Note: Descriptions are shown in the official language in which they were submitted.
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BOX WITH REMOVABLE TOP
FIELD OF THE INVENTION
[0001] The present invention relates to boxes and blanks for boxes.
BACKGROUND OF THE INVENTION
[0002] Many goods and products are shipped and stored in shipping
containers, such as cardboard or paperboard boxes. In many cases, such as in a
retail store, it is desirable to store or display certain goods and products
on shelves
so that the goods and products are conveniently visible and accessible by a
user.
Thus, some shipping containers have been designed to be convertible from a
shipping configuration to a display configuration. For example, US 7,451,878
to
Rochefort et al., issued November 18, 2008, discloses shipping containers that
are
convertible to display containers. A container disclosed in US 7,451,878 is
formed
of an outer wrap portion and an internal divider/structural support portion.
Openings are provided in the face panel of the container. Zipper pull tabs are
also
provided in the side face panels so that the face panel and the top half of
the outer
wrap portion may be removed to convert the container into a dispensing
container
or a tray. The blank for forming the outer wrap portion has an irregular
shape, with
a width varying substantially along its length. Another shipping/display
container is
disclosed in US 5,657,872 to Leftwich et al., issued August 19, 1997. The
disclosed container has a tray portion and a cover portion. The front side
panel of
the tray portion has a severable portion, which may be removed to allow
products
be extracted from the resulting opening. US 6,168,027 to Esser, issued January
2,
2001, discloses a shipping/display box having a tear-out segment spaced from
all
eight corners of the box. The tear-out segment can be removed at a store for
display.
[0003] However, improvements to existing shipping/display containers
are desirable.
CA 02698194 2015-03-27
SUMMARY OF THE INVENTION
[0004]
In accordance with an aspect of the present invention, there is provided a box
blank that comprises a top panel, a bottom panel, a first side panel, and a
second side panel,
said panels serially attached to one another and each of said panels having
two side edges;
a side flap attached to each side edge of each panel; a first tear line
extending across said
top panel and the side flaps attached to said top panel; and a second tear
line extending
across said top panel and said side flaps attached to said top panel, or
extending across said
first side panel and the side flaps attached to said first side panel, wherein
said panels and
flaps are foldable to form a box comprising a bottom formed from said bottom
panel, a top
formed from said top panel, a first side formed from said first side panel, a
second side
formed from said second side panel, third and fourth sides each formed from a
plurality of
said side flaps each extending from one of said panels, wherein said side
flaps are sized so
that said third and fourth sides of said box are partially open, and wherein
said first and
second tear lines are positioned so that said top and said third and fourth
sides of said box
are each partially removable by separating them along said first and second
tear lines, and
after said separating, remaining portions of said third and fourth sides
remain attached to a
remaining portion of said top and at least a portion of said first side. The
first and second tear
lines may be substantially parallel. Two of the panels may be end panels each
having an end
edge. The blank may further comprise an end flap attached to the end edge of
at least one of
the end panels, where the end flap may be foldable along the end edge. An end
flap may be
attached to each end panel. The first tear line may be substantially
perpendicular to the side
edges of the top panel and may be positioned so that a portion of the first
tear line is adjacent
a terminal edge of the side flaps attached to the second side panel in the
box. A fold line
may be provided between each pair of the panels and flaps that are attached to
each other.
The first and second tear lines may be substantially parallel to a fold line
between the top
panel and a side panel adjacent to the top panel. A fold line may be provided
on each one of
the side flaps attached to one of the side panels, such that the side flap is
foldable along the
fold line on the side flap to form a reinforced edge in the box. Two fold
lines may be provided
on each side flap, such that each side flap is foldable to form a triangular
prism shaped
reinforced edge in the box. At least one of the first and second tear lines
may be
substantially straight. The blank may comprise a material selected from
cardboard, paper,
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and plastic. At least one of the first and second tear lines may be provided
by a line of
perforation or a tear strip. The blank may have a substantially rectangular
shape.
