BOX INSERT AND CORRESPONDING BOX ASSEMBLY

Abstract

The present invention relates to a box insert and a box system that uses said box insert. The box insert may have an insert bottom and four insert side walls extending from the insert bottom. A flap may extend from each insert side wall. Each flap may have a first panel connected to its respective insert side wall by a first score line, a second panel connected to the first panel by a second score line, and a third panel connected to the second panel by a second score line. The box insert may be configured inside of a box whereby one of the score lines of each flap is folded over a box edge to suspend the box insert inside of the box. A box lid may be configured over the box insert to help secure the box insert to the box.

Claims

1. A box insert comprising: an insert bottom; an insert opening opposite the insert bottom; an insert depth extending from the insert opening to the insert bottom; four insert side walls; four insert flaps, each flap extending from one of the four insert side walls, each flap comprising: a first panel; a second panel; a third panel; a first score line separating the first panel from its corresponding insert side wall; a second score line separating the second panel from the first panel; and a third score line separating the third panel from the second panel, wherein the box insert is placed into a box whereby the insert bottom is parallel to a bottom of said box, wherein the first score line of each flap is used to fold each flap over an edge of said box whereby the box insert is suspended inside of the box, wherein each flap extends outward from the box at a flap angle, and wherein a box lid is placed over the box and the box insert thereby reducing the flap angle and causing each flap to press against an inside of the box lid.

2. The box insert of claim 1, wherein the insert depth is increased by using the second score line of each flap to fold each flap over the edge of the box.

3. The box insert of claim 1, wherein the insert depth is increased by using the third score line of each flap to fold each flap over the edge of the box.

4. The box insert of claim 3, wherein the box comprises: a. a box opening opposite the bottom of the box; and b. a box depth extending from the box opening to the bottom of the box, wherein the insert depth is not more than 50% the box depth.

5. The box insert of claim 4, wherein the insert depth is not more than 30% the box depth.

6. The box insert of claim 5, wherein the insert depth is not more than 20% the box depth.

7. The box insert of claim 1, wherein the box insert is made of corrugated cardboard.

8. The box insert of claim 1, wherein the box is Gaylord box.

9. The box insert of claim 8, wherein the box is a standard Gaylord box.

10. A box system comprising: a. a box comprising: i. a box bottom; ii. a box opening opposite the box bottom; iii. a box depth extending from the box opening to the box bottom; iv. a box edge configured at the box opening; b. a box lid; c. a box insert comprising; i. an insert bottom; ii. an insert opening opposite the insert bottom; iii. an insert depth extending from the insert opening to the insert bottom; iv. four insert side walls; v. four insert flaps, each flap extending from one of the four insert side walls, each flap comprising: 1. a first panel; 2. a second panel; 3. a third panel; 4. a first score line separating the first panel from its corresponding insert side wall; 5. a second score line separating the second panel from the first panel; and 6. a third score line separating the third panel from the second panel, wherein the box insert is placed into the box via the box opening whereby the insert bottom is parallel to the box bottom, wherein the first score line of each flap is used to fold each flap over the box edge whereby the box insert is suspended inside of the box, wherein each flap extends outward from the box at a flap angle, and wherein the box lid is placed over the box and the box insert thereby reducing the flap angle and causing each flap to press against an inside of the box lid.

11. The box system of claim 10, wherein the insert depth is increased by using the second score line of each flap to fold each flap over the edge of the box.

12. The box insert of claim 10, wherein the insert depth is increased by using the third score line of each flap to fold each flap over the edge of the box.

13. The box insert of claim 12, wherein the insert depth is not more than 50% the box depth.

14. The box insert of claim 13, wherein the insert depth is not more than 30% the box depth.

15. The box insert of claim 14, wherein the insert depth is not more than 20% the box depth.

16. The box insert of claim 10 wherein the box, box lid, and box insert are made of corrugated cardboard.

17. The box insert of claim 10, wherein the box is Gaylord box.

18. The box insert of claim 17, wherein the box is a standard Gaylord box.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0014] FIG. 1 shows a top front perspective view of a box insert of a box system.

