Note: Descriptions are shown in the official language in which they were submitted.
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CA 02621029 2008-12-29
SHIRT BOX
Technical Field
The present invention relates to retail packaging and in particular, to a
shirt box for
displaying a shirt in an assembled state and being constructed to fold flat to
permit easy
bundling and shipping of a number of boxes.
Background
In the retail sale of dress shirts and dress shirts and tie combinations, it
is desirable
to present the merchandise i.n a manner that permits potential customers to
have a good look
at the product. On the other hand, it is important for retailers to keep the
product clean and
free of any soil or stains that may result from handling, to protect against
theft, and to
maintain the shirts in an orderly and well-folded condition so that their
displays remains
attractive to passers by.
It is also desirable that the packaging that is used be economical to
manufacturer,
that it be made from a recyclable material, and that it be made with minimal
waste.
1
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WO 2007/030579 PCT/US2006/034793
It is also desirable to have a packaging that addresses the foregoing needs
and which
permits shirts to be stacked in great number to promote efficient shelf and
display space
usage.
The present invention satisfies these and other needs.
Summary
In accordance with one aspect of the present invention, a combination of
clothing
articles and a substantially transparent box is constructed and arranged to
include a collared
shirt, a necktie supported by the shirt, and a single sheet of substantially
transparent plastic
having a series of first panels each defined by a respective fold in a series
of first folds and
a set of second panels each defmed by a respective fold in a set of second
folds in the
plastic sheet. A bond permanently connects one of the first panels to another
of the first
panels so as to define a hollow central cavity for the box. The hollow cavity
is sized to
receive the shirt and necktie. The second panels are folded to defme first and
second
peripheral ends of the box. The plastic sheet comprising the box includes a
hole positioned
relative to the clothing articles such that the outline of the hole overlies a
portion of the
articles.
In a further aspect, the invention includes the combination as described above
having the necktie folded intermediate its ends and seated relative to the
folded shirt by an
elastic band which passes transversely to a length of necktie, within the
fold. The band can
coinprise a loop and can be sized to be stretchably received about the shirt
collar.
Optionally, a clip can engage with the fabric of the necktie proximate to the
fold to pinch
the fabric and thereby emulate the appearance of a tie knot.
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WO 2007/030579 PCT/US2006/034793
In a still further aspect, the invention as described above can include a band
or loop
disposed about the folded shirt, and a channel adjacent the loop. The necktie
can be
disposed within the channel.
In yet another aspect, the invention as described above has the bond
connecting the
first panels defined by a plurality of individual bond sites which are
intermittently spaced
apart. Optionally, the individual bond sites can be arranged in at least one
line.
In still another aspect, the invention as defined above can further have
double-sided
tape members with opposing sides in adhesive contact with respective second
panels to
permit ready closing of the box once filled with' a shirt and tie.
In accordance with one aspect of the present invention, a combination of
clothing
articles and a substantially transparent box is constructed and arranged to
include a collared
shirt, a necktie supported by the shirt, and a single sheet of substantially
transparent plastic
having a series of first panels each defined by a respective fold in a series
of first folds and
a set of second panels each defined by a respective fold in a set of second
folds in the
plastic sheet. A bond permanently connects one of the first panels to another
of the first
panels so as to defme a hollow central cavity for the box. The hollow cavity
is sized to
receive the shirt and necktie. The second panels are folded to define first
and second
peripheral ends of the box. The plastic sheet comprising the box includes a
hole positioned
relative to the clothing articles such that the outline of the hole overlies a
portion of the
articles.
In a further aspect, the invention includes the combination as described above
having the necktie folded intermediate its ends and seated relative to the
folded shirt by an
elastic band which passes transversely to a length of necktie, within the
fold. The band can
comprise a loop and can be sized to be stretchably received about the shirt
collar.
3
CA 02621029 2008-02-29
WO 2007/030579 PCT/US2006/034793
Optionally, a clip can engage with the fabric of the necktie proximate to the
fold to pinch
the fabric and thereby emulate the appearance of a tie knot.
In a still further aspect, the invention as described above can include a band
or loop
disposed about the folded shirt, and a channel adjacent the loop. The necktie
can be
disposed within the channel.
In yet another aspect, the invention as described above has the bond
connecting the
first panels defined by a plurality of individual bond sites which are
intermittently spaced
apart. Optionally, the individuaf bond sites can be arranged in at least one
line.
In still another aspect, the invention as defined above can further have
double-sided
tape members with opposing sides in adhesive contact with respective second
panels to
permit ready closing of the box once filled with a shirt and tie.
A shirt box suitable for receiving one or more shirts includes a single sheet
of
substantially transparent plastic that has a plurality of fold lines formed
therein including a
first set of generally parallel fold lines and a second set of generally
parallel fold lines. The
box includes a series of first panels, each being separated from a next panel
in the series by
a respective fold line in the first set of fold lines. The first panels are
foldable along the
respective fold lines in a first direction to define a hollow central cavity
for the shirt box.
The box also includes a set of second panels each having a boundary along a
respective fold
line in the second set of fold lines to a respective first panel. The second
panels are
foldable along the respective fold lines in a second direction which is
substantially
perpendicular to the first direction to define first and second peripheral
ends of the shirt box.
In this embodiment, the box includes first and second fastening panels that
are part
of the set of first panels are attached to another along a fastening region to
connect the set
of first panels in series and define the central cavity. The shirt box has a
collapsible
4
CA 02621029 2009-02-25
(collapsed) state in which the sides of the collapsed box are defined by first
and second fold
lines that are part of the first set of fold lines and in the fully assembled
(closed) state, the
box has a substantially trapezoidal shape the sides of which are defined by a
third fold line
that is different from the first fold line and a fourth fold line that is
different from the
second fold line.
In particular, the present invention is directed, in one aspect, to a method
for packaging a necktie and shirt combination, comprising the steps of:
providing a
shirt having a shirt collar; providing a necktie comprising a length of fabric
having
first and second ends; folding the necktie along a line transverse to the
length of
fabric and intermediate the first and second ends, to create at least one
fold;
positioning an elastic band within the fold; wrapping the elastic band around
the
shirt collar; and pinching the necktie at a position proximate to the fold
with a clip
with the length of the fabric between the fold and the clip being exposed.
These and other aspects, features and advantages shall be apparent from the
accompanying Drawings and description of certain embodiments of the invention.
Brief Description of the Drawings
Fig. 1 is a top plan view of a first embodiment of the invention;
Fig. 2 is a perspective view of the embodiment of Fig. 1 showing the shirt box
in a
partially folded position;
Fig. 3 is a detailed end view of the embodiment of Fig. 1 showing a securement
for
securing the box in a closed state;
Fig. 4 shows the box of Fig. 3 in the closed state;
Fig. 5 is a cross-section through lines 5-5 of Fig 4;
Fig. 6 is a top plan view of a second embodiment of the invention;
5
CA 02621029 2009-02-25
Fig. 7 is a cross-section of the second embodiment taken along the same lines
as that
of Fig. 5;
Fig. 8 shows the shirt and tie combination disposed within the box;
Fig. 9 is a front view of the shirt and tie combination;
Fig. 10 shows a clip useful in configuring the tie to appear knotted;
Fig. 11 shows an elongated body useful in holding the shirt and tie
combination in a
preferred alignment;
5a
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CA 02621029 2008-12-29
Still another aspect is directed to a combination of clothing articles
packaged
for sale comprising:
a folded shirt having a collar;
a necktie formed of a length of fabric having first and second ends, the
necktie being folded along a line transverse to a length of the fabric and
intermediate the first and second ends, to create at least one fold so as to
define a
closed end of the folded tie and creating a space between the folded tie
through
which a member can be inserted, wherein the first and second ends of the tie
point
in the same direction;
a clip engaged with the fabric proximate to the fold and between the shirt and
tie, the clip having legs and open top slot between the legs for receiving the
folded
necktie, the legs pinching the fabric so as to emulate the appearance of a tie
knot,
the clip remaining open and a pinched portion of the necktie being exposed
between the legs when the necktie is disposed therein to allow for easy
removal of
the folded necktie, wherein the closed end of the folded tie is positioned on
one
side of the clip proximate the collar and the first and second ends of the tie
are
positioned on an opposing side of the clip, the folded tie having a first
portion that
terminates in the closed end that is located on the one side of the clip and
has an
inward tapered look in a direction towards the clip, the folded tie having a
second
portion that is located on the opposing side of the clip, the second portion
having an
inward tapered look in a direction towards the clip; and
a box having at least a transparent top to permit viewing of the shirt and
necktie.
