and the lid portion are each hingedly connected to the base
portion rear panel.
Inventors: |
Conroy; Timothy; (Hong Kong,
CN) |
Family ID: |
39722184 |
Appl. No.: |
13/054120 |
Filed: |
July 13, 2009 |
PCT Filed: |
July 13, 2009 |
PCT NO: |
PCT/GB2009/050835 |
371 Date: |
April 8, 2011 |
Current U.S.
Class: |
229/126 ;
229/100 |
Current CPC
Class: |
B65D 5/4204 20130101;
B65D 5/248 20130101; B65D 5/32 20130101; B65D 5/422 20130101 |
Class at
Publication: |
229/126 ;
229/100 |
International
Class: |
B65D 5/66 20060101
B65D005/66; B65D 5/00 20060101 B65D005/00; B65D 5/56 20060101
B65D005/56; B65D 5/62 20060101 B65D005/62 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 14, 2008 |
GB |
0812777.1 |
Jul 23, 2008 |
GB |
0813412.4 |
Sep 18, 2008 |
US |
12212668 |
Claims
1. A collapsible pack comprising a base portion, a lid portion and
an inner flap portion, the base portion comprising a bottom panel,
opposing front and rear panels and opposing side walls wherein the
front panel, rear panel and the side walls are each hingedly
connected to the bottom panel, the lid portion comprising a top
panel, and the inner flap portion comprising a rear panel, wherein
the inner flap portion and the lid portion are each hingedly
connected to the base portion rear panel.
2. A collapsible pack according to claim 1, wherein the lid portion
top panel is hingedly connected to the base portion rear panel.
3. A collapsible pack according to claim 1, wherein, during
assembly of the pack, the inner flap portion rear panel is folded
about the hinge line connecting same to the base portion rear panel
so as to cover the base portion rear panel.
4. A collapsible pack according to claim 1, wherein the inner flap
portion rear panel is hingedly attached to the base portion rear
panel.
5. A collapsible pack according to claim 1, wherein the inner flap
portion rear panel is hingedly attached to, or proximate to, an
edge of the base portion rear panel.
6. A collapsible pack according to claim 5, wherein when hingedly
attached proximate to an edge of the base portion rear panel, the
inner flap portion rear panel is attached to the inner face of the
base portion rear panel.
7. A collapsible pack according to claim 1, wherein the lid portion
further comprises a side panel hingedly connected to the lid
portion top panel.
8. A collapsible pack according to claim 1, wherein the inner flap
portion further comprises a bottom panel hingedly connected to the
inner flap portion rear panel.
9. A collapsible pack according to claim 8, wherein the inner flap
portion bottom panel is hingedly connected to a free edge of the
inner flap portion rear panel, which free edge is opposite the edge
of the inner flap portion rear panel hingedly connected to the base
portion rear panel.
10. A collapsible pack according to claim 8, wherein during
assembly of the pack, the inner flap portion bottom panel is folded
about the hinge line connecting same to the inner flap portion rear
panel so as to lie against the base portion bottom panel.
11. A collapsible pack according to claim 1, wherein the pack
further comprises a base portion inner front panel.
12. A collapsible pack according to claim 11, wherein the base
portion inner front panel is hingedly connected to the base portion
front panel.
13. A collapsible pack according to claim 1, further comprising
first, second, third and fourth pairs of base side wall flaps.
14. A collapsible pack according to claim 13, wherein each pair of
base side wall flaps depends from an edge of a base side wall of
the pack.
15. A collapsible pack according to claim 13, wherein a first base
side wall flap of each pair of base side wall flaps depends
directly from an edge of a base side wall and a second base side
wall flap of each pair depends from the other base side wall flap
of the same pair.
16. A collapsible pack according to claim 15, wherein the second
base side wall flap of each pair of base side wall flaps depends
from the first base side wall flap of a pair along a diagonal hinge
line between diagonally opposed vertices of the connected pair of
base side wall flaps.
17. A collapsible pack according to claim 16, wherein one of the
pair of base wall side flaps depends from an edge of a base portion
side wall and the other of the pair from the diagonal hinge
line.
18. A collapsible pack according to claim 1, wherein the opposing
base portion side walls are hingedly attached to the base portion
bottom panel.
19. A collapsible pack according to claim 18, wherein the opposing
base portion side walls are hingedly attached to, or proximate to,
opposing side edges of the base portion bottom panel.
20. A collapsible pack according to claim 1, further comprising a
second lid portion top panel.
21. A collapsible pack according to claim 20, wherein the second
lid portion top panel is hingedly connected to the base portion
front panel.
22. A collapsible pack according to claim 1, wherein the base
portion front panel is further hingedly connected to a base portion
inner front panel.
23. A collapsible pack according to claim 1, wherein the lid and
the base portion panels share a common longitudinal axis in the
collapsed (flat) pack.
24. A collapsible pack according to claim 1, wherein the inner flap
portion panels are connected to one another along a hinge line.
25. A collapsible pack according to claim 1, wherein the panels of
the base portion and the panels of the lid portion are each and all
separate from one another.
26. A collapsible pack according to claim 1, wherein some or all of
the panels of the base portion and/or some or all of the panels of
the lid portion are connected to one another.
27. A collapsible pack according to claim 1, wherein some or all of
the panels of the base portion and lid portion are formed
integrally with one another.
28. A collapsible pack according to claim 1, further comprising at
least one cover layer.
29. A collapsible pack according to claim 28, wherein the at least
one cover layer is a flexible material.
30. A collapsible pack according to claim 28, wherein the cover
layer is a flexible paper-based material.
31. A collapsible pack according to claim 27, wherein the at least
one cover layer has an adhesive coating applied to one surface
thereof.
32. A collapsible pack according to claim 28, wherein the at least
one cover layer provides the hinge connections between adjacent
panels/walls/flaps.
33. A collapsible pack according to claim 28, wherein one or more
of the panels of the base portion and the panels of the lid portion
are connected by the cover layer.
34. A collapsible pack according to claim 33, wherein the base
portion bottom, front and rear panels, and the lid portion top
panel, are covered by the at least one cover layer.
35. A collapsible pack according to claim 28, wherein the inner
flap portion further comprises a second cover layer.
36. A collapsible pack according to claim 35, wherein the outer
surface of the inner flap portion rear panel and, where present,
the inner flap portion top panel, are covered by the second cover
layer.
37. A collapsible pack according to claim 35, wherein the inner
flap portion rear panel is hingedly connected to the base portion
rear panel by the second cover layer.
38. A collapsible pack according to claim 1, wherein each panel is
covered at least one cover layer.
39. A collapsible pack according to claim 1, further comprising an
insert.
40. A collapsible pack according to claim 39, wherein the insert is
formed by an extension to or, as an additional panel attached to,
one or more of the panels or walls of the pack.
41. A collapsible pack according to claim 39, wherein one or both
of the base side walls comprises at least one additional panel
forming an insert.
42. A collapsible pack according to claim 39, further comprising a
removable insert.
43. A collapsible pack according to claim 1, further comprising a
closure member.
44. A collapsible pack according to claim 1, further comprising a
window in a side wall thereof.
45. A collapsible pack according to claim 1, further comprising a
window in a lid and/or a base panel thereof.
46. A blank assembly erectable into a collapsible pack, the blank
assembly comprising: an outer blank having first and second major
panels interconnected along hinge lines by a first minor panel and
further having a second minor panel depending from the first major
panel along a further hinge line; a first inner blank comprising a
first minor panel; and a second and a third inner blank each
comprising a first major panel and a first and a second minor panel
depending from opposing edges of the major panel.
47. A blank assembly according to claim 46, further comprising a
third minor panel depending from the second major panel.
48. A blank assembly according to claim 46, further comprising a
fourth minor panel depending from the second minor panel along a
further hinge line.
49. A blank assembly according to claim 46, further comprising a
fifth minor panel depending from the outer blank second minor panel
along a further hinge line.
50. A blank assembly according to claim 46, wherein the inner blank
further comprises a first major panel depending from the first
minor panel of the inner blank along a hinge line.
51. A blank assembly according to claim 46, wherein the panels,
flaps and walls are formed of a rigid material.
52. A blank assembly formable into the collapsible pack of Claim 1.
Description
[0001] The present invention relates to a collapsible pack and, in
particular, to a flat-pack box and also to a blank assembly
formable into a collapsible pack.
[0002] Retail staff are under pressure to serve as many customers
as possible, in as short a time as possible, and to focus their
attention on the client they are serving at the same time.
Likewise, businesses are under continual pressure to offer high
quality products, which are well presented at the point of sale
and/or to provide high quality packaging that is fit for purpose.
Furthermore, there is often limited storage space in business
premises, retail spaces and in the logistics chain on a product's
journey from factory to consumer.
[0003] Typical boxes, lids and fitments require some form of
transportation or storage. In addition, freight is charged by
volumetric weight (volume and weight being used in the cost
calculation), so shipping assembled boxes and packaging means
paying for shipping the contents which may include a large volume
of air in addition to the packaged products themselves. In order to
overcome one or more of the drawbacks of known packaging, the
invention proposes a re-foldable, flat-pack box which is simple and
quick to erect.
[0004] This invention is such that the box may be assembled and
disassembled quickly and easily without the need to use glue or
adhesives during folding (or unfolding).
[0005] According to a first aspect, the present invention provides
a collapsible pack comprising a base portion, a lid portion and an
inner flap portion, the base portion comprising a bottom panel,
opposing front and rear panels and opposing side walls wherein the
front panel, rear panel and the side walls are each hingedly
connected to the bottom panel, the lid portion comprising a top
panel, and the inner flap portion comprising a rear panel, wherein
the inner flap portion and the lid portion are each hingedly
connected to the base portion rear panel.
[0006] In embodiments of the invention, the lid portion top panel
is hingedly connected to the base portion rear panel.
[0007] During assembly of the pack, the inner flap portion rear
panel is folded about the hinge line connecting same to the base
portion rear panel so as to cover the base portion rear panel. In
this way, in the erected pack, the inner flap portion rear panel
reinforces the rear face of the pack giving further strength to the
assembled pack.
[0008] In preferred embodiments, the inner flap portion rear panel
is hingedly attached to the base portion rear panel. More
specifically, the inner flap portion rear panel is hingedly
attached to, or proximate to, an edge of the base portion rear
panel. More specifically still, when hingedly attached proximate to
an edge of the base portion rear panel, the inner flap portion rear
panel is attached to the inner face of the base portion rear panel.
In embodiments of the invention, the lid portion further comprises
a side panel hingedly connected to the lid portion top panel. It is
preferred that, in the fully assembled pack, the lid portion side
panel will lie against the base portion front panel of the
pack.
[0009] In embodiments of the invention, the inner flap portion
further comprises a bottom panel hingedly connected to the inner
flap portion rear panel. More specifically, the inner flap portion
bottom panel is hingedly connected to a free edge of the inner flap
portion rear panel, which free edge is opposite the edge of the
inner flap portion rear panel hingedly connected to the base
portion rear panel.
[0010] During assembly of the pack, the inner flap portion bottom
panel is folded about the hinge line connecting same to the inner
flap portion rear panel so as to lie against the base portion
bottom panel. In this way, in the erected pack, the inner flap
portion bottom panel reinforces the bottom face of the pack giving
further strength to the assembled pack.
