Note: Descriptions are shown in the official language in which they were submitted.
CA 02678267 2009-09-09
METHOD AND APPARATUS FOR MAKING, SHIPPING AND ERECTING BOXES
BACKGROUND OF THE INVENTION
1. TECHNICAL FIELD
The invention relates generally to shipping and storage boxes. More
particularly,
the invention relates to cardboard boxes which are shipped in a flat
configuration and are
erected at the time of use. Specifically, the invention relates to a box in
which the top and
bottom flaps are retained in abutting contact with the side panels by living
hinges when the
box is shipped to a first consumer.
2. BACKGROUND INFORMATION
Various types of boxes exist which may be manufactured of any flat material
such
as cardboard, and which are configured to efficiently fold into the final box
shape. As
people move about the country and the world, it becomes ever evident that the
need for
individuals to purchase and utilize storage and shipping boxes is ever
increasing.
Additionally, with the advent of e-commerce and more specifically the advent
of online
sites that permit people to purchase goods from remote sellers after bidding
on the same
over the Internet, there is a need for companies that conduct such e-commerce
to send
shipping boxes to their sellers for boxing up of the sold goods. However,
presently known
cardboard boxes, even when shipped, stored or displayed in a flattened,
unassembled
configuration tend to take up a significant amount of space. This is
especially problematic
if such flattened, unassembled boxes are to be forwarded to sellers through
the regular
postal service.
Cardboard cartons or boxes which are purchased in a flattened position and are
assembled for manual loading generally include a plurality of flaps which
extend upwardly
into the air from a top edge of the sidewall panels. These flaps can be
cumbersome to
work around when loading the box. Various box configurations have been
proposed in the
prior art to try and deal with this problem. For example, U.S. Patent No.
2,718,348 to
Monfort, discloses a box having four sidewall panels joined together along
four fold lines.
The box includes top and bottom flaps that extend respectively outwardly from
the top and
bottom edges of those sidewall panels. Some of the top flaps are secured to
each other by
a bridging member on the respective fold line. The box is shipped in a first
collapsed
position where the top flaps and bottom flaps are coplanar with the sidewall
panels and
extend outwardly away from the top and bottom edges thereof. The bridging
members
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between some of the top flaps are positioned on the folds that form the outer
corners of
the collapsed box. A pair of diametrically opposed folds fall intermediate
these outer
corners. The top flaps are not connected together by bridging members along
these
intermediate folds. When it is time for the box to be erected, it is
manipulated into a
second collapsed position where the folds with the bridging members are moved
to a
position intermediate the outer corners. When in this second position, the top
flaps are not
connected by bridging members at the outer corners. This arrangement permits
the
assembler to fold the top flaps downwardly from their shipping position into a
position
where the exterior surface of each flap is in abutting contact with the
exterior surface of
one of the sidewall panels. The box is then opened up and the bottom flaps are
used to
close the bottom opening of the box. The exterior surfaces of the top flaps
remain in
abutting contact with the exterior surfaces of the sidewall panels.
Consequently, the top
flaps do not interfere with the loading of goods into the box's interior. When
the box is fully
loaded, the bridging members are broken and the top flaps are rotated to a
position where
they may be used to close off access to the interior of the box.
U.S. Patent No. 2,783,933 to Sharts discloses a similar arrangement where
diametrically opposed folds include bridging members on the top flaps. Once
again, the
collapsed box is shipped with the top and bottom flaps coplanar with the
sidewall panels
and extending outwardly away from the top and bottom edges thereof. The
bridging
members are positioned on the folds that fall intermediate the outer corners
of the
collapsed box. The top flaps are not connected together by bridging members at
the outer
corners. Consequently, the box does not have to be moved from a first
collapsed position
to a second collapsed position, as was the case with the Montfort box, before
folding the
top flaps downwardly into abutting contact with the exterior surface of the
sidewall panels.
After purchasing the box, the consumer simply folds the top flaps from their
shipping
position into a loading position where the exterior surface of each of the top
flaps is in
abutting contact with the exterior surface of one of the sidewall panels. The
box is opened
up and the bottom flaps are rotated into a position where they close off
access to the
bottom of the box. The bridging members between some of the top flaps are
broken once
the box is loaded. The top flaps are then rotated out of contact with the
exterior surfaces of
the sidewall panels and into a position where they close off access to the
box's interior.