[0005] In another aspect of the present invention, there is provided a
box. The box
comprises: a bottom; a top; first and second sides opposite one another; third
and fourth
sides opposite one another, each being partially open and comprising a top
flap and a bottom
flap separated from said top flap, said top flap attached to said top of said
box; a first tear line
extending across said top and said top flaps; and a second tear line extending
across said
top and said top flaps, or extending across said first side; wherein said
first and second tear
lines are positioned so that said top and said top flaps are each partially
removable by
separating them along said first and second tear lines, and after said
separating, remaining
portions of said third and fourth sides remain attached to a remaining portion
of said top and
at least a portion of said first side, and wherein said top, said bottom, and
said sides are
formed from a single box blank. The first and second tear lines may be
substantially parallel.
The first and second tear lines may be substantially parallel to an edge
between the top and
one of the first and second sides. At least one edge between two adjacent
sides may be
reinforced. The reinforced edge may comprise a folded flap. A folded flap may
be folded
along one fold line to form a double-layered support. A folded flap may be
folded along two
parallel fold lines to form a substantially triangular prism support. At least
one of the first and
second tear lines may be provided by a line of perforation. At least one of
the first and
second tear lines may be provided by a tear strip.
[0006] In accordance with a further aspect of the present invention,
there is provided
a display box, which comprises a box described in the preceding paragraph,
where the top,
one of the first and second sides, and the top flaps have each been at least
partially removed
along the first and second tear lines.
[0007] Other aspects and features of the present invention will become
apparent to
those of ordinary skill in the art upon review of the following description of
specific
embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] In the figures, which illustrate, by way of example only,
embodiments
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of the present invention,
[0009] FIG. 1A is a plan view of a blank for a box, exemplary of an
embodiment of the present invention;
[0010] FIGS. 1B, 1C, 1D, 1E, and IF are perspective views of the blank of
FIG. 1, at different stages of being folded into a box, exemplary of an
embodiment
of the present invention;
[0011] FIG. 1G is a perspective view of a display box formed from the box
of
FIG. IF by removing a portion thereof, exemplary of an embodiment of the
present
invention;
[0012] FIG. 2A is a plan view of another blank for a box, exemplary of an
embodiment of the present invention;
[0013] FIGS. 2B, 2C, 2D, and 2E are perspective views of the blank of
FIG.
2A, being folded into a box, exemplary of an embodiment of the present
invention;
[0014] FIG. 2F is a perspective view of a display box formed from the box
of
FIG. 2E by removing a portion thereof;
[0015] FIG. 3A is a plan view of a further blank for a box, exemplary of
an
embodiment of the present invention;
[0016] FIGS. 3B, 3C, 3D and 3E are perspective views of the blank of FIG.
3A, being folded into a box, exemplary of an embodiment of the present
invention;
[0017] FIG. 3F is a perspective view of a display box formed from the box
of
FIG. 3E by removing a portion thereof;
[0018] FIG. 4A is a plan view of another blank for a box, exemplary of an
embodiment of the present invention;
[0019] FIGS. 4B, 4C, 40, and 4E are perspective views of the blank of
FIG.
4A, being folded into a box, exemplary of an embodiment of the present
invention;
[0020] FIG. 4F is a perspective view of a display box formed from the box
of
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FIG. 4E by removing a portion thereof;
[0021] FIGS. 4G, 4H, and 41 are perspective views of the blank of FIG.
4A,
being folded differently as shown in FIG. 4C;
[0022] FIG. 5A is a plan view of another blank for a box, exemplary of an
embodiment of the present invention;
[0023] FIGS. 5B, 5C and 5D are perspective views of the blank of FIG. 5A,
being folded into a box, exemplary of an embodiment of the present invention;
and
[0024] FIG. 5E is a perspective of a display box formed from the box of
FIG.
5D by removing a portion thereof.
