U.S. patent application number 13/779076 was filed with the patent office on 2013-08-29 for high-strength double wall/triple wall box, box form, and method of creating same.
This patent application is currently assigned to Technology Container Corp.. The applicant listed for this patent is Technology Container Corp.. Invention is credited to Fred Dowd, Keith B. Perron.
Application Number | 20130221079 13/779076 |
Document ID | / |
Family ID | 49001754 |
Filed Date | 2013-08-29 |
United States Patent
Application |
20130221079 |
Kind Code |
A1 |
Dowd; Fred ; et al. |
August 29, 2013 |
High-Strength Double Wall/Triple Wall Box, Box Form, and Method of
Creating Same
Abstract
A pre-folded automatic bottom box form made from a unitary blank
of material. The form has a blank of corrugated material that is
die cut and creased so as to form a series of panels and flaps
arranged in three rows of four panels or flaps each and a fourth
row with two panels, all arranged in four columns, a first row
comprising four panels that end up in the box as an automatic
bottom, a second row comprising four panels that end up in the box
as sidewall and end wall panels, a third row contiguous with the
second row and comprising four panels that end up in the box as
reinforcing sidewall and end wall panels, and a fourth row coupled
to the third row and comprising first and second panels making
additional end wall reinforcing panels.
Inventors: |
Dowd; Fred; (Princeton,
MA) ; Perron; Keith B.; (Methuen, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Technology Container Corp.; |
|
|
US |
|
|
Assignee: |
Technology Container Corp.
Worcester
MA
|
Family ID: |
49001754 |
Appl. No.: |
13/779076 |
Filed: |
February 27, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61603649 |
Feb 27, 2012 |
|
|
|
Current U.S.
Class: |
229/117 |
Current CPC
Class: |
B65D 5/443 20130101;
B65D 5/10 20130101; B65D 5/0281 20130101; B65D 5/02 20130101 |
Class at
Publication: |
229/117 |
International
Class: |
B65D 5/02 20060101
B65D005/02 |
Claims
1. A pre-folded automatic bottom box form made from a unitary blank
of material, comprising: a blank of corrugated material that is die
cut and creased so as to form a series of panels and flaps arranged
in three rows of four panels or flaps each and a fourth row with
two panels, all arranged in four columns, a first row comprising
four panels that end up in the box as an automatic bottom, a second
row comprising four panels that end up in the box as sidewall and
end wall panels, a third row contiguous with the second row and
comprising four panels that end up in the box as reinforcing
sidewall and end wall panels, and a fourth row coupled to the third
row and comprising first and second panels making additional end
wall reinforcing panels; wherein the two panels of the fourth row
are configured to be folded onto, and secured to, the two
contiguous panels of the third row; and wherein the blank is
configured to be folded along two fold lines located between
columns, and the edges of the end panels of the second row are
configured to be fastened together to create a completed box.
2. A box created from the pre-folded file bottom box form of claim
1.
3. The box form of claim 1 wherein the edges of the end panels of
the second row are fastened together by one of gluing, stitching,
or stapling.
4. A pre-folded file bottom box form made from a unitary blank of
material, comprising: a blank of corrugated material that is die
cut and creased so as to form a series of panels and flaps arranged
in three rows of four panels or flaps each and a fourth row with
two panels, all arranged in four columns, a first row comprising
four panels that end up in the box as the bottom and end wall
reinforcing flaps, a second row comprising four panels that end up
in the box as sidewall and end wall panels, a third row contiguous
with the second row and comprising four panels that end up in the
box as reinforcing sidewall and end wall panels, and a fourth row
coupled to the third row and comprising first and second panels
making additional end wall reinforcing panels; wherein the two
panels of the fourth row are configured to be folded onto, and
secured to, the two contiguous panels of the third row; and wherein
the blank is configured to be folded along two fold lines located
between columns, and the edges of the end panels of the second row
are configured to be fastened together, to create a completed
box.
5. A box created from the pre-folded file bottom box form of claim
4.
6. The box form of claim 4 wherein the edges of the end panels of
the second row are fastened together by one of gluing, stitching,
or stapling.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority of Provisional Application
Ser. No. 61/603,649 filed on Feb. 27, 2012, the contents and
teachings of which are hereby incorporated by reference in their
entirety.
FIELD
[0002] This disclosure relates to a box.
BACKGROUND
[0003] Box stacking strength is dictated primarily by the quantity
of vertical walls (sidewalls and end walls) with their corrugations
running in the vertical direction. Panels with corrugations running
horizontally contribute little to crush resistance. It is thus
desirable to increase the quantity of sidewall and end wall panels
with vertical corrugations in both file bottom and automatic bottom
style file storage boxes.