[0011] In embodiments of the invention, the pack further comprises
a base portion inner front panel. More specifically, the base
portion inner front panel is hingedly connected to the base portion
front panel. During assembly of the pack, the base portion inner
front panel is folded about the hinge line connecting same to the
base portion front panel so as to lie against the base portion
front panel. In this way, in the erected pack, the base portion
inner front panel, when present, reinforces the front face of the
pack giving further strength to the assembled pack.
[0012] In embodiments of the invention, the pack further comprises
first, second, third and fourth pairs of base side wall flaps. More
specifically, each pair of base side wall flaps depends from an
edge of a base side wall of the pack. Even more specifically, a
first base side wall flap of each pair of base side wall flaps
depends directly from an edge of a base side wall and a second base
side wall flap of each pair depends from the other base side wall
flap of the same pair. In this way, each base side wall assembly
will comprise two pairs of base side wall flaps depending from
opposing edges of a base side wall.
[0013] Preferably, the second base side wall flap of each pair of
base side wall flaps depends from the first base side wall flap of
a pair along a diagonal hinge line between diagonally opposed
vertices of the connected pair of base side wall flaps.
[0014] During assembly of the pack of the invention, the first,
second, third and fourth pairs of base side wall flaps are folded
about their respective hinge lines so as to lie on the inner
surface of the base portion front and rear panels. In the assembled
base portion, the base portion rear and front panels oppose one
another and the base portion side walls oppose one another. The
base side wall flaps are located at each corner of the assembled
base portion, one pair of base side wall flaps at each corner.
[0015] In embodiments of the pack wherein a pair of base side wall
flaps comprises a diagonal hinge line between diagonally opposed
vertices of the connected pair of base side wall flaps, one of the
pair depends from an edge of a base portion side wall and the other
of the pair from the diagonal hinge line. During assembly, the base
side wall flaps are folded about a hinge line connecting same to
the edge of the base side wall inward of the base portion and one
of the pair is attached to either the base portion rear panel or
the base portion front panel. The pair of base portion side wall
flaps is folded about the diagonal hinge line which, in turn,
raises the base portion rear and/or front panels into position.
[0016] In embodiments of the invention, one of the pair of base
portion side wall flaps is attached to either the base portion rear
panel or the base portion front panel by a releasable mounting.
More specifically, the releasable mounting may be a hook and eye
fastening, a non-permanent adhesive, or the like. In alternative
embodiments, the attachment is by permanent mounting such as
permanent adhesive or the like.
[0017] The opposing base portion side walls are preferably hingedly
attached to the base portion bottom panel. More specifically, the
opposing base portion side walls are hingedly attached to, or
proximate to, opposing side edges of the base portion bottom panel.
When hingedly attached proximate to opposing side edges of the base
portion bottom panel, the attachment is to the inner face of the
base portion bottom panel.
[0018] In certain embodiments, the pack further comprises a second
lid portion top panel. More specifically, the second lid portion
top panel is hingedly connected to the base portion front panel. In
these embodiments, the first and second lid portion top panels will
abut one another in the assembled pack. In this way, the assembled
pack has a split lid arrangement formed of two separate panels.
[0019] In particularly preferred configurations of the present
invention, the lid and base portion panels are aligned as follows:
lid portion side panel hingedly connected to lid portion top panel
which is further hingedly connected to base portion rear panel
which is further hingedly connected to base portion bottom panel
which is further hingedly connected to base portion front
panel.
[0020] In various embodiments, the base portion front panel may
further be hingedly connected to a base portion inner front panel.
In these embodiments, in the assembled pack, the base portion inner
front panel lies over the base portion front panel at an inner
surface thereof. In this way, the base portion inner front panel
reinforces the front panel of the pack thereby giving further
strength to the assembled pack.
[0021] In embodiments of the invention, the lid and the base
portion panels share a common longitudinal axis in the collapsed
(flat) pack. In embodiments of the invention wherein the pack
comprises a cover layer, the base portion inner front panel may be
commonly share the cover layer or, alternatively, may have a
further cover layer of its own.
[0022] In certain embodiments, the inner flap portion panels are
connected to one another along a hinge line. The inner flap portion
rear panel and the inner flap portion bottom panel may be hingedly
connected to one another along a common fold line formed in the
material of the pack. More specifically, the inner lap portion rear
panel and the inner flap portion bottom panel may be attached to
one another along a hinge line. In alternative embodiments, the
inner lap portion rear panel and the inner flap portion bottom
panel may be covered by an inner flap cover layer. In this way, the
inner lap portion rear panel and the inner flap portion bottom
panel are hingedly connected to one another by the inner flap cover
layer along a hinge line formed by the inner flap cover layer where
the two separate panels abut one another.
[0023] It is preferred that the inner flap rear portion has
substantially the same dimensions as the base portion rear panel
and that the inner flap portion bottom panel and the base portion
bottom panel are substantially the same dimensions. In this way,
the inner flap serves to cover the hinge lines of the base portion
of the pack, thereby providing a neat and high-quality product
finish.
[0024] In preferred embodiments, the lid portion, base portion and
incorporated inner flap portion are joined together as one piece,
preferably by at least one cover layer.
[0025] Due to its rigid construction, during assembly of the pack
from its fully collapsed position, the base portion of the pack is
maintained in an erect set-up position. This allows the pack and
lid to be re-used and re-folded, it frees the hands of the
end-user, the quick assembly without glue or other adhesives means
minimal time or effort is required for assembly or disassembly by
the end user.
[0026] The rigidity of the pack construction allows the base
portion of the box to be erected into a set-up position, whether or
not the lid portion is in a closed or open position, whilst at the
same time hiding the internal mechanism of the base of the pack by
virtue of the inner flap portion. This provides a presentable and
practical solution, and the pack is designed to minimise the amount
of raw edges showing on the main faces as the folding panels cover
the internal mechanism.
[0027] When used herein, the terms top, bottom, rear, front, side
or the like, are not intended to define or to imply any specific
orientation of the pack, rather the terms are used to assist the
skilled artisan in their understanding of the present
invention.
[0028] In the fully assembled position of the pack, it is preferred
that the base and lid portions together form a parallelepiped
box.
[0029] In embodiments of the invention, during assembly and also
when the pack is fully assembled, the rear panel of the inner flap
portion lies on the rear panel of the base portion and the inner
flap portion bottom panel lies on the base bottom panel. In this
way, the base portion is reinforced in strength when the inner flap
portion is in position.
[0030] It is preferred that, in the collapsed (flat) position of
the pack, the inner flap portion rear panel and bottom panel (if
present) lie on the lid portion of the pack. In this way, the
flat-pack orientation of the collapsible pack has a compact
footprint which is easy and convenient to transport and is
protected from damage occurring to the inner flap portion because
of same lying within the footprint of the lid and base portion in
the collapsed position of the pack.
[0031] In embodiments of the present invention, the panels of the
base portion and the panels of the lid portion are each and all
separate from one another.
[0032] In alternative embodiments, some or all of the panels of the
base portion and/or some or all of the panels of the lid portion
may be connected to one another. More specifically, one or more
panels of the pack may be connected to one another along hinge
lines.
[0033] In further alternative embodiments, some or all of the
panels of the base portion and lid portion may be formed integrally
with one another. More specifically, the panels may be integral
with one another and delimited from one another by fold lines. The
fold line may be creased, scored, perforated or otherwise defined
in order to be hinge lines in the pack of the present
invention.
[0034] In certain embodiments, the collapsible pack further
comprises at least one cover layer.
[0035] It is preferred that the at least one cover layer is a
flexible material. More specifically, the cover layer is a flexible
paper-based material. In certain embodiments, the cover layer is a
flexible laminated paper-based material.
[0036] It is further preferred that the at least one cover layer
has an adhesive coating applied to one surface thereof. In this
way, the cover layer can be adhered to one or more of the
panels/walls/flaps of the pack.
[0037] In preferred embodiments, the at least one cover layer
provides the hinge connections between adjacent panels/walls/flaps.
In this way, the panels/walls/flaps of the pack may be repeatedly
hinged with respect to one another thereby allowing the pack to be
collapsed and assembled as required.
[0038] Preferably, the one or more of the panels of the base
portion and the panels of the lid portion are connected by the
cover layer. More specifically, the base portion bottom, front and
rear panels, and the lid portion top panel, at least, are covered
by the at least one cover layer. The connection lines between the
panels provided by the cover layer form hinge lines between
adjacent panels.
[0039] In embodiments of the invention, the inner flap portion
further comprises a second cover layer. More specifically, the
outer surface of the inner flap portion rear panel and, where
present, the inner flap portion top panel, are covered by the
second cover layer.
[0040] In embodiments of the invention, the inner flap portion rear
panel is hingedly connected to the base portion rear panel by the
second cover layer.
[0041] When the inner flap portion comprises a top panel, the
second cover layer provides the hinged connection between the inner
flap portion rear and top panels.
[0042] Where present, the first cover layer covers the external
surface of the panels to which it is applied.
[0043] In embodiments of the invention, each panel is covered at
least one cover layer. More specifically, each panel is covered on
its outer and its inner surface by at least one cover layer. In
this way, each panel is increased in strength by the presence of
one or more covering layers applied to at least one of its
surfaces. The cover layer(s) also serves to connect one or more of
the panels of the pack together thereby forming a hingeable
connection between adjacent panels.
[0044] The pack of the present invention can also be flat packed,
saving valuable space in retail, home, business and logistics
environments. The flat packed feature also requires less packaging
for transportation (fewer export cartons) and is more secure for
transportation--as ready-assembled boxes are more likely to be
damaged in transit.
[0045] In embodiments of the invention, the pack may further
comprise an insert. More specifically, the insert may be formed by
an extension to or, as an additional panel attached to, one or more
of the panels or walls of the pack. In certain embodiments, the
insert is integrally formed with one or more of the panels of the
pack. Alternatively, the insert may be hingedly connected to one or
more of the panels of the pack.
[0046] In embodiments of the invention, the inner flap portion may
be modified to provide an integrated insert for a contents or
product(s) to be contained in the erect pack.
[0047] In further embodiments, one or both of the base side walls
may comprise at least one additional panel forming an insert.
[0048] Alternatively, or in addition, the pack may further comprise
a removable insert.
[0049] The insert of the pack may be configured to retain and/or
support a product to be contained in the pack.
[0050] In embodiments of the invention, the pack comprises a
closure member. The closure member is configured to maintain the
pack in the closed position. The closure member may be a magnet and
metallic element or, alternatively or in addition, may comprise a
ribbon or string-like member.
[0051] The pack may comprise one or more carrying handles.
[0052] The pack may further comprise a window in a side wall
thereof. Alternatively, or in addition, the pack may comprise a
window in a lid and/or a base panel thereof.
[0053] According to a second aspect, the present invention provides
a blank assembly erectable into a collapsible pack, the blank
assembly comprising an outer blank having first and second major
panels interconnected along hinge lines by a first minor panel and
further having a second minor panel depending from the first major
panel along a further hinge line; a first inner blank comprising a
first minor panel; and a second and a third inner blank each
comprising a first major panel and a first and a second minor panel
depending from opposing edges of the major panel.
[0054] The outer blank may further comprise a third minor panel
depending from the second major panel.
[0055] The outer blank may further comprise a fourth minor panel
depending from the second minor panel along a further hinge
line.
[0056] The outer blank may further comprise a fifth minor panel
depending from the outer blank second minor panel along a further
hinge line. In embodiments comprising both a fourth and a fifth
minor panel, each depending from the second minor panel, it is
preferred that the fifth minor panel depends from an edge of the
second minor panel and that the fourth minor panel depends from the
inner surface of the second minor panel proximate the edge
thereof.