U.S. Patent No. 3,727,827 to Stice discloses a variable size container. Each
of the
adjacent pairs of the top and bottom flaps on Stice's box is connected
together by a
bridging member. The box is provided with a plurality of additional horizontal
and vertical
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fold lines in various positions. This permits a variety of differently shaped
and sized
containers to be constructed from a single blank. The box is shipped to the
end consumer
in a collapsed position with the top and bottom flaps coplanar with the
sidewall panels and
extending outwardly away from the top and bottom edges thereof. In this
instance, the top
flaps are not folded downwardly into abutting contact with the exterior
surface of the
sidewall panels. Instead, the consumer folds the box along selected horizontal
and vertical
fold lines to make up the size and shape container they need. The bridging
members that
fall on the outer corners of the eventually constructed box are broken so that
the top and
bottom flaps can be rotated into a suitable position to close the box.
Rendall (U.S. Patent No. 2,936,239) discloses a box with bridging members
between each pair of top flaps. The box is shipped in a collapsed position
with the top and
bottom flaps coplanar with the sidewall panels. When the box reaches the
consumer, they
manipulate it into an open position and then rotate the bottom flaps to a
position where
they close off access to the bottom of the box. The top flaps may be left
extending
upwardly from the sidewall panels and the box may be used as an open top
container.
Alternatively, the bridging members between the top flaps may be broken and
the top flaps
may be rotated to close off the top of the box.
All of the above patents disclose that the box blank is shipped to the
consumer in a
position where the top and bottom flaps are coplanar with the sidewall panels
and extend
outwardly away from the top and bottom edges thereof. Consequently, the
shipping size of
all of these boxes is fairly large.
Therefore, the need exists in the art for a box which takes up less space when
it is
in a flattened, unassembled configuration and which is able to fit within the
confines of a
standard-size postal carrier's delivery bag, and which may be easily assembled
by the user
once received or purchased.
BRIEF SUMMARY OF THE INVENTION
The device of the present invention comprises a box that has four side panels,
four
bottom flaps and four top flaps. The box is made from a blank having a first
height
measured between the outermost edges of the top and bottom flaps. The flaps
are rotated
into abutting contact with the exterior surface of the panels thereby reducing
the overall
height of the box to the height of the panel. Adjacent pairs of top and bottom
flaps are
provided with living hinges that enable them to remain in this position when
the box is
collapsed. The collapsed box is shipped through the mail in this diminished
size and then
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erected into a box of the same height as the panels. Thus, the box is of a
height that is
substantially equal to the height of a sidewall panel when in each of a
shipping position,
erected position and storage position.
A shipping label is applied to an interior surface of one of the top and
bottom flaps
and includes a shipping address for mailing of the collapsed box to a first
consumer. When
the box is fully erected, the shipping label is moved to an interior of the
box as the one of
the top and bottom flaps is rotated to close off access to the interior of the
box.
Additionally, the box includes a mailing label that is applied to an exterior
surface of one of
the panels, top and bottom flaps in a region that is not visible when the box
is in a
collapsed position. When the box is erected, the mailing label becomes visible
and a
mailing address of a second consumer made be written thereon. Similarly, a
prepaid
postage decal is applied to an exterior surface of one of the panels, top and
bottom flaps
in a region that is not visible when the box is in a collapsed position but
becomes visible
when the box is fully erected. The mailing label with the mailing address and
the prepaid
postage decal is used when the fully erected and loaded box is mailed on to a
second
consumer by the first consumer.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
A preferred embodiment of the invention, illustrated of the best mode in which
Applicant contemplates applying the principles, is set forth in the following
description and
is shown in the drawings and is particularly and distinctly pointed out and
set forth in the
appended claims.
