CORRUGATED BOX ASSEMBLY WITH COMBINATION SELF-LOCKING LID AND TAB-STYLE FOLD OVER TAB AND METHOD OF CONSTRUCTION
20200324933 ยท 2020-10-15
Inventors
Cpc classification
B65D5/003
PERFORMING OPERATIONS; TRANSPORTING
B65D5/28
PERFORMING OPERATIONS; TRANSPORTING
B65D5/2057
PERFORMING OPERATIONS; TRANSPORTING
B65D5/10
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65D5/28
PERFORMING OPERATIONS; TRANSPORTING
B65D5/00
PERFORMING OPERATIONS; TRANSPORTING
B65D5/20
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A Corrugated Box Assembly with Combination Self-Locking Lid and Tab-Style Fold Over Tab includes a box assembly that lies flat as a box blank having two rectangular sidewalls, two square sidewalls, rectangular flaps, and square flaps. The box blank assembles into a rectangular box having six faces and twelve edges. A fold over tab extends along the lateral edge of rectangular sidewall. The fold over tab has an adhesive, so that when folded over the joint between the square sidewall and the rectangular sidewall, the sidewalls of box are fastened together. Also, fold over tab creates a bulge on outer surface of box to help loose boxes stacked into each other. Multiple tongues and slots interlock in an intimate relationship to form constructed box. Multiple stacking tabs extend from top flaps to mate with corresponding stacking holes in an adjacent box assembly to stabilize multiple stacked boxes.
Claims
1. A corrugated box assembly with combination self-locking lid and tab-style fold over tab, the assembly comprising: a box blank having: two rectangular sidewalls defined by a pair of rectangular lateral edges, a rectangular top edge, and a rectangular bottom edge; two square sidewalls defined by a pair of square lateral edges, a square top edge, a square bottom edge, the rectangular and square sidewalls joining at the lateral edges in an alternating arrangement to form an enclosed region defined by a rectangular cross section and four parallel outer edges; at least one fold over tab longitudinally attached along the rectangular lateral edges of at least one of the rectangular sidewalls, fold over tab comprising an adhesive, whereby fold over tab folds along the parallel outer edges of constructed box assembly; two top rectangular flaps hingedly connected by a top score line along the top edge of the rectangular sidewalls, the top rectangular flaps forming a pair of top locking slots, each top rectangular flap comprising two top stacking tabs, the top stacking tabs extendable from the top rectangular flaps; two bottom rectangular flaps hingedly connected by bottom score lines along the bottom edge of the rectangular sidewalls, each bottom rectangular flap forming two bottom locking slots, each bottom rectangular flap forming two bottom stacking holes, the bottom stacking holes adapted to intimately receive the top stacking tabs of the top rectangular flaps, whereby the top stacking tabs engage the bottom stacking holes to help stabilize stacking multiple box assemblies; two top square flaps hingedly connected by the top score line along the top edge of the square sidewalls, the top square flaps forming a pair of top locking tongues defined by a heel portion, the top locking tongues adapted to lock under the corresponding and adjacent top locking slots that form in the top rectangular flaps; and two bottom square flaps hingedly connected by the bottom score line along the bottom edge of the square sidewalls, each bottom square flap comprising two bottom locking tongues, the bottom locking tongues adapted to lock under the corresponding and adjacent bottom locking slots that form in the bottom rectangular flaps, each bottom square flap forming two end stacking holes adapted to receive the top locking tongues.
2. The box assembly of claim 1, wherein the square sidewalls are defined by at least one grab hole.
3. The box assembly of claim 1, wherein the top rectangular flaps are die-cut.
4. The box assembly of claim 1, wherein the bottom rectangular flaps are die-cut.
5. The box assembly of claim 1, wherein the two top square flaps are die-cut.
6. The box assembly of claim 1, wherein the two bottom square flaps are die-cut.
7. The box assembly of claim 1, wherein the two bottom rectangular flaps and the two bottom square flaps form at least one air hole.