These and other aspects, features and advantages shall be apparent from the
accompanying Drawings and description of certain embodiments of the invention.
5b
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.... .. ~ .
CA 02621029 2008-12-29
Brief Description of the Drawings
Fig. 1 is a top plan view of a first embodiment of the invention;
Fig. 2 is a perspective view of the embodiment of Fig. 1 showing the shirt box
in a
partially folded position;
Fig. 3 is a detailed end view of the embodiment of Fig. 1 showing a securement
for
securing the box in a closed state;
Fig. 4 shows the box of Fig. 3 in the closed state;
Fig. 5 is a cross-section through lines 5-5 of Fig 4;
Fig. 6 is a top plan view of a second embodiment of the invention;
Fig. 7 is a cross-section of the second embodiment taken along the same lines
as that
of Fig. 5;
Fig. 8 shows the shirt and tie combination disposed within the box;
Fig. 9 is a front view of the shirt and tie combination;
Fig. 10 shows a clip useful in configuring the tie to appear knotted;
Fig. 11 shows an elongated body useful in holding the shirt and tie
combination in a
preferred alignment;
5c
CA 02621029 2008-02-29
WO 2007/030579 PCT/US2006/034793
Fig. 12 shows the elongated body being folded;
Fig. 13 shows the elongated body in a folded state and disposed around the
shirt;
Fig. 14 shows a second embodiment of the elongated body in a folded state and
disposed around the shirt;
Fig. 15 is a top plan view of a third embodiment of the invention in an
unfolded
substrate form;
Fig. 16 is a partial top plan view of the embodiment of Fig. 15 showing the
box in a
partially folded collapsed state;
Fig. 17 is perspective view of one end of the embodiment of Fig. 15 in a first
partially folded state;
Fig. 18 is a perspective view of one end of the embodiment of Fig. 15 in a
second
partially folded state;
Fig. 19 is a perspective view of one end of the embodiment of Fig. 15 in a
closed
state showing securement of an end panel;
Fig. 20 is a perspective view of the box of the embodiment of Fig. 15 in the
closed
state with a pair of shirts contained therein;
Fig. 21 is a top plan view of the. box of Fig. 15 with a tuxedo arrangement
contained therein;
Fig. 22 is a bottom plan view of the embodiment of Fig. 21;
Fig. 23 is an exploded top perspective view of a shirt box according to
embodiment
of the present invention;
Fig. 24 is a cross-sectional view of the shirt box of Fig. 23 in a fully
assembled
state;
6
CA 02621029 2008-02-29
WO 2007/030579 PCT/US2006/034793
Fig. 25 is a partial rear plan view of the shirt box of Fig. 23 with a box
cover being
moved to a rear position; and
Fig. 26 is cross-sectional taken along the line 26-26 of Fig. 25.
Detailed Description of Certain Embodiments of the Invention
Referring to Fig. 1, a shirt box container 10 includes a substrate 20 in the
form of a
transparent plastic sheet having fold lines generally designated Fl and F2.
The fold lines
Fl are generally parallel and preferably are parallel to one another. The fold
lines F2 are
also generally parallel and preferably are parallel to one another. The fold
lines Fl, F2
define boundaries of respective panels of the substrate 20. A series of first
panels 30 all
fold in a first direction and include panels 32, 34, and 36. Each of the
panels in the series
30 is disposed adjacent another panel in the series and is separated from a
next panel by one
of the fold lines F l.
As shown in Fig. 2, the first series of panels 30 is foldable along the fold
lines
Flalong a common, parallel direction to defme a hollow central cavity for the
shirt box.
Referring now to Figs. 1 and 2, a set of second panels 40 have a boundary
along the
fold lines F2 to respective panels in the first series 30. Thus, panels 42 are
bounded along
one margin at the fold lines F2 to panel 34 and flaps 44 are bounded along
fold lines F2 to
panels 32. In the embodiment of Fig. 1, the second set of panels 40 further
includes end
flaps 46 which fold about fold line F2 and which are joined to a free end of
panels 42.
Each of the panels 42 and 44 has a free end, opposite its bounded end and each
is adjacent
to a notch 50, which separate a portion of the panels 42, 44 from the
remainder of the
substrate 20. As can be appreciated from Fig. 2, the panels in the second set
40 are
foldable along their respective fold lines F2 in a direction which is
substantially
7
CA 02621029 2008-02-29
WO 2007/030579 PCT/US2006/034793
perpendicular to the direction of fold lines Fl. In folding the second set of
panels 40,
peripheral ends of the shirt box 10 are defined.
The notches 50 are generally oriented to extend in the same direction as the
fold
lines F 1, and preferably are axially aligned with the fold lines F 1.
In accordance with a salient aspect of the present invention, the shirt box 10
can be
configured in a partially assembled state in which a hollow central cavity for
containing a
shirt or a shirt and tie combination is defined, yet which is collapsible into
a generally flat
state until such time that a shirt (or a shirt and tie combination) is to be
inserted into the box.
When the shirt box 10 is to be filled, it is brought to an uncollapsed state,
the shirt is
introduced into the hollow cavity, and the peripheral ends of the shirt box
are bonded so as
to define a substantially rectangular and sealed shirt box construction.
With further reference to Figs. 1 and 2, a securement 50 extends along an
inner
margin of the panel 36 for permanently connecting pane136 to another panel in
the series,
preferably one of the panels 32. As shown in Fig. 3, the securement 50
comprises a bond
(e.g., thermal or adhesive) which is made between panels 36 and 32 so as
permanently
connect those panels and secure the shirt box 10 in a rectangular
configuration. The bonds
preferably comprise a contact cement; however, the bond can comprise other
generally
permanent connections as understood by those skilled in the art. Preferably,
the bond is
"permanent" in that it is of such character that it is not readily opened by a
consumer, and
yet is sufficiently strong to permit the box to be collapsed laterally, so
that the panels of the
first series 30 can be folded along fold lines Fl to define the shirt cavity
while the
peripheral ends remain unattached to thereby permit the shirt box to assume a
flat condition.
Optionally, the bond includes a series of individual bond sites intermittently
spaced
apart and arranged (e.g. linearly, evenly spaced, or both) along the length of
pane132 to
8
CA 02621029 2008-02-29
WO 2007/030579 PCT/US2006/034793
define the securement. Each such bond site can be formed by applying heat and
pressure
such that the panels are adhered to one another. The resulting bond site can
be indented on
one side and bulged on the opposite side. Each individual bond site can
therefore have the
appearance of the two panels having been crimped together.
The shirt box 10 further includes a first and second double sided tape member
60
having a first side in adhesive contact with a respective panel in the second
set of panels 40.