Fig. 1 is a perspective view of the box of the present invention;
Fig. 1A is a plan view of a blank used to form the box of the present
invention and
showing the exterior surface thereof;
Fig. 1 B is a plan view of the blank of Fig. 1A showing the interior surface
thereof;
Fig. 1 C is a plan view of an alternative blank used to form the box of the
present
invention and showing the exterior surface thereof;
Fig. 2 is a perspective view of the box shown in Fig. 1 in a collapsed
configuration;
Fig. 3 is a perspective view of the box shown in Fig. 1 with the flaps moved
to a
second position;
Fig. 4 is a perspective view of the box shown in Fig. 1 in a first collapsed
position
with the flaps collapsed against the body;
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Fig. 5 is a perspective view of the box shown in Fig. 1, with the box rotated
into a
second collapsed position where the flaps are retained against the body;
Fig. 6 is a perspective view of the box shown in Fig. 5 with a printer acting
thereon;
Fig. 6A is a perspective view of a plurality of boxes banded together for
shipping;
Fig. 7 is a perspective view of the box shown in Fig. 6 moved back to the
first
collapsed position shown in Fig. 4 for opening;
Fig. 8 is a perspective view of the box shown in Fig. 6 with the bottom set of
flaps
moved to the open position;
Fig. 9 is a perspective view of the box shown partially constructed;
Fig. 10 is a perspective view of the box of Fig. 1 shown with the bottom of
the box
more fully constructed;
Fig. 11 is a perspective view of the box shown in Fig. 1 fully constructed and
with
the top flaps in the retained position; and
Fig. 12 is a perspective view of the box shown in Fig. 1 with the top flaps
moving
towards a closed position.
Similar numbers refer to similar parts throughout the drawings.
DETAILED DESCRIPTION OF THE INVENTION
The storage and shipping box of the present invention is indicated generally
at the
numeral 1, and is shown specifically in Figs. 1-12. Figs. 1A and 1 B show a
blank 2 that is
used to construct the box 1. Blank 2 is a planar sheet of material that
preferably is of a
uniform thickness "T (Fig. 3). Fig. 1 A shows the exterior surface "E" of
blank 2 and Fig. 1 B
shows the interior surface "I" of blank 2. As is well-known in the art, blank
2 may be made
of a variety of materials including corrugated cardboard, non-corrugated
paperboard, or a
variety of wax-coated products including paper and plastic.
In accordance with a specific feature of the present invention, blank 2
includes a
plurality of foldlines that are used to erect box 1. Blank 2 preferably is
provided with two
horizontally oriented and spaced-apart foldlines 3 and four vertically
oriented and spaced-
apart foldlines 5. It will be understood, however, that other arrangements and
numbers of
foldlines 3, 5 may be provided to construct boxes of different shapes to that
shown in Fig.
1. Foldlines 5 divide blank 2 into a first panel 4a, a second panel 6a, a
third panel 4b, a
fourth panel 6b, and a connector panel 7. Foldlines 3 form a top edge and
bottom edge
for each of the panels 4a through 6b and separate them from a top flap and a
bottom flap,
respectively. First panel 4a has a top edge 8 with a top flap 21 B extending
outwardly away
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therefrom and a bottom edge 10 with a bottom flap 22B extending outwardly away
therefrom. It will be understood that top and bottom edges 8, 10 are disposed
along the
spaced apart foldlines 3. It should further be understood that top and bottom
flaps 21 B,
22B are substantially coplanar with first panel 4a before the construction of
box 1 is
initiated.
Second panel 6a has a top edge 12 with a top flap 20A extending outwardly away
therefrom and a bottom edge 14 with a bottom flap 22A extending outwardly away
therefrom. Top and bottom edges 12, 14 are disposed along foldlines 3 and top
and
bottom flaps 20A, 22A are substantially coplanar with second panel 6a. First
panel 4a is
separated from second panel 6a by a joint 15 that is disposed along one of
foldlines 5. It
should be noted that a gap 29 exists between top flaps 21 B and 20A and
between bottom
flaps 22B and 22A. These gaps 29 extend substantially from the foldlines 3 to
the
respective outermost edges 2a or 2b of blank 2.
Third panel 4b has a top edge 8 with a top flap 21A extending outwardly away
therefrom, and a bottom edge 10 with a bottom flap 23A extending outwardly
away
therefrom. Once again, top and bottom edges 8, 10 are disposed along the
spaced apart
foldlines 3 and top and bottom flaps 21AB, 23A are substantially coplanar with
third panel
4b. Third panel 4b is separated from second panel 6a by a joint 16 that falls
on another of
foldlines 5. In accordance with a specific feature of the present invention,
top flaps 20A,
21A are partially separated from each other by a gap 28 while a hinge 26
connects a
portion of the top flaps 20A, 21A together. Hinge 26 originates a distance
outwardly away
from foldline 3 and continues to the outermost edge 2a of blank 2. Similarly,
a portion of
bottom flap 22A is separated from a portion of bottom flap 23A by a gap 28
while a hinge
24 connects another portion of flaps 22A, 23A together. Hinge 24 originates a
distance
outwardly away from foldline 3 and continues to outermost edge 2b of blank 2.