SUMMARY
[0004] This disclosure features a box for file storage and the
like. The box is made from a unitary blank of material that is
partially preassembled by the manufacturer into a box form. The box
form is then assembled (typically by the user) into the final box.
The box, when assembled, has four interconnected vertical walls
(two sidewalls and two end walls) that define an open storage
volume between them. The vertical walls are typically each
rectangular in shape, to define a generally rectangular
prism-shaped storage volume.
[0005] Featured herein are two different box designs that achieve
superior stacking strength for record file boxes. When complete,
one design forms double wall length panels and quadruple wall width
panels with a manually assembled, double thick flat bottom. The
other design forms double wall length panels and triple wall width
panels along with an auto assembly easy fold bottom design. The
first design is a file bottom design with a double thick flat
bottom that is formed when the bottom is manually assembled,
creating a smooth surface that is less prone to catching on storage
shelving. Automatic bottom style boxes have bottoms that assemble
and fold into place automatically as the box form is pushed into
the assembled box. The automatic bottom has an irregular surface
that can catch on shelving. Automatic bottom style boxes are thus
very easy to assemble, but are typically not well suited for use in
situations in which the boxes are going to be stored on
shelves.
[0006] In an embodiment a pre-folded automatic bottom box form is
made from a unitary blank of material and comprises a blank of
corrugated material that is die cut and creased so as to form a
series of panels and flaps arranged in three rows of four panels or
flaps each and a fourth row with two panels, all arranged in four
columns, a first row comprising four panels that define an
automatic bottom of the box, a second row comprising four panels
that define sidewall and end wall panels of the box, a third row
contiguous with the second row and comprising four panels that
define reinforcing sidewall and end wall panels of the box, and a
fourth row coupled to the third row and comprising first and second
panels that form additional end wall reinforcing panels. The two
panels of the fourth row are folded onto and fastened to the two
contiguous panels of the third row, such as by using an adhesive.
The blank is then folded along two fold lines located between
columns, and the edges of the end panels of the second row are
fastened together, to create the completed form. The edges of the
end panels of the second row can be fastened together by gluing,
stitching or stapling. Also featured is a box created from this
pre-folded box form.
[0007] In another embodiment a pre-folded file bottom box form is
made from a unitary blank of material and comprises a blank of
corrugated material that is die cut and creased so as to form a
series of panels and flaps arranged in three rows of four panels or
flaps each and a fourth row with two panels, all arranged in four
columns, a first row comprising four panels that end up in the box
as the bottom and end wall reinforcing flaps, a second row
comprising four panels that end up in the box as sidewall and end
wall panels, a third row contiguous with the second row and
comprising four panels that end up in the box as reinforcing
sidewall and end wall panels, and a fourth row coupled to the third
row and comprising first and second panels making additional end
wall reinforcing panels. The two panels of the fourth row are
folded onto and fastened to the two contiguous panels of the third
row, such as using an adhesive. The blank is then folded along two
fold lines located between columns, and the edges of the end panels
of the second row are fastened together, to create the completed
form. The edges of the end panels of the second row can be fastened
together by gluing, stitching or stapling. Also featured is a box
created from this pre-folded box form.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The foregoing and other objects, features and advantages
will be apparent from the following description of particular
embodiments of the innovation, as illustrated in the accompanying
drawings in which like reference characters refer to the same parts
throughout the different views. The drawings are not necessarily to
scale, emphasis instead being placed upon illustrating the
principles of various embodiments of the innovation.
[0009] FIG. 1 shows a blank used to create an automatic lock bottom
type file storage box, before it is folded and glued to create the
box form.
[0010] FIGS. 2A and 2B show both sides of the flat box form made
from the blank of FIG. 1.
[0011] FIG. 3 shows a blank used to create a file bottom type file
storage box, before it is folded and glued to create the box
form.
[0012] FIGS. 4A and 4B show both sides of the flat box form made
from the blank of FIG. 3.
DETAILED DESCRIPTION
[0013] One arrangement of an automatic bottom file storage box is
formed from the unitary blank of material 10 shown in FIG. 1. Blank
10 may be constructed of any material that will form a stiff panel
surface. Preferably, blank 10 is made from a single thickness
corrugated material (corrugated paper or corrugated plastic); that
is a material with two layers of linerboard separated by a single
layer of fluted material. Such a corrugated material can be
constructed from different substances, as is known in the art. The
material can have several different constructions. Corrugated
material is typically constructed from fiber materials or plastic
materials.