As illustrated in Figs. 1-3, the double-sided tape meinber is disposed on end
panel 42. A
second side of the double-sided tape meinber 60 includes a removable strip 62
(best seen in
Fig. 3) which overlies the second side of the tape member 60. The removable
strip
maintains the second side of the tape member 60 free of tackiness so that
shirt boxes 10 can
be stacked in a collapsed state without sticking to one another. However, the
removable
strip 62 can be separated from the second side of the tape member 60 by
releasing it in the
direction of arrow A so as to expose an adhesive surface which permits
engagement of one
pane142 with another pane142 (see Fig. 4). Once the panels 42 have been
adhesively
joined by the tape member 60, the shirt box 10 is in the second state in which
the hollow
central cavity is sized to receive the shirt or shirt and tie combination.
Preferably, the material of the substrate has a thickness so that, in
combination with
the fold lines Fl and F2, a stable, second state results in which the shirt
boxes 10 can be
stacked in great number, one upon another, to promote efficient shelf and
display space
usage.
In order to facilitate folding of the shirt box, in a preferred form, the end
panels 46
have chamfered corners adjacent their respective free ends. The chamfered
corners reduce
interference of one panel member with another as the box is folded.
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CA 02621029 2008-02-29
WO 2007/030579 PCT/US2006/034793
As illustrated in Figs. 1-4, it is preferred that the panels in the second set
40 extend
symmetrically from the margins of the panels in the first series 30.
Fig. 5 is a cross-sectional view through the folded box in accordance with
first the
embodiment described above. Fig. 5 shows the relative relationship of the
different panels
with the shirt box 10 in the fully folded configuration.
Referring now to Fig. 6, a second embodiment of shirt box 10' is illustrated
in
which like reference numbers are used to refer to corresponding features. In
relevant part,
the second embodiment differs from the first embodiment in that it has been
specially
configured in order to minimize waste material as the substrate 20 is stamped
from a web
of material by providing an overall rectangular configuration free of cut-
outs. As in the
first embodiment, it is preferred that a single sheet of substantially
transparent plastic is
used to define the panels of the shirt box 10'; however, in order to minimize
waste material,
the end flaps 46 have been eliminated, and new flaps 48a and 48b are included
in the
second set of panels 40. The flaps 48A, 48B are folded about fold line F2 when
the
substrate 20 is folded to define the shirt box 10' . Thus, as shown in Fig. 7,
the folded shirt
box lacks the end panel 46, so the top and bottom margins of the folded box
have the same
thickness throughout the length of the shirt box. The additional flap 48a is
accommodated
within the folded box , as illustrated in Fig. 7.
The fold lines Fl and F2 can be continuous or discontinuous, but preferably
are
continuous and inore preferably comprise score lines in the substrate 10.
Depending on the
material chosen for the substrate, fold lines can be defined by material at
locations that are
axially aligned with the notches 50. Also, at least one of the notches 50
preferably has a
depth (that is, in a direction parallel to the axis of the fold lines F1)
which is equal to the
CA 02621029 2008-02-29
WO 2007/030579 PCT/US2006/034793
width of the flaps 44. By so-constructing at least some of the notches 50, a
substantially
rectangular shirt box 10, 10' can result.
Referring to Fig. 8, a shirt and tie combination 80 is disposed within the
hollow
central cavity of shirt box 10. Preferably, shirt box 10 is formed with a hole
90 in one of
the panels that forms the box. Hole 90 is positioned such that the outline of
the hole
overlies a portion of the shirt and tie combination 80. This arrangement
provides access to
the garments inside the shirt box 10 so that consumers can touch and feel the
garments yet
does not compromise the structural integrity of the box 10.
Fig. 9 is a front view of the shirt and tie combination 80. The shirt 100 is
preferably folded as shown. The shirt 100 includes a collar 101. A necktie 102
is located
proximate to the collar. The necktie essentially comprises a length of fabric.
It may be any
suitable fabric such as silk. The necktie may also comprise a combination of
fabrics. The
fabric of the necktie generally extends in the vertical direction (along line
A-A') as shown
in Fig. 9. The necktie has a first end 104 and a second end 105.
The necktie 102 is folded between the first and second ends to create a fold
103.
The fold is horizontal in Fig. 9, thus being in a direction transverse to that
of the fabric of
the necktie (namely, transverse to line A-A'). An elastic band 106 is placed
within the fold,
or within at least one of the several folds if several are present. The
elastic band 106 is
preferably manufactured from rubber, but may be manufactured from an elastic
fabric, or a
flexible elastic plastic material. The elastic band 106 passes through the
fold in a generally
horizontal direction, i.e. direction transverse to that in which the necktie
extends. The
elastic end is resiliently stretched upward and preferably around the collar
101. Preferably,
the elastic band comprises a loop which is slightly shorter than the
circumference of the
collar, thus necessitating it to be stretched when wrapped around the collar.
11
CA 02621029 2009-02-25
A clip 107 is placed on the necktie in a position proximate to the fold. The
clip 107
is preferably placed about 1-1.5 inches below the fold. The clip pinches the
necktie in
order to create the appearance of a knot, as shown in Fig. 9. If a knot is
already present,
the clip is not required. As can be seen in Fig 10, the clip 107 is preferably
U-shaped.
Additional details concerning the arrangement of the necktie, elastic band
and clip are disclosed in the currently co-pending U.S. Patent Application
Publications No. US 2005/0160515 of Kim, filed January 23, 2004.
Referring to Figs. 11 and 12, an elongated body 200 is shown in Fig. 11 in an
unfolded state and in Fig. 12 being brought to the folded state. The elongated
body has
first and second ends 201 and 202, and first and second attachment points 203
and 204
intermediate of the ends but positioned, as will be apparent, to secure the
body in a closed-
loop configuration while simultaneously defining a channel for receiving a
necktie. The
end 202 is brought into engagement with attachment point 203 whereas end 201
is brought
into engagement with attachment point 202.
The elongated body 200 is used in conjunction with the shirt (100 in Fig. 13 )
with
the necktie tie (102 in Fig. 12 ) attached to the shirt. When folded, the
elongated body can
be made to wrap around the shirt, as shown in Fig. 13.
Fig. 13 shows an end view of the elongated body 200 wrapped around a folded
shirt
100. There it can be seen that when end 201 is connected to attachment point
204 and when
end 202 is connected to attachment point 203, a channel 300, suitable for the
insertion of
the tie 102 therein, is defined. When the elongated body 200 is plastic, these
attachment
joints may be defined by cooperation of a lock-tab and a lock-joint, as
disclosed in the
12
. .. .~: . ...... .. .. . ... . .. . .. .. . . . . . ........ ... . ~ .. . ...
.. .... . .,... . .
CA 02621029 2009-02-25
currently co-pending U.S. Patent Application Publications No. US 2006/0010560
of
Kim, filed June 23, 2005, or by any other method,
12a
CA 02621029 2008-02-29
WO 2007/030579 PCT/US2006/034793
such as, for example, the use of glue, tape, staples, heat-seal, sewing, etc.
Sewing is a
particularly preferred approach for achieving the engagement at the attachment
points then
when the elongated body 200 is made from fabric.
A second embodiment the elongated body of the present invention is depicted in
Fig.
14. In this embodiment an elongated body 400 is used. The elongated body is
made to form
a main loop by attaching its ends 401 and 402. The main loop is suitable for
the placement
of a folded shirt 100 tlierein. An additional wa11405, composed, preferably of
the same
material as the elongated body 400, is attached to the elongated body 400 at
two attachment
points 403 and 404. A channel 406 is formed between the elongated body 400,
the wa11405
and the attachment points 403 and 404 using any of the foregoing attachment
methods noted
above. The channe1406 is suitable for the placement of a tie therein.