Fourth panel 6b has a top edge 12 with a top flap 20B extending outwardly away
therefrom and a bottom edge 14 with a bottom flap 23B extending outwardly away
therefrom. Top and bottom edges 12, 14 are disposed along foldlines 3 and top
and
bottom flaps 20B, 23B are substantially coplanar with fourth panel 6b. Fourth
panel 6b is
separated from third panel 4b by a joint 17 that falls along another of
vertical foldlines 5. A
gap 29 is defined between each of top flaps 21A, 20B and bottom flaps 23A,
23B. Gaps 29
extend substantially from the foldline 3 to the respective outermost edge 2a,
2b of blank 2.
Consequently, top flaps 21A, 20B are not connected to each other and bottom
flaps 23A,
23B are not connected together.
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As is apparent from a review of the present invention, hinges 24 -27 may
simply be
manufactured of the same material and be integrally formed with blank 2. In
this instance,
hinges 24-27 are of the same thickness "T" as the rest of the material used in
blank 2 and
therefore may need to be cut with a knife or other implement in order to break
the same. It
will be understood that hinges 24-27 could, alternatively, be manufactured out
of material
with a reduced thickness relative to the rest of the blank, or could be made
with a fracture
line formed therein to make breaking the hinge easier. It will further be
understood that
hinges 24-27 may all be of different lengths. This is accomplished by
increasing or
decreasing the length of gaps 28.
Connector panel 7 has a top edge 11 and a bottom edge 13 that are disposed
along
the respective foldlines 3. A top connector flap 7A extends outwardly away
from top edge
11 and a bottom connector flap 7B extends outwardly away from bottom edge 13.
Top and
bottom connector flaps 7A, 7B are substantially coplanar with connector panel
7.
Connector panel 7 is separated from fourth panel 6b by a joint 18 that falls
on another of
foldlines 5. In accordance with a specific feature of the present invention, a
portion of top
flap 20B is separated from a portion of top connector flap 7A by a gap 28. A
hinge 27
connects other portions of these flaps 20B, 7A together. Hinge 27 originates a
distance
outwardly from the associated foldline 3 and continues to the outermost edge
2a of blank
2. Similarly, a portion of bottom flap 22B is separated from a portion of
bottom connector
flap 7B by a gap 28. A hinge 25 connects other portions of flaps 22B, 7B
together. Hinge
originates a distance outwardly from the associated foldline 3 and continues
to
outermost edge 2b of blank 2.
Fig. 1A shows that the blank 2 has a first height Was measured between the
outermost edges 2a and 2b. The panels are all of a second height H2 as
measured
25 between top and bottom edges 8, 10 and 12, 14. The second height H2 is
smaller than the
first height H1.
Fig. 1 C shows an alternative blank 2 that may be used to form box 1. The
blank is
substantially identical to the blank illustrated in Figs. 1A and 1B except
that the connector
flap 7 does not have flaps 7A and 7B connected thereto. Instead, connector
flap 7 has
beveled edges 35, 37 and is of a height H2 as measured between edges 35, 37.
Additionally, the fourth panel 6b is disposed adjacent the first panel 4a
instead of being
disposed between the third panel 4b and the connector panel 7 as was the case
in the
blank of Fig. 1A. In this version of the blank, the fourth panel 6b is
separated from the first
panel 4a by a joint 19. Furthermore, the flap 20B is connected to flap 21 B by
a hinge 33
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and the flap 22b is connected to the flap 23B by a hinge 31. The box
constructed from this
blank is substantially identical in external appearance to the box constructed
from the
blank shown in Figs. 1A and 1B. It will be understood that other modifications
may be
made to blank 2 without departing from the scope of the present invention.
In accordance with the present invention, a shipping address label 70
preferably is
applied to exterior surface "E" of blank 2 before construction of the box 1
begins. Label 70
preferably includes a plurality of spaced apart horizontal lines that a
consumer may use to
write a shipping address. Label 70 may be printed directly onto the exterior
surface "E" of
blank 2 or may be an adhesive type label that is applied onto exterior surface
"E".
In accordance with yet another specific feature of the present invention, a
prepaid
postage decal 72 is also applied to the exterior surface "E" of blank 2. The
prepaid postage
decal 72 represents a flat rate for mailing the erected and loaded box through
the mail.