[0057] In embodiments of the invention, the inner blank further
comprises a first major panel depending from the first minor panel
of the inner blank along a hinge line.
[0058] In preferred embodiments, the first and second minor panels
of the second and third inner blanks each comprise a diagonal fold
line between diagonally opposing corners of the panels.
[0059] In embodiments of the pack and the blank assembly of the
present invention, the panels, flaps and walls are formed of a
rigid material. More specifically the rigid material may be a rigid
cartonboard material. The rigid material provides strength to the
pack and provides protection against crush forces for the contents
of the assembled pack. The rigid material also allows the pack to
be repeatedly collapsed and assembled for multiple re-use
thereof.
[0060] The blank assembly according to the second aspect of the
invention may be assembled into the collapsible pack of the first
aspect of the invention.
[0061] More specifically, the major and minor panels of the blank
assembly are folded about respective hinge lines to form the
collapsible pack of the invention.
[0062] In embodiments of the invention, the major and minor panels
of the blank assembly correspond to the panels, walls and flaps of
the collapsible pack as shown in Table 1 below:--
TABLE-US-00001 TABLE 1 Corresponding Blank Assembly Collapsible
Pack Feature Feature Base portion front panel Outer blank second
minor panel Base portion bottom panel Outer blank first major panel
Base portion rear panel Outer blank first minor panel Base portion
inner front panel Outer blank fourth minor panel Lid portion top
panel Outer blank second major panel Second lid portion top panel
Outer blank fifth minor panel Lid portion side panel Outer blank
third minor panel Inner flap portion rear panel Inner blank first
minor panel Inner flap portion bottom panel Inner blank first major
panel First base portion side wall Second inner blank first major
panel Second base portion side wall Third inner blank first major
panel First pair base portion side wall Second inner blank first
minor panel flaps Second pair base portion wall side Second inner
blank second minor panel Third pair base side wall flaps Third
inner blank first minor panel Fourth pair base portion side wall
Third inner blank second minor flaps panel Inner flap portion
second rear Inner blank second minor panel panel Inner flap portion
connecting strip Inner blank third minor panel Inner flap portion
second rear Second inner blank third minor panel panel Inner flap
portion connecting panel Inner blank third minor panel Base portion
inner bottom panel Outer blank sixth minor panel Base portion inner
firs side wall Second inner blank third minor panel Retaining
element top panel Third inner blank third minor panel Retaining
element side panel Third inner blank fourth minor panel Retaining
element bottom panel Third inner blank fifth minor panel
[0063] The invention will now be described, by way of example only,
with reference to the accompanying drawings, in which:--
[0064] FIG. 1 shows a perspective view of a partially assembled
collapsible pack according to an embodiment of the first aspect of
the present invention;
[0065] FIGS. 2 to 8 shows a blank assembly formable into the pack
of FIG. 1 during various stages of formation;
[0066] FIGS. 9 to 13 shows a perspective view of the collapsible
pack of FIG. 1 at various stages of assembly;
[0067] FIG. 14 shows a perspective view of a partially assembled
collapsible pack according to a first alternative embodiment of the
first aspect of the present invention;
[0068] FIGS. 15, 16a and 16b show the pack of FIG. 14 at various
stages of assembly;
[0069] FIGS. 17 to 22 show a perspective view of a collapsible pack
according to a second alternative embodiment of the invention at
various stages of assembly;
[0070] FIG. 23 shows a variation of the embodiment depicted in
FIGS. 19 to 22;
[0071] FIG. 24 shows a blank assembly formable into the pack of
FIGS. 17 to 22;
[0072] FIGS. 25 to 28 show a perspective view of a collapsible pack
according to a third alternative embodiment of the invention at
various stages of assembly;
[0073] FIG. 29 shows a blank assembly formable into the pack of
FIGS. 25 to 28;
[0074] FIG. 30 shows a partial cross-sectional representation of
the pack of FIG. 27;
[0075] FIGS. 31 to 33 show a perspective view of a collapsible pack
according to a fourth alternative embodiment of the invention at
various stages of assembly;
[0076] FIG. 34 shows a blank assembly formable into the pack of
FIGS. 31 to 33;
[0077] FIGS. 35 to 38 show a perspective view of a collapsible pack
according to a fifth alternative embodiment of the invention at
various stages of assembly;
[0078] FIG. 39 shows a blank assembly formable into the pack of
FIGS. 35 to 38;
[0079] FIG. 40 shows a partial cross-sectional representation of
the pack of FIG. 38;
[0080] FIGS. 41 to 43 show a perspective view of a collapsible pack
according to a sixth alternative embodiment of the invention at
various stages of assembly;
[0081] FIG. 44 shows a blank assembly formable into the pack of
FIGS. 41 to 43;
[0082] FIG. 45 shows a cross-sectional representation of the pack
of the sixth alternative embodiment in its fully assembled
state;
[0083] FIGS. 46 to 48 show a perspective view of a collapsible pack
according to a seventh alternative embodiment of the invention at
various stages of assembly;
[0084] FIG. 49 shows a blank assembly formable into the pack of
FIGS. 46 to 48;
[0085] FIG. 50 shows a partial cross-sectional representation of
the pack of FIG. 48;
[0086] FIGS. 51 to 55 show a perspective view of a collapsible pack
according to an eighth alternative embodiment of the invention at
various stages of assembly;
[0087] FIG. 56 shows a blank assembly formable into the pack of
FIGS. 51 to 55;
[0088] FIGS. 57 to 60 show a perspective view of a collapsible pack
according to a ninth alternative embodiment of the invention at
various stages of assembly;
[0089] FIGS. 61 to 63 show a perspective view of a collapsible pack
according to a tenth alternative embodiment of the invention at
various stages of assembly;
[0090] FIG. 64 shows a blank assembly formable into the pack of
FIGS. 61 to 63; and
[0091] FIGS. 65 to 74 show perspective views of a collapsible pack
according to a various alternative embodiments of the invention in
the fully assembled position.
[0092] While the invention is susceptible to various modifications
and alternative forms, specific embodiments thereof are shown by
way of example in the drawings and will herein be described in
detail. It should be understood that the drawings and detailed
description thereto are not intended to limit the invention to the
particular form disclosed, but on the contrary, the intention is to
cover all modifications, equivalents and alternatives falling
within the spirit and scope of the invention as defined by the
appended claims.
[0093] Further, although the invention will be described in terms
of specific embodiments, it will be understood that various
elements of the specific embodiments of the invention will be
applicable to all embodiments disclosed herein.
[0094] In the drawings, similar features are denoted by the same
reference signs throughout.
[0095] Referring to the figures, FIG. 1 depicts an embodiment of a
partially assembled collapsible pack according to an embodiment of
the first aspect of the present invention.
[0096] FIG. 1 shows one example of the pack, in a partially folded
state. In this example, the collapsible pack consists of Panel A,
made up of A1, A2, A3 which for the base portion of the pack and
panels A4 and A5 which, in this example, form the lid portion,
Panel B (B1 and B2 which form, the inner flap portion), Panel C,
being panel C1 which is also an inwardly folding panel, Panels D
(D1, D2, D3, D4, D5) and E (E1, E2, E3, E4, and E5) which form the
side walls and associated side wall flaps.
[0097] The collapsible pack has a base portion and a lid portion,
together with an inner flap portion B. The base portion itself
comprises a front panel A1, a bottom panel A2 and a rear panel A3
each hingedly connected to the adjacent panel along a hinge/fold
line. Side walls D3 and E3 complete the main walls and panels of
the base portion and are connected along respective fold/hinge
lines to the bottom panel A2. Side walls D3 and E3 each have a pair
of side wall flaps D1/D2, D4/D5, and E1/E2, E4/E5 respectively,
depending from opposing edges thereof. One of each pair of side
wall flaps D2, D4, E2, E4 depend directly from an edge of the side
wall D3, E3. The second flap of each pair D1, D5, E1, E5 depend
along a diagonal hinge line from the other flap of the same pair
D2, D4, E2, E4. Side flaps D1 and E1 are each adhered to the front
panel A1 of the base portion and side flaps D5 and E5 are each
adhered to the rear panel A3 of the base portion. In the depicted
embodiment, the base portion further comprises an inner front panel
C1, depending from a free edge of the front panel A1 along a hinge
line.
[0098] The lid portion comprises a top panel A4 connected to the
base portion at an edge of the rear panel A3 along a hinge line. In
the depicted embodiment, the lid portion further comprises a side
panel A5 depending from the free edge of the lid top panel along a
further hinge line.
[0099] The inner flap portion B comprises a rear panel B1 hingedly
connected to the base portion rear panel A3. In the depicted
embodiment, the inner flap portion also has a bottom panel B2
connected to the free edge of rear panel B1 along an
interconnecting hinge line. Bottom panel B2 has a lifting tag X2
attached to a free edge of the panel B2 to facilitate its lifting
from the bottom of the fully assembled pack.
[0100] FIG. 1 shows the grey board panels which make up the body of
the pack. The panels are A1, A2, A3, A4, and A5. Panels A1, A2, A3
will eventually form part of the base portion, and panels A4 and A5
will eventually form the lid of the pack.
[0101] FIG. 1 shows covering layer X1, in the form of a piece of
paper, glued to the back side of the five "A" grey board panels.
There are small gaps in between the grey board panels to allow
flexibility of movement of the panels that make up the pack. The
paper is of a thin material such that it bends with the movement of
the boards, but is strong enough to hold them in place during
movement of the panels. Thus, there are five panels of grey board
which are held in place by covering material X1, but their movement
is flexible, due to the nature of the gaps between the panels and
the covering layer material adhered to them.
[0102] Referring to FIG. 2, a first cover layer X1 is adhered to
the outer surface of each of panels A1, A2, A4, A4 and A5. The
panels A1, A2, A4, A4 and A5 are each separately formed of a rigid
cartonboard material. The panels abut one another at hinge lines,
with the hinges being formed by the first cover layer X1. A second
cover layer X3 is applied to the inner surface of lid top panel A4
and lid side panel A5. The second cover layer X3 partially covers
the inner surface of base portion rear panel A3. The second cover
layer X3 thus forms a further the hinge line between the lid top
panel A4 and the lid side panel A5 and also between the lid top
panel A4 and the base portion rear panel A3.
[0103] FIG. 2 depicts the edges of the paper covering layer X1
attached to back of boards A1, A2, A3, A4, A5 is then folded over
the edges of the panels to securely hold these panels in place. A
further sheet of paper X3 is then glued onto the inside face of
panels A4 and A5. This additional covering layer hides the material
of the grey board and also acts to reinforce the structure of the
pack.
[0104] As with any component in the pack, the covering layer(s) can
be printed with graphics and/or indicia, decorated or coloured. In
this way, the covering layer serves to enhance the aesthetic
features of the final pack.
[0105] Referring to FIGS. 3, 4 and 5, separate inner flap portion
rear panel B1 and bottom panel B2 are, together, covered at their
outer surface by a further cover layer X4 and at their inner
surface by a yet further cover layer (not shown). The cover layer
X4 is larger in all dimensions that the panels B1 and B2 and is
folded over the edges of the panels at three edges. Joining panel
Z1 of cover layer X4 is left unfolded. Inner flap portion rear
panel B1 is then hingedly connected to the base portion rear panel
A3 by adhering joining panel Z1 of cover layer X4 to the base
portion rear panel A3.