Additional reference
concerning the use of an elongated body in connection with a shirt and tie is
disclosed in
U.S. Patent No. 6,901,636, to Kim, issued June 7, 2005.
Referring to Figs. 15-20, a shirt box container 500 is made from a substrate
510 in
the form of a transparent plastic sheet having a series of fold lines
generally designated F1
and F2. The fold lines F1 are generally parallel and preferably are parallel
to one another
and can be characterized as being vertical fold lines that run from one end of
the container
to the opposite other end. The fold lines F2 are also generally parallel and
preferably are
parallel to one another and can be characterized as being horizontal fold
lines. The fold
lines Fl, F2 define boundaries of respective panels of the substrate 510.
More specifically, the substrate 510 is divided into a number of different
panels that
define particular segments or regions of the substrate 510. A series of first
panels 512 all
fold in a first direction and include panels 520, 522, 524, and 526. Each of
these panels
520, 522, 524, 526 is disposed adjacent another panel in the series and is
separated from a
13
CA 02621029 2008-02-29
WO 2007/030579 PCT/US2006/034793
next panel by one of the fold lines Fl. As shown in Figs. 15-20, the first
series of panels
512 is foldable along the fold lines Fl along a common, parallel direction to
define a
hollow central cavity for the shirt box. Two of these panels, namely, panels
520, 524,
form a top wall (pane1524) and a bottom wall (panel 520), as well a pair of
side walls that
are defines by panels 522, 526. As shown in Fig. 20, when the box 500 is
assembled, the
box 500 has a trapezoidal shape in that it is a quadrilateral with two sides
parallel.
In the illustrated embodiment, each of the panels 520, 524 has a generally
rectangular shape and the widths of the panels 520, 524 are preferably equal.
In addition,
the panels 522, 526 also have a generally rectangular shape, with the panel
522 being
disposed between the panels 520, 524 and the panel 526 being formed on the
other side of
the panel 524. The panels 522, 526 have widths that are preferably equal to
one another
but are less than the width of the panels 520, 524.
Referring now to Fig. 15, the second series of panels 514 includes a pair of
end
panels 530 that have a boundary along the fold lines F2 to the panel 520. The
end panel
530 is defined by two parallel edges 532, one of which defines the fold line
F2, and a first
end edge 534 that is perpendicular to edges 532 and a beveled end edge 536
that is formed
at an angle to the edges 532. The end edge 536 is formed at an angle other
than 90 degrees
and therefore it is not parallel to the first end edge 534. The outer edge 534
has a greater
width than the inner edge 534 as illustrated.
On one side of each end panel 530, a flap 560 is provided. The flaps 560 are
bounded along one margin at the fold lines F2 to the panel 522. The flap 560
thus folds
about fold line F2 and is generally in the shape of a trapezoid in that it
includes two non-
parallel side edges 562. It will be appreciated from Fig. 15, that the
distance that the flap
560 extends from fold line F2 (the inner edge of the flap) is less than the
distance that the
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end pane1530 extends from fold line F2. In other words, the outer edge of the
end panel
530 is at a greater distance from the fold line F2 than the outer edge of the
flap 560 as
illustrated.
The pane1522 is bounded at its ends by the flaps 560 and along its sides by
panel
520 and 524. In other words, the panel 522 is disposed between the panels 520
and 524
and is joined thereto along fold lines Fl.
On the other side of the panel 520 and the end panel 530, a first fastening
panel 550
is formed and includes a main section 552 that extends between fold lines F2
and thus has a
general rectangular shape and end sections 554 that extend from the fold lines
F2 to the
outer edge of the end pane1530. The end sections 554 thus extend the same
distance from
the fold lines F2 as the end panels 530; however, each end section 554 has a
generally
triangular shape, with the hypotenuse of the triangle being defined by an edge
556. The
other two sides of-the end section 554 are defined by the end edge 534 and the
edge 532
that defines the fold line F2.
A free edge 558 of the fastening panel 550 and in particular, of the panel
520,
represents a free edge that is used to construct and configure the substrate
510 into its
sealed folded construction shown in Fig. 20. This aspect will be described in
greater detail
below. The free edge 558 includes first fastening elements 551 that serve to
fasten and
securely attach the substrate 510 into its assembled but folded collapsed
state.
A pair of end panels 540 is also provided and is constructed to have a
boundary
along the fold lines F2 to the pane1524 which is located between panels 522
and 526 and is
joined thereof along fold lines Fl. The end panel 540 is defined by two
parallel edges 542,
one (inner edge) of which defines the fold line F2 and the other is an outer
edge of the end
pane1540. . The end panel 540 has a trapezoid shape and is therefore, also
defined by a pair
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of angled edges 544. The angled edges 544 are tapered inward toward the fold
line F2 so
as to cause the inner edge (the fold line F2) to have a lesser width than the
outer edge 542.
In the embodiment of Figs. 15-20, the panels 540 furtlier includes end flaps
580
which fold about fold line F2 and which are joined to the outer edges (outer
edge 542) of
the panels 540. The end flap 580 similarly has a trapezoid shape and is
defined by the edge
542 at fold line F2 and an outer edge 582, with a pair of angled edges 584
extending
between edges 542, 582. In an opposite manner relative to the end panel 540,
the end flap
580 is constructed so that the outer edge 582 has a less width than the width
of the inner
edge (F2 fold line/edge 542).
As can be seen, a slit 561 separates the flap 560 and the adjacent panel 540
and
therefore, permits folding of the flap 560. There is a gap between the other
side edge 562
of the flap 560 and the adjacent panel 530 and therefore, there is no slit
present in this
location.
As illustrated in Fig. 15, each of the panels 520, 522, 524 and 526 has a
rectangular
shape, with the width of the panels 522, 526 being less than a width of the
panels 520, 524.
The panels 520, 524 can have the same dimensions and shapes and the panels
522, 526 can
have the same dimensions and shapes.
On one side of each panel 540, a flap 570 is provided. The flaps 570 are
bounded
along one margin at the fold lines F2 to the panel 526. The flap 570 thus
folds about fold
line F2 and is generally in the shape of a trapezoid in that includes two non-
parallel side
edges 572 and an outer edge 574. It will be appreciated from Fig. 15, that the
distance that
the flap 570 extends from fold line F2 (the inner edge of the flap) is less
than the distance
that the outer edge 542 of the end panel 540 extends from fold line F2. In
other words, the
outer edge 542 of the end panel 540 is at a greater distance from the fold
l'ine F2 than the
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outer edge 574 of the flap 570 as illustrated. Preferably, the distances that
the flaps 560,
570 extend from the panels 522, 526, respectively, are equal and therefore,
the outer free
edges of the lie in the same plane.
Similar to the flap 560, the flap 570 is defined by the pair of side edges 572
that are
angled with respect to the fold lines F2 and outer edge 574, with one of the
side edges 572
being formed by a slit or cut that also defines one of the edges 542 of the
panel 540.
One the other side of the panel 526 and the flaps 570, a second fastening
panel 590
is formed and includes a main section 592 that extends between fold lines F2
and extends
from the fold line Fl. The main section 592 can generally have a trapezoid
shape and is
defined by an inner edge 594 (fold line F1), an outer edge 596 that is
parallel to the inner
edge 594 and has a lesser length, and a pair of end edges 598 that extend
between the inner
edge 594 and the outer edge 596. The edges 598 are angled relative to the
edges 594, 596.
The second fastening panel 590 is similar to and complementary to the first
fastening panel 550 with the exception that the second fastening panel 590
does not include
the end sections 554 that are present as part of the first fastening panel
550.