This flat rate is a pre-negotiated rate with a postal service of any
particular country or
countries and is dependent upon the dimensions of the box once erected and
upon the
maximum permissible weight of the box once loaded. Preferably, the flat rate
is not
dependent upon the delivery address of the loaded box if delivered within a
pre-negotiated
region. For example, the flat rate may be a rate negotiated with either or
both of the postal
services of the United States and Canada for delivery of a box of particular
dimensions
and maximum weight anywhere within North America.
Decal 72 may be printed directly onto the exterior surface "E" or may be an
adhesive label that is applied thereto. Both of the label 70 and decal 72
preferably are
applied in regions of the blank 2 that are adjacent one of the top and bottom
edges 8, 10,
12, 14 and which will be covered by one of the top and bottom flaps as will be
hereinafter
described when the blank 2 is folded.
When box 1 is erected, the panels and flaps are folded about these horizontal
and
vertical foldlines 3, 5 as will be hereinafter described. In the erected box
panels 4a and 4b
comprise a pair of opposed, substantially parallel and spaced apart sidewalls
4 and panels
6a and 6b comprise a pair of opposed, substantially parallel and spaced apart
endwalls 6.
The top flaps 21 B, 20A, 21A, and 20B are folded inwardly toward each other to
close off
access to a top opening in the box. The bottom flaps 22B, 22A, 23A, and 23B
are folded
inwardly toward each other to close off access to a bottom opening in the box.
It will be understood that hinges 24, 25, 26 and 27 may be of any of a variety
of
lengths without departing from the spirit of the present invention, but are
preferably
between 1/2 and 2 inches in length. Furthermore, while hinges 24, 25, 26 and
27 are
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shown as being located proximate the outermost edges 2a, 2b, they may be
spaced a
distance inwardly away therefrom without departing from the spirit of the
present invention.
Blank 2 is erected into a box 1 in the following manner. The planar sheet of
material
that comprises blank 2 is folded about each of the foldlines 5. Blank 2 is
folded along the
foldline 5 between fourth panel 6b and connector panel 7 and the connector
panel 7 is
caused to overlap a portion of first panel 4a. This causes connector flap 7A
to overlap a
portion of top flap 21 B and causes bottom connector flap 7B to overlap a
portion of bottom
flap 22B. An adhesive or other securing mechanism is applied between the
overlapped
areas to fixedly secure connector flap 7 to first panel 4a, top connector flap
7A to top flap
21 B, and bottom connector flap 7B to bottom flap 22B. The blank 2 is then
manipulated to
fold along the appropriate foldlines 5 to form joints 15 and 17 (Fig. 2) and
is oriented so
that these joints 15, 17 constitute the outermost corners of the blank 2. In
order to do this,
box 1 is moved from the position shown in Fig. 1 to the position shown in Fig.
2 by rotating
box 1 in the direction of Arrow A (Fig. 2) and by flexing joints 15 and 17 to
have a 180
bend associated therewith. Joints 16 and 18 are moved to a substantially flat
configuration.
In this first folded position (Fig. 2), hinges 24, 25, 26, and 27 are disposed
in the region of
the box that is intermediate the outer corners formed by joints 15 and 17. It
will be
understood that gaps 29 are oriented along joints 15, 17 and are therefore
disposed along
the outer corners when box 1 is in this first folded position. It should also
be noted that at
this point Fig. 2 illustrates the exterior surfaces of the box 1, and most
specifically the
exterior surfaces of second panel 6a, third panel 4b together with their top
flaps 20A/21A
and bottom flaps 22A/23A. If the box 1 were flipped over, then the exterior
surfaces of the
fourth panel 6b and the first panel 4a and their associated flaps 21 B/22B and
208/238
would be seen.
Once the box 1 is in the position shown in Fig. 2, then the top flaps 20A/21A,
which
are joined together by hinge 26, and the top flaps 20B/21 B, which are joined
together by
hinge 27, are rotated along Arrows B and C, respectively, until they are in
the position
shown in Fig. 3. Similarly, bottom flaps 22A/23A, which are joined together by
hinge 24,
and bottom flaps 23B/22B, which are joined together by hinge 25, are rotated
in the
direction of Arrows D and E, respectively, until they are moved into the
position shown in
Fig. 3. As these joined flaps 20A/21A; 208/21 B and 22A/23A; 23B/22B continue
to be
rotated, they will ultimately move to the position shown in Fig. 4. In this
position, the
exterior surfaces of each of the joined top flaps 20A/21A and 20B/21B abut the
exterior
surface of the associated first, second, third and fourth panels.