[0014] Blank 10 is formed through die cutting and creasing of
corrugated material as is known in the art. Blank 10 essentially
defines four rows of panels and flaps labeled A, B, C and D, and
four columns of panels and flaps labeled E, F, G and H. As
illustrated, the panels in each column are foldably coupled to each
other. Accordingly, in column E, panels 32, 34, and 52 are foldably
coupled to each other along seams 33 and 35, respectively. In
column F, panels 12, 14, 16, 56, and 58 are foldably coupled to
each other along seams 13, 15, 17, and 57, respectively. In column
G, panels 42, 44, and 54 are foldably coupled to each other along
seams 43 and 45, respectively. In column H, panels 22, 24, 26, 60,
and 62 are foldably coupled to each other along seams 23, 35, 27,
and 61, respectively. Additionally, the panels 32, 14, 42, and 24
in row C define spaces 70, 71, 72 disposed therebetween which allow
independent relative movement among the panels 32, 14, 42, 24.
Accordingly, panel 32 can be folded along seam 33 independent from
panel 14, panel 14 can be folded along seam 15 independent from
panels 32 and 42, and panel 42 can be rotated along seam 42
independent from panels 14 and 24.
[0015] Panels 12, 14, and 16, once assembled, form a first triple
thickness end wall, with the corrugation in all three panels
running vertically along axis 82 to maximize crush resistance.
Similarly, panels 22, 24, and 26, once assembled, form a second
triple thickness end wall, with the corrugation in all three panels
running vertically along axis 82 to maximize crush resistance.
Panels 42 and 44, once assembled, form a first double thickness
sidewall, with the corrugation in both panels running vertically
along axis 82 to maximize crush resistance. Similarly, panels 32
and 34, once assembled, form a second double thickness sidewall,
with the corrugation in both panels running vertically along axis
82 to maximize crush resistance. Panels or flaps 52, 54, 56 and 60
form the bottom of the box with panel 54 on the inside and
overlying the other panels to provide load bearing strength to the
inside bottom of the box. Portion 58 of panel 56 is secured to
panel 52, and portion 62 of panel 60 is secured to panel 54 to
create an automatic bottom.
[0016] During assembly, the pre-folded box form is created from
blank 10 as follows. Beginning with form 10 as shown in FIG. 1, an
assembler folds panels 12 and 22 about seams 13 and 23 and onto
panels 14 and 24, respectively. The assembler then secures panel 12
to panel 14, as well as panel 22 to panel 24, using a fastening
mechanism, such as an adhesive, to form sets of double walled
panels. The assembler then folds flap 52 onto panel 34 along fold
line or score 35 and folds flap 56 along fold line or score 17 to
panel 16 while, at substantially the same time, reverse folding
flap 58 along score 57 in the opposite direction. With such
assembly, flap 58 is disposed against flap 57 while flap 57 is
disposed against panel 16. The assembler then folds flap 54 along
score 45 onto panel 44. Next, the assembler folds flap 60 along
score 27 onto panel 26 while reverse folding flap 62 along score
61. The assembler then folds panel 34 along score 72 and panel 26
along score 74 such that flap extension 80 contacts one of the
interior or exterior of flap 34 and couples to the flap 34 via an
adhesive or other attachment mechanism. This creates the flat,
pre-folded box form 82 shown in FIGS. 2A and 2B.
[0017] To assemble the box form into a box, an end user opens the
flat pre-folded box form to form a rectangle (i.e., such that the
adjacent walls of columns E, F, G, and H are substantially
perpendicular to each other). As this box is squared up to form a
rectangle, bottom panels 52, 56, 54, and 60, which have been
preassembled and adhered to one another, pull themselves into
position by the force of squaring the box so that flaps 52, 56, 54,
and 60 are now substantially parallel to the floor and
substantially perpendicular to the sidewalls 34, 16, 44, and 26.
Flap 54 is disposed on the innermost portion of the bottom of the
box with the other flaps supporting it.
[0018] To assemble the box form 82 into a box, an end user folds
combined panels 12 and 14 (i.e., a double walled panel) along seam
15 and onto panel 16. The user then folds combined panels 22 and 24
(i.e., a double walled panel) along seam 25 and onto panel 26. This
forms opposing triple paneled walls of the box. The end user then
folds panel 32 along seam 33 onto panel 34 and folds panel 42 along
seam 43 and onto panel 44. This forms opposing double paneled walls
of the box. This completes the assembly.