The outer edge 596 of the fastening panel 590 represents a free edge that is
used to
construct and configure the substrate 510 into its sealed folded construction
shown in Fig.
16. This aspect will be described in greater detail below. The free edge 596
includes
second fastening elements 591 that are complementary to the first fastening
elements 551
and serve to fasten and securely attach the substrate 510 into its assembled
but folded state
shown in Fig. 16.
As can be appreciated from Figs. 15-20, the panels 530, 540 and flaps 560,
570,
580 are foldable along their respective fold lines F2 in a direction which is
substantially
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perpendicular to the direction of fold lines F1. In folding the above panels,
peripheral ends
of the shirt box 500 are defined.
In accordance with a salient aspect of the present invention, the shirt box
500 can be
configured in a partially assembled state in which a hollow central cavity for
containing one
or more shirts or one or more shirt and tie combinations is defined, yet which
is collapsible
into a generally flat state until such time that one or more shirts (or a
shirt and tie
combination) are to be inserted into the box. When the shirt box 500 is to be
filled, it is
brought to an uncollapsed state, the shirt is introduced into the hollow
cavity, and the
peripheral ends of the shirt box are bonded so as to define a substantially
rectangular and
sealed shirt box construction.
The first and second fastening elements 551, 591 are designed to
interlockingly mate
together for permanently connecting the pane1590 to the panel 550. According
to one
embodiment and as illustrated, the fastening elements 551, 591 are in the form
of an
interlocking based structure or a crimped based structure where the two panels
550, 590 are
securely connected to one anotlier so as to form a closed box blank that and
be stored flat
prior to use. When the securement technique is an interlocking based
structure, the
elements 551, 591 when pressed together interlock with one another. The
elements 551,
591 can thus be a snap-fit based system that interlocks with one another when
mated
together.
With further reference to Figs. 15-20, the shirt box 500 can further include
first and
second double sided tape members 600 that have a first side in adhesive
contact with a
respective panel in the second set of panels. As, illustrated in Fig. 15, the
double-sided tape
member 600 is disposed on end pane1580. A second side of the double-sided tape
member
600 includes a removable strip 612 (best seen in Fig. 18) which overlies the
second side 6f
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the tape member 600. The removable strip 612 maintains the second side of the
tape
member 600 free of tackiness so that shirt boxes 500 can be stacked in a
collapsed state
without sticking to one another. However, the removable strip 612 can be
separated from
the second side of the tape member 600 by releasing it in the direction of
arrow A so as to
expose an adhesive surface which permits engagement of one pane1580 with
another panel
520 (see Figs. 18-19). Once the panels 580, 520 have been adhesively joined by
the tape
member 600, the shirt box 500 is in the state in which the hollow central
cavity is sized to
receive one or more shirts.
Preferably, the material of the substrate has a thickness so that, in
combination with
the fold lines F1 and F2, a stable, second state results in which the shirt
boxes 500 can be
stacked in great number, one upon another, to promote efficient shelf and
display space
usage.
In order to facilitate folding of the shirt box, in a preferred form, the end
panels 530,
540, 580 can have chainfered corners adjacent their respective free ends. The
chamfered
corners reduce interference of one panel member with another as the box 500 is
folded.
In the assembled, folded state, the angled sides of the trapezoidal shape box
500 are
defined by panels 522, 526 and the top is defined by panel 524 and the bottom
is defined by
panel 520. In the assembled state, the ends of the box 500 are defined by the
folded panels
530, 540 and flaps 560, 570. When the box 500 is fully assembled into the
folded state of
Figs. 19-20, the panel 530 and the corresponding end section 554 of the first
fastening
pane15501ie in the same plane.
In one embodiment of the present invention, the side edges of the partially
folded,
collapsed box 500 shown in Fig. 16 are defined by side edges that are
different than the
side edges,that define the sides of the fully assembled box 500 as shown in
Fig. 20. More
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specifically, in the partially folded, collapsed state, one side edge of the
box 500 is defined
by the fold line F1 between panels 522, 524, while the other side edge of the
box 500 is
defined by the fold line Fl between the first fastening panel 550 and the
panel 520. In
contrast, when the box 500 is further folded from the collapsed state of Fig.
16 to the
assembled, fully folded, closed state of Fig. 20, both of the side edges of
the box 500 are
different than the two side edges in the collapsed state. In particular, one
of the side edges
is defmed by the free edge 558 of the first fastening panel 550 which is
joined to the edge
596 of the second fastening panel 590, and the other side edge of the box 500
is defmed by
the fold line Fl between the panels 520, 522. It will therefore be appreciated
both fold
lines Fl associated with the first fastening panel 550 define the side edges
of the box 500 in
both the collapsed state of Fig. 16 and the assembled, closed state of Fig.
19. This is due
to the fact that the first fastening panel 550 is folded over the panel 520 in
the collapsed
state and is then folded so that it is in the same plane as the pane1550 in
the closed state of
Fig. 19.
In the flat storage position (collapsed state) that allows a number of boxes
500 to be
easily stacked on top of one another, the box 500 is folded about the fold
line Fl between
the panels 522, 524 so that the panel 524 is disposed above and lies across a
portion of the
panel 520 and a portion of the panel 522 and both panels 526, 590 lie above
the panel 520.
The outer edge 596 of the fastening panel 590 does not extend all the way to
the fold line
F1 that is formed between the panel 520 and the fastening panel 550. In this
orientation,
the flaps 570 lie above the end panel 530 but do not extend all the way to the
outer edge of
the end panel 530. Each end pane1540 is disposed over a portion of the end
panel 530 and
one flap 560. The outer edge 542 of the end panel 540 preferably overlies the
outer edge
532 of the underlying end panel 530 in this folded construction. The outer
edge of the
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underlying flap 560 does not extend to the fold line F2 that is defined by the
overlying
outer edges of the end panels 530, 540.
One angled edge 544 of the end pane1540 that is adjacent the flap 570 is
disposed
over the end panel 530, while the other angled edge 544 does not overlie any
structure and
is angled outwardly from the fold line Fl between the panels 522, 524 and
therefore, the tip
where the angled edges 544 and 584 intersect represents the furthest point of
one side of the
unassembled, folded, collapsed box 500.
In the unasseinbled, folded, collapsed position of Fig. 16, the two side edges
of the
folded box are defined by the fold line Fl defined between the panels 522, 524
and the fold
line Fl defined between the fastening pane1550 and the panel 520.
In the folded, closed position of Fig. 20, the fastening panel 550 is folded
about the
fold line Fl between the fastening panel 550 and the pane1520 and the end
sections 554 are
thus folded over the end panel 530. The free edge 558 of the fastening panel
550 is
positioned proximate the fold line F1 between the fastening pane1590 and the
panel 526.
When the fastening pane1550 is folded over, as shown, the first and second
fastening
elements 551, 591 generally align with one another in an overlying manner to
permit the
interconnection/fastening thereof. As discussed above, when the fastening
elements 551,
591 are in the form of interlocking structures, the elements 551, 591 are
joined together
using appropriate tools. In the case of snap-fit elements, the elements 551,
591 are joined
and mated to form an interlocking snap-fit connection between the elements
551, 591 or in
the case of a crimp, using crimping tools.
To construct and assemble the box 500 into its normal condition for use as
shown in
Fig. 20, the box 500 is first formed by cutting a plastic sheet to have the
shapes and cuts
shown in Fig. 15 and is then folded about the fold line Fl between the panels
522, 524 and
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the fastening panel 550 is folded and the fastening elements 551, 591 are
joined to yield,
the folded construction described above and shown in Fig. 16. Next, the folded
box 500 is
manipulated by raising the panels 526, 526 relative to panel 520 by folding
the structure
about the fold line F1 between the panels 520, 522 as shown in Fig. 17. As the
panel 524
is raised in the manner, the panel 522 no longer lies flat but starts to pivot
upward at an
increasing angle relative to the panel 520 and simultaneously, the panel 526
begins to lift
away from its initially flat position by pivoting about the fold line Fl
between the fastening
panel 550 and the panel 520 (the side edge of the folded box).