[0106] In much the same way, base portion inner front panel C1 is
covered by cover layer X5, leaving joining panel Z2 to be adhered
to the inner surface of base portion front panel A1, thus formed a
hinged connection between the two panels proximate the free edge of
the base portion front panel A1.
[0107] Also in much the same way, side walls D3 and E3 and their
respective side wall flaps D1, D2, D3, D4 and E1, E2, E3, E4 are
covered by further cover layers X6 and X7 leaving joining panels Z3
and Z4 to be adhered to the inner surface of the base portion
bottom panel A2 thereby forming a hinged connection between the
side walls and the bottom panel at opposing edges thereof. Joining
panels Z3 and Z4 do not extend to the side wall flaps D1, D2, D3,
D4 and E1, E2, E3, E4. The side wall flaps are hinged only to their
respective side wall panel edges.
[0108] As depicted in FIG. 6, a further cover layer X8 is adhered
to the inner surface of joining panel Z1, base portion rear panel
A3, base portion bottom panel A2, joining panels Z3 and Z4, base
portion front panel A1 and joining panel Z2. In this way, cover
layer X8 covers and secures all of the joining points and hinge
lines of the base portion of the pack. This cover layer X8 hides
all the internal mechanism of the pack, leaving a clean and tidy,
high-quality internal finish.
[0109] As depicted in FIG. 9, side wall flaps D1 and E1 are adhered
to the base portion front panel A1 and side wall flaps D5 and E5
are adhered to the base portion rear panel A3. This step completes
the assembly of the blank assembly of the depicted embodiment and
the collapsible pack is ready for assembly. The dimensions of the
inner flap panels B1 and B2 and their hinged connection to the base
portion rear panel A3 provide a compact footprint for the collapsed
pack reducing the volume of pack for transportation.
[0110] FIG. 10 depicted the collapsible pack in a partially
assembled position. Each pair of side wall flaps D1/D2, D4/D5,
E1/E2 and E4/E5 are folded about the diagonal hinge line between
the two flaps in each pair. This causes the side wall flaps of each
pair to lie one over the other and raises the base portion rear and
front panels A3 and A1 into their erect position. Base portion
inner front panel C1 is hinged about the hinge line connecting same
to the base portion front panel A1 to cover the inner surface of
the base portion front panel A1 with panel C1. Inner flap rear
panel B1 is folded onto the inner surface of base portion rear
panel A3 and inner flap bottom portion B2 is folded over to cover
base portion bottom panel A2 (FIGS. 11 and 12). Finally, the lid
panels A4 and A5 are folded so as to close the pack as depicted in
FIG. 13.
[0111] Panels C1, B1 and B2 each provide inner reinforcing panels
for the assembled pack giving additional strength thereto.
[0112] FIG. 7 depicts the pack in the fully collapsed position and
an additional space reduced stowage position (FIG. 8).
[0113] In all of the depicted embodiments, grey board (a rigid
paper based material) is used for the panels, and paper as the
flexible covering layer material, to form a rigid, paper-wrapped,
re-foldable one piece collapsible pack and lid. In this example,
paper is used as the interconnecting cover layer material. In
alternative embodiments, the panels can be made flexible and
foldable through the use of materials that have been pre-cut,
pre-creased, pre-folded, or by connecting the panels with a
flexible material, which may be a thicker or thinner substrate, or
may connect the panels along their entire edges to each other or
along part of their abutting edges.
[0114] In the embodiment depicted in FIGS. 1 to 13, the inner flap
portion B is made up of 2 panels, namely a rear and a bottom panel.
Additional embodiments will be described in detail hereinafter, in
which the number of panels making up the inner flap portion B is
either 1 or more panels. The use of 1 or more panels to make up the
inner flap portion gives rise to alternative ways of holding the
pack in an erect set up position during assembly. Some of the
different variations of the invention will be described in detail
herein. Other examples, including constructions where an insert is
incorporated into the panels making up the box, will also be
described in detail hereinafter.
[0115] FIG. 2 shows the inner flap portion B which, in this
example, is formed of 2 panels, B1 and B2, which are also made from
grey board. A sheet of paper X3 is laminated to the back surface of
the grey board panels B1 and B2 such that it holds the pieces in
position with a gap between the 2 boards. The gap is sufficient to
allow the panels to bend and fold. It will be understood that this
same effect may be achieved by other methods, for example, by
pre-creasing the material at the join line between the panels to
allow bending. In these alternative embodiments, the panels B1 and
B2 may be integrally formed.
[0116] The cover sheet of paper X3 that is laminated to the back of
the two grey board panels is larger than the grey board panels,
such that three of the edges of the paper layer X3 can be wrapped
over the edge of the grey board as shown in FIG. 3, to secure them
more firmly. The fourth edge is left unfolded, i.e. not wrapped
over the top surface of panels B1 and B2, thereby forming joining
panel Z1.
[0117] A separate covering sheet of paper (not shown) is then
affixed to the other surface of the panels B1 and B2. One edge of
the paper protrudes from the outline of the panels B1 and B2 so
that it lies over the fourth edge of the bottom paper X3. These two
sheets of paper can then be glued together. These panels B1 and B2
and the two paper sheets together form the integral panel, which is
key to the function and assembly of the pack.
[0118] FIGS. 3 and 4 show how the inner flap portion is then
attached to the body of the pack, by gluing the excess flap of
paper forming joining panel Z1 to the inner surface of the base
portion rear panel A3, during construction.
[0119] Panel C1 is also formed by wrapping a cover layer X5 of
paper on the underside and on to the top surface of a piece of grey
board. The construction is also such that a piece of excess paper
protrudes from one edge of C1 to form joining panel Z2. The panel
C1 is shown in FIG. 4, which illustrates C1 being attached to panel
A1. This is done by gluing the excess paper flap on C1 to the inner
surface of A1, such that there is a small gap between panel C1 and
the surface of A1 connected by flexible material (in this example
paper) forming joining panel Z1.
[0120] Panel C1 in the depicted embodiment is constructed of 1
panel piece only, however, this can be altered in size or structure
and additional panels or parts may be added.
[0121] The next stage in the construction of the pack from the
blank assembly is to add the side panels, as shown in FIG. 5. In
the depicted embodiment, the side panels are each constructed of
five pieces of grey board. Panel D is made up of D1, D2, D3, D4 and
D5. Side wall flap D4 is made of a thicker grey board, to give it
more stiffness, and panels D1, D2, D4 and D5 are made of a thinner
grey board which eases the folding and unfolding of the pack. Panel
E is made up of E1, E2, E3, E4 and E5. Side wall flap E4 is made of
a thicker grey board, to give it more stiffness, and panels E1, E2,
E4 and E5 are made of a thinner grey board. Panels D and E are
wrapped in paper on their front and back surfaces, such that there
is a piece of excess paper on one edge of D3 and E3, forming
joining panels Z4 and Z3 respectively.
[0122] The side panels are then attached to the body of the pack by
gluing the excess flaps of paper forming joining panels Z4 and Z3
to the inner surface of panel A2, as shown in FIG. 5. A covering
layer of paper X8, as shown in FIG. 6, is then glued to the inner
surface of panel A2, so that it covers the inner surface of A1, A2
and A3 and so that this paper also overlaps the excess flaps of
paper forming joining panels Z4 and Z3 that have been glued onto
the surface of A2, to hold panels C1, B, D and E to the body of the
pack. This is further illustrated in FIG. 6, which shows how the
cover layer of paper X8 overlaps the joining panels of paper
holding C1 and B1 to the body of the pack. This arrangement has the
effect of reinforcing the bond between the various panels.
[0123] Panels D1 and D5, E1 and E5 are then glued to the top
surface of the paper cover layer X8 that lines the inner surfaces
of the pack, in this example, as illustrated in FIG. 6. The edge of
D1, D3 and D5 and correspondingly the edge of E1, E3, and E5 are
joined respectively to each side of the panels A1, A2 and A3, and
all the Panels D and E lie flat against the surface of A1, A2 and
A3 when the box is in a flat position. There are alternative
constructions, in which panels D1 and D5, E1 and E5 do not all need
to be glued, and these will be explained and illustrated
hereinafter.
[0124] FIG. 9 illustrates the completed collapsible pack as
described in this embodiment. The pack can be further flat packed
for transportation and storage as depicted in FIGS. 7 and 8.
Folding and Assembly
[0125] The following steps as depicted in FIGS. 9 to 13, describe
how the pack in the above embodiment can be folded and unfolded by
the user.
[0126] The positions of the panels and the flexible joins between
the individual panels making up the main parts of the collapsible
pack are such that the pack can be folded into a setup position and
easily disassembled into a flat pack position. In the depicted
embodiment, the paper covering layer interconnecting material that
wraps the grey board, is flexible, thus allowing movement at the
joins and the panels to fold. The hinge line between D3 and A2 and,
correspondingly the hinge line between E3 and A2, are flexible so
that D3 and E3 can lie flat against the surface of A2 or fold
upwards to a position at 90 degrees to the surface of A2.
Similarly, the hinge line between panels C1 and A1 is flexible, as
is the hinge line between the inner flap portion B and panel A. The
hinge line between panels making up the body of the pack, A, namely
A1, A2, A3, A4, A5, are also flexible, as are the panels making up
the side panels D and E, with the exception of D1 and D5, E1 and E5
are they are glued to the inside surfaces of panels A1 and A3, in
this example.
[0127] The process of folding the collapsible pack into a set-up
position is illustrated in FIG. 9 through to FIG. 13. The process
can be reversed to unfold the pack back to a flat/collapsed pack
position. Lifting tags (X2) such as ribbons, or the like, may be
added to the edge of panel B2 and/or panel C1 to make unfolding
even simpler as they provide an area that can easily be gripped by
the user to unfold the panels; an exemplary ribbon X2 is
illustrated in FIG. 10 to FIG. 12 attached to B2. Alternative
solutions for gripping the edge of the panels could also be used,
an example of which are small cuts or finger holes.
[0128] To assemble the pack from a flat/collapsed position, A1 and
A3 are pushed towards each other by the end user either by holding
onto the Lid (A4/A5) and inner front panel C1, or at some other
location such that A1 and A3 lie at 90 degrees against the surface
of the inner face of panel A2.
[0129] This motion will automatically fold D3 and E3 into a
vertical (90 degree) position against the inner surface of A2, if
the panels D1, D5, E1 and E5 have been affixed to A1 and A3
respectively as described in this example, otherwise the user will
need to push these side panels in. The position of the panels is
now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner
surface of A2, thus forming the beginnings of the base structure of
the pack. Due to the folding up of panels D3 and D4, the panels D1
and D2, D4 and D5, E1 and E2, E4 and E5 will all fold together such
that their surfaces lie flat against each other, this processes is
illustrated in FIG. 11, where D4 and D5, E4 and E5 are pushed
towards each other as the box is set up.
[0130] Panel C1 is then folded over such that its inner surface
lies flat against the inner surface of panel A1, as illustrated in
FIG. 10. The panel C1, in its folded position, will cover the
panels D1 and D2, E1 and E2, so that they lie underneath panel C1
between C1 and A1.
[0131] An integral feature of this flat packing, quick-fold erect,
re-foldable one piece box & lid, the incorporated Panel B, is
then folded over such that the inner surface of panel B1 lies flat
against A3, as shown in FIG. 11 and FIG. 12. The panel B1, in its
folded position, will cover the panels D4 and D5, E4 and E5, so
that they lie underneath panel B1 between B1 and A3.