DETAILED DESCRIPTION
[0025] FIG. 1A depicts a box blank 100, exemplary of an embodiment of the
present invention.
[0026] Blank 100 includes serially attached bottom panel 110, back side
panel 120, top panel 130, and front side panel 140.
[0027] Bottom panel 110 has end edge 111, side edge 112, end edge 113
and side edge 114. An end flap 115 is attached to end edge 111. A fold line is
provided at the joint of bottom panel 110 and end flap 115 along end edge 111.
A
side flap 116 is attached to bottom panel 110 along side edge 112, and a side
flap
117 is attached to bottom panel 110 along side edge 114.
[0028] Side panel 120 has end edge 121, side edge 122, end edge 123 and
side edge 124. A side flap 126 is attached to side panel 120 along side edge
122,
and a side flap 127 is attached to side panel 120 along side edge 124.
[0029] Bottom panel 110 and side panel 120 are attached to each other
along end edges 113 and 121.
[0030] Top panel 130 has end edge 131, side edge 132, end edge 133 and
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side edge 134. A side flap 136 is attached to top panel 130 along side edge
132,
and a side flap 137 is attached to top panel 130 along side edge 134. A tear
line is
provided by way of a tear strip 138 across top panel 130 and side flaps 136
and
137. As depicted, tear strip 138 may be substantially parallel to end edges
131 and
133, and substantially perpendicular to side edges 132 and 134. Tear strip 138
may be located in proximity to end edge 131 so that a portion 139 of top panel
130
is between end edge 131 and tear strip 138, as depicted. However, the distance
between end edge 131 and tear strip 138 may vary in different embodiments.
[0031] Side panel 120 and top panel 130 are attached to each other along
end edges 123 and 131.
[0032] Side panel 140 has end edge 141, side edge 142, end edge 143 and
side edge 144. An end flap 145 is attached to end edge 143. A side flap 146 is
attached to side panel 140 along side edge 142, and a side flap 147 is
attached to
side panel 140 along side edge 144. A tear line is provided by way of a tear
strip
148 across side panel 140 and, optionally, across side flaps 146 and 147. As
depicted, tear strip 148 may be substantially parallel to end edges 143, and
substantially perpendicular to side edges 142 and 144. Tear strip 148 may be
located near or at end edge 143, as depicted, but the distance between end
edge
143 and tear strip 148 may vary in different embodiments.
[0033] In a different embodiment, one or both of tear strips 138, 148 may
be
partially or entirely replaced with a line of perforation or score line to
provide the
desired tear line(s). Tear lines may also be provided with another form of
weakened
line or portion. For example, any suitable tear line construction known to
those
skilled in the art may be used.
[0034] Top panel 130 and side panel 140 are attached to each other along
end edges 133 and 141.
[0035] A fold line is provided at the joint between each pair of attached
panels 110, 120, 130, 140 and flaps 115, 116, 117, 118, 119, 126, 127, 136,
137,
145, 146, 147, so that the panels and flaps are foldable along the fold lines
to form
a box.
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[0036] Blank 100 may be formed of any suitable material for box blanks
and
packaging boxes. For example, cardboard, paper board, fibreboard, or plastics
may be used. Suitable material may include double faced corrugated cardboard.
Other materials typically used for forming shipping or packaging boxes may be
used.
[0037] Glues or other adhesive materials or suitable configurations for
attaching or fixing different parts of blank 100 may be additionally provided
at the
appropriate locations on blank 100, if desired.
[0038] Blank 100 may have any suitable thickness and size. Blank 100 may
have a substantially uniform thickness. In some embodiments, blank 100 may
have
a thickness from about 1 mm to about 5 mm. In a particular embodiment, blank
100 may have a thickness of about 3 or about 4 mm.
[0039] Blank 100 may be folded into a box 150, as illustrated in FIGS.
1B,
1C, 1D, 1E, and IF, according to an exemplary embodiment.