As the panel 524 continues to be raised and the panels 522, 526 pivot upwardly
toward an axis that is normal to the panel 520, the end panels 540 are also
raised and
assume a position above the end panels 530, with the flaps 560, 570 being
positioned
between the end panels 530, 540. As the panel 524 is raised, the flaps 560,
570 move in
direction that causes them to become inore normal relative to the underlying
panel 520. In
this initial movement, the end sections 554 begin to pivot upwardly about the
first end edge
534 (Fl fold line between the end section 554 and the end panel 530).
In this intermediate position, the end sections 554 are close to or even in a
perpendicular orientation relative to the end pane1530 and the panel 522 can
likewise be in
position where the panel 522 is substantially perpendicular to the panels 520,
524 as shown
in Fig. 17. When the ends sections 554 and the panel 522 are in perpendicular
orientations,
the panel 526 is at an angle other than 90 relative to the panel 520.
To go from the intermediate position to the final, closed position of Fig. 20,
the box
500 is manipulated to cause the free edge 558 of the fastening panel 550 and
the fold line
Fl between the panel 526 and the fastening panel 590 to become the side edge
of the
complete, assembled box 500 structure. This is done by pushing down on in the
area
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where the fastening panels 550, 590 are joined (i.e., near or along the joined
fastening
elements 551, 591) and then tucking the fastening panel 550 underneath the
panel 526 by
causing the first fastening panel 550 to lie flat and in the same plane as the
panel 520 (as
well as the same plane as the end panel 130 prior to its folding) as sho,,vn
in Fig. 18. This
is accomplished by folding the first fastening panel 550 about the fold line
F1 between the
first fastening panel 550 and the pane1520. In other words, the original side
edge of the
folded box construction, namely, the fold line Fl between the end pane1550 and
the panel
520 no longer is the side edge of the assembled box 500 shown in Fig. 19.
Similarly, the
other side edge of the box 500 is different in the collapsed and closed states
in that in the
collapsed state, the side edge is defined by the fold line Fl between the
panels 522, 524 and
in the closed state, the side edge is defmed by the fold line F1 between the
panels 520, 522.
As a result of folding the first fastening panel 550 in this manner into a
position
where it lies in the same plane as the panel 520, the two panels 522, 526 of
the box 500
form and define the two angled sides of the trapezoid shaped box 500. The
assembly of the
box 500 is then completed by bending the flaps 560, 570 inwardly towards the
interior
compartment of the box 500 (e.g., folded over towards the panels 522, 526,
respectively)
and then the end panels 530, including the end sections 554, are folded up
towards the
folded flaps 560, 570 and brought into contact therewith to close off the
interior
compartment of the box 500. As shown, the combination of the end section 554
and the
adjoining end panel 530 itself defmes a trapezoid shaped end.
The final sealing of the box 500 is performed by folding down the end
pane1540, at
the fold line F2 between panels 540, 524 so as to fold the panel 540 over the
folded end
panel 530 so that the trapezoidal shaped end pane15401ies over the
complementary
trapezoidal shaped end panel 530, with one angled edge 544 being generally
aligned with
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and overlying the edge 556 associated with the end section 554 and the other
angled edge
544 being aligned with and overlying the edge 536. The end flap 580 is then
folded about
the fold line F2 so as to position the end flap 580 on an underside (bottom
surface) of the
pane1520. To secure the end flap 580 to this underside surface of the
pane1520, the
removable strip of the double-sided tape member 600 is removed so as to expose
the second
side of the tape member 600, thereby exposing an adhesive surface which
permits the
engagement of the end panel 580 with the underside of the panel 520. Once the
panels 580
have been adhesively joined by the tape member 600, the shirt box 500 is in
the second
state, namely, the assembled state, in which the hollow central cavity is
sized to receive one
or more shirts.
It will be appreciated that the area of the end section 554 and the end panel
530 is
about equal to the area of the end panel 540 which, unlike the end pane1530
does not
include a fold line Fl since these two structures mate together as described
herein. In
addition, the bottom of the box 500 is defmed by the panel 520 and the first
fastening panel
550, while the top of the box 500 is defined by the panel 524.
The fold lines F1 and F2 can be continuous or discontinuous, but preferably
are
continuous and more preferably comprise score lines in the substrate 520.
The set of first panels of the shirt box 500 thus includes a bottom pane1520,
a top
panel 524 and a pair of side panels 522, 526 that extend between the bottom
and top panels
510, 524, each of the first and second side panels 522, 526 being formed at an
angle other
than 90 degrees with respect to the top panel 524 and the bottom panel 520. In
the
collapsed box, one side panel 5221ies adjacent and in the same plane as the
bottom panel
520, while the other side panel 526 lies above the bottom panel 520 and in a
different plane.
The first fold line is formed between the first fastening pane1550 and the,
bottom panel 520
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that is part of the first set of panels, wherein in the collapsed box 500, the
first fastening
panel 550 is folded over the bottom panel 520, while in the assembled state,
the first
fastening pane1550 and the bottom panel 520 lie at least substantially in the
same plane.
It will be appreciated that the box 500 is constructed to receive and display
one or
more shirts. For example, when displaying two shirts, the shirts are arranged
side by side
and one shirt can at least partially overlie the other shirt so that both
collars of the shirts are
spaced apart and fully visible. It is also possible for one or more of the
shirts to include a
tie as described above with reference to previous embodiments.
Now referring to Figs. 21-22 in which a new application for the shirt box 500
is
shown. In this embodiment, the shirt box 500 contains a tuxedo shirt
arrangement 700 that
includes a tuxedo shirt 710 that is arranged in a folded manner so that a
collar 712 thereof
is visible through the top panel 524 and sleeves 714 of the shirt 710 are
folded over the
front of the shirt 710 so that cuff links 716 that are already inserted and
secured through
button holes of the sleeves 714 are visible through the top panel 524. The
shirt 710 has a
bow tie 720 that is arranged around the collar 712 in the standard position
and manner of
wear so that once again, the consumer is shown how the bow tie 720 looks in
its standard
location. A clip or the like can be used to attach the bow tie 720 to the
shirt 710 so that the
bow tie 720 does not move relative to the shirt 710 during transportation or
display.
The shirt 710, along with the attached bow tie 720 and cuff links 716, occupy
a first
section of the central cavity of the box 500, while a cununerbund 730 is
disposed in and
occupies a second section of the central cavity that is adjacent the first
section. The
cummerbund 730 can be folded so that its folded length is about the same as
the length of
the folded shirt 710. As is well known, the cummerbund 730 has a pair of free
ends or
straps 732, 734 that are releasably attached to one another, as by a hook or
buckle type
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mechanism. In one aspect of the invention, a support structure 740, such as a
piece of
cardboard, is provided to support the folded cummerbund 730 and help locate
and confine
the cummerbund 730 to the second section of the box 500. The support structure
740 thus
has a length that is about the same as the length of the folded shirt 710. The
folded
cummerbund 730 can be further secured to the support structure 740 by any
number of
different means, including, the use of a clip or the like (this further
ensures that the
cummerbund 730 will not move excessively relative to the support structure
740). By
placing the cummerbund 730 in the second section of the box next to the folded
shirt 710 in
the first section, the consumer can view the cummerbund 730 directly next to
the folded
shirt 710. The consumer can thus view the complete tuxedo shirt arrangement
prior to
purchase to select the desired tuxedo shirt design.