8. The box assembly of claim 1, wherein the bottom square flaps form a bottom score line.
9. The box assembly of claim 1, wherein the box blank is defined by a cardboard or a plastic material.
10. The box assembly of claim 1, wherein the rectangular lateral edges are narrow and elongated.
11. The box assembly of claim 1, wherein the fold over tab is elongated and L-shaped.
12. The box assembly of claim 1, wherein the top locking tongues are indented in the top rectangular flaps.
13. The box assembly of claim 1, wherein the rectangular flaps laterally extend out past the width of the rectangular sidewalls to create a width difference.
14. The box assembly of claim 1, wherein a constructed configuration of the box blank is rectangular shape or a square shape.
15. The box assembly of claim 14, wherein the constructed configuration is defined by 6 faces and 12 edges.
16. A corrugated box assembly with combination self-locking lid and tab-style fold over tab, the assembly comprising: a box blank having: two rectangular sidewalls defined by a pair of rectangular lateral edges, a rectangular top edge, and a rectangular bottom edge; two square sidewalls defined by a pair of square lateral edges, a square top edge, a square bottom edge, the rectangular and square sidewalls joining at the lateral edges in an alternating arrangement to form an enclosed region defined by a rectangular cross section and four parallel outer edges, the square sidewalls further being defined by at least one grab hole; at least one elongated, L-shaped fold over tab, the fold over tab being longitudinally attached along the parallel outer edges, one side of the fold over tab comprising an adhesive; at least one elongated, L-shaped fold over tab longitudinally attached along the rectangular lateral edges of at least one of the rectangular sidewalls, fold over tab comprising an adhesive, whereby fold over tab folds along the parallel outer edges of constructed box assembly; two die-cut top rectangular flaps hingedly connected by a top score line along the top edge of the rectangular sidewalls, the top rectangular flaps forming a pair of top locking slots, each top rectangular flap comprising two top stacking tabs, the top stacking tabs extendable from the top rectangular flaps; two die-cut bottom rectangular flaps hingedly connected by bottom score lines along the bottom edge of the rectangular sidewalls, each bottom rectangular flap forming two bottom locking slots, each bottom rectangular flap forming two bottom stacking holes, the bottom stacking holes adapted to intimately receive the top stacking tabs of the top rectangular flaps, whereby the top stacking tabs engage the bottom stacking holes to help stabilize stacking multiple box assemblies, the two bottom rectangular flaps forming at least one air hole; two die-cut top square flaps hingedly connected by the top score line along the top edge of the square sidewalls, the top square flaps forming a pair of top locking tongues defined by a heel portion, the top locking tongues adapted to lock under the corresponding and adjacent top locking slots that form in the top rectangular flaps, the two bottom square flaps forming the at least one air hole; and two die-cut bottom square flaps hingedly connected by the bottom score line along the bottom edge of the square sidewalls, each bottom square flap comprising two bottom locking tongues, the bottom locking tongues adapted to lock under the corresponding and adjacent bottom locking slots that form in the bottom rectangular flaps, each bottom square flap forming two end stacking holes adapted to receive the top locking tongues, the bottom square flaps forming a bottom score line.
17. The box assembly of claim 16, wherein the box blank is defined by a cardboard or a plastic material.
18. The box assembly of claim 16, wherein a constructed configuration of the box blank is rectangular shape or a square shape.