[0015] FIG. 2 shows a front cross-section view of a box system with a box insert folded along a first score line.

[0016] FIG. 3 shows a front cross-section view of a box system with a box insert folded along a second score line.

[0017] FIG. 4 shows a front cross-section view of a box system with a lid placed over a box and box insert.

DETAILED DESCRIPTION

[0018] The description provided herein describes example embodiments of the present invention and is not intended to limit the invention to any particular embodiment, features, components, shape, size, design, material, or any other property. Furthermore, the drawings provided herein show example embodiments of the present invention and are not intended to limit the invention to any particular embodiment, features, components, shape, size, design, material, or any other property.

[0019] As shown in FIG. 1, a box insert 40 of a box system 10 has an insert bottom 42 and an insert opening 44 opposite the insert bottom 42. Four insert side walls 48 extend an insert depth 46 from the insert bottom 42 to the insert opening 44. Four flaps 50 extend from the four insert side walls 48 whereby one flap 50 extends from each insert side wall 48. Due to the view of FIG. 1, only two flaps 50 are shown. Each flap 50 has a first panel 51, a second panel 52, and a third panel 53. The first panel 51 of each flap 50 is separated from its respective insert side wall 48 by a first score line 61. The second panel 52 of each flap 50 is separated from the first panel 51 by a second score line 62. The third panel 53 of each flap 50 is separated from the second panel 52 by a third score line 63. As shown in FIG. 1, each panel 50 is folded along its first score line 61 whereby the first score line 61 of each panel is adjacent to the insert opening 44.

[0020] As shown in FIG. 2, a box system 10 has a box 20 with a box bottom 22 and a box opening 24 opposite the box bottom 22. A box edge 28 is adjacent to the box opening 24. A box depth 26 extends from the box bottom 22 to the box opening 24, which means that the box depth 26 also extends from the box bottom 22 to the box edge 28. A box insert 40 is configured within the box 20 whereby the first score line 61 of each flap 50 of the box insert 40 is folded along the box edge 28. Each flap 50 extends from the box 20 at a flap angle 56. Since each flap 50 is folded along its first score line 61; the first panel 51, second panel 52, and third panel 53 of each flap 50 extend from the box 20 at the flap angle 56. The insert depth 46 extends from the first score line 61 of each flap 50 down into the box 20 to the insert bottom 42. In this configuration, an item 70 may be configured on the insert bottom 42 whereby the item 70 is suspended above the box bottom 22.

[0021] As shown in FIG. 3, each flap 50 of the box insert 40 is folded along its second score line 62 whereby the first panel 51 of each flap 50 is configured to be part of its respective insert side wall 48. In this configuration, the second score line 62 of each flap 50 is folded along the box edge 28 and is configured adjacent to the insert opening 44. This causes the insert 40 to sit lower inside of the box 20, thereby increasing the insert depth. This causes the item 70 to be suspended closer to the box bottom 22. The second panel 52 and third panel 53 of each flap 50 extend from the box 20 at a flap angle 56. The flap angle shown in FIG. 2 is larger than the flap angle shown in FIG. 1 due to the fact that the flaps in FIG. 1 are longer than the flaps in FIG. 2. This is because the flaps shown in FIG. 1 are each made of three panels rather than two. Therefore, the flaps shown in FIG. 1 weigh more than the flaps shown in FIG. 2, and therefore have a greater force pulling them downwards, thereby decreasing the flap angle between the flaps and the box.

[0022] As shown in FIG. 4, a box lid 30 is configured over the box 20 and box insert 40 whereby an inside 32 of the box lid 30 contacts the box insert 40. Similar to the configuration shown in FIG. 3, each flap 50 shown in FIG. 4 is folded along its second score line 62 whereby the second score line 62 of each flap 50 is folded along the box edge 28. Each flap 50 extends from the box 20 at a flap angle 56. The flap angle shown in FIG. 4 is less than the flap angle shown in FIG. 3 since the box lid 30 of FIG. 4 pushes the flaps 50 towards the box 20. The box lid 30 may push the flaps towards the box 20 so that the flaps 50 contact the box 20.