Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02785111 2012-08-09
BOX WITH FULL-HEIGHT SIDE SUPPORTS
AND BLANK AND PROCESS FOR FORMING SUCH BOX
FIELD
[0001] The present invention relates to boxes, and blanks and processes for
forming boxes.
BACKGROUND
[0002] Cardboard or paperboard boxes are useful for shipping and storing
goods or products. 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. The
adjacent flaps are separated by wide gaps (or slots) for ease of production
and
assembly. Tear lines may be provided on the blank so that a portion of the box
may
be removed along the tear lines to convert a packaging box to a display box.
Such
blanks and boxes are disclosed in, for example, WO 01/87721 to Maus, and US
7,784,676 to Borek et al. In some situations, the known blanks and boxes such
as
those disclosed in the above references are adequate, but in some situations,
they are
either not suitable, or do not provide sufficient box strength to resist
deformation under
an applied pressure during use.
SUMMARY
[0003] In an aspect of the present application, there is provided a blank for
forming a box. The blank comprises a plurality of panels joined to one another
at
respective fold lines, the panels comprising a top panel for forming a box
top, a bottom
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panel for forming a box bottom, a front panel for forming a box front and a
back panel
for forming a box back, each one of the panels having two side edges; and a
plurality
of flaps each extending from one of the side edges, for forming box sides,
wherein
flaps extending from the front and back panels are as tall as the total height
of the box
to be formed from the blank.
[0004] In another aspect of the present application, there is provided a blank
for forming a box. The blank comprises a plurality of panels joined to one
another at
respective fold lines, the panels comprising a top panel for forming a box
top, a bottom
panel for forming a box bottom, a front panel for forming a box front and a
back panel
for forming a box back, each one of the panels having two side edges; and a
plurality
of flaps each extending from one of the side edges, for forming box sides,
wherein
flaps extending from the front and back panels are taller than the front and
back
panels and have ends each offset from the fold lines by at least about a
thickness of
the blank.
[0005] In an embodiment of a blank provided herein, a fold line may be
provided on each flap extending from the front panel or the back panel, for
folding the
flap along the fold line to form a double-layer support. The fold line on the
flap may be
configured for folding the flap inward. The blank may comprise a tear line
defining a
removable portion in the top and front panels, for removing the portion from
the box
along the tear line. The blank may have a substantially uniform thickness. The
flaps
may be separated from one another by slits. Flaps extending from the top and
bottom
panels may be minor flaps. The blank may be formed of a corrugated cardboard
having a flute direction substantially perpendicular to the fold lines joining
the panels.
[0006] In a further aspect of the present invention, there is provided a box
comprising a top, a bottom, a front, a back, and two sides each comprising a
top flap
extending downward from the top, a bottom flap extending upward from the
bottom, a
back flap extending forward from the back, and a front flap extending rearward
from
the front, wherein the back and front flaps are affixed to outside surfaces of
the top
and bottom flaps, and are as tall as the total height of the box.
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[0007] In another aspect of the present invention, there is provided a box
comprising a top, a bottom, a front, a back, and two sides each comprising a
top flap
extending downward from the top, a bottom flap extending upward from the
bottom, a
back flap extending forward from the back, and a front flap extending rearward
from
the front, wherein the back and front flaps are affixed to outside surfaces of
the top
and bottom flaps, and have top and bottom ends flush with the top and bottom
respectively.
[0008] In an embodiment of a box provided herein, the front and back flaps
may be folded inwardly to form double-layer supports. The front and back flaps
may
be glued to the outside surfaces of the top and bottom flaps. The box may
comprise a
tear-line for removing a portion of the top and a portion of the front. The
top and
bottom flaps may be minor flaps. The box may be formed of a corrugated
cardboard,
and the flute directions in the front and back flaps may be substantially
vertical. The
box may be formed from a blank described herein.
[0009] In a further aspect of the present invention, there is provided a
process
for forming a box from a blank comprising at least four panels and flaps
extending from
opposite edges of each one of the four panels, wherein the four panels are
foldable to
form a top, a bottom, a front and a back of the box. The process comprises
folding
flaps extending from the top and bottom to form two partial sides; and folding
each flap
extending from the front or back to form a side support and attaching the side
support
to an outside surface of a respective one of the partial sides. The blank is
configured
such that the side support is as tall as the total height of the box.
[0010] In another aspect of the present invention, there is provided a process
for forming a box from a blank comprising at least four panels and flaps
extending from
opposite edges of each one of the four panels, wherein the four panels are
folded to
form a top, a bottom, a front and a back of the box. The process comprises
folding
flaps extending from the top and bottom to form two partial sides; and folding
each flap
extending from the front or back to form a side support and attaching the side
support
to an outside surface of a respective one of the partial sides. The blank is
configured
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such that the side support has a top end flush with the top and has a bottom
end flush
with the bottom.
[0011] In an embodiment of a process provided herein, each flap extending
from the front or back may be folded to form a double-layer side support.
Attaching
may comprise bonding with an adhesive. The blank may be a blank described
herein.
[0012] 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
[0013] In the figures, which illustrate, by way of example only, embodiments
of
the present invention,
[0014] FIG. 1A is a plan view of a blank for a box, exemplary of an embodiment
of the present invention;
[0015] FIGS. 1 B is an enlarged view of the portion 1 B of the blank of FIG.
IA;
[0016] FIG. 1C is a perspective view of a box formed from the blank of FIG.
IA,
exemplary of an embodiment of the present invention;
[0017] FIG. 1 D is a perspective view of a display box formed from the box of
FIG. 1C by removing a portion thereof, exemplary of an embodiment of the
present
invention;
[0018] FIG. 2A is a plan view of another blank for a box, exemplary of an
embodiment of the present invention;
[0019] FIG. 2B is a perspective view of a box formed from the blank of FIG.
2A,
exemplary of an embodiment of the present invention;
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[0020] FIG. 3A is a plan view of a further blank for a box, exemplary of an
embodiment of the present invention;
[0021] FIG. 3B is a perspective view of a box formed from the blank of FIG.
3A,
exemplary of an embodiment of the present invention;
[0022] FIG. 3C is a perspective view of a display box formed from the box of
FIG. 3B by removing a portion thereof, exemplary of an embodiment of the
present
invention;
[0023] FIG. 4A is a plan view of a further blank for a box, exemplary of an
embodiment of the present invention; and
[0024] FIGS. 4B is a perspective view of a box formed from the blank of FIG.
4A, exemplary of an embodiment of the present invention.
DETAILED DESCRIPTION
[0025] In brief overview, boxes with full-height side supports are found to be
able to withstand stronger vertical compression without substantial
deformation, as
compared to a box with side supports or flaps that do not extend over the full
height of
the box. Blanks for forming boxes with full-height side supports are disclosed
herein.
Full-height side supports have top and bottom ends that are flush with the top
and
bottom of the box. In other words, the full-height side supports are as tall
as the total
height of the box.
[0026] FIG. 1A depicts a box blank 100, exemplary of an embodiment of the
present invention. Blank 100 has a plurality of panels including front panel
110, top
panel 120, back panel 130, and bottom panel 140, which serially extend in a
direction
referred to as the lengthwise or longitudinal direction herein.
[0027] The terms "lengthwise", "length", "longitudinal", "widthwise", "width",
and
"transversal" are used herein for ease of reference, and it should be
understood that it
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is not necessary that the length of blank 100, or any component thereon, is
longer than
the corresponding width. In some embodiments, a length may be equal to or
shorter
than a corresponding width of the same blank or a given portion of the blank.
[0028] As depicted, each panel 110, 120, 130, 140 has two side edges 111,
112; 121, 122; 131, 132; 141, 142. A flap 113, 114, 123, 124, 133, 134, 143,
or 144
extends from each respective side edge 111, 112, 121, 122, 131, 132, 141, or
142.
[0029] As depicted in FIG. 1, front panel 110 and bottom panel 140 are
terminal (end) panels, but in different embodiments, box 100 may be assembled
in a
different orientation such that the terminal panels are the top and back
panels in
assembled form. Optionally, an end flap such as end flap 145 may extend from a
terminal panel such as bottom panel 140, which may be used to join the ends of
panels 110 and 140, and form a joint known as the manufacturer's joint.
[0030] Each flap 113, 114, 133, 134 has a fold line 115, 116, 135, 136
thereon,
for folding the respect flap to form a double-layer support.
[0031] Fold lines 150, 151, 152 are provided between adjacent panels 110,
120, 130, 140 for folding panels 110, 120, 130, 140. In other words, panels
110, 120,
130, 140 are joined to one another at respective fold lines 150, 151, 152.
When end
flap 145 is provided, an optional additional fold line 153 may be provided for
folding
end flap 145.
[0032] Fold lines (not separately numbered) are also provided at side edges
111, 112, 121, 122, 131, 132, 141, and 142 between the panels 110, 120, 130,
140
and their respective flaps 113, 114, 123, 124, 133, 134, 143, and 144.
[0033] Optionally, as depicted, a tear line 160 may be provided on blank 100,
which may form a closed loop enclosing a removable portion 162 of front panel
110
and top panel 120, such that removable portion 162 can be conveniently removed
along tear line 160 during use. Tear line 160 may be provided by way of a tear
strip.
[0034] The shape, size, and position of the loop formed by tear line 160 are
not
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necessarily as shown in FIG. 1A and may vary in different embodiments,
depending
on which portion of the resulting box should be removed. For example, the
shape,
size and position of the tear-line loop may be selected to meet requirements
or
balance factors such as ease of display and access, and maintaining box
integrity
during use. Multiple tear lines may also be used for removing a portion of the
resulting
box for these purposes.
[0035] For convenience of removing removable portion 162, a notch portion
164 may be optionally provided at a convenient location along tear line 160.
For
example, it may be convenient to position notch portion 164 on top panel 120
as
shown in FIG. 1A. More than one notch portions may also be provided in
different
embodiments. For ease of use, notch portion 164 may be pre-cut or partially
severed
(such as by a score line as depicted) so that it can be pushed out easily by a
user
using a finger.
[0036] As is typical for blanks used to form packaging boxes, the widths of
front
and back panels 110, 130 are substantially the same, the lengths of front and
back
panels 110, 130 are substantially the same, the widths of top and bottom
panels 120,
140 are substantially the same, and the lengths of top and bottom panels 120,
140 are
substantially the same, so that the resulting box will 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.
[0037] The widths of flaps 123, 124, 143, 144 extending from top and bottom
panels 120, 140 may also be substantially equal, and these flaps may be minor
flaps.
As used herein, minor flaps refer to flaps that do not meet in the middle in
the formed
box, as shown in FIGS. 1 C-1 D. As depicted, there is a gap between each pair
of flaps
123, 143, and 124, 144. In comparison, major flaps refer to flaps that can
meet in the
middle of the formed box. To provide minor flaps, the width of each flap 123,
124, 143,
144 may be less than half of the length of front and back panels 110, 130.
Minor flaps
123, 124, 143, 144 are provided to form partially open sides of box 190.
[0038] For reasons that will become clear below, in the present embodiment,
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the length of flaps 113, 114, 133, 134 is longer than the length of front and
back
panels 110, 130, such as by about twice the blank thickness. A difference in
length
between flaps 113, 114, 133, 134 and front and back panels 110, 130 is
necessary to
provide side supports that are flush with the top and bottom of the resulting
box as will
be further described below. In cases where a blank has a varying thickness,
the
skilled person should be able to adjust the difference between the lengths of
flaps 113,
114, 133, 134 and panels 110, 130 in view of the present disclosure to achieve
a
similar result.
[0039] Further, the width of front and back panels 110, 130 is wider than the
width of top and bottom panels 120, 140, such as by about four times of the
blank
thickness. This difference in width allows flaps 123, 124, 143, 144 to be
folded inside
and fit between the top and bottom of the box to be formed, as can be
appreciated by
those skilled in the art.
[0040] In the present embodiment, to provide the necessary width difference
between front and back panels 110, 130 and top and bottom panels 120, 140, and
length difference between flaps 113, 114, 133, 134 and panels 110, 130, side
edges
111, 112, 131, 132 are transversely offset from side edges 121, 122, 141, 142,
such
as by about twice of the blank thickness, and each pair of adjacent flaps 113,
114,
123, 124, 133, 134, 143, 144 is severed and separated by a slit cut 170, 172,
174,
176, 178, or 180, which is longitudinally offset from the respective fold line
150, 151,
152, such as by about the box thickness. That is, each slit 170, 172, 174,
176, 178, or
180 is offset from the closest one of fold lines 150, 151, 152 by about the
box
thickness. In other words, the end of each flap is offset from all fold lines
150, 151, 152
by at least about the box thickness.
[0041] A slit cut is a cut where little material is removed by the cut and the
adjacent flaps may still be in contact with one another after the slit cut, or
there may be
only a narrow gap between the adjacent flaps after the slit cut. With such
slit cuts, the
adjacent flaps 113, 114, 123, 124, 133, 134, 143, 144 are severed from one
another
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but may still abut each other, as depicted in FIG. 1A and better shown in the
enlarged
intersection of slit cut 180, side edges 132, 142, and fold line 152 in FIG.
113.
[0042] As illustrated in FIG. 113, to offset slit 180 from fold line 152, and
offset
side edge 132, from side edge 142, a small portion 182 of slit cut 180 is
slanted with
respect to fold line 152 and side edges 132, 142. The offset between slit 180
and fold
line 152 may be about half of the offset between side edges 132, 142. The
offsets
may be designed to provide close fit between the respective panels and flaps
in the
resulting box.
[0043] Slit cuts allow the provision of flaps 113, 114, 133, 134 that are
taller
than the height of panels 110, 130, and at the same time flaps 123, 124, 143,
144 that
can extend the full length between the front and back of the resulting box. As
can be
appreciated, when flaps 123, 124, 143, 144 extend over the full length between
the
box front and back, they can improve or reinforce box integrity, and provide
support
when the box front and back are compressed towards one another.
[0044] In comparison, wider cuts sometimes referred to as slots in the
literature
are used in known blanks, as exemplified in WO 01/87721 to Maus and US
7,784,676
to Borek et al., where the adjacent flaps are separated by a wide gap. With
such wide
gaps between the flaps as shown in these references, the length of each flap
is shorter
than, or equal to, the length of the panel to which the flap is attached.
[0045] 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. When a corrugated board is used to form blank
100,
the flute direction of the corrugated board may be substantially parallel to
the
lengthwise direction of blank 100, or substantially parallel to fold lines
150, 151, 152,
so that the flute direction in the sides of the box to be formed is
substantially vertical.
[0046] Glues or other adhesive materials or suitable configurations for
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attaching or fixing different parts of blank 100 may be additionally 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 flaps 113, 114, 123, 124, 133, 134,
143,
144 and 145, as will be further discussed below.
[0047] 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 5 mm. In a particular
embodiment, blank 100 may have a thickness of about 3 or about 4 mm.
[0048] Blank 100 may be folded into a box 190, as illustrated in FIG. 1C, in
selected embodiments. A box packing machine may be used to fold blank 100 and
package box 190.
[0049] In selected embodiments, panels 110, 120, 130, 140 and end flap 145
may be first folded along fold lines 150, 151, 152, 153 to form a tube shape.
End flap
145 and a portion of front panel 110 may overlap and may be glued together, or
otherwise attached to each other. For example, a hot melt adhesive may be used
and
may be applied using, for example, a hot glue gun.
[0050] Optionally, goods (not shown) to be packaged within the box, may be
inserted into the tube from one or both of the open sides at this time.
[0051] Flaps 123, 124, 143, 144 extending from top and bottom panels 120,
140 are then folded inwardly along fold lines at side edges 121, 122, 141,
142, to form
partial sides.
[0052] Next, flaps 113, 114, 133, 134 extending from front and back panels are
folded inwardly along fold lines 115, 116, 135, 136 and glued or otherwise
bonded to
form double-layer supports 191, 192, 193, 194. Double-layer supports 191, 192,
193,
194 are then folded inwardly along fold lines at side edges 111, 112, 131,
132, and
glued or otherwise attached to the outside surfaces of respective partial
sides formed
by flaps 123, 124, 143, 144. This completes the formation of sides of box 190,
and
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thus box 190.
[0053] Box 190 thus has a front formed from front panel 110, a top formed from
top panel 120, a back formed from back panel 130, a bottom formed from bottom
panel 140, and partially open sides formed from flaps 113, 114, 123, 124, 133,
134,
143, 144.
[0054] As now can be understood, the length of each flap 113, 114, 133, 134 is
the height of the corresponding support 191, 192, 193, 194 when box 190 is in
the up-
right position. The length of front and back panels 110, 130 is also their
height when
box 190 is in the up-right position. Thus, in this disclosure, for convenience
of
reference, the length of each flap 113, 114, 133, 134 and front and back
panels 110,
130 may also be interchangeably referred to as its height.
[0055] As illustrated in FIG. 1C, because the height of flaps 113, 114, 133,
134
is taller than the height of front and back panels 110, 130 and is
appropriately
selected, the top end of each side support 191, 192, 193, and 194 is flush
with the top
of box 190, and the bottom end of each side support 191, 192, 193, and 194 is
flush
with the bottom of box 190. It is to be understood that a top end of a side
support is
flush with the top of box 190 when it is substantially flush with the top
surface of box
190 provided the top surface is substantially flat. Similarly, a bottom end of
a side
support is flush with the bottom of box 190 when it is substantially flush
with the
bottom surface of box 190 provided the bottom surface is substantially flat.
