Folding Box

Abstract

A box formed from a single blank and being so constructed as to be selectively collapsible to a flattened state for storage, easy loading and removal of products of items, and for shipping purposes. The box and blank from which it is formed include side panels positionable upright and incorporating reinforcing flaps or flanges which, in the assembled box, form a peripheral shoulder about the opening therein. Cooperating closure and lock flaps effect a locked closing of the box.

Description

The present invention relates to folding boxes, and is more particularly concerned with a box foldable from a single sheet-like blank, utilizing only four securing point, and when formed, being selectively collapsible in nature so as to assume a flattened state for easy removal or placement of products or items, storing and shipping.

A significant object of the instant invention resides in the provision of a highly sturdy reinforced box, usable as a cake or flower box, or for that matter a box of general utility, with the box being formed from a single integral flat blank specifically configured and foldable.

In conjunction with the above object, it is another important object of the instant invention to provide a box construction wherein the basic blank thereof is retained in the box forming configuration utilizing only four securing points, the securing preferably utilizing adhesive.

Other objects of the instant invention reside in the simplicity of construction, the ease of assembly, the positive lock provided for the finished box, the collapsible nature of the finished box, and the sturdiness and reinforced nature of the finished box notwithstanding the utilization of a single blank in the formation thereof.

These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout, and in which

FIG. 1 is a perspective view of the completed box of the instant invention with a portion thereof broken away for purposes of illustration;

FIG. 2 is an enlarged cross-sectional view taken substantially on a plane passing along line 2--2 in FIG. 1;

FIG. 3 is an enlarged cross-sectional view taken substantially on a plane passing along line 3--3 of FIG. 1;

FIG. 4 is a plan view of the blank of the instant invention;

FIG. 5 illustrates the initial step in the folding of the blank, and at the same time the collapsed box; and

FIGS. 6 and 7 illustrate sequential steps in forming the erected box from the collapsed position of FIG. 5.

Referring now more specifically to the drawings, the completely assembled box is generally referred to by reference numeral 10, while the blank from which it is formed is designated by reference numeral 12.

The blank 12, and hence the box 10, includes a rectangular bottom panel 14 having front and back edges 16 and 18, defined by fold lines or lines of weakness. The bottom panel 14 similarly includes fold line defined side edges 20. Front and back panels 22 and 24 are integrally engaged with the bottom panel respectively along the front and back edges 16 and 18 thereof, the font and back panels 22 and 24 being of equal width or coextensive with the bottom panel 14 and similarly of a rectangular configuration.

A rectangular top panel 26, of approximately equal size with the bottom panel 14, is integrally engaged with the fold line defined outer edge 28 of the back panel 24. The outer edge 30 of the top panel 26 is defined by a full width fold line which separates the top panel 26 from the closure flap 32 which is divided into two substantially full width sections 34 and 36 by a centrally located fold line 38. The outer edge of the closure flap 32 is provided with an integral outwardly projecting gripping tab 40, while the opposed side edges thereof are centrally relieved, as at 42, so as to reduce the effective width thereof along the fold line 38, this portion of the closure flap being that portion initially introduced into the locking compartment of the box as shall be explained subsequently.

The front panel 22 is of a greater height than the back panel 24 and includes an outer edge 44 defined by a fold line between the front panel 22 and a full width locking flap 46. The locking flap 46 is in turn divided into inner and outer full width sections 48 and 50 by a central fold line 52. The inner section 48 is of a height substantially equal to the height of panel 22 beyond that of the back panel 24. The outer section 50 has a centrally located integral tab 53 thereon, this tab being severed from the inner flap section 48.

Located to the opposed sides of the bottom panel 14 are a pair of outwardly directed side panels 54 integrally formed with the bottom panel along the corresponding side edge fold lines. Each side panel 54 is equal height with the back panel 24 and coextensive in length with the bottom panel 14.

A pair of end panels 56 are of an equal height and integrally formed with the opposed ends of each side panel 54, each being separated therefrom by a fold line 58 constituting a continuation of fold line 16 or 18. Each of these end panels 56 is likewise integral with the adjoining front or back panel, being separated therefrom by a fold line 60 constituting a continuation of the adjoining fold line 20. Each end panel 56 is substantially square in shape and thereby also of approximately equal height with the back panel 24. At the intersection of each free side edge 62, of the end panels 56 integral with the front panel 22, and the adjoining edge of the front panel 22, a slight notch or recess 64 is formed so as to introduce a degree of flexibility at this point in facilitating a folding of the blank and a closing of the lock flap 46.

The outer edge 66 of each side panel 54 is defined by a full length fold line which separates the side panel 54 from a full length center reinforcing flap 68, the opposite ends 70 of which are inwardly beveled at approximately a 45.degree. angle. The outer edge of each end panel 56, that is that edge aligned with the outer edge 66 of the adjoining side panel 54, is similarly defined by a fold line which separates the end panel 56 from an equal length end reinforcing flap 74 aligned with and independent of the central flap 68 on the adjoining side panel 54. In those instances where pre-applied adhesive is to be utilized in assembling the blank 12 into the box 10, the adhesive will be applied to the inner face of each center flap 68 adjacent the beveled ends thereof as indicated by reference numeral 76 and, so as to overlap therewith as shall be described presently, on the undersurface of the adjacent ends of the end flaps 74, as indicated by reference numeral 78. As will be appreciated from the drawings, the flaps 68 and 74 are relatively narrow, providing appropriate reinforcement and acting in the nature of a supporting shoulder without reducing the opening into the box 10 to any substantial degree.