[0132] The Panel B2, is then be pushed down so that it lies flat
against the panel A2. The length of the panels in this example are
such that the base of panel C1 rests just above the base of the
box, the length of panel B2 is such that the end of panel B2 pushes
against C1. In this way, the pushing down of panel B2, or an
incorporated panel added for this purpose, has the effect of
holding panel C1 and B1 in place in their folded positions, hence
holding the base of the box in a set up position. Thus, the base of
the pack is now erected with A1, A3, D3 and E3 all at 90 degrees to
the inner surface of A2 and held in place by the folding of the
inner panels B and also C1 as described above. With the panels in
this position, the bottom part of the box will remain erected
whether or not the lid, comprised of A4 and A5, is opened or
closed. This arrangement of panels making up B (in this example B1
and B2) and the folding of these panels is one of several
variations of the invention demonstrating how the inner flap
portion panel (or panels) holds the base of the box in an erect
set-up position. There are alternative ways to hold the base of the
box in a set up position, using an incorporated panel (or panels)
without the panel B2 resting against the base of the box, or
against C1, and examples of this will be described and illustrated
hereinafter.
[0133] The panel A4 can be folded over the top of the erected
bottom part of the box to act as a lid or cover, with the panel A5
folding over the outer surface of A1, as illustrated by FIG. 13. To
keep the lid closed on the box when in an erected position, A5 can
be attached to the outer surface of panel A1 through the use of
magnets, clips, cuts, additional parts, ribbons, ties or other
suitable retaining means.
[0134] The pack has advantages over known pack constructions in
that the base, lid and incorporated integral inner flap portion can
be folded into a flat-packed position. FIG. 7 illustrates a top
view of the pack in a flat position. FIG. 8 demonstrates how the
panels of the pack may be further folded, to minimise the area the
flat packed pack requires. FIG. 7 illustrates the direction in
which panel C1 may be folded over. FIG. 8 illustrates how panels B1
and B2 are folded over the inside face of panels A1, A2, A3 and the
folded panel C1. FIG. 8 also shows how panels A4 and A5 are folded
around the back of the pack. Alternatively, panels A4 and A5 may be
folded around the back, and panels B1, B2 and C1 folded over the
inside of the box, all in a flat packed position. The folding of
the panels reduces the footprint area the collapsed pack takes up,
making it easier to store and also more compact for shipping which
reduces the risk of damage in transit, as well as saving space.
[0135] The following is a description of an alternative embodiment
of the construction of a collapsible pack of the invention,
described solely by way of example, in which the inner flap portion
B is made of one panel. In this example, grey board (a rigid paper
based material) is used for the panels, and paper as the flexible
connecting material, to form a rigid paper wrapped re-foldable one
piece box and lid. In this example, an alternative method of
holding the box in an erect set up position shall be described,
whereby the panels B and C are held in place by magnets.
[0136] FIGS. 14 to 16b show an alternative example of the
construction of a collapsible pack of the invention, made of panels
wrapped with a cover layer of paper interconnecting material. This
particular embodiment differs from that depicted in FIGS. 1 to 13
in that the incorporated inner flap portion B is formed of one
panel, namely inner flap portion rear panel B1.
[0137] The collapsible pack depicted in the embodiment is held in
the erect position by magnets X11 (FIG. 15). Alternatively, Velcro
fasteners may be used. Permanent fixings may be used however it is
preferred that the pack may be disassembled and is re-foldable.
[0138] FIGS. 16a and 16a show how the pack maybe folded into a set
up position by the user. In this example, the folding of the
incorporated panels is such that B1 and C1 are held in place by
magnets X11 (FIG. 15), thus holding the box in a set up position.
In this embodiment, the lifting tag X2 is located on inner flap
rear panel B1. Although not shown, inner front panel C1 may have a
further lifting tag at an edge thereof to assist the user in
disassembling the pack.
[0139] FIGS. 16a and 16b illustrate the assembled pack in an open
position with the lid portion A4 and A5 being foldable to close the
pack.
Folding and Assembly
[0140] The following steps will now describe how the pack of FIGS.
14 to 16b can be folded and unfolded by the user, thus illustrating
how this alternative version of the invention functions.
[0141] The process of folding into a set-up can easily be reversed
to unfold the boxes back to a flat pack position.
[0142] To assemble from a flat position, base portion front panel
A1 and rear panel A3 are pushed towards each other by the end user
(either by holding onto the Lid (A4/A5) and end panel C1, or some
other location) such that A1 and A3 lie at 90 degrees against the
surface of the inner face of base portion bottom panel A2, as
illustrated by FIG. 15.
[0143] This motion will automatically fold side walls D3 and E3
into a vertical (90 degree) position against the inner surface of
bottom panel A2. The position of the panels is now such that A1,
A3, D3 and E3 all lie at 90 degrees to the inner surface of A2,
thus forming the beginnings of the base structure of the pack.
[0144] Inner front panel C1 is then folded over such that its inner
surface lies flat against the inner surface of base front panel A1.
The inner front panel C1, in its folded position, will cover the
side wall flaps D1 and D2, E1 and E2, so that they lie underneath
inner front panel C1 between C1 and A1. In this example, C1 is held
in place by magnets X11 under the paper surface of panel C1 and by
magnets correspondingly on the inside surface panel A1 (not
shown).
[0145] The inner flap rear panel B1, is then folded over such that
the inner surface of panel B1 lies flat against base portion rear
panel A3, as shown in FIG. 16a. The inner flap portion rear panel
B1, in its folded position, will cover the panels side wall flaps
D4 and D5, E4 and E5, so that they lie underneath panel B1, between
B1 and A3. In this example, B1 is held in place by magnets (X11)
under the paper surface of panel B1 and by magnets (not shown)
correspondingly on the inside surface panel A3.
[0146] Thus, the bottom part of the pack is now erected with A1,
A3, D3 and E3 all at 90 degrees to the inner surface of A2 and held
in place by the folding of the inner panel B1 and also C1 as
described above, as illustrated by FIG. 16a and FIG. 16b. With the
panels in this position, the bottom part of the pack will remain
erected whether or not the lid, comprised of lid top panel A4 and
lid side panel A5 is opened or closed. The panel lid top panel A4
can be folded over the top of the erected bottom part of the pack
to act as a lid or cover, with the lid side panel A5 folding over
the outer surface of base portion front panel A1.
[0147] FIGS. 17 to 22 show a second alternative embodiment of a
collapsible pack according to the invention, described solely by
way of example, in which the inner flap portion B is formed of two
panels and an additional second lid portion top panel F1 is
connected to base portion front panel A1 of the pack. In this
example, the pack will open in the centre, as the lid is formed by
second lid portion top panel F1 on one side and first lid top panel
A4 on the other, as illustrated by FIGS. 21 and 22 in particular.
In this example, grey board (a rigid paper based material) is used
for the panels, and paper as the flexible cover layer connecting
material, to form a rigid paper wrapped re-foldable one piece box
and lid.
[0148] In the depicted second alternative embodiment of a
collapsible pack according to the invention, the panels are wrapped
with a paper interconnecting material. In this particular example,
the inner flap portion B is formed of two panels, rear panel B1 and
bottom panel B2 and the lid portion can be opened in the centre of
the pack, through the incorporation of a second lid top panel F1.
Thus, the depicted embodiment differs from the embodiment shown in
FIGS. 1 to 13 only in that there is an additional top lid panel
F1.
[0149] FIG. 18 to FIG. 22 show how the pack of the depicted
embodiment can be folded into a set up position by the user. In
this example, the folding of the incorporated panels is such that
inner flap portion bottom panel B2 rests against base portion inner
front panel C1 thereby holding the box/base portion in a set up
position.
[0150] FIG. 22 illustrates the completed, fully assembled pack as
described in this example. This can be further flat packed for
transportation and storage.
Folding and Assembly
[0151] The following steps will now describe how the pack in the
above example can be folded and unfolded by the user.
[0152] The process of folding into a set-up position is similar to
that described in respect of FIGS. 1 to 13. The folding process can
easily be reversed to unfold the boxes back to a flat pack
position.
[0153] To assemble from a flat position, base portion front panel
A1 and base portion rear panel A3 are pushed towards each other by
the end user, either by holding onto the lid panels (A4/A5) and
inner front panel C1, or some other location, such that base
portion front panel A1 and base portion rear panel A3 lie at 90
degrees to the surface of the inner face of base portion bottom
panel A2, as illustrated in FIGS. 19 and 20.
[0154] Base portion inner front panel C1 is then folded over such
that its inner surface lies flat against the inner surface of base
portion front panel A1. Base portion inner front panel C1, in its
folded position, will cover the side wall flaps D1 and D2, E1 and
E2, so that they lie underneath panel C1 between C1 and A1.
[0155] An integral feature of this flat packing, quick fold erect,
re-foldable one piece base and lid, is that the inner flap Panel B,
is then folded over such that the inner surface of inner flap
portion rear panel B1 lies flat against base portion rear panel A3.
The inner flap rear panel B1, in its folded position, will cover
the side wall flaps D4 and D5, E4 and E5, so that they lie
underneath panel B1 between B1 and A3.
[0156] The inner flap portion bottom panel B2, is then be pushed
down so that it lies flat against the base portion bottom panel A2
as illustrated in FIGS. 19, 20 and 21. The pushing down of panel B2
or, an incorporated panel added for this purpose, has the effect of
holding base portion inner front panel C1 and inner flap portion
rear panel B1 in place in their folded positions, hence holding the
base of the box in a set up position, as illustrated in FIG. 21.
Thus the bottom part of the box is now erected with base portion
front panel A1, base portion rear panel A3, first base portion side
wall D3 and second base portion side wall E3 all at 90 degrees to
the inner surface of base portion bottom panel A2 and held in place
by the folding of the inner flap panels B and also base portion
inner front panel C1 as described above. With the panels in this
position, the bottom part of the box will remain erected whether or
not the lid, comprised of first lid portion top panel A4 and second
lid portion top panel F1, is opened or closed.
[0157] The lid top panels A4 and F1 can then be folded over the top
of the erected bottom part of the box to act as a lid or cover, as
illustrated in FIGS. 21 and 22. This example shows the lid being
held closed through the use of a ribbon tie, which is attached to
the box through small holes in the lid panels A4 and F1.
[0158] FIG. 23 shows variation of the embodiment shown in FIGS. 19
to 22. In this particular example, the inner flap portion B is made
of 1 rear panel B1 only. As with the second alternative embodiment
of FIGS. 17 to 22, the lid portion is formed of two top lid panels
A4 and F1, thus the lid of the pack opens in the centre. In this
particular embodiment, inner front panel C1 and inner flap portion
rear panel B1 may be held in place in their erect positions by way
of magnet, or the like (not shown), located on the base portion
front and rear panels respectively.
[0159] FIG. 24 shows a blank assembly formable into the collapsible
pack depicted in assembled form in FIGS. 19 to 22. The depicted
blank assembly differs from that depicted in FIGS. 2 to 8 in that
the outer blank third minor panel A5 is absent and, in its place is
outer blank fifth minor panel F1. Furthermore, the outer blank
second major panel is reduced in size relative to the full lid
sized panel of FIGS. 2 to 8. In the embodiment depicted in FIG. 24,
the outer blank second major panel is approximately half the width
of the corresponding panel in FIGS. 2 to 8. The blank assembly
depicted in FIG. 24 has an outer blank second major panel and an
outer blank fifth minor panel of equal width dimension. Panels A4
and F1 will form the lid portion top panels in the collapsible pack
formed from the depicted blank assembly.