19. The box assembly of claim 16, wherein the rectangular lateral edges are narrow and elongated.
20. A method for constructing a corrugated box assembly with combination self-locking lid and tab-style fold over tab, the method comprising: providing a generally flat box blank, the box blank having: two rectangular sidewalls; two square sidewalls; four corner sidewalls, whereby the rectangular and square sidewalls joining at the lateral edges in an alternating arrangement to form an enclosed region defined by a rectangular cross section and four parallel outer edges; at least one elongated, L-shaped fold over tab, one side of the fold over tab comprising an adhesive; two die-cut top rectangular flaps hingedly connected by a top score line along the top edge of the rectangular sidewalls; two die-cut top square flaps hingedly connected by the top score line along the top edge of the square sidewalls; two die-cut bottom square flaps hingedly connected by the bottom score line along the bottom edge of the square sidewalls; folding the rectangular sidewalls towards each other, whereby the box assembly is partially formed; folding the square sidewalls towards each other, whereby the lateral edges of the rectangular and square sidewalls engage; folding the fold over tab along the parallel lateral edges of the partially formed box assembly, whereby the adhesive helping to fasten the sidewalls together; folding the bottom rectangular flaps and the bottom square flaps inwardly; interlocking a bottom locking tongue from the bottom square flap with a corresponding and adjacent bottom locking slots from the bottom rectangular flap; filling an enclosed region of the box assembly with an object; folding the top rectangular flaps and the top square flaps inwardly; interlocking a top locking tongue from the top square flap with a corresponding and adjacent top locking slots from the top rectangular flap, whereby the box assembly is fully constructed and defined by six faces and twelve edges; and stacking multiple box assemblies, whereby a top stacking tabs intimately engage a bottom stacking hole in the sidewalls and flaps.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0030]
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[0038]
[0039] Like reference numerals refer to like parts throughout the various views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word exemplary or illustrative means serving as an example, instance, or illustration. Any implementation described herein as exemplary or illustrative is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms upper, lower, left, rear, right, front, vertical, horizontal, and derivatives thereof shall relate to the invention as oriented in
[0041] A corrugated box assembly 100 with combination self-locking lid and tab-style fold over tab is referenced in
[0042] As referenced in
[0043] However in other embodiments, the box assembly may form, without limitation, a hexagonal shape, a cube shape, a pyramid shape, a cylindrical shape. In any shape however, the self-locking lid and tab-style fold over tab 140 is utilized.
[0044] In some embodiments, box assembly 100 may include a plastic or cardboard corrugated container that assembles to a generally polyhedron-shaped box, and that can be easily folded from a collapsed, flat sheet to an operational, three-dimensional container that is defined by 6 faces and 12 edges.
[0045] The method 900 for assembly of box assembly 100 is relatively straight forward, as the sidewalls and flaps are folded inwardly to join at locking slots and tongues that interlock in intimate engagement to create a generally rectangular, upright box. Additionally, stacking tabs help stabilize stacking of multiple box assemblies. Further, the box assembly 100 can better support vertical and lateral loads, such as are present when many like boxes are stacked in a column, making box ideal for packaging and shipping heavy objects, fragile goods, and easily damaged produce, for example. And, as described above, box collapses to a flat box blank 102 when not operational for facilitated stowage and transporting.
[0046]
[0047] Turning now to
[0048] In some embodiments, grab hole 142a-b that forms in square sidewalls 112a-b provides a surface area for gripping and carrying box. Grab hole 142a-b may have a curved shape that fits the hand. In one embodiment, square sidewalls 112a-b are disposed in a spaced-apart, parallel relationship from each other, and in a generally perpendicular relationship to rectangular sidewalls 104a-b. In one non-limiting embodiment, square sidewalls 112a-b have a length of about 11 11/16, and a width of about 11.
[0049] Box assembly 100 provides a unique sidewall construction that utilizes two different dimensions of sidewalls arranged in a generally rectangular shape with fold over tabs, which adds strength to the vertices and corners of box assembly 100. This helps reduce the need for fastening mechanisms, such as metallic staples and cloth tape to reinforce the vertices and corners of the box assembly 100.
[0050] In addition, box assembly provides a fold over tab 140 that is configured to help create a box assembly 100 with greater vertical and lateral support (
[0051] In one embodiment, fold over tab 140 is configured to fold over an outer corner edge of box assembly, extending longitudinally along the outer lateral edge of the constructed box assembly. The adhesive 158 on fold over tab serves to fasten the sidewalls of the box assembly together. Fold over tab 140 also creates an outer bulge that helps in separating multiple box assemblies stacked into each other. In one non-limiting embodiment, fold over tab 140 has a width of about 1.
[0052]
[0053] Top rectangular flaps form a pair of top locking slots 124a, 124b, 124c, 124d utilized to intimately engage correlating top locking tongues 132a-d in the top square flaps 130a-b to construct the top portion of box assembly 100. The tongue and slot form an intimate relationship, where the tongue slides into the slot and remains affixed due to frictional forces and the weight of box assembly 100 and contents therein. This works to close the top of box assembly 100.
[0054] The interlocking slots 124a-d and tongues 132a-d also prevent tucking, as the flaps can be more easily accessed, and the packer does not have to put hands into the interior of the box to engage and disengage the flaps to a closed or open position. The flaps are easily accessed from the outside of the box assembly 100. In one non-limiting embodiment, top flaps have a width of about 4, and bottom flaps have a width of about 5.