Consequently, when box 1
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is in the position shown in Fig. 4, the interior surfaces of the flaps
20A/21A; 22A, 23A are
visible. Similarly, if the box 1 were flipped over, the interior surfaces of
flaps 208/21 B and
238/228 would be visible.
Referring particularly to Fig. 4, box 1 is shown in a first collapsed position
with first
hinge 24 and second hinge 26 aligned along joint 16 and where the joint is
substantially
flattened so that the second panel 6a is substantially coplanar with the third
panel 4b. It
will be understood that, similarly, third hinge 26 and fourth hinge 27 are
aligned along joint
18 which is also substantially flattened with the fourth panel 6b and first
panel 4a being
substantially coplanar with each other. As mentioned previously, in this first
collapsed
position, joints 15 and 17 include a 1800 bend and constitute the outer
corners of the
collapsed box.
Box 1 is then moved from the first collapsed position (Fig. 4) into a second
collapsed position (Fig. 5) by rotating box 1 in the direction of Arrow F.
This causes the
panels to move so that joints 16 and 18 are positioned at the outermost
corners of box 1.
Each joint 16, 18 has a 180 bend therein and each joint 15 and 17 is
substantially
flattened. By rotating the box along the direction of Arrow F, it can be seen
that first hinge
24 and third hinge 26 are moved into a position where they have a 180 bend in
them as
they wrap around joint 16. Second hinge 25 and fourth hinge 27 also are caused
to have a
180 bend as they wrap around joint 18. The forces supplied by hinges 24-27
assure that
the top flaps 20A/21A and 20B/21 B and the bottom flaps 22A/23A and 23B/22b
are all
held in abutting contact with the exterior surface of the associated panels 4a-
6b. Hinges
24-27 provide sufficient force to assure that the free ends of each of the top
and bottom
flaps adjacent gaps 29 are also held in abutting contact with the exterior
surface of the
associated panels 4a-6b.
When box 1 is in this second collapsed position it is in a configuration that
is
suitable for shipping. Box 1 in this second collapsed position is of a reduced
height relative
to the original blank 2. The overall height of box 1 when it is in each of the
first and second
collapsed positions is H2. In other words, the height of box 1 is
substantially equal to the
height H2 of the panels 4a-6b alone. This is due to the fact that the top and
bottom flaps
have been folded into abutting contact with the exterior surface of the panels
4a-6b. This
arrangement allows the user to more easily ship the box 1 as it is of a
diminished size
relative to the original blank 2. The overall thickness W of box 1 in the
second collapsed
condition is equal to the combined thickness of two abutting panels, such as
4b and 6b
and two flaps, such as 21A and 20B. The diminished dimensions of box 1 in the
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CA 02678267 2009-09-09
collapsed condition preferably are one that is suitable for easy insertion of
the box into a
standard postal mailbag. Additionally, the positioning of hinges 24-27 on the
outermost
corners presents a box configuration that does not have free edges that can
snag or catch
on other objects being shipped, mailed or carried in a mailman's bag.
Additionally, the
diminished dimensions of box 1 when in the first or second collapsed condition
also makes
it possible to store or display box 1 in a smaller space compared to
previously known
boxes in which the top and bottom flaps extend outwardly away from and
coplanarly with
the panels that form the sidewalls and endwalls thereof.
It is often appropriate to provide information such as assembly instructions
or the
like on a piece of packaging. In accordance with a specific feature of the
present invention
and referring to Fig. 6, it can be seen that a printer 30 may be utilized to
print indicia 32
onto the interior surface "I" of at least one of the top and bottom flaps,
such as top flap
21A. Inasmuch as this printed indicia 32 is on the interior surface of top
flap 21A, when
box 1 is fully erected and moved to the closed position as will be discussed
hereinafter, the
indicia will be moved to a position disposed in the interior of the box and
will not detract
from the appearance of the box exterior. It will be understood that instead of
printing
directly onto the folded blank 2, an adhesive label containing the printed
indicia 32 may be
applied to the interior surface "I" of one of the top and bottom flaps.