[0160] FIGS. 25 to 28 show a third alternative embodiment of a
collapsible pack according to the invention. The associated blank
assembly is depicted in FIG. 29. In this example, a product
retaining compartment is incorporated into the base portion of the
box, and the side wall panels D and E have been modified to provide
an integral insert in the pack to hold a product in the top of the
box. The box is held in a set up position by the folding of the
inner flap panels B and base portion front panels C.
[0161] The embodiment is an example of a pack with an integrated
fitment or insert and integrated compartment. The number of panels
used, cut-outs, panel dimensions and configuration can all be
altered to hold a variety of products.
[0162] FIG. 29 shows a blank assembly for the collapsible pack
depicted in FIGS. 25 to 28 in its flat packed state. In this
example, the blank assembly consists of Panel A, made up of outer
blank second minor panel A1, outer blank first major panel A2,
outer blank first minor panel A3 which, in the collapsible pack,
will together form the base of the pack, and outer blank second
major panel A4 and outer blank third minor panel A5, which in the
collapsible pack will form the lid top panel and lid side panel
respectively. Panel B is formed of inner blank first minor panel
B1, inner blank first major panel B2, inner blank second minor
panel B3 and inner blank third minor panel B4 which form the inner
flap portion rear panel, bottom panel, second rear panel and
connecting strip respectively in the collapsible pack. Panel C
which is also an integral folding panel, made of base inner front
panel C1 and second base inner front panel C2.
[0163] Panels D and E form the side walls of the collapsible pack
as follows:--first pair of base side wall flaps D1/D2, base first
side wall D3, second pair of base side wall flaps D4/D5, base inner
side wall D6, third pair base side wall flaps E1/E2, second base
side wall E3, fourth pair base side wall flaps E4/E5, retaining
element top panel E6, retaining element side panel E7, retaining
element bottom panel E8/E9.
[0164] The panels B, C, D and E in this example fold together to
form an integral insert in the form of a retaining element, which
will be described in more detail below.
Folding and Assembly
[0165] The following steps will now describe how the pack in the
above example can be folded and unfolded by the user.
[0166] The interconnecting material between the joins of the panels
is flexible, allowing movement at the joins, and the panels to
fold. The process of folding into a set-up position is illustrated
step by step in FIGS. 25 to 28. This process can easily be reversed
to unfold the boxes back to a flat pack position.
[0167] To assemble from a flat position, base portion front panel
A1 and base portion rear panel A3 are pushed towards each other by
the user, either by holding onto the panels of the lid (A4/A5) and
end panel C, or some other location such that A1 and A3 lie at 90
degrees to the surface of the inner face of panel A2, as
illustrated in FIG. 26.
[0168] This motion will automatically fold D3 and E3 into a
vertical (90 degree) position against the inner surface of A2. The
position of the panels is now such that A1, A3, D3 and E3 all lie
at 90 degrees to the inner surface of A2, thus forming the
beginnings of the base structure of the box. Due to the folding up
of Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2, E4
and E5 will all fold together such that their surface lie flat
against each other, as previously explained.
[0169] Panel B is folded over, as illustrated in FIG. 26. The
panels B1, B2, B3, B4 are folded such that B1 lies against the
inside surface of A1 (thus holding D4, D5 and E4, E5 in place).
Panels B2 and B4 lie parallel to A2. Panel B4 lies against the
inside surface of A2. This forms a ledge, as illustrated by the
side view FIG. 30.
[0170] Panel C1 is then folded over such that its inner surface
lies flat against the inner surface of panel A1, as illustrated in
FIG. 30. The panel C1, in its folded position, will cover the
panels D1 and D2, E1 and E2, so that they lie underneath panel C1
between C1 and A1, thus holding them in place. C2, is then folded
over so that the under surface of the edge of C2 lies against the
top surface of the panel B2, thus forming a compartment under C2,
and this will hold the box in a set up position. This is
illustrated in the cross-sectional view of FIG. 30. This is an
alternative method for holding the box in a set up position by the
use of integral incorporated panels.
[0171] The compartment defined by panels D6, E6, E7, E8 and E9 has
a variety of functions and can be used to hold any product or may
be left empty. In this example base inner bottom panel C2 has a
recess cut in one side edge so that a cable or wire of an
electrical product (or any other product) can be fed into the
bottom compartment during packing, and the main body of the product
held in the top part of the box for display, for example.
[0172] Base inner side wall panel D6 is then folded over. In this
example, panel D6 has a "U"-shaped recess cut into it to receive an
insert Y1 as illustrated in FIGS. 27 and 28. At the opposite side
of the box, the retaining element top panel E6, retaining element
side panel E7, and retaining element bottom panels E8 and E9 are
folded over onto the top surface of the base portion inner bottom
panel C2. Together, a recess formed in the retaining element side
and bottom panels, and the insert Y1 held in place by base inner
side wall D6, can be used to hold the main body of the product in
this top compartment of the box. As the base of the box is held in
an erect set-up position the lid can be left open, thus allowing
the product to be displayed, or closed.
[0173] The lid portion top panel A4 can be folded over the top of
the erected bottom part of the box to act as a lid or cover, with
the lid portion side panel A5 folding over the outer surface of
base portion front panel A1, as illustrated by FIG. 28. In this
example a CD holder Y2 is attached to the inner surface of lid
portion top panel A4, by way of example.
[0174] FIG. 31 to FIG. 34: show a fourth alternative embodiment of
a collapsible pack and associated blank assembly of the invention.
In the depicted embodiment, an insert is incorporated into the side
wall panels D and E to hold a product.
[0175] The following is an example of a box with an integrated
insert fitment incorporated into the side wall panels of the
box.
[0176] FIG. 34 shows the box in a flat position with the blank
assembly fully formed and flat. In this example the pack consists
of Panel A, made up of base portion front panel A1, base portion
bottom panel A2, base portion rear panel A3 which form the base of
the box and lid portion top panel A4 and lid portion side panel A5
which form the lid of the assembled pack; Panel B, made up of inner
flap rear panel B1 and inner flap portion bottom panel B2 which
form the integral incorporated folding panel; base portion inner
front panel C1 which is also an integral folding panel; Panels D
and E (D1, D2, D3, D4, D5, D6, D7, D8 and D9, E1, E2, E3, E4, E5,
E6, E7, E8 and E9) which form the side wall panels and flaps as
well as the insert elements of the pack. In this example, the extra
panels incorporated into the side wall panels D and E fold to form
an integral insert fitment, which will be described in more detail
below.
Folding and Assembly
[0177] The process of folding into a set-up position is illustrated
step by step in FIGS. 31 to 33. This process can easily be reversed
to unfold the boxes back to a flat pack position.
[0178] As with the other collapsible pack described previously, to
assemble from a flat position, panels A1 and A3 are pushed towards
each other by the end user (either by holding onto the Lid (A4/A5)
and end panel C, or some other location) such that A1 and A3 lie at
90 degrees to the surface of the inner face of panel A2, as
illustrated by FIG. 31.
[0179] This motion will automatically fold side wall panels D3 and
E3 into a vertical (90 degree) position against the inner surface
of base portion bottom panel A2. The position of the panels is now
such that A1, A3, D3 and E3 all lie at 90 degrees to the inner
surface of A2, thus forming the beginnings of the base structure of
the box. Due to the folding up of Panels D3 and D4 the panels D1
and D2, D4 and D5, E1 and E2, E4 and E5 will all fold together such
that their surface lie flat against each other, this processes is
illustrated in FIG. 31, where D4 and D5, E4 and E5 are pushed
towards each other as the box is set up.
[0180] Base portion inner front panel C1 is then folded over such
that its inner surface lies flat against the inner surface of base
portion front panel A1, as illustrated in FIG. 31. The panel C1, in
its folded position, will cover the panels D1 and D2, E1 and E2, so
that they lie underneath panel C1 between C1 and A1.
[0181] A feature of this flat packing, quick fold erect,
re-foldable one piece box & lid of this embodiment is that the
inner flap portion Panel B, is then folded over such that the inner
surface of inner flap rear panel B1 lies flat against base portion
rear panel A3, as shown in FIG. 32. The panel B1, in its folded
position, will cover the panels D4 and D5, E4 and E5, so that they
lie underneath panel B1 between B1 and A3.
[0182] The inner flap portion bottom panel B2, is then be pushed
down so that it lies flat against the base portion bottom panel A2
as illustrated in FIG. 32. The pushing down of panel B2, or an
incorporated panel added for this purpose, has the effect of
holding panel C1 and B1 in place in their folded positions, hence
holding the base of the box in a set up position. Thus, the bottom
part of the box is now erected with A1, A3, D3 and E3 all at 90
degrees to the inner surface of A2 and held in place by the folding
of the inner panels B and also C1 as described above, as
illustrated by FIG. 32. With the panels in this position, the
bottom part of the box will remain erected whether or not the lid,
comprised of A4 and A5, is opened or closed.
[0183] The side wall panels D6, D7, D8 and D9 are then folded to
form an insert fitment at one end of the inside of the box. On the
opposite side of the box, retaining element panels E6, E7, E8, and
E9 are also folded to form an insert fitment. The folding is
illustrated by FIG. 32. In this example, the insert fitment is
design to hold a bottle, which is held in place by the insert
fitment, and displayed when the lid (panels A4 and A5) is open.
[0184] The lid portion top panel A4 can be folded over the top of
the erected bottom part of the box to act as a lid or cover, with
the lid portion side panel A5 folding over the outer surface of
base portion front panel A1, as illustrated by FIG. 33. To keep the
lid closed on the box when in an erected position, A5 can be
attached to the outer surface of panel A1 through the use of
magnets, clips, cuts, additional parts, ribbons, ties or any other
suitable means.
[0185] FIGS. 35 to 39 show a collapsible pack and associated blank
according to a fifth alternative embodiment of the invention. In
this example, an insert fitment has been incorporated into the base
portion panel C, and this example shows an alternative way the
panels can be configured and folded to hold the box in a set up
position.
[0186] The following is an alternative example of a box with an
integrated fitment incorporated into the panels of the box.
[0187] FIG. 39 shows the fully assembled blank assembly for the
collapsible pack of this embodiment in a flat state. The
collapsible pack formed from the blank assembly of FIG. 39
comprises Panel A, made up of base portion front panel A1, bottom
panel A2, and rear panel A3 which form the base of the box and lid
portion top panel A4 and side panel A5 which in this example form
the lid of the pack; Panel B, formed of inner flap portion rear
panel B1, bottom panel B2, second rear panel B3 and connecting
strip B4 which form the integral inner flap folding panel; Panel C
which is also an integral folding panel, made of base portion inner
front panel C1, inner bottom panel C2, inner bottom connecting flap
C3, second inner bottom panel C4, retaining flaps C5, C6, C7, C8,
C9, C10, and C11; Panels D and E (D1, D2, D3, D4, D5, E1, E2, E3,
E4, E5) which form the side walls and flaps. In this example, the
extra panels incorporated into the panels B and C fold to form an
integral insert fitment, which will be described in more detail
below.