[0040] First, as shown in FIG. 1B, panels 110, 120, 130, 140 and end
flaps
115, 145 are folded along the fold lines at the edges between them to form a
tube
shape as shown in FIG. 1C. End flaps 115 and 145 overlap and may be glued
together, or otherwise attached to each other.
[0041] For example, a hot melt adhesive may be used and may be applied
using, for example, a hot glue gun.
[0042] Next, side flaps 115, 116, 117, 118, 119, 126, 127, 136, 137, 145,
146, 147 are folded inwardly, as shown in FIGS. 1D and 1E, to form a partially
open
box 150, as shown in FIG. IF. As depicted, side flaps 116, 136 may be folded
first
and then side flaps 126 and 146 are folded over side flaps 116, 136. However,
the
order in which the flaps are folded may be varied in different embodiments and
does not have to be the same as shown in FIGS. 1D and 1E. For example, in a
different embodiment, flaps 126, 146 may be folded before flaps 116, 136 are
folded.
[0043] Box 150 has a bottom formed from bottom panel 110; a top formed
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from top panel 130; a back formed from back side panel 120; a front formed
from
front panel 140; a partially open left side formed from side flaps 116, 126,
136, 146;
a partially open right side formed from side flaps 117, 127, 137, 147.
[0044] Side flaps 116, 126, 136, 146, 117, 127, 137, 147 are sized so
that
the right and left sides of box 150 are partially open. For example, as
depicted,
each side flap 116, 126, 136, 146, 117, 127, 137, 147 may have a width that is
less
than half of the width of the panel to which the side flap is attached. In a
different
embodiment, a different arrangement or configuration of side flaps may be used
to
form the partially open sides, as can be appreciated by those skilled in the
art.
[0045] Side flaps 116, 126, 136, 146, 117, 127, 137, 147 may be shaped
and sized so that each side flap partially overlaps with each adjacent side
flap. The
overlapped portions of the side flaps may be glued, stapled, taped, or
otherwise
attached or affixed together, to seal box 150.
[0046] The goods (not shown) to be packaged may be placed inside box
150 before both left and right sides of box 150 are sealed.
[0047] The partial openings on the left and right sides of box 150 may
allow
partial viewing of the goods, and may reduce the materials needed to form box
150.
However, the openings should be shaped and sized to prevent the goods from
falling out of box 150.
[0048] Box 150 with the contained goods may then be transported or
stored.
For example, box 150 with the contained goods may be conveniently placed on a
storage or display shelf.
[0049] Box 150 may be opened by tearing off tear strips 138 and 148, thus
separating a portion of each of top panel 130, side panel 140, and side flaps
136,
137, 146, 147 from the remainder of box 150 along the tear lines provided by
tear
strips 138 and 148. As can be understood, box 150 may be opened by tearing off
tear strips 138 and 148 within a limited space, such as on a storage or
display
shelf. As tear strips 138 and 148 are located on the top or in the front of
box 150, it
is not necessary to remove any portion of box 150 at the back of box 150,
which
may be inconvenient to do when box 150 is placed on a shelf.
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[0050] The remainder of box 150 forms a display box 160 with partially
opened top and front, as shown in FIG. 10. Therefore, the goods placed in box
150 become accessible and visible in box 160. It is not necessary to remove
the
goods from box 150 or 160 to place them on the shelf, to view them, or to
access
them. A user can conveniently remove the goods from the partially open box
160,
either from the open front side or the open top.
[0051] As a relatively large portion of the top and front of box 150 can
be
conveniently removed, relatively large items may be stored in box 150 on a
shelf
and may be conveniently displayed and removed from display box 160.
[0052] The back panel 120 and top panel portion 139 and other remaining
portions of side flaps can conveniently provide structural support for
confining the
goods on display. For example, back panel 120 can prevent the goods from
falling
off the shelf from the back side.
[0053] As now can be appreciated, to remove the desired portions of the
panels and side flaps, tear lines need to be properly positioned in blank 100.