It will be understood that if the printed indicia 32 is a shipping address
then that address
may be one that is selected from a computerized database of addresses of
consumers to
whom the folded blanks 2 are to be mailed.
In accordance with a specific feature of the present invention, the printed
indicia 32
preferably, but not exclusively, includes a shipping address for a consumer.
This shipping
address enables the post office or a shipping company to ship the box when in
a second
collapsed condition (Fig. 6) to a remote consumer.
In accordance with another specific feature of the present invention, it is
possible to
ship a number of boxes together when in the second collapsed position. This is
illustrated
in Fig. 6A where three folded blanks 2 are shown in the second collapsed
position. The
folded blanks are stacked one on top of the other and are banded together by
restraining
straps 80. A single shipping label, in the form of indicia 32, is applied to
one of the flaps on
an outermost blank 2. Although not illustrated herein, it will be understood
that one or more
restraining straps 80 may also be applied around a single folded blank 2 in a
position that
will ensure the top and bottom flaps do not separate from the exterior surface
"E" of panels
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CA 02678267 2009-09-09
4a-6b. This strap 80 will ensure that no loose corners of the top and bottom
flaps become
damaged as the folded blank is shipped.
Referring to Fig. 7, the folded blank 2, having been received or purchased by
the
consumer in the second collapsed position, may now be erected into a position
where it is
ready for use. The erection of box 1 is accomplished as follows. Firstly, the
folded blank 2
is moved from the second collapsed position back to the first collapsed
position, i.e., blank
2 is rotated from the position shown in Fig. 7 along the direction indicated
by Arrow G to
the position shown in Fig. 8. This causes hinges 24-27, which were disposed at
the outer
corners of the blank in Fig. 7 to be moved away from the outer corners and to
a position
where they are disposed intermediate the outer corners. In this first
collapsed position,
flaps 20A and 21A remain in abutting contact with the exterior surface "E" of
the
associated panels 4a-6b. Bottom flaps 22B, 22A, 23A, 23B are then rotated
downwardly in
the direction of Arrows H and I as shown in Fig. 8 to where they once again
extend
coplanarly with and outwardly away from panels 4a-6b. Box 1 is then moved to a
partially
erected state (Fig. 9) with top flaps 21 B, 20A, 21A, 20B remaining in
abutting contact with
the exterior surface "E" of the panels 4a-6b and with the hinges 26 and 27
intact. Hinges
24 and 25 on bottom flaps 22B, 22A, 23A, 23B are broken apart (Fig. 9). This
permits the
bottom flaps 22B, 22A, 23A, 23B to be rotated in the direction of Arrows J
inwardly toward
each other and so as to close off the bottom opening of box 1 (Fig. 10). A
suitable sealing
mechanism, such as an adhesive or staples is then applied to bottom flaps 22B,
22A, 23A,
23B to fix them in place relative to each other. Box 1 is now in a loadable
condition where
any desired articles 34 may be introduced into the cavity defined by panels 4a-
6b and
bottom flaps 22B, 22A, 23A and 23B. Box 1 may be loaded with articles goods 34
while
top flaps 21B, 20A, 21A, 20B remain positioned in abutting contact with the
exterior
surface "E" of panels 4a-6b. Top flaps 21 B, 20A, 21A and 20B remain in this
position as
they are held there by hinges 26 and 27.
Fig. 11 shows that at this stage, indicia 32 are still visible as the interior
surface "I"
of top flap 21A.upon which the indicia are printed still faces outwardly. Once
box 1 is fully
loaded, hinge 26 and hinge 27 are broken and top flaps 21 B, 20A, 21A, 20B are
rotated
inwardly toward each other in the directions of Arrows K and into the closed
position as
shown in Fig. 12. When this occurs, the interior surface "I" of top flaps 21
B, 20A, 21A, 20B
is disposed within the interior of box 1 and indicia 32 are no longer visible.
Thus, the
exterior appearance of box is not marred by the indicia 32 once box 1 is
closed.
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CA 02678267 2009-09-09
As is evident from the above description and method of operation, box 1 may be
shipped and stored in a relatively small space limited to only to the height
H2 of panels 4a-
6b and to the thickness "W" (Fig. 5) and length L of body 2 when in the second
collapsed
position (Fig. 5 or 6). As is also apparent and in accordance with one of the
primary
features of the invention, a portion of the interior surface of box 1 may be
easily printed
with directions or information assuring that when the box is in the closed
position, there is
no information on the exterior of the box to get in the way of further
shipping or packaging.