Folding and Assembly
[0188] The process of folding into a set-up position is illustrated
step by step in FIGS. 35 to 38. This process can easily be reversed
to unfold the boxes back to a flat pack position.
[0189] The base portion of the pack is assembled in the same way as
described in respect of previous embodiments.
[0190] Panel B is folded over, as illustrated in FIG. 35 and FIG.
36. The panels B1, B2, B3, and B4 are folded such that B1 lies
against the inside surface of A1 (thus holding D4, D5 and E4, E5 in
place). Panels B2 and B4 lie parallel to A2. Panel B4 lies against
the inside surface of A2. This forms a ledge, as illustrated by the
side view FIG. 40.
[0191] Panel C1 is then folded over such that its inner surface
lies flat against the inner surface of panel A1, as illustrated in
FIG. 36. The panel C1, in its folded position, will cover the
panels D1 and D2, E1 and E2, so that they lie underneath panel C1
between C1 and A1, thus holding them in place. C2, which is
attached to C1, is then folded over so that the under surface of
the edge of C2 lies against the top of B2.
[0192] The panels C2 and C4 have a number of slots cut out of them
to hold products. In this example, C2 has 3 slots to hold 3
bottles. To hold the bottles more securely, the panel C2 has small
retaining panels (C6, C7, C8, C9, C10 and C11) attached to each
side of the 3 bottle slots, as illustrated in FIG. 37. FIG. 37
shows a bottle being placed into the assembled insert fitment.
Panel C4 is then folded over the top of the products to hold them
in place.
[0193] The lid top panel A4 can be folded over the top of the
erected bottom part of the box to act as a lid or cover, with the
lid side panel A5 folding over the outer surface of base front
panel A1. To keep the lid closed on the box when in an erected
position, A5 can be attached to the outer surface of panel A1
through the use of magnets, clips, cuts, additional parts, ribbons,
ties or other method.
[0194] FIGS. 41 to 45 depicted a sixth alternative embodiment and
associate blank assembly of the invention. FIG. 45, in particular,
depicts a partial cross-sectional representation of the pack of the
sixth alternative embodiment.
[0195] In this example, an alternative insert fitment has been
incorporated into the inner flap portion panels B, and this example
shows an alternative way the integral incorporated panels can fold
to hold the box in a set up position.
[0196] The sixth alternative embodiment is an example of a box,
which in its fully assembled form is a cube shaped pack, with an
integrated insert fitment. This example also describes an
alternative construction, in that side wall flaps D1 and D5 are not
attached to the inside surface of base portion front and rear
panels A1 and A3 respectively.
[0197] FIG. 44 shows the box in a flat/collapsed state following
formation of the associated blank assembly. In this example the box
consists of Panel A made up of base portion front panel A1, base
portion bottom panel A2, base portion rear panel A3 which form the
base of the box, and lid top panel A4 and lid side panel A5 which,
in this example, form the lid of the pack; Panel B made up of inner
flap portion rear panel B1 and inner flap portion bottom panel B2
which form the integral inner flap folding panel; Panel C which is
also an integral folding panel, made of base portion inner front
panel C1, base portion inner bottom panel C2, base portion inner
bottom connecting panel C3, and second base inner bottom panel C4;
base side walls and flaps D and E made up to first pair base side
wall flaps D1/D2, first base side wall D3, second pair base side
wall flaps D4/D5, third pair base side wall flaps E1/E2, second
base side wall E3, fourth pair base side wall flaps E4/E5 which
together form the side panels of the pack.
Folding and Assembly
[0198] The process of folding into a set-up position is illustrated
step by step in FIGS. 41 to 43. This process can easily be reversed
to unfold the boxes back to a flat pack position.
[0199] To assemble from a flat position, base portion panels A1 and
A3 are pushed towards each other by the end user (either by holding
onto the Lid (A4/A5) and end panel C, or some other location) such
that A1 and A3 lie at 90 degrees to the surface of the inner face
of panel A2, as illustrated in FIGS. 41, 42 and 43.
[0200] This motion will automatically fold side wall E3 into a
vertical (90 degree) position against the inner surface of bottom
panel A2. As D1 and D5 are not glued to the inner surface of A2 and
A3 respectively, panel D3 will need to be pushed in by the user, so
that it is at 90 degrees to the surface of A2, as illustrated by
FIG. 41.
[0201] The position of the panels is now such that A1, A3, D3 and
E3 all lie at 90 degrees to the inner surface of A2, thus forming
the beginnings of the base structure of the box. Due to the folding
up of Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2,
E4 and E5 will all fold together such that their surface lie flat
against each other, this processes is illustrated in FIG. 42, where
D4 and D5, E4 and E5 are pushed towards each other as the box is
set up.
[0202] Then, Panel C is folded over, as illustrated in FIG. 42. The
panels C1, C2, C3, and C4 are folded such that C1 lies against the
inside surface of A1 (thus holding D4, D5 and E4, E5 in place).
Panels C2 and C4 lie parallel to A2. Panel C4 lies against the
inside surface of A2. This forms a ledge, as illustrated by the
partial cross-sectional view of FIG. 45.
[0203] Panel B1 is then folded over such that its inner surface
lies flat against the inner surface of panel A3, as illustrated in
FIG. 42. The panel B1, in its folded position, will cover the
panels D1 and D2, E1 and E2, so that they lie underneath panel B1
between B1 and A3, thus holding them in place. B2, which is
attached to B1, is then folded over so that the under surface of
the edge of B2 lies against the top of C2.
[0204] In this example, panel B2 has a circular hole cut in the
centre to hold a candle.
[0205] The panel A4 can be folded over the top of the erected
bottom part of the box to act as a lid or cover, with the panel A5
folding over the outer surface of A1, as illustrated by FIG. 45. To
keep the lid closed on the box when in an erected position, A5 can
be attached to the outer surface of panel A1 through the use of
magnets, clips, cuts, additional parts, ribbons, ties or other
method.
[0206] FIGS. 46 to 49 show a collapsible pack and associated blank
assembly of a collapsible pack according to a seventh alternative
embodiment of the invention. FIG. 50 shows a partial cross-section
representation of the insert of FIG. 48. In this example, a
compartment been incorporated into the box.
[0207] The following is an alternative example of a box with an
integrated internal compartment incorporate into the panels that
form the box.
[0208] FIG. 49 shows the box in a flat/collapsed state following
formation of the associated blank assembly. In this example as in
previously described examples, the box consists of Panel A (made up
of A1, A2, A3 which for the base of the box and panels A4 and A5
which in this example form the lid), Panel B (B1 and B2) which form
the integral incorporated folding panel), Panel C which is also an
integral folding panel, made of panel C1. The box further consists
of Panels D and E (D1, D2, D3, D4, D5, D6, D7, D8, D9, D10, E1, E2,
E3, E4, E5) which form the side wall panels of the pack. Panels D6,
D7, D8, D9 and D10 fold to form the internal compartment.
Folding and Assembly
[0209] The process of folding into a set-up position is illustrated
step by step in FIGS. 46 to 48. This process can easily be reversed
to unfold the boxes back to a flat pack position.
[0210] As in previous examples, to assemble from a flat position,
A1 and A3 are pushed towards each other by the end user (either by
holding onto the Lid (A4/A5) and end panel C, or some other
location) such that A1 and A3 lie at 90 degrees against the surface
of the inner face of panel A2, as illustrated by FIG. 46.
[0211] This motion will automatically fold D3 and E3 into a
vertical (90 degree) position to the inner surface of A2. The
position of the panels is now such that A1, A3, D3 and E3 all lie
at 90 degrees to the inner surface of A2, thus forming the
beginnings of the base structure of the box. Due to the folding up
of Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2, E4
and E5 will all fold together such that their surface lie flat
against each other, this processes is illustrated in FIG. 47, where
D4 and D5, E4 and E5 are pushed towards each other as the box is
set up.
[0212] Panels D6, D7, D8, D9 and D10 are then folded to form a
compartment, as illustrated by FIGS. 46 and 47.
[0213] Then, Panel C is folded over, as illustrated in FIG. 46,
such that C1 lies against the inside surface of A1 (thus holding
D4, D5 and E4, E5 in place).
[0214] Panel C1, whose width has been adjusted for this purpose,
also covers panel D10 and hence holds the internal compartment in
place.
[0215] Panel B, is then folded over such that the inner surface of
panel B1 lies flat against A3, as shown in FIG. 47. The width of
panels B1 and B2 is reduced so that they do not overlap the
compartment. The panel B1, in its folded position, will cover the
panels D4 and D5, E4 and E5, so that they lie underneath panel B1
between B1 and A3. B1 also covers panel D9, hence holding the
internal compartment in place.
[0216] The Panel B2, is then be pushed down so that it lies flat
against the panel A2 as illustrated in FIG. 48. The pushing down of
panel B2, or an incorporated panel added for this purpose, has the
effect of holding panel C1 and B1 in place in their folded
positions, hence holding the base of the box in a set up position.
Thus the bottom part of the box is now erected with A1, A3, D3 and
E3 all at 90 degrees to the inner surface of A2 and held in place
by the folding of the inner panels B and also C1 as described
above. With the panels in this position, the bottom part of the box
will remain erected whether or not the lid, comprised of A4 and A5
is opened or closed.
[0217] The panel A4 can be folded over the top of the erected
bottom part of the box to act as a lid or cover, with the panel A5
folding over the outer surface of A1. The box is now divided, by
the incorporated internal panels into a larger and smaller
compartment.
[0218] FIGS. 51 to 56 show a collapsible pack and associated blank
assembly of a collapsible pack according to a eighth alternative
embodiment of the invention. In this example, extra panels have
been incorporated onto panels B and C and this example demonstrates
an alternative configuration of the folding of the incorporated
panels to hold the box in a set up position.
[0219] The following is an alternative example of a box with
incorporated internal panels. This example of the construction of
the box is designed to hold a wallet.
[0220] FIG. 56 shows the box in a flat/collapsed state following
formation of the associated blank assembly. In this example, as in
previously described examples, the box consists of Panel A (made up
of A1, A2, A3 which for the base of the box and panels A4 and A5
which in this example form the lid), Panel B (B1, B2 and B3) which
form the integral incorporated folding panel), Panel C which is
also an integral folding panel, made of panels C1 and C2, Panels D
and E (D1, D2, D3, D4, D5, E1, E2, E3, E4, E5) which form the side
walls and flaps of the pack.
Folding and Assembly
[0221] The process of folding into a set-up position is illustrated
step by step in FIGS. 51 to 55. This process can easily be reversed
to unfold the boxes back to a flat pack position.
[0222] To assemble from a flat position, A1 and A3 are pushed
towards each other by the end user (either by holding onto the Lid
(A4/A5) and end panel C, or some other location) such that A1 and
A3 lie at 90 degrees against the surface of the inner face of panel
A2, as illustrated in FIG. 51.
[0223] This motion will automatically fold D3 and E3 into a
vertical (90 degree) position to the inner surface of A2. The
position of the panels is now such that A1, A3, D3 and E3 all lie
at 90 degrees to the inner surface of A2, thus forming the
beginnings of the base structure of the box. Due to the folding up
of Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2, E4
and E5 will all fold together such that their surface lie flat
against each other, this processes is illustrated in FIG. 52, where
D4 and D5, E4 and E5 are pushed towards each other as the box is
set up.
[0224] Then, Panel C is folded over, as illustrated in FIG. 52 and
FIG. 53, such that C1 lies against the inside surface of A1 (thus
holding D4, D5 and E4, E5 in place). Panel C2 is then pushed down
so that it lies flat against the panel A2.