[0019] The above-described configuration increases the number of
width panels to three (i.e., the combination of panels 12, 14, and
16 and the combination of panels 22, 24, and 26) and increases the
number of side wall panels to two (i.e., the combination of panels
42 and 44 and the combination of panels 32 and 34) relative to
conventional boxes. The configuration increases the vertical
strength of the final assembled box compared to conventional
boxes.
[0020] One arrangement of a file bottom file storage box is formed
from the unitary blank of material 100 shown in FIG. 3. Blank 100
may be constructed of any material that forms a stiff panel
surface. Preferably, blank 100 is made from a single thickness
corrugated material (corrugated paper or corrugated plastic); that
is a material with two layers of linerboard separated by a single
layer of fluted material. Such a corrugated material can be
constructed from different substances, as is known in the art. The
material can have several different constructions. Corrugated
material is typically constructed from fiber materials or plastic
materials.
[0021] Blank 100 is formed through die cutting and creasing of
corrugated material as is known in the art. Blank 100 essentially
defines four rows of panels and flaps labeled A, B, C and D, and
four columns of panels and flaps labeled E, F, G and H. Panels 112,
114, 116, and 156 are configured to form one quadruple thickness
end wall, with the corrugation in three of the panels (112, 114 and
116) running vertically along axis 182 to maximize crush
resistance. Similarly, panels 122, 124, 126 and 158 are configured
to form a second quadruple thickness end wall, with the corrugation
in three of the panels (122, 124 and 126) running vertically along
axis 182 to maximize crush resistance. Panels 142 and 144 are
configured to form a double thickness sidewall, with the
corrugation in both panels running vertically along axis 182 to
maximize crush resistance. Additionally, panels 132 and 134 are
configured to form a double thickness sidewall, with the
corrugation in both panels running vertically along axis 182 to
maximize crush resistance. Panels 152 and 154 are configured to
form the bottom of the box, with panel 152 configured to be
disposed on an interior portion of the box.
[0022] During assembly, the pre-folded box form is created from
blank 100 as follows. Beginning with form 100 as shown in FIG. 3,
an assembler folds panels 112 and 122 about seams 113 and 123 and
onto panels 114 and 124, respectively. The assembler then secures
panel 112 to panel 114, as well as panel 122 to panel 124, using a
fastening mechanism, such as an adhesive. The assembler then folds
the form 100 along fold lines 172, and 174, respectively, and
secures extension flap 180 to an outer portion of panel 126, such
as by using an adhesive. This creates the flat pre-folded box form
shown in FIGS. 4A and 4B.
[0023] To assemble the box form into a box, an end user opens the
flat pre-folded box form to form a rectangle (i.e., such that the
adjacent walls of columns E, F, G, and H are substantially
perpendicular to each other) and folds certain panels into the box,
thereby allowing the panels to mechanically interlock and form the
bottom of the box.
[0024] For example, the end user forms the box bottom by rotating
panel 152 along line 135 up into the box interior and against panel
134. The end user then folds flaps 156 and 158 about lines 155,
157, respectively and onto panel 154. The end user then rotates
panel 154 along line 145, into the interior of the box, and
disposes the panel 154 against panel 144. The end user can then
rotate the panel 154 down 90 degrees to panel 144 about line 145 to
form the outer bottom of the box and can fold flaps 156 and 158 up
from the panel 154 and about lines 155 and 157, respectively, until
the flaps 156 and 158 contact walls 116 and 126, respectively. The
end user can then rotate panel 152 about line 135 and down onto
panel 154 to form the inner bottom of the box.
[0025] Next, the end user can fold the combination of panels 112
and 114 (panel 112 having been previously secured to panel 114)
about seam 115 and over panels 116 and 156. Additionally, the end
user can fold the combination of panels 122 and 124 (panel 122
having been previously secured to panel 124) about seam 125 and
over panels 126 and 158. This forms opposing box walls having
quadruple wall width panels. The end user can then fold panel 142
about seam 143 to contact panel 144 and can fold panel 132 about
seam 133 to contact panel 134. This forms opposing box walls having
double wall length panels.
[0026] The above-described configuration increases the number of
sidewall panels to four (i.e., the combination of panels 112, 114,
116, 156 and the combination of panels 122, 124, 126, 158) and
increases the number of end wall panels to two (i.e., the
combination of panels 142 and 144 and the combination of panels 132
and 134) relative to conventional boxes. The configuration
increases the vertical strength of the final assembled box compared
to conventional boxes.
[0027] While various embodiments of the innovation have been
particularly shown and described, it will be understood by those
skilled in the art that various changes in form and details may be
made therein without departing from the spirit and scope of the
innovation as defined by the appended claims.
* * * * *