The ends
(or edges) of the side supports are considered flush with the top and bottom
respectively as long as when the box is under vertical compression, the side
supports
191, 192, 193, and 194 bear at least part of the applied load before box 190
substantially deforms under the vertical compression.
[0056] A vertical compression may be applied 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.
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[0057] Conveniently, side supports 191, 192, 193, and 194 provide improved
vertical support and resistance against deformation under vertical
compression, as
compared to boxes without full-height side supports.
[0058] As can be appreciated, when a corrugated board is used to form blank
100 and hence box 190, and the flute direction is substantially parallel to
the
lengthwise direction of blank 100, the flute direction (not shown) in the
front, back and
the side supports of box 190 as depicted in FIG. 1C would be substantially
vertical.
Conveniently, such an orientation of the flute direction can provide increased
vertical
strength, as compared to other orientations of the flute direction.
[0059] Conveniently, double-layered supports provide improved resistance
against vertical compression, as compared to a single layer side support that
is of the
same material and thickness. To provide even stronger support, side-supports
may be
formed with three or more layers, such as by further folding flaps 113, 114,
133, 134.
In some embodiments, however, single layer side supports may be sufficient,
depending on the particular application and use.
[0060] For example, stronger side supports 191, 192, 193, and 194 may be
required when flaps 123, 124, 143, 144 are sized such that there are gaps
between
them when they are folded to form partial sides of the box. In comparison, if
flaps 123
and 143 abut or overlap with each other and flaps 124 and 144 abut or overlap
with
each other in the formed box, some side support can be provided by 123, 124,
143,
144. However, such a configuration will require more blank material and
increase the
weight of the blank and the box. Further, with such a configuration, the sides
of the
box are closed by the overlapping flaps, so that the content of the box is not
visible
from the side. In some applications, it may be desirable to be able to view
the content
in the box from the sides.
[0061] Also conveniently, when side supports 191, 192, 193, and 194 are
attached to the outside surfaces of flaps 123, 124, 143, 144, the internal
space in box
190 can have a substantially regular shape, so that it may be convenient to
package
goods or products that have regular individual shapes, such as bars. In
comparison, if
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side supports, such as folded side supports, are provided inside flaps 123,
124, 143,
144, the internal space in the box would be irregular due to protrusions
formed by the
side supports.
[0062] When two overlapping portions are to be attached, the overlapping
portions may be glued, or may be stapled, taped, or otherwise attached or
affixed
together.
[0063] As noted above, the goods (not shown) to be packaged may be placed
inside box 190 before the sides of box 190 are closed and sealed.
[0064] The partial openings on the sides of box 190 may allow partial viewing
of the goods, and may reduce the materials needed to form box 190. However,
the
openings should be shaped and sized to prevent the goods from falling out of
box 190.
[0065] Box 190 with the contained goods may then be transported or stored.
For example, box 190 with the contained goods may be conveniently placed on a
storage or display shelf.
[0066] Box 190 may be opened by tearing off removable portion 162 along tear
line 160. When notch portion 164 is provided, the user may push off notch
portion 164
first and insert a finger into the resulting notch opening to facilitate
tearing off and
removal of portion 162.
[0067] The remainder of box 190 forms a display box 195 with partially opened
top and front, as shown in FIG. 1 D. Therefore, the goods (not shown) placed
in box
190 become accessible and visible in box 195. It is not necessary to remove
the
goods from box 190 or display box 195 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
190, either from the open front side or the open top.
[0068] In some embodiments, a portion of the top opening or front opening may
be widened, such as to the full width of the box to allow easier removal of
goods from
the display box. An example box blank 200 and a corresponding display box 210
are
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shown in FIGS. 2A and 2B. With the exception of the shape of the tear line and
the
removable portion, box blank 200 is otherwise similar to box blank 100, and
display
box 210 can be formed from blank 200 in a similar process as described above
for
forming display box 195 from blank 100. The removable portion 202 is defined
by a
tear line 204 and has a widened portion 208 in the top panel 206. The widened
portion
is of the full width of top panel 206 such that in display box 210, the top
opening 212
has a portion that spans the full width of the box to allow easy removal of
goods,
particularly goods of regular shapes and goods which have a length that is
about the
full width of the box 210.
[0069] A further optional difference in blank 200 is that two notch portions
209
(as compared to one notch portion 164 in blank 100) may be provided as
depicted.
[0070] In a specific embodiment, the dimensions in blank 100 or 200 may be as
shown in Table I.