[0225] Inner flap portion rear panel B1, and inner portion side
flaps B2 and B3, which depend from the side edges of rear panel B1,
are then folded over. This arrangement would hold the product, in
this example, a wallet in place in the box. The surfaces, as with
any part of the box, could be printed on to improve the aesthetic
appeal of the product, as well as printing text on the surface.
[0226] The lid portion top panel A4 can be folded over the top of
the erected bottom part of the box to act as a lid or cover, with
the lid portion side panel A5 folding over the outer surface of
base front panel A1, as illustrated by FIG. 54. The box is now
divided, by the incorporated internal panels into a larger and
smaller compartment. Base portion rear panel A3, in this embodiment
is covered by lid rear split panel A6 and A7. Panels A6 and A7 are
connected along a hinge line positioned half way between the bottom
and the top of base portion rear panel A3. This hinge line allows
the lid portion of the pack to be hinged completely away from the
base portion.
[0227] FIGS. 57 to 60 depict a ninth alternative embodiment of a
collapsible pack of the invention and how it can be folded into a
set up position by the user. In this example, extra panels have
been incorporated onto inner flap panel B to form a divider in the
box.
[0228] The following is an alternative example of a box, with an
integrated divider, which forms two separate compartments, to hold
a product such as shoes.
[0229] FIG. 57 shows the box in a flat state. In this example the
box consists of Panel A (made up of A1, A2, A3 which for the base
of the box and panels A4 and A5 which in this example form the
lid); Panel B made of inner flap portion rear panel B1, inner
portion bottom panel B2 and inner flap portion divider panel B3
which form the integral incorporated folding panel; Panel C which
is also an integral folding panel, made of base portion front inner
panel C1, Panels D and E (D1, D2, D3, D4, D5, E1, E2, E3, E4, E5)
which form the side walls and flaps. In this embodiment, inner flap
bottom panel B2 is dimensioned to cover only a portion of the base
portion bottom panel A2 when the inner flap portion is in the
folded position.
Folding and Assembly
[0230] The process of folding into a set-up position is illustrated
step by step in FIGS. 58 to 60. This process can easily be reversed
to unfold the boxes back to a flat pack position.
[0231] The base portion of the pack is folded (FIG. 58) in
accordance with the steps described in respect of FIGS. 2 to 8.
[0232] Panel B, is then folded over such that the inner surface of
panel B1 lies flat against A3, as shown in FIG. 59. The panel B1,
in its folded position, will cover the panels D4 and D5, E4 and E5,
so that they lie underneath panel B1 between B1 and A3.
[0233] The Panel B2, is then be pushed down so that it lies flat
against the panel A2 as illustrated in FIG. 60. Panel B3 is folded
up so that it lies diagonally across the box, thus forming a
divider, as illustrated in FIG. 60.
[0234] The panel A4 can be folded over the top of the erected
bottom part of the box to act as a lid or cover, with the panel A5
folding over the outer surface of A1, as illustrated by FIG.
60.
[0235] FIGS. 61 to 64 depict a tenth alternative embodiment and
associated blank assembly of a collapsible pack of the invention
and how it can be folded into a set up position by the user. In
this example, a window panel/cut out is incorporated into the base
second side wall E3, behind which a product image or description or
other can be placed.
[0236] FIG. 64 shows the box in a flat state with the blank
assembly fully formed. In this example the box consists of Panel A
(made up of A1, A2, A3 which for the base of the box and panels A4
and A5 which in this example form the lid), Panel B (B1 and B2)
which form the integral incorporated folding panel, Panel C which
is also an integral folding panel, made of panel C1, Panels D and E
(D1, D2, D3, D4, D5, E1, E2, E3, E4, E5 and E6) which form the side
walls.
Folding and Assembly
[0237] The process of folding into a set-up position is illustrated
step by step in FIGS. 61 to 63. This process can easily be reversed
to unfold the boxes back to a flat pack position.
[0238] Side wall panel E3 has a rectangle cut out portion and a
clear substrate (e.g. PVC) is glued to the back of the cut out to
act as a window panel. FIG. 61 shows a piece of paper, which in
this example has a product description that sits behind the window.
Panel E6 is folded over to hold the paper in place, prior to the
folding of panels B and C during set up.
[0239] The panel A4 can be folded over the top of the erected
bottom part of the box to act as a lid or cover, with the panel A5
folding over the outer surface of A1.
[0240] Various alternative embodiments of the collapsible pack of
the invention are shown in FIGS. 65 to 74. In particular,
FIGS. 65 and 66 show alternative versions of the pack with a window
panel or cut out in the lid panel A4. A panel, window or cut out
can be included on any panel or side of the box or lid, to act as
an adornment, decoration, and feature or to allow visibility or
access to the products.
[0241] FIG. 67 shows an alternative version of the box with extra
panels D6 and E6 incorporated onto panel D and panel E to act as
dust flaps to prevent the ingress of dust when the pack is in the
assembled position.
[0242] FIG. 68 shows an alternative version of the box in different
proportions and size with a carrying handle, and a string tie
closure. In variations of this arrangement, a handle may be
attached to a panel in various sizes and proportions. The invention
could be made with other methods for carrying it attached to any
location on the outer or inner surface, or carrying method not
attached directly to the product. Attachments could also be added
for as a feature or for decorative or adornment purposes to the
outside or inside of this invention. A handle, made from a ribbon,
string or other material could be affixed to the outer surface of
panel A1 such that it passes through a cut, whole or slot in A5, or
on any other panels, to act as a handle or adornment, or decoration
or other use. FIG. 68 further shows an alternative closure for the
lid, which in this example is held down by a piece of string
attached to A5, which is wrapped around a tag affixed to the outer
surface of A1.
[0243] FIG. 69 shows an alternative version of the box in different
proportions and size with a carrying handle. The size and
proportions of the pack and the corresponding position of the
carrying handle will depend upon the purpose and use of the pack.
For example, FIG. 70 shows an alternative version of the box in
different proportions and size with a carrying handle.
[0244] FIGS. 71 to 74 illustrate various alternative versions of
the pack of the invention with alternative methods for holding the
lid (in this example parts A4 and A5) closed. The examples include
the use of magnets (FIG. 74), ribbons (FIG. 73), studs clips,
locks, Velcro and straps.
[0245] FIG. 71 shows an alternative version of the one-piece box
closed with a lock holding the lid shut. FIG. 72 shows an
alternative version of the one-piece box closed with a tag closure.
FIG. 73 shows an alternative version of the one-piece box closed
with ribbon closure. FIG. 74 shows an alternative version of the
one-piece box closed with a magnet holding the lid shut.
[0246] Various other changes and modifications are envisaged, such
as for example, there are a number of ways in which an insert may
be integrated into a pack according to the invention, including
altering the size, shape and number of panels, adding flaps, parts,
cuts or interlocks to create an integrated insert. Some additional
examples of alternatives for integrated inserts include fitments
made using more incorporated integral panels, flaps, interlocks,
cut outs, slots, holes and slits. In these examples, the fitment
can also be flat packed, and is directly connected to the panels of
the pack.
[0247] More panels can be incorporated, or part of the panels may
be altered in size or structure, on the pack. Further panels, or
parts, can also be incorporated to the existing panels and flaps
which may also be changed in size and or structure.
[0248] This invention can also be made by altering the panel B2 or
incorporating more panels, flaps, parts, cuts or interlocks so that
the invention is held together in an erect set up position without
the need for the panel B2 to touch or lie flat against the inner
surface of the panel.
[0249] The base and lid could also be lined on the inside or the
outside with material for decorative purposes or to protect the
contents when in a set-up position. The base and lid could be lined
with fabric material, for example.
[0250] The panels making up the compartment may be integrated with
inner flap panel B2, as an extension of panel B2 or it may be
incorporated to the other panels that make up the box and lid, or
new panels or flaps incorporated to the box. Additional
incorporated panels may act as an integrated compartment when
folded in the set-up position. More panels can be integrated to
form a combination of compartments and fitments. Alternative
methods for holding the lid closed are also envisaged. Examples
include the use of magnets, ribbons, studs clips, locks, Velcro and
straps, or the like.
[0251] The collapsible pack of the invention is re-foldable so that
it may be assembled and disassembled repeatedly by a user. The pack
may be used to contain many different and varied products such as
footwear, bottles, clothing, jewelry, wallets or the like. In this
way, the pack is multifunctional and has the advantage that, in its
collapsed form it is capable of flat-packing and also a quick fold
erect process.
[0252] The one piece box and lid incorporating an integral internal
panel or panels in the form of an inner flap portion allows the
base of the box to be held erected in a set up position by the
folded incorporated integral internal panels whether or not the
attached lid is open or closed, without the use of additional glue,
adhesives, tape, clip, or other fastener.
[0253] The pack is preferred to have a folding lid, folding side
walls and incorporated integral internal folding panels, in which
the lid, integral internal panels and side walls are attached to
the main body of the box, and all are foldable such that the
structure folds to form a fully covered complete box with attached
lid (and not a box comprised of a separate lid and base parts).
[0254] Furthermore, the box can be assembled from the flat pack
position to the set-up position and the box can be disassembled and
returned to the flat pack position, without the use of adhesives,
double sided tape, tape, or other fastener to hold it in the set-up
position.
[0255] In preferred embodiments, the lid, side walls, base and
internal panels are made flexible and foldable through the use of
materials that have been pre-cut, pre-creased, pre-folded, or
through by connecting the panels making up the sides and parts of
the box with a flexible material, which may be a thicker or thinner
substrate, or may connect the panels totally to each other or in
part.
[0256] The box, lid and integral panels can be of varying
dimensions, proportions, and sizes.
[0257] Further, any part of the box, lid or integral panels may
have a window, slot, cut out or panel or may have part of the
material replaced by a different material which is clear,
see-through or not see-through to act as a window, or adornment or
decoration, or access to the product.
[0258] A carrying mechanism, handle or part by which the box can be
carried may be added to any of the internal or external panels,
including but not limited to a ribbon, string, plastic, paper or
metal handle affixed to the box.
[0259] When the lid is in a closed arrangement, the lid can be held
in position by magnets, a ribbon, a clip, a slotting method, or
other such method for securing the position of the lid of the box
when in a set-up arrangement, or the lid can be left open and
unattached.
[0260] The internal inner flap portion panels hold the box in an
erect set up position by a fold erect mechanism of internal panels
or by engaging frictionally, via slots or cuts in either flap, via
a clip, or magnet, or by altering the shape of the panels or by
interlocking between panels of the box, including more incorporated
panels.
[0261] The internal flaps or panels may act as a fitment/insert.
The internal flaps may have additional panels, flaps or material
attached to them to support a product as a fitment, or to act as an
adornment or decoration.
[0262] The internal flaps may have panels attached to them, or
material cut out from them or the size or shape alerted in order to
support a product as a fitment, or to act as an adornment or
decoration.
[0263] The internal flaps may have additional panels, flaps or
material attached to form a compartment or multiple
compartments.
[0264] Part or all of the materials may be lined or coated with
fabric or other materials, or various materials are used to make up
the parts of the box.
[0265] The integral inner flap panel or panels may be fixed
permanently in a set up position the use of additional glue,
adhesives, tape, clip, or other fastener, or interlocking, clips or
other method for permanently holding the box in a set-up
position.
* * * * *