For
example, to avoid tearing off a portion of side flaps 126 and 127, tear strip
138
should be positioned away from end edge 131 by a distance that is
substantially
equal or greater than the width of side flaps 126 and 127, as depicted. In
some
embodiments, tear strip 138 may be distanced from edge 131 such that in box
150
the tear line provided by tear strip 138 is aligned with the free edge of each
of side
flaps 126 and 127. In some embodiments, when a smaller portion 139 is desired,
tear strip 138 may be moved closer to edge 131, and the width of side flaps
126
and 127 may be correspondingly reduced. In any event, the tear strips are
positioned so that when the tear strips are torn off, the desired portions of
top panel
130, front side panel 140, and selected side flaps are each at least partially
removed.
[0054] Further, as depicted, tear lines provided by tear strips 138 and
148 in
blank 100 are substantially straight lines. Blanks with straight tear lines
may be
easier to design and produce. Further, the openings formed by removal of the
removable portions along the tear lines may be conveniently adjusted when the
tear lines are straight and are substantially parallel to the edges of top
panel 130.
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[0055] As tear strip 138 extends across top panel 130 between its side
edges 132 and 134, and across side flaps 136 and 137, the top of box 150 may
be
conveniently opened by removing tear strip 138, without using any opening or
cutting tools. A portion of each side flap 136, 137, 146, 147 is also
conveniently
removed when tear strips 138 and 148 are torn off.
[0056] As depicted, two openings may be formed in the sides of box 150 by
the gaps between side flaps 116, 126, 136, 146, 117, 127, 137, 147. These
openings may be conveniently utilized to handle the box, and to provide a
viewing
window for viewing the content in box 150 without opening it. Further, less
material
is needed as compared to a box with fully covered sides. Conveniently, the
design
of blank 100 allows the openings to be formed during assembly, without having
to
form openings in blank 100 during fabrication of the blank. The size and
position of
the openings may be conveniently adjusted by adjusting the sizes of one or
more of
side flaps 116, 126, 136, 146, 117, 127, 137, 147.
[0057] In different embodiments, side flaps 116, 126, 136, 146, 117, 127,
137, 147 may also be sized so that they cover the entire side of the box
formed by
these side flaps and no opening is left.
[0058] Further, as depicted, blank 100 as a whole is substantially
rectangular. As such, it is easier to produce and waste of material is limited
during
production, as compared to production of blanks that have irregular shapes and
varying widths along their lengths.
[0059] In an exemplary embodiment, blank 100 or other blanks described
herein may be formed using various different types of known methods and
systems
for forming such blanks, appropriately adapted to form the features disclosed
herein.
[0060] For example, the making of a blank 100 from a corrugated
fibreboard
material can start with making with first forming a sheet of corrugated
material using
a corrugator machine, such as one provided by BHS Corrugated Maschinen- und
Anlagenbau GmbHTM. The corrugator machine may produce a length of corrugated
material of a given width that can be used immediately or stored in a roll
until it is
CA 02698194 2010-03-31
ready to be utilized.
[0061] The next step may involve utilizing a roll or sheet of such
corrugated
material that may have an approximate width that may be the same as the width
of
the desired blank that may be used to form the case. The roll or sheet can be
also
cut transversely such as to create sections of cardboard that are generally
rectangular in shape. The corrugated material may then be fed through what is
known as a flexo-folder gluer machine. In passing through such a machine, the
corrugated sheet may pass through a printer, which prints words or pictures on
one
or both sides of the sheet. Next, the material may be creased both across and
along the sheet material such that when the blank is folded/erected it may
easily
bend along the crease (fold) lines to form the desired shape.
[0062] The creased sheet may then be "slotted" with a slotting device
which
cuts thin transversely oriented "slots" in the board in intervals along a
desired
direction. These slots create the panels that may be folded. Finally, the
sheet
material may go through a rotary die cutter to remove excess corrugated
material
along one end of the board and crush down a portion along a fold line, to
create a
thin "hinge". The purpose of the hinge is to later allow the board to be
doubled
back on itself (i.e. glue one end of the board to the other to create a tube)
and
glued.