[0055]
[0056] Looking now at
[0057] This unique interlocking mechanism serves to significantly increase the strength of box assembly 100 when fully assembled and closed. The interlocking mechanism also works to provide additional rigidity to sidewalls on each of the corners when the box assembly 100 is fully assembled, without utilizing additional support means.
[0058] Looking now at a bottom view of box assembly 100 in
[0059] In one non-limiting embodiment, the two bottom rectangular flaps 126a-b and the two bottom square flaps 136a, 136b form at least one air hole 144a, 144b, 144c, 144d, 144e, 144f, 144g, 144h. Air hole 144a-h can be useful for storing produce and other perishable items. Air holes may have circular, rectangular, elongated, ovular, or irregular shapes.
[0060] Looking back at
[0061] As
[0062] Further, as
[0063]
[0064] In some embodiments, method 900 may include an initial Step 902 of providing a generally flat box blank, the box blank having: two rectangular sidewalls; two square sidewalls; four corner sidewalls, whereby the rectangular and square sidewalls joining at the lateral edges in an alternating arrangement to form an enclosed region defined by a rectangular cross section and four parallel outer edges; at least one elongated, L-shaped fold over tab, the fold over tab being longitudinally attached along the parallel outer edges; two die-cut top rectangular flaps hingedly connected by a top score line along the top edge of the rectangular sidewalls; two die-cut top square flaps hingedly connected by the top score line along the top edge of the square sidewalls; and two die-cut bottom square flaps hingedly connected by the bottom score line along the bottom edge of the square sidewalls.
[0065] Method 900 further comprises a Step 904 of folding the rectangular sidewalls towards each other, whereby the box assembly is partially formed. The sidewalls may fold along an indented crease or score line forming in the box blank. A Step 906 includes folding the square sidewalls towards each other, whereby the lateral edges of the rectangular and square sidewalls engage. A rectangular cross section forms at this point.
[0066] In some embodiments, a Step 908 comprises folding the fold over tab along the parallel lateral edges of the partially formed box assembly, whereby the adhesive helping to fasten the sidewalls together. The fold over tab is folded to extend longitudinally along the outer lateral edge of the constructed box assembly. The adhesive on the fold over tab, which may include glue, staples, a weld, and the like, serves to fasten the sidewalls of the box assembly together. The fold over tab also creates an outer bulge that helps in separating multiple box assemblies stacked into each other.
[0067] In some embodiments, a Step 910 may include folding the bottom rectangular flaps and the bottom square flaps inwardly. The bottom flaps come together to form a bottom portion of the box assembly. A Step 912 includes interlocking a bottom locking tongue from the bottom square flap with a corresponding and adjacent bottom locking slots from the bottom rectangular flap. The tongue and slot form an intimate relationship, where the tongue slides into the slot and remains affixed due to frictional forces and the weight of the box assembly and contents therein. In some embodiments, a Step 914 may include filling an enclosed region of the box assembly with an object.
[0068] In some embodiments, a Step 916 comprises folding the top rectangular flaps and the top square flaps inwardly. Method 900 may further comprise a Step 918 of interlocking a top locking tongue from the top square flap with a corresponding and adjacent top locking slots from the top rectangular flap, whereby the box assembly 100 is fully constructed and defined by six faces and twelve edges. A final Step 920 includes stacking multiple box assemblies, whereby a top stacking tabs intimately engage a bottom stacking hole in the sidewalls and flaps. This is effective in supporting boxes stacked on their flaps. However, when box assemblies are stacked into each other, fold over tab 140, which extends along the outer corner edge of assembled box, creates a bulge in the stacked boxes that allows for easy separation.
[0069] Although the process-flow diagrams show a specific order of executing the process steps, the order of executing the steps may be changed relative to the order shown in certain embodiments. Also, two or more blocks shown in succession may be executed concurrently or with partial concurrence in some embodiments. Certain steps may also be omitted from the process-flow diagrams for the sake of brevity. In some embodiments, some or all the process steps shown in the process-flow diagrams can be combined into a single process.
[0070] These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings.
[0071] Because many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalence.