Note: Descriptions are shown in the official language in which they were submitted.
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BLANK AND BOX WITH MUTI-LAYER INTERNAL SUPPORT
FIELD
[0001] The present invention relates to boxes and blanks for forming
boxes.
BACKGROUND
[0002] Cardboard or paperboard boxes are useful for shipping and storing
materials. It is common to form such a box from a single blank. Typically, the
blank
has four main panels for forming the top, bottom, front and back of the box,
and has
side panels extending from the main panels for forming the sides of the box.
In some
situations, the known blanks and boxes formed by simply folding them are not
adequate for storing or transporting liquids, resins, powders, bulk food
products,
pastes, or other similar bulk materials or products. Such bulk materials or
products
may need to be transported in a carton, and their quantities are typically
measured by
weight or volume, e.g., by the number of filled cartons. For example, when the
boxes
are stacked during storage or transportation, the boxes may not have
sufficient
resistance to vertical compression applied to the boxes and may deform and
collapse
under pressure. Further, when materials such as mud, powder, gypsum, or
cement,
are stored in the box, the liquid content can leak out through the gaps
between the
folded main panels and side panels. These gaps may need to be sealed with a
separate sealing material, such as a tape applied to the edges of the box, or
by a bag,
to contain the materials.
SUMMARY
[0003] In an aspect of the present application, there is provided a blank
for
forming a box.
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[0004] In an embodiment, the blank comprises a bottom panel for forming
a
box bottom having four sides; a side panel foldably attached to each one of
the four
sides for forming a side wall extending from the each side of the box bottom;
a flap
foldably attached to a terminal end of the side panel for forming a portion of
a box top;
and support panels foldably attached to a first pair of opposite ones of the
side panels,
each one of the support panels being foldable onto itself along a fold line
thereon to
form a side support member; wherein the panels are sized and attachments of
the side
panels at the four sides are offset such that two of the side support panels
are foldable
to form side support members overlapping inside each side wall formed by one
of a
second pair of the side walls, and each one of the side support members abuts
the box
top and the box bottom when the box is formed.
[0005] The fold line may comprise a double score line to allow each
support
panel to be folded about 180 degrees along the fold line. Each support member
may
extend across the box bottom and may be folded at a corner formed by two side
walls.
Each pair of overlapping support members may form a three-layer support inside
the
respective side wall. Each support member may comprise a full-width support
layer
and a partial-width support layer. The partial-width support layer may be a
half-width
support layer. The support panels may be sized and configured such that each
pair of
overlapping support members are foldable to offset their partial-width support
layers
and sandwich their partial-width support layers between their full-width
support layers.
The separation between adjacent panels may be provided by slit cut. The two
sides of
the box bottom attached to the second pair of side panels may be defined by
straight
parallel fold lines. Each side of the box bottom attached to one of the first
pair of side
panels may have a middle portion defined by a straight fold line and two end
portions
defined by inclined cuts such that the box bottom is inwardly recessed at the
middle
portion. The inclined cuts at a first side may comprise a tapered section and
a stepped
section, each of the tapered section and stepped section may have a cut length
of
about a thickness of the blank. The inclined cuts at a second side may
comprise
straight, tapered cuts each having a cut length of about three times of the
blank
thickness. The blank may have a substantially uniform thickness. The blank may
be
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formed of a corrugated cardboard having a flute direction substantially
parallel to the
fold lines on the support panels. The support panels may be sized such that
when the
box is formed, the side support members sealingly abut the box top and the box
bottom. The support panels may be sized such that when the box is formed, each
pair
of the side support members comprise an inner support member and an outer
support
member, and each terminal edge of the inner support member sealing abuts an
internal surface on the box top, the box bottom, or one of the side walls.
[0006] In another aspect, there is provided a box formed from a blank as
described herein. In the box, the overlapping support members and the
respective side
wall at each side may be attached to one another by an adhesive.
[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 of
the present invention,
[0009] FIG. 1 is a plan view of a blank for a box, exemplary of an
embodiment
of the present invention;
[0010] FIG. 1A is an enlarged view of the portion marked as IA in the
blank of
FIG. 1;
[0011] FIG. 2 is a perspective view of the blank of FIG. 1;
[0012] FIGS. 3, 4, 5, and 6 are perspective views of the blank of FIG. 1,
at
different stages of being folded to form a box;
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[0013] FIG. 7 is a perspective view of a box formed from the blank of
FIG. 1,
exemplary of an embodiment; and
[0014] FIG. 8 is a plan view of a blank for a box, exemplary of an
embodiment
of the present invention.
DETAILED DESCRIPTION
[0015] FIG. 1 depicts a box blank 100, exemplary of an embodiment of the
present invention. It should be understood that, unless expressly indicated
otherwise,
the solid lines in the drawings indicate edges that are not directly attached
to one
another, and the thin dashed-lines indicate fold lines, which may be formed of
score
lines. The thick dash-dotted line in FIG. 1 does not indicate any physical
feature or
boundary but is used to indicate a region 1A, an enlarged view of which is
shown in
FIG. 1A.
[0016] Blank 100 has a plurality of panels including a bottom panel 110,
and a
first pair of opposite panels 120, 130 and a second pair of opposite panels
140, 150.
Bottom panel 110 has four edges 112, 113, 114, 115. Each side panel 120, 130,
140,
150 is attached to a respective edge 112, 113, 114, 115 of bottom panel 110.
[0017] As depicted, each one of panels 120, 130, 140, 150 has a lower
edge
121, 131, 141, 151 attached to a respective edge of bottom panel 110, and an
upper
edge 122, 132, 142, 152. Each one of panels 120, 130, 140, 150 also has side
edges
123, 124; 133, 134; 143, 144; 153, 154. Fold lines are provided at the edges
between
bottom panel 110 and respective panels 120, 130, 140, 150.
[0018] Panels 160, 170 are attached to opposite side edges 123, 124 of
panel
120 respectively. Panels 180, 190 are attached to opposite side edges 133, 134
of
panel 130 respectively. Each panel 160, 170, 180, 190 has a lower edge 161,
171,
181, 191, an upper edge 162, 172, 182, 192, and side edges 163, 164; 173, 174;
183,
184; 193, 194 respectively.
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[0019] Panels 140, 150, 160, 170, 180, 190 are separated from one another
at
the respective adjacent edges by slit cuts, such that panels 120, 130, 140,
150 folded
upwards at their respective lower edges 161, 171, 181, 191, and each panel
160, 170,
180, 190 can be folded at the respective side edge 163, 173, 183, 193 attached
to the
respective panel 120, 130.
[0020] As depicted, each panel 140, 150 may optionally have a pre-cut
slot
portion 145, 155. Each slot portion 145, 155 is only partially connected and
can be
conveniently detached to form a slot suitable for receiving a human hand for
handling
the box to be formed, as will be further described below.
[0021] A half-length panel 146, 156 may be attached to panel 140, 150 at
its
upper edge 142, 152. A fold line is provided at the upper edge 142, 152 to
allow panel
146, 156 to be folded at the respective upper edge 142, 152. The two half-
length
panels 146, 156 are sized to form a full-length top of the box to be formed.
In a
different embodiment, instead of providing two half-length top panels, a full-
length top
panel may be attached to one of side panels 140, 150. The half-length panels
146,
156 may be sized such that in the box to be formed, panels 146, 156 would not
overlap but the terminal edges 147, 157 of panels 146, 156 would be close to,
or even
abut, each other to fully cover the top of the box.
[0022] For convenience of description, it is assumed that bottom panel
110 and
side panels 120 and 130 are serially connected in a direction referred to as
the
widthwise or transversal direction, and bottom panel 110 and panels 140 and
150 are
serially connected in a direction referred to as the lengthwise or
longitudinal direction.
Accordingly, the dimension of the blank, and of the formed box, in the
widthwise
direction is referred to as the width; and the dimension of the blank, and of
the formed
box, in the lengthwise direction is referred to as the length. As depicted in
the figures,
the length of blank 100 is larger than its width. However, it should be
understood that
the terms "lengthwise", "length", "longitudinal", "widthwise", "width", and
"transversal"
are used herein for ease of reference, and it is not necessary that the length
of blank
100, or any component thereon, is longer than the corresponding width. In some
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embodiments, a length may be equal to or shorter than a corresponding width of
the
same blank or a given portion of the blank. Further, references to the length
or width of
a component portion of the blank or box may change depending on how the
component portion is relatively positioned with respect to the bottom panel.
For
example, a portion of the blank may be folded so that its length in the blank
becomes
its width in the folded box or becomes its height. It should also be
understood that the
terms "full-length," "full-width,", "half-width," and "half-length" refer to
the length and
width of the formed box or its sides, not the blank itself.
[0023] Each panel 160, 170, 180, 190 has a fold line 165, 175, 185, 195
extending parallel to its side edges and positioned at less than 1/3 or one-
half of the
length of the panel from its terminal edge 164, 174, 184, 194, to provide a
foldable
portion 166, 176, 186, 196. As such, and as will be further described below,
each
panel 160, 170, 180, 190 can provide a full-width support layer and a partial-
width (e.g.
half-width) support layer. Fold lines 165, 175, 185, 195 may be provided by
double
score lines to allow the panel to be conveniently folded 180 degrees at the
double
score line. In a particular embodiment, the double score lines may be
separated by a
distance of about 8 mm. However, in different embodiments the distance between
the
double score lines may change, and may be selected depending on the specific
material used for the particular application, to provide the needed
flexibility to fold the
panel 180 degrees without significant separation between the folded portions.
[0024] As depicted, each panel 160, 170, 180, 190 may optionally have a
cut
out slot 168, 178, 188, 198, which is sized and positioned to correspond with
respective slot portions 145, 155. A correspondingly shaped and sized notch
169,
179, 189, 199 may be provided at each terminal edge 164, 174, 184, 194.
[0025] Slot portions 145, 155, slots 168, 178, 188, 198 and notches 169,
179,
189, 199 are positioned and sized to provide hand slots in the formed box for
easy
handling of the box, as will be further described below.
[0026] A flap 125, 135 is attached at upper edge 122, 132 of each panel
120,
130, and is foldable to provide support for the top of the box to be formed.
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[0027] Panels 110, 120, 130, 140, 146, 150, 156 are sized and shaped so
that
when they are folded they can form the respective external sides of a box
having the
desired shape and size, which will be selected based on the particular
application.
[0028] Panels 160, 170, 180, 190 and portions 166, 176, 186, 196 are
shaped
and sized to form multi-layer internal side support and to provide self-
sealing in the
box, as will be further described below.
[0029] The cuts at or near different corners of bottom panel 110 are
different
and are specifically arranged to provide the desired configuration of the side
panels
and supports. The cuts in the depicted embodiment are better illustrated in
FIG. 1A. To
make it clear where each slit cut extends, the opposite edges of the panels
separated
by slit cuts are indicated by two solid lines separated by a gap in FIG. 1A.
However, it
should be understood that, in reality, it is not necessary the two opposite
edges are
separated by a gap. In many cases, the two separate edges may still contact
each
other and there is no gap in between before the panels are folded.
[0030] As depicted, edges 114, 115 are defined by straight parallel fold
lines,
and each of edges 112, 113 has a middle portion defined by a straight fold
line and
two end portions defined by inclined cuts such that bottom panel 110 is
inwardly
recessed at the middle portion.
[0031] The inclined cuts defining the end portions of edge 112 may
comprise
straight, tapered cuts, each of which has a cut length of about three times of
the blank
thickness. The inclined cuts defining the end portions of edge 113 may include
a
tapered section and a stepped section, as can be seen in the depicted
embodiment.
Each of the tapered section and stepped section may have a cut length of about
the
blank thickness.
[0032] As can be appreciated from the depicted embodiment shown in FIG. 1
and 1A, the lower edge 131 of side panel 130 is defined by the two tapered
sections
and the middle portion of edge 113. The length of side panel 130 is thus the
length of
bottom panel 110 minus the total length of the two stepped sections at the
ends of
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edge 113. The lower edge 121 of side panel 120 is defined by the middle
portion of
edge 112, and the length of side panel 120 is thus the length of bottom panel
110
minus the total length of the two tapered cuts at the ends of edge 112.
[0033] Thus, the slit cuts at the corners of edges 112, 113, 114, 115 of
bottom
panel 110 are formed such that bottom panel 110 is longer than each of panels
120,
130, and panel 130 is longer than panel 120. As the length of the blank is
generally
uniform, panels 160, 170 are consequently longer than panels 180, 190.
Further, due
to the shapes of the cuts, panels 120, 130 are taller (wider) than panels 160,
170, 180,
190.
[0034] As can be better seen in FIG. 1A, panel 110 is not strictly
rectangular
shaped. Rather, panel 110 has a recessed middle portion between edges 112 and
113. That is, panel has a larger (max) width at, and near, edges 114 and 115
and a
smaller (min) width away from edges 114 and 115.
[0035] Correspondingly, due to the slit cuts at the corners of bottom
panel 110,
panel 120 has a rectangular shape with a straight lower edge 121 extending to
the full
length of panel 120, but panel 130 is not strictly rectangular shaped, as
panel 130 has
tapered corners at its lower edge 131, and the portion of lower edge 131 that
is
connected to bottom panel 110 does not extend to the full length of panel 130.
Panel
130 thus has a taller (wider) middle portion away from its side edges 133,
134, and
shorter (narrower) side portions at side edges 133, 134. Panels 120, 130 are,
however, of the same maximum height (width).
[0036] The lower edges 161, 171 of panels 160, 170 are tapered near side
edges 163, 173 such that panels 160, 170 are taller (wider) at side edges 163,
173. In
comparison, lower edges 161, 171 of panels 180, 190 are straight and do not
taper at
side edges 163, 173. With the exception of the tapered ends at side edges 163,
173,
panels 160, 170, 180, 190 are of the same height (width).
[0037] As will become clear below, the slit cuts and the above noted
differences between corresponding panels in shape, height (width) and length
allow
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panels 160, 170, 180, 190 to be folded inside the box, and to extend the full-
height, so
as to provide internal support and self-sealing.
[0038] In blank 100, any fold line may be provided by a score line.
[0039] As shown, blank 100 is generally rectangular, and only a small
portion
of the original blank material needs to be cut off from the original blank
material.
However, in different embodiments, the blanks may have other general shapes
suitable for the particular applications.
[0040] In a specific embodiment, blank 100 may have the dimensions as
shown in Table I.
Table I. Example Blank Dimensions
(blank thickness: 3 mm)
Component Size (mm)
Width Length
Blank (overall) 752 (not at flaps); 1091
852 (at flaps 125/135)
Bottom panel 110 284 (in the middle); 310
284+ (at edges 114/115)
Panel 120 233 310
Panel 130 233 310
Panel 140, 150 284 238
Panel 160, 170 233 390
Panel 180, 190 233 390
Panel 146, 156 284 152
Flaps 125, 135 51 vary
but less than 283
[0041] During use, the panels and flaps may be folded as illustrated
in FIGS. 2-
6 to form the box shown in FIG. 7.
[0042] As shown in FIG. 2, portions 166, 176 of panels 160, 170 are
folded 180
degrees along fold lines 165, 175 towards outside of panels 160, 170, and
portions
186, 196 of panels 180, 190 are folded 180 degrees along fold lines 185, 195
towards
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inside of panels 180, 190. Optionally, an adhesive such as glue may be applied
to the
outside of panels 160, 170 and the inside of panels 180, 190 to glue the
respect folded
portions 166, 176, 186, 196 thereon.
[0043] As shown in FIG. 3, panels 120, 160, 170 may be folded along the
fold
lines at the respective connected edges to form walls at 90 degrees with
respect to
one another and bottom panel 110.
[0044] As shown in FIG. 4, panels 130, 180, 190 may be folded along the
fold
lines at the respective connected edges to form walls at 90 degrees with
respect to
one another and bottom panel 110. Panels 180, 190 are folded onto the outside
of
panels 160, 170 respectively. Optionally, an adhesive such as glue may be
applied to
surfaces of the panels that will be in contact with one another to glue the
panels in
contact together.
[0045] As shown in FIG. 5, top flaps 125 and 135 may be folded at 90
degrees
along upper edges 122 and 133 of panels 120 and 130.
[0046] An adhesive may be applied to the top surface of top flaps 125 and
135,
and may be applied to outside of panels 180, 190.
[0047] As shown in FIG. 6, panels 140, 150 are folded 90 degrees to
outside of
panels 180, 190 at lower edges 141, 151, and top panels 146 and 156 are folded
at 90
degrees along upper edges 142 and 152. It can be seen that support panels 160,
170,
180, 190 extend across and overlap inside respective box sides formed by
panels 140,
150.
[0048] The folded box 200 is shown FIG. 7. As can be seen, the slot
portions,
slots and notches in the panels are sized and positioned so that they co-
register in the
formed box. The slot portions 145, 155 may be removed, or folded up, to
provide a
handling slot 202 on each of the opposite sides formed by panels 140, 160, 180
and
panels 150, 170, 190 respectively.
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[0049] As now can be appreciated, due to the particular cut and
configuration
of the panels, panels 160, 170, 180, 190 provide a three-layer side support
inside each
side panel 140, 150 of box 200. Specifically, as can be seen in FIGS. 5 and 6,
each
three-layer support includes an inner full-width layer formed of panel 160 or
170, a
middle layer formed of half-width portions 166 and 186 or 176 and 196, and an
outer
full-width layer formed of panel 180 or 190. The off-sets provided by the
different
widths and lengths of the panels allow the different layers to fold without
difficulties or
bulging. Further, the off-sets are provided such that each of the three-layer
supports
abuts the inside surfaces of the top and bottom of the box, and can provide
self-
sealing at the lower and upper edges. Conveniently, when the box is vertically
compressed, the pressure applied to the sides of the box further improves the
sealing
effect.
[0050] Fold lines 165, 175, 185, 195 on panels 160, 170, 180, 190 may be
positioned such that the folded support panel can abut the folded opposite
side panel
120 or 130 as illustrated in FIG. 5, so as to provide sealing at the side
edges of box
200.
[0051] Conveniently, box 200 can withstand increased vertical
compression, as
compared to some conventional boxes formed of a single blank, and can, at the
same
time, provide self-sealing. Thus, the boxes may be filled with liquid contents
such as
mud, gypsum, or cement, or powder; and may be stacked during storage or
transportation with a reduced chance of collapsing the boxes or causing
leakage of the
liquid contents. The quantity of the materials or products contained in the
box may be
measured by volume or weight. For example, certain liters of the material per
box or
certain kilograms of the material per box.
[0052] Blank 100 may have a substantially uniform thickness, which in
some
embodiments may be from about 3 mm to about 13 mm.
[0053] To provide the required configuration and off-sets, in an
embodiment,
each of edges 133, 134 is off-set from the nearest one of edges 114, 115 by at
least
the thickness of blank 100; each of edges 123, 124 is off-set from the nearest
one of
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edges 114, 115 by about three times of the thickness of blank 100.
[0054] Blank 100 may be formed of a corrugated cardboard having a flute
direction substantially parallel to edges 114, 115 of bottom panel 110, such
that in the
formed box the flute direction is vertically oriented.
[0055] In an alternative embodiment, a blank may have a configuration as
shown in FIG. 8.
[0056] As is typical for blanks used to form packaging boxes, the panels
may
have generally rectangular shapes so that the resulting box may have a
substantially
rectangular or cubic shape. Boxes with a substantially rectangular or cubic
shape may
be convenient to handle and store in many situations.
[0057] In cases where a blank has a varying thickness, the skilled
person
should be able to adjust the off-sets in view of the present disclosure so
that the
resulting folded box will have the same or similar support and sealing
properties as
described here.
[0058] As used herein, a slit cut is a cut where little material is
removed by the
cut and the adjacent panels after the slit cut may still be in contact with
one another, or
there may be only a narrow gap between the adjacent panels after the slit cut.
With
such slit cuts, the adjacent panels are severed from one another but may still
abut
each other.
[0059] Blank 100 may be formed of any suitable material for box blanks
and
packaging boxes. For example, corrugated boards, 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. Known box materials that are particularly
suitable for
containing the specific liquid contents for which the boxes will be used, may
be
conveniently selected. For example, the blank material may have a suitable top-
to-
bottom compression strength, which may be measured by an Edge Crush Test
(ECT).
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In selected embodiments, the blank may have 23, 26, 29, 32, 40, 44, 42, 48, or
51
ECT. The blank formed of corrugated boards may have a flute size of E, F, B.
C, A, or
N, depending on the strength required. Liners and mediums may also be selected
and
used to help to achieve the desired stacking strength. Various options for the
above
parameters may be considered and selected to achieve the overall strength
desired in
a particular application.
[0060] Glues or other adhesive materials or suitable configurations for
attaching or fixing different parts of blank 100 may be optionally provided at
the
appropriate locations on blank 100, if desired. In particular, glues or other
adhesive
materials may be applied to some or all of the surfaces of the panels or flaps
which will
come into contact with one another when the box is formed.
[0061] Blank 100 may have any suitable thickness and size. As noted
earlier,
Blank 100 may have a substantially uniform thickness. In some embodiments,
blank
100 may have a thickness from about 1 mm to about 13 mm. In a particular
embodiment, blank 100 may have a thickness of about 3 or about 4 mm.
[0062] Blank 100 may be manually folded into a box 200 in selected
embodiments. In other embodiments, a box packing machine may be used to fold
blank 100 and package box 200.
[0063] A vertical compression may be applied to the box during assembly,
packaging, shipping, storage, or unpacking. For example, when a machine is
used to
form and package the box, a vertical compression may need to be applied by the
machine during the packaging process. When boxes are stacked for storage or
transportation, a vertical compression may also be applied on the lower boxes.
[0064] Conveniently, folded panels 160, 170, 180, and 190 provide
improved
vertical support and resistance against deformation under vertical
compression, as
compared to conventional boxes without such internal supports.
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[0065] As can be appreciated, when a corrugated board is used to form
blank
100 and hence box 200, and the flute direction in side walls of box 200 is
substantially
in the vertical direction, it can conveniently provide increased vertical
strength, as
compared to other orientations of the flute direction.
[0066] Conveniently, three-layer supports can provide improved resistance
against vertical compression, as compared to a single- or double-layer
supports that
are formed of the same blank material with the same thickness.
[0067] Conveniently, the three-layer support as disclosed herein can be
formed
with a single blank and without forming undesirable protrusions inside the
box. In
particular, the internal side surfaces of the box can be conveniently all
flat. Thus, the
internal space in box 200 can have a substantially regular shape, so that it
may be
convenient to package goods or products that have regular individual shapes.
Of
course, the box may also be used to package goods or products that are of an
irregular shape, or do not have a defined shape.
[0068] When two overlapping portions in the box are to be attached, the
overlapping portions may be glued, or may be stapled, taped, or otherwise
attached or
affixed together.
[0069] In an exemplary embodiment, blank 100 may be formed using various
different types of known methods and systems for forming such blanks,
appropriately
adapted to form the features disclosed herein.
[0070] For example, the making of a blank from a corrugated fibreboard
material can start with first forming a sheet of corrugated material using a
corrugator
machine, such as one provided by BHS Corrugated, Maschinen-und Anlagenbau
GmbH TM. 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 ready
to be
utilized.
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[0071] 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 box. 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, rotary die cutter, or flatbed die cutter. 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.
[0072] The creased sheet may then be slit with a cut device which cuts
thin
slits in the board at designed intervals along desired directions. These slits
create
panels and flaps that may be folded.
[0073] A flat blank may thus be formed. Certain portions of the blank may
be
pre-folded and glued using a suitable folding mechanism or folding machine.
[0074] The box may be filled with the desired content by any known
technique.
[0075] As can be understood, blank 100 may be modified without losing all
of
its benefits.
[0076] For example, the slots 202 for handling may be omitted,
particularly if it
is desirable to avoid any possible leakage. A tear line may be provided on the
blank
for purposes known to those skilled in the art.
[0077] Conveniently, as illustrated above, a storage and shipping
container
may be formed from a single blank according to exemplary embodiments disclosed
herein. Thus, the manufacture and assembly process may be simplified as
compared
to boxes that are formed from multiple pieces of blanks. However, in different
embodiments, additional components or attachments may be added to the blanks
or
assembled boxes, if desired.
CA 02882399 2015-02-19
[0078] As can be understood, the panels in the blank are typically
substantially
rectangular, except as specifically described herein, as depicted in the
drawings.
However, in different embodiments, one or more of the panels may have a
different
shape. For example, one or more panels may have a curved terminal edge.
[0079] 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.
[0080] To describe blank 100 in alternative languages, it may be said
that blank
100 comprises a bottom panel 110 for forming a box bottom having four sides
112,
113, 114, 115. A side panel 120, 130, 140, 150 is foldably attached to each
side for
forming a side wall extending from each side of the box bottom. A flap 125,
135, 146,
156 is foldably attached to a terminal end 122, 132, 142, 152 of the side
panel 120,
130, 140, 150 for forming a portion of a box top. Support panels 160, 170,
180, 190
are foldably attached to a first pair of opposite side panels 120, 130. Each
support
panel 160, 170, 180, 190 is foldable onto itself along a fold line 165, 175,
185, 195
thereon to form a side support member. The panels are sized and attachments of
the
side panels at the four sides are offset such that two of the side support
panels are
foldable to form side support members overlapping inside each side wall formed
by
one of a second pair of side walls 140, 150, and each side support member
abuts both
the box top and the box bottom when the box is formed. Each support member may
extend across the box bottom and may be folded at a corner formed by two side
walls.
Each pair of overlapping support members may form a three-layer support inside
the
respective side wall. Each support member may comprise a full-width support
layer
and a partial-width support layer. The support panels may be sized and
configured
such that each pair of overlapping support members are foldable to offset
their partial-
width support layers and sandwich their partial-width support layers between
their full-
width support layers. Sides 114, 115 of the box bottom are defined by straight
parallel
fold lines. Each side 112, 113 has a middle portion defined by a straight fold
line and
two end portions defined by inclined cuts such that the box bottom is inwardly
recessed at the middle portion. The inclined cuts at side 113 comprise a
tapered
16
CA 02882399 2015-02-19
=
section and a stepped section, each of the tapered section and stepped section
may
have a cut length of about a thickness of the blank. The inclined cuts at side
112
comprise straight, tapered cuts each having a cut length of about three times
of the
blank thickness. The blank may be formed of a corrugated cardboard having a
flute
direction substantially parallel to fold lines 165, 175, 185, 195. The support
panels may
be sized such that when the box is formed, the side support members sealingly
abut
the box top and box bottom. The support panels may be sized such that when the
box
is formed, each pair of the side support members comprise an inner support
member
(e.g. support members formed by panels 160, 170 as seen in FIG. 4) and an
outer
support member (e.g. support members formed by panels 180, 190 as seen in FIG.
4),
and each terminal edge of the inner support member sealing abuts an internal
surface
on the box top, box bottom, or a side wall (e.g. side wall 130 as seen in FIG.
5). In a
box formed from blank 100, the overlapping support members and the respective
side
wall at each side may be attached to one another by an adhesive.