[0063] At some stage of this process, tear strips 138 and 148 may be
formed in the blank such as by applying a device to create perforations in the
blank.
For example, a steel die may be pre-applied to a part of the blank to form the
perforations.
[0064] The result up to this point can be a flat blank. Thereafter a
flexo-
folder gluer may apply glue to the hinge portion of the blank. The panels of
the
blank are then folded over by a folding mechanism such that one end of the
blank
is now glued to the other in a flattened tube-shaped orientation to create a
flat
tubular shaped blank such as is shown in FIG. 1C.
[0065] After the tubular shaped blank has been created, it may be grouped
with other blanks and shipped to another location where the boxes are to be
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erected and packed.
[0066] When it is desired to fill a box with one or more products, a two
step
operation may be required. First, the box can be erected from its knock-down
configuration, either by hand or using a "case erector" machine. Examples of
commercially available case erectors include case packers made by iPak
Machinery Ltd. TM
[0067] The second step may be the placing of the products into the formed
case, either by hand or using a "case packer" machine. Examples of commercial
case packers include case packers made by iPak Machinery Ltd. TM of Canada.
The box can then be sealed with the product inside.
[0068] It may also be possible to utilize blanks that have not been
formed
into tubular forms such as in FIG. 1C in a first step, but rather using flat
blanks and
a wrap around machine. An example of a commercial wrap around machine is
available from CERMAXTm of France. The wrap around machine, utilizing a flat
blank, may place one or more products on one panel such as panel 110 and then
cause the remaining panels to be folded around and glued in the sequence
identified in FIGS. 1A to IF.
[0069] As can be understood, blank 100 may be modified without losing all
of its benefits.
[0070] For example, in place of a tear strip, a tear line may be provided
in
another suitable form. A tear line may refer to any line or elongated portion
in the
blank that is configured or adapted to facilitate the removal of a portion of
the blank.
Tear lines may be provided in the form of tear-away or tear-out strips, pull
strips,
tear- or pull-away tabs, perforation lines such as punch-out perforation
lines, score
lines, thinned or weakened strips or sections, or the like.
[0071] FIG. 2A depicts a modified box blank 200, exemplary of another
embodiment of the present invention.
[0072] Blank 200 includes serially attached bottom panel 210, side panel
220, top panel 230, and side panel 240.
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[0073] Bottom panel 210 has end edge 211, side edge 212, end edge 213 and
side
edge 214. A fold line is provided at the joint of bottom panel 210 and side
flap 220 along
end edge 211. A side flap 216 is attached to bottom panel 210 along side edge
212, and a
side flap 217 is attached to bottom panel 210 along side edge 214.
[0074] Side panel 220 has end edge 221, side edge 222, end edge 223 and
side
edge 224. A side flap 226 is attached to side panel 220 along side edge 222,
and a side
flap 227 is attached to side panel 220 along side edge 224.
[0075] Bottom panel 210 and side panel 220 are attached to each other
along end
edges 211 and 223.
[0076] Top panel 230 has end edge 231, side edge 232, end edge 233 and
side
edge 234. An end flap 235 is attached to end edge 231. A side flap 236 is
attached to top
panel 130 along side edge 232, and a side flap 237 is attached to top panel
230 along side
edge 234. Two tear lines are provided by way of tear strips 238, 239 across
top panel 230
and side flaps 236 and 237.
[0077] Side panel 240 has end edge 241, side edge 242, end edge 243 and
side
edge 244. A side flap 246 is attached to side panel 240 along side edge 242,
and a side
flap 247 is attached to side panel 240 along side edge 244.
[0078] Bottom panel 210 and side panel 240 are attached to each other
along end
edges 213 and 241.
[0079] A fold line is provided at the joint between each pair of attached
panels 210,
220, 230, 240 and flaps 235, 216, 217, 218, 219, 226, 227, 236, 237, 246, 247,
so that the
panels and flaps are foldable along the fold lines to form a box.
[0080] Further, two substantially parallel fold lines 228 are provided on
each of side
flaps 226, 227, 246 and 247 attached to side panels 220 and 240 respectively.
Fold lines
228 are also substantially parallel to side edges 222, 224 or 242, 244.
[0081] Blank 200 may be folded into a box 250, as illustrated in FIGS. 2B,
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2C, 2D and 2E.
[0082] As shown in FIGS. 2B and 2C, side flaps 226, 227, 246 and 247 are
each folded along fold lines 228 and side edge 222, 224, 242, or 244 to form a
triangular prism shaped reinforced edge.
[0083] As shown in FIGS. 2C, 2D and 2E, panels 210, 220, 230, 240, end
flap 235, and side flaps 216, 217, 236, 237 are next folded along the
respective fold
lines at the edges between them to form a box 250 with two partially open
sides.
The reinforced edges formed from side flaps 226, 227, 246 and 247 can provide
a
strengthened support frame for box 250. The overlapping portions may be glued
or
stapled together.
[0084] Box 250 has a bottom formed from bottom panel 210, a top formed
from top panel 230, closed sides formed from side panels 220, 240, and
partially
open sides respectively formed from side flaps 216, 226, 236, and 246, or 217,
227, 237, and 247.
[0085] In this embodiment, tear strips 238, 239 may be distanced from
edges 231, 233 so that tear strips 238, 239 are aligned or clear of the free
edges of
side flaps 226, 227 and 246, 247, respectively. Such alignment or clearance
allows
convenient removal of tear strips 238, 239 with the removable portions of top
panel
230 and side flaps 236, 237.
[0086] The top 230 and the top parts of the partially opened sides of box
250 may be removed by tearing off tear strips 238 and 239, to form a display
box
260, as shown in FIG. 2F. Display box 260 has a closed bottom (formed from
panel 210), two closed sides (formed from panels 220 and 240), an open top,
and
two partially open sides (formed mainly by flaps 216 and 217). The four
vertical
edges of box 260 are reinforced with the folded flaps 226, 227, 246, 247.
[0087] The reinforced edges may have a substantially triangular prim
shape
as depicted in FIGS. 2B, 2C, 2D, and 2F. The triangular support edges may be
vertically oriented during use to provide improved support, such as when boxes
are
stacked one on top of another. When the removable top portion is removed, the
remaining reinforced edges may also provide improved support for the remaining
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side panels 220, 240.
[0088] In different embodiments, further tear-strip(s) (not shown) may be
provided on blank 200, such as on panel 240 parallel to edge 241, or on flaps
216
and 217, so that front panel 240 may be conveniently removed, either partially
or
completely, during use.
[0089] In a different embodiment, the reinforced edges may be formed of
double-folded flaps, as shown in FIGS. 3A, 3B, 3C, 3D, 3E, and 3F.
[0090] Blank 300 shown in FIG. 3A is similar to blank 200, except that
flaps
326, 327, 346, 347 each has only one fold line 328 or 348. Blank 300 may be
folded to form a box 350, and then transformed to display box 360, in a
similar
manner as for forming box 250 and display box 260 from blank 200, as
illustrated in
FIGS. 3B, 3C, 3D, 3E, and 3F. A difference is that flaps 326, 327, 346, 347
only
need to be folded once to form double layer.
[0091] On the one hand, the edges reinforced by folded flaps 226, 227,
246,
247 may be stronger. On the other hand, the edges reinforced by folded flaps
326,
327, 346, 347 may provide sufficient strength in some applications, and blank
300
and box 350 may be easier to form as compared to blank 200 and box 250.
[0092] FIG. 4A shows another blank 400, exemplary of an embodiment of
the present invention. Blank 400 is similar to blank 100, but with the
differences
discussed below.