In one aspect of this embodiment, one of the panels 540 contains a hanger 750
that
has a hook member 752 to permit the box 500, with the tuxedo shirt arrangement
700
contained therein for display to the consumer. The hanger 750 includes a body
portion 754
from which the hook member 752 extends and the hanger 750 is preferably
attached to the
panel 540 by securely attaching an underside of the body portion 754 to the
outer face of
the panel 540. The hanger 750 can be attached using any number of different
techniques,
including using an adhesive (e.g., glue or cement) or by otherwise bonding or
welding the
hanger 750 to the panel 540.
It will also be appreciated that the tuxedo arrangement 700 does not have to
include
the cummerbund 730 and support structure 740 but instead, the shirt box 500
can contain
only the folded shirt 710, along with the bow tie 720 and cuff links 716.
As with the earlier embodiment, the shirt box 500 can be formed with hole 90
in
one of the panels that forms the box 500. Hole 90 is positioned such that the
outline of the
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hole overlies a portion.of the shirt or the tuxedo arrangement. This
arrangement provides
access to the garments inside the shirt box 500 so that consumers can touch
and feel the
garments yet does not compromise the structural integrity of the box 500.
Referring to Fig. 23, a shirt box 800 is formed of a base or bottom box
portion 820,
a removable box cover 830 that mates with the box portion 820, and an
intermediate
transparent shirt cover or protector 840 that is received within and is
removable from the
base 820 and between the box cover 830 and the base 820. While the box 800 can
be
formed of any nuinber of different materials, including synthetic materials,
one exemplary
box 800, as illustrated, is formed of a combination of paper material (e.g.,
reinforced
cardboard, etc.) and synthetic material (e.g., a plastic) in the case of the
shirt cover 40.
The base or box bottom 820 can be formed to have any number of different
shapes,
such as a square, oval, circle, triangle, rectangle (as shown), etc. The base
820 is defined
by a bottom wall or floor 822 and a plurality of upstanding walls that extend
upwardly from
the floor 822. In the case of a rectangular shaped base 820, the upstanding
walls consist of
a pair of opposite end walls 824 and a pair of opposite side walls 826. The
end walls 824
and side walls 826 are joined to one another to completely surround the floor
822 and form
a bounded structure. The ends walls 824 and side walls 826 preferably are
formed at or
about at right angles to the floor 822. The floor 822 thus has an inner
surface 823 on
which a shirt or some other object rests, and an opposite outer surface or
face 825 which
represents the bottom surface of the entire box 800. The ends walls 824 have
corresponding inner surfaces or faces 827 and the side walls 826 have
corresponding inner
surfaces or faces 829.
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The base 800 is preferably formed from paper materials, such as rigid
cardboard,
and is constructed using conventional box making techniques so as to form a
rigid, robust
structure.
The box cover 830 includes a top wall or ceiling 832 and a plurality of walls
that are
arranged around and are integrally attached to the top wall 832 and in the
illustrated
embodiment, where the box cover 830 has a rectangular shape, the cover 830
includes a
pair of opposing end walls 834 and a pair of opposing side walls 836. The end
walls 834
and side walls 836 are joined to one another to completely surround the top
wall 832 and
form a bounded structure. The end walls 834 and side walls 836 preferably are
formed at
or about at right angles to the top wall 832. The top wall 832 thus has an
inner surface 833
(an underside) that faces the floor 822 and an opposite outer surface or face
835 which
represents the top surface of the entire box 810. The ends walls 834 have
corresponding
inner surfaces or faces 837 and the side walls 836 have corresponding inner
surfaces or
faces 839.
The box cover 830 is preferably formed from paper materials, such as rigid
cardboard, and is constructed using conventional box making techniques so as
to form a
rigid, robust structure.
According to one exemplary embodiment of the present invention, the box cover
830 and more particularly, the top wall 832 thereof, includes an opening,
window or cutout
850 formed therein to permit the item (e.g., shirt) contained in the box base
820 to be
easily viewed. The formation of the opening 850 defines a peripheral edge 852
that defines
the boundaries of the opening 850. It will be appreciated that the location,
size and shape
of the opening 850 can be varied and can be chosen from a great number of
different sizes
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and shapes so long as a substantial portion of the object (shirt) in the base
820 can be easily
viewed through the opening 850.
In the illustrated embodiment, the opening 850 has a rectangular shape and is
centrally located within the top wall 832 so as to define top border portions
represent
portions of the top wall 832 that are formed around the opening 850. In other
words, the
opening 850 is preferably formed at a location such that the distance between
the top edges
of the opening 850 and wall 832 and the bottom edges of the opening 850 and
wall 832 is
about equal and the distance between the side edges of the opening 850 and the
wall 832 is
about equal. The illustrated opening 850 has rounded corners 54 to give a
smoother,
flowing appearance.
The mating of box cover 830 to the base 820 is similar to standard box design
in
that the end walls 832 and side walls 834 of the box cover 830 are received
over the
corresponding end walls 822 and side walls 824 of the base 820. The distance
between the
opposing side walls and end walls in each structure are thus selected so that
a snug fit
results between the box cover 830 and the base 820 when the box cover 830 is
mated to the
base 820. As shown in the Figures, the top wall 832 of the cover 830 extends
inwardly
from the end and side walls 822, 824 of the base 820 so as to conceal the end
and side
walls 822, 824 and thus, position the opening 850 over the floor 822 of the
base to permit -
clear viewing of the object (shirt). The sections of the top wall 832 around
the opening 840
are in the form of flange-like sections of the box cover 830 that extend
inwardly over a
cavity or compartment 860 that is defined in the base 820 for receiving the
shirt.
In contrast to conventional box designs where any transparent window portion
is in
the form of a flat sheet of transparent plastic that is adhered to an
underside of wall sections
formed around an opening formed in the box cover, the transparent portion of
the box 800
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of the present invention is in the form of a member that is separate and
independent from
both the base 800 and the box cover 830, and in particular, the transparent
window section
of the box 800 is provided by the shirt protector or cover 840.
The shirt cover 840 is a self-supporting, free standing, upstanding structure
that is
received within the compartment 860 and stands upright therein around the
shirt or other
object that is resting on the floor 822 of the base 820. The shirt cover 840
is defined by a
top wall or panel 842 and a number of upstanding walls and more particularly,
the shirt
cover 840 has a pair of opposing end panels 844 and a pair of opposing side
panels 846.
The shirt cover 840 is transparent or semi-transparent in nature and is
typically formed of a
plastic material and in particular, can be manufactured as a substrate'that is
folded along
fold lines to form a folded structure. For example, the shirt cover can have a
pair of end
fold lines 870 that are formed between the top panel 842 and each of the end
panels 844
and a pair of side fold lines 872 that are formed between the top panel 842
and each of the
side panels 846. The fold lines 870 are parallel to one another and the fold
lines 872 are
parallel to one another, with the fold lines 870 being perpendicular to the
fold lines 872 and
vice versa.
To form the upstanding, free standing structure 840, the side panels 846 are
folded
along the fold lines 872 and the end panels 844 are folded along the fold
lines 870. It will
therefore be appreciated that the individual end panels 844 are not directly
attached to the
side panels 846 and vice versa but instead, slots 847 are formed between
adjacent panels.
The slots 847 permit each panel 844, 846 to have a degree of freedom or
movement or
flexing to permit the end panels 844 and side panels 846 to flex and be
received within the
adjacent and complementary end walls 824 and side walls 826.