[0081] Examples
[0082] Sample blanks having the configuration of blank 100' as shown in
Fig. 8
were made and tested for compression resistance. Blank 100' was similar to
blank
100 in construction and configuration except that the dimensions of the
various panels
and portions were different as can be seen from Fig. 8 and as listed in Table
II. The
internal dimensions of the sample boxes formed from the sample blanks were
roughly
280 mm x 280 mm x 229 mm. The sample blanks were made of corrugated paper
boards with ECT 32 (referred to as Example A) or ECT 40 (referred to as
Example B).
The sample blanks were formed by rotary die cutting (RDC). The overlapping
layers in
the side support walls were glued together using adhesives such as hot melt
glue.
17
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Table II. Dimensions of Tested Sample Blanks
(blank thickness: 3 mm)
Component Size (mm)
Width Length
Blank (overall) 812 (not at flaps);
1170
900 (at flaps 125/135)
Bottom panel 110 246 (in the middle);
297
251 (at edge 114/115)
Panel 120 283 271
Panel 130 283 287
Panel 140, 150 251 287
Panel 146, 156 251 149
Panel 160, 170 280 (away from edge
163/173) 365
283 (at edge 163/173)
Portion 166, 176 280 114
Panel 180, 190 280 368
Portion 186, 196 280 117
Flaps 125, 135 44 265
Slot 168, 178, 188, 198 32 89
Slot 169, 179, 189, 199 32 40
Slot 145, 155 83 51
[0083] Compression tests were conducted for boxes formed from the sample
blanks as described herein, and for a comparison box (referred to as
Comparison Box).
[0084] The
Comparison Box was a Single-Wall Standard Flat (SWSF) box
formed of ECT 51 corrugated board material by Platen Die Cutting (PDC). The
Comparison Box had internal dimensions of about 255 mm x 255 mm x 229 mm. The
overlapping panels were also glued inside.
[0085] The tested boxes were all rated to hold 23 kg weight. The tests
were
conducted at room temperature (23 C) with 50% relative humidity (RH). Further
properties of the components of the test boxes and representative test results
are
listed in Table Ill. In Table Ill, the weights indicated are average weights;
"MRA"
refers to Moisture Resistant Adhesive; and "1/VT" refers to White Top. The
take-up
factors for medium wt. calculation is B = 1.31 and C = 1.40.
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Table Ill. Properties and Test Results of Tested Box Materials
Box Comparison Example I Example II Example III
(ECT 51) (ECT 32) (ECT 40)
Combined Wt.
1050 588 637 711
(gim2)
Outside Liner
178 WT 213 210 266
(g/m2)
Medium "B"
(g/m2) 113
Centre
272
Liner(g/m2)
Medium "C"
107 117 112 117
(g/m2)
Inside Liner
270 207 262 266
Corrugating
MRA MRA MRA MRA
Adhesive
Peak Strength
1267 1702 2118 1949
(lbs)
Deflection
0.42 0.45 0.46 0.50
(inches)
[0086] The test results indicated that the compression strength of the
Examples
I, II and III was improved over the Comparison Box, even though the Comparison
Box
had a smaller dimension and was made of a stronger blank material. For
example, as
compared to the Comparison Box, the example boxes formed from the sample
blanks
had markedly increased peak strength, e.g., by about 35% with Example I, and
by
about 70% with Example II. Each side wall formed of glued multiple-support
layers in
Examples I, II, and III provided the equivalent strength of five (5) times of
a single-wall
corrugated board. This improved compression resistance provided improved
stacking
strength.
[0087] It will also be understood that the word "a" or "an" is intended
to mean
"one or more" or "at least one", and any singular form is intended to include
plurals
herein.
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[0088] It will be further understood that the term "comprise", including
any
variation thereof, is intended to be open-ended and means "include, but not
limited to,"
unless otherwise specifically indicated to the contrary.
[0089] When a list of items is given herein with an "or" before the last
item, any
one of the listed items or any suitable combination of two or more of the
listed items
may be selected and used.
[0090] 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.