Thus, the folded box 1, shown in Fig. 6, can be shipped to a consumer with the
shipping
address printed as indicia 32 on the interior surface "I" of one of the flaps.
But, once the
box 1 is fully erected, loaded and closed, it may be shipped to a second
consumer at a
remote location without indicia 32 being visible. The shipping address that
constituted
indicia 32 is no longer visible since the flap containing said indicia has
been folded so that
the exterior surface of that flap is now visible instead of the interior
surface thereof. This
removes the likelihood of any confusion as to which is the correct address for
delivery of
the loaded box. Once the box 1 is fully loaded with articles, the first
consumer may write
the mailing address of the second consumer onto the mailing label 70 applied
to the
exterior surface "E" of one of the panels.
While it has been illustrated herein that the blanks 2 are printed with the
indicia 32
when in the second folded position, it should be understood that such indicia
32 may be
printed on the blank 2 prior to it be folded (i.e. when it is in the position
shown in Fig. 1 B) or
when the blank 2 is in the first folded position (Fig. 4). Preferably,
shipping label 70 and
decal 72 are applied to blank 2 when it is still a planar sheet (Fig. 1A).
Fig. 1A shows that the distance between the outermost edges 2a, 2b of blank is
the
first height identified as H1 and the distance between the two horizontal fold
lines 3 is
identified as the height H2, with H2 being smaller than H1. As seen from Figs.
5 and 12,
the height of both the shipped box (Fig. 5) and the erected box (Fig. 12) is
H2, i.e., the
height of the panels 4a-6b. This is in contrast to previously known erectable
boxes where
the height of the shipped box would be the equivalent of the height H1 and the
height of
the previously known erected box would be the equivalent of the height H2. The
present
inventor has therefore found a way to reduce the overall size of a shipping
box to
substantially the same height as the erected box and not substantially the
height of the
blank as was previously the case. This arrangement reduces the mailing cost
for
collapsed boxes sent through the regular mail as the postage rates are at
least partially
determined by the overall dimensions of the article shipped.
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CA 02678267 2009-09-09
There is thus disclosed a method of shipping products comprising:
mailing a collapsed box 10 through the mail to a first location at a non-flat
postage
rate;
erecting the collapsed box 10 at the first location;
loading the products 34 to be shipped into the erected box 34; and
mailing the loaded box 34 to a remote second location at a flat postage rate.
The steps of mailing the collapsed box 34 and mailing the loaded box 34 each
further include the step of inserting the box into a standard size mail
carrier's bag (not
shown).
The step of mailing a collapsed box 10 as previously disclosed is preceded by
the
steps of providing a box 34 that has four side panels 4, 6, each panel having
a top edge 8,
12 and a bottom edge 10, 14 with a top flap 20, 21 extending outwardly from
the top edge
and a bottom flap 22, 23 extending outwardly from the bottom edge; and wherein
each
panel 4, 6 is of a first height H2 as measured between the top and bottom
edges thereof.
When the box 10 is collapsed for mailing it has a height that is equal to the
first height H2.
Furthermore, the step of collapsing the box 10 includes the steps of folding
the top
flaps 20, 21 downwardly into contact with an exterior surface of the side
panels 4, 6;
folding the bottom flaps 22, 23 upwardly into contact with the exterior
surface of the side
panels 4, 6; and moving the box 10 to a collapsed condition where a hinge 26,
27 that
connects two adjacent top flaps or a hinge 24, 25 that connects two adjacent
bottom flaps
together is disposed on an outermost corner of the box 10.
The step of mailing the collapsed box to the first location is preferably
further
preceded by the step of applying a flat-rate postage decal 72 to one of the
side panels 4, 6
of the box 10 prior to collapsing the box for mailing.
The step of mailing the box 10 to a second location further includes the step
of
applying a mailing label 32 to an outwardly facing interior surface of one of
the folded top
and bottom flaps 20, 21, 22, 23.
In the foregoing description, certain terms have been used for brevity,
clearness,
and understanding. No unnecessary limitations are to be implied therefrom
beyond the
requirement of the prior art because such terms are used for descriptive
purposes and are
intended to be broadly construed.
Moreover, the description and illustration of the invention is an example and
the
invention is not limited to the exact details shown or described.
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