Table I. Example Blank Dimensions
Component Size (inches)
Width Length
Blank (overall) 23.44 54.874
Front and back panels 15.94 9.061
Top and bottom panels 15.31 17.501
Flaps on front and back panels 1.78+1.97 = 3.85 9.155
Flaps on top and bottom panels 4.06 17.376
End flap 15.31 1.781
Removable portion 12.56 19.56
widened portion of Removable portion 15.31
[0071] In some embodiments, a relatively large portion of the top and front of
the box can be removed, and as a result, relatively large items may be stored
in the
box on a shelf and may be conveniently displayed and removed from display box
195
or 210.
[0072] As can be appreciated, when only a portion of the front and the top of
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box 195 or 210 is removed, the remaining portions connected to the back and
side
supports, can together conveniently provide structural support for confining
the goods
on display.
[0073] When side openings are provided in the box such as box 190, the side
openings may be conveniently utilized to handle the box, and to provide a
viewing
window for viewing the content in box 190 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 the flaps.
[0074] Further, as depicted, blank 100 or 200 as a whole may be 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.
[0075] In an exemplary embodiment, blank 100, 200 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.
[0076] 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
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 ready
to be
utilized.
[0077] 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-
CA 02785111 2012-08-09
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.
[0078] 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 flaps
that may be folded.
[0079] 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.
[0080] At some stage of this process, a tear line 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.
[0081] The result up to this point can be a flat blank. Thereafter a flexo-
folder
gluer may apply glue to appropriate portions on 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.
[0082] 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 erected
and
packed.
[0083] 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
16
CA 02785111 2012-08-09
commercially available case erectors include case packers made by iPak
Machinery
Ltd.TM
[0084] 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 products inside.
[0085] It may also be possible to utilize blanks that have not been formed
into
tubular forms 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 and then cause the remaining panels to be folded around
and
glued in sequence.
[0086] As can be understood, blank 100 or 200 may be modified without losing
all of its benefits.
[0087] For example, a tear line may be provided by a tear strip, or 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.
[0088] FIG. 3A depicts a modified box blank 300, exemplary of another
embodiment of the present invention.
[0089] Blank 300 shown in FIG. 3A is similar to blank 100 or 200, except that
front panel 310 and bottom panel 320 are terminal panels, and a removable
portion
302 is provided by two separate tear lines 304 and 306, which as depicted may
be
provided as tear strips. Panel 330 is the back panel and panel 340 is the top
panel. As
in blank 100, side flaps 313, 314, 333 and 334 attached to front and back
panels 310
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CA 02785111 2012-08-09
and 330 are provided with fold lines 315, 316, 335 and 336 respectively and
are taller
than front and back panels 310 and 330.
[0090] Blank 300 may be folded to form a box 350 as illustrated in FIG. 3B,
and
then transformed to display box 360 as illustrated in FIG. 3C by removing the
removable portion 302 along tear lines 304 and 306, in a similar manner as for
forming
box 190 and display box 195 or 210 from blank 100 or 200. As in box 190 or
display
box 195 or 210, in box 350 and display box 360, double-layer side supports,
such as
supports 351 and 352, are formed from side flaps 313, 314, 333 and 334, and
the side
supports such as supports 351 and 352 are of the same height as the total
height of
the box. As illustrated in FIG. 3B, the top end of each side support such as
side
support 351 or 352 is flush with the top of box 350, and the bottom end of
each side
support is flush with the bottom of box 350.
[0091] FIG. 4A depicts another modified box blank 400, exemplary of another
embodiment of the present invention. Blank 400 shown in FIG. 4 is similar to
blank
100, except that no fold lines are provided on the side flaps 402 for forming
side
supports and no tear lines are provided for removing a portion of the box.
Blank 400
may be folded to form a box 410 as illustrated in FIG. 4B, in a similar manner
as for
forming box 190 from blank 100 with the exception that no side flaps 402 are
double
folded and the resulting side supports such as supports 412 are single layer
supports.
As depicted in FIG. 4B, in box 410 formed from blank 400, side supports 412
are still
full-height supports, as in box 190.
[0092] Conveniently, as illustrated above, a shipping and display 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.
[0093] As can be understood, the panels in the blank are typically
substantially
rectangular, as depicted in the drawings. The flaps may also be substantially
18
CA 02785111 2012-08-09
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, one or
more
flaps extending from the top and bottom panels may have a curved terminal
edge.
[0094] 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.
[0095] 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.
[0096] 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.
[0097] 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.
[0098] 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.
19