The basic construction is completed by the provision of a pair of cross fold lines 80 and 82 on each end panel 56. The fold line 80 extends between the outer corner of the end panel 56, where the fold lines 58 and 72 meet at the adjacent ends of the center and end flaps 68 and 74, to the corner defined between the fold line 60 and the free outer edge of the end panel adjacent the side edge of the front or top panel, depending upon the particular end panel flap 56. The fold line 82 of each end panel 56 crosses the fold line 80 at right angles and extends from the outer corner of the end panel 56 to the inner corner thereof defined adjacent the corresponding corner of the bottom panel where the fold lines 58 and 60 meet.

As an initial step in forming the box 10, noting FIGS. 4 and 5, each end panel 56 has the outer portion thereof folded inwardly about the fold line 80 where by the fold line 72 aligns over the fold line 58 and the free outer edge of the end panel 56 aligns over the adjoining fold line 60. When folded in this manner, the adhesive areas 78 will be upwardly exposed. The next step involves inwardly folding each of the center flaps 68 so as to overlie the adhesive areas 76 with the now upwardly directed adhesive areas 78, at which point the adhesive areas are bonded so as to lock the reinforcing flaps into a generally U-shaped configuration. The configuration formed in this manner, illustrated in FIG 5, in addition to constituting the initial step in the formation of the completed box 10, also constitutes a knockdown or collapsed position for the box in that the further steps in forming the box involve only folding steps and require no additional bonding of the panels to each other. Accordingly, the box at this stage is readily adapted for shipping and storage purposes should it be desirable to eliminate the bonding step for the ultimate user of the box. Incidentally, as will be appreciated at this point, only four areas of bonding are utilized in the formation of the rigid reinforced and lockable box from a single blank or sheet.

The next step in the setup of the box 10 has been illustrated in FIG. 6 and consists of an upward folding of the front and back panels 22 and 24 perpendicularly to the bottom panel 14. This is effected in conjunction with a combined movement of the end panels 56 whereby the end panels 56 are unfolded about the fold lines 80 and folded about the fold lines which define the edges 58, whereby the end panels are coplanar with the adjoining front or back panel and each U-shaped reinforcing flap unit is vertically oriented.

The next step, illustrated in FIG. 7, involves an upward folding of the side panels 54, about the fold lines defined by side edges 20, to the vertical. In effecting this movement, the end panels 56 are folded inwardly about the fold lines 82, this in turn requiring, so as to enable a passage of the folded end panels 56, a slightly outward inclining of the front and back panels 22 and 24, after which the panels 22 and 24 are again brought to the vertical.

When folded in this manner, the U-shaped reinforcing flap units are horizontally orientated in opposed relation about the open upper end of the box so as to introduce substantial rigidity thereto without greatly reducing the size of the opening, this rigid upper edge protecting the contents of the box even upon a stacking of several boxes on each other. The folded end panels 56 are, adjacent the front and rear edges of the bottom panel, generally coplanar and parallel to the adjacent upstanding panels 22 and 24 so as to provide in effect multiple layer front and back walls on the box 10.

The closing of the box 10, noting FIGS. 1, 2 and 3 in particular, involves a downward folding of the top panel about the edge 28 so as to overlie the open top of the box and rest on the now peripherally orientated reinforcing flaps 68 and 74. The closure flap 32 is folded downwardly about the top panel edge 30 and the outer section 36 of the closure flap 32 is upwardly folded about the fold line 38 so as to lie adjacent the downwardly folded flap section 34 with the tab 40 projecting upwardly therebeyond and beyond the top panel 26. The closure flap 32, folded in this manner, is inserted, with the fold line 38 lowermost, into a locking compartment 84 defined between the front panel 22 and the adjacent folded end panels 56. The tab 40 projecting upwardly is utilized to facilitate a withdrawal of the compartment received closure flap 32. The reduced width of the closure flap 32 along the central fold line 38 facilitates a slipping of the folded closure flap 32 into the locking compartment 84.

A locking of the top panel 26 in the closed position thereof is effected by downwardly folding the lock flap 46 about the fold line defining edge 44 and inserting the lock flap 46 within the upwardly opening pocket defined by the adjacent closure flap sections 34 and 36, the lock flap 46 overlying the upwardly directed tab 40 and having its own pull tab 53 upwardly directed for a simplified upward pulling and disengagement of the lock flap.

The lock flap fold line 52 enables a proper flexing of the lock flap 46 for an insertion and removal thereof, the slight degree of additional flexibility introduced by the corner recesses 64 also facilitating the introduction and removal of the lock flap 46. Inasmuch as the height of the lock flap section 48 is generally equal to the height of that portion of the front panel 22 beyond the height of the back panel 24, the upwardly projecting release tab 53 will be substantially entirely exposed for easy access thereto, while at the same time being in a protected position behind the upwardly directed flange defined on the finished closed box 10 by the extra height of the front panel 22. Incidentally, if so desired, this upwardly projecting flange can be utilized as a convenient means for aligning stacked boxes.