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The height of the shirt cover 840 is selected such that when the shirt cover
840 is
placed in the compartment 860 on the floor 822, the top panel 842 is generally
in the same
plane as the top edges of the end panels 824 and side panels 826 of the base
820. When the
shirt cover 840 is in its self supported, freely upstanding position, the
distance from the top
panel 842 to floor 822 is sufficient to permit the shirt or other object to be
received therein
such that when the shirt (object) sits on the floor 822, the top of the shirt
is close to or even
in slight contact with the top panel 842 of the shirt cover 840. The
transparent or even
semi-transparent nature of the protective shirt cover 840 permits the consumer
to easily
view the contents (e.g., a shirt) contained in the compartment 860 without
manipulation of
the box 800 and more particularly, without any manipulation of the box cover
830.
Since the protective shirt cover 840 is totally independent from the base 820
and the
box cover 830, it can be easily removed from the base 820 to permit reception
of the shirt
on the floor 822 of the base 820. In addition, since the shirt cover 40 is
totally independent
from the box cover 830, the box cover 830 can easily be removed from the base
820
without worrying about the integrity of the transparent window portion of the
box 800, in
this case, the protective shirt cover 840.
By folding the end panels 844 and side panels 846 about the fold lines 870,
872, a
free standing, self-supported, upright structure is formed that can stand on
the floor 822
without collapsing or otherwise deform due in part to the presence of the
walls 824, 826
which serve to restrict any outward movement of the end panels 844 and the
side panels
846 and retain the generally rectangular shape of the protective shirt cover
840.
The width of the top panel 842 is therefore about equal to or slightly less
than the
distance between the side walls 826 of the base 820 to permit reception of the
protective
shirt cover 840 into the compartment 860. The dimensions of the end panels 844
and side
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panels 846 are therefore complementary to the corresponding walls 824, 826 of
the base
820 so that when the protective shirt cover 840 is received in the compartment
860, the
protective shirt cover 840 at least substantially occupies the area of the
compartment 860.
Fig. 24 is a cross-sectional view of the box 800 in an assembled condition
where the
protective shirt cover 840 is inserted into the compartment 860 of the base
820, where it
remains as an independent, free-standing structure, and then the box cover 830
is inserted
over the base 820 and the protective shirt cover 840 so that an underside of
the top wall 832
of the box cover 830 seats against the top surface of the top panel 842 of the
protective shirt
cover 840. In this position, there is an appearance that the protective shirt
cover 840 and
the box cover 830 are an integral single structure since when the consumer
views the top of
the box cover 830, the underlying protective shirt cover 840 extends across
and occupies
the entire window/opening 850 and since the box cover 830 is securely held on
the base
820, the flange-like structure of the top wall 832 of the box cover 830 serves
to apply a
force to the protective shirt cover 840 and prevent it from upward movement
out of the
compartment 860. In this manner, the protective shirt cover 840 is securely
held in place
and the appearance of the protective shirt cover 840 relative to the box cover
830 is one of
a taut nature.
It,will be appreciated and as illustrated, at least the opposing side panels
846 seat
against the floor 822 of the base 820; however, the shorter end panels 844 do
not
necessarily have to seat against the floor 822 and as shown in Fig. 24, the
end panels 844
can have a height that is slightly less than the height of the side panels 846
and therefore,
the end panels 844 do not seat against the floor 822. However, even in this
embodiment,
the height of the end panel 844 is selected so that the end pane1844 extends a
substantial
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length of the end wall 824 of the base 820 as illustrated. The longer side
panels 46 extend
completely to the floor 822.
However, it will be appreciated that the end panels 844 can be formed so that
they
extend completely to the floor 822 in the same manner as the side panels 846.
As mentioned earlier, one of the disadvantages to having a protective plastic
sheet
directly attached to the underside of the box cover is that this type of
arrangement is much
more prone to fracture since a force applied directly to the top of the
plastic sheet in the
area of the window can easily cause a local dislodgment of the plastic sheet
from the
underside of the box cover. Not only does this create an unsightly appearance
since the
tautness of the plastic sheet is lost but it also jeopardizes the integrity of
the object (e.g., a
shirt) that is contained within the box since a person could easily insert a
finger or other
object into the area of dislodgment and come into direct contact with the
object. In the case
of a shirt contained in the compartment, the shirt could become soiled by such
contact.
Preferably and as shown in the Fig, 23, the shirt box 800 is formed with an
opening
870 in one of the surfaces (e.g., the floor 822) that forms the box. Opening
870 is
positioned such that the outline of the hole overlies a portion of the
article, such as a shirt,
that is contained in the box 800. This arrangement provides access to the
garments inside
the shirt box 800 so that consumers can touch and feel the garments yet does
not
compromise the structural integrity of the box 800, especially, the integrity
of the
transparent protective shirt cover 840.
Figs 25 and 26 illustrate a second position of the components of the box 800
and
more specifically, the box cover 830 has been removed from its position where
it is inserted
over the base 820 and instead, is placed on an underside or bottom of the base
820. In
other words, the box cover 830 is removed and lifted off the base 820 so as to
expose the
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protective shirt cover 840 and then is inverted and mated with the base 820 by
receiving the
base 820 within an interior space 831 that is defined by the end walls 832 and
side walls
834 of the box cover 830. In this manner, the base 820 is received within the
box cover
830 so that the end and side walls 834, 836 of the box cover 830 are received
over and
exterior to the corresponding end and side walls 824, 826 of the base 820 as
is sliown in
Fig. 26. Once again, even in this arrangement, the top panel 842 of the
protective shirt
cover 8401ies generally in the same plane as the top edges of the upstanding
walls of both
the base 820 and the box cover 830.
It will be appreciated that even in this second position when the box cover
830 is
inverted and mated with the bottom of the base 820, the opening 870 is still
accessible and
the article in the box can be touched since the opening or window 850 is in
registration with
the opening 870 and the window 850 is free of any transparent, protective
plastic sheet
since, according to the present invention, the protective shirt cover 840 is
completely
separate from the box cover 830. The ability to access the opening 870 would
not be
possible with conventional box design where the window of the box cover is
formed by
adhering a transparent plastic sheet around a cutout formed in the box cover
since the
plastic sheet is permanently attached across the cutout and therefore, it
would prevent a
person from accessing the opening 870 in the floor 822 if the box cover was
placed in the
second position shown in Figs. 25 and 26.
It will also be appreciated that the arrangement of the protective shirt cover
840
relative to the box cover 830 in the box 800 of the present invention provides
improved
stacking capability since the stacking of boxes applies a force, due its
weight, to the
underlying box and therefore, in the standard box cover design, in which the
transparent
plastic sheet is attached directly the box cover, the weight of one box can
puncture and
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WO 2007/030579 PCT/US2006/034793
locally separate the plastic sheet from its point of attachment to the shirt
box since the mass
of the top box can not be borne by thin plastic sheet that is only attached
along its
peripheral edges to the underside of the box cover. Not only does this damage
the integrity
of the box but it also blemishes the appearance of the box. In contrast, since
the protective
shirt cover 840 is a separate, self-supported, upstanding structure, relative
to the box cover
830, the shirt cover 840 is able to better support the weight of the top
stacked box, which is
also supported by the flange sections of the box cover 830. Since there is no
direct
attachment between the protective shirt cover 840 and the box cover 830, the
weight of the
top stacked box cannot cause detachment of the protective shirt cover from the
box cover.
Instead, the self-supporting, free standing protective shirt cover 840 offers
improved weight
bearing capabilities.
While the invention has been described in connection with certain embodiments
thereof, the invention is capable of being practiced in other forms and using
other materials
and structures. Accordingly, the invention is defined by the recitations in
the claims
appended hereto and equivalents thereof.