[0093] Specifically, blank 400 includes serially attached bottom panel
410,
side panel 420, top panel 430, and side panel 440. An end flap 415 and two
side
flaps 416, 417 are attached to bottom panel 410. End flap 415 is also attached
to
two side flaps 418, 419. Two side flaps 426, 427 are attached to side panel
420.
Two side flaps 436, 437 are attached to top panel 430. An end flap 445 and two
side flaps 446, 447 are attached to side panel 440. Tear lines are provided by
way
of tear strip 438 on panel 430 and tear strip 448 on panel 440.
[0094] Blank 400 may be folded as shown in FIGS. 4B, 4C, 4D, and 4E, to
form box 450.
CA 02698194 2010-03-31
[0095] As can be seen, a fold line is provided on each of side flaps 418,
419, 426, 427, 446, 447 so that each of these side flaps may be folded to form
a
double layer to provide a reinforced edge in box 450, as illustrated.
[0096] Portions of the top and front of box 450 may be removed by tearing
off tear strips 438 and 448, to form a display box 460 as shown in FIG. 4F. As
depicted, in blank 400, the length of side flaps 418 and 419 are approximately
equal to the width of side flaps 416 and 417; and tear strip 448 is aligned
with the
edges of side flaps 416, 417, 418 and 419 in box 450. As a result, after
removal of
tear strip 448, the top edges of the remaining sides formed by end flap 415
and
side flaps 416, 417, 418 and 419 are substantially flush with each other.
[0097] As discussed above, a blank, such as blank 400, may be fully
assembled on a case erector, following the procedure shown in FIGS. 4B to 4E.
[0098] Alternatively, blank 400 may be partially pre-assembled such as
shown in FIGS. 4B, 4G and 4H, before being assembled on a case erector such as
shown in FIGS. 41, 4D, and 4E, in that order. In particular, after folding
side flaps
418, 419, 426, 427, 446, 447 as shown in FIG. 4B, panels 430 and 440 may be
folded together along the edge between panels 420 and 430, towards panels 410
and 420, as shown in FIG. 4G. The partially assembled blank is flattened as
depicted in FIG. 4H and is thus convenient to store and transport before being
completely assembled. End flap 445 may be glued to end flap 415 during pre-
assembly or at a later time.
[0099] FIGS. 5A, 5B, 5C, 5D, and 5E show a blank 500 for forming a box
550 and display box 560, which are similar to blank 400, box 450 and display
box
460, except that the corner edges are reinforced with triangular prism shaped
supports that are formed by side flaps 518, 519, 526, 527, 546, 547, folded
along
two fold lines, similar to the corner supports in box 250 formed from blank
200.
[00100] Conveniently, as illustrated above, a shipping and display
container
may be formed from a single blank according to exemplary embodiments of the
present invention disclosed herein. Thus, the manufacture and assembly process
may be simplified as compared to boxes or containers that are formed from
multiple
16
CA 02698194 2010-03-31
pieces of blanks. However, in different embodiments, additional components or
attachments may be added to the blanks or assembled boxes, if desired.
[00101] As can be understood, the panels in the blank are typically
substantially rectangular, as depicted in the drawings. The side and end flaps
may
also be substantially rectangular, as depicted in the drawings. However, in
different
embodiments, one or more of the flaps and panels may have a different shape.
For
example, some of the flaps may have a substantially trapezoidal shape or
triangular
shape. It is also possible that one of the flaps has a curved terminal edge.
[00102] One or more permanent openings may also be provided in one or
more of the panels and flaps of the blanks for various purposes depending on
the
application.
[00103] Of course, the above described embodiments are intended to be
illustrative only and in no way limiting. The described embodiments are
susceptible
to many modifications of form, arrangement of parts, details and order of
operation.
The invention, rather, is intended to encompass all such modification within
its
scope, as defined by the claims.
17