From the foregoing, it will be appreciated that a highly unique reinforced box construction has been defined wherein the box is formed from a single one-piece blank utilizing, in addition to a unique configuration and the arrangement of fold lines, only four bonding or interlocking points which, while described as preapplied adhesive areas, can in fact be any appropriate means. The initial step in the folding and bonding of the involved portions of the blank produces a collapsed unit which can be easily expanded into the material receiving box without requiring any additional fastening means or the like, the completely expanded box being in turn readily collapsible into a storing or shipping condition.

The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Claims

What is claimed as new is as follows:

1. In box construction, a generally rectangular bottom panel having front and back edges and side edges, front and back panels extending from the front and back edges of said bottom panel and being of substantially equal length with said front and back edges, side panels extending from the side edges of said bottom panel and being of substantially equal length with said side edges, said front, back and side panels having, in each instance, an outer edge and opposed side edges, end panels extending from each side panel side edge and the adjacent side edge of the corresponding front or back panel, each end panel having a first outer edge generally aligned with the outer edge of the adjacent side panel and a second outer edge perpendicular to the first outer edge and defining an outer corner therebetween, each end panel including a diagonal fold line extending from the outer corner to an inner corner diagonally opposed therefrom, said fold line allowing an inward folding of the end panel adjacent the adjacent front or back panel, the aligned outer edges of said side and end panels having flaps thereon with adjacent inner ends, each end panel having a fold line diagonally thereacross perpendicular to the first end panel fold line for a selective folding of the end panel thereon with the end panel flap and the adjacent side panel flap having their adjacent ends overlapped.

2. The structure of claim 1 including a top panel integral with the back panel along the outer edge thereof and projecting therefrom, said top panel having an outer edge, and a closure flap foldably engaged with the outer edge of the top panel along the length of this top panel outer edge, said closure flap being selectively engageable between the front panel and the inwardly folded adjacent end panels.

3. The structure of claim 2 including an elongated lock flap engaged with the outer edge of said front panel along the length of this outer edge, said lock flap being selectively engageable with the closure flap for a retention thereof between the front panel and the inwardly folded end panels adjacent thereto.

4. The structure of claim 3 wherein said closure flap includes a pair of fold line joined sections orientatable so as to define an upwardly opening generally V-shaped pocket between the front panel and the adjacent inwardly folded end panels for a selective reception of the downwardly directed lock flap therein.

5. The structure of claim 4 wherein said closure flap and said lock flap each incorporates tab means thereon upwardly positionable upon an interengagement of the closure flap and lock flap between the front panel and the adjacent inwardly folded end panels.

6. The structure of claim 5 wherein said end and side panel flaps selectively assume, in the assembled box, a horizontal position in overlying spaced parallel relation to the bottom panel.

7. In a collapsible box, bottom, front, back and side panels, inwardly foldable end panels interconnecting the front and back panels with the adjacent edges of the side panels, said side panels being movable between a position perpendicular to the bottom panel wherein the end panels are folded inwardly of the adjacent front and back panels and a second position coplanar with the bottom panel wherein the end panels are extended outwardly from the adjacent front and back panels, each side panel and the adjacent end panels have inwardly directed horizontal flaps in both the first and second positions thereof, said flaps, in the first position, being perpendicular to the corresponding panels, and in the second position being in overlying parallel relation to the associated panels, a top panel foldably engaged with the back panel and selectively positionable in overlying parallel spaced relation to said bottom panel for an enclosing of the box, said top panel including a closure flap foldably secured thereto, said closure flap being selectively receivable between the front panel and the inwardly folded end panels adjacent to said front panel, and an elongated lock flap foldably secured to said front panel and selectively engaged with the closure flap subsequent to an introduction of the closure flap between the front panel and the adjacent inwardly folded end panels.

8. For use in the construction of a reinforced box, a single sheet of material, said sheet of material including a rectangular bottom panel having front and back edges and opposed side edges, front and back panels respectively extending from the front and back edges of the bottom panel, side panels extending from the opposed side edges of the bottom panel, said front and back panels and side panels each having opposed side edges, and an end panel extending from each side panel side edge and the adjacent side edge of the corresponding front or back panel, each end panel having an outer corner defined thereon remote from both of the adjacent panels, and a diagnonal fold line extending from said corner to an inner corner defined at an intersection between the side edges of the two adjacent panels, each end panel including an outer edge aligned with the outer edge of the adjoining side panel, and foldably connected flaps engaged with the aligned end panel and side panel outer edges, the flaps on the aligned end and side panel outer edges having adjoining spaced ends, and a second fold line defined in each end panel extending perpendicularly across the first mentioned fold line and between a second pair of corners.

9. The structure of claim 8 including a top panel foldably connected to the outer edge of the back panel and in turn having a closure flap foldably connected to the outer edge thereof, and a lock flap foldably connected to the outer edge of the front panel.